E - C Manual - R1 - 28.8.18

TRIVENI TURBINE LIMITED
INSTALLATION, PRE-COMMISSIONING & COMMISSIONING PROCEDURE
12-A Peenya Industrial Area

Bangalore -560058.
India.
1. MECHANICAL ACTIVITIES
DOCUMENTS REQUIRED FOR ERECTION, PRE-COMMISSIONING & COMMISSIONING
REFERENCE DRAWINGS:
SL.NO. Description of Drawing / Document

1 Foundation Block Plan
2 G.A. of Turbine
3 Power House & Equipment layout
4 Auxiliary Equipment Foundation Details
5 P & I diagram for Lube & Control Oil system

P & I diagram for Steam system, Condensate System,
6
Ejector System
7 P & I diagram for RTD system
8 P & I diagram for Turbo visory system
9 Cut out Insert Plate Details
10 Valves Schedule
11 G.A. of Lube oil System, Isometric drawings
12 G.A drawings of all equipments
13 G.A. of Over Head Tank
14 Performance Curve
15 Data Sheet of Alignment/ MRT Report
16 O & M manual
17 Protocol for OIL flushing, Protocol for Alignment

Protocol for Alignment for Rotor pinion shaft & Gear
18
Alternator shaft
19 Protocol for Steam Blowing
Standard Installation & Commissioning procedure * Refer page 85 Special Conditions Applied 1
Mechanical Activities where Triveni Engineers supervision is required:
Sl. No. Activity Remarks

Only for Foundation
1 Unloading and Foundation Inspection.
Inspection
2 Grouting of Packer plates
3 Positioning and Leveling of Surface Condenser

If required - Triveni Engineer
4 Shrink Fitting of Coupling Hub on Alternator Shaft
Required
Lifting and Placing of Condenser, Turbine And
5 Triveni Engineer Required
Alternator.
6 Leveling and Alignment of Turbine and Alternator Triveni Engineer Required
Final leveling & checking of HS/LS Alignment prior to

7 Triveni Engineer Required
Grouting & Grouting of Turbine and Alternator
Placement of Auxilillaries (Oil Cooler, Oil Filter, Oil
8
Centrifuge, GVC, Ejector System and CEP
Fabrication of Pipings between Auxiliaries, Turbine,
9
Alternator, Condenser and drain lines
10 Cleaning of pipelines and refitting. Triveni Engineer Required

Witness of final steam blowing for clear target plate
11 and parallelity checking before connecting to Triveni Engineer Required
Turbine
12 Pre Commissioning Activities Triveni Engineer Required
13 Commissioning activities Triveni Engineer Required
PURPOSE
These guidelines are formed as necessary steps for the service Engineer to carry out Erection and
Commissioning activities as per ECD/QAP/001.
SCOPE
This procedure is applicable to only Triveni make Turbines
METHODOLOGY
 SITE MOBILISATION
 After necessary erection clearance from the concerned department, site mobilization
shall be done. Following details shall be ascertained before departing to site.
 SCOPE OF WORK:
 Details of mechanical & electrical contractor (if applicable)
 Details of Mechanical & electrical activities
 Project schedule/ Planning
 GUIDELINES FOR SITE MOBILIZATION
 Travel to site.
 Meet the concerned customer representative.
 Make site survey.
 Ensure that site is ready in all respects to start the erection activity.( Site building shall be
dust free, no probability of water entering building, civil provisions as per power house
layout. Etc)
 Safety precautions are implemented at site such as availability of staircase with Railings,
Cut outs properly secured etc.
 TG foundations as well as other equipment foundations are ready for installation.
 Availability of EOT crane and functionality of the same shall be ascertained. Ensure that
EOT crane is tested for overload and respective test certificates are available.
 Availability of service points for electricity, water, compressed air has nearest to TG
Building..
 Availability of space for storage of equipment and site office.
 Arrangement of gate-pass for TTL engineers and if any sub-contractors.
 Completion of statutory formalities by sub-contractor (legal, safety etc).
 Mobilization of sub-contractor to site.
 Ensure that sub-contractor carries all the tools required for erection and commissioning of
the TG set, and all the precision tools are calibrated and have valid calibration certificate.
Lifting tackles are suitable for load applicable at site and have valid test certificates.
 Discussion with sub-contractor about the project schedule.
 Receipt and shifting of materials.
 Verification of received materials and reporting of damaged/missing items if any.
 Prepare and send the progress report to respective TTL office.
 Documentation:
 Protocol for Storage ECD/FOR/288,
 Protocol for Site handing over meeting ECD/FOR/297
 Site Report ECD/FOR/200
 Weekly progress report cum Time Sheet (ECD/FOR/201).
MECHANICAL ACTIVITIES
 Erection
 Pre-casting/Post casting Foundation Inspection
 Unloading and Safe storage
 Leveling & Grouting of Packer plates(Check availability of Sikador-42)
 Positioning and Leveling of Surface Condenser.
 Fixing of Spool piece and Expansion bellow.(Expansion Bellow Yellow Bracket should not
be cut. Refer OEM Drawing)
 Shrink Fitting of Coupling Hub on Alternator Shaft(If applicable)
 Lifting and Placing of Turbine and Alternator.
 Make sure Alternator Magnetic center.
 Turbine Leveling and High speed Alignment/ Low speed Alignment from Turbine to
Alternator.
 Half Grouting of Turbine & Alternator foundation bolts.
 Grouting of Turbine and Alternator
 Placement of Auxiliaries (Oil Cooler, Oil Filter, Oil Centrifuge, GVC, Ejector System and CEP
etc.)
 Fabrication of Piping between Auxiliaries, Turbine, Alternator, Condenser, Drain lines and
Impulse line ( Turbine to Gauge Panel)
 Pre-commissioning activities
 Cleaning of oil pipelines and refitting.(Acid pickling HCL & Caustic Soda. Refer Turbine
Manual.)
 Clean Turbine oil tank before oil filling.
 Oil Flushing
 Make dummy filters for oil flushing and start with 150Mesh and 200Mesh to be clear for
24hrs.
 Oil temperature to be obtained as per protocol ECD/FOR/219 60degC to 65 degC.
 After oil flushing is completed remove flushing oil and clean again Turbine oil tank and
Refill New oil as per requirement.(Refer Turbine Manual)
 Condenser flushing, Condensate pipeline cleaning and CEP Commissioning
 Condenser Commissioning & Vacuum Build Up
 Interlocks and Logic check
 Barring Gear Trial
 Steam Blowing
 Steam line flange parallelism
 Commissioning Activities
 STG rolling & No Load Trial
 Load Trial
 PG test
LIST OF DOCUMENTS REQUIRED FOR ERECTION, PRE-COMMISSIONING & COMMISSIONING REFERENCE
DRAWINGS (WHICHEVER IS APPLICABLE FOR TURBINE MODELS)
SL.NO. Description of Drawing / Document
1 Purchase order copy of E&C sub-contractor
2 All applicable Protocols & Check Lists (Latest revision)
3 All Check list for Toll gate reviews (If applicable)
4 Progress chart
5 QAP for Mechanical & Electrical Activity
6 Shop Assembly, Alignment readings & MRT reports
7 Dispatch details of DBO materials with packing list
8 Manuals & erection instructions of all equipment’s
9 Dispatch details of all materials with Box wise packing list from TTL
10 Master bill of material supplied by TTL and vendors
11 Foundation Block Plan.
12 G.A. of Turbine.
13 Power House & Equipment layout.
14 P & I diagram for Lube & Control Oil system.
15 P & I diagram for Steam system,
16 P & I diagram for Condensate & Ejector system.
17 P & I diagram for Turbovisory system.
18 P&I system for cooling water system.
19 Cut out Insert Plate Details.
20 GA of all Auxiliaries equipment and foundation details.
21 G.A for Alternator & Alternator Manual.
22 Index Sheet for Turbine Sub Assembly.
23 Interconnecting piping layout ( if applicable )
24 Cold alignment data sheet.
25 Performance curve, Correction curve, Start-up curve, Load curve
26 System Trip Logic.
27 Typical Alternator Piping Diagram.
28 GA of pressure transmitter & differential pressure Transmitter.
29 GA of Condenser, Ejector, condensate extraction pump (CEP)
30 GA of Isolation valve
31 GA of governor & its accessories
32 Interconnecting piping BOM (Vendors)
33 GA of gland vent condenser (GVC)
34 GA of oil cooler, Oil filter
35 GA of expansion bellow & spool piece
36 GA of Full flow relief valve, NRV & QCNRV
37 GA & Manual for oil centrifuge (if applicable )
38 Piping Layout
39 Isometric drawing for Steam lines, Condensate Lines, Oil lines, CEP
equalizer, Vapor lines, Cooling water lines, steam drain line
40 GA of Coupling, gear box
41 GA of Main Oil tank , Pump & motor skid , oil cooler and oil filter skid (if
applicable)
42 GA of LP & HP heaters ( if applicable)
43 GA of pressure reducing & De-super heater system (PRDS) ( if

applicable)
44 GA of Temperature Control valve (TCV) ( if applicable)
45 GA of all turbine skid mounted pump & motor
46 GA of Overhead oil Tank with mounted Accessories (if Applicable)
47 GA of level control valve, level switch, level gauge
48 Manual for accumulator, gear box, all turbine skid mounted pump &
Motor, oil cooler, oil filter, Vapour Extractor/ Oil Mist Separator.
49 Procedure to be handed over to customer for main activities e.g..- acid

