10 DISASSEMBLY AND RE-ASSEMBLY

MANUAL
10.1 Disassembly and Re-assembly of the Turbine Block HTCZ 591 058 V0001 EN

HTMV 400 234/11

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Disassembly and Re-assembly of

the Turbine Block

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Revision History
Revision Content of Change Document Pages
total :
- - 65

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Contents

1 GENERAL REMARKS ......................................................................................................... 9

1.1 General information ............................................................................................... 9
1.1.1 Use as Designed.......................................................................................... 9
1.1.2 Identification of Residual Dangers and Dangerous Areas ............................ 9
1.1.3 Safety ........................................................................................................ 10
1.1.4 Components and Spare Parts .................................................................... 11
1.1.5 Exclusions from Liability ............................................................................. 11
1.2 Information for the operator / owner of the plant .............................................. 12
1.2.1 Preparation of Staff .................................................................................... 12
1.2.2 Safety and Monitoring Equipment .............................................................. 12
1.2.3 Safety Rules that Apply .............................................................................. 12
1.2.4 Your Responsibilities.................................................................................. 13
1.2.5 Further Duties of the Operator ................................................................... 14
1.3 Instructions for the supervisor ........................................................................... 14
1.3.1 Authorized Operation ................................................................................. 14
1.3.2 Following Existing Safety Rules ................................................................. 15
1.3.3 Responsibilities of the Supervisors............................................................. 15
1.3.4 Manning the Operating Stand .................................................................... 15
1.4 Instructions for the operating and maintenance staff ....................................... 16
1.4.1 Working with Safety in Mind ....................................................................... 16
1.4.2 Safe Condition for Maintenance Work ........................................................ 16
1.4.3 Safety Rules that Apply .............................................................................. 17
1.4.4 Questions concerning Safety ..................................................................... 17
1.4.5 Conduct following Malfunctions .................................................................. 17
1.4.6 Emergency Shut-Down .............................................................................. 17
1.4.7 Denial of Access to Unauthorized Individuals ............................................. 17
1.4.8 Reporting Damage and Defects ................................................................. 17
1.4.9 Special Tools and Spare Parts ................................................................... 18
1.4.10 Inspections and tests ................................................................................. 18
1.4.11 Special Dangers......................................................................................... 18

2 DISASSEMBLY AND ASSEMBLY GUIDELINES .............................................................. 21

2.1 Introduction .......................................................................................................... 21
2.2 General ................................................................................................................. 22
2.2.1 Safety Precautions ..................................................................................... 22
2.2.2 Standard Engineering Practices ................................................................. 23

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2.2.3 Technical Knowledge Required ................................................................. 23

2.2.4 Replacement Parts .................................................................................... 24
2.2.5 Tools and Lifting Devices........................................................................... 24
2.2.6 Inspections and Checks............................................................................. 25
2.2.7 Reassembly............................................................................................... 25
2.2.8 Pipework ................................................................................................... 26
2.3 Shutting down the turbine .................................................................................. 26
2.3.1 Steam Temperature Distribution ................................................................ 26
2.3.2 Steam Turbine Shut Down and Isolation .................................................... 26
2.3.3 Removal of Split-line Insulation Mats ......................................................... 27
2.3.4 Removal of the Sound-proof Structure (if applicable) ................................. 27
2.3.5 Pre-dismantling Visual Checks .................................................................. 27
2.3.6 Inspections Prior to Dismantling ................................................................ 28
2.3.7 Dismantling Sequence ............................................................................... 28
2.3.8 Reassembly Sequence .............................................................................. 28
2.3.9 Inspections After Reassembly ................................................................... 28
2.4 Lubricating the components and parts.............................................................. 29
2.4.1 Lubricants for bladings............................................................................... 29
2.4.2 Lubricants for turbine parts ........................................................................ 29
2.4.3 Reassembly of Journal and Thrust Bearings ............................................. 29
2.4.4 Reassembly of Turbine and Bearing Housings .......................................... 29
2.4.5 Tightening Torques and Pre-stressing Forces ........................................... 30
2.4.6 Special Maintenance Precautions .............................................................. 30
2.4.7 Test Certificates......................................................................................... 30

3 DISASSEMBLY PREPARATIONS .................................................................................... 33

3.1 Shutting down the turbine .................................................................................. 33
3.1.1 Turbine insulation ...................................................................................... 33
3.1.2 Removing the insulation ............................................................................ 33
3.1.3 Re-installing the insulation ......................................................................... 34
3.2 Isolating the auxiliary systems ........................................................................... 35
3.3 Providing the auxiliary means ............................................................................ 35
3.4 Sequence of disassembly ................................................................................... 35

4 DISASSEMBLY OF THE TURBINE .................................................................................. 37

4.1 Preparations ........................................................................................................ 37
4.2 Check measurements before dismantling the inner casing ............................. 37

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4.3 Dismantling the inner casing upper half ............................................................ 37

4.3.1 Loosening the parting flange bolts of the inner casing ................................ 37
4.3.2 Lifting off the inner casing upper half ......................................................... 40
4.3.3 Loosening the parting flange bolts of the balancing piston casing .............. 40
4.3.4 Lifting off the balancing piston casing upper part........................................ 42
4.4 Check measurements before removing the rotor .............................................. 43
4.5 Lifting out the turbine rotor................................................................................. 43

5 MAINTENANCE ................................................................................................................. 47
5.1 General recommendations .................................................................................. 47
5.1.1 Checks and tests ....................................................................................... 47
5.1.2 Cleaning the components .......................................................................... 47
5.1.3 Marking the dismantled components .......................................................... 47
5.1.4 Replacing components............................................................................... 47
5.1.5 Tools .......................................................................................................... 48
5.1.6 Test certificates .......................................................................................... 48
5.1.7 Turbine ...................................................................................................... 48
5.1.8 Visual checks ............................................................................................. 48
5.1.9 Cleaning the machine parts........................................................................ 48
5.1.10 Turbine instruments ................................................................................... 49
5.1.11 Replacing machine parts............................................................................ 49
5.1.12 Re-assembly recommendations ................................................................. 49
5.2 Blading ................................................................................................................. 49
5.2.1 Visual checks ............................................................................................. 49
5.2.2 Cleaning the blading .................................................................................. 50
5.2.3 Replacing blading parts.............................................................................. 50

6 RE-ASSEMBLY OF THE TURBINE ................................................................................... 52

6.1 Starting point ....................................................................................................... 52
6.1.1 Bearing pedestals ...................................................................................... 52
6.1.2 Turbine ...................................................................................................... 52
6.2 Lifting into place the turbine rotor ...................................................................... 53
6.2.1 Installing the lifting device .......................................................................... 53
6.2.2 Lifting into place the rotor ........................................................................... 54
6.2.3 Check measurements after lifting into place the rotor ................................. 55
6.3 Re-mounting the balancing piston casing upper part ....................................... 56
6.3.1 Lifting into place the balancing piston casing upper part ............................ 56
6.3.2 Tightening the parting flange bolts of the balancing piston casing .............. 58

