STEAM TURBINE

500 MW

SPRING LOADED FOUNDATION

ERECTION

SPRING LOADED FOUNDATION

The spring support for TG foundation in our country is a new development though some of
the machines are already in operation with spring loaded foundation at various power stations.
Most of TG foundation built in Germany in last 20 years are spring loaded foundation. The
various machines in operation with BHEL supplied equipment and spring loaded foundations
are Dadri 4x210 MW , Trombay 1x500 MW, Dahanu 2 x 250 MW. Similarly the machines
which are going to come with spring loaded foundation with BHEL equipment are Chandrapur
1 x 500 MW , Suratgarh 2x250 MW , Unchahar 2x210 MW and Vindhyachal 2x500 MW.
The spring units for all the above TG foundations are supplied by M/s GERB which they call
the GERB vibration isolation system for TG foundation.
In BHEL , we have yet to satisfy fully ourselves about the advantages of this system after
getting the feed back from various machines under operations with spring loaded foundation
though the advantage claimed by M/S GERB are listed below:

1.0 REDUCTION IN BASE MAT SITE AND ITS COST :

The vibration to the main column are isolated by the spring element resulting to small size base
mat which reduces the construction cost and time.

Bharat Heavy Electricals Limited

Rev 00, 7-98

T1-08-0909G
Page No. 1of 9

2.0 REDUCTION IN NUMBER OF COLUMNS:

The same column of TG deck may also be used to support surrounding floors at the building ,
so that the total number of columns are reduced and the space to accommodate more
equipment is increased. This results in more rigidity of building structure of surrounding
floors and further in cost saving.

3.0 EASY HANDLING OF SETTLEMENT PROBLEMS :

Excessive settlement of column can easily be adjusted by inserting or removing shims in spring
units.

4.0 SUBSEQUENT TUNING OF THE FOUNDATION :

It is possible to tune the foundation subsequently by replacing the spring elements having
different load capacity of the springs.

5.0 EARTHQUAKE PROTECTION :

Machine will have more steadiness and stability in the event of earthquake compared to
normal foundations.

STEAM TURBINE
500 MW

SPRING LOADED FOUNDATION

ERECTION

INSTALLATION OF SPRING ELEMENT:

The spring element in 500MW machines and further higher rating machines are used with
visco dampers. The springs units are not supplied to site with required pre-tension values
through these are supplied with some amount of pre-tension. The required pre-tension of the
spring units are done at site before its installation in position. A special device for precompression of these springs units is also supplied by spring supplier.
The shuttering of RCC slab of TG deck is furnished before installation of these spring units.
The top surface of individual column where these spring units are mounted should be within
accuracy of +00 mm to -3.00 mm. If necessary these may be corrected by chipping before
installations of the spring units. The level deviation among various columns is permitted +00
mm to -5.00 mm in total including individual column variation of +00 mm to -3.00 mm.
The bottom shuttering of pedestal must be cut over the column head for lowering the spring
units. After lowering the spring unit the cover steel plates are placed in position with
shuttering supports. An air gap of about 5.00 mm to 10.00 mm is left between cover plate
and spring units for settlement of deck during casting. The visco dampers are also filled up at
site only with visco liquids supplied by spring supplier. The filling procedure of visco liquid is
explained separately by the spring supplier.
Each spring units are placed over the resistance pad to avoid movement of the spring units
during operation of the machine. Similarly the resistance pad is given on top of the steel shim
to avoid the shifting of the shim during operation of the machine. Each spring unit is provided
with 10.00 mm of steel shim for future adjustment.
The spring units are not only pre-compressed for dead load of the machine but it is further
pre-compressed to prevent the loosening of the spring during installation of the equipment due
to unforeseen additional loads. If major variation in calculation of load over the spring units
are not expected then an additional compression of 5.00 mm is sufficient for this purpose.
Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0909G
Page No. 3of 9

During installation of spring units, additional shims are provided for this 5.00 mm additional
compression and which are removed at the time of loosening of the spring elements before
final alignment of the machine. These additional shim are removed in minimum two stages
after ensuring, that all the major parts of the machine are installed and condenser have been
filled upto operating water level including CW pumps in operation for full load condition of
the machine. It is also not necessary to remove this complete 5.00 mm shims from each spring
unit and the same may vary from spring unit to spring unit depending upon the variation of
column level/elevation and variation in level of spring cover plate etc.
Releasing of TG Deck Spring for removal of additional shims.

Refer section

STEAM TURBINE
500 MW

SPRING LOADED FOUNDATION

ERECTION

RELEASING OF TG DECK SPRING

The TG deck springs are released after installation of all Turbine Generator components
including piping and the condenser has to be filled up to operating level including CW pump in
operation for full load condition. The shims provided for additional compression of the spring
units are also adjusted during this stage, the final alignment of various rotors and turbine
casing are done after release of the spring unit. The Generator hydrogen cooler & LP heater if
any inside the condenser are to be filled up in cooling water space for their operating condition
before release of TG desk spring. The insulation of various casing / pipe lines including
cladding if any are also to be installed otherwise the equivalent weight is to be incorporated
before release of desk spring. All the pipe lines connected with the Turbine and Generator
should be made available on permanent hangers and supports to avoid any additional load on
the TG deck afterwards. The TG deck should also be made free all- around to avoid any
obstruction in its movement.
Many time it is not possible to wait till completion of all the works on Turbine Generator area
as required for final alignment of all the rotors for reaming / honing of the various coupling.
In such cases without releasing of the spring units the alignment of all the rotors can be done
and reaming / honing including fitting of all final coupling bolts can be completed. The
coupling bolts need not be elongated at this stage and once all other works are ready for final
alignment of rotors ,the coupling may be opened and realigned. After realignment , the
coupling bolts are to be fitted without any further reaming / honing of the coupling holes. The
radial alignment of HP, IP and LP casing i.e. rolling test of all these casing are also to be
carried out after final alignment of rotor and with the CWP in operation etc. i.e. with similar
conditions of final alignment of rotors.
During release of TG deck springs and final alignment of rotors the condenser spring is also to
be kept in floating condition considering that condenser neck welding is already done.
Similarly the condenser spring measurement should be with in + 1.00 mm otherwise the shims
may be adjusted in condenser springs. No adjustment of TG deck springs or condenser

