汽轮机安装及维护说明书d660f 000105asm Cn EManual de instalacion de turbina a vapor DONFANG

MANUFACTURER
DONGFANG TURBINE CO.,LTD.

DOCUMENT
(WBA)D660F-000105ASM
DOCUMENT TITLE :
NO.:
REV.: A
INSTALLATION INSTRUCTION OF N660-16.7/538/538 TURBINE
PROPER
Date
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(WBA)D660F-000105ASM
DESIGN
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Document No.: (WBA)D660F-000105ASM
Document Title: Installation Instruction of

N660-16.7/538/538 Turbine Proper
Revision Record
Rev No.
Date
Description on Revision
2011.5
May,2011
The first issue

Contents

No.
Chapter
II
III
Page
Remarks
Description
Overview
Site Turbine Installation Flow Chart
Installation Procedure
14
III-1
III-2
III-3
Installation of Foundation Bolt and Bed 15

Frame
Installation of Low Pressure Cylinder
Installation of Bearing Housing
20
26
III-4
III-5
III-6
10
III-7
11
III-8
12
III-9
Installation of High and Medium Cylinder 32

Parts
Cylinder Alignment (Top-On Alignment)
Cylinder Alignment (Half Empty Cylinder)
Rotor Alignment
Diaphragm Alignment
iaphragm Alignment Adjustment
36
41
45
52
55

No.
Chapter
13
III-10
14
III-11
15
III-12
16
III-13
17
III-14
18
III-15
19
III-16
20
III-17
21
III-18
22
III-19
23
III-20
24
III-21
25
III-22
Description
Flow Passage Clearance Check
Pouring
Final Assembling
(HIP/ALP/BLP)
Final Alignment (HIP/ALP/BLP)
BLP-GEN
BLP-GEN Final Alignment
BLP/GEN
BLP/GEN Coupling Reaming and Honing
Tightening of ALL Coupling Bolts
Installation of Accessories
Preparation Work for Oil Flushing
First Oil Flushing
Second Oil Flushing
Bearing Resetting
Final (Third) Oil Flushing
Page
Remarks
57
64
67
74
80
83
88
91
97
102
108
112
116
26
III-23
Steam Pipe Blowing
118

No.
Chapter
27
28
29
30
31
III-24
1
Appendix 1
2
Appendix 2
3
Appendix 3
4
Appendix 4
Description
Page
Remarks
122
Resetting after Steam Blowing

T-G
T-G Foundation Embedded Parts Installation 129

Manual
T-G
T-G Foundation
Manual
Template
Installation 153
Regulations of Gas Shielded Welding for 156

Connecting Lower Half of Lower Pressure
Cylinder to Condenser
Combined Reheat
Regulations
Valve
Connection 163

I
1
I. Overview
1. Scope of application
D660F This instruction manual is only applicable to
the installation and maintenance work of

D660F turbine.
This instruction manual only provides the

installation items and requirements of the
turbine proper and its related parts and
components and does not provide specific
description of the conventional procedures in
the installation (e.g. cleaning, cutting,
fastening blot, lock washer etc).
This instruction manual is a general purpose
instructive technical document and is not for

a particular project or tool.
Before installation, the installation personnel
shall carefully read and get familiar with the

content of this instruction manual.
2
2. Direction for use of this instruction

manual
This instruction manual

following two aspects:
(1) Turbine installation flow chart
contains
the
This part provides the turbine installation

work process to be performed on site. It is
recommended that this flow chart be used as

the instruction for the turbine installation
schedule on site.
(2) Description
procedure on site
of
turbine
installation
This instruction manual provides the site

turbine installation sequence and its relation
as well as necessary precautions in the
installation and the site turbine installation
shall be carried out according to this
instruction manual.
This instruction manual lists in detail all steps
and descriptions of turbine installation on

Page 1 of 176

site.
This instruction manual also provides some
site turbine installation data and related
instructive description for site installation.

3
3. Requirements for inspection tools
All measuring tools mentioned in this
instruction manual and to be used in site

turbine installation shall be confirmed and
calibrated.
4
4. Basic requirement for record
(1) The site turbine installation record shall
be filled in according to the requirements of

this instruction manual.
(2) Content of installation record shall meet
the requirements of the certificate.

(3) Installation record data shall be in the

allowable range of this instruction manual
(conventional requirements for site turbine
installation) conform to the requirements of
the Manual of Turbine for Site Engineer
(Dongfang Turbine Works Standard).
(4) The over-limit dimension must be

rechecked and specially noted in the record
and submitted to the Dongfang Turbine
Works Quality Assurance Department for
confirmation.
(5) All dimension records must be approved
by the inspector (quality inspector or

Dongfang Turbine Works supervision
engineer) for approval.
5 5. Conventional requirements for turbine
installation inspection on site
(1) Site welding is prohibited
Unless otherwise required in the drawings or

this manual, site welding (including spot
welding) of turbine parts and components is

strictly forbidden.
(2) Storage of loose parts

Page 2 of 176

As loose parts have been removed of the

manufacturers antirust protection during
turbine installation on site, the loose parts in
this case must undergo temporarily
rust-proofing treatment and be stored indoors.
(3) Remove parts antirust protection
The antirust protection prior to delivery by

the manufacturer is divided into temporary
antirust protection and permanent antirust

protection, and the manufacturers temporary
antirust protection should be removed when
the turbine is installed on site.
(4) Requirement for package removal
It is not allowed to disassemble the parts (e.g.

rotor) already calked and locked in the
manufacturers factory as well as those

adjusted independent parts (e.g. governor,
protection equipment etc.)
(5) Protection in turbine installation on site
When the turbine is installed on site, the

installed parts should be covered with fire
plate for protection in the non-working hours
to avoid dust contamination and foreign
matter drop-in. At the same time, rubber plate
(or other similar materials) should be inserted
into the horizontal joint to avoid serious
scratch (excessive scratch will cause the unit
to leak in operation).
(6) Rust preventive measures for turbine

installation on site
Since the manufacturers antirust protection

for all parts has been removed when the
turbine is installed on site and some parts
(e.g. high and medium outer casing and low
pressure outer casing upper half) are not used
before completion of final unit installation,
these parts should undergo temporary antirust
treatment on site.
(7) Precautions for site turbine installation
Page 3 of 176

and lifting
All parts are provided with lifting lugs or

screws and all sizes of lifting screw holes are
provided with corresponding sizes of lifting
screws. When lifting the parts, it is necessary
to choose matching lifting screws and
completely screw in the lifting screws.
When the lifting screw can not be completely
threaded into the screw hole, the lifting screw

hole should be re-tapped.
The lifting screws, after tightened, should not
be knocked, or deformation will be caused.
Lifting of some parts (e.g. rotor) need special

tooling.
Before lifting, all parts should be adjusted for
center of gravity and always kept balance

during lifting.
Page 4 of 176

Example of installation instruction manual

No.
1
Working content
Record Reference drawing
Remarks
1. Preparation for low pressure

cylinder installation:
Bed frame
Need check
Ensure the height between the

top surface of bed frame and
condenser. Check the condenser
throat flange planeness and
elevation from the flange
surface to the top surface of the
bed frame.
2
Condenser throat
Low pressure cylinder steam exhaust port

Weld clearance
Condenser throat flange
2. Contact check between the

lower half of the low pressure
cylinder and the bed frame:
After the lower half of the low

pressure cylinder is installed,
check its contact with the bed
frame and ensure their even
contact.
Also check
Page 5 of 176

II
AB
M/SH/R
Page 6 of 176

II. Site Turbine Installation Flow Chart

Installation of embedded
parts
Template check
Placement of operating
floor concrete
Correction of reference
point levelness
Turbine foundation dimension record

Record of burial pipe position in the embedded
parts and perpendicularity
Record of bed frame concrete pillar gasket and
Adjustment of bed frame its contact with bed frame
Record of bed frame levelness, contact and
clearance
Record of bed frame levelness, contact and

clearance
Installation of low pressure Check record of vertical joint face clearance of
low pressure cylinder
casing
Install outer casing and inner casing of low
pressure cylinders A and B
Install steam piping
Installation of bearing
housing
Bearing pedestal alignment record

Record of bearing assembling and contact
between bearing spherical surface and bearing
pedestal
Dye penetrant inspection record of low level oil
pipe weld
Bearing span record
Low level oil pipe clearance record
Positioning of high and medium outer casings

Positioning of high and medium inner casings
Installation of high and
Pre-alignment
medium cylinders
Parallelism check record
High pressure main steam regulating valve
installation record
Combined reheat valve installation record
Install the upper half casing (inner casing and

outer casing)
Casing alignment
Tighten the horizontal joint bolt
Casing alignment record (top on alignment)
M/S, H/R pipe welding
Pre-adjustment of backing plate under the upper
Disassembling of upper
casing lug
half casing
Lug sag check record
Condenser throat welding record
High pressure cylinder installation record
Date list
Page 7 of 176

//
No.1
A No.2
B No.3
Page 8 of 176

Cylinder alignment
Rotor alignment
Diaphragm alignment
check
Cylinder alignment record (top off alignment)

Adjust the adjusting block under the lower casing
lug
General levelness and clearance record of
horizontal joint
Clearance record of inner casing horizontal joint
after complete tightening
Lube oil hole and oil drain hole dimension check
Bearing bush contact record

Journal and bush installation record
Journal and bush contact record
High and medium pressure rotor and low
pressure rotor deflection record
Stub shaft deflection record
Rotor alignment record
Journal levelness record
Temporary center alignment of high pressure/low
pressure and low pressure/generator rotor
coupling
Diaphragm bottom key clearance and adjusting

amount record
Diaphragm alignment record
Diaphragm suspension pin and axial locating pin
clearance record
Diaphragm center
adjustment
Diaphragm center adjustment

Adjusted diaphragm center record
Impeller clearance
High and medium pressure rotor clearance record

(No.1)
A low pressure rotor clearance record (No.2)
B low pressure rotor clearance record (No.3)
Steam seal body clearance record
Steam seal ring clearance record
Main oil pump alignment record
Coupling hood clearance record
Sensor installation record
Thrust bearing installation record
Thrust bearing pad dimension and contact record
Grouting
Final grouting
Page 9 of 176

/AB
B /
A B
/AB B
/
Page 10 of 176

Final installation
Cylinder high temperature bolt and main steam

inlet flange bolt tightening record
Atmospheric valve installation record
Data list
Oil retainer installation record
Coupling runout record

High pressure/A, B low Rotor alignment record
pressure final alignment Coupling installation record (between high and
medium pressure and low pressure rotor A)
Coupling installation record (low pressure rotor
A and low pressure rotor B)
Concentricity record of rotor connecting
B low pressure/generator coupling
Journal uplift record
final alignment
Key installation record
Reference levelness check

Coupling installation record (recorded if needed)
Turbine/generator coupling Coupling bolt processing
reaming
Fitting bolt adjustment
Fitting bolt balancing
High pressure/A, B low

Coupling runout check
pressure and B low
Rotor alignment record
pressure/generator coupling
Coupling installation record
connecting
Coupling hood clearance record

Installation of auxiliary
Sensor installation record
equipment
Thermocouple pre-installation
Installation of insulation
layer
Disassemble bearing
Preparation for oil flushing Configure all equipment bypasses
Install cooling pipe
Initial oil flushing
Perform oil flushing

Clean the main oil tank
Page 11 of 176

Page 12 of 176

Second oil flushing

Second oil flushing
Flushing record and judgment
Remove temporary pipe

Bearing resetting
Record oil system orifice dimension
Fill operating oil

Final oil flushing
Sufficient oil circulation

Preparation for final oil flushing
Final oil flushing
Preparation work
Steam pipe blowing Blow wash main steam pipe and steam
manifold
Criteria for steam blow out
Main valve bolt tightening record

Reinstallation after
steam pipe blowing
Main steam pipe restoration
Reference levelness
check
Vacuum lifting test
Page 13 of 176

III
III Installation Procedure
Page 14 of 176

III-1
III-1 Installation of Foundation Bolt

and Bed Frame
After the primary grouting is finished, install

the foundation bolt and bed frame. Before
installing the foundation bolt and bed frame,
it is necessary to confirm that that the central
axis and elevation of the turbine generator
unit and the condenser center position are
correct.
When the bed frame is installed, it should be

supported by concrete pillar. In this case, it
should be ensured that bed frame and
concrete pillar are closely joined and the
concrete pillar and the operating floor
primary grouting layer are firmly combined.
Then install the bed frame and low pressure
outer casing and gradually extend to the
generator side and the front bearing housing
side. At the same time, install, adjust and
pre-tighten the foundation bolts.
No.
1
Work content
Record
Reference drawing
Remarks
1. Confirm turbine
condenser centerline
generator
unit,
Determine the center and elevation of the

turbine generator unit and condenser with
reference to the reference line of the
power building and clearly mark them for
easy alignment.
2
2. Check foundation bolt sleeve and

embedded parts
Page 15 of 176

No.
Work content
Record
Reference drawing
Remarks
Before roughening the foundation surface

prior to secondary grouting, check the
position and quantity of all foundation
bolts and embedded parts against the
drawings.
3
Foundation
bolt sleeve
Roughening
surface
Cut off sleeve
depth
20mm
head
3. Foundation surface roughening prior

secondary grouting
Bed frame mounting position needs to

roughen the foundation surface.
Operating floor
platform
Surface roughening work should be done

according to the dimensions shown in the
drawings and it should be ensured that
foundation reinforcement is not exposed.
After surface roughening work is

finished, cut off the foundation bolt
sleeve head along the roughened surface.
Page 16 of 176

No.
4
Work content
Record
Reference drawing
Remarks
4. Bed frame positioning
Pull the music wire to mark the

central axis of the turbine
generator unit based on which to
determine the position of the bed
frame.
5
Adjusting screw
Steel plate
Foundation bolt
5. Adjust bed frame levelness
Use the adjusting screw provided

on the bed frame to adjust the
bed frame levelness and then use
the foundation bolt to fix the bed
frame.
6
Overflow
outlet
Bed
frame
Placement Placement
port template
Toughened
surface
6. Place concrete pillar
Overflow
chute
MF870C
(The material for the bed frame pillar of
the turbine generator unit is MF870C)
According to the distance

between bed frame and concrete
pillar, use wood or plastic
template to make the shape of the
concrete pillar and then place the
concrete pillar according to the
Page 17 of 176