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6.3.3 Lifting into place the inner casing upper half ............................................. 58
6.3.4 Tightening the parting flange bolts of the HP inner casing ......................... 60
6.4 Check measurements before re-mounting the outer casing ............................ 60
6.4.1 60

7 FINAL WORK .................................................................................................................... 63

7.1 Adjusting the operating positions...................................................................... 63
7.2 Pipelines and pipe unions .................................................................................. 63
7.3 Power supply ....................................................................................................... 63
7.3.1 Connecting the auxiliary systems .............................................................. 63
7.3.2 Bearing pedestals ...................................................................................... 63
7.3.3 Valve actuators .......................................................................................... 64
7.3.4 Turbine ...................................................................................................... 64
7.4 Lube oil supply to the bearing pedestals .......................................................... 64
7.5 Functioning of the valve actuators .................................................................... 64
7.6 Auxiliary systems ................................................................................................ 64
7.7 Insulation and enclosure .................................................................................... 64
7.7.1 Insulation ................................................................................................... 64
7.8 Checks and final work......................................................................................... 65

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Additional Documents
Synopsis of test certificates
Inspection plans for turbines

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CHAPTER 1
GENERAL REMARKS

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GENERAL REMARKS 1

1 GENERAL REMARKS
Introduction
This chapter comprises four sections:
1.1 General Information
1.2 Information for the operator / owner of the installation;
1.3 Information for the plant supervisor;
1.4 Information for the operating and maintenance staff

Note

The operating and maintenance staff must read Sections 1.1, "General
Information," and 1.4, "Information for the Operating and Maintenance
Staff."
The owner/operator and the supervisor must be familiar with the entire
document.

1.1 General information

1.1.1 Use as Designed
The following points must be noted to ensure that the machine (gas turbine, steam
turbine, or generator) will be used as intended:
a) The operating instructions for the individual systems, blocks, and components
define their respective use as designed.
b) The machine may only be used within the permissible operating ranges.

1.1.2 Identification of Residual Dangers and Dangerous Areas

Symbols in the operating instructions highlight special safety rules.

DANGER
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury. This signal word is to be limited
to the most extreme situation.

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WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

CAUTION
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury. It may also be used to alert
against unsafe practices.

Caution
Information pointing out possible damages to the machine.

Note
Is an important element of the procedure and should be observed.

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3 Illustrated parts list

Informs the user of the relevant Parts List where further details of
each component can be found.

1.1.3 Safety
The plant has been designed according to state-of-the-art technology (at the time of
its production) and complies with the generally recognized safety regulations. All the
same, dangers may arise when operating the plant. To limit these dangers, always
pay attention to all of the instructions in the operating instructions and to all safety
rules.

WARNING
Hazardous operation
 Operate the plant only when it is in a proper condition and always
follow the operating instructions.
Operating safety is no longer guaranteed if the plant is used inappropriately. Here
some examples of inappropriate use:

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a) Faulty maintenance work

b) Omission of tests and measurements that also serve to detect defects at an early
stage
c) Non-compliance with maintenance intervals
d) Operation without the prescribed safety devices
e) Operation of the plant, blocks, or components in a manner other than as de-
signed

Note

Inappropriate use renders any and all liability on the part of the manufac-
turer null and void.

1.1.4 Components and Spare Parts

All plant components and accessories have been designed, selected, and approved
by Alstom especially for this plant. This applies only if Alstom has made the delivery
and bears overall responsibility for it.
The installation or use of spare parts other than those approved by ALSTOM can
change the characteristics of the plant and impair safety of operation.

1.1.5 Exclusions from Liability

Alstom excludes liability for any damage resulting from:
a) the use of parts not expressly approved and supplied by ALSTOM (This may also
apply to parts included in the original delivery)
b) inappropriate handling of the plant or parts thereof during transport, storage, as-
sembly, operation, maintenance, etc.
c) force majeure (Acts of God) and normal wear
d) the intrusion of third parties
e) overstressing
f) inappropriate tools or operating materials
g) Extreme ambient temperatures
h) air pollution, relative humidity, radioactivity, fluctuations in voltage and/or temper-
atures
i) failure to comply with safety regulations

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j) any change or modification to the safety equipment that has not expressly been
approved beforehand in writing by ALSTOM
k) any other cause that does not fall within the responsibilities of ALSTOM

1.2 Information for the operator / owner of the plant

Inappropriate operation of the plant causes danger to man and machine, For this
reason, the operating personnel must be trained in plant assembly, operation, and
maintenance.
The dangers involved include, among others:
a) danger to life and limb of operating staff and other individuals
b) damage to the plant
c) environmental pollution
d) impairment of plant performance and function

1.2.1 Preparation of Staff

Every individual whose assignments include assembly, operation, or maintenance of
the machine must read, understand, and follow the relevant sections of these in-
structions, "General Safety Rules." You must provide appropriate training for this !

1.2.2 Safety and Monitoring Equipment

WARNING
Safety / Monitoring
Do not alter the installed safety and monitoring equipment!

1.2.3 Safety Rules that Apply

Make certain that your employees have access to local safety and accident regula-
tions that apply at their workstation.
Here, for reference, a few regulations that apply in Germany and in Switzerland:
a) General Accident Prevention Regulations, VGB1
b) Noise Protection Regulations, VGB121
c) Regulations for Safety Marking at the Workplace, VGB125
d) Regulations for Electrical Plant and Equipment

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e) Safety Rules for Generators per DIN 57105 Sheet 1, VDE0150 Part 1
f) Firefighting in the Area of Electrical Installations, VDE 0132
g) Further pertinent guidelines, e.g.,: VDE0100 / 0101 / 0107
h) Regulations covering Power Tools, VGB5 §2 Para. 1

1.2.4 Your Responsibilities

As the plant operator, you are responsible for operating it as designed and according
to safety regulations.

Note

Do not make any compromise at the cost of safety !