pickling, oil flushing.
50 Valves Schedule.
51 Turbine O & M manual.
52 G.A and foundation drawing of all electrical panels.
53 G.A. of Drain oil Tank and accessories (If applicable)
1. ERECTION
1.1 Pre cast Foundation Inspection
Procedure:
Pre cast Foundation inspection should be done to avoid errors / Missing’s before of Bulk TG deck civil
casting. It is advisable to mark the centerlines of both turbine and alternator shaft lines and also Turbine
exhaust and Alternator centerline. Check all the lines are parallel and perpendicularity to each other
with reference of Foundation block plan drawing. Also refer GA of both driver and driven equipment’s.
All necessary dimensions to be checked with references of these centerlines to foundation bolt holes.
Piano wires can be used for having an accurate reading. Perpendicularity of foundation bolt holes
should be checked using a plumb and positions of holes should be checked by referring foundation
block diagram. Following points to be discuss and strictly followed by customer civil end.
a. All dimensions (distances of bolt holes, bolt hole sizes, openings & pockets dimensions etc.)
strictly to be maintained as per foundation block diagram.
b. Turbine & Alternator foundation elevation of TOC (Top of concrete) to be maintained as per
foundation block diagram
c. Turbine & Alternator foundation bolt Sleeves / pockets verticality and diagonals to be
maintained with in the tolerance and also care to be taken not to disturb as well as
cements/civil debris are not to enter in the Sleeves / pockets during casting.
d. Foundation concrete to be done in a single stretch and not to stop in between also maintains
the temperature below the ambient level.
e. After completion of concrete proper curing to be taken care. Also elevation & ref. centerlines
marking to be done on the TG deck for future reference.
1.2 Post cast Foundation Inspection
Procedure:
Post cast Foundation inspection should be done before placing the turbine (the packer plates should
also be grouted) i.e. perpendicularity of foundation holes should be checked using a plumb and
positions of holes should be checked by referring foundation block diagram. To help in the correct
positioning of the turbine and alternator it is advisable to mark the centerlines of both turbine and
alternator shaft lines from the foundation block bolt holes. Check particularly the two lines are parallel to
each other. Refer the GA and foundation Drawings of both driver and driven equipments for above
markings. Piano wires can be used for having an accurate position of the TG. All holes should be clear
from civil materials.
Documents Required:
a) Foundation Block Diagram, Power house layout.
b) GA drawings for Turbine, Gear box & Alternator.
c) GA drawing Auxiliary equipment’s
Tools required:
a) Measuring tape
b) Piano wire / String with Plumb
c) Tri square
Documentation/Records:
a) Protocol for Pre-Casting of TG set Foundation (ECD/FOR/298)
b) List of Drawings and documents for E&C Activities (ECD/CKL/003)
c) Protocol for Site handing over Meeting at site before start of dispatches (ECD/FOR/297)
1.3 Unloading
Procedure:
All the materials should be unloaded near the TG deck at site and maximum care should be taken
during unloading to prevent it from any damages. In case any damages are observed, same shall be
informed to respective TTL office along with additional details like LR, DC and photos etc. All the
electrical panels and Instruments were to be unloaded / placed in the covered and rain/water
protected stored area only.
1.4 Unloading by Manual
Procedure:
Manual unloading is permissible if suitable crane is not available as well as if Plant is not ready by civil
side. Turbine, Gear box, Alternator & condenser etc shall be unloaded by manual jack lift method.
Unloading area should be levelled and compacted well. Also ensure no obstructions in surroundings of
unloading equipment’s. Before unloading to be ensured the all lifting jacks and tools are should be
suitable capacity and tested with validity. Steel structure / wooded blocks are to be placed away from
the vehicle with proper distances. Lift the equipment all the ends equally leveled. Before removing the
vehicle it has to be ensured equipment’s weight fully transferred to steel structure / wooden blocks and
also equipment’s is free from vehicle with proper distances / gap. After removed the vehicle,
equipment’s are needs to be lower to the ground level and Ensure the equipment’s are kept to above
the wooden blocks or steel structure.
1.5 Unloading and lifting by Crane
Procedure:
Unloading of all equipment’s should be done with suitable capacity of crane. Turbine, Gear box,
Alternator & condenser etc shall be unloaded or lifted by suitable capacity of EOT or Mobile crane.
Unloading area should be levelled and compacted well. Also ensure no obstructions in surroundings of
unloading equipment’s. Before unloading or lifting, to be ensured that the all lifting tools and tackles are
should be suitable capacity and tested with validity. Also crane load test to be conducted as per
protocol. Lift the equipment all the ends equally leveled. Before removing the vehicle it has to be
ensured equipment’s are fully lifted. After removed the vehicle, equipment’s are needs to be lower to
the ground level and Ensure the equipment’s are kept to above the wooden blocks or steel structure.
Documents Required:
a) Erection Clearance (PRJ/FOR/007)
b) Materials Dispatch details
c) GA drawings of Turbine, Gear box & Alternator.
d) GA drawings of All Auxiliaries
e) Complete Packing list
a) Checklist for safe unloading/Lifting of TG and Major Equipment. (ECD/FOR/287)
b) Protocol for Storage (ECD/FOR/288)
c) Protocol for Receipt of Materials (ECD/FOR/211)
1.6 Grouting of Packer plates (using Sikadur 42 compound):
Procedure:
Mark the center line of foundation bolt pockets & clean the areas (By Air & water) near the foundation
bolt pockets for placing packer plates perpendicular to the Turbine axis on both sides of the Foundation
holes. (There are chances that corner pads of the corner bolts of turbines needs change in orientation),
also pads to be checked for proper machining and filled for burrs and high points. Make jacking
arrangement in the pads for fine adjustment to match the required elevation.
Fabricate a Shuttering box (MS or wood) of required dimensions to accommodate both the pads of
single pocket and enable grouting of both the pads simultaneously. Prepare the mixture of Sikadur 42
compound as per recommendation of manufacturer. Place the fabricated boxes around the Pads &
foundation pocket. Mark the required elevation as per the drawing. Pour the compound up to the
marked elevation, Check the level using Master level above the pads and fine adjust by jack screw.
(Max allowed tolerance is 0.25mm/meter taper)
After leveling of all individual pads place a straight edge (Master Level) on the pads in diagonal &
lengthwise, check and ensure the level in both horizontal planes. Then allow the pads for curing.
Documents Required:
a) Foundation Block Diagram.
b) GA drawing for Turbine.
Tools Required:
a) Chisel
b) Hammer.
c) Precision Blue
d) Straight Edge
e) Scale (yellow paint for marking)
f) Master level.
a) Turbine erection record. ECD/FOR/206.
1.7 Positioning and Leveling of Surface Condenser: (Wherever applicable)
Procedure:
Erection of condenser should be as per OEM manual recommendations.
Arrange to lead the condenser to the foundation area taking adequate cares not to damage the
condenser or subassemblies of the condenser and ensure that only one support is casted i.e. Also
known as fixed support (another support should be casted after placing condenser i.e. known as sliding
support).
Carefully lift the condenser to the height of the fixed support by supporting the condenser from bottom,
and then carefully place the condenser on the support.
A temporary support should be given to the other end of the condenser (This support should be in area
not closer to permanent support). Cooling water flanges can be used for better support)
After placing the condenser cast the other permanent support. Teflon Sheet is placed between
pedestal and the sole plate. Both the matching plates of Teflon sheet must be free of burrs, foreign
partials and proper edge preparation. Ensure that sliding support is on the opposite side of cooling
water line. Once the support is ready make arrangements to lift the condenser so as to take out the
temporary support. Place the condenser on the permanent support. Put the condenser bolts and then
level the condenser in both X & Y direction.
Documents Required:
b) GA drawing of condenser
c) Foundation block Diagram
d) Power House Layout
Tools Required:
a) Chain Blocks
b) Jacks
c) Wooden Sleepers / Steel Structures
Documentation:
e) Turbine Erection Record ECD/FOR/206.
1.8 Shrink Fitting of Coupling Hub on Alternator Shaft (if applicable)
Procedure:
For export projects shrink fitting carried out in house before dispatch of turbine. This activity has to be
carried out before position the Alternator on the Foundation. Ensure the key should be fitted properly in
shaft by blue matching so that the contact area is at least 70 %. Shaft Key to be tightened with the Allen
bolts. Clearance between the top of key and hub to be ensured, Clean the coupling hub (Remove the
anti-corrosive paint by using petrol and cloth).
Take the dimension of shaft & coupling hub respectively (i.e. ID of coupling hub & OD of the shaft)
Interference between shaft & coupling should be 0.05mm to 0.15 mm. (0.15mm is on higher side)
accordingly make temporary gauge to ensure the thermal expansion in the coupling hub
Stopper should be provided at the hub face to ensure the matching of Coupling and Shaft faces.
For shrink fit, coupling to be heated with oil for that take an oil barrel or suitable steel vessel to heat
same. Pour transformer oil in to the barrel / vessel to a level which hub gets completely immersed in to it.
Ensure that the barrel / vessel is kept at a suitable height such that the flame never reaches the top of
the barrel at any time during heating. Keep sufficient quantity of water and sand nearby in case of any
emergency. Slowly start heating the oil. If electric oven is available the above procedure can be
followed.
Immerse/dip the coupling hub in the heating oil making sure that the hub can be removed in balance
condition from the oil in hot condition itself either manually or by crane. Further heat the oil and check
the temperature by using a dial type temperature gauge. Once the temperature of 200˚C is attained,
maintain the temperature between 200°C to 230°C for a period of three hours. Ensure that the ID of the
HUB is greater than the OD of the shaft by 0.15MM using inside caliper / temporary gauge.
Lift the coupling hub carefully and position the hub level horizontally and in front of the driven
equipment shaft. Carefully insert the hub in to the shaft, during inserting the hub should not get tapered
or tilted (use safety gloves while doing this operation). Press the hub completely to the driven shaft.
Ensure both the faces of the hub and shaft are flushed and allow the heated portion to get cooled
naturally. (For safety water soaked gunny bags can be placed on the DE bearing pedestal of shaft area
to reduce the heat transfer further from the coupling hub area).
Drawings:
a) GA of Turbine and Alternator.
Tools required:
a) Inside micro meters
b) Emery paper
c) Outside micrometer
d) Fire extinguisher
e) Inside caliper
f) Petrol 2 Ltrs
g) Transformer oil/Electric oven
h) Blue tube.
Documentation:
a) Turbine erection record (ECD/FOR/206)
1.9 Lifting and Placing of Turbine and Alternator:
Procedure:
Erection of equipment should be as per OEM manual recommendations.
Position the Exhaust Bellow and Spool piece on the Condenser flange after ensuring the blue contact
between spool pieces. The same can be checked using a glass piece/ surface plate.
Note; Bellow shipping Yellow bracket should not be removed.
Lift the Turbine/Alternator using suitable crane and place them on the grouted packer plates. (While
lifting there might be requirement to open certain pipes of turbine/cladding to avoid damage and also
proper balancing of equipment while lifting)
Tools required:
1. Suitable Mobile crane
2. Chain Blocks
3. Slings/wire rope
Drawings required:
1. Foundation block diagram
2. GA drawing of turbine and alternator
Note: Load test to be carried it for a period of 30 Minutes before lifting.
Documentation:
Checklist for safe unloading/Lifting of TG & major equipment (ECD/FOR/287)
1.10 Leveling and Alignment of Turbine and Alternator
Leveling Procedure:
After lifting and positioning of turbine and alternator on the TG deck, completion of shrink fitting of
coupling Hub to Alternator shaft,(If applicable) match the center line of the Turbine (X & Y), fix all the
foundation bolts, anchor plates, nut and washers. Ensure the contact area of Anchor plates with the
foundation by 70 - 80%.
Level the Turbine using the leveling pads (Jack bolts of the turbine) provided on the Turbine base frame
by using the master level and necessary taper wedges/plates/shims. Allowed limit is 0.1mm/ meter.
Turbine leveling to be carried out (without opening of Gear Box) w.r.t leveling wedges provided in the
gear box. Leveling of the turbine can be achieved by adjusting the jackscrew and by increasing or
decreasing the packing. Allowed limit is 0.05mm/per meter.
After leveling the Turbine and Alternator. Alternator along with its sole plate is placed on the grouted
packer plates. Sufficient height should be provided so as to adjust with shim plates to match with the
Turbine center height and care should be taken during positioning of the Alternator that DBSE of the low
speed shafts is as per the drawing.
Also ensure Alternator shaft is located in its magnetic center, this can be ensured by checking the thrust
face gap on either side of the drive and non-drive end bearings. (TDPS does not allow opening the
bearings hence it has to be checked from outside only is given pointer on the bearing housing w.r.t
shaft.
Alignment Procedure:
Remove high speed coupling using gagging screw for compressing the coupling and fix the clamp to
check the high speed alignment (Clamping fixture should be rigid and should does not show any sag in
the readings).
Alignment should be checked in both radial and facial direction between rotor and pinion with dial on
pinion flange. Use taper wedges and shim plates for alignment.(DBSE / DBFF to be ensured by keeping
rotor and pinion in center).
After achieving the required values (as recommended by design) start tightening the foundation bolts
in sequence using a torque wrench. (For Torque details Refer Turbine Operation and Maintenance
Manual).
Ensure that all the packer plates are uniformly loaded by slightly tapping with hammer. (Alignment
readings to be enclosed)
Similarly alternator alignment is done with dial on alternator shaft and alignment should be checked in
both radial and facial direction by maintaining low speed DBSE..
After achieving the required values (as recommended by design i.e. within 0.05mm) start tightening the
foundation bolts in sequence using torque wrench. (For Torque details Refer Turbine Operation and
Maintenance Manual).
Ensure that all the packer plates are uniformly loaded by slightly tapping with hammer (Alignment
readings to be enclosed).
Bolt the spool piece to the turbine exhaust flange after the completion of alignment.
Check &confirm the high-speed alignment as earlier.
1.11 Fixing of Spool Piece and Expansion Bellow
Procedure:
Spool Piece to be bolted/welded with the turbine exhaust-mating flange, which is supplied loose along
with the turbine. (if applicable)
Erect / Connect the Expansion Bellow (OEM installation procedure should be followed) to the Spool
piece by Tack Welding. Till pre-commissioning Don’t remove the shipping bracket which is provided on
the bellows.
Match the Condenser Flange to the other end of Bellow and level the Condenser. Carry out Tack
welding between the Bellow and Condenser neck.
