Report on 500 MW Generator Stator Unloading , lifting and placement in TG Floor foundation at NTPC Kahalgaon - Stage-II for Unit

# 5 & 6 ( 3 X 500 MW )

Team members : Shri P.K.Das , Sr.DGM (Team Leader ) Shri M.K.Majilya ,DGM Shri S.K.Mondal ,Manager Shri R.K.Srivastava,Chargeman Under the guidance of Shri D.Guha ,AGM,BHEL,Kahalgaon Site Report prepared and compiled by : M.K.Majilya

BHEL:PSER:Kahalgaon Site Design & Execution by : M/s Fagioli PSC,Mumbai Review Consultant : M/s DCL,Kolkata Customer : NTPC
1

Brief History As a standard practice followed earlier by BHEL-Power Sector Regions , the operation of unloading , lifting and placement on TG Foundation for 500 MW Generator Stator weighing around 265 MT for Thermal Power Stations used to be done with the help of Portal Crane arrangement. At present 2 such Portal Crane sets are available with BHEL for above type of jobs. In case of Kahalgaon Stage II ( 3 X 500 MW ) , Portal crane was not available as the both the sets were pre-occupied for the projects under execution by PSSR & PSWR. To come out with a solution ,BHEL/ PSER/Kahalgaon Site started exploring alternative feasibility in lieu of Portal Crane for doing stator unloading , lifting from zero meter and placement on TG Floor foundation at 17.00 meter elevation. The idea of using strand jack method was thought as an alternative as Boiler Drum lifting was done for Kahalgaon Unit #5 , 6 & 7 ( 3 X 500 MW ) by this method. The concerned agencies M/s Fagioli PSC and M/s Freight Wings who have executed the job for 500 MW Boiler Drum Lifting weighing around 244 MT at an elevation of around 78.00 meters elevations were shown the details of the job. Both the parties have shown keen interest and presentations were made by both the parties to NTPC and BHEL. It was briefed to the interested executing agencies that they will be using existing 2 foundation footings outside TG Hall A Row adjacent to the rail line for transportation of Generator Stator at zero meter and 2 foundation footings on TG Deck at 17.00 meter elevation. With the idea of existing Portal Crane system for Generator Stator Handling of 500 MW Sets and Boiler drum lifting at NTPC Kahalgaon Unit # 5,6 & 7 ( 3 X 500 MW ) by strand jack method , basic information for preparation of technical specifications was prepared by BHEL, Kahalgaon Site. In the beginning, certain design aspects were appearing as hindrances , as NTPC raised doubt that certain loading and bending moment components by Strand Jack methods were crossing design limit on the piles and rafts on the top of piles.
2

The matter was referred to many corners of BHEL/Manufacturing Units , but no concrete solutions came out. The matter was internally taken up by our Construction Manager Shri D. Guha/AGM with BHEL/Trichy Boiler Engg. Group informally as they do design of the Boiler Civil design aspects like heavy loading and moments coming on Boiler foundations etc. BHEL/Trichy design group after rechecking the available parameters gave us clearance and they confirmed that the existing civil design of 6 nos. piles with raft can very well take care of the combined load of Generator stator Handling Structure and Generator Stator. This gave us confidence for using the Strand Jack Method for doing 500 MW Generator Stator Handling and lifting. Finally the tender specifications were prepared jointly by BHEL/Kahalgaon Site , Kolkata /FEX & PMX Department. Finally the job was awarded to M/s Fagioli PSC,Mumbai. Tendering went a long drawn process as many clarifications and doubts were raised by the bidding parties and NTPC. AA :: Important Features of the Strand Jack System 1. Right from the beginning BHEL:PSER informed all the concerned Units of BHEL to participate in this job of Generator Stator lifting with strand jack method as this was an MOU Project of BHEL with Govt.of India. From BHEL , CPMG, New Delhi ,PS-TS/NOIDA alongwith our PSER Groups have shown keen interest and they have taken all the pains to interact with NTPCCorporate Engg and execution Vendors for getting design clearance .BHEL/Hardwar from time to time has given vital design information as per the queries raised by both the vendors , BHEL-PSER , NTPC. Our special thanks to Shri J.Kar,AGM/Project/NTPC/Kahalgaon who has personally taken lot of initiatives NTPC Engg Office Complex and he himself was personally (EOC) / present at NOIDA during the final design

clearance from NTPC/ Corporate Engg.