Your employees must be able to act with safety in mind. To ensure this:
a) If there are not already alarm plans and rules of conduct existing for cases of
emergency, prepare such plans and rules.
b) Instruct your employees to maintain the plant in a clean and manageable condi-
tion and make certain that such instructions are followed.
c) Prepare company-internal safety and work procedures.
d) Appoint a safety director and make certain that he either has the necessary
know-how or obtains it promptly.
e) Define responsibilities and authority. Unclear authority can detract from safety.
f) Define which personnel must be at which workstation while the plant is in opera-
tion.
g) Train your employees for their assignments.
h) Have your employees confirm in writing their receipt of the procedures and their
participation in the training courses and drills.
i) Carefully drill your employees.
j) Your employees must have available to them personal safety gear (eye, ear,
feet, body protectors, helmets, etc.).
k) Every employee must have read and understood the section that applies to him
before starting to carry out any activities in the plant.
l) Only individuals who understand the language and content of the relevant sec-
tions of the operating instructions may carry out work in the plant.

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m) Every employee must have access to the operating instructions and, in particular,
the safety rules.The operating staff is to be given access to the following instruc-
tions:
1. For generators and all other electrical facilities:
first aid following accidents involving electricity
information sheet on fighting fires in electrical plants and their vicinity
2. For turbines:
Instructions for First Aid in Case of Accidents, for reference VDE0134 or
ZH/403

1.2.5 Further Duties of the Operator

Note

You alone, the operator, are responsible for fulfilling the inspection duties
(the acceptance report for safety).
Make sure that dangers in the workplace are identified with clear safety markings in-
telligible at the plant location. Also make sure that zones to which no access is per-
missible (e.g., during operation) are clearly identified. This also includes identification
of noisy areas.

Note

The identification of danger zones frees you neither from observing the
applicable safety rules and regulations, nor from checking to see that such
rules are being followed by others.
Implement the safety measures described in the general rules and regulations and in
the operating instructions.

1.3 Instructions for the supervisor

1.3.1 Authorized Operation
The machine may be operated and maintained only by trained and authorized oper-
ating staff.
The responsibilities of the staff for the various activities at the plant must be defined
clearly.

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Note

From the point of view of safety, no unclearly defined authority is permis-

sible. This is particularly the case when working on electrical, control, hy-
draulic, and pneumatic equipment. Such work must only be carried out by
technical staff trained specifically for these activities and familiar as well
with special local governmental provisions and requirements.

1.3.2 Following Existing Safety Rules

Always follow the applicable accident prevention and safety rules of the country in-
volved when erecting, working on, and operating the plant.

1.3.3 Responsibilities of the Supervisors

a) Make sure that your fellow employees read and understand the pertinent instruc-
tions in the operating instructions, particularly the information therein that is rele-
vant to safety.
b) Familiarize yourself with the operating instructions and the activities relevant to
safety.
c) As supervisor, you are also responsible for removing any deficiencies relevant to
safety. Instruct your employees to inform you immediately of any safety deficien-
cies.
d) Explain to your employees the dangers involved with noise, fatigue, and psycho-
logical stress.
e) Make sure that the intervals for maintenance and inspections are maintained.
f) Check regularly the condition of your special tools and spare parts yourself, or
make sure that your employees take over and perform this inspection work.

1.3.4 Manning the Operating Stand

Do not start the plant into operation until the prescribed staff trained to operate the
plant is ready for work.
Prior to starting into operation, make sure that the alarm plans and other documents
pertaining to safety are readily available.

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1.4 Instructions for the operating and maintenance staff

1.4.1 Working with Safety in Mind
Pay particular attention to the following safety rules:
a) Help make your workplace safe ! Only carry out tasks that you are authorized to
handle and for which you have read the operating instructions and understood
them completely.
b) Follow the instructions of the safety director and his technical staff.
c) Use the safety equipment and wear the prescribed protective gear in the danger-
ous working areas.
Note particularly:
a) Applicable safety and accident prevention procedures
b) Do not remove or disable safety devices (protective caps, etc.)
c) Follow "No smoking" rules
d) Do not carry out any work that may impair safety. For example:
No work on or in systems that have not been disconnected (blocked)
No work on systems under pressure or with high temperature
No work on systems that are electrically live
e) Use the safety equipment
f) Wear protective clothing where necessary or prescribed
g) Wear the prescribed ear protection where necessary
h) Remain at the workplace prescribed in the operating instructions while the plant
is in operation.

1.4.2 Safe Condition for Maintenance Work

Only carry out work on the plant or on a system when it is in a non-operating state
permissible for doing such work. Refer to the operating instructions for the necessary
switch and equipment settings.
Secure sections of the plant that have been disconnected to prevent them from start-
ing up accidentally. Remove the key from the key-operated switch, remove the fus-
es, and post notices to warn against restarting the plant or section of the plant.

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GENERAL REMARKS 1

Make sure before starting the maintenance work that the turbine and all interface
systems are shut down, drained, pressure-free, temperature-less and secured
against switching on

1.4.3 Safety Rules that Apply

Pay attention to the applicable safety and accident prevention procedures when
erecting, commissioning, operating, doing maintenance, and repairing the machine.

1.4.4 Questions concerning Safety

Contact your safety director or supervisor immediately whenever you have any ques-
tions concerning safety or detect dangers.
Your safety director or your superior will provide you with the safety regulations that
apply for you.

1.4.5 Conduct following Malfunctions

Note the operating parameters and warning and malfunction reports and carry out
the checking prescribed.

Note
React immediately to warning and malfunction reports and conduct your-
self according to the regulations, operating instructions, and alarm plans.

1.4.6 Emergency Shut-Down

In case of obvious dangers (fire, unusual noise, escaping steam, oil, or gas, glowing,
etc.) use the manual emergency shut-off.

1.4.7 Denial of Access to Unauthorized Individuals

Only authorized individuals who are familiar with at least the minimum safety rules
are granted access to the plant and the individual components thereof. Even em-
ployees of the operator have no access unless explicitly authorized.

1.4.8 Reporting Damage and Defects

Inspect the plant once per shift for damage visible externally.
Report immediately any changes that impair the safety or reliability of the plant. The-
se also include unusual vibrations and sound.

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1.4.9 Special Tools and Spare Parts

Keep the special tools and spare parts supplied by the manufacturer ready for use.
Keep them clean and store them in a dry place. In addition, follow the operating in-
structions for them.

1.4.10 Inspections and tests

Carry out all inspections and tests on machines and equipment in accordance with
the Alstom guidelines and recommendations.
Use copies of the test certificates and data sheets for recording the results of inspec-
tions and tests.
Send the completed forms to the Alstom Service Department.

1.4.11 Special Dangers

1. Shipment, Machine Assembly
Use only the fastening points, suspensions, and support and transport equipment
detailed in the operating instructions.
This also applies for the disassembly and assembly done during maintenance and
repair work.
2. Initial Start-Up after a Standstill for Maintenance Work
Special rules apply here. It is not permissible to enter potentially dangerous zones.