Condenser Foundation bolts to be grouted and tightened.
Then Full welding for Expansion Bellow (Spool piece end and Condenser end) to be carried out. Bellow
to be welded to the spool piece taking care that the high-speed alignment is not disturbed. Welding to
be done diagonally to avoid distortion. Refer QAD-WKI-006 and QAD_CKL_53
There has to be edge preparation and also gap between the spool piece and bellow as per drawing
before welding the coupler.
Also the pedestal of the condenser elevation is to b maintained as per the drawing.
Before final welding the pocket grouting/final grouting and tightening of the condenser fixed bolts has
to be carried out.
Placement of heaters and erection alignment shall be as per checklist no.ECD-CKL-014 (If applicable)
Tools required
a) Persian blue
b) Scrapper
c) Straight wedge/ glass (not less than12 mm thickness)
d) Ag-4 grinding machine
e) Diesel, cotton, emery paper.
f) Filler gauge, Dial gauge
g) Welding Machine
Drawings/Documents:
a) Foundation drawings
b) GA drawing of Turbine
c) GA drawing of Condenser
d) Spool piece & Bellow drawing
1.12 Installation procedure for TDPS Alternator, Exciter, PMG & Cooler:
OEM installation procedure should be followed.
The various dimensions required for erection of generator are described in the outline drawings.
Attention should be paid to the following points regarding the erection & location of generator,
The TG Deck location should be free from loose mortal, influx of harmful gas, moisture and tidal winds.
Ensure that Packer plates are placed on Hard Rock Land surface to avoid shrinkage. This need to be
ensured for Turbine & Alternator packer plate and Bolt fixing area
Regarding the various steps of erection, following list should be followed.
The main components of the generator, which may be disassembled condition, are as follows. It has to
be assembled in the following stages.
a) Exciter stator with sole plates: covers will be fixed after placing on foundation.
b) Sole plates: to be assembled before placing generator on foundation.
c) Alternator Coolers : to be assembled on the top after final grouting of the Alternator
d) PMG : To be assembled after grouting of Exciter
Note: The main components of the generator which are in disassembled condition are to be
assembled in the following stages, Sole plates-to be assembled before placing generator on
foundation.
a) Exciter stator with sole plates--- covers will be fixed after placing on foundation.
b) Air guides—to be assembled after final grouting of generator & exciter on foundation.
Removal of shaft locker:
(Thrust clamping metal-ware of rotor) Shaft locker is provided at the end of the shaft with an objective
of arresting the movement of the rotor during transport. This shaft-locker should be removed during
installation. Refer fig
Erection of main generator:
Check whether all contractual drawings, specifications pertaining to erection are available at site.
Check whether all components, parts, as per the packing list are available at site. Check whether they
are in good condition. Assemble them as mentioned in below paragraphs
Ensure that proper tools & safety are gadgets available to handle the equipment.
It is important to lift the machine /components by the lift arrangement provide on them.
The positions in the concrete bed where the Packer plates are to be placed have to be chipped as
explained in Micro chipping and Grouting of Packer plates. Packer plates, item 1 in fig 5.2(1)) by the
side of the foundation bolts & check their levels & height,
Place the taper wedges (on the packer plates). Two taper wedges to be placed one above the other
with taper faces mating each other. Ensure that they do not slide off. Now check their level and height.
Now the place the main generator with sole plates on the foundation. The sole plate now rests on taper
wedges. Check the level of the machine by placing spirit level on the sole plates. Adjust the level if
required, by adjusting the taper wedge below the sole plate. It is necessary to jack the sole plate for
adjusting the taper wedges.
Ensure the level at all the four corners of alternator parting plane.
Ensure that required numbers of foundation bolts are placed in the foundation pockets. The Centre
distance of these bolts should match with the fixing holes provided on the generator. The same to be
checked for exciter stator during erection.
Care to be taken to set the “magnetic center gauge” position. Three basic operations of the axial
positioning, paralleling and centering of the shafts to be ascertained, after ensuring these points
tightens the nuts of the foundation bolts. After tightening also ensure the above all points.
Tighten the foundation nuts lightly first and align the generator with respect to turbine as explained in
Leveling and Alignment of Turbine and Alternator.
Adjust the taper wedges if necessary to align. Set the alignment between generator and reduction
gearbox as explained in Leveling and Alignment of Turbine and Alternator.
If required the Lateral movement (along with axis of shaft) of Turbine can be adjusted by moving
wedge plates provided
Procedure for Erection of Exciter: - (wherever applicable)
Set the foundation packer plates and taper liners on concrete foundation as outlined in fig
Remove the exciter stator from the packing box. Dismantle PMG, Exciter NDE cover and Exciter DE
cover from exciter stator.
Lift exciter stator to approximately match the centerline of exciter stator to the shaft centerline Slowly
move exciter stator in the direction as marked in the figure.
Insert the exciter stator on to the exciter rotor & position it such that the exciter stator & rotor core
matches, approximately. Hang the foundation bolts & nuts on sole plate. Check with Exciter Magnetic
Gauge.
Measure the air gap at 4 locations using feeler gauge as shown. The air gap shall be equal on all four
sides, Measure the distance between Exciter frame cover fixing spigot to the rotor shaft at four positions
using a scale or measuring tape as shown in below fig. The level should be within 0.02mm. Refer figure.
Apply Non shrink cement into all foundation. After curing tighten the foundation bolts & nuts then grout
up to base frame of exciter.
Procedure for Erection of PMG: - (Wherever applicable).
The Fig 5.4(1) shows the complete Exciter stator with PMG mounted on it. Loosen the PMG fixing bolts
and remove the PMG. Insert the male Spline of cardon shaft into the female counter part in the slip ring
Shaft as shown in fig.5.4 (2) and tighten the PMG fixing bolt. This assembly is to be carried out after.
Assemble air guide to main generator frame. Assemble top end shield and tighten all bolts. Assemble
top covers.
Assemble the coolers on top side of stator frame as per alternator GA drawing/ Important Note: Please
ensure no welding activity to be carried out in Turbine and Generator. This may cause Electric spark in
bearing area and will damage Bearing.
Tools required:
a) Dial Gauge
b) Feeler gauge
c) Fixing clamp
d) Master Level
e) Water level
f) Plumb
g) Hammer
h) Torque wrench
i) Vernier/inside micro meter
Drawings/Documents:
a) Foundation Drawings
b) GA Drawings of Turbine
c) GA Drawings of alternator
d) Alignment data sheet (Refer Operation and Maintenance, Chapter Overhaul and Inspection).
e) MRT Report
1.13 Arrangement of foundation for WEG Alternator
For Erection of WEG make alternator please follow manufacturer guidelines and instruction. Top side
view of foundation assembly
Details of foundation arrangement
Side view of foundation assembly
Top view of foundation assembly
Bottom view of foundation assembly
FOUNDATION PRIMARY CONCRETE
ANCHOR BOLT AND LEVEL PLATE ASSEMBLY
SOLE PLATE ASSEMBLEY GROUTING
Documentation:
a) Turbine erection record: ECD/02/206.
b) Pre-commissioning/commissioning record sheet: ECD/02/207.
1.14 Grouting of Turbine, Alternator
Procedure:
 Recheck the final alignment of High speed and Low speed, which has been recorded before.
 Clean the grouting surface with air blower to avoid dust.
 Clean the oily surface with caustic soda on grouting area before grouting.
 Storage, usage and disposal of Caustic soda:
 Caustic soda is to be stored in a plastic container.
 The container should be labeled.
 Face shield, gloves, breather mask are to be used by the individual while handling.
 The collected caustic soda containers to be properly closed.
 Check the availability of required quantity of grouting material as per civil engineer assessment
and suggestion.
 Shuttering should be made around the equipment area properly. (Area of around 250mm
around the equipment to be considered)
 Fill the mortar in the bottom of the Foundation hole to a height of 1 ½ inch depth and then
sand in the sleeve up to the top of the deck.
 Ensure for no leakage of grouting material in cut outs and holes during grouting
 Grouting should be carried out as per civil engineer assessment and suggestion.
 Ensure the grouting material is filled between turbine/alternator base frame and foundation,
and there is no air gap between the base frame and foundation. (To ensure this grouting
material can be poured from height and from only corner only so that due to gravity material
flow is maintained in all directions)
 Suitable cut outs to be provided at turbine base frame oil doors for maintenance purpose.
Tools Required:
a) Air Blower 300 Watts, Single phase.
b) Concrete mixer
c) Wooden pieces or channels for shuttering
d) Caustic Soda
Grouting Procedure
Surface Preparation:
Ensure a clean and strong concrete base. Remove all dust by suction or compressed air. Wet the
surface thoroughly before grouting. Remove all free water.
Mixing: (To be followed OEM instruction’s)
Mix dry grout with recommended quantity of water in a mechanical paddle / drum type mixer.
Conventional 200 /140 ltr mixer is suitable for 200 kg dry grout.
Restrict mixing to quantities, which can be placed in ten to fifteen minutes. Mix for a minimum of three
minutes. The temperature of the Grout while mixing should be preferably below 25ºC.
Placing and Compaction:
The grout should be placed quickly and continuously, either through the holes in the base plates or from
one side only to ensure complete filling without entrapment of air. Grout should be properly spread and
compacted by' rodding. Judidous vibration with a Needle vibrator could also be used, but over-
vibration should be avoided as it can cause segregation and bleeding. A preferable method to ensure
flow and compaction of the grout below the bed plates is to use long pieces of doubled-over flexible
steel strapping or chains. The forward and backward movement of the strap or chain will assist in the
flow of the grout into place. Steps must be taken to keep the grout in full contact with the underside of
the bed plate until the grout sets. Maintaining a small head of fresh grout in the forms would help.
Restraint:
Restrained expansion induces pre compression in the grout, thereby improving its strength and bonding
property. Heavy backup blocks of timber or concrete should be fixed on all sides of the base plate to
prevent the grout escaping, through the openings in the base plate. To obtain effective shrinkage
compensation, adequate restraint must be ensured on all sides for a period of seven days. In the case
of bolt holes, this restraint is naturally ensured. When using in locations with exposed top, reinforcement
of at least 0.3 per cent of area in both directions within four cms from the top should be provided.
Curing:
Cure for a minimum of seven days for Shrinkomp 10,20 and 30 and one to three days for Shrinkomp 40,
by pounding water or with wet Hessian cloth. Cover top and stray openings of restraint formwork with
wet sack for a minimum of seven days.
DO’s:
 Provide adequate restraint preferably on all sides for a minimum of seven days for Shrinkomp 10,
20 and 30 and one to three days for Shrinkomp 40, to ensure effective shrinkage compensation.
 When using in locations with exposed top, reinforcements of a minimum of 0.3 percent of cross
sectional area in both directions within 4 cms from the top area is essential.
 Consult the design engineer before placing / commissioning machine on foundation.
 Use recommended quantity of water only.
 For extreme hot weather conditions use chilled water (5 - 10' C).
 Use grouting cement preferably within 6 months from the date of manufacture.
 Grouting Cement should be stored in dry place.
Don’ts:
 Do not use any admixtures.
 Do not batch grout by fraction of a Cement Bag.
 Do not add water in excess:
 Do not expose to moisture and direct sunlight when storing the cement.
 Do not place the mixer under direct sunlight and place it closest to the area of operation.
 Do not expose the area of grouting to heat and sunlight.
Note: After grouting of turbine and alternator, once again high speed & low speed alignment should be
checked. After grouting of turbine, condenser final leveling and alignment should be done.
1.15 Placement of Auxiliaries (Oil Cooler, Oil Filter, Oil Centrifuge, GVC, Ejector System and CEP
Procedure:
Position the auxiliaries as per the drawing and also to ensure whether the location is convenient for the
ease of operation and maintenance.
Check the Dimension and elevation of the foundation as per the drawing.
Placing and orientation of the equipment w.r.t centerlines marked as per the drawing.
Half grouting (filling the foundation pockets) of foundation bolts after leveling. Leveling is checked at
the pedestal of the equipment and also the perpendicularity of the equipment nozzles to be ensured.
After curing, equipment is to be leveled to maintain parallelity and perpendicular with shims/packers at
required elevation with the help of spirit level/plumb.
For CEP master level is to be used and acceptable limit is +/- 0.02mm/mtr.
Ensure all the foundation bolts are tightened as per the torque recommended using a torque wrench.
Refer section – Overhauling &inspection in instruction manual.
Grouting should be carried out as per civil engineer assessment and suggestion.
Tools required:
a) D-clamps
b) Wire slings
c) Ropes
d) Chain blocks
e) Master level
f) Spirit level
g) Torque wrench
h) Welding Machine
Drawings required:
a) GA Drawing
b) Layout drawing
a) Checklist for safe unloading/Lifting of TG and Major Equipments. ( ECD-02-287).
1.16 Fabrication of Pipelines
 Oil System pipeline
 Condensate system pipeline
 Steam system pipeline
 Drain lines.
 Instrumentation pipeline
Procedure:
After completion of positioning of Auxiliaries, Turbine, Alternator, Condenser Lube oil piping between
Alternator/Turbine to cooler, cooler to filter, filter to lube oil header, Condensate pipe lines between
CEP, LCV, ejectors and de-aerator to be fabricated as per P & I drawings, piping layout and isometric
drawings.
The following procedure to be followed for fitment of pipelines before carrying out welding. Ensure a
gap of 2.5mm between two pipes. With edge preparation and gap to be maintained on the thickness
of welding rod/filler rod.
Ensure Slope of the pipeline towards the direction of flow for fast draining in drainpipes. Level of the
pipes to be maintained using spirit level for all other pipelines.
TIG welding to be carried out for all the piping joints using Argon gas and filler wire no 70 S2 for CS and
308L for SS. Full welding with the TIG. Welding Protocol No. E&C- 02-301 to be referred.
GVC inlet and drain pipeline are to be fabricated as per P & I and isometric drawings.
Tools required:
a) Arc Welding Machine with Electrodes for welding process as per the recommendation.7018 for
CS pipe lines
b) Organ gas set. Filler wire dia 2.5mm, 70S2 for CS, and 308L for SS.
c) Tungsten Rod of 2.5mm dia.
d) AG4 &AG8 Grinding Machine with wheels.
e) AG4 Buffing Wheels
f) Right angle
g) Wire brush & chisel
h) Hand Gloves
i) Shield
j) Spirit Level
k) Ac Power Supply
Drawings required:
a) P & I Drawings for Lube oil.
b) Power house layout drawings.
c) Vendor piping drawings,
d) Auxiliary Foundation Drawings.
e) Condensate piping isometric drawings.
WELDING PROCEDURE
Sl. No Activity Instruments/ EQPTS/ Remarks