No.
Work content
Record
Reference drawing
Remarks
service performance of cement

materials. (Note: trial placemetn
should be made before formal
placement and the requirements
of the Installation Specification
for Foundation Bed Box of
Turbine and its Auxiliary
Equipment should be met.
7
7. Correct concrete pillar for bed

frame
After cement pillar is completely

cured, remove the bed frame and
grouting template and confirm that
concrete pillar is already closed
combined with the operating floor
roughened surface. Also check the
contact between bed frame bottom
surface and concrete pillar and if
necessary, trim the concrete pillar
surface so that the bed frame and
concrete pillar are well contacted.
Page 18 of 176

No.
Work content
Record
Reference drawing
Remarks
8
8. Prepared to install the low
pressure outer casing
Remove the jacking screw at the

bottom of the bed frame and
re-mount
the
dowel
pin
according to the bed frame dowel
pin erecting drawing and then fix
the grouting baffle.
Check the distance from the top

surface of the bed frame to the
condenser throat and the
levelness and elevation of the top
surface of the condenser throat
flange.
Weld the foundation bolts and

nuts exposed from the bottom
surface of the operating floor as
shown and mount the lifting
screws to tht top end of the
foundation bolts.
9
9. Record bed frame levelness
Foundation
bolt
Bed frame
gasket
Grouting
baffle
bolt
operating
floor
spot weld
Tack welding
Condenser
throat
Record the accurate levelness of

all bed frames of the turbine
generator unit.
Page 19 of 176

III-2
III-2 Installation of Low Pressure

Cylinder
The instillation of the low pressure cylinder is

closely related to the installation of the
condenser. Before the low pressure outer casing
is installed, the condenser upper part, shell and
low pressure heater must be positioned, because
once the low pressure outer casing is installed,
these parts can not be installed. Therefore, the
low pressure cylinder must be erected after these
parts are installed.
It should be vary careful when erecting the low

pressure cylinder, because the position of the
low pressure cylinder is the basis of turbine
generator unit alignment and once it is
determined, the centerline of the whole turbine
generator unit is determined accordingly.
As the low pressure outer casing

splice-welded from steel plate and tends
deform very easily, residual stress should

avoided on the low pressure outer casing
general assembling.
is
to
be
in
It is noteworthy that when the upper half of the

low pressure outer casing is installed and the
upper half is placed on, it is necessary to make

the low pressure cylinder center consistent with
the foundation center.
The lifting work subsequent to low pressure
cylinder position should be extremely careful
and it should be lifted according to the

equipment lifting standard. Be very careful not
to damage the part of connection to the high
pressure cylinder.
In normal cases, the unit front, back, right and
left are defined by a person standing at the
machine head and facing the machine end.
Page 20 of 176

No.
Work content
Record
Reference drawing
Remarks
1 AB
1. Check the contact between A

and B low pressure outer casing
bed plates
The low pressure outer casings,

after cleaned, are erected in
turn along the turbine side.
After installation, check the
contact and clearance between
casing bed plate and bed frame
and confirm that the casing bed
plate and bed frame are
contacted evenly.
2
Low pressure outer casing
Horizontal joint
Lower half of turbine side low

Lower half of motor side low

2. Preparation work for

installation of low pressure
outer casing
Prepare the key, fix the

connecting pieces connected to
the condenser and check the oil
line.
3
AB
3. Erect lower halves of low

pressure outer casings A and B
Page 21 of 176

No.
4
Work content
Record
Reference drawing
Remarks
4. Check the vertical joint face in

unbolted condition
Use the feeler gage to check the

clearance of low pressure outer
casing vertical joint faces in
unbolted condition
5
5. Apply linseed oil to the

vertical joint faces
6
shims
Foundation bolt
6. Tighten the vertical joint face

bolts
After the horizontal joint is

leveled, tighten the vertical joint
face bolts and then check the
clearance between casing bed
plate and bed frame. By adjusting
the shims between bed frame and
concrete pillar, eliminate the
clearance between bed frame and
casing bed plate.
7
L shim
clearance
7. Erect the upper half of the low

Gasket
bolt
Page 22 of 176

No.
Work content
Record
Reference drawing
Remarks
Place the upper half of the low

pressure outer casing on the
lower half of the low pressure
outer casing.
8
8. Check the vertical joint faces

of the low pressure outer casing
upper half
Tighten the horizontal joint bolts

and, in unbolted condition, use
feeler gage to check the
clearance of the vertical joint
faces of the low pressure outer
casing upper half.
9
9. Back off the horizontal joint

bolts
10
10. Check the vertical joint face

11
11. Apply linseed oil to the

vertical joint face
12
12. Tighten the vertical joint face

bolts of the low pressure outer
casing upper half
Page 23 of 176

No.
Work content
Record
Reference drawing
Remarks
The vertical joint face bolts of

the low pressure outer casing
upper half are finally tightened,
the
deformation
prevention
bracing of the outer casing upper
half is cut off and the horizontal
joint bolts are temporarily
tightened.
13
13. Back off horizontal joint

bolts
14
14. Check the horizontal joint
clearance
Back the horizontal joint bolts

and check joint clearance. At this
moment, the joint clearance
should be the same as delivery
state.
15
15. Disassemble the upper half of
the low pressure outer casing
16
16. Install the low pressure inner

casing and its locating key
17
17. Music wire alignment
Page 24 of 176

Contact check
Clearance check
Clearance check (vertical joint face)
Clearance check (horizontal joint face)
Foundation
Low pressure exhaust port
Condenser flange
Welding clearance
Contact check
Clearance check
Motor side
Turbine side
Unbolted check
Foundation
Page 25 of 176

III-3
III-3 Installation of Bearing Housing
After the low pressure cylinder is positioned

(top on) and music wire alignment is
finished, start to install the intermediate
bearing housing and then install the front
bearing housing (For the installation method
of the intermediate bearing housing, refer to
the installation method of the front bearing
housing).
Adjust the contact and clearance between the

sliding pin system sliding block and sliding
block groove according to the installation
requirement and ensure that the front bearing
housing can slide freely with the expansion of
the high and medium cylinders after the high
and medium pressure cylinders are connected
to the front bearing housing.
No.
Work content
Record
Reference drawing
Remarks
1. Install the seal parts of the

front bearing housing oil pipe
Install the front bearing housing

oil discharge pipe according to
the drawing and install the
flange and seal ring together on
the bed frame.
2
2. Preparation work procedure

for installation of front bearing
housing is as follows:
Page 26 of 176

No.
Work content
Record
Reference drawing
Remarks
Reinstall the sliding bock and

key, tighten the foundation bolt
and hold down the bed frame.
Remove the front bearing
housing cover and install the
adjusting part in the front
bearing housing to the original
position.
3
3. Front bearing housing contact

check
Put the front bearing housing on

the bed frame and check the
contact of the front bearing
housing sliding block and the
horizontal joint levelness.
4
Shim
4. Adjust the bed frame height
With the low pressure cylinder

centerline (top on) as reference,
add or remove shims between
bed frame and concrete pillar to
adjust the front bearing housing
elevation.
5
Page 27 of 176

No.
Work content
Record
Reference drawing
Remarks
5. Adjust the front bearing

housing
Axially position the front

bearing housing along the
determined centerline. Adjust
the front bearing housing
position based on the center
determined with the low
pressure parts according to the
drawing.
6
6. Install the front bearing

housing
Confirm the clearance around

the front bearing housing oil
pipe and the clearance between
the key and keyway to prevent
interference due to front and
back and right and left
movement of the front bearing
housing. Then install the front
bearing housing hold-down
plate.
7
7. Check the adjusting parts in

the front bearing housing
Page 28 of 176

No.
Work content
Record
Reference drawing
Remarks
As the front bearing housing

cover is not put on until the
general assembling is finished, it
is necessary to carefully check
and protect the adjusting parts in
the front bearing housing and
the pipe openings in the housing
should be sealed.
8
8. Install the oil piping in the

bearing housing
Fix the pipe when welding and

painting the pipes.
9
9. Fix the front bearing housing
Before installing the high and

medium pressure outer casings,
use the temporary supporting
bolts on the two sides of the bed
frame to firmly fix the front
bearing housing to prevent its
shift when the high and medium
pressure outer casings are
installed.
10
10. Adjust the front bearing

housing hold-down plate gasket
Page 29 of 176

No.
Work content
Record
Reference drawing
Remarks
Adjust the gaskets under the

front
bearing
housing
hold-down plate to ensure that
the front bearing housing can
freely move axially and is not
inclined.
Page 30 of 176

#3 bearing center
#1 bearing center
Front bearing
housing
#2 bearing center
Music wire
Front
(turbine side)
Span
Bed frame
Seal ring
Main oil pump

inlet oil pipe
Bolt
Hold down plate

Fixing bolt
Plate
Temporary supporting bolt

Gasket
Center key
Gasket
Bed frame
Support
column
Supporting pillar
Page 31 of 176

III-4
No.
1
III-4 Installation of High and

Medium Cylinder Parts
Work content
Record
Reference drawing
Remarks
1. Turnover of the lower half of

high and medium outer casings
After cleaning the high and

medium outer casing lower half
lugs, turn over the lower half of
the high and medium outer
casings.
2
2. Installation preparation of high

and medium pressure outer
casing lower halves
1
1) Prepare the supporting key

and longitudinal key and used for
the lower half of high and
medium outer casings and the
connecting bolts between the
casings and bearing housings.
2
2) Prepare the casing lifting
tools.
3
3. Install the lower halves of high

and medium pressure outer
casings
4
Page 32 of 176

No.
Work content
Record
Reference drawing
Remarks
4. Install the high pressure inner

casing, medium pressure inner
casing and steam seal body
Install the steam seal body and

high and medium pressure inner
casings.
Measure the high and medium

cylinder joint levelness.
5
5. Alignment after temporary

supporting of high and medium
pressure cylinder lower halves
1 6
Align and position each of #1~#6

bearings with music wire and
check each bearing twice.
6
6. Install high and medium

pressure inner casings
Tighten high, medium pressure

inner casings and steam seal
body connecting bolts and then
check the horizontal joint to
ensure that no clearance exists at
the joint.
Page 33 of 176

No.
Work
content
Record
Reference
drawing
7. Install the high and medium

outer casing upper halves
Insert the high and medium

pressure outer casing joint bolts
and check the clearance of the
horizontal joint in free state.
Tighten every other joint bolt and
check the horizontal joint
clearance.
8
8. Preliminary cylinder alignment
With the low pressure cylinder as

the reference, align the steam seal
bore at the two ends of the high
and medium cylinders.
9
9. Recheck
Check the contact of the key at

the casing lug and check the
perpendicularity and parallelism
between high and medium
pressure cylinders and bearing
housing.
Page 34 of 176

Casing paw
Front bearing housing
Upper half of HP&IP outer casing
Safety key
Tops-on key
Lower half of HP&IP outer casing
Zero
Thrust key
Front thrust key
Tops-off key
Straight edge
Check parallelism
Bolts with marks

shall be tacked
Casing paw
Page 35 of 176

III-5
III-5 Cylinder Alignment (Top-On

Alignment)
All cylinders are aligned after installed.
Install the music wire for alignment.
During alignment, maintain the cylinders and

surrounding environment in stable condition,
because any change may affect alignment.
During alignment, avoid vibration of music

wire.
All aligning works should be done by one
person to avoid human error.
No.
Work content
Work
content
Reference drawing
Remarks
1. Preparation for alignment
Before alignment, install the joint

bolts, every three holes, to ensure
that the joint clearance is
eliminated. Install all bolts near
the lug.
After these bolts are tightened,

the high and medium pressure
cylinders should be supported by
the upper lug.
2
2. Install the music wire

3 6
Page 36 of 176

No.
Work content
Work
content
Reference drawing
Remarks
6#
Determine the positions of #3 and

#6 bearings and then install the
music wire along this center from
behind the front bearing housing
to #6 bearing. Check twice the
measuring dimensions of all the
positions that should be checked.
3
3. Recheck the music wire

,
Confirm the music wire again

and recheck twice the measuring
dimensions of the positions that
should be checked.
4
4. Alignment record
Measure the distance between

respective measuring points and
the music wire respectively and
record the data and positions in
the certificate.
5
5. Verify the cylinder position
Page 37 of 176

No.
Work content
Work
content
Reference drawing
Remarks
Check the cylinder horizontal

joint levelness and compare it
with the factory documentary
evidence to determine whether
the cylinder installation state is
appropriate. Confirm that the
cylinder
horizontal
joint
coarseness is acceptable.
6
6. Determine
position
the
cylinder
456
When the center of the unit high
and medium pressure parts is
found inaccurate, adjust the
shims under the front bearing
housing bed frame for alignment.
Then repeat above 4, 5 and 6.
7
7. Complete cylinder alignment
Install the music wire and

measure twice each data to be
measured at the measuring
positions and record them as
required.
8
8. Lug sagging record
Page 38 of 176

No.
Work content
Work
content
Reference drawing
Remarks
After cylinder alignment

completed, check lug sagging
9
is
Key gap
9. Install the longitudinal key at

the two ends of the low pressure
cylinder
Adjust the clearance between

longitudinal keyway plate before
and after the low pressure outer
casing and the longitudinal key to
be left and right equal and weld
the longitudinal keyway plate.
Install adjusting shims and
accurately adjust the clearance.
Then install the lock cover plate.
10
10. Disassemble the cylinder

upper half
Page 39 of 176

Turbine Alignment Sketch
Accurate turbine alignment is performed according to the main machine certificate.
Page 40 of 176

III-6
III-6 Cylinder Alignment (Half

Empty Cylinder)
After all cylinder lower halves are positioned,

weld the connection between corresponding
pipes and valves and weld the connecting
positions between low pressure cylinder and
condenser. It should be noted that welding
deformation will occur during welding.
After the cylinder upper half is removed,
carry out half empty cylinder alignment and
confirm that the difference between top-on

alignment and half empty cylinder alignment
is in the allowable range.
No.
1
Work strip
Record
Reference drawing
Remarks
1. Check of top-on alignment
After cylinder and corresponding

pipe and valve and condenser are
connected, use the music wire to
align. Compare the difference of
these pipes, valves and condenser
before and after installation and
record it in the alignment card.
2
2. Alignment correction
(The connection part between turbine

low pressure exhaust port and
condenser should be welded using the
shielded arc welding method).
LP exhaust casing
Backing strip
Condenser throat
Inside
Outside
To reduce difference, you can

knock the welded position and if
Page 41 of 176

No.
Work strip
Record
Reference drawing
Remarks
necessary, cut off the pipe for

correction (note: do not adjust
the music wire).
3
3. Replace the key
To disassemble high and medium

pressure cylinders, first install
the supporting key between the
high and medium pressure
cylinder lower half lugs and the
front bearing housing and take
out the key under the high and
medium pressure cylinder upper
half lugs. While this work must
be carried out according to the
above
procedure
and
no
difference is allowed.
4
4. Remove cylinder upper half
After alignment is approved and

completed, remove the joint
bolts.
Page 42 of 176

No.
Work strip
Record
Reference
drawing
Measure the clearance of

horizontal joint of inner and outer
casings (this clearance value is
the final clearance value of the
casing horizontal joint).
5
5. Levelness check of horizontal

joint
Check the axial level of the high

and medium cylinder and low
cylinder joint. Measuring tools
should be edge ruler and level
meter (this data is the final data
of the cylinder horizontal
levelness).
6
6. Top off alignment
Confirm that top-off alignment

data is in the allowable range
specified
in
the
machine
certificate.
7
7.
Evaluation
for
top-on
alignment and top-off alignment
Page 43 of 176