Note

These may also include zones which may be entered during normal op-
eration.
Such initial start-ups may only be carried out by qualified staff. This staff must under-
stand the construction and operation of the plant and follow the operating instruc-
tions.
3. Standstill
Take the precautions customary locally with regard to preventing the escape of com-
bustible or poisonous liquid, gas or steam.
Escaping gas or liquid presents the risk of an explosion when doing welding (gas or
fuel leakage).

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WARNING
Risk of poisoning / Risk of explosion
 It is not permissible to enter the machine if gas or steam is escap-
ing.
4. Protective Covers
Regularly check the protective covers on rotating machine parts to make sure they fit
correctly and are secure.
If you have removed the protective covers for maintenance or repair work, secure
them in place again with the locking elements provided for this purpose before you
recommmission the machine. Only then has the work been completed.
5. Danger of Fire
Keep inflammable materials away from the turbine. It is not permissible to store in-
flammable materials near the turbine. Be particularly careful to keep liquid media of
any kind away from the insulation on the generators and the turbines.
6. Noise
Wear ear protectors in the designated noise zones.
7. Danger of Explosions
Note the explosion danger zones. In these zones, in accordance with the explosion
protection documents, safety procedures (conduct, access, marking) and restrictions
(tools, clothing, structural modifications) must be observed.
8. Power Supply System
No work is permitted on the DC power supply and the uninterruptible power supply
(UPS) while the machine is running.
9. Lifting Equipment Loads
When using lifting gear, cranes, etc., make sure that such equipment is not over-
loaded. Refer to the operating instructions for the weights of the individual machine
parts.
10. Cleaning Agents and Lubricants
Use only the cleaning agents or lubricants specified or recommended by Alstom. Al-
stom has tested the characteristics of these materials.
11. Aggressive and Environmentally Harmful Media
Follow all safety regulations when handling these media and observe the regulations
covering their disposal.

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CHAPTER 2
DISASSEMBLY AND ASSEMBLY GUIDELINES

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DISASSEMBLY AND ASSEMBLY GUIDELINES 2

2 DISASSEMBLY AND ASSEMBLY GUIDELINES

2.1 Introduction
This section contains general and technical instructions that are to be complied with
when performing the dismantling and reassembly tasks detailed in this document.
Symbols, inserted throughout the maintenance text, precede the text of a Danger,
Warning, Caution, Note and Parts List Reference. These symbols are used in the fol-
lowing circumstances:

DANGER
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury. This signal word is to be limited
to the most extreme situation.

WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

CAUTION
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury. It may also be used to alert
against unsafe practices.

Caution

Information pointing out possible damages to the machine.

Note
Is an important element of the procedure and should be observed.

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12
3 Illustrated parts list

Informs the user of the relevant Parts List where further details of
each component can be found.

2.2 General
2.2.1 Safety Precautions
The following general safety precautions apply to both dismantling and reassembly
procedures. Throughout the maintenance text, where applicable, a specific warning
and/or caution is inserted prior to the affected procedural step.
Maintenance personnel should also comply with the local/regional safety require-
ments.
Prior to starting maintenance, ensure that the turbine and all interfacing systems are
shut down, drained and made safe as detailed in the Operation Manual.
Ensure that the steam turbine is stationary, because - on single-shaft units - even
with the clutch coupling disengaged, the possibility exists of inadvertent engagement
of the coupling.
When handling thermal insulation mats, always wear approved face masks and
gloves.
When using cleaning solvents, always wear approved protective goggles, gloves and
clothing.
When operating welding equipment or grinding machines, always wear approved
protective goggles, gloves and clothing. Ensure that fire prevention procedures are
observed and all personnel not involved in these operations are clear of the immedi-
ate area.
When using the special hydraulically operated tools, ensure that the manufacturers
recommendations for the specific fastener are followed. Do not lean over the tool
when pressure is applied.
When lifting heavy equipment:
use only the approved lifting devices and operate them in accordance with the
appropriate instructions
ensure that the load is correctly secured
Do not stand under suspended load

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ensure that all personnel not involved with the lifting operation are kept clear of
the immediate area.

2.2.2 Standard Engineering Practices

Standard engineering practices, described in the following paragraphs, should be fol-
lowed during all maintenance procedures. Knowledge of, and the correct use of,
tools and equipment is assumed throughout.
To prevent housing deformation, loosen/tighten split-line fasteners in the correct se-
quential order.
To prevent equipment (for example: instrumentation) against deformation or damage
use suitable covers.
To prevent ingress of foreign objects during dismantling, seal all pipe/housing orific-
es with the approved maintenance covers provided, see the instruction manual Tools
according to the manufacturer. During reassembly, remove the blank from a sealed
pipe/casing housing immediately prior to reconnection.
On reassembly, renew all O-rings, seal rings, gaskets, safety locking plates and
spring washers that were removed during dismantling.
On reassembly, renew all fasteners that had a locking bead weld ground off during
dismantling.
After shut-down, use the rotor turning gear system to rotate the turbine rotor shaft
until the ST set has cooled to less than 150 °C. (302 °F). Failure to do this could re-
sult in distortion of the turbine rotor shaft.
For fasteners not listed in the Test Certificates, use standard torque loading practic-
es.

2.2.3 Technical Knowledge Required

Extensive technical knowledge and experience is required by personnel tasked with
the maintenance work.

Note

Only ALSTOM staff should do overhaul work.

All maintenance must be undertaken in accordance with the instructions detailed in
the Operating and Maintenance Manuals.
Common site repairs require only the use of standard practices and basic engineer-
ing knowledge.

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DISASSEMBLY PREPARATIONS 3

All welding must be done only by technical staff possessing the valid licences to per-
form such work. Where the performance or safety of the steam turbine is in question,
consult with the ALSTOM service department.
ALSTOM assumes no liability for damage caused by defective maintenance work or
by inadequate preventive maintenance programmes.

2.2.4 Replacement Parts

Serious damage can be incurred as a result of using replacement parts that have not
been approved by ALSTOM. ALSTOM assumes no liability for damage caused by
the use of non-approved replacement parts.
Always check which replacement parts will be required and ensure that all replace-
ment parts are available before starting work.

Note
When ordering spare parts, only use the identification detailed in the rele-
vant Parts List.

2.2.5 Tools and Lifting Devices

In some cases the maintenance tasks require the use of special tools and lifting de-
vices. Where such tools and lifting devices are required, their use is detailed in the
relevant text and highlighted both in text and on the appropriate figure by the symbol.
Unless stated otherwise, return all jacking screws, guide bolts, taper pins and ap-
proved maintenance covers to the relevant tool chest after each stage of disman-
tling/reassembly.
Taper pins should always be inserted in the housing flanges before the flanges are
brought together. When inserting a taper pin, it should be a tight fit.

