1. BHUSHAN POWERS AND STEELS
RENGALI,JHARSUGUDA
ORISSA
2012
ERECTION AND COMMISSIONING OF 130*1 MW STEAM
TURBINE AND GENERATOR
PREPAIRED :
SREENATH M

2. Objective
 The idea of this project to achieve the customer requirement in the
power generation field for there steel production and also for the
grid supply
 According to Siemens this is our 3rd unit of 130 MW with bhushan
powers and steel in jharsuguda, Orissa
 As per Siemens quality manual of integrated management system,
ISO 9001:2000,ISO 10005:2000 and some of the company supports
for the material and ,machine manuals and for the procedure for
specifications the company are ABB STAL,ABB Alstom , ALSTOM
power and L&T to achieve good quality in Erection and
commissioning safe working environment of turbine and generator
For that the time of operation.

3. Typical diagram of a coal-fired thermal power station
1. Cooling tower 2. Cooling water pump 3. transmission line (3-phase) 4. Step-up transformer (3-phase) 5. Electrical
generator (3-phase) 6. Low pressure steam turbine 7. Condensate pump 8. Surface condenser 9. Intermediate
pressure steam turbine 10. Steam Control valve 11. High pressure steam turbine 12. Deaerator 13. Feed water heater
14. Coal conveyor 15. Coal hopper 16. Coal pulveriser 17. Boiler steam drum 18. Bottom ash hopper 19. Super heater 20.
Forced draught (draft) fan 21. Reheated 22. Combustion air intake 23. Economiser 24. Air preheater 25. Precipitator 26.
Induced draught (draft) fan 27. Flue gas stack
Scope of work in
bhushan power
& steel 1x130MW

4. ABOUT DEAERATOR SYSTEM
 Deaerators is a device that is widely used for the removal of oxygen and other
dissolved gases from the feed water to steam-generating boilers. In particular,
dissolved oxygen in boiler feed waters will cause serious corrosion damage in steam systems
by attaching to the walls of metal piping and other metallic equipment and
forming oxides (rust). Dissolved carbon dioxide combines with water to form carbonic
acid that causes further corrosion. Most deaerators are designed to remove oxygen down to
levels of 7 ppb by weight (0.005 cm³/L) or less as well as essentially eliminating carbon
dioxide.

5. BHUSAN 130 MW
DEAERATOR SPECIFICATIONS
DEAREATOR
Equipment from : ALLIEDS ENERGY
SYSTEMS
Designed pressure : 6.12 kg/cm² (g)
Designed temperature : 260 ⁰c
Operating pressure : 3.82 kg/cm² (g)
Capacity : 420.084 TPH
Hydro tested on : 9.18 kg/cm² (g)
Vessel ID & Heigh:2410mm&2853mm
STORAGE WATER TANK
 Equipment from : ALLIEDS ENERGY
SYSTEMS
Designed pressure : 6.12 kg/cm² (g)
Designed temperature : 260 ⁰c
Operating pressure : 3.82 kg/cm² (g)
Capacity : 138.79 mᶟ
Hydro tested on : 9.18 kg/cm² (g)
Vessel ID & Heigh:3568mm&4066mm
DEAREATOR
SECTION WITH
PLATFORM
STORAGE WATER
TANK SECTION
OF DEAREATOR
WITH PLATFORM
Tray and nozzle
arrangement
inside the
deaerator
At the one end
Placed the
Teflon sheet for
the prevention
of operation
vibration and
expiation

6. • Condensate line to deaerators inlet
• Pegging steam inlet
• Overflow & drain for deaerator
• BFP suction to deaerators
• Initial heating steam
• Pump recirculation line
• HP3 normal drain
• Safety valve
• Erection of deaerator & water storage tank completed in :5/7/2012
The pipe line which are connected to deaerators
system

7. About surface Condenser
 A surface condenser is a commonly used term for a water-cooled shell and tube
heat exchanger installed on the exhaust steam from a steam turbine in thermal
power stations. These condensers are heat exchangers which convert steam from
its gaseous to its liquid state at a pressure below atmospheric pressure. Where
cooling water is in short supply, an air-cooled condenser is often used. An air-
cooled condenser is however significantly more expensive and cannot achieve as
low a steam turbine exhaust pressure as a water-cooled surface condenser.

