PRESENTATION ON CONSTRUCTIONAL

FEATURES OF 57.02MW
STEAM TURBINE AT AES KELANITISSA
BY
G.SRIDHAR
DEPUTY MANAGER/BHEL
STEAM TURBINE
Single shaft non-reheat type reaction Turbine
1
st
stage is an impulse stage
Steam enters the turbine from the valves through
the inter-connecting piping to the HP stages
17 HP stages
After the doing work in the HP stages, the steam
makes its way to the IP stages
The IP stages are housed in Guide Blade
Carriers(GBCs) 1, 2, 3 & 4

GBC-1 consists of 13 stages
GBC-2 consists of 8 stages
GBC-3 consists of 4 stages
GBC-4 consists of 4 stages
The last 4 stages are housed in the Exhaust Hood
and are called the LP stages.
A very important part of the rotor is the Balance
Piston Disc/Drum which balances a major part of
the thrust that is caused by impingement of steam
on to the blades. The residual thrust is absorbed by
the Thrust Bearing.
The HP and IP stages of the Turbine are separated
by the Intermediate Gland
The rotor is fixed at the thrust bearing and the
expansion takes place towards the Generator.
The casing is fixed at the Exhaust hood and
expands towards the front bearing pedestal
The front bearing housing rests on the bearing
pedestal and slides on graphite studded packers
along with the casing.
The rotor rests on bearings in the front and rear
bearing pedestals and resembles a simply
supported beam.

In between the 2 bearing pedestals and the casings
are the front and the rear glands. Gland steam for
sealing the motive steam from coming out of the
casing is supplied to these glands.
The exhaust hood is provided with 2 nos. of
explosion/bursting diaphragms which will operate
when the exhaust hood pressure increases beyond a
certain limit. The diaphragm is made of lead.
On either side of the Turbine are the Main Steam
Stop and Control Valves with servomotors. Steam
from the Boiler enters the valves through a nozzle
provided at the bottom of the valves. The valves
house the strainer which prevents foreign particles
from entering the Turbine.
From the valves, the steam is led to the Turbine
through the Inter-connecting piping/Steam transfer
piping.
Looking from the Turbine towards the Generator,
all that is in front, is front and that at the rear, the
rear. Similarly the left and the right.
The valves are fixed at the rear end in the axial
direction and at one of the resting palms in the
transverse direction thus enabling expansion of the
valve towards the front and away from the Turbine
laterally.
The rear set of thrust pads are the active pads.
Mounted on the front bearing pedestal is the Main
Oil Pump which is driven by the Turbine shaft.
This pump comes into operation after the Turbine
has attained 95% of rated speed. Till then the AOP
shall be in operation.
The front portion of the Turbine rotor is also
equipped with a toothed wheel for sensing speed
and a overspeed testing eccentric pin. The
overspeed trip lever is lifted by the eccentric pin
when the machine overspeeds, there by causing
draining of oil and immediate closure of stop
valves.
The Rear Bearing pedestal houses the rear bearing
and the Turning/Barring Gear assembly. The
coupling portion of the Turbine rotor is assembled
with 1 stage of impulse blades on to which oil will
impinge when the Turning Gear valve is opened.
This will result in rotation of the rotor. For this the
rotor has to be lifted on jacking oil by 0.07 to
0.10mm.
Unlike the front bearing housing, the rear bearing
housing does not slide.
The rear bearing pedestal is also the house of the
Turbine-Generator coupling.
The Steam Turbine is equipped with the
following auxiliaries:
a. Main Oil Tank
b. Auxiliary Oil Pump-tank mounted
c. Emergency Oil Pump-tank mounted
d. Duplex Oil Filter
e. Oil Coolers
f. Oil Centrifuge
g. AC & DC Jacking Oil Pumps
h. CEPs, BFPs, Deaerator etc.
Sequence of Steam Turbine Erection
1. Mark the longitudinal and transverse center lines
on the TG deck/verify the center lines marked
by the civil agency.
2. The foundation shall be checked for dimensional
accuracy by a measuring tape within a tolerance
of +2mm.
3. Before the foundation is cast, check the location
of inserts, pockets etc. The foundation bolt
sleeves shall be checked for verticality and shall
not deviate by more than 3mm along the entire
height of the sleeve. The sleeves shall then be
locked firmly to the reinforcement rods to arrest
any movement during casting.
Care shall be taken to cast the entire deck in one
stretch spanning 24 to 36 hours.
The dimensional and verticality check shall be
repeated after casting to check for any deviations
during casting. After the minimum curing time of
the deck has elapsed, its ready for erection. All
dimensional checks shall be carried out with
respect to the longitudinal axis of the Turbine and
the Condenser center line.
All areas where secondary grout is to be poured or
where primary packers are to be grouted shall be
roughly chipped. This is important for adhesion
between the primary and the secondary grout.