2. In the tender , a condition was included that the executing vendor should get the total design to be vetted by a reputed 3rd party design consultant .This had to be done because as per Contract condition of NTPC, BHEL was supposed to do Generator Stator lifting by Portal Crane and that is why NTPC wanted that this type of job being a new one for the first time being executed by BHEL , total design needs to be vetted by a reputed 3rd party consultant. As a result , the Executing agency M/s Fagioli engaged M/s DCL,Kolkata as design consultant. Final concurrence was given by both M/s DCL and customer NTPC after studying the detailed calculations and series of meetings had to be conducted for clarification and approval. 3. Major components which were fabricated in Mumbai by M/s Fagioli were tested in presence of our BHEL/Kolkata/FEX representative before arranging dispatch clearance. 4. Major items dispatched were brought from different parts of India and abroad .The details of the consignments received are as per following details.
Sl. No 1 2 3 4 5 6 Description Embedment Bolts (Locally Fabricated) Gantry crane Beams (4nos) Tower, Base beams, Tie Down beams,L300 Jack, MK4 Jack etc. Tower legs, Ladder set, Bracings, Ladder Platform, Stabbing Guides etc. 1 Office container + 1 bundle imported strands 1 bundle imported strands Swivel System Ships name ---------------Rickmer Dubai Indian Lotus/ Achiver Material lying At Anjar Site (Gujarat) Material lying ready at Cochin U.K Airport to Kolkata Airport Remarks/Mode of despatch

Road Road

5. While doing calculations on the TG Hall outside Column Foundation , M/s Fagioli expressed difficulties as they opined that, the proposed 2 foundation footings on the top of civil raft outside TG Hall can not take care of Generator Stator and strand jack structural load and bending moments . Rather they suggested that , they require 4 column types of strand jack system structure. Accordingly they came out with a proposal of 4 nos. of foundation footings so that they can go ahead with 4 columns structure instead of 2 foundation footings on the top of raft. This called for major design changes on top of raft tops of the civil
4

foundation. No change was done on the construction of sizes of 6 nos. piles and raft. The proposed design conditions were reviewed by both NTPC and Design Consultant M/s DCL and both the agencies confirmed that the existing raft can accommodate 4 nos. of foundation footings with all the loads and moments coming on to the foundation within design limits. NTPC was convinced and arranged 4 no. foundation footings instead of the earlier designed 2 no. foundation footings BB :: Constructional features of Strand Jack System The outside structure TG Hall has a feature of 4 columns of Tubular structure type ( Pipe size 457 mm OD X 16.00 mm thk ) with provision of flanges , attachments ,arrangement for bolting and other lengths to suit transportation lugs to accommodate bracings and their fasteners in between for assembly of modular types of structures of different and ease of assembly at site.

The outside columns structure contains the following Base plates assembly with shear lugs on all 4 foundations. The bottom portion is square in construction and the top is of circular type. The height of stool is 400 mm. The plates are grouted with foundation. Foundation bolts size was M36 X 1000 mm length with materials grade of 10.9 class. The weight of these 4 plates and foundation bolts are 1.20 MT(approx.). On the top of it , 1st piece of modular structure of 12.00 meter length is assembled with bracings with the help of both 100 MT Crane and 25 MT Crane .The fasteners are of pin type with locking pins. The assembled weight of this piece is 22 MT. On the top of the 1st piece , 2nd piece of modular structure of 4.0 meter length is assembled with bracings with similar types of pin type fasteners and locking pins. The assembled weight of this piece is 8.0 MT.