8. SURFACE CONDENSER IN
BHUSAN 130*1 MW
NAME: TWO PASS,DIVIDED WB
RECTANGULAR CONDENSER
MANUFACTURER : LANSER & TURBO Ltd
WORKING PRESSURE : In shell/tube :-
0.0992 bar/0 bar
OPERATING TEMP : In shell/tube :-
45.66 ⁰C/33⁰C in & 42⁰C out
OPERATING FLUID : In shell/tube :-
saturated steam/cooling water
DESIGN PRESSURE : In shell/tube :-
1&F.V./5 bar
TEST PRESSURE : In shell/tube :-
water filling at site/6.5 bar
DESIGN TEMPARATURE : In shell/tube:-
100 ⁰C/100 ⁰C
CORROTION ALLOWANCE :
In shell/tube :- 1.6mm/3.2mm
STEAM CAP : 345.384 TPH
NORMAL OP WEIGHT : 261 Kg (approx)
EMPTY WEIGHT : 155 Kg (approx)
MATERIAL COUNSTRACTION :
SA516.Gr.70,SA 249.TP.304
TUBE
ARRANGEMENT
INSIDE THE
CONDENSER
WATER INLET AND
OUTLET NOZZLE
IN CONDENSER &
Guiding the
condenser to the
TG deck
After assembly of two
segment condenser &
placed on spring
support
Spring locking
system after
condenser
floating test
Hot well
level of
condenser

9. PIPE LINE WHICH ARE CONNECTED TO CONDENSER
• CONDANSATE OUTLET
• CEP MIN. RECIRCULATION LINE
• VACUUM BREAKER CONNECTION
• COOLING WATER INLET AND OUTLET LINE
• SPARE CONNECTION NOZZLES
• HOTWELL DRAIN LINE
• LP FLASH TANK DRAIN
• PRESSURE AND TEMPARATURE GAUGES
• PRESSURE TRANSMITTER CONNECTIONS
• Condenser erection and alignment fully completed on :-
24/9/2012

10. ABOUT Feed water heater
A feed water heater is a power plant component used to pre-heat water delivered to
a steam generating boiler. Preheating the feed water reduces the irreversibility's involved
in steam generation and therefore improves the thermodynamic efficiency of the system.
This reduces plant operating costs and also helps to avoid thermal shock to the boiler
metal when the feed water is introduced back into the steam cycle.
There are four processes in the Rankin cycle. These states are identified
by numbers in the Ts diagram.
Process 1-2: The working fluid is pumped from low to high pressure. As
the fluid is a liquid at this stage the pump requires little input energy.
Process 2-3: The high pressure liquid enters a boiler where it is heated at
constant pressure by an external heat source to become a dry saturated
vapour. The input energy required can be easily calculated using mollier
diagram or h-s chart or enthalpy-entropy chart also known as steam
tables.
Process 3-4: The dry saturated vapour expands through a turbine,
generating power. This decreases the temperature and pressure of the
vapour, and some condensation may occur. The output in this process
can be easily calculated using the Enthalpy-entropy chart or the steam
tables.
Process 4-1: The wet vapour then enters a condenser where it is
condensed at a constant temperature to become a saturated liquid.

11. FEED WATER HEATER IN
BHUSAN 130*1 MW
HPH 3 & 4
MANUFACTURED L & T
SHELL TUBE UNIT
DESIGN
PRESSURE
17/FV &
35/FV
200 kg/cm² (g)
DESIGN TEMP 300 & 265 230 & 265
⁰c
HYDRO
TESTED
25.5 &
52.5
3OO kg/cm² (g)
OPERATING
FLUID
STEAM FEED
WATER
OPERATING
WEIGHT
19000 &
14600
Kg
WEIGHT FULL
OF WATER
24600 &
18400
Kg
EMPTY
WEIGHT
16900 &
13300
Kg
HIGH PRESSURE
HEATER 4 IN BHUSAN
130
HIGH PRESSURE
HEATER 3 IN BHUSAN
130

12. PIPE LINE WHICH CONNECTED TO FEED WATER HEATER 3 & 4
• Extraction Bleed 3&4 pipe line to turbine
• HPH 3 normal drain to deaerator
• HPH 3&4 drain to HP flash tank
• Drain from HPH 4 to HPH 3
• HPH 4 emergency to flash tank drain line