Precaution to be taken
Ensure that the circumference of the Pipe cutting M/c, Pipes to be chamfered by
pipe is chamfered by around 30 / 35 0 grinding M/c / Lathe use grinding / machining (Tri
1 goggles square to be used for
checking uniformity in the
grinding process)
In case pipes to be welded to a flange, Refer carbon of the electrodes

ensure the pipe is inside the flange bore being used for details.
2 by half the thickness of the flange
Set the voltage and ampere in

accordance to the electrode being
3 used
Choose proper electrode i.e. size and For S.S. pipes use TIG / E106
type in accordance to the nature of the electrodes and for
4 pipe i.e. C.S. / S.S. pipes
C.S. pipes use, MIG / over
chord SS electrodes
5 Keep spark plate ready for initial Do not spark on the job
sparking initially
Start welding circumferentially over the Use hand gloves, weld

pipe and its mating part shield, Apron
6
If any blow-hole or crack is found then

the weld-bead is to be removed by
7 chipping or grinding / gouging and to
be
dressed before depositing the next

successive bead
8 All slag/spatters to be removed by Chipping hammer, wire Weld joints to be neatly

chipping and to be cleaned with wire brush formed and weld spatters to
brush. be removed
1.17 Cleaning of Pipe Lines:
Oil pipeline cleaning
Procedure:
The oil pipelines fabricated at site are to be cleaned by acid pickling for CS pipelines and by Caustic
Soda for SS pipelines.
Before acid pickling the pipes should be thoroughly flushed with air for removing of loose particles.
Acid pickling pipes should be dummied one end with rubber gasket and filled with acid of 5 to 8% of
concentrated HCL acid and keep the pipes filled with acid for 24 hours, so that all loos metal particles
will come out.
There after remove the acid from pipes & clean the pipes thoroughly with water and neutralize with
caustic soda. Fill the 3 to 4% of concentrated caustic soda solution in the acid cleaned pipelines and
keep the pipes for 24 hours, so that all acid contents gets neutralized.
Ensure the time between acid cleaning and soda wash should be kept minimal Also chemical solution
should not exceed 60˚C.
After that all soda washed pipes are thoroughly cleaned/rinsed with water and dry with Air, Lube oil (ISO
VG 46) to be applied inside the pipelines to avoid rusting.
All the passivated pipelines are covered both the ends of pipes with plastics caps / lids so that no dust
particles can enter inside. All passivated pipelines are to be fitted immediately in the original position
and start the oil circulation / flushing.
Storage, usage and disposal of Chemicals: Chemicals is to be stored in a plastic container. The
container should be labeled Face shield, gloves, breather mask are to be used by the individual while
pouring the acid.
Acid is to be poured in a slow and steady manner into the pipelines. Keep water source and caustic
solution near acid pickling area to neutralize immediately in case of any spillage.
Acids to be drained from pipeline and should be collected in a plastic container. Face shield, gloves,
breather mask are to be used by the individual while draining the acid.
Tools/Material required:
a) Air Blower
b) HCL
c) Caustic Soda
1.18 Condenser flushing, condensate pipe line cleaning and CEP commissioning
Purpose:
Pipelines must be cleaned to remove any foreign material that may have been left behind during the
construction period or formed during piping work. Naturally generated rust also needs to be removed.
Otherwise, debris from uncleaned pipelines can lead to contamination, clogging of pipe or control
valves, failure of mechanical seal or malfunctioning of equipment.
Medium:
Flushing of pipe lines will be done by fresh water from normal supply network of the plant.
Procedure:
 Ensure that the rupture disc is removed before cleaning of condenser and install a dummy
flange at place of rupture disc before filling of water in condenser.
 Water to be filled using make-up water line, up to the exhaust flange (This can understand by
providing temporary visible plastic hose which one end connected condenser drain point
another end free to atmosphere at the height of turbine shaft center) and hold for 4-6 Hrs.
Check for the weld joints leakage if any & to be attended. (Also can ensure the water is filled up
to exhaust flange by temporarily opening exhaust pressure impulse line provided in turbine skid.
Reconnect the line after filling is done.)
 After ensuring there are no leakages, drain the water by removing the CEP suction line strainer
by operating isolation valve. (Each line to be flushed separately for 5min Interval.)
 Close the CEP suction line isolation valves & Re-install the strainers in the suction line after
completion of above step
 Ensure all the CEP suction isolation valves are closed completely and open hot-well drain for
condenser flushing completely.
 Remove water accumulated in CEP pit by de-pumping it.
 Ensure the hot well is clean by viewing it through the manhole provided on hot-well, if not, clean
the same manually.
 Ensure there is no foreign particle inside the pump. Pump mechanical seal locking plates to be
removed which are generally used for transportation.
 Ensure that all the gaskets are placed in the flange joints of the pipelines and open the CEP
suction Isolation valves.
 Re-fill make-up water up to 50% of the hot well in the condenser.
 Close the level control valve and Isolation valve (both before and after LCV) in re-circulation
and de-aerator line completely.
 Open bypass valve of the re-circulation line completely and ensure the bypass valve of de-
aerator line is closed.
 Flushing to be done by taking recirculation system in line, i.e. the suction of water will be done by
CEP, from Condenser hot well and its discharge will pass through the Ejector condenser, GVC
and back to the condenser through by pass line.
 Start the CEP pump and maintain the discharge pressure of 6-8 kg/cm2 (As per pump pressure
rating). Also verify that there is no leakage in the line. Motor amps to be controlled by throttling
the pump discharge valve/ valve in bypass line of the level control valves.
 If the pressure differential across the strainer increases above 0.4 kg/cm2 stop the CEP and clean
the strainer in the CEP suction line. Continue the procedure till we get DP across the CEP suction
strainer below 0.3kg/cm2 for minimum 6 hours of operation.
 If the DP switch is not available in the system, observe the discharge pressure of the pump. If the
discharge pressure drops to 5-6 Kg/cm2, stop the CEP and clean the strainer in the CEP suction
line. Continue the procedure till we get constant set discharge pressure for minimum 6 hours of
operation.
 After cleaning the recirculation line, close the bypass valve in recirculation line.
 Clean the de-aerator line by opening the valve in by-pass line provided and to be drained from
the maintenance flange provided in line or de-aerator storage tank drain. (For min. 1 Hr. interval,
depending upon pipeline condition.
1.19 Condenser Commissioning & Vacuum Build Up
1. After successful completion of water fill test drain the water & install the Rupture disc
assembly/shell safety device.
2. Charge the condenser with cooling water in advance before turbine rolling and any other
equipment that connect into the condenser. During cooling water charging to condenser open
water box vent to remove entrapped air & thereafter it shall be closed.
3. Fill water through make up water line around 50% of hot well level & Ensure the hot well level
gauges and switches are working properly..
4. Check and ensure that all water box vent valves on the tube side (water side) are open
5. Cooling water parameters to be maintained as per design recommendation.
6. Open the suction, discharge and vent valves on the condensate extraction pumps and allow
the pumps to completely fill with water. Check the hot well water level. This should be
approximately 50% in the hot well gauge glass.
7. Ensure pressure balancing valves provided in the suction line of CEP is in open condition.
8. During initial commissioning CEP shall be run in recirculation mode until the suction strainer is
clean and free from debris/choking.
9. Start the condensate pump. Check to insure that the automatic level controls are maintaining
the 50%hotwell water level.
10. Ejector motive steam line inlet line pressure and temperature to be maintained as per design.
11. Hogger ejector should be charged first. Its purpose is to rapidly evacuate the air in the
condenser and associated piping (including the turbine casing) in a short period of time (usually
30 to60 minutes). After vacuum pr. -0.5 to -0.6 achieved can provide gland sealing steam of
required pressure and temperature to Turbine glands to achieve further vacuum.
12. Start the steam turbine. (Refer to the instruction manual supplied by turbine manufacturer for
specific start-up instructions.)
13. Ensure ejector drains to condenser flash tank are in open condition through the steam trap &
the steam trap bypass valves shall be completely closed.
14. After 30% load on TG set, carefully change over to ejector system from hogger to main ejector
by opening isolation valves of Ejector. Monitor the vacuum pressure, if any drop in vacuum
pressure is observed, immediately normalize to hogger ejector system and check the cause of
vacuum drop.
15. Ensure the vacuum to be maintained as per the design parameters.
2. PRE- COMMISSIONING (Mechanical)
If turbine is in storage for more than one year at site, rubber seals, gaskets shall be replaced as per OEM
recommendations.
Replace sealing, anti-seizing compound as per O&M recommendations.
Fastening/tightening as per DEI (Design Engineering Instructions).
Rotor Float/dump and Bearing clearance check to be re-verified as per assembly values.
Turbine Insulation to be done as per drawing (if opened/not done) with the help of assembly checklist.
2.1 Oil flushing
Prerequisites for Oil flushing Stage -1.
Firefighting system at MOT and STG area is ready to use.
Main oil tank should clean thoroughly using sponge/Cloth, diesel and with compressed air.
Ensure AOP suction strainers are cleaned and boxed up properly
Fill the Oil Tank with flushing oil of Grade ISO VG 46 (refer O&M Manual) through centrifuge by site
suitable temporary flexible hose connection. Temporary hose connection one end is immersed in the oil
barrel and another end is connected to oil centrifuge inlet point. Centrifuged oil should be send from oil
centrifuge outlet to Main oil tank by permanent piping. Flushing oil should be same as per first fill oil. The
detailed specification & makes are specified in the operation & Maintenance manual Q1,Q2 & Q3.
Ensure Main oil tank level should be > 65% or as per requirement in local level gauge.
Before start up the LOS system please ensures there is no bypass in protections of motors like-Over load,
single phase preventer etc.
All the Oil Pumps & Main oil tank fans are kept ready for operation. Ensure Emergency local Buttons of all
the motors are released condition.
MOT heaters should on. Also ensure Heaters to be cut of at 65 ˚C of MOT Oil temperature. IF heaters not
considered in the MOT temporary shall be arranged by erector.
Ensure MOT Mist fans power supply panel are in charged condition and Mist fan kept ready to start.
Ensure Aux. Oil pump power supply panel is in charged condition kept ready to start.
Ensure STG Barring gear motor, EOP motor & ACOP motors power supply is switched off condition.
Ensure AOP pump suction and discharge Pressure Gauges are working and its isolation valves are in
opened condition.
Dummy blanks (SS304-1mm thick with tagging leg) to be provided by erector in following areas to avoid
not to enter dust & foreign particles.
Shaft driven pump MOP discharge piping flange.
EOP pump discharge piping flange.
Control oil & Trip oil circuit inlet flanges.
PRVs of AOP & MOP and lube oil header.
Note: The dummies used for bypassing the Bearings and others should be tagged, noted and recorded
Ensure any one of the Lube oil cooler is line up i.e the inlet 3 way valves is directed in one cooler only
and cooler equalizing valve is in closed position. Also ensure corresponding lube oil cooler vents and
drains are in closed condition.
Lube oil cooler inlet and outlet cooling water valves are in closed condition. Ensure cooling water to be
charged up to isolation valves during flushing.
Ensure lube oil cooler inlet Pressure Gauge isolation valves are open. Also ensure All PTs (if applicable)
isolation valve is closed condition during flushing to avoid entry of any foreign particles.
Remove the original filter elements (625 mesh) from filters skid & put Temporary made filters element
(perforated pipe and rolled with temporary filter screen having sizes start from 50 mesh and fastened by
wire) to both filter shell. (Temporary filters are to be fabricated at site by erector using suitable pipeline
material).
Ensure any one of the Lube oil filter is line up i.e. inlet 3 way valves are directed in single oil filter only and
equalizing valve is in closed condition. Ensure Lube oil temporary filters are cleaned and box up
properly. Ensure Lube Oil filter drains and vents are in closed condition. Ensure Lube Oil filter line inlet &
outlet Pressure Gauges is working and its isolation valves are open.
Ensure lube Oil filter DPT isolation valves are closed condition during flushing to avoid entry of any
foreign particles. During flushing Differential pressure can be monitored through Upstream &
downstream of the lube oil line pressure gauges.
Ensure Lube oil header Pressure Gauge is working and its isolation valve is open and PT’s isolation valves
are closed condition during flushing to avoid entry of any foreign particles.
Site suitable temporary hose connections are to be provided by erector in the following areas to by-
pass the following
Turbine front & Rear bearing pedestal flanges oil inlet to out let.
Gear box flanges oil inlet to out let.
Alternator Front & Rear bearing pedestal flanges oil inlet to Out let.
OHT (If applicable) inlet line terminal flange to Overflow line terminal flange.
DOT / SOT (If applicable) inlet line terminal flange to Overflow line terminal flange.
Oil centrifuge (If applicable) inlet line to Oil barrel.
Knowledge Field operators are to be arranged up to completion of oil flushing. Field operator should
continuously monitor the oil flushing; close monitoring of MOT level & overall flushing circuit to avoid any
oil leakage. Since all logics & interlocks can't be implemented during oil flushing. Immediate actions are
to be taken, in case of any temporary joint failure. Round the clock monitoring is required, hence
manpower to be planned accordingly.
OIL FLUSHING STAGE-1 START UP PROCEDURE
Start the AOP with clearance from field operator. Ensure and monitor the motor current. 2 to 3 times
Start & Stop is required to fill the oil in cooler and filter skid and piping system and also ensure no air
entrapped in cooler and filter by open & close of vent valves. During this process closely monitor the
MOT level if oil level, if goes below low level top-up is required and ensure the required level. Also
monitor any spillages or leakages in the lube oil circuit, if noticed same to be attended immediately.
Lube oil header pressure will slowly rise and reach around 2.0 bar(g) Watch the lube oil pressure before
lube oil cooler and same around >1.0 bar(g). Monitor the lube oil which is circulating through bearings
by pass lines.
Monitor the AOP discharge pressure regularly, If discharge pressure drops means AOP suction strainer is
getting choked. Stop the oil flushing temporarily. Clean the suction strainer, box up properly and then
restart the flushing.
Monitor the lube oil filter differential pressure by comparison of Upstream & downstream pressure
gauges, if its increase above 0.7 bar(g) immediate action required changing over to standby filter.
Before change over the running lube oil filter open the vent valve in Stand by filter and Open the
Balancing valve to fill the oil in stand by filter skid. Once the proper oil venting ensured change over the
filter through three way valve. If required follow the same in vise versa.
To clean the choked filter, drain the oil from filter and remove temporary filter. Remove the mesh clean
with pressurized air along with by site suitable cleaning medium. Once cleaned the mesh and tie with
temporary filter (perforated pipe) and insert to filter skid. Close the filter drain valve. Fill the oil through
equalizing valve and ensure no air entrapped in the filter skid by open the vent valve. Then restart the
flushing.
Raise the lube oil temperature 55 to 65 ˚C by MOT heaters or Temporary heaters. Once the oil
temperature raised 55 to 65 ˚C lightly hammer the line with mallet or soft hammer so that all the loose
materials will come out with the oil.
After duration of two to three hours, change over the filter to the stand by one and check for the
cleanliness of the mesh and if required replace the same. These processes are to be repeated by
changing the filters in line and also mesh if required at intervals of 2hrs, 4hrs, 8hrs durations.
Thermal shock to be provided for fast removal of the dirt and the particles. It can be done by
passing cooling water in the Oil Cooler. It makes a steep drop in temperature and temp can be
increased by heater. Cyclic map attached for ready reference.
55 - 65℃
30 - 35℃
4h 4h
Thermal Shock Requirement
(Ensure oil tank heaters should be cut off at 65℃ and switch on at 30℃)
Also oil cooler is to be changed over interval of every 4 hrs. Before change over the running lube oil
cooler open the vent valve in the stand by cooler and Open the Balancing valve to fill the oil in stand
by cooler. Once the proper oil venting ensured changed over the cooler through three way valves. If
required follow the same in vise versa. Temperature change during flushing by heating the oil 55 to 65
Deg C, then cooling the entire oil volume 30 to 35 Deg.C by supplying cooling water in the oil cooler.
The same should follow 2-3 times in every 24 hours of flushing operation.
Once 50mesh cleared then change to 100mesh then 150mesh and then 200mesh.This process to be
continued up to 200mesh cleanness. Once 200 meshes are cleared then follow the Stage -2 flushing.
Prerequisites for Oil flushing Stage -2.
Remove top half of the bearings (Thrust, Front & Rear) of T u r b i n e Rotor and keep / store safely. Clean
the preservatives which applied in the rotor. Replace the bearing cap and its housing/cover in its
position and ensure that oil will not spill out during flushing.
Turbine front and rear pedestal loop line (flexible hoses) to be removed and normalized the inlet and
out let connections as per original. Ensure Loop will be continued in the gearbox & Alternator bearings
which are bypassed with flexible hoses.
Ensure Loop will be continued in the OHT & DOT / SOT (if applicable).
