NATIONAL THERMAL POWER CORPORATION OPERATION DIVISION FORMAL DOCUMENTATION SYSTEM OPERATION GUIDANCE NOTE- OGN/OPS/MECH/023

Issue No. : 1 Date : October, 1994

SAFETY PRECAUTIONS TO BE TAKEN WHEN CARRYING OUT INSPECTION AND MAINTENANCE ON TURBINE - GENERATOR COMPONENTS WHICH ARE NOT COMPLETELY SELF-SUPPORTING

Approved for Implementation by ..................................................... Director (Operation) Date :.............................................

Enquiries to : Executive Director, Operation Services.

SUMMARY

This Guidance Note has been written to ensure safe working practices and to avoid accidents when carrying out inspection/maintenance on turbine generator components such as top half cylinders which contain secondary components which are not completely self-supporting.

SAFETY PRECAUTIONS TO BE TAKEN WHEN CARRYING OUT INSPECTION AND MAINTENANCE ON TURBINE - GENERATOR COMPONENTS WHICH ARE NOT COMPLETELY SELF-SUPPORTING

CONTENTS

Page Nos. 1.0 2.0 3.0 4.0 5.0 Introduction Superseded Documents Scope Precautions Review 1 1 1 1 3

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SAFETY PRECAUTIONS TO BE TAKEN WHEN CARRYING OUT INSPECTION AND MAINTENANCE ON TURBINE - GENERATOR COMPONENTS WHICH ARE NOT COMPLETELY SELF-SUPPORTING
1.0 INTRODUCTION Fatal accidents have occurred due to diaphragms from LP turbine top half cylinders in a set down condition falling onto personnel working below. It is therefore mandatory that work on diaphragms and/or their support systems must never be carried out from below unless suitable and adequate measures have been taken to ensure that the diaphragms cannot fall. 2.0 3.0 SUPERSEDED DOCUMENTS - Nil SCOPE This Guidance Note applies to all turbines where top half diaphragms and other components (e.g gland carrier rings) are secured to and lift off integral with the top half cylinders. 4.0 4.1 PRECAUTIONS The Guidance Note recognises that on lifting top half cylinders unforeseen obscured defects/failures in the diaphragm securing system constitute a major safety hazard to personnel and that severe damage to plant can occur. When top half cylinders are being lifted, complete with diaphragms and gland carrier rings, purpose designed back-up supports for these components shall be fitted wherever this is practicable (e.g in the form of plates/beams clamped along or across the underside of the flanges) before the cylinder is moved away from the machine. This will involve partial lifting of the top half cylinder to provide sufficient access to fit the additional supports. If required, the original equipment manufacturer

4.2

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will advise on suitable designs which can be fitted without exposing personnel to the potential risk of falling components. Instruction on the fitting procedures shall be given to all personnel carrying out this operation. 4.3 Inspection of maintenance work shall not be carried out beneath a suspended component. All personnel shall be kept clear during transportation of suspended components by the overhead crane. No person shall be allowed to pass under a suspended component. If major work is required within a top half cylinder, such as removal/adjustment of diaphragms or replacement of their securing devices, the half cylinder complete with assembled components shall be inverted and set down on suitable supports before work commences. If there is good reason for the work such as inspection and/or cleaning to be carried out underneath a turbine cylinder in its assembled condition, suitable and adequate support measures shall be taken. The cylinder shall first be set down on substantial, purpose designed, steel supports or timber baulks. Then all sub-components held within the cylinder but not already secured by the flange plates/beams (see 4.2 above) shall be provided with adequate back-up support to guard against possible failure of holding devices. Power Station General Managers shall review local working procedures/Management Instructions to ensure that they adequately cover the requirement to establish safe conditions during all phases of activity involving lifting, transportation inspection/testing and maintenance work on top half turbine cylinders containing diaphragms and other assembled components. Particular emphasis shall be placed on the danger of potentially defective/fractured component securing devices when carrying out this review. Any difficulties in applying these requirements shall be referred to the original equipment manufacturer.

4.4 4.5

4.6

4.7

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4.8

This Guidance Note shall also apply where turbine cylinder work is undertaken at workshops. REVIEW The Executive Director, (Operation Services), will be responsible for reviewing of this Guidance Note on a 2-yearly basis.

5.0