Note

Exceptions from the above mentioned rule are mentioned in the mainte-
nance instructions.
ALSTOM denies any responsibility for damages caused by the use of un-
suitable or damaged tools or hoisting equipment.
ALSTOM assumes no liability for damage incurred by the use of unsuitable or dam-
aged tools and lifting devices.

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DISASSEMBLY AND ASSEMBLY GUIDELINES 2

2.2.6 Inspections and Checks

The maintenance text details the inspections and checks required during disman-
tling/reassembly procedures and provides references to the relevant Test Certifi-
cates.

2.2.7 Reassembly
All component parts being reassembled must:
be clean, free of scale and solvent residues
be fully functional
have no cracks or mechanical damage
have no excessive wear
Seal surfaces must be clean and free of cross-grooving and damage. If necessary,
smooth the surfaces with an oil stone.
Immediately before reassembly, lubricate all threads, fits and contact surfaces with
high-heat resistant lubricant. Refer to paragraph 2.4.
Always reassemble components in their original positions, noting the alignment iden-
tifications marked on them prior to dismantling.
Make sure that all bolted joints are tightened and secured in accordance with the in-
structions, guidelines of the manufacturer, data sheets or test certificates.

Caution
Do not use securing wires in the steam chambers or inside pipelines be-
cause broken wires may damage machine parts. Use other securing
methods.

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2.2.8 Pipework
Seal the openings correctly and protect the flange and/or seal surfaces from dam-
age.
Use only blanking flanges, blanking plugs, etc. to seal the openings. Never block the
pipe lines with cleaning cloths or similar materials.
After the pipe lines and hoses have been cleaned and sealed, ensure that they are
correctly identified and place them in a protected storage area.
Prior to reassembly, remove all blanks and check the pipeline for cleanliness and
signs of damage.

2.3 Shutting down the turbine

Caution
The turning gear may only be switched off if the max. metal temperature is
less than 150 °C. (302 °F).
In case of an emergency the turning gear may be switched off for a maxi-
mum of 15 min after one day and 30 min after 2 days of turning gear oper-
ation, provided that the vacuum is broken and the gland steam system
switched off.
The turning gear may be switched off, if required, for a longer period of
time (e.g. overhauls) if the max. metal temperature is less than 200 °C.
(392 °F). The auxiliary lube oil pump can be switched off at that time as
well.
Consult the Alstom Service Department on deviations. Non-fulfillment of
this requirement may cause deformation of the turbine rotors and severe
damage of the turbine components.
The following sub-paragraphs detail the tasks to be performed before commencing
the dismantling procedures contained in the following sections.

2.3.1 Steam Temperature Distribution

Prior to shut down and at full load, measure and record the temperature distribution
as detailed in the Operation Manual.

2.3.2 Steam Turbine Shut Down and Isolation

The following actions are to be performed in accordance with the specific shut down
and isolation procedures detailed in the Operation Manual:
shut down the steam turbine

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DISASSEMBLY AND ASSEMBLY GUIDELINES 2

allow the automatic rotor turning gear to operate until the highest steam turbine
temperature is 150 °C. (302 °F) or less
isolate the rotor turning gear system
isolate the steam systems
isolate all electrical systems.

2.3.3 Removal of Split-line Insulation Mats

Prior to the removal of the split-line insulation mats, check to ensure that the identifi-
cation markings of the insulation mats are legible.
In accordance with the manufacturers instructions for the steam turbine insulation
remove, as necessary for access, the split-line insulation mats. Examine the insula-
tion mats and their fastenings for damage. Renew any damaged items prior to reas-
sembly. Store the removed insulation items in a clean, dry protected area.

2.3.4 Removal of the Sound-proof Structure (if applicable)

For maintenance access, it is necessary to remove only those components of the
sound-proof structure that are above the steam turbine.
In accordance with the manufacturers instructions remove the following components
of the sound-proof structure:
guard rails
roof and wall panels
associated roof and wall support structure.
Check all portions of the removed structure for damage (damaged items are to be
renewed prior to reassembly) and store them in a protected area.

2.3.5 Pre-dismantling Visual Checks

Prior to commencing the dismantling procedures contained in Sections , visually ex-
amine:
all lubrication, hydraulic and fuel-oil filters for signs of leaks and damage
all housing/casing split-lines, pipe lines and pipe joints for signs of leaks and
damage
all electrical cables for chafing, fraying and other damage.

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2.3.6 Inspections Prior to Dismantling

The following inspections are to be performed before commencing the dismantling
procedures contained in the following Sections.
Radial Position of Rotor
Axial Bearing Clearance
Expansion Sleeve Coupling
Alignment of Shafts
Casing Deflection

2.3.7 Dismantling Sequence

The maintenance instructions contain the dismantling procedure for the main areas
of the steam turbine. Depending on the availability of personnel, there are certain
dismantling tasks that can be performed simultaneously.

2.3.8 Reassembly Sequence

The maintenance instructions contain the reassembly procedures for the main areas
of the steam turbine. Depending on the availability of personnel, there are certain re-
assembly tasks that can be performed simultaneously.

2.3.9 Inspections After Reassembly

The following inspections are to be performed after the assembly of the steam tur-
bine have been completed.
Radial Position of Rotor
Alignment of Shafts
Screw Plug: Torque
Expansion Sleeve Coupling
Axial Bearing Clearance
Radial Bearing Clearance
Bolting, Coupling Cover
Clearance of Oil Scraper,
Pipelaying

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2.4 Lubricating the components and parts

2.4.1 Lubricants for bladings
Use special grease 27 (Klueber HEL 46-450) for blade grooves in circumferential di-
rection and special grease 18 (Molykote TP42) for fir-tree grooves.

2.4.2 Lubricants for turbine parts

Use special grease 27 (Klueber HEL 46-450) in the following manner for all other
turbine parts.
Immediately prior to component assembly, using a brush, apply a thin even coat of
the relevant lubricant type as follows:
expansion stud /nut assemblies; lubricate the contact surface of the nut and all
threads
stud/nut assemblies; lubricate the contact surfaces of the nut and flange and all
threads
hexagon head screws and socket head screws; lubricate their contact surfaces
and threads
sliding surfaces in accordance with the instructions, guidelines of the manufactur-
er, data sheets or test certificates

2.4.3 Reassembly of Journal and Thrust Bearings

Immediately prior to reassembly of the turbine rotor shaft journal bearings and thrust
bearing, lubricate all bearing surfaces with clean lube oil.

2.4.4 Reassembly of Turbine and Bearing Housings

Caution

Do not let silicon-based or teflon-based materials get onto the turbine

Shaft, bearings or any part of the lubrication system.
Silicon-based or teflon-based materials can cause contamination of the
lubrication system.