 On the top of 2nd piece , 3rd piece of modular structure of 4.0 meter length similar to the 2nd piece is assembled with bracings with similar types of pin type fasteners and locking pins. The assembled weight of this item is 8.0 MT. On the top of it , 4th piece of modular structure of 2.0 meter length similar to the 3rd piece is assembled with bracings with similar types of pin type fasteners and locking pins. On the top of this 4th piece , a box type fabricated assembly with beams is done .The combined weight of this 2 meter long modular assembly and fabricated structure is 8.0 MT. The assembly is shown in Annexure -1. Over this piece , the girders are placed with one end at the top of outside structure and other end at the top of inside 2 column structure on TG deck. On the top of TG Deck , 2 base plates of 20 mm thick MS Plates of approx. 500 x 500 mm size with shear lugs of 200 mm size below it is installed. The 2 columns structures are assembled on the top of the base plates and bolted with base plates. There are 2 types of bracings in the 2 column structures. First type is of diagonal bracings in 2 Column structures and assembled in 2 tiers. Additionally 2 more diagonal beams with the Aux.Coulmns of TG Hall towards B-Row in TG Hall to restrict movement of Generator during the dragging process of Generator Stator. On the top of it one fabricated box made out of beams is mounted on this structure with the help of bolts. Secondary Grouting is done on the TG Deck portion below base plates and similarly grouting was done below the 4 columns foundation footings outside TG Hall. This grouting was done by BHEL. The combined weight of this structure is 8.0 MT. The assembly details are shown in Annexure-2.

 On the top of the outside Column structures outside TG Hall and inside TG hall 2 girders are installed. The weight of individual girders are 36 MT. CR100 Rails are installed on the top of these girders for movement of trolleys. Each Girder is 34.700 meter long and dispatched in 2 pieces . Total no.of girder pieces received are 4.The girders are of I-Section of built up beams 2.00 meter height and are assembled at site with splice plates assembled at the flanges and webs with bolts. Around 1600 nos. of bolts are required and these are tightened with electrically operated torque wrenches. The girders are assembled inside TG Hall alongside of TG axis and lifted on the top of fabricated structures outside TG Hall and inside TG Hall with the help of TG Hall EOT Crane main hook. The girders are rotated slowly and taken outside for the portion projected outside TG Hall. The total assembly of the Strand Jack System structure is explained in drawing no.HL1/F/004 of M/s Fagioli which was submitted approval of M/s DCL and NTPC. Railings and walkways Annexure-3. The moving trolley is mounted on top the Railline of the girders for moving from outside TG Hall upto the CG of TG Central Line. The moving trolley with the arrangement of L-300 Jacks are installed on the top of girders from outside TG Hall with the help of 100 MT Mobile which is parked outside TG Hall near A Row. The weight is around 8.0 MT. Trolley can not be erected from inside TG Hall as the height available over the top of the girders and highest position of the main hook of the EOT Crane This is explained in Annexure - 4. Swiveling beam is assembled in the A-row of TG Hall and strands of 18 mm dia and 29 meters long are inserted from the bottom of the swiveling beam and pulled with chain pulley blocks from the moving pulley top .These strands
7

to

us

after

are assembled

on the top of girders for working at height. The assembly details are shown in

are passed through the moving trolley jacks strand holders. A strand guide is made at the top of the moving trolley. This is explained in Annexure - 5. CC :: Activities involved in the process (i) Unloading of Generator Stator from the Generator Special Wagon on Aux. Pedestals with the help of Hydraulic Jacks (Pictorial view is as per Annexure-6) . (ii) Removal of the Load carrying beam from inside Generator Stator and taking it out completely from the Generator Stator (Pictorial view is as per Annexure - 7). (iii) Lifting of Generator stator from Aux. Pedestals with the help of Strand Jack method (Pictorial view is as per Annexure - 8). (iv) Rotation of the Generator Stator to suit insertion of the stator inside A Row as the position of the Stator on the Rail track is 500 mm offset. For Unit # 5 , the rotation was done after crossing TG Floor elevation as the operating floors at 17.00 meter was ready (Pictorial view is as per Annexure - 9). In case of Unit # 6 , the rotation was done at zero meter as there was no operating floor either at 8.5 meters and 17.0 meters elevation at TG Building towards A-Row adjacent to TG Deck (Pictorial view is as per Annexure - 10). (v) The dragging operation is started with the help of 2 nos. hydraulically operated jacks of 15 MT Capacity each towards B-row from A-row. Further to readjust the movement of generator stator from other side is done with the help of 2 manually operated Maxpullers of Capacity 5.0 MT each and to give breaking action in case of emergency. Although , requirement of Maxpullers was not required ( Pictorial view is as per Annexure- 11) This is an unique feature which is not required during boiler drum lifting. (vi) Once the above rotation is complete , the Stator is further rotated to make parallel to TG Axis and slowly it is made almost in line with TG Axis with the help of swiveling beam assembly (Pictorial view is as per Annexure - 12).