Ensure the temporary made filters element filter screen having sizes start from 50 mesh.
Apart from above Prerequisites will be remain same as per Stage-1 flushing.
OIL FLUSHING STAGE-2 START UP PROCEDURE
Repeat the procedure as per Oil flushing Stage -1
Continue flushing further till system is clear.
Once 200 meshes are cleared Oil flushing is completed and Protocol (ECD/FOR/219) to be signed.
Photos of final clear mesh will be recorded.
Post requisites for Oil flushing Stage -2.
Once system oil flushing is cleared stop AOP & reassemble turbine bearing assemblies, all pipelines to be
reconnected / Normalized.
This involves the following action.
a) Ensure entire LOS power system to be switched off.
b) Completely drain the oil from MOT, coolers, filters and piping system.
c) Once the MOT is drained completely, open oil tank cleaning doors (cleaning doors provided in
the sides of the tank if MOT inbuilt with base frame), Clean the tank internals using site suitable
special wipers with long rod along with compressed air. After cleaning, apply fresh lube oil inside
the tank, ensure that oil is sprayed throughout inside of the tank (Sprayer-site suitable hose
connection). Once the oil fogging is over fix the oil cleaning door with oil gasket and applies the
grease on the gasket before tightening the bolts.
d) OHT & SOT (if applicable) also should clean thoroughly using sponge/Cloth, diesel and with
compressed air. (There is no confined space entry, its easily accessible man hole door is
provided)
e) Remove the Turbine thrust, front & rear bottom half the bearings from respective pedestals by
small amount of lifting the Turbine rotor (max 0.1mm only) Note:- Should be permitted Controlled
lift by using suitable chain block.
f) Turbine front & rear bearing pedestals should clean thoroughly using sponge/ lint free Cloths,
diesel and with compressed air.
g) Completely disassemble and clean the Turbine thrust, front & rear bearings by petrol or site
suitable cleaning medium. All bearings pads to be inspect. Clean/polish both top & bottom
halves. Ensure their correct fitting. Clean the holes provided in Thrust Bearings Pads holder &
Journal Bearing holes also.
h) Insert the Turbine thrust; front & rear bottom half of the bearings in the respective places. Rest
the Turbine rotor on the bearings.
i) Assemble thrust, front & rear top half of the bearings in the respective places. Ensure required
clearances as O&M Manual recommendations. RTD functioning to be checked (if applicable).
j) Count and note the Number of teeth for the speed sensing gear.
k) Position the bearing caps/cover and tightens the cap studs as per torque recommended, ref
O&M manual for Torque details. Also tie bolts nuts with steel wire through the locking holes.
l) RTD cables are to be clamped and routed properly.
m) Visually inspect the oil inlet fitting and seating area and assemble the same.
n) Before assemble the pedestal cover ensure no foreign particles (like spanner, cloth etc) inside
the pedestal. Assemble the pedestals covers and use silicon sealant which supplied in the loose
supply items package or any equivalent, also ensure the proper tightening. Once again Bearing
RTD’s should be re-checked after positioning of the pedestal cover.
o) Ensure all pumps (AOP, MOP, EOP & ACOPs) suction strainers are well cleaned and boxed up
properly.
p) Ensure both filters skid temporary filters are removed and filter skid is thoroughly cleaned. Insert
the original filters in the respective places.
q) Main oil tank – Oil should be filled through centrifuge with first fill oil of Grade ISO VG 46. If Flushed
oil to be reused, only after filtration and testing to be carried out and quality should meet as per
Q3 .The detailed specification & makes are specified in operation & Maintenance manual
Q1,Q2 & Q3.
r) Ensure Loop lines (flexible hoses) to be removed in the gearbox & Alternator bearings and
normalized the inlet and out let connections as per original
s) Ensure all dummies are removed which installed in PRVs, MOP & EOP discharge piping, control oil
line and trip oil line system.
t) Ensure all instruments (PT, DPT, LT) isolation valves are normalized as per requirements.
u) All the pressure, temperature gauges, vibration probes, etc. to be fixed properly.
v) All PRV’s to be taken in line.
w) Ensure all flange joints are fitted correctly and are oil tight.
x) Before start up the system please ensure there is no bypass in interlocks & Logics of oil system
Start the AOP motor.
y) Ensure there is any oil leakage in the lube oil system.
Note: Passing of oil to be ensured in all the bearing after final box up.
All the waste oil (from the oil flushing) shall be disposed as per the guidelines.
Documentation:
 Oil flushing protocol.(ECD/FOR/219).
 Pre-Commissioning & Commissioning record sheet (ECD/FOR/207).
 Protocol for oil quality (ECD/FOR/294).
 Protocol for overhead oil tank commissioning (ECD/FOR/289)
Tools/material required:
 Dial gauge
 Micrometer
 Lead wire
 Feeler gauge
 Vernier Calipers
2.2 Checking of Safety Trips
Procedure:
Before starting AOP, ensure all oil pipeline instruments are fitted and final box up of the turbine is
completed.
Check the functioning of AOP and discharge pressure is set to as per Data provided in the Technical
Data in the Instruction Manual. (Refer Turbine Operation and Maintenance Manual).
Set the lube oil pressure, control oil pressure through pressure relief valve and ensure the trip oil pressure
(Refer Turbine Operation and Maintenance Manual).
Take OHT (Over Head Tank if applicable) in line and note down the time taken to fill the Over Head
Tank till oil starts to overflow. Now switch off AOP motor and note down the oil pressure at lube oil
header (should be between >0.3 kg/cm2 G) and rundown time (should be >15 mins). If required
Change the OHT outlet line orifice size to match the above mentioned outcome. Record the details in
the E&C document No. ECD/FOR/289 OHT commissioning protocol.
Check and ensure Accumulator pre-charged pressure to be around 60% to 70% of control oil pressure If
pre-charged pressure is low than charge the accumulator with Nitrogen gas by using of Nitrogen
charging kit.
Check the functioning of L.P Trip, SEV and Throttle valve. (Reset the LP trip ,open the SEV & lift the
linkages assembly to check the throttle valve operation . check the LP trip pressure by moving the hand
trip to trip position slowly ensure the LP trip pressure is around 0.5 to 0.8 Kg/cm 2 .Also ensure closing of
SEV & throttle valve when hand trip is activated to trip position).
Check the functioning of SEV and TV when Hand trip actuated.
Check the functioning of vibration monitoring system and the alarm and trip set points are configured
as recommended, (Refer Turbine Operation and Maintenance Manual).
Check the function of all the pressure switches and pressure transmitter at TCP with reference to field
mounted instruments.
Set the pressure switch set points given in the instruction manual (Refer Turbine Operation and
Trip circuit oil pressure to be less then 0.1/0.2 from the lube oil pressure/Bearing oil pressure AOP, ACOP,
Barring gear & EOP inter locks & function to be checked and ensure. (Refer Turbine Operation and
Check the tightness of the linkages of HP actuator, Relay cylinder, Throttle valve and LP actuator.
Maintain the throttle valve Z-setting as mentioned in the O&M manual or design supplied setting sheet.
Check and note the HP actuator and LP travel (displacement) at different actuator opening
percentage and record the same in E&C document no. ECD/FOR/290
Check the function of GVC blower. (Check the rotation of motor & airflow at the out let).
Documentation:
 Pre-commissioning and Commissioning record sheet.( ECD/FOR/207).
 Protocol for actuator stroking (ECD/FOR/290) (wherever applicable)
2.3 Barring Gear Trials
Procedure:
Start AOP and check the oil pressure and oil flow to Turbine, Gear Box and Alternator bearings is as per
recommendations mentioned earlier.
Check the functioning of barring gear and lube oil pressure interlocks. (Ensure barring gear motor should
not be started when AOP in off mode.
Switch off AOP when barring gear motor in operation, ensure the barring gear get stopped because of
low lube oil pressure.
Check the functioning of EOP. (Check the discharge pressure as per recommendation given in manual
& ensure the flow to all bearings by watching flow glass.
Ensure EOP get switched off when AOP get started & vice versa)
Ensure all the Bearing temperatures, vibration system are inline and ready for monitoring.
Start the barring gear motor and check the vibration level, speed and bearing temperatures are within
the specified limits mentioned earlier.
Check for any abnormality at barring motor, Turbine gearbox, Turbine bearings and casing.
Continue the barring gear operation as per recommendation given in (refer Instruction manual) before
starting the Turbine with steam.
In case of emergency (No power supply), manual barring operation to be carried out with EOP in line if
the turbine is hot condition. Before start manual barring gear operation ensure barring gear motor stop
button should be locked / feeder should be kept locked condition.
Documentation:
➢ Pre-commissioning and Commissioning record sheet.( ECD/FOR/207).
2.4 Open inspection:
Please refer the manual chapter Overhaul and inspection in the Operation and Maintenance manual.
2.5 Steam Blowing
A steam turbine is vulnerable to damage if any debris is fed into the machine with the steam supply.
It is essential, therefore, that the steam line to the turbine is completely clean and free of any clinging
matter, particularly weld splatter, before steam is fed to the turbine on commissioning. This also applies
after any repairs to the piping or boiler.
The purpose of blowing the steam lines prior to starting up a new unit is to remove any foreign matter
remaining in the equipment (i.e., super heater) and steam piping after erection is completed.
Considerable damage could result if such foreign matter was allowed to enter the plant steam system
during initial operation.
On older units the need for steam line blowing should be considered following major pressure parts
repairs, where the possibility of introduction of foreign material into the system exists.
Since prevention of damage to the plant steam system is the prime concern, the responsibility for
determining the effectiveness of the steam line blowing operation rests with the plant operator. During
the steam line blowing process the unit should be operated in accordance with the vendor
recommended procedures, with all control systems & protective interlocks functioning.
It is strongly recommended that blowing of steam to be witnessed by a Triveni service engineer.
The principle behind steam blowing is that the thermal cycling (heating/cooling) and high velocity gas
flowing through the line will “shock” the pipe & tend to break the mill scale & weld slag away from the
pipe wall. Ideally, steam blowing should be done prior to the system being insulated to maximize the
thermal cycling of the equipment. If the system is insulated, a greater time between blows may be
necessary to allow the system to cool.
Ideally, to obtain optimum cleaning, the flow conditions in the system during steam line blowing should
equal those during normal operation at maximum load. Since it is impossible to exactly duplicate these
conditions when blowing through the piping to atmosphere, it is desirable to produce equivalent
conditions by using lower pressure
steam with flow rate such that the friction force during blow out condition will be 1.5 or more times the
friction force under normal full load conditions. This ratio is commonly known as the disturbance factor
or cleaning force ratio (CFR)
Steam flow quantity during blowing to be calculated as below,
(W2 * V)
CFR = -------------- > 1.5
(Wr2 * Vr)
Where:
W = Mass flow rate during steam blow out condition (TPH)
Wr = Mass flow rate during normal operation, or the maximum value (TPH)
V = Specific volume during steam blow out condition
Vr = Specific volume during normal operation
The temporary piping is normally equipped with a shutoff valve that is used as a blowing valve. With this
arrangement, the super heater and the upstream portion of the temporary piping are maintained at
drum pressure at all times when not actually blowing.
SAFETY WHILE STEAM BLOWING
Safety Precautions:
Necessary safety precautions must be taken such as fencing off the area and providing ear protection
against the inevitable noise generated during the blowing down process.
The process of steam blowing imposes abnormal and severe conditions upon the boiler, steam
equipment and steam piping. Large, rapid temperature changes occur during each blowing cycle. This
cycling of temperature is far more severe than is incurred in normal operation. Thermal stresses may be
excessive in the heavy wall portions of the system such as steam drums, headers and piping. It is prudent
to consider this fact when performing the blowing procedure and to limit the number of blows to the
minimum consistent with cleaning the system.
Since the temporary steam blowing piping may be designed for lower pressure than the boiler, care
must be used to prevent over pressuring this piping during the entire steam line blowing operation. The
pressure in the temporary piping should be monitored continuously and operators need to be alert to
prevent over pressure.
It is recommended that a means of over pressure protection be provided in the temporary piping, such
as, safety valves set at the design pressure of the temporary piping.
Noise levels will be very high during the steam blow. Hearing protection is mandatory for those in the
immediate vicinity of the steam outlet. An area at least 100m from the blow point must be roped off to
prevent personnel from approaching too close.
Equipment:
The following will be required for steam blowing
 Temporary piping
 Temporary piping support a restraints
 Blow off valve with quick opening actuator
 Silencer
 Target Plate – Aluminum plate with mirror finish (minimum area 50x75 mm)
Procedure:
The unit is started in the normal manner. All normal recommendations and limitations with respect to fuel
firing equipment, air handling equipment, drains and vents, etc., should be followed, as if the unit were
being started for normal operation. As for any new unit, the steam blowing operation is the first
occasion that the unit is fired at any significant rate. Consequently, the start-up as well as the steam line
blowing must be conducted with great care. The normal start-up rate does not apply; the unit must be
brought up much slower, while all equipment is checked and expansion movements monitored closely.
If the unit is equipped with a fired super heater, the 1000 deg. F (538deg.C) furnace exit gas
temperature limitation must not be exceeded when the unit is fired. The same general precautions
taken on any new unit for this period of operation apply equally here.
General Pre cleaning Procedure:
 Check all pipe anchors and the pipes for the adequate support of piping, including the
temporary vent pipe.
 Insure that all the lines have been inspected and hydro tested.
 Remove all the control valves, de-super heater nozzles, flow elements, thermo well, pressure
gauge, orifice plate, safety valves and instruments that may be damaged during the steam
blow.
 Insure all vents pipes have adequate drains and that these drains are routed to a safe location.
 Install temporary pressure gauge as required to monitor the progress of the steam blow and
make arrangements for to record pressure reading.
 Establish adequate radio communication between the control room and the operator at the
shutoff valve. Back this up with a system of visual communication, such as lights or flags, since
audio communication may be difficult due to high noise levels at the steam shutoff valves.
 Insure personnel controlled in area during steam blow. Insure the area near the vent pipe is clear
of personnel during the steam blow. Protect neighbouring equipment from damage due to the
steam vents.
 Individuals operating the steam blow valves (especially near the vent pipe) should wear double
ear protection.
Steam Blow Operation
(Applicable for main steam inlet, bleed & extraction pipe lines.)
Maximum effectiveness of steam blowing operation will be achieved by starting the blow at maximum
possible flow & maintaining the said CFR value.
Caution:
 The first blow should be done at reduced pressure, In order to check the temporary piping
system, its supports and the anchors.
 With no target plate in place, bring the boiler up to possible working pressure. Generally there is
always issue for rated pressure and temperature during blow down, hence the CFR value to be
maintained to achieve maximum effect. Blow steam down the line for 20 minutes or until
pressure has dropped to 50% of initial pressure and then allows the line to cool (half to one hour
for bare pipes, 1 ½ to 2 hours for lagged pipes).
 Repeat this Three times as the heating & cooling helps to loosen clinging matter from the internal
pipe surface due to thermal expansion and contraction.
 Now place the Mirror finished Aluminum target plate. Run a series of blow downs for 10 minutes
allowing cooling between each cycle. Stamp the cycle number on the receiving face of the
target piece.
Post Cleaning Procedures:
 Drain the temporary and permanent piping.
 Remove temporary spools, blind flanges, temporary bend piping, etc, and re-install all
components removed prior to steam blow.
 Cleanliness criteria:
 Two successive targets must result in mirror finishes that meet the specified criteria.
 After a cooling down period of at least 12 hours, two more successive steams blows must result in
mirror surfaces that meet the specified criteria.
 Criteria:
 No indentation exceeding 0.8 mm diameter.
 Indentation exceeding 0.4 mm diameter to number not more than 2 per 2500 mm 2 of the target
plate surface.
 Indentations exceeding 0.2 mm to number, not more than 10 per 2500 mm 2 of the target plate
surfaces.
 Indentation less than 0.2mm to be well dispersed and nowhere present in concentration.
If a separator is included in the steam inlet pipe to the turbine then it should be emptied after the last
‘Blowdown’.
Documentation:
 Protocol for completion of steam blowing. (ECD/FOR/218).
 Protocol for steam quality(ECD/FOR/293)
ELECTRICAL ACTIVITIES
Sl.No. Activity
1 Leading and positioning of panels
2 Erection of Cable Trays
3 Erection of Junction Boxes and LPBS.
4 Cable laying and Termination
5 Impulse Piping
6 Erection of Field Instruments
7 Earthing
8 Pre Commissioning Activities
9 Commissioning activities
Documentation required for Erection,
➢ Pre-commissioning and Commissioning.
Reference documents:
SL.NO. DRAWING DESCRIPTION
01 Master bill of material supplied by TTL/vendor (Electrical)
1.a Instrument Schedule
1.b Electrical Erection material – (Channel ,Angle, Pipes& Anchor fasteners,