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2.4.5 Tightening Torques and Pre-stressing Forces

For details of the tightening torques and pre-stressing forces for hexagonal head
screws, hexagonal socket head screws, expansion studs, expansion bolts, waist-
ed hexagonal head screws and hexagonal socket head screws manufactured
from Steel guidelines are required in accordance with the details given in the data
sheets.

2.4.6 Special Maintenance Precautions

Caution
During maintenance, ensure that the rotor is only turned in working direc-
tion.
Before commencing the removal of turbine top-half housings, supports
and jacks must be installed as described in accordance with the instruc-
tions, guidelines of the manufacturer, data sheets or test certificates.
Once installed and locked, the jacks must remain undisturbed and locked
until the top-half housing has been refitted and completely bolted in posi-
tion.
Reference should be made to instruction manual 'Split-plane Flange Bolt-
ing; Hydraulic Tightening of Expansion Bolts', in accordance with the in-
structions, guidelines of the manufacturer, data sheets or test certificates

2.4.7 Test Certificates

Inspections and checks to be carried out in areas where defects are most likely to
occur are detailed in the maintenance instructions.
Copies of the Test Certificates and Assessment Sheets are to be used to record the
results of the inspections and checks. The completed forms are to be forwarded to
the ALSTOM Service Department.

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Blank Page

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CHAPTER 3
DISASSEMBLY PREPARATIONS

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3 DISASSEMBLY PREPARATIONS
Carry out the work described below in accordance with the shutting down and isolat-
ing instructions of the operating manual.

3.1 Shutting down the turbine

Caution
The turning gear may only be switched off if the max. metal temperature is
less than 150 °C. (302 °F).
In case of an emergency the turning gear may be switched off for a maxi-
mum of 15 min after one day and 30 min after 2 days of turning gear oper-
ation, provided that the vacuum is broken and the gland steam system
switched off.
The turning gear may be switched off, if required, for a longer period of
time (e.g. overhauls) if the max. metal temperature is less than 200 °C.
(392 °F). The auxiliary lube oil pump can be switched off at that time as
well.
Consult the Alstom Service Department on deviations. Non-fulfillment of
this requirement may cause deformation of the turbine rotors and severe
damage of the turbine components.

3.1.1 Turbine insulation

3.1.2 Removing the insulation

Before removing the hard shell and the insulation, inspect visually the surfaces and
connecting parts of the insulating mats and packages, also for possibly existing
steam leakage.
Inspect the area of the bearing pedestals, especially for lube oil which might have
entered.
Check the marking of re-usable insulation (mats or packages) and mark once again,
if necessary.
Where access is necessary, remove the insulation in accordance with the manufac-
turer's instructions and store it in a clean, dry and protected room until re-installation.
Check the re-usable insulation and fastening parts for damage.

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3.1.3 Re-installing the insulation

Follow the manufacturer's instructions when re-installing the insulation.
Replace damaged insulation or fastening parts.
Strictly follow the relevant drying and application instructions when installing new or
partly new insulation.
Make sure that insulating mats which are fastened to the casing lower half have par-
ticularly good contact.

Caution
The insulation material for austenitic steels may not contain any halogens
or halogenide salts because of the danger of stress corrosion cracking.

Cover the movable parts, for example in the area of the valves and actuators, if a
new insulation has to be applied and clean the parts once again, if necessary.

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3.2 Isolating the auxiliary systems

Isolate the auxiliary systems according to the overhaul plans or according to the in-
structions of the manufacturer.
Keep in service the auxiliary systems which are required for maintenance such as
the jacking oil system or turning gear system and take them out of operation tempo-
rarily for the required maintenance work.
Make sure when isolating the lube oil, control oil and hydraulic supply systems that
the relevant pumps are out of operation and secured against unintended switching-
on.
This applies particularly for all redundant components which are operated and
switched via a direct current set.
Ensure absolute cleanliness when opening and servicing such systems, even if the
connections are open for a short time only.
Take out of operation the seal air system and secure it against unintended starting.
Take out of operation the gland steam and auxiliary steam systems.

3.3 Providing the auxiliary means

Make available the spare parts in accordance with the spare part recommendations.
Check the required tools for completeness, proper functioning and operational readi-
ness and make them available.
Make available the test certificates and data sheets required for the overhaul.

3.4 Sequence of disassembly

This document contains the instructions for disassembly and re-assembly of the new
main components of the turbine block only (rotor, innercasing and balancing piston
casing).Depending on the available personnel, some of the activities can be carried
out simultaneously.
Please refer to the relevant original maintenance documents of the components
orsystems for disassembly of the subassemblies, mounted on the turbine.

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DISASSEMBLY PREPARATIONS 3

CHAPTER 4
DISASSEMBLY OF THE TURBINE

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DISASSEMBLY OF THE TURBINE 4

4 DISASSEMBLY OF THE TURBINE

Note

Inspect all parts removed from the turbine for damage and store them at a
dry and safe area until re-assembly.
Clean the tools used, check their completeness and put them in the tool
cabinet.

4.1 Preparations
Note

Mark all electric connections for the thermocouples and instruments at the
turbine bearing for re-assembly and disconnect them.

4.2 Check measurements before dismantling the inner casing

Check the possible axial displacement of the turbine rotor relative to the inner cas-
ing

Check the radial and the axial position of the turbine rotor in the inner casing

4.3 Dismantling the inner casing upper half

4.3.1 Loosening the parting flange bolts of the inner casing

Loosen the flange bolting 53 refer to Fig. 4-8

Screw two guide bolts 914 at diagonally opposite positions into the inner casing
lower half 51.

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WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

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51 52 53 914

Pos Designation Pos Designation

51 Inner casing lower half 914 Guide bolt
52 Inner casing upper half
53 Flange bolting

Fig. 4-8 Loosening the parting flange bolts of the inner casing

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DISASSEMBLY OF THE TURBINE 4

4.3.2 Lifting off the inner casing upper half

Attach the hoisting equipment to the inner casing upper half 52, refer to Fig. 4-8

Note
Keep the casing horizontal when lifting it off. Make sure that the guide
bolts move freely in the bores.

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

4.3.3 Loosening the parting flange bolts of the balancing piston casing

Loosen the flange joints 153 to 155 refer to Fig. 4-9 and the test certificate.

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

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151 152 153

Pos Designation Pos Designation
151 Balance piston casing lower part
152 Balance piston casing upper part
153 Flange bolting

Fig. 4-9 Loosening the parting flange bolts of the balancing piston casing

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DISASSEMBLY OF THE TURBINE 4

4.3.4 Lifting off the balancing piston casing upper part

Attach the inner casing upper part 152 to the hoisting equipment, refer to Fig. 4-9

Note

Keep the casing horizontal when lifting it off. Make sure that the guide
bolts move freely in the bores.