13. LOW PRESSURE HEATER
SPECIFICATION IN BHUSAN 130
• Low pressure heater is to use steam turbine
exhaust to heat boiler feed water to reach the
required water temperature in the thermal
power plant. According to water flow, low
pressure heater is installed after condensate
export and before the deaerator. Feed water is
through low pressure heater before without
through deaerator, so feed water is with high
oxygen content and will corrosion the low
pressure heater. Therefore, heat exchange tube
is made by stainless steel tube or thick wall
carbon steel tube.
• Our high-pressure heater can be installed
according to users’ site conditions. There are
Upright Vertical, inverted vertical, horizontal,
etc.
LPH L&T SHELL TUBE UNIT
Design
pressure
3.5/fv 25 kg/cm²
(g)
Design
temp
150 150 ⁰c
Hydro
tested
5.25 37.5 kg/cm²
(g)
Operating
fluid
steam Feed
water
Weight full
of water
25200 Kg
Area: Gross
& Effective
603.50&
582.22
Empty
weight
13700 Kg
Operating
weight &
area
16800 Kg
Inside the heater
Before causing
assembly

14. PIPE LINE WHICH ARE CONNECTED TO LP HEATER
Turbine extraction to LP heater
LPH to deaerator piping for condensation
LPH emergency drain and Normal drain to LP
flash tank

15. JACKING OIL SYSTEMS
• This pump is generally used only for large turbine-generators , and then only during
the period when the shaft is rotated by the turning gear.
• At the time of turbine start up, the shaft journals are in contact with the white
metal of the bearings due to the weight of the rotor. The low pressure of the
lubricating oil supply when the set is stationary is insufficient to stop the metal to
metal contact between journals and bearing shells. In order to prevent the metal to
metal contact between journal and bearing shell during start up, which is damaging
in the long term, an oil pocket machined into the bottom shell of the journal
bearing is supplied with oil under high pressure. This lifts the shafting system
slightly and it floats on a film oil. this is called jacking oil system of turbine
JOP motor
after
alignment
Jacking Oil
system

16. FUNCTION OF JACK OIL SYSTEM IN POWER
SECTOR
 A jacking oil pump also called a lift
pump is commonly used on rotor
shafts of steam driven Turbine
Generators prior to start-up or
after shutdown to provide even
cooling of the shaft
 And eliminate rotor distortion
caused by sags due to weight and
bows due to uneven cooling.
 The jacking oil pump uses high
pressure oil supplied at the bearing
journals to initiate an oil film and
lift the shaft off its bearings.
 The rotor can then be put on a
turning gear and rotated slowly to
create even cooling and or roll out
any distortions caused by the
weight of the shaft while at rest.
 Line normalizing at:14-01-2013
Working & empty
weight
1500 & 1000 Kg
Operating pressure 250 Bars
Operating
temperature
45 ⁰c
Fluid used 150 VG 32
Flow 80 Lpm
TURNNING OIL FILTER
WEIGHT 190 & 200 Kg
Design pressure &
temp
210 bar & 90 ⁰c
FILTER rate
10 microns
ENPRO INDUSTRY PVT

17. OPERATION OF LUBE OIL SYSTEM IN STEAM TURBINE AND GENERATOR
 It Reduces friction between
rotating and fixed elements of the
turbine and generator such as occur in
the journal bearings and thrust
bearings. This reduces wear, reduces
heat and improves efficiency.
 It Removes heat from the
bearings. This heat may either be
generated by friction within the bearing
or by conduction along the shaft from
the turbines.
 In mechanical hydraulic governing
systems, it is used as a hydraulic
pressure fluid. In these governing
systems , lubricating oil is used for both
the pilot oil and power oil systems.
 Line Normalization at : 06-01-2013
Empty & working
weight
310 & 340 Kg
Fluid used 150 VG 32
Flow &Filter rate 1300 Lpm & 20 microns
Design pressure &
temperature
8 bar & 100 ⁰c
LUBE OIL COOLER
WEIGH WORKING & op
ENPRO INDUSTRY PVT
1710 & 1320 Kg
Design pressure in shell and
tube
8 & 5 Bars
Design TEMP in shell and
tube
100 ⁰c
Hydro tested on 12 bars7.5

