Book No.

Standard Work * * * * *

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Import
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Possibil
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Freque
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Risk
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Instruction Assess TJPSC-ASR-WI-005, R00
ment Operation classification
Basic operation
Plant
Before C/ 3 4 3 21 II Regular operation
Operation TURBINE ROTOR
After C/M 3 4 3 21 II Irregular Operation Dept. Name Shop Name
ASSEMBLY
Risk mitigation II II On-site operation

Product Name Operation No. of personsW

Steam Turbine Rotor Inside Dovetail Blade Assembly (T - Type Blade) 2perso

Required Qualification Applicable tools/Measuring instruments Applicable materials/consumable goods Protecti

Vernier Caliper ,Copper Hammer, Thickness gauge,
Marker,Molykote,Color paste,White Safety Shoes, Safety fo
Sr.Team member/Team member Air gun,flate file,Cleaning agent,
Petrolatum gel, Gog
Anti-seize device,Brush,BlockTightening bar

Incidents occurred in the past : Remarks

Incidents prone to occurrence:
1)Safety Check the large blades in sequence sheet
Hammer hit the finger and got injuired Check the instructions of shot peening
Chips entering into eyes while cleaning of rotor

Quality Non-conformity .
In box balde get damage .
Fixing of blades non sequenceing
Reading error occur

Countermeasure :

1) Safety
Wear hand gloves and to avoid accident
Cleaning after work be done carefully

2) Quality(Confirmity)
Put partion of card board plate in the box and keep all the blades
Check the moment sequence sheet
Check Calibration of instruments.

1) Purpose: Standards :
In turbine rotor for entring the indside dovetail Blades For shot peening refer the drawing 2KS105243
For shot peening refer the KM SI 8008
2) Scope For Notch Blade insertion refer KM SI6032
In turbine rotor assemble the inside dove tail blades as per moment squence sheet
 Part Name Operation Book no.
Turbine Rotor Inside Dovetail Blade Assembly (T - Type Blade) TJPSC-ASR-WI-005, R00

Confirmed by

Prod. Engineering
Operation chief
Applicable
Operation

Operator
S.No Operation StepOperation details Operation Points tools/Measurign

QC
duration
instruments

1 Preparing tools and work spot

1 Prepare the tools reqiured for the blade assembely Molykote P-37
2 Clean the work spot before starting the work Anti-seize agent
Cleaning Cloth
2 Prepartion for blade fixing White petrolatum
1 Clean inside groove area with cleaning agent Gel
2 Apply molykote entire groove section Copper rod

Molykote P-37 White Petrolatum gel

3 Blade Checking and Arranging

1 Arrange all the blades as per sequence chart list
2 Confirm the number stamp inspection in all blades
3 Deburr the radial contat surface with a file if required. Blade sequence stamp
 Blade sequence stamp
4 Apply white petrolatum gel on axial contact type bucket.

Part Name Operation Book no.

TURBINE ROTOR Inside Dovetail Blade Assembly (T - Type Blade) TJPSC-ASR-WI-005, R00

Confirmed by

Operator

Operation chief
Applicable

Engineering
Operation
S.No Operation StepOperation details Operation Points tools/Measurign

Prod.
duration

QC
instruments

4.) Blade Insertion

1 Check the blade insertion direction in the drawing Molykote
2 Blow air and remove the foreign obstacles from the groove Oil
3 Start the blade insertion
4 If the blade is not enter smoothly , file the contact condition and reassemble
5 Insert remaining all the blades.

Caution !
Please wear the hand gloves in order
to avoid hand scratch with burr.

Inside Dovetail blade insertion (I-Type )

6 Checking blade clearance
1 After inserting all the blades hit the blades with copper hammer
to close the clearance gap
2 Check the clearances of blades as per drawing mentioned
QY
QY careful!
careful! !
3 If clearance is overlimit grind the blade Check
Check the cover gap dimensions as indicated
4 To apply color solution and check the eye spot area of the blade in
in the drawing!
 QY
QY careful!
careful! !
Check
Check the cover gap dimensions as indicated
in
in the drawing!

Feeler Gauge

Clearance check

Clearance check

Part Name Operation Book no.