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

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4.4 Check measurements before removing the rotor

Precondition

Note

The turbine rotor is in operating position.

Check the radial and axial clearances of the stationary and the Test certificate
rotating blading refer to the test certificate. HTCZ459119

Check the radial and axial clearances of the balance piston Test certificate
refer to the test certificate. HTMD401496

Check the radial and axial clearances of the shaft seals refer Test certificate
to the test certificate. HTMD401496

Check of impulse blading clearances refer to the test certifi- Test certificate
cate. HTCZ459380

4.5 Lifting out the turbine rotor

Attach the turbine rotor 1 to the hoisting equipment using the rotor lifting device
800, refer to Fig. 4-17
Slightly lift the turbine rotor 1 and check the horizontal position.

Caution

Keep the rotor horizontal and monitor it with a precision water level to pre-
vent damage to the blading and sealing elements. Re-adjust the rotor lift-
ing device, if necessary, to ensure the horizontal position.

Lift out the turbine rotor 1 carefully and vertically, refer to Fig. 4-17.

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DISASSEMBLY OF THE TURBINE 4

Caution

The rotor must not jam during lifting off. It must always be possible to
move it slightly. Place the rotor on the prepared assembly supports. The
support surfaces must be protected.

800

Pos Designation Pos Designation

1 Turbine rotor 800 Rotor lifting device

Fig. 4-17 Lifting out the rotor

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DISASSEMBLY OF THE TURBINE 4

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

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CHAPTER 5
MAINTENANCE

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 MAINTENANCE
MAINTENANCE 5

5 MAINTENANCE
5.1 General recommendations
5.1.1 Checks and tests
Inspect all components visually and in accordance with the overhaul recommenda-
tions and specified data of the test certificates and replace the parts, if necessary for
reasons of operational safety.

Caution

This applies to all components, but especially to those which are heavily
stressed during operation and have an effective or equivalent life expec-
tancy in operating hours.

5.1.2 Cleaning the components

Clean thoroughly all dismantled or still installed components which show visible
signs of wear, deposits, scale or stress and check their re-usability.
This applies particularly to:
Screw threads, contact surfaces of nuts, bolt heads, expansion sleeves and sup-
port rings
Joint and sealing surfaces of casings and flanges
Sliding surfaces, fits and adjusting elements.

5.1.3 Marking the dismantled components

Mark all components with their location code and store them at a safe and dry place
until re-installation.

5.1.4 Replacing components

Replace principally all dismantled non-metallic sliding and guiding elements, seals
and O-ring seals.
Replace also all pipe unions, metallic ring or crimp seals at particularly exposed loca-
tions or if subjected to high operating pressures.

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 MAINTENANCE
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5.1.5 Tools
Check the tools, to be used during re-assembly, for completeness and operational
readiness.

5.1.6 Test certificates

Make available the test certificates required for re-assembly.

5.1.7 Turbine

Caution
All adjustments of the inner and outer casings, the radial and axial posi-
tions of the rotor in the casings may only be changed by qualified person-
nel.

5.1.8 Visual checks

Carry out at least the following checks on the turbine components:
Seal strips and seal rings for wear and rubbing marks
Seal segments for free mobility and compression springs for pre-tension
Steam duct rings for wear and proper functioning
Casing parts for erosion and cavitation
Exposed components for stress corrosion cracking
Guiding, sliding and adjusting elements for wear.

Note

Carry out a dye test with magnetic particles to detect cracks in the ma-
chine parts. This test is particularly important in the coupling section of the
turbine rotor.

5.1.9 Cleaning the machine parts

If the visual checks show deposits which require thorough cleaning of the machine,
follow the instructions for removing salt and silica deposits in steam turbines.

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MAINTENANCE 5

It is recommended to coordinate these activities with the ALSTOM Service Depart-

ment.

5.1.10 Turbine instruments

Check the functioning of the startup probe and thermocouples.

5.1.11 Replacing machine parts

Replace the components in case of heavy wear or malfunctioning.

Caution

Replace the elongation bolts with recorded pre-stress, which are exposed
to high stress and temperatures above 420° C in operation, after 150'000
operating hours. See the relevant remarks in the test certificates.

5.1.12 Re-assembly recommendations

Secure all bolts in the steam chamber.
Remove all tools before re-assembly.

5.2 Blading

Note

Deposits cause a decrease in efficiency and may endanger the operation-

al reliability of the turbine.

5.2.1 Visual checks

Carry out at least the following checks on the turbine blading:
Seal strips and seal rings for wear and rubbing marks
Blading parts for deposits, erosion and cavitation
Components for stress corrosion cracking
Stationary and rotating blading for cracks and proper condition.

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MAINTENANCE 5

Note

Carry out a dye test with magnetic particles to detect cracks in the ma-
chine parts. This test is particularly important in the coupling section of the
turbine rotor.

5.2.2 Cleaning the blading

If the visual checks show deposits which require thorough cleaning of the blading,
follow the instructions for removing salt and silica deposits in steam turbines.
Thorough cleaning is particularly important if the blading has to be subjected to a dye
penetrant test with magnetic particles.
In this case the specific work instructions have to be ordered from the Service De-
partment. The relevant activities have to be co-ordinated with and carried out by the
ALSTOM Service Department.

5.2.3 Replacing blading parts

Note
Only ALSTOM personnel are authorized to carry out maintenance work on
the blading.

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CHAPTER 6
RE-ASSEMBLY OF THE TURBINE

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 MAINTENANCE
RE-ASSEMBLY OF THE TURBINE 6

6 RE-ASSEMBLY OF THE TURBINE

6.1 Starting point

6.1.1 Bearing pedestals
The bearing pedestals are ready for re-assembly of the turbine.

Caution

Make sure that the radial and axial positions of the turbine bearings rela-
tive to the turbine are correctly adjusted. Check this even if the positions
were not changed.

Note
Lubricate slightly the bearing surfaces of the turbine rotor in the region of
the journal bearing with lube oil. Ensure absolute cleanliness.

6.1.2 Turbine
The turbine is ready for re-installing the turbine rotor.

Caution

Make sure that the radial and axial positions of the inner casing lower half
are correctly adjusted. Check this even if the positions were not changed.

Note

Lubricate slightly the bearing surfaces of the turbine rotor in the region of
the journal bearing with lube oil. Ensure absolute cleanliness.

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6.2 Lifting into place the turbine rotor

6.2.1 Installing the lifting device

Attach the turbine rotor 1 to the hoisting equipment using the lifting device 800
Lift slightly the rotor and check the horizontal position. If necessary, lift it higher on
the heavier side.