Bharat Heavy Electricals Limited

Rev 00, 7-98

T1-08-0909G
Page No. 5of 9

springs are permitted after final alignment of the rotors. During any subsequent adjustment of
TG deck spring the final alignment of all rotors are to be checked.
After placement of TG deck springs in locked condition with shims and resistance pad etc, an
equal air gap between 5 .00 to 10.00 mm is left between all the springs and bottom of the steel
cover plate. The exact value of air gap can be determined by the civil engineer depending
upon his experience but generally it is between 5.00 to 10.00 mm only. The form work and
support of TG deck are removed once the concrete has hardened sufficiently. This is
generally done after 28 days of casting of the deck and all load of deck is transferred over
the spring units . Afterwards TG pedestals are placed /aligned and their elevation are
maintained as per required catenary of the machine before grouting the pedestals with the
non-shrinking cements . During releasing of TG deck spring while this additional 5.00 mm
shims (for additional compression) are removed the catenary of the machine is to be achieved
within + 0.20 mm bearing No. 1&4 with the help of TG deck springs by adjusting the shims
and afterwards only the rotors alignments should be taken up. Any minor variation in catenary
left after releasing of TG deck spring may be adjusted in the spherical/cylindrical seat of the
bearings for achieving the correct alignment of the shaft.
The height of TG deck spring are taken on four corners near the springs. Here some punch
mark may be provided on all springs so that measurements are taken at the same place always.
Certain minor variations on height of the spring units are permitted , if it is required for
achieving the Catenary of the machine. The TG deck spring shims are adjusted with the help
of hydraulic jacks. Either two/four numbers hydraulic jacks are used for this purpose which
are supplied by the spring supplier. Similar methods are used for release of the spring locking
bolts also. These hydraulic jacks are group operated type and works with one pumping unit
which is electrically operated. The ready-made galvanized shims are also supplied in required
sizes alongwith spring unit in 3.00 mm and 2.00 mm thickness so an adjustment of upto 1.00
mm is possible in spring Units.
After finally release of TG deck spring and with water in condenser hotwell upto operating
level including CWP in operation then spring heights are measured on four corners for all
future reference. The sizes of the shims are also recorded for each spring. A bench mark may
also be preserved on TG floor as reference for LP rear pedestal parting plane height for all
future reference. During realignment of machine in subsequent overhauling the `catenary of
the machine are to be checked and if necessary the shims of the springs are to be adjusted to
achieve the correct catenary or at least to the old values . The catenary checking and

STEAM TURBINE
500 MW

SPRING LOADED FOUNDATION

ERECTION
alignment of rotors may be done together but all major adjustment for correction of catenary
is to be done by adjusting the shims of the spring units. Any minor adjustment for alignment
may be done on bearing if it is in permissible values and margins is available on the bearings
seals bores.

Bharat Heavy Electricals Limited

Rev 00, 7-98

T1-08-0909G
Page No. 7of 9

CONDENSER NECK WELDING IN SPRING LOADED

FOUNDATION OF 200/250/500 MW KWU
DESIGN MACHINE.

Before neck welding all the major components of the condenser are to be installed including
its tubing , water boxes, dome wall assembly and its stiffener pipe, etc. After installation of all
the major components of the condenser the spring are released i.e. condenser is floated for
welding with the Turbine.
After floating the condenser, the spring height is recorded on its four corner and further they
are pre-compressed for the value of welding shrinkages by an amount of 3.00 mm depending
upon the designer requirements. The required pre-compression of the condenser spring can be
done by filling the equivalent weight of the water in the hot well of condenser and then locking
the condenser spring at that position. The locking of springs can be avoided if water is filled
up to required level and level is maintained during neck welding of the condenser. Sometime
during floating of condenser an additional weight of water is filled up in condenser depending
upon the designers requirement.
The TG deck springs are kept in locked condition during the neck welding of the condenser.
After completing the neck welding and draining of condenser ( for equivalent value of the
pre-compression of the condenser springs) the condenser springs height are recorded and if
variation are noticed for more than +/- 1.00 mm than the necessary adjustment is to be
carried out. This can be done by adjusting the shims in the springs although if proper care is
taken during the neck welding no such variation are noticed.
Further during floating of TG deck springs the condenser spring heights are also monitored
and if necessary the shims may be adjusted on condenser springs to maintain the old values of
the condenser spring at the time of floating of condenser. During subsequent overhaul of the
unit the condenser spring height alongwith TG deck spring height need a monitoring. As a
general practice whenever the TG deck spring height are checked then the condenser springs
height are also to be checked.

STEAM TURBINE
500 MW

SPRING LOADED FOUNDATION

ERECTION
During floating of the condenser it is to be ensured that condenser is free all a round and
none of the pipe line are obstructing the movement of the condenser. All the connected pipe
lines of the condenser are to be ensured on permanent hangers before floating of the
condenser. The condenser neck welding is carried out as per the back-step method for which
the procedure is laid down in KWU manual of steam Turbine assembly sheet No 1-2-63300001/1.
During neck welding the complete height of L.P. inner and L.P. outer casing is installed in
position.

Bharat Heavy Electricals Limited

Rev 00, 7-98

T1-08-0909G
Page No. 9of 9