No.
Work strip
Record
Reference
drawing
The difference between top-on

alignment data and top-off
alignment data is in the allowable
range.
8
8. Final top-off alignment
Record
and
alignment data.
store
top-off
Page 44 of 176

III-7
III-7 Rotor Alignment
After cylinder alignment (to-on alignment

and top-off alignment) is completed, use the
turbine rotor to replace music wire and start

rotor alignment.
Work content
Record
Reference drawing
Remarks
No.
As rotor alignment and adjustment are

completed on the supporting bearing, the
bearing babbit metal surface should be
thoroughly cleaned and no scratch and scar is
allowed on the bearing babbit metal surface.
1. Bearing installation
1#6#
Turbine side
Generator side
Install #1~#6 bearings, check

contact and clearance of each
bearing and supply turbine oil to
each bearing to check whether
oil feed and discharge positions
of each bearing are correct.
2
2. Lift the rotor
The rotor should be slowly lifted

up and always kept level.
In any case wire rope sling and

lifting position should meet the
Page 45 of 176

No.
Work content
Record
regulations of the drawings and
wire rope position also should
conform to the drawings and
should not be changed at will.
Reference drawing
Remarks
Wire rope should collide with

other parts to avoid damaging
important rotation positions.
Rotor should be lifted with the

lifting tool so that the rotor is in
level state.
Put the rotor in the cylinder and

support it with bearings.
3
3. Install the upper bearing half
Check the parallelism of rotor

journal and bearing babbit metal
surface and check play between
journal and bush and their
assembling.
Tighten bearing and bearing

cover bolts.
4
4. Check
position
the
rotor
center
Page 46 of 176

No.
Work content
Record
Reference drawing
Remarks
Check the position of the rotor

at each bearing oil retainer and
compare the check result with
the certificate.
5
5. Correct the rotor position
When the bearing position needs

adjustment, first lift the rotor
and then adjust the cushion
block under the bearing bush
sleeve.
At the same time, confirm that

the cushion block is well
contacted and bearing oil supply
and return positions are correct.
Page 47 of 176

Bearing top clearance (lead wite check)
Oil gap
Shim
Shim
Location of pad
Bearing holddown bolt

Measure face of bearing
Pad face adjustment

Area a detail
Pad clamping bolt
Lubricating hole
Bearing assembly
Pad
Width of contact
Contact check with journal to bearing
Upper casing
1# bearing
Micrometer measurement
Left
Right
Straight edge
Lower casing
Rotor position check
Page 48 of 176

Dial indicator
Generator rotor end
Turbine rotor end
Measuring points
Temporary bolt
Dolly bar
Coupling alignment check
Upper coupling guard
Temporary bolt
Generator rotor end
Turbine rotor end

Dial indicator
Generator rotor
Oil deflector
Lower coupling guard
Coupling guard
Turbine side
Turbine rotor
Coupling run-out check
Page 49 of 176

Face
Periphery
Position
Left
Top
Right
Bottom
1
2
3
4
Total
Average
Note:
1 mm
1) Unit: mm;
2 2) Circumferential runout is measured with
dial indicator and end face is checked with

inside micrometer;
3 3) Left and right are defined by the left
and right hand directions of the observer who
stands in front of the turbine front bearing

housing and looks at the generator end;
4
4) Dial indicator is installed on the turbine

side rotor.
Page 50 of 176

90
Coupling bolt
Each rotor should be measured for roundness

and runout and four points should be
measured at each position in the
circumferential direction (90 apart for two
adjacent points).
Dial indicator
Rod
Jack bolt
Page 51 of 176

III-8
III-8 Diaphragm Alignment
After rotor position check and preliminary
coupling alignment are completed, install and

align the diaphragm.
During diaphragm alignment, find a relatively
short reference line in each cylinder as

reference.
The position for diaphragm alignment is the
same as that for rotor alignment check.
No.
1
Work content
Record
Reference drawing
Remarks
Lead wire
1. Install the music wire

1# 2#3# 4#
5# 6#
AB
Support bar
Erect a music wire between #1

and #2 oil retainers, #3 and #4
bearings, and #5 and #6 bearings
as the centerline for alignment of
cylinders and low pressure
cylinders A and B.
2
Bottom key
2. Diaphragm alignment
Check and record the lower

diaphragm
alignment
(for
reference line) reading. The
check method is the same as
cylinder aligning method.
Page 52 of 176

No.
Work content
Record
Reference drawing
Remarks
All diaphragms should be aligned

into the tolerance range.
3
3. Steam seal body centerline

check
Check the alignment of each

steam seal body centerline.
Page 53 of 176

Piano wire
Straight edge
Micrometer measurement
Bottom key
Alignment of diaphram
Upper half casing
Upper half
diaphram
Steam-tight face
Centering pin
Gap
External ring of diaphram
Spacer Top gland seal
Steam
Lower half
diaphram
Support bar
Guide vane
Internal ring of diaphram
Adjusting shim
Lower half casing
Gland seal groove
Support bar (Above a detail)

Take measurement
Diaphragm
Gland casing
Gland casing
Front bearing
housing
Installation of gland casing
Page 54 of 176

III-9
III-9 Diaphragm Alignment

Adjustment
Diaphragm alignment is carried out in half

cylinder but it should be noted that in this
case the weight of the upper cylinder half
does not exist. Therefore diaphragm center
position must be adjusted to substitute the
design position with the compensation
position.
No.
1
Work content
Record
Reference drawing
Remarks
1. Adjustment principle
Shim
1-1
1-1 For the high and medium

pressure parts, adjust the shims
under the lower casing lug and
use this shim to support the lower
half of the outer casing.
1-2
1-2 For the low pressure part,

adjust the supporting shim and
use this shim to support the lower
half of the inner casing.
2
2. Check again the diaphragm

position and confirm that the
design position has been
compensated.
Page 55 of 176

No.
3
Work content
Record
Reference drawing
Remarks
3. Re-adjustment of diaphragm
alignment
This work is done if re-alignment

is needed.
Page 56 of 176

III-10
III-10 Flow Passage Clearance

Check
After rotor position check and re-alignment

are finished, measure the clearance between
the rotor and the stator which can not contact

each other in actual operation.
There are three types of clearances, i.e. axial
clearance, radial clearance and steam seal
axial clearance, and each type of clearance

needs to be obtained correctly and precisely.
These three types of clearances, after
measured, should be reported to the

Dongfang Turbine Works quality inspector
for approval.
The following points should be noted in

clearance measurement:
1 1. The axial clearance can not be measured
until the axial locating key of the thrust

bearing is fitted;
2 2. As the rotor is installed in narrow and
small space or between diaphragm sets, it is
critical to maintain accurate levelness and

position (axial and radial).
No.
1
Work content
Record
Reference drawing
Remarks
1. Preparation for rotor clearance

measurement
Prepare slope feeler gage and

keep the feeler gage and
diaphragm contact surfaces in
proper contact.
Page 57 of 176

No.
2
Work content
Record
Reference drawing
Remarks
2. Thrust bearing
Assemble the thrust bearing and

measure joint and clearance.
Leave the lower bearing half at
the assembling position for rotor
lifting.
3
3. Adjust rotor position
50mm
Push forward the rotor till the
allowable position of the thrust
bearing. Rotate the rotor to have
the assembling mark reach the
left position 50mm higher than
the horizontal joint.
4
4.
Measurement
clearance
of
axial
Use the slope feeler gage to

measure the axial clearance of all
stages without omission. All
clearances should be measured
twice to ensure data reliability.
Page 58 of 176

No.
5
Work content
Record
Reference drawing
Remarks
5. Rotate the rotor to measure

clearance
0
90
N
Rotate the rotor to zero position
so that the assembling mark is in
the same position as the left
horizontal joint, and then
measure clearance N each time
turn the rotor for 90.
Casing
For the low pressure exhaust

stage
blade,
measure
the
clearance between guide vane
and blade top.
6
Diaphra
Gland seal
6. Measurement of steam seal

axial clearance
a detail
Front
side
Rotor
Rear side
Measure the axial position of the

steam seal long tooth, measure
the clearance between each long
tooth of the steam seal and the
end face of the rotor boss at the
corresponding
position
and
record the measuring result.
Page 59 of 176

No.
7
Work content
Record
Reference drawing
Remarks
7.
Measurement
of
axial
clearance and other clearance
Measure the axial clearance and

other clearance specified in the
drawings.
8
8. Rotor lifting
Remove the thrust bearing and

the upper halves of all supporting
bearings and lift up the rotor
slowly and maintain its levelness.
In any case wire rope sling

should be the type specified in
the drawing and its position
should be the same as shown in
the drawing and should not be
changed at will. The wire rope
should not touch its parts and
components to avoid bruise of
important rotating parts.
Page 60 of 176

No.
Work content
Record
Reference drawing
Remarks
9. Preparation for installation and

measurement of the lower half of
steam steal ring
Steam-tight
surface
Packing
segment
Wedge
Wedge
Lead wire
Spring
Diaphragm
Install the lower half of the steam

seal ring and use the process
block to push it to the contact
surface in exhaust direction. At
the same time, use wedge block
to fix the arc section of the steam
seal from the right and left so
that it will not sink.
10
10.
Lead
wire
clearance
measurement at the bottom
Place lead wire on all the lower

diaphragm halves in the axial
direction and also place lead wire
on all radial labyrinth strips. Lift
the rotor onto it and measure the
clearance by measuring the
compressed thickness of all lead
wires.
11
11.
Lead
wire
clearance
Page 61 of 176

No.
Work content
Record
Reference drawing
Remarks
measurement in the upper part
After the rotor is placed, install

and fix the steam seal ring to the
upper diaphragm half and the
method is the same as installing
the lower half steam seal ring.
Install the upper half of each pair
of diaphragms onto their lower
half and measure the clearance
by measuring the compressed
thickness of all lead wires.
12
12. Clearance recording
Record the top, bottom, right and

left clearances at each steam seal
in the clearance table and record
other clearances in the record
paper.
Send these records to Dongfang

Turbine Works for approval.
Page 62 of 176

No.
13
Work content
Record
Reference drawing
Remarks
13. Positioning of main oil pump
Measure and adjust all clearances

of the main oil pump and then
drive in the locating pin to fix the
position of the main oil pump.
14
14. Positioning of emergency

governor
Measure the clearance between

all moving parts and finally fix
the emergency governor.
Page 63 of 176

III-11
III-11 Grouting
Before grouting, carefully clean up

foundation top and spray water to the
foundation. When grouting work starts, it is
necessary to work continuously until grouting
is finished. It should be particularly pointed
out that it is extremely difficult to grout the
space under the front bearing housing bed
frame and therefore grouting work should be
done with spare caution to ensure the space is
full of mortar.
For this reason, pay special attention to
mixing ratio of the mortar and especially

water proportion.
No.
Work content
Record
Reference drawing
Remarks
1. Installation of foundation
retaining plate
Align and install the foundation

retaining plate and expose
reinforcement and weld it to the
retaining plate to avoid retaining
plate movement during grouting.
In addition, cut off and grind
support column flat to prevent
them from exposing out of
grouting surface. But do not cut
off the support column of the
generator, because they will be
Anchor bolt
Wedge
Wedge
Base
Sole plate
Grout pad
Page 64 of 176

No.
Work content
Record
moved away during adjustment
and alignment.
2
Reference drawing
Remarks
2. Alignment of low pressure

cylinder side foundation bolt
Remove the nuts from the

foundation bolts at the low
pressure cylinder and use the
tapered wedge to adjust each
foundation bolt to make it in line
with the sleeve and fixed.
3
3. Foundation cleanup
Carefully clean up the concrete

foundation at the front bearing
housing end and low pressure
cylinder end and pay special
attention to the concrete areas
contaminated by oil or other
substances. Carefully dress and
chip until new concrete surface
exposes.
It is necessary to clean up those

areas covered by the bed frame
Page 65 of 176

No.
Work content
Record
and use compressed air to
thoroughly remove concrete
debris and sand and foreign
matters around the foundation.
4
Reference drawing
Remarks
4. Spray water
Before grouting, spray water to

concrete surface to maintain
sufficient moisture.
5
Sole plate
5. Prepare for pouring template
Prepare and install the pouring

template to divide grouting areas
6
6. Confirm the ratio of cement,

sand, gravel and water
When grouting, use vibrator or

similar tool to prevent cavity in
the grout blanket. After concrete
grout is poured, at least leave
the grouting area more than 3d.
Page 66 of 176

III-12
III-12 Final Assembling
Confirm the following matters in final

assembling:
(1) All parts and assembling parts need to be

thoroughly cleaned up;
(2) All bolts for parts and assembling parts
should be correctly connected;

(3) All positions that need lubrication should
be applied with lubricant or grease.

Never drop unrelated materials or tools in the
lower half assembling parts of the turbine.