Caution
Keep the rotor horizontal and monitor it with a precision water level to pre-
vent damage to the blading and sealing elements. Re-adjust the rotor lift-
ing device, if necessary, to ensure the horizontal position.

800

Pos Designation Pos Designation

1 Turbine rotor 800 Rotor lifting device

Fig.6-1 Lifting into place the rotor

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6.2.2 Lifting into place the rotor

Lift the rotor and align it axially exactly with the turbine axis using the hoisting
equipment, refer to Fig. 6-1.
Lower the rotor carefully and exactly vertically into the inner casing and blade carrier
lower halves.

Caution

The rotor must not jam during lowering. It must always be possible to
move the rotor a small distance. Monitor the installation of the rotor in the
inner casing on both sides. Rubbing of the sealing elements and blading is
not permitted.

Note
Check the horizontal position of the rotor during lifting with a precision wa-
ter level and keep it horizontal to prevent damage to the blades and shaft
seals.

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

Remove the rotor lifting device and store it at the appropriate place.

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6.2.3 Check measurements after lifting into place the rotor

Note

The turbine rotor is in operating position.

Check the radial and axial clearances of the stationary and the Test certificate
rotating blading refer to the test certificate. HTCZ459 119

Check the radial and axial clearances of the balance piston Test certificate
refer to the test certificate. HTMD401 496

Check the radial and axial clearances of the shaft seals refer Test certificate
to the test certificate. HTMD401 496

Check of impulse blading clearances refer to the test certifi- Test certificate
cate. HTCZ459 380

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6.3 Re-mounting the balancing piston casing upper part

6.3.1 Lifting into place the balancing piston casing upper part

Attach the blade carrier upper part to the hoisting equipment

Align the upper part 2 with the lower part 1 in the parting plane.

Note

Keep the casing horizontal when lifting it.

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

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1 2 103

Pos Designation Pos Designation

1 Balancing piston casing lower half
2 Balancing piston casing upper half
103 Flange bolting

Fig. 6-8 Re-installing the balancing piston casing upper part

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6.3.2 Tightening the parting flange bolts of the balancing piston casing

Tighten the flange bolting 103, refer to Fig. 6-8 and the test Test certificate
certificate. HTGD 630 147

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

6.3.3 Lifting into place the inner casing upper half

Screw the guide bolts 914 on opposite sides into the inner casing lower half 51, re-
fer to Fig. 6-9.
Attach the inner casing upper half 52 to the hoisting equipment refer to the data
sheet "Disposition of slings".

Note

Keep the casing horizontal when lifting it into place. Make sure that the
guide bolts move freely in the bores.

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51 52 53 914

Pos Designation Pos Designation

51 Inner casing lower half 914 Guide bolt
52 Inner casing upper half
53 Flange bolting

Fig. 6-9 Re-mounting the inner casing upper part

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WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.
Align the upper half 52 with the lower half 51 in the parting plane, remove the guide
bolts 914 and store them in the tool cabinet.

6.3.4 Tightening the parting flange bolts of the HP inner casing

Tighten the flange bolting 53 refer to Fig. 6-9 and the test cer- Test certificate
tificate. HTGD 630 147

WARNING
Suspended Load
Load or part of load can fall down and cause injury.
 Wear correct personal protective equipment, hard hat, safety boots.
 Do not stand under suspended loads.
 Make sure that persons not involved in the procedure are out of the
danger area.

6.4 Check measurements before re-mounting the outer casing

Check the possible axial displacement of the turbine rotor rela- Test certificate
tive to the inner casing refer to the test certificate. HTGD 667 257

6.4.1

Check the radial and the axial position of the turbine rotor in Test certificate
the inner casing refer to the test certificate. HTGD 667 255

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Final remarks

Note
Tighten and secure all screws and bolts without rec- Document
orded prestress according to document. HTGD 630 147

Note
Re-connect all thermocouples and instruments of the turbine refer to the
markings applied during disassembly and check their functioning.
Clean all tools used for maintenance, check their completeness and store
them in the tool cabinets.

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CHAPTER 7
FINAL WORK

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7 FINAL WORK
7.1 Adjusting the operating positions
Make sure that all components are again in the operating position. Remove assem-
bly aids and tools.
Re-install all dismantled components and parts at their location and original position,
in accordance with the markings applied during disassembly.
Pre-tension and secure all bolted joints in accordance with the instructions, manufac-
turer's guidelines, data sheets and test certificates.
Flange joints of the bearing pedestals
Flange joints of the turbine inner and outer casings
Flange joint of the cover flange at the compensator.

7.2 Pipelines and pipe unions

Re-install pressure-tight all pipelines.
Replace the bolted joints if the locking welds had to be ground off.
Secure all bolted joints according to instructions.

7.3 Power supply

7.3.1 Connecting the auxiliary systems
Re-connect correctly all auxiliaries. Replace worn, damaged or broken cables.
Lube oil supply
Control oil supply
Rotor turning gear supply.

Note

Check the power consumption of all direct and alternating current motors
of the pumps and the direction of rotation.

7.3.2 Bearing pedestals

Re-connect the thermocouples for measuring the bearing metal and oil drain tem-
peratures and make a functional test.

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Re-connect the instruments for the vibration, phase and differential expansion
transmitters and make a functional test.
Re-connect the control elements of the rotor turning gear and make a functional test.
Re-connect the grounding devices and the busbars to the foundation and make a
functional test.

7.3.3 Valve actuators

Re-connect the proportional and directional control valves of the valve actuators and
make a functional test.
Re-connect the limit switches and stroke transmitters of the valve position transmis-
sion and make a functional test.

7.3.4 Turbine
Re-connect the startup probe and the temperature sensors for temperature supervi-
sion and make a functional test.

7.4 Lube oil supply to the bearing pedestals

Caution
Remove the blank flanges in the lube oil supply pipes and replace them by
feed orifices.

7.5 Functioning of the valve actuators

After re-assembling the actuators and connecting them with the valves, check the
functioning and adjustment of the valve strokes, electric equipment and hydraulic
supply.

7.6 Auxiliary systems

Re-connect gland steam and auxiliary steam systems and make a functional test.

7.7 Insulation and enclosure

7.7.1 Insulation
If a completely or partly new insulation has to be applied, follow strictly the relevant
drying and application instructions.

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Make sure that insulating mats which are fastened to the casing lower parts have
particularly good contact.

Note

Cover adequately the area of the movable parts if a new insulation has to
be applied near the valve and valve actuator.
Clean once again, if necessary.

7.8 Checks and final work

Clean the tools and assembly aids and store them in the tool cabinets.
Clean all provisional covers and hoods, used for maintenance, and store them at the
appropriate places.
Check whether all test certificates have been completed and initialled.
Send a copy of the test certificates to the ALSTOM Service Department.

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