A bench mark for reference elevation of the TG center line
shall be transferred from the Boiler/any reference which
the civil agency has marked. The elevation of all
components of the Steam Turbine Generator shall be set
w.r.t this bench mark.
Mark location of packers for placement of the Turbine
Front and Rear pedestals, Exhaust hood base plate, the
Generator sole plate and the Exciter sole plates.
Place, align, set elevation and level the packers and grout
with quick setting non-shrink cement. Cure the grout for as
long as the manufacturer of the cement recommends.
Packers shall be so placed to allow for provision of shims
for adjustment.
48 hours after the packers have been grouted, they are
ready for loading of the equipment.
Place the Exhaust hood sole plates, the Turbine front and
the Rear Bearing pedestals. All the above shall be aligned
w.r.t the longitudinal and transverse axes of the Turbine.
The elevations of the parting planes of the bearing
pedestals shall be set w.r.t to the bench mark made earlier
and shall correspond to the machine center line.
Place the exhaust hood lower half on the sole plates.
Bolt the lower half of the Outer Casing with the Exhaust
hood lower half, while taking care to match the joint. The
joint shall be checked on either side with a dial gauge. The
outer casing bottom half rests on jack screws on the FBP.
A piano wire is then stretched from a temporary structure
in front of the front bearing pedestal to a structure beyond
the rear bearing pedestal at the same elevation as that of
the machine centerline and shall hence forth be regarded as
the longitudinal centerline of the machine.
The seal bore of the pedestals and the front & rear portion
of the casing shall be aligned w.r.t to the piano wire to an
accuracy of 0.10mm.
Place the top half of the outer casing and the exhaust hood
and bolt the two together. This assembly cannot be made
later as there is no space to tighten the bolts of the vertical
joint.
Remove the top half of the casing and place it on a level
surface at a convenient location.

Level the rotor on the lifting beam and place the
rotor on bearings.
Clamp dial gauges to the rotor and achieve
centering values of at the Turbine front and rear
seal bore, at the front gland portion and the bellow
location of the casing as has been recorded at
works.
Insert exhaust hood radial keys.
Remove the rotor and place it back on the stands.
Insert eccentric pin assemblies of the BP Gland,
Inner casing and GBCs.
Place the lower halves of BP Gland, Inner casing
and all Guide Blade Carriers.
Set the gaps at the parting planes and the elevation
of the parting planes of the BP Gland, Inner
Casing and GBCs w.r.t the outer casing as given
in the test bed protocols/shop quality records.
Place the rotor now and check flow path
clearances. The flow path clearances will be very
nearly the same as recorded in the shop quality
records.
Check axial float of the rotor without the thrust
bearing and record.
Place the top halves of the BP Gland, Inner Casing
and GBCs and check top clearances by lead wire
or by float as is applicable.

Place the outer casing top half and carryout a
mock box up.
Lock the hexagonal screws of the eccentric pins in
this position.
Remove the top halves of all the assemblies and
the rotor.
Assemble the rotor simulation thermoelement and
the 1
st
stage pressure piping on the Inner Casing.
Remove the bottom halves of the BP Gland, Inner
Casing and all GBCs.
Fix a date for final box-up and carryout complete
cleaning of the bottom half of the casing.
Place the bottom halves of the BP Gland, Inner
Casing and all GBCs.
The rotor shall now be lifted with the axial
compensator(bellow) assembled and placed in
position.
Restricted entry to the area may be allowed and it
may be ensured that all personnel working on the
Turbine have emptied pockets.
Once the rotor is placed in position, the box-up
shall be completed with no interruptions at least
until the top halves of the BP Gland, Inner Casing
and all GBCs are placed.

Place the top halves of the BP Gland, Inner Casing
and all GBCs. Apply Steam Jointing Paste at the
parting plane. The usually recommended pastes
are BIRKOSIT or STAG-B
Heat tighten the Inner casing parting plane bolts.
Tighten all other parting plane bolts as mentioned
in the bolt tightening protocol. It is important to
follow the sequence of tightening as given in the
drawing.
Remove all vertical dowel pins from the BP
Gland, Inner Casing and all GBCs.
Tack weld those nuts which have not been heat
tightened.