To prevent foreign matters or dust from
entering the turbine, the assembling work

cycle should be as short as possible.
Work content
Record
Reference drawing
Remarks
No.
1. Check whether the hold-down

bolts of the lower half of the
lower pressure inner casing are
tightened.
Lead gap measurement
Gasket adjustment
2. Check the height of cushion

block on the suspension pin of
the lower diaphragm half.
3
Lead wire
Support bar
Shim
3. Check whether the bolts of

the lower half of the shaft seal
body are tightened.
4
4. Rotor check
Page 67 of 176

No.
Work content
Record
Reference drawing
Remarks
(1) Clean and check rotor blades
(2) Check shroud band
(3) Supply oil to bearings

N
(4) Mount the rotor and measure

again rotor clearance at position
N

(5) Install the thrust bearing as

well as thrust block and thrust
pad
5
5. Assemble the upper bearing

half
Install the upper halves of all

bearings and temporarily install
the upper halves of the thrust
bearing to make preparation for
oil flushing.
6
6. Install oil retainer
Clean up the lower half of each

oil retainer and install it.
Page 68 of 176

No.
Work content
Record
Reference drawing
Remarks
(1) Clean up bore area
(2) Check comb teeth of each oil

retainer
(3) Use oil sealant

(4) Measure and adjust the right,

left and bottom clearance of the
oil retainer and rotor

(5) Check and install the upper

half of each oil retainer.
7
7. Assemble the upper half

diaphragm
(1) Clean and wipe clean each

pair of diaphragms

(2) Clean and check tooth groove

before inserting the steam seal
arc
(3) Clean and check steam seal

arc

Page 69 of 176

No.
Work content
Record
Reference drawing
Remarks
(4) Install each steam seal and

calk the locating pin

(5) Apply lubricant to the two

sides of the seal key in the
horizontal position of each pair
of diaphragm.
(6) Install the upper half of each

pair of diaphragm

(7) Bolt the upper and lower

halves of each pair of
diaphragms (apply lubricate to
thread)
8
8. Assemble the upper half of the

steam seal body

(1) Clean all parts of each steam

seal body
(2) Apply to linseed oil to

horizontal position

(3) Apply lubricant to thread of

the bolts used to tighten the
upper and lower halves
Page 70 of 176

No.
Work content
Record
Reference drawing
Remarks
(4) Tighten the upper and lower

halves mutually

(5) Put the assembled upper half

steam seal body onto the lower
half and shift it outwards (to
avoid interference with low
pressure cylinder in assembling)
(6) Completely install the upper

half steam seal
9
9. Assemble the upper casing half

(1) Clean and check cylinder and

diaphragm upper halves
(2) Mount guide pillar on the

lower half of the inner casing

(3) Lift up the upper casing half

and keep it level

4
(4) Mount the upper casing half

via guide pillar onto the lower
Page 71 of 176

No.
Work content
Record
Reference drawing
Remarks
casing half and measure the

distance between upper and low
half casing flanges at four
different points. Be careful not to
damage guide pillar and other
parts during installation.

500mm
(5) When the distance between

the upper and low half joints is
less than 500mm, apply linseed
oil to the upper half joint.
(6) Install the locating pin of the

horizontal joint.

(7) When tightening the bolts,

prevent wrench from falling into
the casing.

(8) After completely tightening

the joint bolts, install the steam
seal body.

(9) Insert the reamed hole bolts

into the horizontal joint holes of
the steam seal body and then
tighten the vertical joint bolts.
Page 72 of 176

HP inner casing
Seal ring
Center key
Seal ring and center key of HP steam admission pipe
Crush pin
Gap
Dowel pin
Dowel pin
Crush pin
Crush pin gap
Window
Bearing
Oil tank
Strainer box
Sight flow
Oil piping
Page 73 of 176

III-13
(HIP/ALP/BLP)
III-13 Final Alignment

(HIP/ALP/BLP)
This alignment work is very important and
care must be taken to reduce serious

consequences due to alignment error.
When the measuring data at rotor center and
in the surrounding area meet the
requirements, directly connect the coupling

and measure the coupling runout data.
After the above work is completed, ream the
coupling holes and install and tighten

coupling bolts.
No.
1
Work content
Record
Reference drawing
Remarks
1. Preliminary work
Temporary locating plate
HIP/ALP BLP
G
(1) Check the mark G on the
external surface of HIP/ALP and
BLP rotor couplings.
HIP/ALP/BLP
G
180
(2) Adjust HIP/ALP/BLP rotor so
that the mark G of these rotors
are distributed 180 apart
mutually.
Adjusting plate
Turbine rotor
Generator rotor
Locating plate
can also be used
as bearing
position
Stopper bolt
Protection plate
Generator rotor
Turbine rotor
Pin
How to apply dial indicator
(3) Supply high viscosity oil to

each bearing.

Rotor
(4) Install dial indicator to check

Page 74 of 176

No.
Work content
Record
Reference drawing
Remarks
the position of the turbine rotor.

2
2. Alignment preparation
While keeping the same gap at

the end faces of the two coupling
halves, insert the coupling bolts
(erection bolt) and jacking bolt
and rotate two rotors.
Use crane and wire rope to lift

the coupling to rotor the rotor.
The rotation direction should be
the specified turbine rotor
rotation direction.
As the rotor may have been

deformed
after
prolong
placement, it is necessary to first
rotate the rotor more than 5min
and start measurement after gate
reading becomes stable.
3
3. Measure alignment accuracy

1/4
4
Page 75 of 176

No.
Work content
Record
Reference drawing
Remarks
For each 1/4 turn of the rotor,

measure the clearance at four
points (top, bottom, right and
left) on the coupling end faces
and record the measuring results
as the circumferential measuring
results. Rotate the rotor a
complete turn and record the
measuring results at the top,
bottom, right and left of the
circumference.
Decide the area to be moved

according to the above records to
control the alignment accuracy in
the allowable range.
4
Wire rope
Generator rotor
Turbine rotor
Sheeting pack
Turbine
rotor
G mark
Generator rotor
G mark
Turbine
rotor
Dial gauge used

for measuring
runout of outer
circumstance
Generator rotor
Cylinder gauge used for rotor

measuring runout of face
4. Connect the coupling
Clean up the end face between

the two coupling halves and
apply molybdenum disulfide
lubricant to the sledge pin
connection. Do not leave any
substance at the direct contact
area.
Page 76 of 176

No.
Work content
Record
Reference drawing
Remarks
4 4
First mount the temporary taper

pin into the turbine-motor
coupling connecting hole and
then insert four bolts into the four
equally spaced holes. When
rotating the rotor with the crane,
slightly tighten the four bolts in
sequence to make the coupling
end face closely join.
5
5. Deviation measurement
12
After the two coupling halves are

connected, measure deviation at
the evenly spaced 12 points on
the circumference of the turbine
and motor end coupling and
record the value.
6
6. Hole honing (if necessary)
Page 77 of 176

No.
Work content
Record
Reference drawing
Remarks
After all couplings are connected,

if any hole is found to be
displaced, hone it till meet the
requirements while ensuring that
the coupling hole will not
become oval.
7
7. Prepare fitting bolt
0.03mm
Measure reamed hole diameter in

longitudinal
and
horizontal
directions and machine the
outside diameter of reamed hole
bolts and make its clearance less
than 0.03mm in the diameter
direction. After the bolts are
machined, weigh bolts, nuts and
washers and choose, combine
and adjust to make the weight
difference of each set of bolt nut
less than 5g. All sets of bolts
should be numbered respectively
after selected.
8
LP rotor
HP&IP rotor
Turbine rotor
LP rotor
Bolt elongation
Turbine-generator coupling (all coupling bolt)
8 Alignment connection
Page 78 of 176

No.
Work content
Record
Reference drawing
Remarks
Carefully clean each part and

component
and
apply
molybdenum disulfide lubricant
to the thread of each nut. Mount
and tighten the bolts as required.
Before tightening, use the
extensimeter to measure bolt
length and then tighten the bolts
to
the
corresponding
to
elongation and lock the bolts
with lock washers.
9
9. Install the coupling hood
Fix the coupling hood, measure

the clearance between the hood
and rotor and adjust the clearance
to the specified value.
Page 79 of 176

III-14 BLP-GEN
III-14 BLP-GEN Final Alignment
HIP/ALP/BLP Confirm
whether
connection
of
BLP-GEN HIP/ALP/BLP has caused the alignment of
BLP-GEN BLP-GEN to change and if so, perform final
alignment for BLP-GEN.
No.
Work content
Record
Reference drawing
Remarks
1 BLP-GEN
1. Check and adjustment of

BLP-GEN final alignment
BLP/GEN
GG
180
During
BLP/GEN
final
alignment, check the mark G
which should be the 180
opposite position on the two
coupling ends.
BLP/GEN
HIP-ALP
ALP/BLP
Check and adjust the alignment

between BLP/GEN and the
method is the same as the
alignment between HIP-ALP and
ALP/BLP rotor couplings as
described above.
Page 80 of 176

Periphery
Face
T
R
L
Position
Left
Top
Right
Bottom
1
2
3
4
Total
Average
Note:
1 mm
1) Unit: mm;
2 2) Circumferential runout is measured with
dial indicator and end face is checked with

inside micrometer;
3 3) Left and right are defined by the left
and right hand directions of the observer who
stands in front of the turbine front bearing

housing and looks at the generator end;
4
4) Dial indicator is installed on the turbine

side rotor.
Page 81 of 176

Coupling bolt
90
Each rotor should be measured for
roundness and runout and four points
should be measured at each position in
the circumferential direction (90 apart
for two adjacent points).
Dial indicator
Rod
Jack bolt
Page 82 of 176

III-15 BLP/GEN
III-15 BLP/GEN Coupling Reaming

and Honing
BLP/GEN
After the final alignment is confirmed, if

necessary, start the honing work for
BLP/GEN coupling holes. When preparing
the bolts in the reamed holes, it is necessary
to machine and test coupling bolt nut and this
work should be completed in the machining
workshop and balance. Therefore it is
necessary to determine whether the
machining workshop and balance can meet
the need. (Dongfang Turbine Works has
completed the coupling reaming and coupling
bolt machining work. In principle, this work
is not required to be done on site).
No.
1
Work content
Remarks
1. Direct
couplings
connection
of
all
(1) Clean up the surface between

two coupling halves and apply
to the bore part.
HIP/ALP
ALP/BLP
G
(2) When connecting HIP/ALP
and ALP/BLP couplings, mark
G to the excircle surface of the
two coupling halves.

G 180
Page 83 of 176

No.
Work content
Remarks
(3) The marks G on the two

adjacent coupling should be 180
opposite angle.

(4) No other substance should be

left on the coupling end faces in
direct contact.
90
4
Use the temporary taper pin to
align turbine end and motor
coupling holes and then insert
one bolt every 90, totally 4 bolts
for the whole coupling, and
mount nuts.
Use the crane to lift and rotate

the rotor and then tighten screw
pair little by little until the
contact surfaces of the two
coupling halves touch each other
closely.
Tighten the screw pair and

measure the clearance between
the contact surfaces of the two
coupling halves.
Page 84 of 176

No.
2
Work content
Remarks
Temporary bolt
2. Runout measurement
12
12
After direct connection, divide

circumference of the turbine end
and motor end couplings into 12
equal parts and measure and
record runout value at the 12
equal parts.
3
Dial indicator
Generator rotor
Turbine rotor
Turbine side
Coupling runout check
3. Reaming
BLP/GEN
This process is only applicable to

BLP/GEN coupling
HIP/ALPALP/BLP
III-13
6
The holes on the HIP/ALP and
ALP/BLP have been completed
in the factory and reaming is not
need on site. For honing of all
holes, refer to Item 6 of III-13.
Confirm that the turbine end and

motor end coupling holes are
mutually aligned before reaming.
Page 85 of 176

No.
Work content
Remarks
At the same time, prepare a

strong clamp to support ratchet
indexing drill to ensure accurate
hole position and round.
Reaming work shall be continued

until the deviation between
turbine end and motor end
coupling holes disappears.
4
4. Preparation of bolts for reamed

hole
0.03mm
Measure the reamed hole
diameter in the longitudinal and
horizontal directions and then
machine the outsider diameter of
the bolts for reamed holes so that
the clearance between bolt and
bolt hole is less than or equal to
0.03mm.
After the bolts are machined,

weigh the bolts, nuts and washers
and choose and combine them so
that the maximum weight
Page 86 of 176

No.
Work content
Remarks
difference of each set of bolts

and nuts is less than or equal to
5g. Print the numbers on each set
of bolts, nuts and washers. The
same set of parts use the same
number.
Page 87 of 176

III-16
III-16 Tightening of ALL Coupling

Bolts
After final alignment, tighten the high and
medium pressure and low pressure couplings.
No.
1
Work content
Record
Reference drawing
Remarks
1. Tightening of all coupling

bolts
Generator rotor
Clean up the faces between two

coupling halves and apply
to the sledge pin connection and
do not leave any substances at
the point of direct contact.
4 4
First mount the temporary taper

pin into the turbine-motor
coupling connecting hole and
then insert four bolts into the
equally spaced four holes. When
rotating the rotor with the crane,
tighten the four bolts little by
lithe in sequence so that the
coupling faces join closely.
2
LP rotor
Bolt elongation
Turbine-generator coupling (all

coupling bolt)
Turbine side
coupling
Generator side c
oupling
2. Runout measurement
Page 88 of 176

No.
Work content
Record
Reference drawing
Remarks
12
12
After direct connection, divide

the circumference of the turbine
end and motor end couplings into
12 equal parts and measure and
record the runout at the 12 equal
parts.
3
3. Carefully clean up all parts and

components
Carefully clean each part and

component
and
apply
to the thread of each nut. Mount
and tighten the bolts as required.
Before tightening, use the bolt
length and then tighten the bolts
to
the
corresponding
to
elongation and lock the bolts
with lock washers.
4
4. Install the coupling hood
Fix the coupling hood, measure

Page 89 of 176

No.
Work content
Record
Reference drawing
Remarks
the clearance between the hood

and rotor and adjust the clearance
to the specified value.
Page 90 of 176

III-17
III-17 Installation of Accessories
TSI
No.
1
Turbines accessories, small devices and

instruments etc should be installed on the
turbine proper, such as atmospheric valve,
turning gear and turbine safety supervision
device (TSI) etc. Although the accessories are
small, they are closely related to the turbine
operation and therefore should be carefully
installed.
Work content
Record
Reference drawing
Remarks
1. Install the turning gear
The turning gear is shipped

integrally. Apply oil sealing
compound to the joint face and
insert and tighten the locating pin
bolts.
Apply read lead to check the

contact
coefficient
between
clutch gear and rotor gear. To do
this, put thin shims in the
meshing position to check gear
contact coefficient. Additionally,
gear tooth contact ratio needs to
be checked. Check the indication
of the limit switch with gear
Page 91 of 176

No.
Work content
Record
Reference drawing
Remarks
engaged and disengaged

normal operation.
2
in
2. Turbine safety supervision

device
Confirm that the tachometer,

sensor, expansion difference
measurer
and
eccentricity
measuring instrument in the front
bearing housing are firmly
installed in the correct positions
and record the check results.
Use the same method to check

the upper expansion difference
measurer. Also check the
performance of these instruments
and confirm that they operate
normally.
3
3. Gasket replacement
Pull out the front bearing housing