18. Centrifugal purifier/Oil Purification System/Turbine Wash Skid
During operation, the lubricating oil becomes contaminated with a variety of
undesirable impurities like
• Water which most likely enters the system during shutdown from humidity in the air
• Fibres which come from the gasket material used to seal joints in the system.
• Sludge which results from the breakdown of the oil into longer chain molecules and
results in a thickening of the oil.
• Organic compounds which result from a slow reaction between the oil, oxygen and the.
metal piping.
• Metal fragments which come from wear products in the bearings and lube oil pumps.
• Not only these contaminants destroy the lubricating properties of the oil and
accelerate corrosion, but they can act as a grit within the bearings to cause bearing
wear and unevenness. The insoluble impurities can be removed with filters, but the
soluble impurities are only removed by centrifuging
Centrifugal
motor and
purification
system

19. CONTROLE OIL SKID/FUEL FORWARDING SKID
 The Fuel Forwarding Skid along with the Fuel Management Spool provides the
turbine with liquid fuel at the appropriate pressure and temperature. Typically
the Fuel Forwarding Skid includes dual pumps and an electric heater, and the
Fuel Management Spool includes a pressure control valve and an EPA certified
flow meter. The benefits of a combined forwarding/preheating skid are to
reduced system cost, reduced field installation cost and reduced equipment
footprint size.
FF S
International
Hydro Technology
GMBH
Max Allowable
Pressure
160 bar
Filtering 12 microns
Max Allowable
Temperature
10 to 80 ⁰c

20. FOUNDATION DETAILS FOR GENERATOR AND TURBINE IN BUSHAN 1X130MW
AREA OF
SOLEPLATE
Bolt
specification
Tighten
torque Nm
ACTUAL
ELIVATION
TE Bearing plate
at rear side
M 30X4850MM 2700 EL :- 12.290 m
TE Bearing plate
at front side
M64X3200MM 10300 EL :- 10.713 m
GE Bearing
plate level
M 36X4850MM 1800 EL :- 11.575 m

21. GENERATOR AND TURBINE SPECIFICATION
GE.MADE BY:
SIEMENS
GERMANY
FREQUENCY:
50Hz
YEAR OF
MANUFACTURE
: 2011
DIRECTION OF
ROTATION: CCW
NUMBER OF
PHASE: 3
TYPE OF
COOLING: AIR
COOLING
RANGE OF RATED
VOLTAGE:
15000 V
RATED CURRENT:
6255 A
RATED SPEED:
3000 rpm
PHASE
SEQUENCE:
U1,V1,W1
COOLING AIR
TEMPERATURE:
40⁰C
RATED POWER:
162500 KVA
RATED POWER FACTOR:
Cos =0.80
TOTAL WEIGHT:
205 T
ROTOR WEIGHT:
36 T
TE.MADE BY:
SIEMENS
SWEDEN
SST 900
(SIEMENS STEAM
TURBINE)
SPEED :
3000 TO 3600 rpm
STEAM
PARAMETER:160
bar TO 550⁰C
Synchronization
at :08-02-2013
09:55 PM,15 MW

22. CEP PUMP AND MOTOR/Vertical installed pump
MFG:-
SIEMENS
Specification:-
MOTOR
Specification:-
PUMP
VOTAGE 6.6 K v 6.6 K v
MAX
SPEED
1450 rpm 1450 rpm
POWER 300 K w 300 K w
CURRENT 33 A 33 A
In a "closed" system, water travels in a loop. Water is
heated in the boiler and made into steam. Steam flows
through a pipe to a turbine. Steam at lower pressure
exhausts into a condenser where heat is removed and
the steam becomes water. The water is removed from
the "hot well" (the point where the water collects) and
moved into a storage tank which is the supply for the
high pressure feed pump which puts the water back into
the boiler so it can go round and round. The pump which
removes the water from the hot well, called condensate
at this point, is the pump you are referring to. It is a high
volume, low pressure pump and it may have one or
more stages. It only raises the pressure enough to get
the water out of the condenser and into the system
which pipes it to the feed pump.
A steam locomotive is an "open" system as it does not
condense the steam back to water, but rather exhausts
the steam to the atmosphere, thus, no condensate pump
needed. It also means a huge waste of the energy since
the water is expelled as steam and carries a lot of energy
with it. In the closed system, it is possible to use the heat
released when the steam condenses to preheat the feed
water, recovering some of the energy the open system
loses, which raises the overall efficiency.