(vii) Placement of Generator Stator on TG Hall foundation (Pictorial view is as per Annexure - 13). (viii) Joining of the 2 parts of Special wagons of Generator for dispatching of the Generator Special wagon for arranging departure to BHEL/Hardwar (Pictorial view is as per Annexure - 14). DD :: Chronological events of Unit # 5 & 6 Sl.No. Description of the activity Unit # 5 01 02 03 04 05 Arrival of Generator Stator at Site
First time No Load Run of Engine on rail track

Duration
Unit # 6 29.04.2006 Not required 17.06.2006 26.06.2006 11 to 16.06.2006

15.04.2006 22.04.2006 26.04.2006 04.05.2006

Generator Stator placed on rail-track Stator unloading on Aux. Pedestals

Strand jack system dismantling from Not applicable Unit # 5 for installation in Unit # 6

06

Strand erection

jack

system

assembly

and 04.05.2006 09.06.2006 10.06.2006

to 17 to 24.06.2006

07

Stator lifting and placement on TG Fdn.

27.06.2006

EE :: Generator Stator Package details : Pkg No. 501 of BHEL/Hardwar . Net weight-265 MT, Gr. Wt.- 275 MT, Size 8830 x 4100 x 4120 mm. Pkg .No. 580 becomes redundant with Strand Jack method.

Generator Transportation
Generator stators are transported from Hardwar to Kahalgaon site on a special wagon either by Kailash-I or II which have been designed by M/s. RDSO. The wagon consists of 24 axles i.e. 8 bogies (4 on each side) of 3 axles each with facility by a carrier beam and the beam is pivoted to 9

the bogies. Pictorial view is enclosed in Annexure-2. Necessary Railway clearances were obtained by BHEL/PSER in consultation with BHE/ROD Kolkata Office.

FF :: Job description
The scope of the vendor was (i) Supervision of Unloading of Generator and arranging all necessary logistics and this includes design of the required fixtures and accessories , (ii) Design , Supply , Erection of Strand Jack System for lifting of Generartor Stator from Rail line alongside A-row and placement on TG Floor foundation.

GG :: Major T&P arranged by BHEL

EOT Crane in TG Hall. 8/10/12 MT Hydra for Transportation and erection of materials. 18/25 MT Mobile Crane for pre-assembly of modular column structures and assembly . 20 MT Truck for transportation of materials inside plant premises. Majority of the big consignments were unloaded at site. 100 MT Mobile Crane with boom length of 70 meters for Pre-assembly and erection of Strand Jack System Outside TG Hall alongside A-Row.

HH :: Methodology adopted by M/S Fagioli is briefly explained below. 1.0 DESIGN CRITERIA
The engineering for installation operations were developed considering the following criteria: The structural calculation is carried with the reference to Indian Standard I.S. Code 800 and British Code for Steel Design (BS 5950-2000). For structural check of each single component is used a Dynamic Amplification Factor DAF = 1.05. The load transfer between upper and lower anchor blocks can give rise to a small amount of load bounce resulting in a effective additional load of up to 5% of the lifted load. For this reason a factor of 1.05 on load was considered. Horizontal load F = 3 % of the maximum vertical load was considered for the tower and for the columns. In this load the effect of wind load was also included (considering wind velocity of 16 m/s) and any the generator during the operation. 10 other effect due to the motion of

2.0 EQUIPMENT USED BY M/S FAGIOLI PSC

The main equipment used are as follows: 1 no. L300 strand jack with Standard Fagioli PSC Strand dia. 18 mm of 29 meters length ( total 19 nos. strands were used). 1 no. Power Pack with total hydraulic systems of high pressure armoured hoses with needle valves was designed to suit the load condition for connecting to different points as per load requirement. 1 number L300 fixed anchor swivel 1 Trolley with 4 Nos. Skate Rollers (50 t capacity and part of the moving trolley) 2 Hydraulic Pullers of 15MT Capacity each to drag the Generator from A row side to B-row Side and 2 Mechanical Max pullers of 5.0 MT Capacity to move the Generator towards A-row from B-row. Each and every Equipment was subjected to periodic inspections, moreover prior to commencement of the operation the equipment was checked according to the daily inspection checking list. Standard rigging hardware (as slings, grommets, shackles etc.) were selected to work within the manufacturers Safe Working Load and were subsequently provided with Manufacturer Test /Fitness Certificates and were inspected before the use.