etc)
1.c Cable Trays
1.d Cable Accessories (Glands, Lugs & Ferrules)
1.e Cable
1.f Panel GA & Wiring Diagram
1.1 From JB to Panel.
1.1a Cable from JB TO Panel.
1.1b Electrical Erection Material – (Channel, Angle, Pipes, & Anchor Fasteners
etc.)
02 Earthing Material and Layout
03 Cable Tray Routing
04 JB Location Details
05 Single Line Diagram(SLD)
06 Trip Logic
07 P & I Diagram for Lub oil and Control Oil system. (P&I D OIL)
08 P& I Diagram for Steam System.
09 P&I Diagram for RTD.
10 Schematic Turbovisory Instruments
INSTRUMENTS
11 Vendor As Built Drawings, Manuals.
12 Pre- Commissioning Formats
13 Governor Programming Sheet.
14 Instruments Setting Chart
15 Relay Setting chart
16 Cable Schedule
17 Auto Synchronizer Program sheet.
18 Junction Box Schedule
19 Alternator GA Drawing, Aux Junction Box Drawing, Manual.
20 Manual for ay Loose supplied Instruments.
21 Cable trench plate Layout
22 Bas Bar Trench Layout
23 Earth Pit Location along with Pit & Material Details
24 Electrical Master BOM including Instrumentation BOM , Pneumatic

Instrumentation Erection BOM
25 Pneumatic Instrumentation Erection BOM
26 PG Test Procedures
27 PLC Detail Consist of Input/ output list, motor logics, trip logics, control
logics, Other PLC Related Document
28 Governor / Detail synchronizer load controller(DSLC)/Master Load

Controller (MSLC) programming sheet
29 GA of alternator
30 GA of flow meter
31 Manual for Electrical Items & Instruments (Imported) like auto synchronizer,
DSLC, MSLC, vibration monitor, governor & its accessories
1. ERECTION (Electrical & Instrumentation)
1.1 Leading and Positioning of Panels
Procedure:
 Check the physical powerhouse layout with the designed layout drgs and take corrective
action if required.
 Open the packing and make visual & dimensional inspection of individual panel.
 Check for any physical damage of cabinet or mounted item.
 Verify the panel mounting dimensions (base channel & GA) with the cut-outs provided in the
powerhouse layout drawing.
 Use rope & Sling to bind the panel using the I- bolts provided on top of the panel if crane is to be
used.
 By using wooden sleepers, rollers or Crane lift & move the panel. Care should be taken not to
secure the slings on the front of the panel and while lifting or moving jerks should not be given.
 Bring the Panel to proper position either on cut-out or on frame in case of false flooring, after
positioning check for leveling of the panel using water tube or spirit level.
 Once all the panels are placed front alignment or back alignment to be checked and adjusted
if necessary. Care should be taken to ensure that no gaps come between the panels. If required
slight adjustment to be made sacrificing the level. Fix the panels with the base or frame using
bolts and nuts or tack (stitch welding).
 Visual inspection of Loose supplied items.
Tools, instruments and machineries used:
a) Measurement Tape, water level/spirit level
b) Crane, wooden sleepers, rollers, rope, slings & chain pulley blocks.
c) Bolts and nuts.
d) Welding machine & its accessories.
a) Power House Layout drawing
b) Panel dimensional (GA) drawing
c) Master Bill of Material (BOM)/Panel BOM
d) Delivery Challan and Receipts at site.
1.2 Erection of Cable Trays
The cable trays for erection is classified into the following categories -
 LT/HT Power Cable tray – Ladder type
 Control Cable tray – perforated type
 Instrumentation / Signal cable tray – perforated type
Procedure:
 Check the cable routing as per tray routing drawing & powerhouse drawing.
 Based on the above inputs, determine the cable tray length and supports as per drawing.
Fabricate Tray supports as per drawing / requirement.
 Fixing of cable tray supports are done by Insert plates. (provided during civil construction)
 Mounting plates (fixed by Anchor fasteners if insert plate not provided)
 The tray support to be fixed at regular intervals & in same level. Straightness can be checked
using plumb block. Runs to be laid referring cable tray routing drawing & Cable schedule.
 Level to be checked by water level or any convenient method applicable. Support welding to
the insert should be full welding. Lay the cable trays on the support and if required trays can be
stitched welded to the supports for safety and aesthetic look.
 For interconnection of trays use fishplate with nut & bolts or by welding
 Tray earthing to be done throughout the length using earth strips. Painting to be done for tray
support & welding point.
a) Measurement Tape/water level
b) Welding machine & its accessories.
c) Cutting machine.
d) Plumb block
a) Power House Layout drawings.
b) Cable tray routing drawings
c) Master BOM
d) Delivery Challan and Receipts at site
Materials required:
a) Iron angle & channels,
b) Inset plates/ mounting plates
c) Anchor fasteners & paints.
1.3 Erection of Junction Boxes and LPBS.
Reference Documents:
a) P& I diagram for Steam, Oil, Cooling water & pneumatic system
b) Power house drawings.
c) Cable schedule & BOM.
d) JB location drawing.
List of Junction Boxes - As per JB schedule. Typically:
a) Vibration Junction Box
b) RTD JB for Turbine and Gear Box
c) Condensers JB i.e. for level switches if applicable
d) RTD JB for cooling water lines & instrument JB if applicable.
e) JB’s for pressure and temperatures of steam lines.
List ofLPBS:
a) AOP MOTOR
b) VEM MOTOR/OMS
c) EOP MOTOR
d) BARRING GEAR MOTOR
e) ACOP MOTORS (If applicable)
f) GVC MOTOR
g) CEP MOTORS (If applicable)
h) LP ACTUATOR MOTOR (If applicable)
PROCEDURE:
 Fabricate the frames using iron angle / channel as per LPBS & JB dimension.
 Paint the frames & supports.
 Mount the equipment on the frame by bolting.
 Fix the LPBS frames nearest to motor as applicable. For JB mounting refer JB location details
document.
 Height of the frame should be between 1.2 mts to 1.5 mts / instruments to be mounted at a
height of 1.2mts to 1.6 mts
 Termination should be done as per cable schedule.
 Labelling / description to be provided for individual JB & LPBS.
Tools, Instruments and Machineries used:
a) Measurement Tape
b) Spanners & Cutting accessories
c) Welding machine & & its accessories
d) Screw Driver & Allen Key set.
1.4 Cable laying and Termination.
Procedure:
 Group the cables into three categories i.e. Power, control and Instrumentation. Suitable cables
can be identified by checking with cable specifications sheet.
 Measure/estimate the distance between panel & equipment, panel& panel, estimate the
required cable length by referring to tray routing & powerhouse layout drawing. Panel internally
around 2.5 Mts minimum to be considered above the gland plate or 1.5Mts from the point of
termination for proper dressing of the cores inside the panel.
 Cut the cable as estimated above. Cable numbering to be provided on both ends as per cable
schedule.
 Lay the corresponding cables in the corresponding cable tray. Ex: Power cable in power cable
tray.
 Gland the cable at one end and dress the cable in the tray using cable ties, finally gland the
cable at the other end.
 Cable numbering tag to be provided on both ends as per cable schedule.
 Skin the cable to the required length. For screened cable connect shield/screen to earth
through sleeves at one end only preferably at panel end or to the terminals provided in the
panels. In JB shield connection to be taken to the unused TB. Don’t connect to ground.
 Ferruling to be done on both ends for individual cores of the cable. Ferruling must describe the
panel name and TB details from where it is coming & TB details of where it connecting.
 Spare cores of the terminated cable to be bunched together and for one core cable No Ferule
to be put for easy identification in the future. Spare cores should not be cut
 Dress individual cable inside the panel up to TB and then lugs to be crimped at the core ends
and to be terminated at the corresponding TB’s. Ferules should be readable after the core is
terminated. For single strand cable core lug is not required.
 For T/C cables direct connection (without lugs) to the end instrument in the panel is preferred.
 For H T cable kit installation and termination, follow the procedure provided in the HT Kit
instruction manual. Cable to be properly dressed & supported. Required bending inside the
terminal box to be made before or during the installation of kit.
 Minimum distance of 500mm should be maintained between the gland plate and termination
point.
 Proper phase identification to be provided on the core/cable before and after kit installation by
using insulation tape.
 For HT cable proper support to be provided at regular intervals, typically 1.5 Mts. Sharp bends to
be avoided.
 Care should be taken to ensure after termination the load/stress of the cable should not get
transferred to the terminals. Cable should be securely supported before entering the terminal
box.
 After proper termination and tightening, open the termination and check whether the cable
core can be pulled out and put back easily. This ensures that there is no stress on the terminals
from the cable.
a) Measurement Tape
b) Cutting accessories
c) Marker pens /stickers
a) Cable Schedule
b) Panel as built wiring drawing.
c) P& I drawing
d) Junction Box location details
e) JB schedule
f) Cable Specifications.
Materials required:
a) Lugs & ferrules.
b) Cable crimping Kit.
c) Insulation tape & cable ties
d) Aluminum cable tags & its accessories
e) Cable binding & clamping material.
1.5 Erection of Field Instruments
Procedure:
 Exact physical location of instruments to be finalizing / decided by referring P&I, powerhouse

