SPRING LOADED TG DECK FOUNDATION

FOLLOWING SLIDES SHOW THE PROCEDURE OF INSTALLING THE SPRING ASSEMBLIES IN A SPRING LOADED TG DECK FOUNDATION :

CHANGE OF CATENARY READINGS SIMHADRI 2X500 MW

FOLLOWING HAS BEEN REPORTED FROM THE ABOVE POWER STATION: CHANGE IN CATENARY READING OF SIMHADRI 1 AFTER FLOATING OF TG DECK. CHANGE IN CATENARY READINGS (BEARING PEDESTAL HEIGHTS) AT SIMHADRI UNIT-2 WITH FOLLOWING CONDITIONS: - CONDENSER NECK NOT WELDED TO TURBINE. - COMPLETE WEIGHT OF MACHINE NOT YET ERECTED ON TG DECK. - TIE ROD BOLTS OF FEW SPRING ASSEMBLIES FOUND LOOSE, OTHERS COULD NOT PROBLEMS. SITE WAS ADVISED TO MAKE FOLLOWING MEASUREMENTS: - BETWEEN TG DECK AND COLUMN TOP. - BETWEEN SPRING ASSEMBLIES (REFER THE ENCLOSED SKETCH). DATA HAS BEEN RECEIVED FROM SITE INDICATING MAJORITY OF SPRING ASSEMBLIES HAVING BEING LOADED BEYOND THE EXPECTED DESIGN LOAD. BE CHECKED DUE TO ACCESSIBILITY

CHANGE OF CATENARY READINGS SIMHADRI 2X500 MW

THE ABOVE FACTS PROVE THAT ELEVATION OF THE DECK KEEPS CHANGING WITH ADDITION OF LOAD ON TG DECK EVEN PRIOR TO UNLOCKING OF SPRING ASSEMBLIES. ERECTION ENGINEERS AT

SIMHADRI SITE ARE FINDING IT DIFFICULT TO FINALISE THE

REFERENCE FOR CENTERING OF CYLINDER, ALIGNMENT AND CATENARY OF THE MACHINE. MOVING DECK HAS RESULTED IN FREQUENT CHECKING OF CENTERING AND ALIGNMENT READINGS. THIS HAS RESULTED IN INCREASE OF ERECTION TIME.

CONCLUSIONS
FROM THE READINGS TAKEN AT SIMHADRI, ANY ONE OF THE
FOLLOWING MAY BE TRUE: 1. ERROR IN COMPUTING THE DESIGN LOAD OF TG DECK ALONGWITH EQUIPMENT. 2. INADEQUATE STIFFNESS OF SPRINGS.

ACTION PLAN FOR SIMHADRI-2

REFER TO ERECTION PROTOCOLS. READINGS SET DURING

PLACEMENTS OF SPRING ASSEMBLIES BEFORE CASTING OF TG DECK.

NO NECK WELDING OF CONDENSER TO TURBINE TO BE DONE.

IF TAG WELDED, REMOVE THESE.

UNLOCK ALL TG DECK SPRINGS ASSEMBLIES AND FLOAT THE TG DECK. CONDUCT NECESSARY SHIMMING TO ACHIEVE THE ELEVATION

AND CATENARY OF THE MACHINE.

LOCK ALL TG DECK SPRING ASSEMBLIES WITH SUFFICIENT MARGIN FOR FURTHER LOADING OF TG DECK. WHILE DOING THIS ACTIVITY, REFER TO BENCH MARK AND BEARING PEDESTAL ELEVATION READING TAKEN BY TURBINE ERECTION RECORD READINGS. GERB TO PROVE THE HEALTHINESS OF SPRING ASSEMBLIES SUPPLIED FOR SIMHADRI.

ISSUES
SITE FEEDBACK INDICATES INCREASE IN ERECTION
CYCLE TIME. NO FLEXIBILITY IN SEQUENCE OF ERECTION ACTIVITIES. NO APPRECIABLE GAIN IN VIBRATION LEVEL ON MACHINE WITH SPRING LOADED TG DECK. INCREASE IN OVERHAULING TIME OF TURBINES WITH

SPRING
LOADED TG DECK. PROTECTION FROM SEISMIC LOADS. PRECAUTION FROM SEISMIC LOADS NOTED. GE / ALSTOM MAKE TURBINES DO NOT ENCOURAGE USE OF SPRING LOADED TG DECK.

WHAT SHOULD BE BHELS STRATEGY FOR FUTURE SETS ?