3.0 OPERATIONS
Before starting the operation, the following checks were carried out under the supervision of BHEL and M/s Fagioli Design Engineer and Lifting Engineer.

3.0.1 Checking before Unloading of the Stator & equipment used

Unloading Area in and around Railway Track is clear from the other working contractors. Unloading Area is checked for lateral / overhead obstructions, over head power lines, underground piping lines strength, soil bearing capacity, and trench / excavation minimum distance. Transverse centre line of TG stator should be transferred onto Rail track and marked and it is ensured that the Centre Line of Strand Jack system when transferred onto the rail track, coincides with the above said transverse centre line. The weight of TG Stator was considered as 275 T & the CG of the Stator was taken as same as the centre line of the stator bore as per confirmation of BHEL/Hardwar/TGE. Installation of the Auxiliary and the Bottom Pedestal alongside the generator unloading foundation area. Installation of 4 Point Lift Systems 480T (Total Capacity ) Hydraulic Jacks of Enerpac make ( 4 nos.Jacks Capacity 120T each) with its accessories alongside the Generator Stator for unloading of Generator Stator on Auxiliary Pedestals. 11

The packer sizes were 20 mm thk 6 nos. on 4 Aux. pedestals of sizes 750x150 mm. 30 mm thk 18 nos. on each pedestals of size 150 x 100 mm 10 mm thk 18 nos. on each pedestals of size 150 x 100 mm and other sizes plus condenser packer plates as per requirement.

3.0.2 :: UNLOADING OF GENERATOR STATOR FROM SPL WAGON & POSITIONING ON AUX. PEDESTALS AND PACKERS. The Stator comes in hanging condition over the Carrier Beam, Which passes through the inside void portion of the Stator and remains supported from the temporary end shield bearings of Stator at both ends, while the Beam ends are mounted on the top of the two end segments of the special carrier wagon and the whole unit is pulled by Railway engine. Once the 500 MW Generator Stator weighing 275MT is received at site, the same is brought on to the Railway track alongside the TG Building A-row. Stator is to be lifted by around 300 mm. with 4 no Jacks of 120 MT Capacity each. Saddles/Trunnions available on the sides of the Stator Body are used for this purpose . One Motor operated Hydraulic operated high pressure pumping unit for controlling movement of all 4 above jacks is used for unloading of Stator on Aux. Pedestals and packers. Slowly the load is released from the temporary end-shield bearings so that the carrier beam becomes free and rests only at the ends on the top of wagon segments. During this time , the total load of the Stator and Carrier beam i.e. 275 + 90 = 365 T is to be handled by the lifting arrangement, and the Jacks are to be of that capacity. One Fabricated moving Trolley structurally suitable to bear the self load of about 100T of the carrier beam with a hydraulic Telescopic jack of at least 150 T capacity( Since the weight of carrier beam is approximately 90 MT) is placed between the stator and Powered end of the wagon. This temporary support is required to take the load of carrier beam when it comes out of stator, so that free end of the beam does not strike and damage the stator core. The trailing end of the beam is made free from the wagon and the carrier beam is pulled out of the stator with the help of the powered wagon very slowly. The operation continues till the beam comes out fully from inside the stator. Stator is to be rested on Jacks and Pedestals for about 24 hours with minimum ground clearance of 500mm at the stator bottom to facilitate blue matching of the bottom terminal box and re-threading and re-tapping for final placement.