layout drawings and instrument mounting drawing if any.
 Support to be fabricated for instruments mounting. (For PT, TT, FT, I/P & PS)
 Mount the field instruments using mounting clamps & brackets.
 Fabricated item & support to be painted.
 Instruments to be fix in such a way that it is easy for maintenance & troubleshooting.
 Provide impulse line/ instruments tapping as per P& I diagram & hook-up drawings. Mount the
instruments like Pressure, Temperature gauges, RTD,TC,PT,FT & LT
 Mount all turbovisory instruments like speed probes, vibration probes & RTD & T/c as per
standards. For MPU minimum 1mm gap to be maintained from the sensing point. For radial
vibration probe mounting a gap in terms voltage –9 to –10 V DC should be maintained. For axial
rotor should be centered and probe should be adjusted to achieve zero reading in the vibration
monitor and at the same time voltage should be around –10 V DC & ensure VMS readings to be
zero.
 Mount all the level switches and level transmitter as per P&ID and connect all the Instruments to
the nearest JB, refer JB schedule using proper instrument cables and lugs.
 All instruments to be wired/ terminate up to JB or Panel as applicable. (Ferule should indicate the
instrument name)
 Provide instrument tag numbers as per P&I diagram/Cable schedule.
a) Measurement Tape
b) Spanner, Cutting accessories & Screw driver set
c) Allen key set.
d) Welding machine & & its accessories
e) Multimeter.
f) Soldering gun
Documentation: -
a) Calibration report of all measuring instruments
a) P& I diagram for Steam, Oil, Cooling water & pneumatic system
b) Power house drawings.
c) Instruments manuals.
d) BOM of instruments & its accessories.
1.6 Impulse and Pneumatic Piping
a) P& I diagram for Steam, Oil, Cooling water & Pneumatic system
b) Instrument hook up drawings.
c) Instrument Manual
d) BOM of Instruments
e) Powerhouse layout.
PROCEDURE:
 Ensure all the instruments are mounted and the required tapings provided.
 Decide the routing as per powerhouse layout drawing.
 Connect the instruments and the tapping points using proper pipes and fittings referring to hook
up drawing and P&ID drawing.
 Proper supports for the lines to be provided at regular intervals. Provide the drain lines wherever
necessary.
 Pneumatic tubing Installation & commissioning procedure.
 Confirm the instrument air pressure as per drawing. Ensure that instrument air is free from
water/moisture. Get confirmation that air dryer is available in system.
 Ensure airline tapping (i.e near to control valve) is taken.
 Ensure correct orientation of airline distributor while erecting.
 In airline distributor isolation valves (needle valve/ball valve with drain plug provision) to be
provided for inlet, all individual distribution tapping & for drain point.
 Physically check air tubing for damages before laying.
 Routing to be finalized for laying the air tubing from distributor to Instrument taking care to
minimize bends and joints. Air tubing to be laid with proper supports at regular intervals. Air
tubing can be laid in cable tray or other suitable structure.
 Both end (i.e- distributor, AFR, I/P, Controller & Valve) connections to be done properly using
correct fittings & Teflon tapes.
 Air tubing connection to be done through regulating air filter only to regulate the instrument air.
 Before opening the instrument air from distributor ensure valve, I/P & Controller end connection
to be open for flushing purpose.
 Line flushing to be done till air is free from any foreign particles/water
 After flushing close the Isolation valve in air distributor and connect the air line to control valve,
I/P & controller.
 Before testing the valve, ensure required pressure (i.e-check drawing, name plate of control
valve and name plate of I/P).
 Adjust the required pressure through regulating air filter.
 Control valves to be checked manually by operating wheel (valve should open & close freely).
 Confirm open/close feedback to respective location.
 Ensure that valve neutral position is maintained as per marking on the control valve before
operating electrically.
 Ensure operation of control valve by providing command from PLC/Controller (4-20)mA.
 Confirm open/close feedback to respective location.
 If I/P is applicable then check the I/P output air signal pressure w.r.t input controller signal.
 For installation/trouble shooting of I/P, control valves etc refer to respective O&M manuals.
a) Measurement Tape
b) Spanner & Cutting accessories
c) Welding machine & & its accessories
d) Pipe /Tube bending machine.
1.7 Earthing
a) Instrument Manual & BOM.
b) Powerhouse layout.
c) Earthing Layout .
d) Earth pit drawing.
e) Earth Resistance certificate.
PROCEDURE:
 Ensure all the panels and instruments are located in their respective locations.
 Confirm the location of earth pits as per layout.
 Select the earth strip size & run as per earthing layout drawing.
 For Control and LT power panels, make separate earth grid by using earth strip.
 For HT panels and alternator body make a separate earth grid.
 In NGR, (Neutral) earthed separately by routing to two separate earth pits. Both the Earth pits
should be interconnected by a strip.
 In LASCPT, (LA &SC) should be earthed separately by routing to two separate earth pits. Both the
Earth pits should be interconnected by a strip.
 Cable tray earthing and all motors and JB’s earthing, Turbine and Alternator earthing can be
combined with control panel body Earthing
 The connections between the earth strip and equipment will be bolted type.
 The connections between one earth strip and other will be of bolted type or welding as per site
conditions. If joints are welded type put the paints at welding points.
 Ensure proper contact and earthing of rotor through Carbon Brush.
 For Instruments, separate earthing to be provided, preferably isolated from the body
earth/common earth.
 After completion of earthing, Earth resistance to be checked by Earth tester and recorded.
Note: 1. Resistance of earth pits to be< 5 Ohms.
2.Resitance of Instrument earth < 2 Ohms
3. Minimum gap between earth Pits to be 2 Meters.
a) Measurement Tape.
b) Spanner & Cutting accessories.
c) Welding machine & & its accessories.
d) Bending machine & its accessories.
e) Earth Tester.
2. PRE-COMMISSIONING OF PANELS:
LIST OF PANELS
a) MOTOR CONTROL CENTER (MCC)
b) BATTERY CHARGER CUM DCDB
c) AC DISTRIBUTION BOARD (ACDB)
d) TUBINE CONTROL PANEL (TCP)
e) TUBINE GAUGE PANEL (TGP)
f) DC MOTOR STARTER PANEL (DCMSP)
g) GENERATOR RELAY PANEL (GRP)
h) METERING CUM SYNCHRONISATION PANEL (MCSPLIGHTNING ARRESTOR,SURGE CAPACITOR