23. Rupture disk on condenser
• A rupture disc, also known as
a bursting disc or burst diaphragm, is
a non-reclosing pressure relief device
that, in most uses, protects
a pressure vessel, equipment or
system from over pressurization or
potentially
damaging vacuum conditions.
• if the pressure increases and the
safety valve fails to operate (or can't
relieve enough pressure fast enough),
the rupture disc will burst. Rupture
discs are very often used in
combination with safety relief valves,
isolating the valves from the process,
thereby saving on valve maintenance
and creating a leak-tight pressure
relief solution.
Rupture disc
specification
Size
: 22.00
Thickness :
0.60mm
Burst temp
and pressure
Temp :
46⁰C
Pressure :
0.70 Kg/cm²
1.Rupture disc
on the
condenser
upper side
2.Area/Flange
where the disc
to be place
3.After placing
the disc in the
flange

24. EJECTOR SYSTEM IN STEAM TURBINE
This the ejector section For
creating a vacuum pressure
in steam turbine and
exhaust condenser

25. • An Ejector, steam ejector, steam injector, educator-jet pump or thermo compressor is a
type of pump that uses the Venturing effect of a converging-diverging nozzle to convert
the pressure energy of a motive fluid to velocity energy which creates a low pressure
zone that draws in and entrains a suction fluid. After passing through the throat of the
injector, the mixed fluid expands and the velocity is reduced which results in
recompressing the mixed fluids by converting velocity energy back into pressure energy.
The motive fluid may be a liquid, steam or any other gas. The entrained suction fluid may
be a gas, a liquid, a slurry, or a dust-laden gas stream.
• The adjacent diagram depicts a typical modern ejector. It consists of a motive fluid inlet
nozzle and a converging-diverging outlet nozzle. Water, air, steam, or any other fluid at
high pressure provides the motive force at the inlet.
• The Venturing effect, a particular case of Bernoulli's principle, applies to the operation of
this device. Fluid under high pressure is converted into a high-velocity jet at the throat of
the convergent-divergent nozzle which creates a low pressure at that point. The low
pressure draws the suction fluid into the convergent-divergent nozzle where it mixes with
the motive fluid.
• In essence, the pressure energy of the inlet motive fluid is converted to kinetic energy in
the form of velocity head at the throat of the convergent-divergent nozzle. As the mixed
fluid then expands in the divergent diffuser, the kinetic energy is converted back to
pressure energy at the diffuser outlet in accordance with Bernoulli's principle. Steam
locomotives use injectors to pump water into the steam-producing boiler and some of
the steam is used as the injector's motive fluid. Such "steam injectors" take advantage of
the latent heat released by the resulting condensation of the motive steam.

26. Alignment and setups
1.Dial gauge(Distance amplifying instrument)
Dial indicators are available in many physical sizes and ranges. For most alignment applications the
smaller sized indicators should be used to reduce indicator bar sag. Dial indicators should be chosen
that have a range of 0.100 inch and accurate to 0.001 inch. Indicator readings, and many other types
of readings, are expressed in several units. A reading of 1/1000" is equivalent to 0.001 inch and is
commonly expressed as 1 mil.
A common convention used when reading dial indicators is that when the indicator plunger is moved
toward the indicator face the display shows a positive (+) movement of the dial needle by sweeping
the needle clockwise. As the plunger is stroked away from the face a negative (-) reading is displayed
by sweeping the needle counterclockwise. Negative movements of the dial needle may be confusing if
the indicator is not observed carefully throughout the rotation cycle of the machine shafts.

27. 2.Shaft alignment
1. Shaft alignment is the process to align two or more shafts with each other to within
a tolerated margin. It is an absolute requirement for machinery.
2. When a driver like an electric motor or a turbine is coupled to a pump, a generator,
or any other piece of equipment, it is essential that the shafts of the two pieces are
aligned. Any misalignment between the two increases the stress on the shafts and
will almost certainly result in excessive wear and premature breakdown of the
equipment fore the machinery is put in service. This can be very costly. When the
equipment is down, production might be down. Also bearings or mechanical seals
may be damaged and need to be replaced. A proper shaft alignment or the use
of disc couplings can prevent this.
3. Tools used to achieve alignment may be mechanical or optical, like the Laser shaft
alignment method, or they are gyroscope based. The gyroscope based systems can
be operated very time efficient and can also be even used if the shafts have a large
distance.
4. There are two types of misalignment: parallel and angular misalignment. With
parallel misalignment, the centred lines of both shafts are parallel but they are
offset. With angular misalignment, the shafts are at an angle to each other.