Page 92 of 176

No.
Work content
Record
Reference drawing
Remarks
push and pull key and evenly

jack up the lugs of the left and
right cylinders. Pull out the front
stop key and use the lower lug
gasket to replace the upper lug
gasket. Then pull out the upper
lug gasket and apply rust
preventive oil and install it to the
predetermined position. Pull the
front bearing housing push and
pull key back to the original
condition.
4
4. Tighten the hold down bolt in

front of the high and medium
cylinders
Mount the hold down bolt to the

front lug of the lower cylinder
half and apply lubricant to the
thread. Hand tighten the nuts and
then mount and lock the lock
nuts.
5
5. Assembling of front bearing

housing cover
Check and confirm that the parts

in the housing have been
installed and preparation work
for oil flushing has been
completed.
Page 93 of 176

No.
Work content
Record
Reference drawing
Remarks
Apply sealant to the joint to

prevent oil leakage.
6
6. Install the center key of the

cylinder upper halves
Mount the center key between

the high and medium pressure
cylinders and front bearing
housing upper halves but do not
completely lock it, because it
needs to removed and cleaned
after oil flushing.
7
7. Connect the water spray pipe
Water flush and install the spray

nozzle and tightly lock the union
joint.
8
8. Install inner casing handhole

cover
Check and confirm that steam

extraction port blind flange etc
has been installed with handhole
cover and bolts have been
tightened and locked.
Page 94 of 176

No.
9
Work content
Record
Reference drawing
Remarks
9. Install the atmospheric valve
Note
the
installation:
following
in
1
1) Spacer pin is embedded;
2
2) Copper plate is not defective;
3
3) After copper plate is mounted,

check the clearance between
knife edge and copper plate.
10
10. Install the outer casing

manhole cover plate
As it is needed to go through the

manhole for inspection after
steam seal pipe etc. is purged, the
outer casing manhole cover only
needs to be installed temporarily.
11
11. Install the high pressure

cylinder dynamic balancing hole
blind flange
Page 95 of 176

No.
Work content
Record
Reference drawing
Remarks
Install the dynamic balancing

hole blind flange for the upper
half of the high pressure cylinder.
As the blind flange is a high
temperature
part,
lubricant
should be applied to thread.
After lubricant is applied to the

inner casing shoulder, mount
screw plug to the oil filler.
12
12. Install the shaft vibration

probe
Temporarily install the shaft

vibration probe and confirm the
connection. These probes are
installed and adjusted after oil
flushing and should be protected.
Page 96 of 176

III-18
III-18 Preparation Work for Oil

Flushing
The purpose of oil flushing procedure is to

remove welding splashing, chip and scale etc
remaining in the oil piping, channel and oil
sump to prevent damage and abrasion of the
bearings and regulating system.
Please refer to the description of oil flushing

procedure.
No.
1
Work content
Record
Reference drawing
Remarks
1. Bearing disassembling
Remove the upper half of each

bearing and connect a temporary
bypass pipe which is led out from
the oil supply hole of the lower
bearing half.
For thrust bearing, remove gasket

and thrust pad.
2
2. Connect the temporary oil

flow observing pipe
100
120
Remove a branch pipe from the
bypass pipe and install the
temporary oil flow observing
Page 97 of 176

No.
Work content
Record
Reference drawing
Remarks
pipe and mount a mesh hood

(100 and 120meshes) to the
outlet end of the temporary
piping.
Remove the throttling orifice.

3
3. Emergency governor
Remove the emergency governor

and install temporary piping and
valve so as to flush the
emergency trip oil piping.
4
4. Main oil pump
5mm
Leave a small gap between
horizontal flange surfaces of the
oil pump case and let oil eject
(about 5mm).
5
5. Main stop valve and combined

reheat valve

(1) Disconnect the oil chamber

pipe connector between the main
stop valve and combined reheat
valve and the valve case.
Page 98 of 176

No.
Work content
Record
Reference drawing
Remarks
(2) Mount the connecting plate to

the pipe connector matching
surface.

(3) Please refer to

electrohydraulic
control
flushing procedure.
6
the
oil
6. AC start oil pump

4060
Use 40~60mesh wire net to wrap

the suction oil filter and provide
temporary pipe for each piping.
7
7. Auxiliary oil pump

emergency oil pump
and
4060
Use 40~60mesh wire net to wrap

the oil filter.
8
8. Temporary pipe of booster oil

pump
Remove the booster oil pump

from the oil tank and install the
temporary
pipe
for
each
Page 99 of 176

No.
Work content
Record
Reference drawing
Remarks
connecting pipe.
9
9. Oil filter
60
100
Install the 60~100mesh wire net
to the oil tank return oil pipe.
10
10.
Temporary
compressed air
pipe
for
Mount a temporary pipe to the

booster pump base and install a
check valve to the temporary
pipe.
11
11. Device internal cleaning
Each device should be internally

cleaned thoroughly until bare
hand can not touch viscous
foreign matters.
12
12. Supervisory instrument
Please refer to the oil flushing

piping system drawing.
Page 100 of 176

Page 101 of 176

III-19
III-19 First Oil Flushing
Oil flushing is a process step prior to trial

operation. Its purpose is to remove foreign
matters remaining in the oil passage and oil
system. Especially when oil temperature
change leads to pipe expansion and
shrinkage, the impurities adhering to the
internal pipe wall will mix into the oil.
This process step is to use oil circulation to
flush relatively heavy and large impurities

without temperature rise.
No.
1

process.
Work content
Record
Reference drawing
Remarks
1. Oil circulation
Bearing oil flushing
30
40
When oil is not heated but oil

temperature reaches 30~40C,
start the flushing oil pump (either
AC start oil pump or auxiliary oil
pump) and make oil circulate for
1h and check oil leakage.
1. Step 1
(1) Remove strainer from the orifice

plate
(2) Install temporary pipe and control

valve
(3) Install temporary blind plate in the

orifice plate box
2. Oil circulation of AC start oil

pump piping
(4) Install temporary collecting bag
Page 102 of 176

No.
Work content
Record
Reference drawing
Remarks
4
Changeover of oil flushing
piping should be controlled by
the valve between the temporary
pipes on the booster oil pump
base. Oil circulation shall last at
least 4h.
Install temporary pipe
Temporary valve
Temporary collection bag
Oil inlet
Lower bearing
Lower busing
Bearing housing
Remove throttle
orifice and
replace with
blind
Main oil pump oil supply

pipeFront
bearing
housingMain oil tank
3
3. Oil circulation to AC start oil

pump piping
Main oil pump

pipeFront
housingMain oil tank
suction
bearing
4
Oil circulation shall last at least
4h
4
4. Oil circulation to AC start oil

pump piping
1 6
Turbine bearing piping (#1~#6

bearings and thrust bearing)
6
Oil circulation shall last at least
6h.
Page 103 of 176

No.
5
Work content
Record
Reference drawing
Remarks
5. Adjust inlet oil amount of each

bearing
Use the valve installed on each

bearing bypass pipe to adjust the
inlet oil amount of each bearing.
6
6. Remove the strainer on the

lube oil filter on the bearing box
Remove the strainers on all oil

filters to increase inlet oil
amount.
7
7. Supply of compressed air

0.5kg/cm2
1
0.5kgf/cm2
Increase oil pressure 0.5kg/cm2
for oil circulation by supplying
compressed air continuously for
1h (Compressed air pressure
must be higher than oil pressure
0.5kgf/cm2).
8
8. Knock the pipe
Page 104 of 176

No.
Work content
Record
Reference drawing
Remarks
In oil circulation, use the hand

hammer to knock each pipe so
that impurities on the internal
wall come off.
9
9. Oil tank blow down

100
Transfer oil to the oil storage

tank and use 100mesh or finer
strainer to filter the oil to remove
the impurities mixed in the oil.
10
10. Cleaning of oil tank and oil

sump
Clean the return oil pipe strainer

and clean the strainer on the AC
start oil pump and auxiliary oil
pump suction oil pipe. Remove
residual dust on the oil tank pipe,
oil tank wall and in the piping.
Use wash leather other than
cloth.
11
11. Oil filling
Page 105 of 176

No.
Work content
Record
Reference drawing
Remarks
Inject the oil in the storage tank

into the turbine oil tank.
12
12. Recording
30
When making oil circulation for

oil flushing, check oil circulation
condition every 30min and
record it according to the
following requirements.

(1) Oil discharge pressure of AC

start oil pump and auxiliary oil
pump;

(2) Oil discharge pressure of the

regulating system and main oil
pump;
(3) Oil pressure of bearing

system;
(4) Inlet oil pressure of main oil

pump;

(5) AC start oil pump and

auxiliary oil pump motor
temperature;
Page 106 of 176

No.
Work content
Record
Reference drawing
Remarks
(6) Oil tank oil temperature;
(7) Oil tank level;
(8) Compressed air pressure;
(9) Cooling water pressure and

temperature;

(10) Current of AC start oil pump

and auxiliary oil pump;

(11) In this stage the basis for

judging whether oil flushing is
completed is the oil circulation
time.
Page 107 of 176

III-20
III-20 Second Oil Flushing
(1) The range of flushing pipe for this time is
the same as the first oil flushing;
(2) Start oil pump and auxiliary oil pump are

used;
(3) Oil cooler is used to reduce oil

temperature;
(4) Please refer to the description of oil

flushing procedure.
No.
1
Work content
Record
Reference drawing
Remarks
Bearing oil flushing
1. Oil circulation of bearing oil

piping is the same as the first oil
flushing.
Additionally, due to high oil

temperature, compressed air is
used and pipe is knocked by
hammer.
2
1. Step 2
(1) Remove strainer from the orifice

plate
(2) Remove temporary pipe and

control valve
2. Temperature reduction
(3) Install temporary bearing bypass

and control valve in the orifice plate
box
Pump oil into the bearing pipe

for
oil
circulation.
Oil
temperature is reduced by using
the oil cooler for cooling water
circulation.
(4) Install temporary collecting bag
Page 108 of 176

No.
3
Work content
Record
Reference drawing
Remarks
3. Record
Install temporary bypass
Record the oil cooler inlet and

outlet oil temperature as well as
other items required in the first
oil flushing, which are used to
supervise
oil
circulation
condition.
4
Temporary valve
Oil inlet
Bearing housing
Temporary collecting bag
4. Oil tank flushing

70
The oil tank inside should be

flushed at least once every 70h.
5
5. Judgment for oil flushing

completion
100
4 100
Install a 100mesh wire net on the

oil filter in each bearing oil
supply pipe and after 4h oil
circulation, visually check the
100mesh wire net.
Page 109 of 176

No.
Work content
Record
Reference drawing
Remarks
Criteria for evaluation

1
0.25mm
1. Conventional inspection: the
pipes are free from internal hard
objects such as sand, rust and
metal debris etc. and a tiny
amount of soft objects such as
paint, cloth chip and burr is
allowed. Size of metal foreign
matters should be less than
0.25mm except iron chips.
2
2. Sampling inspection
(1) Sampling position
NAS8
(1) Bearing oil supply: <NAS8
NAS6
(2) Control oil: <NAS6
Take inspection oil sample from

the main oil tank.
(2) Sampling time
Take samples after the second

and third oil flushing.
(3) Each sampling inspection is

performed twice
Page 110 of 176

No.
Work content
Record
Reference drawing
Remarks
(4) Inspection reference

NAS National Aerospece Standard 1638
NAS Standard (National Aerospece Standard 1638)
NAS etc.
Grain
size
00
10
11
12
m
515
125 250 500 1000 2000 4000 8000 16000 32000 64000 128000 256000 512000 1024000
1625 22
44
59
178
356
712
1435 2350
5700
11400 22800
45600
91200
182400
2650 4
16
32
63
126
253
506
1012
2025
4050
8100
16200
32400
11
22
45
90
180
360
720
1440
2880
5760
16
32
64
128
256
512
1024
51
100
101
250
251m 0
NAS standard
JOP
Yes
JOP
No
Page 111 of 176

III-21
III-21 Bearing Resetting
Remove the oil filter from the bearing oil

piping and restore all pipes completely to the
original installation state. Please refer to the

description of oil flushing procedure.
No.
1
Work content
Record
Reference drawing
Remarks
1. Check of lower bearing half
Before resetting each bearing to

its original state, remove the
lower half of bearing bush and
confirm that no foreign matter
exists between rotor and bearing
bush.
(1) Jack up the rotor and install

bearing bush parts;
(2) Use the jack to jack up the

rotor;
(3) Lift up the bearing bush and

remove it;
(4) Check and remove foreign

matters;

(5) Reset the lower half of the

bearing bush to the original
Page 112 of 176

No.
Work content
Record
Reference drawing
Remarks
installation state.
2
2. Bearing assembling
This is the final assembling work

for bearings and therefore
bearings should be assembled
one by one correctly and
accurately.
When the bolt is tightened, the

lock gasket locks the bolt.
Generally, such locking can be

used three times but should be
judged according to the actual
locking condition.
3
3. Installation of accessories
Install thermocouple and adjust

turbine supervisory instrument
etc.
Especially
as
the
thermocouple is installed to the
rotor supporting area, it must be
locked firmly and reliably.
Page 113 of 176

No.
4
Work content
Record
Reference drawing
Remarks
4. Reinstall bearing cover and

coupling hood
Carefully check and clean up the

inside and assemble them as
quickly as possible. Remember
to note down clearance with oil
deflector.
5
5. Adjust oil piping
Restore the piping around the

governor and other devices to the
originally installed position and
confirm that the connection is not
loose.
Confirm
that
locking
is
satisfactory and lock it according
to drawing requirements. Do not
lock the pipe connector nut by
welding.
6
6. Oil tank resetting
Page 114 of 176

No.
Work content
Record
Reference drawing
Remarks
Discharge all oil from the oil

tank and restore the internal
pipes and other temporarily
provided parts and components
to the original position to obtain
the final assembling state.
Clean the oil tank and lock the

parts and components that should
be locked.
Remove the oil cooler and check

its inside.
Page 115 of 176

III-22
III-22 Final (Third) Oil Flushing
Generally, the first and second oil flushing

uses flushing oil (different from operating oil)
but the final oil flushing uses the operating oil

(i.e. the oil used in actual operation).
No.
1

procedure.
Work content
Record
Reference drawing
Remarks
Temporary oil control valve
1. Oil filling
Fill the oil tank with oil as

quickly as possible through oil
filter.
2
Oil inlet
To sight flow box
Bearing housing
Remove throttle
orifice and replace
with blind plate
Orifice box
2. oil pump operation
First start the auxiliary oil pump

and then start the AC start oil
pump for carry out oil flushing.
To sight flow box
Oil inlet
Bearing housing
1. Install orifice plate in the

orifice box
2. Install 100 or 120 mesh
gauze to the outside orifice
plate
Check the total amount of

foreign matters at the orifice box,
bypass pipe, oil discharge port
and temporary filter and observe
oil flushing condition.
3
3. Oil flow
100
Page 116 of 176

No.
Work content
Record
Reference drawing
Remarks
Wrap the orifice plate in a layer

of 100mesh strainer and let oil
flow through as long as possible
to remove impurities.
If flowing time is insufficient,

never put the turbine into
operation.
Page 117 of 176

III-23
III-23 Steam Pipe Blowing
Steam pipe blowing should be carried out

before steam is supplied to the turbine first
time. Its purpose is to discharge various weld

slag, iron chips and rust etc from the steam
pipes.
6
C.F.R
1
The steam pipe blowing conditions can be:

steam pipe blowing duration should be at
least 6times pipe flushing duration so that the
pipe flushing force ratio (C.F.R) in operation
is greater than or equal to 1.
Please refer to the gland steam flushing

procedure.
No.
1
Work content
Record
Reference drawing
Remarks
1. Blind plate installation
The following areas that do not

need steam blowing are sealed
with blind plates.
(1) Main stop

leakage, 2 points;
valve
stem
(2) Combined reheat valve stem

leakage, 2 points;
(3) Regulating
leakage, 4 points;
valve
step
BDV
(4) BDV valve stem leakage;

Page 118 of 176

No.
Work content
Record
Reference drawing
Remarks
(5) Ventilation
leakage;
valve
stem
SSR
(6) SSR outlet end;
SV
(7) Safety valve (SV).