3.0.3 GENERATOR STATOR LIFTING AND PLACEMENT ON TG FOUNDATION The four Slings at the ends of the swivel beam are properly tied with the Lifting Lugs of the Generator. The strands of the Strand Jacks are tightened by operating the power pack of the strand jack. Verticality of lifting wires is continuously maintained during the lifting at +/- 1. The strands are slowly raised to lift the stator from the supports so that there is a clear gap of about 100mm between the carrier / supports and the stator and the total load is transferred on the 4 nos. slings.

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 Overall vertical dimension of the system is checked that , these are within the tolerance limit as the access over T.G. deck is very narrow. The transverse centre line of the Stator is marked at its location on the TG deck. Proper checking & ensuring of the longitudinal centre line is marked on the Stator body. This is done just to facilitate matching with the Centre line of the skid Trolley. In the next step , pulling is done with the Trolley/Strand Jacks together with the Generator, along the skid tracks by using the L15 MT capacity pulling jacks, restrained at the end of the skidding beam. The Rotation of the generator is done with the help of Slings and the shackles connected to the lifting beam assembly or on the generator body at the ground. This is done manually. The Stator is rotated to the required angle. Once the generator is rotated it is pulled with the help of strand jack until it clear the Column along grid line A. On completion of the above activities , the Generator is made parallel to column line A after it clears the Column A/6. The Generator stator is further pulled and lifted with the help of the strands using the strand jack up to an elevation of 17m (bottom of generator stator). The generator should be lifted to a clearance of 500mm above the TG Deck top. The Two main Skid Beams over which the Stator lifting trolley is going to skid has to be properly braced together for stability. At the time of skidding care should be taken that only four brace between the two skid beams is removed while longitudinal movement for access & the same shall be braced again to the position after the stator is passed. This is important for stability of the main Skid beams. The above procedure is continued till the stator reaches above the exact foundation on T.G deck Skiding of the Generator is continued so that it exactly reaches over its foundation. Lowering of the Generator Stator is done on to its foundation and MS packer plates are inserted underneath Stator body on both sides of the anchor bolt location. The Strands are slowly lowered so that Stator is aligned properly on its foundation. After all the dimensional check the Stator load is released onto the foundation & the Strands are released.

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JJ :: Comparison between Strand Jack method and Portal Crane. Sl.No. Description 01. Foundation TG Deck Portal Crane method on 2 Raised foundation Strand Jack Method of 2 base plates of 500 x 500 mm

around 500 mm height with size with shear lugs and M36 packer plates and foundation Foundation bolts. The base plate of 580 Package. level is almost on TG Floor. of 4 base plates of 500 x 500 mm

02.

Foundation

on 2

Raised

foundation

Outside TG Hall around 250 mm height with size with shear lugs and M36 alongside A-row 03. Package No.580 packer plates and foundation Foundation bolts. The base plate of 580 Package. Used level is almost on TG Floor.

Not

required

and

this lakhs

leads to around
04. Erection Time 3 weeks

savings of Rs.2.0

approx. per 500 MW Unit.

For 1st Unit 25 days including fabrication of many items . For 2nd Unit 7 days. 05. 06. 07. 08.
Transportation Cost

Rs.2.0 Lakhs(approx.) Rs.2.0 Lakhs(approx.) Rs.1.0 Lakhs(approx.)

Rs.5.0 Lakhs(approx.) Rs.1.0 Lakhs(approx.) Lump sum

Erection cost Maintenance /preservation cost

Generator Stator 75 mm dia endless slings 75 mm dia slings of 3.50 meters Lifting Slings 2nos. supplied by BHEL. 2 hours 100 MT approx. Not applicable 365 MT length 4 nos. & supplied by the executing vendors 6 hrs. 140 MT approx.
19 Nos. of 18 mm dia. Of 29.00 meters length

09. 10. 11 12.

Operation Time
Total weight of structure and girders etc.

Strands Lifting Capacity

400 MT

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4 Base Stools bolted with base plates

4 Nos, Base plates with Shear lugs levelled and grouted

Annexure 1 ( 1) Assembly of Base plates and 1st Set of Stools

Assembly of 1st Modullar Column set with bracings ( length 12 meters and weight 22 MT)

Base Stools 4 Nos.