28. 3.Misalignment details
The parallel misalignment can be further divided up in horizontal and
vertical misalignment
 Horizontal misalignment is misalignment of the shafts in the horizontal plane and vertical
misalignment is misalignment of the shafts in the vertical plane
 Parallel horizontal misalignment is where the motor shaft is moved horizontally away from the
pump shaft, but both shafts are still in the same horizontal plane and parallel.
 Parallel vertical misalignment is where the motor shaft is moved vertically away from the
pump shaft, but both shafts are still in the same vertical plane and parallel.
Similar, angular misalignment can be divided up in horizontal and vertical
misalignment:
 Angular horizontal misalignment is where the motor shaft is under an angle with the pump
shaft but both shafts are still in the same horizontal plane.
 Angular vertical misalignment is where the motor shaft is under an angle with the pump shaft
but both shafts are still in the same vertical plane.
 Errors of alignment can be caused by parallel misalignment, angular misalignment or a
combination of the two.

29. SOME OF THE PHOTOS WE USED TO CHECK THE ALIGNMENT IN
130X1 MW BHUSAN STEEL
For the alignment of the
turbine and generator
following system are we
used in the site,
1
2
3
4 5
6
7

30. BLOWING DEVICE ASSEMBLY
Steam blowing of MS lines, CRH,HRH,SH,RH,HP & LP bypass pipe lines of turbine
is carried out in order to remove welding slag, loose foreign materials, iron
pieces, rust etc. from the system, generated during manufacturing,
transportation & erection which causes the operation defect of serious damage
on turbine & other steam systems.
1) Thermal shock
2) Removal force of steam
3) Cleaning force of steam
Blowing Device fixing completed on :19-Oct-2012
1
2 3

31. 4
5
6
7
8
9

32. 10
11
12
13
14

33. 1. First blowing device is fixed to the right of the turbine in
SST900 which is guide main steam inlet.
2. These is to show that the main steam inlet nozzle this lead the
steam strike to the turbine blades.
3. The space washer seat hole, Which help to stopping the west
steam getting inside while blowing undergoes.
4. Space washer seat with steel rod and gasket to help fixing in
side the lead and also help damage cause on the nozzle after
blowing due to the thermal expansion and contraction.
5. Space washer are inserted inside the ESV seat and removed
the guide rode .
6. Next is to fixing of lifting tool to the cover and this help to fix
the arrangement in to the seat .
7. To the cover place the bimetal ring and graphite ring before lift
Placing.

34. 8. The cover arrangement taken into the ESV seat after space
washer assembly fixed.
9. After the cover assembly insert split ring into the groove for
fixing the cover by using grub screw and tighten to 170NM
torque and maintain the spilt ring gap equally inside the ESV
seat.
10. After the assembly of cover place horizontally the sleeve fix
with the hexagon socket screw.
11. Notice that before fixing the sleeve to cover place steel gasket to
the two ends .
13. Lead the assembly inside the ESV seat and tight it.
14. At last fix the copper gasket and plug in the device.

35. ESV ASSEMBLY(Emergency System Vent) PROCEDURE AT
SITE
• The ESV (Emergency System Vent) valves are normally closed letting the
process continue normally and prevent-ing the expensive media from
flowing to flare and burn-ing to waste. In an emergency situation, when
part of the process or the whole process goes down or does not continue
to work normally, the production is sent to flare via ESV valves and
burned to avoid dangerous materials harming people working at the
plant. ESV valves are typi-cally furnished with fail-to-open automatic
actuators.
• After completing the Blowing process on 15-jan-2012 we start the
assembly of ESV on 28-jan-2012.

36. 1
2
3
4
5
7
6 9
8

37. 10
11
12
13
14
15
16
17
18

38. 19
20
21
22
23

39. ESV ASSEMBLY PROCEDURE AT SITE
• After the dismantling the whole blowing tools from ESV seat the area fully
and start preparation of ESV400 assembly.
• After the assembly of lifting tool in valve seat(Material: STAL 23 37 02)
carry the whole arrangement into the ESV.
• Carry the valve seat and place parallel to the ESV mouth and allow the
seat valve right parallel inside the seat and check the parallelise by using
master level.
• And maintain the equal gap in between seat and the nozzle, masher the
gap by using filler gauge.
• Cleaning the steam strainer and preparation for the assembly of lifting
equipment .
• Place the assembly parallel to the valve seat and move inside and make
parallel by using parallel pin check the gap using filler gauge.
• Assembly the Gland; Ring gasket, Support ring carefully before the
assembly of split ring to fix the steam strainer in to the hole.