2
2. Temporary pipe
13
(1) Use temporary pipe to

connect steam supply pipe and
steam discharge pipe for #1 and
#3 shaft seals;
47
(2) Use temporary pipe to

connect steam supply pipe and
steam discharge pipe for #4~#7
shaft seals;

(3) Connect the temporary pipe

to the suction pipe of the steam
seal heater to discharge steam to
the atmosphere.
3
3. Pipe blowing

1520kg/cm2
Page 119 of 176

No.
Work content
Record
Reference drawing
Remarks
(1) The blowing pressure of the

auxiliary
steam
pipe
is
2
15~20kg/cm and its residual
pressure is used to blow the main
steam pipe, cold and hot reheat
stem pipes.

(2) To increase steam flow speed

and force during pipe blowing,
the pipes are divided as follows.
Blind plate (non-operating blind
plate) is inserted into the pipes to
carry out steam pipe blowing
operation.
13
Steam supply pipe for #1 and #3
shaft seal blowing
47
Steam supply pipe for #4~#7
shaft seal blowing
Page 120 of 176

Page 121 of 176

III-24
III-24 Resetting after Steam Blowing
After steam blowing and before oil pressure
test, reset the main valves to the originally

installed positions.
In this case, it is very important to prevent

steam leakage.
Note: when the valves are finally assembled,

consider the operating sequence to ensure that
the assembling work can be completed in the
same day (The purpose is not to leave the
opening overnight to avoid ingress of foreign
matters into the opening).
No.
1
Work content
Record
Reference drawing
Remarks
1. Main stop valve
(1) Clean up the inside of the

main stop valve body
Clean the inside of valve seat and

drain port and clean the valve
inside.
(2) Check contact.
Apply red lead to check the

contact between valve disc and
valve seat and use soft oil stone
to grind the contact surface to
ensure the required contact.
Page 122 of 176

No.
Work content
Record
Reference drawing
Remarks
(3) Valve stem boss
Apply red lead to check its

contact with the seal ring and if
necessary, grind the contact
surfaces on the two sides and
face up the two surfaces.
(4) Valve seat and valve case

assembling
Install the metal wound gasket

and tighten the lower flange.
Apply molybdenum
lubricant to the joint.
disulfide
(5) Strainer installation
After installation, confirm that

the installation position is
appropriate and strainer bottom
surface and valve case join
closely.
(6) Valve cover installation
Page 123 of 176

No.
Work content
Record
Reference drawing
Remarks
Check the depth at the seal and

the thickness of the metal wound
gasket and determine the
compression degree
Apply molybdenum disulfide

lubricant to the seal surface and
apply crane lubricate (a high
viscosity oil) to bolt and nut
thread.
(7)Hot tightening of bolts

Before tightening, use the bolt

length;

When the bolt is not heated,

tighten the bolt and measure
flange clearance;
Measure bolt elongation;
Decide nut arc of rotation;
Heat the bolt for

tightening and cooling;
hot
Page 124 of 176

No.
Work content
Record
Reference drawing
Remarks
Measure and record bolt

elongation and flange clearance;
(8) Valve stem connecting part
When the valve stem is

connected to the oil servo motor
connecting part, note the
connecting part clearance and
install limit stop and lever.
2
2. Combined reheat valve
(1) Clean up the inside of the

combined reheat valve body
Clean up the inside of valve seat

and drain port and clean up and
check the inside of combined
reheat valve
(2) Check valve seat contact
Apply as thin red lead layer as

possible to check the contact
between valve disc and valve
seat as well as contact between
valve stem and seal ring.
Page 125 of 176

No.
Work content
Record
Reference drawing
Remarks
If the contact is not ideal, it

should be ground with soft oil
stone.
(3) Valve step assembling
Apply read lead to the contact

with valve case matching surface
and apply molybdenum disulfide
lubricant to the seal surface.
(4) Connection of valve body,

valve bush and valve stem

Measure the clearance

between valve bush and flange at
the two ends and confirm that the
measured value is the same as
drawing dimensions.

Check the two end clearance

of the connecting rod matching
with the valve seat and its value
should be the same as the
specified value in the drawing.
Page 126 of 176

No.
Work content
Record
Reference drawing
Remarks
Apply crane lubricant to the

thread of the straight pin.
Tighten the straight connecting

pin and then lock it with lock
washer.
3
3. Gland steam pipe
(1) Reset temporary pipe to the

original position
Remove the temporary pipe

connecting the gland steam
supply pipe and exhaust pipe and
reinstall the pipe to the original
position.
Check the pipe installation bolt

and confirm that each bolt is
properly tightened and locked.
(2) Remove baffles
Confirm that all baffles mounted

at the valve leakage are removed.
Page 127 of 176

No.
Work content
Record
Reference drawing
Remarks
(3) Resetting of steam seal heater

steam inlet pipe
Remove the temporary pipe and

check the internal pipe and then
reset it.
Use special care in heliarc

welding to avoid foreign matters
from being left in the pipes.
Page 128 of 176

T-G
Appendix 1 T-G Foundation Embedded Parts Installation Manual
Contents
--
Chapter
1
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
Name
Pages
General
Installation record
Check parts
Mark off reference line
Install embedded parts
Install foundation bolt sleeves
Concrete placement
Final concrete placement

T-G
Final check of T-G foundation dimensions
1 3
Figure 1~Figure 3
Page 129 of 176

1. General
(1) Scope
T-G This installation manual is only applicable to

the installation of T-G foundation embedded
parts and foundation bolt sleeves. The work

needs to be implemented by the professional
contractor and participation of other
organizations is not allowed.
T-G This manual mainly introduces the technical
problems for installation of T-G foundation
embedded parts and foundation bolt sleeves

and the normal problems (e.g. chamfer,
cleanliness etc) are not introduced here.
In addition, this manual does not cover the
working methods resulting from different

tools and construction sequences.
Please carefully read this manual and
completely understand its contents before

actual work.
All works in this manual are implemented by
the professional contractor.

(2) The content and use of this manual are
composed of the following.

A
A. Flow chart and diagram
Flow chart and diagram indicate working
sequence and also can be used as index.

B
B. Specifications
They are related to the formation of late stage
working steps and as an outline describe the

problems that should be noted in the works.
Every working procedure is carried out by

steps according to the specifications.
All these steps should be recorded and
relevant records should be submitted to

Dongfang Turbine Works for approval.
C
C. About attached drawings

Page 130 of 176

For better understanding of this specification,
attached drawings are given in the last several

pages of this manual.
(3) Precautions.
A A. Completely understand the contents of the
drawings before starting the complete

assembling work.
B B. Do not weld any area unless specially
noted in the drawings.

C C.
Before
assembling,
remove
all
anti-corrosive agents applied before delivery.

D D. Each day after work, cover the product
with refractory board or waterproof board or
the materials that can prevent equipment

damage and rust formation.
E E. When lifting the foundation bolt sleeve,
align it to its installation hole and do not use

wire rope to lower the sleeve.
Page 131 of 176

2. Installation record
This manual has specially indicated the points
that need to be recorded on site and the

record should be correct.
Site record is divided into the following two
types according to importance and can be

properly adjusted properly according to the
following requirements.
(1) Acceptance record
The record, after completion, should be
immediately submitted to Dongfang Turbine

Works (Mark in the Approval column).
In examining these measuring records,
sometimes other records are required.

When examining these measuring records,
sometimes the data should be corrected.

Therefore, recording result should be
immediately submitted to us so that we have

enough time to correct them.
(2) Other records
The record should be complete and reliable
and submitted together to Dongfang Turbine

Works after completion.
T-G Installation instruction of T-G foundation
embedded parts and foundation bolt

sleeves
When the foundation concrete is placed and
embedded parts and foundation bolt sleeves

are installed, they should not be moved at all.
Therefore embedded parts and foundation
T-G bolt sleeves should be installed to the
accurate positions to easily match with the

parts of T-G condenser and auxiliary
equipment.
This work is relatively difficult because civil
engineering and precision mechanical

Page 132 of 176

instruments must be used concurrently.

To easily determine the center position of the
foundation bolt sleeves, the professional

contractor needs to prepare the construction
structure drawings.
All drawings must be collected together to
prevent mistake in installation.
Concrete is poured after foundation bolt

sleeves are installed.
After foundation bolt sleeves are installed,

measure the center and height of each
foundation bolt sleeve from the relevant

reference line.
Before concrete placement, check whether its
position is appropriate and record the

measuring result.
Page 133 of 176

2-1
2-1 Check parts
Before installing parts, check their quantity
and dimension so that installation will not be

interfered.
Serial No., construction item and content
Installation record
Remarks
Record
Approval
1. Parts classification
Parts are divided into two classes, i.e.

embedded part and foundation bolt sleeve.
2
2. Check quantity
Check the quantity of embedded parts and

foundation bolt sleeves according to the
drawings and Detailed List of Supplies:
(1) Arrangement drawing of turbine

generator foundation embedded parts
(2) Arrangement drawing

generator foundation bolt
of
turbine
(3) Detailed list of supplies.

3
3. Check parts dimension
Page 134 of 176

Installation record
Remarks
Record
Approval
Check the dimensions of each part and

ensure no problem will occur after
installation.
4
4. Embedded parts color classification
The contractor decides color classification

details.
We recommend the following classification:
Foundation concrete is generally divided

into 2~4 times placement and therefore, to
facilitate
concrete
placement
and
differentiation, different colors are used in
the drawings for identification. For example,
colors are classified as follows and all parts
should use the same color. In addition, it is
recommended that the corresponding parts
color is marked in the drawings.

First time concrete placement area: brown

Second time concrete placement area:
orange

Third time concrete placement area: yellow
Page 135 of 176

Installation record
Remarks
Record
Approval

Fourth time concrete placement area: green
Note: For the parts that are not differentiated

with color in the drawings, reserve enough
space for their name and quantity to check
the parts after embedded parts are installed.
Page 136 of 176

2-2
2-2 Mark off reference line
The reference line is not only used to install

embedded parts but also to install turbine
generator,
condenser
and
auxiliary
equipment.
Therefore,
the
calibrated
measuring instruments are used and no error
is allowed. Particularly centerline should be
scribed with steel tools but this is not
necessary for others.
Installation record
Remarks
Record
Approval
1. The centerline of turbine generator and

condenser should be measured and scribed
with power station reference as the reference
point.
The first layer surface (bottom layer)

centerline should be checked carefully and
then it is ensured that steel plate is mounted
in along the line.
2
2. Auxiliary reference line
T-G
1
Figure 1
With only turbine generator and condenser

centerline and identification, it is difficult to
check the installation position of embedded
parts. Therefore auxiliary reference line is
accurately marked in and out of the T-G
Page 137 of 176

Installation record
Remarks
Record
Approval
foundation.
T-G
To facilitate subsequent embedded parts

inspection, the above auxiliary reference line
should be made and match with the
reference line (centerline) on the T-G
foundation drawing.
3
3. Reference line of vertical surface

0
Vertical surface=0 and it should be

marked near the supporting pillar in the
installation area. Each layer vertical surface
should be marked with the same mark.
4
4. Check the verticality of the reference line
T-G
If the verticality of the reference line is
inaccurate, T-G condenser and auxiliary
equipment can not be installed.
Therefore verticality check must be accurate

and correct.
Page 138 of 176

2-3
2-3 Install embedded parts
After cement foundation reinforcement and

foundation bolt template are installed, the
embedded parts are installed. When installing
the embedded parts, fix them firmly to avoid
their movement during unit operation.
Installation record
Remarks
Record
Approval
1. Mark the position of embedded parts
Measure and identify the template surface

reference line and determine the installation
position of the embedded parts relative to
the reference line.
During laying out, centerline marking

should be extended and exceeds the actual
embedding range of the embedded parts.
2
2 Identification record
After marking on the template is finished,

collect the position marking record and
check whether it is consistent with the
drawing.
3
3. Cut template
Page 139 of 176

Installation record
Remarks
Record
Approval
When the embedded parts are installed, if it

is necessary to cut the template, appropriate
measures should be taken, e.g. mark the
identification line on the back.
4
4. Remove oil and grease
Completely remove oil and grease

(including paint) from the embedded parts
so that they better join with concrete.
5
5. Buried pipes
When pipes and other fittings are buried, the

plug or pad made of steel plate or similar
material should be attached to the pipe
opening to prevent cement from entering the
pipe.
Drain pipe and similar pipe should have

drain slope and it is necessary to refer to the
drawing to install them to the position.
6
6. Reinforce the embedded parts
Page 140 of 176

Installation record
Remarks
Record
Approval
Determine that each embedded part is well

connected to a concrete reinforcement so
that the embedded parts will not move or
leave when concrete is placed (do not weld).
7
7. Installation tolerance of embedded parts
10.0mm
Unless specially noted in the drawings, the

center dimension and installation tolerance
of the whole embedded part should be
within 10.0mm (axial and vertical) and
related dimensions are shown in the
drawings.
Page 141 of 176

2-4
2-4 Install foundation bolt sleeves
T-G
When the foundation bolt sleeves are buried

in the cement foundation, never move them.
Position the foundation bolt sleeves based on
T-G and condenser centerline. Accurately
install and reinforce the foundation bolt
sleeves so that they will not be dislocated due
to concrete flow. In order to reinforce
foundation bolt sleeves, they should be
supported with stand column and wood plug
(supplied by the contractor) other than
cement foundation reinforcement. In addition,
each foundation bolt sleeve should be
arranged in the area where reinforcement will
not be touched and sufficient clearance
should be left between the two.
Installation record
Remarks
Record
Approval
1. Check the reference line
T-G
T-G
Before installing the foundation bolt sleeves,

check and the T-G and condenser centerline
marked on the platform. Make sure that
these reference lines conform to the T-G and
condenser centerline marked on the
foundation frame.
2
2. Check the verticality of the reference line.