Place the outer casing top half and tighten the parting plane
bolts.
This completes box-up.
Until this point, the entire weight of the front portion of the
casing had been transferred to the front bearing pedestal
vide jacking screws. Now, transfer the load of the casing
from the jack screws to the load bearing screw and pad
assembly in the FBP. Release the jack screw.
Recheck centering of the Turbine casing w.r.t after
transferring of load and in case of change, re-center the
casing to the original values.
Fill a sand-cement mixture into the foundation bolt sleeves,
carryout shuttering and grout the Front Bearing pedestal,
the Exhaust hood sole plate and the Rear Bearing Pedestal
with quick setting cement.
48 hrs after grouting, tighten all foundation bolts of the
Turbine FBP, EH and RBP to required values mentioned in
the drawing.
Align Generator rotor with the Turbine rotor.
A misalignment of +0.02mm radially and axially is
permissible.
Record free runouts of the Turbine and Generator rotors at
the journals and the coupling.
Couple the Turbine and Generator rotors using the 4
auxiliary coupling bolts supplied and achieve runouts, the
same or with minor variation of free runout.
Ream and Hone the coupling bolt holes and machine the
bolts so as to have a clearance of 0.02mm between the bolt
and the hole. Stretch the coupling bolts to the required
value and record coupled runout again.

While Reaming and Honning of the Turbine-Generator
coupling is in progress, Inter-connecting pipes between
valves and Turbine can be installed.
The Main Steam Inlet Insert is inserted through the outer
casing into an opening in the inner casing. The insert is
kept in position by ring nuts which are threaded on to the
outer casing.
Leakage of steam from the inner casing to the outer casing
is sealed by the U-sealing ring.
The inter-connecting pipes are supported by dampers and
supports extending from the valve block.
After welding and stress relieving of the inter-connecting
pipes is completed, the centering of the casing w.r.t the
rotor shall be checked.

TURBOGENERATOR
The Turbogenerator supplied for this project is of
Air cooled type. 5 coolers have been supplied, of
which 1 shall be spare.
The Generator Stator rests on sole plates which are
welded at site to form an assembly.
The Generator rotor rests on 2 bearings, much like
the Turbine rotor.
The air gap of the Generator is adjusted by shims
provided underneath the bearing pedestals.
The air gap is set and the bearing pedestals are
dowelled.
For alignment of the Generator rotor with the
Turbine rotor, the Turbine rotor is assumed to be
the reference rotor. The entire Turbogenerator
assembly is moved left/right and top/bottom to
achieve the desired alignment.
While carrying out the radial and axial alignment,
care shall be taken to fix the axial position of the
stator by measuring the axial clearances at various
locations.
The Generator rotor has 2 sets of fan blades, one
each on the front and rear sides. These fan suck air
and discharge them into the stator for cooling of
the windings.
The radial and axial clearances of the fan blades rings and
the end shields shall be maintained as per drawing.
After alignment of Turbine-Generator rotors, alignment of
Exciter rotor with Generator rotor shall be done.
The Exciter rotor shall be axially aligned and swing check
carried out. The swing check values for this Exciter shall
be </= 0.05mm.
After the alignment and swing check of Exciter the axial
and radial clearances of the Main Exciter and the PMG
shall be maintained as per drawing.
In this condition, the Generator and the Exciter can be
boxed-up.
The rotor, all along until now required rotation for
alignment, coupling, swing check, etc. Since rotation of the
rotor will not be required any longer, the ZERO position
of the rotor can be set and released for Turbovisory work.
The Zero position of the rotor is that position of rotor
about which, the float on either side of the thrust bearing is
equal i.e; the rotor has been set at mid float. It is this
position of the rotor w.r.t which the Differential expansion
probe and the axial shift probe are set.
While Turbovisory works are on, thermal clearances on
holding down bolts at various locations are to be made as
per drawings.
On completion of Turbovisory works in the pedestals, the
bearing pedestals can be boxed-up.
The machine is now ready for Turning Gear operation.
Set rotor lift of 0.07 to 0.10mm by adjusting jacking oil
pressure in each bearing and put the machine on Turning
Gear.
The machine is now set to receive steam.