TURBINE ROTOR Inside Dovetail Blade Assembly (T - Type Blade) TJPSC-ASR-WI-005, R00

Prod. chief
Confirmed by
Applicable
Operation

Operator

eering
Engin
S.No Operation StepOperation details Operation Points tools/Measurign

Operation

QC
duration
instruments
4.) Grinding of Blade
1 Remove the blade outside from the assembely Color contact paste
2 Apply color contac paste in master piece blade Marker
3 Grind the eye spot area and recheck again
4 After completion of grinding assemble the blade
5 Recheck all the blade clearances Master piece
blade

5 Notch Blade Check Vernier Caliper

1 Take notch blade and noted down the dimensions C A
as mention in the check recorder (CR) B
2 Note down the dimensions in CR

Notch blade dimensions

Checking

6 Notch Blade Gap Checking

!! QY !!
Is better check the caliparation of the instrument
 1 After Assemble of all the blades expect notch blade
2 Check the gap of notch balde (using vernier Caliper ) !! QY !!
Is better check the caliparation of the instrument
3 Note down the values in CR
4 Calculate the amount of machining in large blades

Part Name Operation Book no.

TURBINE ROTOR Inside Dovetail Blade Assembly (T - Type Blade) TJPSC-ASR-WI-005, R00

Confirmed by

Operation chief
Applicable

Operator

Engineering
Operation
S.No Operation StepOperation details Operation Points tools/Measurign

Prod.
duration

QC
instruments

7.) Machining Of Large Blade

1 In large blade only maching have to do Dial gauge
2 Set the machine as centre and mark the cutting points in blade Spanner
3 Check in dial gauge balde is in zero position Allen key
4 Start the blade machining Tool cutter
Air gun

Note KY! !
During processing always wear protective glasses
Also, be careful that you do not cut the hands and fingers when
handling the cutter wear a leather hand-gloves!

Blade in zero position Blade Machining

 Blade in zero position Blade Machining

8.) Blade Chamfering,Shot peening and Polishing Micro hand tool

1 Maching blades have to do shot peening (in tooth section) Grinding machine
2 In blade cover and tooth grinding,chamfering and polishing have to do Color solution
3 Repeat the step 4
4 Using polishing cutter to polish the blade

Blade Grinding

Part Name Operation Book no.

TURBINE ROTOR Inside Dovetail Blade Assembly (T- Type Blade) TJPSC-ASR-WI-005, R00

Confirmed by

Operator

Operation chief
Applicable

Engineering
Operation
S.No Operation StepOperation details Operation Points tools/Measurign

Prod.
duration

QC
instruments

8 Notch Blade insertion

1 Assemble the machining of large blades Tightening bar
2 Check the gap of notch blade Copper hammer
3 Insert the notch blade Copper round bar
4 Fix the jig in blade cover and hit with hammer Packing tape
to insert the notch blade
5 Check the clearance of blade
 Note KY! !
While hiting the blade the hammer may swing

Notch Blade Insertion

9 Notch Blade Clearance Checking

1 After assembled the notch blade
check the clearance

Clearance Zero Clearance checking

Part Name Operation Book no.

TURBINE ROTOR Inside Dovetail Blade Assembly (T- Type Blade) TJPSC-ASR-WI-005, R00

Confirmed by

Operator

Operation chief
Applicable

Engineering
Operation
S.No Operation StepOperation details Operation Points tools/Measurign

Prod.

QC
duration
instruments

1 Check the noth blade tooth section
2 Normal blade and noth blade level are equal
 Checking blade insert
level

7 1 In step eight gap not enough to insert notch blade

2 Again check the gap and machining of large blade
3 Repeat the step 7

8 1 After completion works clean the area

2 Return the tools and rearrange the array table
k No. Page No.

WI-005, R00 7

Name Blade Assembly (W1)

f personsWork duration

2persons/20hrs

Protection Wears

oes, Safety foot Wear, Gloves, Safety

Goggles
o. Page No.
005, R00 7

Operation
Remark
duration
o. Page No.

005, R00 37

Operation
Remark
duration

dicated
dicated

o. Page No.

005, R00 47

Operation
Remark
duration

nstrument
nstrument

o. Page No.

005, R00 57

Operation
Remark
duration

gers when
ngers
o. Page No.

005, R00 67

Operation
Remark
duration
may swing

o. Page No.

I-005, R00 77

Operation
Remark
duration