T-G
Page 142 of 176

Installation record
Remarks
Record
Approval
Check the verticality of T-G centerline and

condenser.
12
3
Figure 1, 2
3. Centerline of foundation bolt sleeves
T-G
From the T-G and condenser centerline,

calculate and measure the foundation bolt
sleeve center and make identification on the
frame.
4
4. Check the verticality of foundation bolt

sleeve centerline
Figure 2
2mm
Measure the centerline diagonal line length;
the maximum difference between diagonal
lines should not exceed 2mm.
5
5. Install foundation bolt sleeves
Figure 3
Measure the axial and vertical distances and

the verticality based on sleeve centerline and 2
install each foundation bolt sleeve as shown.
6
6. Final check of foundation bolt sleeve
position
T-G
Page 143 of 176

Installation record
Remarks
Record
Approval
After T-G foundation placement and

foundation bolt sleeve installation are
completed, it is necessary to finally check
the reference line and sleeve centerline
position and record the check result.
The chief person on site from Dongfang

Turbine Works gives witness according to
the above record.
If the chief person on site from Dongfang

Turbine Works is not present on site, the
above records should be submitted to
This process is a long period of time

involving final record collection, certificate
check, submission of record for approval,
record return etc. Therefore in the beginning
sufficient time should be reserved for this
procedure.
7
7. Final check

(1) Check whether each foundation bolt

sleeve is reinforced firmly.
Page 144 of 176

Installation record
Remarks
Record
Approval
(2) If any foundation bolt sleeve contacts

concrete reinforcement, keep sufficient gap
between foundation bolt sleeve and
reinforcing bar.

(3) Check whether concrete reinforcement

height is the same as drawing.

(4) Check whether sufficient gap is reserved

between foundation bolt sleeve and
template.

(5) Check whether dust and foreign matters

(wood chip, metal chip etc) have been
removed on the template.

(6) Check whether sufficient gap is reserved

between template and embedded parts.
(7) Check whether template dimension is the

same as shown in the drawing.
(8) Check whether template is inclined.
Page 145 of 176

2-5
2-5 Concrete placement
If concrete is placed only in one direction,

template may be inclined or sink, thus it is
necessary to place concrete evenly from
different
directions.
During
concrete
placement, use bamboo stick and vibrator etc
to fill each corner with concrete.
Installation record
Remarks
Record
Approval
1. Check before concrete placement

(1) Before concrete placement, remove dust

and foreign matters (wood chip, metal chip
etc) from the template.

(2) It is required that strength of cement

main bar be specified and the specified
strength borne by its material be determined.
(3) Check and record template dimension

and verticality.
2
2. Concrete placement height
Concrete placement height should be

predetermined and it is necessary to check
Page 146 of 176

Installation record
Remarks
Record
Approval
whether the actual height of concrete

placement is the same as the predetermined
value.
3
3. Marking
After concrete placement and setting, mark

the reference line for installation of
embedded parts next time and install
embedded parts.
2
Marking specification of the reference line is
the same as 2.
Page 147 of 176

2-6
2-6 Final concrete placement
1
50mm
2mm
1. After final concrete placement, concrete

surface should be chiseled for 50mm depth so
that cement slurry for secondary grouting can
completely adhere to the concrete. Therefore,
it is necessary to measure the distance from
concrete main bar to concrete surface to
ensure main bar will not expose after surface
toughening. In addition, the embedded part
levelness of generator air duct must be within
2mm (subject to generator requirements).
2 2. If concrete is placed in one direct, template

may be inclined or sink or the main bar may
be shifted to get in contact with foundation

bolt sleeve.
3 3. During concrete placement, use bamboo
stick and vibrator etc to fill each corner with

concrete.
Page 148 of 176

2-7 T-G
2-7 Final check of T-G foundation

dimensions
After final concrete placement and setting, it

is necessary to measure and record the
following dimensions and send the record to

(1) Reference line and foundation bolt sleeve

centerline
T-G
(2) T-G foundation opening dimension.
T-G
(3) T-G foundation opening verticality.
(4) Locating dimension of foundation bolt

sleeve.
(5) Verticality of foundation bolt sleeve.
(6) Locating dimension of oil discharge pipe

sleeve.
Page 149 of 176

Figure 1 (Type Fixing Drawing)

Condenser centerline
(Floor 3)
T-G centerline
(Floor 3)
T-G foundation
T-G centerline (reference

line) (Floor 1)
Condenser centerline
(reference line) (Floor 1)
Check reference line verticality and measure diagonal length. Check method is as follows:
C-F C-F C-F C-F
T-G
If there is any difference between lines, e.g. difference between C-F and C-F and C-F, it
indicates that condenser centerline and T-G centerline are not at the correct angle (not
orthogonally).
Page 150 of 176

Figure 2
T-G centerline
(reference line)
Foundation bolt
sleeve center
reference line
Condenser
centerline
(reference line)
Check the verticality of reference line.

-------------------------------------------A-A
(1) Condenser centerline

-------------------------B-B C-C
(2) Foundation bolt sleeve center reference

line
Record the foundation bolt sleeve center

position.
Measure and record the position dimension of

each foundation bolt sleeve relative to
reference line.
For example:
123
To condenser reference line: 1, 2, 3;
T-G
To T-G centerline: (a), (b).
(a)(b)
Page 151 of 176

Figure 3 Installation of Foundation Bolt Sleeve
Frame
Workholding fixture
Foundation bolt sleeve
Plumb
Wood plug
Template
For the verticality of foundation bolt sleeve, it
is necessary to measure the following

dimensions and calculate their difference.
a X-Y
Part a: dimension X-Y
b X-Y
Part b: dimension X-Y
Page 152 of 176

2
1
T-G
Appendix 2 T-G Foundation

Template Installation Manual
1. General
This manual only introduces the installation
of foundation template and other data will be

supplied separately.
2
2. Foundation
instruction
template
installation
Foundation template is used to accurately
position the foundation bolts and therefore

their assembling and positioning must be very
accurate.
2-1
T-G
2-1 Assembling of foundation template

(1) Suspend a plumb at the T-G center and
exhaust hood and motor center marked on the
foundation 0m floor and mark the T-G center,
exhaust hood and motor center on the
concrete surface pointed by the plumb.
(2) Based on the above centerlines, measure

and mark the installation position of the
template support pillar and then install the

support pillar which should be firm and
should not fall.
(3) Level the template bottom surface.
(4) Measure the template diagonal length to

T-G determine the relative position of foundation
bolt to exhaust hood, motor and T-G center.
2-2
2-2 Positioning of foundation bolt
(1) Check whether foundation bolt is clean
and free from oil stain and sleeve and nut are
welded.
T-G (2) Use steel tape to measure the distance
between bolt hole and T-G and exhaust hood
center to determine the installation position
and ensure the levelness by adjusting sleeve
and shim and also ensure tolerance
requirements.
Page 153 of 176

(3) Adjust foundation bolt nut to ensure that
foundation bolt height meets the tolerance

requirements.
(4) After (2) and (3) are completed, confirm
that the foundation bolt is not vertically

inclined and then weld the template and
adjusting shim.

(5) Ensure that lower end of foundation bolt

is rigidly welded and stiffened with
reinforcing bar to further enhance its rigid
connection with template so that the
foundation bolt does not shift during concrete
placement.
2-3
2-3 Removal of foundation template
In principle, removing process is a reverse

process of installation but safety should be
ensured in removal. Additionally, do not

destruct the thread position of foundation
bolt.
Notes:
(1) For details, refer to the relevant drawings.
(2) Foundation bolt should be welded to

concrete reinforcement.
(3) Concrete should be grouted into the
foundation bolt sleeve (grouted when turbine

bed frame bed plate is installed).
(4) Use transit level to check the height of

foundation bolt.
T-G (5) Recheck the distance between foundation
bolt and T-G, exhaust hood and motor center

(also recheck diagonal length).
(6) Allowable tolerance for foundation bolt

installation
A A. Vertical direction-the top of foundation

5~7mm
bolt is allowed to be 5~7mm higher than the
shown height.
Page 154 of 176

B +1mm
B. Horizontal direction-shown dimension

1mm.
C +2mm
C. Orthogonal centerline-total length 2mm.
Page 155 of 176

Appendix 3 Regulations of Gas

Shielded Welding for Connecting
Lower Half of Lower Pressure
Cylinder to Condenser
1. Scope
This instruction is used for the gas shielded

welding for connecting the low pressure
ASME IX
cylinder lower halt to the condenser. Unless
other specially noted in this instruction, all
welding shall meet the Chapter IX of ASME.
2
2. Preparation before welding
(1) At all workpieces that need to be welded

in the condenser, erect a scaffold and connect
batten root and then install handrail according

to surrounding environment.
(2) Before welding, do the following work.
JIS ANSI (3) Determine that the welders have the
qualification specified in JIS or ANSI

standard.

(4) Determine the groove dimension of the

low pressure exhaust hood and condenser
connecting shell. If the gap is too wide, the
turbine proper may be deformed in welding
and therefore the gap should be adjusted to be
within the shown tolerance range.
(5) Before welding, determine the clearance

of the matching surfaces of the supporting
strips placed between the low pressure
exhaust hood and condenser connecting shell.
If there are two many ruffles, they should be
polished or the condenser connecting shell
should be welded to ensure groove
dimension.

500mm
120mm
1
(6) Position marks at 500mm pitch in the

internal surface between the low pressure
exhaust hood and condenser connecting shell.
The drilling distance between the two in the
Page 156 of 176

vertical direction should be 120mm (See

Figure 1 for details).

600mm
2
(7) Determine that the groove dimension of

the welding area is in the shown tolerance
dimension range. Make the groove shaped
supports of appropriate sizes and install them
on the low pressure exhaust hood at 600mm
pitch (See Figure 2 for details).
Vertical measuring dimensions may be slightly longer or shorter than the post-weld
dimensions.
Low pressure
exhaust hood shell
Supporting strip
Low pressure
exhaust hood shell
Supporting strip
Weld
Condenser
connecting shell
Condenser
connecting shell
Support
[Figure 1]
[Figure 2]
Page 157 of 176

3. Welding instruction
3-1 4 3 3-1 Welding needs to be performed by four
welders according to the numerical sequence

shown in Figure 3.
4 1 4
1 150mm
50mm
(1) Weld Point 1 point from four centers.

Four welders start diagonal welding from the
center in the opposite sides. When Point 1 is
welded, the discontinuous welding length is
150mm and pitch is 50mm. Welding in this
area directly affect the bearing part of the low
pressure cylinder.
JIS-D4316 (2) Electrode should be low hydrogen
electrode JIS-D4316 or other equivalent

materials.
(3) After discontinuous welding is completed,
50mm
the remaining welding part is about 50mm for
each section.
Figure 3
Welding Instruction
Turbine centerline
3-2 1 3-2 After Point 1 is welded, weld Point 2 in

2
the opposite direction and polish it.
3-3 1 3 3-3 In welding the exhaust hood, the welding
distance should be adjusted accordingly from
Point 1 to Point 3.
3-4
3-4 Therefore, the change of this distance

Page 158 of 176

should be carefully measured.

3-5 4
3-5 Point 4 and other points of the exhaust

hood should be welded continuously. Check
any change frequently during welding and
observe and determine that everything is
normal until all points are welded.
3-6 3-6 To release stress, all points, after welded,
should be polished with air hammer except

the last point.
3-7 3-7 After all points are welded, check the
foundation plate levelness record.

3-8
4 A
A
3-8 After each point is welded, measure

casing deformation, e.g. dimension A in
Figure. Then adjust the welding sequence
based on the measuring result. For example,
if the dimension of a certain part A is larger
than the other parts after measurement, this
part should be welded first.
3-9 B 4 3-9 After welding, measure the exhaust hood

7mm 5
deformation at B (See Figure), which
should be less than 7mm (See Figure 5 for
details).
Figure 4 Welding Drawing

Outside
Figure 5 Exhaust Hood Deformation

Inside
Outside
Inside
Supporting
strip
Turbine centerline
Exhaust hood
before welding
Exhaust hood
after welding
3-10
3-10 Welding sequence

Welding sequence is shown in Table 1:
Page 159 of 176

Table 1 Welding Sequence
Point
Electrode diameter
1/8(3.2mm)
Point 1
5/32(4.0mm)
3/16(5.0mm)
Point 2 and other points
1/4(6.0mm)
1/8(3.2mm)
Last point
3-11
3-11 Electrode
2 AWS The material equivalent to or better than
AWS () in the table can be used.