ACTION PLAN FOR FUTURE SETS:

TASK DURING ERECTION ELEVATION OF TG DECK SHOULD NOT CHANGE

WITH CHANGE OF LOAD IN TG DECK. TO ACHIEVE THIS WE PROPOSE:

GERB SHOULD PROVIDE BOTH SIDE LOCKING IN SPRING ASSEMBLIES AS IN CONDENSER SPRING ASSEMBLIES. GERB TO RECONSIDER THE AMOUNT OF ADDITIONAL PRESTRESSING. FOLLOWING ADDITIONAL PROTOCOLS NEEDS TO GENERATED WHILE PRE-STRESSING THE SPRINGS AT SITE FOLLOWING MEASUREMENTS TO BE NOTED: GAP BETWEEN SPRING ASSEMBLY WITH TIE BOLTS LOOSE (FREE LENGTH OF SPRINGS) AT FOUR LOCATIONS. FORCE REQUIRED TO PRE-STRESS TO THE DESIRED VALUE TO COMPUTE SPRING INDEX AND COMPARE WITH DESIGN VALUE FOR EACH SPRING ASSEMBLY.

ACTION PLAN FOR FUTURE SETS:

RANDOMLY SELECT FEW SUCH PRESTESS SPRING ASSEMBLIES, LOOSENING ITS TIE ROD. MEASUREMENT FREE LENGTH AND CAMPARE WITH FREE LENGTH REFERENCE COMPRESSION. ALL READINGS AS DEPICTED IN THE SKETCH TO BE TAKEN WITH INSIDE MICROMETER, LOCATION OF THE READING TO

BE DEFINED, IDENTIFIED AND PUNCHED (USE METAL

MARKER, WHERE PUNCHING CANNOT BE CARRIED OUT). LOCATION OF MEASUREMENT A SHOULD BE CHIPPED AND SMOOTHENED TO AVOID ANY DISTURBANCES DUE TO LOOSE CONCRETE. BEFORE FLOATING OF TG DECK PUT FOUR DIAL GAUGE INDICATORS ON TOP OF TG DECK. SET IT ZERO W.R.T. TG FLOOR. CHECK AND RECORD THE READINGS AFTER FLOATING OF TG DECK.

ACTION PLAN FOR FUTURE SETS:

VENDOR TO GIVE INSTALLATION MANUAL TO PROVIDE A
STEPWISE INSTRUCTIONS AND NUMBER OF PROTOCOLS TO BE GENERATED. BHEL TURBINE ERECTION ENGINEER TO INVOLVE DURING THE COMPLETE INSTALLATION OF DECK SPRINGS.

SCHEMATIC FOR GERB SPRING

TG DECK

SHIM TIE ROD

TG COLUMN

NOTE: 1. THESE READINGS ARE IN ADDITION TO READING TAKEN BY GERB ON THE PROTOCOL DOCUMENT. 2 TURBINE ENGINEER ALONG WITH CIVIL ENGINEER TO ASSOCIATE.

A.

B. C

STICK MICRO METER READING AT FOUR LOCATIONS BETWEEN DECK AND COLUMN. MARK THE LOCATION OF READING (USE METAL MARKER). STICK MICROMETER READING AT FOUR LOCATION OF EACH SPRING ASSEMBLY. RECORD TOTAL THICKNESS OF SHIM HEIGHT AND NUMBER OF SHIMS.