40. • After the assembly of (4 no's)split ring maintain the gap between the rings
equal and lock allow Lock ring; Locking ring to fixing the split ring. After the
assembly of lock ring tighten the hexagonal socket head screw in 80 NM which
is the required torque.
• Stand; Support ESV will assembled with the steam strainer and bolt to the
required torque of 200 NM and tighten the Stand with turbine ESV section at
194 NM torque
• After the tighten the bolt assemble the gland plate tight with Spring unit; Live
load Assembly. Maintain the gap of 1mm in between gland plate and the spring
unit and torque tighten at 45 NM .
• Servo motor; ESV Servo Motor assemble after the link up with stand stud to
strainer stud,and tight the servo motor with stand at the torque of 100 NM
• Connect all COP pipe line to the seromotor solinoidal valves .And operate
throught DCS.

41. TURNING GEAR & QUILL SHAFT ASSEMBLY
• A Jacking gear (also known as a Turning gear) is a device placed on the
main engine shaft of a marine vessel. Its main purpose is to rotate the
shaft and associated machinery.
• The jacking gear motor is designed to rotate the shaft at approximately
1/10rpm. Most jacking gear motors are rated at 5hp. The jacking gear
motor assembly applies power and torque to the reduction gear by a
flexible coupling or clutch that can freely engage and disengage to the
high-pressure pinion (driving gear). Engaging is accomplished by means of
a simple lever. Some newer propulsion arrangements utilize an automatic
control system located in the engine room. Jacking gears often feature a
lock to prevent the shaft from turning during current or tide changes or
when being towed.
• A quill shaft, by definition, is a solid shaft which is strategically designed
and carefully machined so that it carries the same torque that a larger
shaft would handle by operating at higher stress levels. In carrying torque
the quill shaft acts like a torsion spring, twisting along its length.

42. TURNING GEAR & QUILL SHAFT ASSEMBLY
PROCEDURE AT SITE
1
2 3
4
5
6
7
8

43. 9
10
11
12
13
14
15
16
17
18

44. TURNING GEAR & QUILL SHAFT ASSEMBLY PROCEDURE AT SITE
1. Before starting the assembly of Quill shaft to clean all the matching
flange, screw holes and etc using oil or some kind of rust preventer and
clean the tactile which is applied from the factories.
2. After the cleaning of All assembly parts. Assembly the bottom cover of
Quill shaft on the front side of the turbine, Which removed while
alignment process undergone.
3. At the same time remove the side plate from the bottom cover which is
used for the fixing of the side glass.
4. Completely tighten the bottom cover and check the gape in between the
matching face using filler gauge.
5. After the completion of above step, start the assembly of Quill shaft, lift
shaft using Crain and place the shaft in between the T and G rotor front.
6. Match the Face and coupled with two end using Cylindrical pin for
maintain the magnetic center.
7. Use the M20x100 screw for pull the rotor and tighten and match the face
of coupling. And torque tighten this at 333NM

45. 9. Lock the pin with shaft by using Set screw of 8x20 mm.
10. After the completion of Quill shaft assembly remove the turning gear
temporary covering plate used for transport.
11. Carry the turning gear using hand and place inside that hole, note that at the
time of assembly the gear system is at the disengage mode .
12 Tighten the screw with required torque.
13 After that according to the nozzles pipe line to fix with the solenoid, Check
weather it get engage or disengage properly with the teeth

46. CONTROL VALVE ASSEMBLY PROCEDURE AT SITE
1 2
3
4 5
6
7

47. 8
9 10 11
12 13 14
15 16 17 18 19 20

48. Final DCS Reading After Commissioning in the
steam system

49. Final DCS Reading After Commissioning of the
Turbine and Generator end

50. Final DCS Reading After Commissioning Of Control oil
system

51. Final DCS Reading After Commissioning Of Lube
oil system

52. Final DCS Reading After Commissioning Of Gland
Steam System

53. THANKS YOU
And Thanks to all our team member and for there hard work for the
successful completion in Erection and commission of steam turbine at
Bhushan steels and power( 130x1 MW )