SUGGESTIONS FOR BEST PRACTICES IN RUN-OUT DEVICES

By: G.Sridhar Sr.Manager/TG BHEL Site Office, TATA Trombay

INTRODUCTION
During the course of erection and commissioning of Higher Rating Steam Turbines, the need to improve upon certain existing methods of erection was felt. Among the many that need improvement are the standard, time consuming, laborious and not so perfect methods of: Setting the pedestal seal bore by piano wire before grouting the pedestals Measurement of face run-out of the IP & LP Rotors by rotating the rotors on saddle supports

1. MEASUREMENT OF FACE RUNOUT OF IP & LP ROTORS BEST PRACTICE

Normal Practice
The normal practice of measurement of face runouts of IP & LP Turbine Rotors is to place them on saddle supports and rotate them. Lifting action of the crane hook causes rotation of the rotor. To aid in rotation of the rotor, copper sheets are placed in between the saddle and the rotor and, grease is smeared to reduce friction during rotation. It has been noticed that this method has a few problems associated with it:-

It is not possible to restrict the axial movement of the rotor in order to avoid overshooting the range of the dial gauge. The area of contact being very small, it requires extreme care and control while operating the EOT, lest it should cause an irreparable accident and lead to loss of both men and material. It has often been noticed that there is quite an error between the measurement made at shop and those made at site leading to avoidable loss of time in correspondence, summoning experts from MUs, etc. It gives the feeling of using a very primitive and unreliable method of measurement. Overall, it is never like measuring the run-outs by anchoring the rotor on a lathe to take the measurements and thats exactly the cause of the error.

Suggested New Method

To tide over the above problems, a very simple device was made at site. To make the device, the following material was made use of: Shaft of 40mm x 1000mm long Ball Bearings with Plummer block for above shaft Supports to anchor the Plummer blocks Cross arm Dial Gauges for mounting to X-arm The sketch of the fixture is as in the adjoining slide. 1 no. 2 nos. 2 nos. 1 no. 2 nos.

Brg with Plummer Block

Dia 40 Shaft

Cross Arm

Dial Pointers

External Support for anchoring the Plummer Block

Shaft Support provided by Unit

Advantages:
This method is very user friendly and costs only Rs.5000/- to make. Does not require too much of a precision in machining the shaft. Does away with repeated rotation of the rotor for every reading. Reduces the risk of the rotor toppling during rotation by EOT crane. Compares well with the values attained at works on a lathe.

Overall, an improvement in the positive direction.

2. CENTERING OF TURBINE BEARING PEDESTALS BEST PRACTICES

Normal Practice
The usual practice is to draw a piano wire coinciding with the centre-line of the TG Axis and centre the pedestals at the seal bore by measuring the distance between the seal bore and the piano wire by an Inside Micrometer. Though the method has been used successfully in the past, there have been elements of doubts cast over its correctness. These are enumerated in adjoining slide:

There is no scientific method to determine the amount of tension to be given to the piano wire During windy seasons, the piano wire oscillates so much that no two readings are consistent, there by introducing the element of human error. The effect of ambient temperature on these measurements has always been noticed and over the years it has been assumed that the best period to record the measurements is the early hours of the day i.e.; between 0600 & 0700 hrs. This method can be used to align the pedestal in one axis only. It cannot be used to set the elevation of the pedestal.

Recommended Method
LASER ALIGNMENT is a method being used by many an OEM to good and accurate effect. This device as is understood from reliable sources takes into account the variations of temperature and also is not affected by wind. It can be used to center the pedestal as well as set the elevation simultaneously. This vastly reduces the time taken for each reading and the overall time taken for alignment of the pedestals as a whole. Also, it eliminates the human error that is likely to occur. The method can be extended to alignment of Condenser Tube Support Plates as well.

3. COUPLING OF TURBINE ROTORS

Normal Practice
The normal practice of coupling of Turbine Rotors is to Ream & Hone the coupling, machine the bolts to the required diameter, balance the coupling bolts, insert and stretch them to the required values. The entire job of Reaming, Honing, Machining of Coupling Bolts and Balancing of the rotors is a time consuming and costly one. There are certain pitfalls associated with this arrangement:

The process is long and arduous. It depends too much on the skill of the person carrying out the job. The requirements are very stringent and many a times in remote areas, facilities for high-accuracy machining is not available. The process is irreversible; meaning, one mistake in the machining of the bolts and the bolt cannot be used.

Recommendation
Since the basic idea is to develop contact pressure and thus transmit torque, the use of coupling bolts and nuts similar to the ones being used in BFPs can be thought of. Once alignment is completed, coupling is a very easy and quick job in a BFP. This concept can be extended to the Turbine as well.

Advantages:
No time lost between alignments and coupling. Reaming, Honing, Bolt Machining and Balancing can be done away with. A significant reduction in cycle time considering that it takes at least a week for each coupling. Due to the above, the element of human error is totally done away with. Easy on the contractor as well; the cost of Reaming, Honing and Bolt Machining is saved.