Annexure I ( 2 ) Outside Structure Assembly

Annexure-1( 3 ) 1st Modular Column is being lifted for erection in position

4th Modular Column Assembly of 2.0 mt.length

Fabricated box assembly

3rd Modular Colums assembly 4.0 mt length 2nd Modular Colums assembly 4.0 mt length

1st Modular Colums assembly 12 mt length

Annexure-1 ( 4 ) Assembly of Outside TG Hall Structure Assembly

Diagonal bracings in between columns

Annexure- 2 ( 1 ) Assembly of Inside 2 Column Strcture inside TG Hall

Bracings weldded and bolted with columns and strctures for arresting movement of Strand Jack structure towards B-row during Dragging of the Stator from A to B Row.

Annexure 2 ( 2 ) Diagonal bracings taken from 2 coulmn structure with TG Hall Aux.Columns and beams

Annexure 3 ( 1 ) Girders pieces unloaded in TG Hall for joining with splice plates and bolts and assessment is being done

Annexure 3 ( 2 ) Girders are joined with splice plates and bolts

Walkways , railing are ready

Annexure 3 ( 3) Girders lifting with TG Hall EOT Crane

Annexure 3 ( 4 ) Lifting of Girders .The lifting lugs angles are so set , that minimum clearance between below hook of main hoist of TG Hall EOT Crane is maintained and girders are placed on top of strand jack strucrures (both outside TG Hall & inside TG Hall )

Annexure 4 ( 1 ) Moving Trolley alongwith Powerpack ready for lifting on Girders top

Annexure 4 ( 2 ) Moving Trolley being lifted on Girders by 100 MT Mobile Crane from outside TG Hall

Rails are welded on top of the girders and welded at regular intervals

Rollers are fixed below trolley for reducing friction during dragging of Stator

Annexure 4 ( 3 ) Moving trolley on top of the Girders with strand arrangement

Annexure 5 ( 1 ) Swivelling beam with strands and lifting slings

Annexure 5 ( 2 ) Strands Guide coming out from top of the powerpack

Annexure 6 ( 1) Hydraulic Jacks 4 nos. of 120 MT Capacity each for Unloading of Generator Stator on Aux. Pedestals

Annexure 6 ( 2 ) Generator Stator unloaded on Aux.Pedestals with the help of Hyd.jacks

Annexure 6 ( 3 ) Unloading of Stator completed total view

Annexure 7 ( 1 ) Arrival of Stator with Load Carrying beam inside and hanging from both side of Spl. Rly.Wagon.

Annexure 7 ( 2 ) Removal of load carrying beam from Stator inside

Annexure 7 ( 3 ) Fixing of 150 MT Hydraulic Jack at the front side of the Spl.wagon for taking out load carrying beam

Annexure 7 ( 4 ) Load carrying beam almost out of the Stator

Annexure 7 ( 5 ) Load carrying beam removal completed and ready for joining with Rly. Spl.Wagon totally

Annexure 8 ( 1 ) Generator Stator Lifting from Aux. Pedestals

Annexure 8 ( 2 ) Stator lifting from Aux. Pedestals

Annexure 8 ( 3 ) Stator Lifting is in progress

Annexure 9 - Rotation of Stator in Unit #5 above TG Floor

Annexure 10 - Rotation of Stator at zero meter floor in Unit # 6 as TG Floor was not ready

Annexure 11 ( 1 ) Dragging of Stator from A Row towards B- Row

Dragging with 2 Hydraulic Jacks of 15 MT Capacity

Annexure 11 ( 2 ) Dragging of Stator towards B-Row from A-row

Annexure 12 ( 1 ) Stator brought on TG Floor near axis before rotation along TG Axis.

Annexure 12 ( 2 ) Rotation of Stator towards TG Axis (View -1 )

Annexure 12 ( 3 ) Rotation of Stator towards TG Axis (View 2 )

Annexure 12 ( 4 ) Stator axis made parallel to TG Axis and ready for placement on TG Foundation

Annexure 13 ( 1 ) Generator Stator placement on TG Foundation

Annexure 13 ( 2 ) Stator placement on TG stator completed

The load carrying beam is being joined after the stator is cleared from the lifting point

Annexure 14 ( 1 ) Joining of Spl. Rly. Wagons

Load carrying beams assembled for Joining

Annexure 14 ( 2 ) Assembly of Spl. Rly. Wagons