SCHEMATIC FOR M/S GERBS CONDENSER SPRING ASSEMBLY

CONDENSER BOTTOM PLATE

TIE ROD JACK BOLTS SHIM

CONDENSER FOUNDATION

BACK

MOUNTING RECORD AT SIMHADRI UNIT-2 BY M/S GERB

Prestressing and setting Mounting Prestressi Static Deflection ng Value Deflection (mm) (mm) 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 31.10.2000 Releasing and adjusting 18.02.2002 Spring Shim Shim Spring Height After Releasing Height Expected Thickness Thickness (mm) Prestressing Settlement Theoretic Actual value (mm) (mm) (mm) 1 2 3 4 (mm) 229 5 16 5 226.9 227.3 228.7 228.6 226 5 22 5 222 224.1 225 224.5 226 5 16 5 226 226.9 226.1 225.8 229 5 16 5 226.4 226.1 225.2 225 229 5 16 5 226.9 225.4 226.3 227 229 5 16 5 226.3 225.8 227.4 228.1 226 5 17 5 225.6 225.7 225.1 225.8 229 5 17 5 228.1 227.9 225.6 226.2 229 5 14 5 228.7 228.6 227.9 226.2 229 5 14 5 226.3 227.2 226.5 225.6 229 5 18 5 225.5 226.3 226.6 226 229 5 20 5 227.6 226.6 227.5 225.9 229 5 13 5 227 226.2 226.7 227.2 226 5 17 5 224.8 225.2 225.6 224.8 229 5 16 5 226.4 225.3 226.8 228.2 226 5 23 5 225 225.6 224.6 224.4 229 5 16 5 227 227 224.7 226.2 226 5 22 5 224.4 223.5 223.2 223.7 229 5 19 5 228.7 228 227.5 226.8 226 5 18 5 225.6 226 226.8 226.3 226 5 22 5 223.9 224 222.8 223.2 229 5 24 5 223.2 227.7 227.9 228.5 229 5 16 5 225.8 226.4 225.8 225.4 226 5 19 5 224.7 223.4 223.3 222 229 5 14 5 227.8 228.5 229 229 229 5 17 5 227.5 228.1 227 227.8 229 5 14 5 225.3 224.9 223.3 225.1 229 5 19 5 225.1 225 225.2 226

Spring Unit Sl No Gr No 1 2 2 1 3 1 4 2 5 2 6 2 7 1 8 2 9 2 10 2 11 2 12 2 13 2 14 1 15 2 16 1 17 2 18 1 19 2 20 1 21 1 22 2 23 2 24 1 25 2 26 2 27 2 28 2 Type TVEH-750 T-1030 TVEH-750 T-650 T-650 T-1200 TVEH-750 T-1200 T-1200 T-800 T-1200 T-1030 T-650 TVEH-750 T-950 T-1030 T-650 T-950 T-500 TVEH-750 T-950 T-1030 T-800 T-950 TVEH-750 T-800 TVEH-750 T-800

MOUNTING RECORD AT SIMHADRI UNIT-2 BY M/S GERB

Prestressing and setting 31.10.2000 Releasing and adjusting 18.02.2002 Spring Shim Shim Expected Mounting Prestressi Height Static Thickness Thickness Settlemen Deflection ng Value Prestressi Deflection Theoretic Actual t (mm) (mm) ng value (mm) (mm) (mm) (mm) 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 226 226 226 229 229 229 226 229 229 229 229 229 226 226 226 229 229 226 229 226 229 226 229 226 226 229 229 229 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 20 26 19 16 19 18 18 18 23 28 25 18 19 16 22 19 15 23 16 16 20 22 18 20 18 18 16 20 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

Spring Height After Releasing (mm) 1 224.3 225 226.5 227.5 227 225.7 229 227.1 222 226.6 227 227.5 224.7 225.9 224 226.6 227.6 224.3 229 226.7 228 224 226.5 224.1 223.7 226.7 226 226.1 2 227 225.3 226.6 227.1 227.6 226.2 229.1 227.1 226.5 226.4 227.4 227.8 224.5 225.2 223.7 225.9 227 225.1 228.3 225.9 227.5 224.5 227.4 222.3 225.3 226.8 224.4 226.3 3 226.3 224 226.8 226.3 225.4 227 229 226.3 227 227.1 225.5 228.8 223.6 226.3 223 228.6 227.3 224.1 224.9 226.7 227.6 225.3 227.4 222.2 226.2 227.3 222.2 222.9 4 223.8 224.8 226.5 226.8 226.2 226.4 229 227 222 226.5 225 228 223.8 226.2 223.6 227 226.4 224.8 225.8 226.9 227.2 224.8 227 222 225.1 226.9 223.5 222.9

Spring Sl No Gr No 31 1 32 1 33 1 34 2 35 2 36 2 37 2 38 2 39 2 40 2 41 2 42 2 43 1 44 1 45 1 46 2 47 2 48 1 49 2 50 1 51 2 52 1 53 2 54 1 55 1 56 2 57 2 58 2

Unit Type TVEH-750 T-1030 TVEH-750 T-650 T-650 T-1200 TVEH-750 T-1200 T-1200 T-800 T-1200 T-1030 T-650 TVEH-750 T-950 T-1030 T-650 T-950 T-500 TVEH-750 T-950 T-1030 T-800 T-950 TVEH-750 T-800 TVEH-750 T-800

BACK

SPRING LOADED TG DECK

FOUNDATION