All electrodes should be dried in electric oven
300~350 1 3
at 300C~350C for 1h (See Table 3).
Table 2 Electrode
Coating type
Low nitrogen
AWS
JIS
E7016
D4316
Manufacturers name
S-16LB-26
American Welding Society
Japanese Steel Welded Product Engineering Co. Ltd (Japan)
Kobe Steel Ltd (Japan)
Page 160 of 176

Table 3 Electrode Heating Temperature
Coating type
Electrode heating temperature
Heating time
Low hydrogen
3-12
300350
1h
3-12 Welding and welding current
4 AC arc welding is used and welding current
is shown in Table 4. Its current is related to

electrode diameter.
Table 4 Welding Current

mm
Electrode diameter
(mm)
A
Welding current (A)
3-13
3.2
80120
130170
170220
230280
3-13 Preheating temperature
Determine the preheating temperature

5
according to ambient temperature. See Table
5.
Table 5 Preheating Temperature
Ambient temperature (C)

Preheating temperature (C)
2050
20
20
Preheating not needed
Page 161 of 176

3-14
3-14 Welders certificate
ASME The welder must obtain ASME boiler and

ASME pressure vessel welding qualification
IX
certificate (in accordance with Chapter IX
Welders Certificate of ASME Boiler and
Pressure Vessel Welding Code.
3-15
3-15 Weld inspection
ASME Inspection should be carried out according to

VIII 8 Appendix 8 Dye Penetrant Test Method
PT 6 (PT), Chapter VIII of ASME Boiler and
Pressure Vessel Welding Code and the
inspection acceptance criteria are shown in
Table.
Linear
indication
Unacceptable
Table 6 Inspection Acceptance Criteria
Acceptance criteria
Defect indication
mm
mm
Maximum allowable diameter
Maximum allowable defect length
(mm)
(mm)
1.0
30
3-16 3-16 Store the welding tools and put them

orderly in the specified area. At the same
time, sweep the condenser inside and remove

scaffold.
Page 162 of 176

Appendix 4 Combined Reheat Valve Connection Regulations
Contents
--
Chapter
1
10
11
12
Name
Page
Scope
Instruction
Material
Welding material
Equipment
Preparation before welding
Welding joint alignment
Welding instruction
Preheating and interlayer temperature
Post weld heat treatment
Weld check
Record
Page 163 of 176

13
14
15
Document submission
Deviation
Appendix
Page 164 of 176

1. Scope
ASME IX
1979
This instruction is applicable to the site

welding of combined reheat valve and high
pressure outer casing. All welding shall
conform to this instruction and Chapter IX of
ASME Boiler and Pressure Vessel Welding
Code (1979).
2. Instruction
GTAW Inert gas shielded arc welding (GTAW) is

2 used and the second layer and subsequent
SMAW
layers are welded with shielded metal-arc
welding (SMAW).
3
3.1
3. Material
3.1 Casing material
A Cr-Mo
A. Combined reheat valve: Cr-Mo steel

casting
B. High pressure outer casing: Cr-Mo steel

casting
3.2
Cr-Mo
3.2 Material specification
This instruction is applicable to the following

steep pipe diameter and wall thickness:
640.0mm
Steel pipe diameter: 640.0mm
58.0mm
Steel pipe thickness: 58.0mm
4
4.1
4. Welding material
4.1 Fusion wel ding metal material
ASME II C Root fusion welding metal is the AWS Class

No.SFA5.28 AWS ER90S-G material in Part C Material
ER90S-G
Specification No.SFA5.28, Chapter II of
ASME or other equivalent materials.
ASME II C Fusion welding metal for other layers is AWS
No.SFA5.5 AWS Class E9015-B3L material in Part C Material
E9015-B3L
Specification No.SFA5.5, Chapter II of
ASME or other equivalent materials.
Before welding, all electrodes are dried in the
300~350 3
electric over at 300C~350C for 3h.
4.2
4.2 Shielding gas

Page 165 of 176

99.9%
99.9% welding argon is used.
0.7m3/ To protect weld during welding, argon flow
needs to be maintained at 0.7m3/h.

5
5.1
5. Equipment
5.1 Welding motor
GTAW Gas tungsten arc welding (GTAW) uses DC

motor.
SMAW Shielded metal-arc welding (SMAW) uses
DC motor
6
6.1
6. Preparation before welding

6.1 Welding groove
6 The welding groove between the combined
reheat valve and the high pressure outer

casing is processed according to Figure 6.
6.2
6.2 Groove face
All groove faces should be undamaged and
be removed of oil, grease, rust and foreign

matters.
7
7.1
7. Welding joint alignment

7.1 Aligning method
A.1 A.2 Four supports are welded at A.1 and A.2

4 1
between the combined reheat valve and the
high pressure outer casing for positioning.
See Figure 1 for details.
7.2
7.2 Support
15~20mm
The support is made of 15~20mm thick low

carbon steel plate.
7.3
7.3 Support welding
Before the support is welding, all welding

250~300
areas should be preheated to 250C~300C
with oxyacetylene welding torch.
First, weld the support to the high pressure
15mm outer casing (fillet weld, weld leg length
15mm) and cover the welding area with

asbestos-free heat-insulating material to
gradually cool to room temperature.
Page 166 of 176

4.1~4.3mm 0.5mm
Then after the high pressure outer casing and

support are cooled, place the combined reheat
valve to the outer casing and ensure that the
groove root gap between the two is
4.1~4.3mm and center error does not exceed
0.5mm. Support welding needs to measure
the groove root gap. After welding, the
welding area is cooled using the above
method.
9 After preheating according to 9, measure and

3.5+0.5mm 3.5mm
ensure 3.50.5mm groove root gap. The best
gap is 3.5mm.
4.0mm When the gap exceeds 4.0mm or is too small,
remove the support and re-position the

combined reheat valve.
7.4
GTAW
SMAW
3mm
7.4 Remove support

After one layer is welded with gas tungsten
arc welding (GTAW) and the second is
welded with shielded metal-arc welding
(SMAW), cut off the support connected to the
casing and valve at 3mm from the flat plate.
After welding and post weld heat treatment

PTMT are finished, polish the weld to perform dye
penetrant inspection (PT) and magnetic

particle inspection (MT).
8
8.1
8. Welding instruction
8.1 General
Welding method is shown in Figure 5.
To prevent welding deformation, two welders

should weld symmetrically.
8.2
8.2 Positioning
All areas should be satisfactorily positioned.
8.3
8.3 Root welding (Layer 1)
GTAW Root is welded with gas tungsten arc welding

(GTAW) and welding area should be visually
checked. Welding is performed after all

defects are removed.
Page 167 of 176

Any movement of reheating interception/stop
valve during welding process shall be

recorded.
8.4
8.4 Welding of other layers
All the other layers are welded with shielded

SMAW metal-arc welding (SMAW). To prevent
welding deformation, two welders should

weld symmetrically and welding process
should not be discontinued.
3mm Increased weld height shall not exceed 3mm
and the thickness is increased from edge to

center.
Any movement of the combined reheat valve
during welding should be recorded.

8.5
8.5 Weld polishing
MT The weld should be polished and undergo
magnetic particle inspection (MT) after

welding. The defects around the weld and its
nearby area should be removed.
8.6
8.6 Welders certificate
ASME The welders must obtain the ASME Boiler

ASME and Pressure Vessel welding qualification
IX
certificate (in accordance with Chapter IX
Welders Certificate of ASME Boiler and
Pressure Vessel Welding Code).
9
9.1
9. Preheating and interlayer temperature

9.1 Preheating
2 Preheating is controlled as per curve in

250~350
Figure 2. Weldment temperature should be
controlled at 250C~350C.
250 Once the temperature is lower than 250C,
immediately stop welding and re-weld after

the temperature rises to the required value.
9.2
9.2 Heating method
100kVA >100kVA electromagnetic induction coil is

used for heating. To protect workpieces, the
8~10 coil is wrapped in the asbestos-free insulating
Page 168 of 176

13mm materials, 8~10 layers, thickness >13mm.

200mm 3
The width of the insulation layers should be
200mm more than the coil width. For details,
refer to Figure 3.
Totally 10~15 turns of electromagnetic
10~15 335mm
induction heating coils are wrapped around
each edge of the working welding groove and
heating width is 335mm.
The number of heating coils on the two sides

of the groove should be the same.
9.3
9.3 Temperature measurement
Thermocouple is placed on top, bottom, left

1 B.1 and right to measure temperature. The
4
thermocouple should be placed at the four
positions close to the weld joint shown in B.1
of Figure 1.
10
10.1
10. Post weld heat treatment

10.1 Stress relief
4 Stress relief is controlled as per curve in

250 Figure 4 and carried out using the
250
electromagnetic induction heating coils when
or before the welding temperature drops to
250C.
3
The width of the heating area is 3 times the

welding area.
10.2
10.2 Temperature measurement
1 C.1 The thermocouple placed at C.1 in Figure is

C.1 C.2 B.1 used to measure temperature change.
80
Temperature gradient at C.1 or C.2 and B.1
should be lower than 80C.
11
11.1
11. Weld check

11.1 General
PT After stress relief, weld surface is polished to

MTRT A
and undergoes PT, MT and RT inspection.
For its specification and acceptance
criteria, refer to Appendix A.
11.2
11.2 Repair of defective weld

Page 169 of 176

Defects around and near the weld should be
removed and rewelded using the above

method.
12
12. Record
Record should include:
(1) Electrode
(2) Welding motor and welding speed
(3) Preheating
(4) Interlayer temperature
(5) Post-weld heat treatment (including
temperature, heating time, heating and

cooling speed)
(6) Weld inspection result
(7)
Welders
conclusion
13
13. Document submission
qualification
inspection
Welders qualification inspection conclusion

should be submitted to Dongfang Turbine
Works before welding and if Dongfang

Turbine Works requires submitting the other
relevant documents, they should be submitted
together.
14
14. Deviation
All deviations should be approved by

Dongfang Turbine Works.
Appendix A Weld Inspection
1
1.1
PT
1. Dye penetrant test (PT)

1.1 Inspection regulation
10
Penetration time: at least 10min
1.2
1.2 Acceptance criteria
2
2.1
MT
Crack not allowed.

2. Magnetic particle inspection (MT)
Magnetization: prod method
Page 170 of 176

Magnetization time: 2s
600~800A
Magnetizing current: 600~800A
150~200mm
Magnetic head distance: two orthogonal

directions 150~200mm
2.2
3
3.1
Crack, undercut and mutual overlapping are

not allowed.
RT
3. Radiographic inspection (RT)
ASTM Execute ASMT standard of equivalent

standard. Radioactive source should be
placed to the center of pipe and welding area

and film placed on the circumferential surface
(as shown in the figure below).
Combined
reheat valve
Film
High pressure
outer casing
Radioactive
source
3.2
5 2mm
2mm

Allowable number of defects is 5. When
defect length is less than 2mm, the number of
defects is the actual number of defects; when
defect length is larger than 2mm, the number
of defects is the actual number of defects by
converting coefficient in the following table.
Page 171 of 176

Converting coefficient
Defect length
<2mm
2.1~
4.1~
6.1~
8.1~
10.1~
4.0mm
6.0mm
8.0mm
10.0mm
12.0mm
10
15
20
Converting
coefficient
1
Metal plate (low
carbon steel)
Figure 1
Support
Site welding (low carbon

steel electrode)
Shop welding (low

hydrogen electrode)
After the combined reheat

valve and high pressure
outer casing are welded,
remove the metal plate.
Combined reheat
valve
High pressure outer casing
Support
Figure 2 Preheating
Welding temperature 250~350C
Stress relief circulation is

performed according to
Figure 4. Do not cool to
room temperature.
Page 172 of 176

Combined reheat valve
Insulation material covering

layer (8~10 layers)
Coil (335mm wide)

3
Figure 3
Covering Layer
Then air cooled in stationary

state with furnace
Control stress relief after welding

4
Figure 4 Stress Relief Circulation
Page 173 of 176

Figure 5 Welding Technique
Layer
3
To Layer 3
1
Last layer
(A)
(V)
Process
Electrode
Current (A)
Voltage (V)
GTAW
Diameter
2.4mm
100~110
10~20
SMAW
Diameter
3.2mm
100~140
20~30
SMAW
Diameter
4.0mm
120~180
20~30
SMAW
Diameter
5.0mm
190~220
20~30
Before welding, all electrodes are dried in the

300~350 3 oven at 300C~350C for 3h. All dirt and slag
in the weld between pipes must be thoroughly

removed.
Final welding
layer (stiffened)
Figure 6 Welding Preparation
Page 174 of 176

Horizontal joint
Turbine center
Support
High pressure
outer casing
Combined
reheat valve
Page 175 of 176

Medium pressure steam

admission centerline
Medium pressure main

steam pipe flange
Support
Turbine centerline
Horizontal joint
Page 176 of 176

汽轮机安装及维护说明书d660f 000105asm Cn EManual de instalacion de turbina a vapor DONFANG

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MANUFACTURER

DONGFANG TURBINE CO.,LTD.

INSTALLATION INSTRUCTION OF N660-16.7/538/538 TURBINE

Document No.: (WBA)D660F-000105ASM

Document Title: Installation Instruction of

The first issue

Document No.: (WBA)D660F-000105ASM

Document Title: Installation Instruction of

Site Turbine Installation Flow Chart

Installation of Foundation Bolt and Bed 15

Installation of Low Pressure Cylinder

Installation of Bearing Housing

Installation of High and Medium Cylinder 32

Cylinder Alignment (Top-On Alignment)

Cylinder Alignment (Half Empty Cylinder)

iaphragm Alignment Adjustment

Document No.: (WBA)D660F-000105ASM

Document Title: Installation Instruction of

Flow Passage Clearance Check

Tightening of ALL Coupling Bolts

Preparation Work for Oil Flushing

First Oil Flushing

Second Oil Flushing

Final (Third) Oil Flushing

Steam Pipe Blowing

Document No.: (WBA)D660F-000105ASM

Document Title: Installation Instruction of

Resetting after Steam Blowing

T-G Foundation Embedded Parts Installation 129

Regulations of Gas Shielded Welding for 156

Document No.: (WBA)D660F-000105ASM

Document Title: Installation Instruction of

D660F This instruction manual is only applicable to

the installation and maintenance work of

This instruction manual only provides the

This instruction manual is a general purpose

instructive technical document and is not for

shall carefully read and get familiar with the

2. Direction for use of this instruction

This instruction manual

(1) Turbine installation flow chart

This part provides the turbine installation

recommended that this flow chart be used as

This instruction manual provides the site

This instruction manual lists in detail all steps

and descriptions of turbine installation on

Document No.: (WBA)D660F-000105ASM

Document Title: Installation Instruction of

instructive description for site installation.

3. Requirements for inspection tools

All measuring tools mentioned in this

instruction manual and to be used in site

4. Basic requirement for record

(1) The site turbine installation record shall

be filled in according to the requirements of

the requirements of the certificate.

(3) Installation record data shall be in the

(4) The over-limit dimension must be

by the inspector (quality inspector or

installation inspection on site

(1) Site welding is prohibited

Unless otherwise required in the drawings or

welding) of turbine parts and components is

(2) Storage of loose parts