POTENTIAL TRANSFORMER PANEL(LASCPT).
i) NEUTRAL GROUNDING RESISTOR PANEL (NGR)
j) TG INCOMING BREAKER PANEL
k) EXCITATION CONTROL PANEL (AVR)
l) ALTERNATOR.
m) HT Cables
n) PLC PANEL
o) LOAD SHEARING PANEL (if applicable)
a) As built drawings of panels
b) Instrument Manuals
c) Cable Schedule
d) Program and setting chart
e) Pre-commissioning & Commissioning Format
f) Software CDs &, Connecting Cables
TOOLS, Instruments and Machineries used:
a) Multimeter
b) Continuity tester
c) Tongue tester
d) 500V Megger
e) Megger – up to 5 KV
f) High Voltage testing kit
g) Primary and Secondary injection kit
h) mA & mV Source Meter
Documents:
a) Test & Calibration certificates of electrical switchgears and used instrumentations.
2.1 MOTOR CONTROL CENTER:
Reference drawings:
a) Vendor supplied Schematic drawing
b) Cable schedule
c) Pre-commissioning format
PROCEDURE:
 Ensure loop checking and termination to be completed before charging panel.
 Check the IR value between phases & earth. (> 1 mega ohm)
 If IR value zero check the bus bar system & control circuit.
 Charge the panel with appropriate supply voltage.
 Check the operation of MCC incoming breaker / SFU operation and indication circuit & set MCC
switchgear settings.
 Check individual feeder logic & operation without connecting load/motor. Check & set
individual feeder switchgear settings.
 Take the individual motor trials through interlocks.
Documentation:
a) Protocol for Pre-commissioning-MCC and AC motors-(ECD/FOR/282).
2.2 BATTERY CHARGER & DCDB:
Reference drawings:
a) Vendor supplied Schematic drawing.
b) Cable schedule.
c) Pre-commissioning format.
PROCEDURE:
 Volt at each battery cell to be checked before connecting. Ensure loop checking and
termination to be completed before charging panel.
 Check the IR value of incoming & outgoing supply terminal
 If IR value zero check the bus bar system & control circuit
 Connected the battery bank to the terminals.
 Switch on the AC supply to the panel; check the FC & FCBC operation as per manual.
 Check the MIMIC or annunciation circuit.
 Check the FC & FCBC auto operation.
 Check the voltages at outgoing terminals.
Documentation:
a) Protocol for Pre-commissioning-Battery Bank, Batteries-(ECD/FOR/274).
b) Protocol for Pre-commissioning-Battery Charger-(ECD/FOR/275).
2.3 AC DISTRIBUTION BOARD :
Reference drawings:
b) Cable schedule
c) Pre-commissioning format
PROCEDURE:
 Check the IR value of incoming & outgoing supply terminal.
 If IR value zero check the power wiring & control circuit.
 Check the voltage at each feeder end by switching on the respective MCB’s.
Documentation:
a) Protocol for Pre-commissioning-ACDB-(ECD/FOR/281).
2.4 TURBINE CONTROL PANEL :
Reference drawings:
b) Cable schedule
c) Programming & setting chart.
d) Pre-commissioning format
PROCEDURE:
 Mount the loose items like Woodward Governor, Vibration monitor and Level Controller etc with
proper nut & bolt. Cable connection to be carried out as per as built drawing.
 Charge the panel with appropriate supply voltage. By switching on the respective MCB’s on
ACDB and DCDB Switch on the individual equipment / instrument, Program the individual
instruments as per programming chart & setting to be done as per setting chart
 Check the turbine trip logics (solenoid circuit) by simulating individual fault & check the
annunciation for the same.
 Check the solenoid operation & indication circuit.
 Check the function / operation of individual equipment after connecting the MPU, vibration
probe, level transmitter & RTD, etc.
 Check the motor logics in Auto/ DCS/ Manual mode & take the Motor trails with necessary
interlocks and check the corresponding indication.
 Guidelines for setting the Axial /Radial Vibration probe:
As vibration probes, MPU’s, RTD’s are delicate items, utmost care shall be taken while handling these
items to ensure these are not damaged during installation.
Step 1 :
Determine the total rotor float by moving the rotor from non-active side to active side or visa versa and
note down the readings. This has to be repeated two three times for getting the correct value of float.
Step 2 :
Push the rotor to active side completely; adjust the axial probe to get voltage between -9.75 V DC and
-10.0V DC & at the same time to confirm zero mils/microns reading on the vibration monitor.
Step 3:
Push the rotor towards non active side completely, note down the readings of the vibration monitor. The
reading should be equal to the actual float of the rotor. If required repeat the process two or three
times to cross check the readings.
Example for calculation:
If the Rotor float is 0.3 mm, then the reading in the vibration monitor should be around 11.8 Mills when
the Rotor is moved from Active side to Non active side. (1Mill =0.0254mm)
Step 4 :
When rotor is moved towards the non-active side the readings on the vibration monitor should read
positive readings and when the Rotor is moved towards Active side the readings should be negative. If
the reading is reverse then setting of the same to be changed in the vibration monitor.
Step 5 :
Active side alarm to be set to 6Mills/150 Microns, trip to be set at 10Mills/250 Microns
Step 6:
Non active alarm to be set at the Mills value got in Step 3 plus 6Mills/150Microns, trip to be set at the Mills
value got in Step 3 plus 10 mils/250Microns.
Example if Float is 0.30 mm, the total float reading will be 11.8 Mills, then the non-active side alarm value
should be 11.8 plus 6 mills = 17.8 Mills and trip 11.8 Mills + 10 Mills = 21.8 Mills.
For radial, vibration probe shall be set so that gap voltage is around -10VDC(-9.5V DC to -10.5 V DC
range).
Documentation:
a) Protocol for Pre-commissioning-TCP-(ECD/FOR/270).
2.4 TURBINE GAUGE PANEL:
Reference drawings:
b) Cable schedule.
c) Programming & setting chart.
d) Pre-commission format
PROCEDURE :
 Ensure loop checking & termination to be completed before charging panel. 22.0.10.2.2 Check
the IR value between phases & earth. (> 1 mega ohm)
 Charge the panel with appropriate supply voltage by switching on the respective MCB’s on
ACDB and Battery Charger Cum DCDB.
 Set the pressure switches and indicators as per the setting chart.
 Impulse lines to be completed for all instruments.
 Check the TT and PT’s using the communicator for proper range and check for operation.
 Check the operation of all indicators and gauges/Pressure Switches.
2.6 DC MOTOR STARTER PANEL:
Reference drawings/Instruments:
a) Vendor supplied As built drawing
b) Cable schedule.
c) Pre-commission format
d) Multimeter.
PROCEDURE :
 Check the IR value of incoming and outgoing supply terminal.
 Ensure loop checking & termination to be completed before charging panel. 22.0.11.2.3 If IR
value zero checks the power wiring & control circuit.
 Check the contactor, timer & indication operation sequence by connecting lamp load at
armature and field terminal of panel.
 Decouple the motor from pump and take trail to ensure the direction of rotation of motor shaft.
 Take the motor trials through interlock (provided in TCP) and check the OLR operation.
Documentation:
a) Protocol for Pre-commissioning-DCMSP & EOP -(ECD/FOR/277).
2.7 GENERATOR RELAY PANEL:
Reference drawings/Instruments
b) Cable schedule
c) Trip logic & setting chart
d) Pre-Commissioning format
e) Multimeter
f) Software and communication cable.
PROCEDURE:
the IR value between phases & earth. (> 1 mega ohm)
ACDB and DCDB.
 Extract and verify the trip and alarm logic of numerical relay as per design approved trip logic
 Set the relay settings as per the relay-setting chart.
 GPR- All functional test & trip simulation of different relay in the microprocessor base GPR by
secondary injection of current & voltage. All individual protection annunciations to be checked
in MCSP/DCS.
 Electromechanical / conventional relays test done by individually by injecting secondary current

& voltage.
 While injecting the current in CT primary & voltage in PT primary in NGR & LAPT respectively,
check the corresponding secondary values at respective terminals of panels as well as in
numerical relay.
 Check the Class A,B & C(86G,86T & 86L) trip logic & observe the individual annunciation in
MCSP/ DCS.
Documentation:
a) Protocol for Pre-commissioning-GRP-(ECD/FOR/283).
2.8 METERING AND SYNCHRONISATION PANEL :
Reference documents :
b) Cable schedule
c) SLD
d) Pre-commissioning format
e) Multimeter
f) Phase sequence meter
PROCEDURE:
 Ensure loop checking, earthing and termination to be completed before charging panel.
ACDB and Battery Charger.
 Mount & wire the loose supplied items like, Auto Synchronizer etc.
 Program & set the necessary instruments.
 Check the meters & transducers by injecting secondary Voltage & current and error measured is
within accuracy class.
 Check the synchronization circuit as per scheme. Check the dead bus & live bus closing if
individual breaker, observe the operation feedback.
check the corresponding secondary values at respective terminals of panels.
 Check indication circuit & annunciation Circuit.
Documentation:
a) Protocol for Pre-commissioning-MCSP-(ECD/FOR/278).
2.9 LASCPT PANEL:
Reference drawings/Instruments
b) Cable schedule
c) Pre-Commissioning format
d) Multimeter
e) Phase sequence meter
PROCEDURE:
the IR value between phases & earth. (> 20 mega ohm) for primary bus & (> 1 M Ohm for control
circuit.
 Measure the distance between phases and phase to panel body (earth). The minimum distance
should 125mm between phases & 75 mm for phase to earth.
 Visual inspection of lightning arrester, Surge Capacitor, CT & PT for any physical damages.
 Insulation resistance test of primary w.r.t earth, primary with respect to core 1, primary with
respect to core 2, core1 with respect to ground, core 2 with respect to earth and core1 with
respect to core2 . Check all CT & PT resistance value and record it.
 Simulation of ratio test by injecting primary voltage to measure its secondary equivalence.
 Check CT polarity & IR values as mentioned in NGR.
 Measure the Magnetizing current for differential CT’s, ensuring within specified within mA as per
design.
 By injecting primary rated current at CT terminal measure all the secondary equivalence.
Documentation:
a) Protocol for Pre-commissioning-LASCPT Panel-(ECD/FOR/279).
2.10 NGR PANEL :
Reference Documents /Instruments
b) Cable schedule
d) Multimeter
PROCEDURE:
 Ensure loop checking & termination of control cables are completed before charging the panel.
 Check the IR value between phases & earth. (> 1 mega ohm for control circuit & >20 M ohm for
primary bus).
 Measure the distances between phases and phase to panel body.
 Insulation resistance test for (CT) primary with respect to ground, primary with respect to
secondary and secondary with respect to ground for all CT’s .
 Check the polarity for individual CT’s.
 Primary injection in steps up to its rated current to measure it s secondary equivalence for all CT’s
at terminals and at meters/relay. Check all CT resistance value and record it.
 Knee point voltage test by injecting 50% of given knee point voltage across the secondary
terminals of CT and recording the current to analyze its saturation (Applicable only for PS class
CT).
 Ensure all CT’s and PT’s are properly earthed.
 Visual inspection of grounding resistor and measure resistance value. Should be nearer to the
value mentioned in the name plate of the Panel.
 Check the operation of Neutral isolator switch and observe the indication in MCSP.
 Operate NIS from Local/ Remote as well as by handle provided and check the interlock when
handle is inserted.
Documentation:
a) Protocol for Pre-commissioning-NGR Panel-(ECD/FOR/280).
2.11 TG INCOMING BREAKER PANEL:
Reference Documents :
b) Cable schedule
PROCEDURE:
 Ensure loop checking and termination of control cables is complete before charging panel.
 Check the IR value between phases & earth. (> 1 mega ohm for control circuit and >20 M ohm
for primary bus).
 Rack out the Breaker to Test position and check the closing and tripping of the breaker from
local.
 Check the breaker operation from remote by operating from MCSP.
 Check interlocks like auto trips and indication circuits on the breaker and remote end in MSC
panel/DCS etc.
Documentation:
a) Protocol for Pre-commissioning-Breaker Panel-(ECD/FOR/273).
2.12 EXCITATION CONTROL PANEL:
b) Cable schedule
PROCEDURE:
 Ensure loop checking & terminations of control cable are complete before charging panel.
 Check the interlocks and tripping as per schematic.
 Power up and program the AVR as per drawing and setting chart.
 By removing the generator field cabling check the output from AVR using lamp load.
 Check the Annunciation, selector switches and push button operation.
 Check the interlocks and AVR change over.
check the corresponding secondary values at respective terminals of panels.
Documentation:
a) Protocol for Pre-commissioning-AVR-(ECD/FOR/272).
2.13 ALTERNATOR :
a) Vendor supplied Schematic drawin
b) Alternator Manual and test certificates.
PROCEDURE:
 Ensure phase connections between alternator and LASCPT and NGR panels. 22.0.18.2.2 By
removing the cables check the IR value between phases and phase to earth (>100M ohm with 5
KV megger)
 Check the Polarization Index (PI) Value of the alternator. The value should be more than 2. PI =
10th minute IR Value/ 1st minute IR value 22.0.18.2.4.1 Check air gap of exciter.
 Ensure slip rings, carbon brushes & RRA are properly fitted.
 Check the resistance of field and IR value.
Documentation:
a) Protocol for Pre-commissioning-Alternator-(ECD/FOR/271).
2.14 HT CABLES :
 Check IR value phase to phase and phase to earth for each run before and after high voltage
test. (> 100 M ohm)
 High voltage test to be carried out for each core in case of multi core and each cable in case of
single core. Ensure Phase identity.
2.15 PLC PANEL:
b) I/O List
c) Motor logic
Documentation:
a) Protocol for Pre-commissioning-AVR-(ECD/FOR/272).
PROCEDURE:
 Ensure loop checking & terminations of control cables, communication cables, and data cables
for engineering station, operator station & printers are complete before charging panel. Ensure
body Earthing & Instrument earthing.
 Switch on the AC supply MCB (UPS) & check AC supply circuit. Switch on the converter MCB,
check the output voltage at respective terminals. Switch on the individual rack (processor)
supply with respective MCB.
 Power up the Engineering Station & establish communication with processor. Down load the
rack (processor) configuration to the engineering station.
 Download the same data to operator station also.
 Check the all inputs & output ranges, tags & type as per P&I and I/O list.
 Compare all logics in the processor with logic scheme provided by M/s TTL, do the modification
if necessary, up load to processor.
 Check the screens compatibility with the P&I drawings. Modify if necessary.
 Set the alarm & trip values for inputs, outputs as per setting chart. Check the alarm & trip
annunciation, logic by simulating I/O. Power up all the instruments.
 Check the operation system through instruments, check the logics by simulating I/P from field,
and take the motor/valves trial through interlocks.
 Check the configuration of the alarm/events data logging screens and modify if required as per
site condition.
 Check trends of all required analog signals.
 EOP motor logic to be prepared as fail safe logic, to avoid any interruption even during DCS fail.
 Configure the 485 Communication port for communication and program the registers of the
instruments to be communicated.
 Check the hot changeover of the processors from first to second and back to first.
Documentation:
a) Protocol for Pre-commissioning PLC (ECD/FOR/284).
2.16 BACK CHARGING WITH RUNNING SUPPLY :
 Isolate the Terminals at the Alternator End (Phase Side) and with all the PT,s in line close the
respective breakers to charge the Running supply up to the HT cables at the Alternator Phase
side.
 Check for phase sequences at all the Synchronizing PT’s and note down the same
3. COMMISSIONING
3.1 CHECKING THE PARELLELITY OF THE STEAM LINES
Procedure:
 After steam blowing is completed connect the inlet steam line back in position & install all the
permanent supports.
 Without bolting the inlet flange to the turbine check the gap between the inlet flange and the
turbine flange. The gap should be less than (+/-) 0.15mm variation all-round the circumference.
(All supports of the steam line to be in cold condition as per support drawing)
 Also ensure that all the bolts can be installed freely without any difficulty.
 Complete the bleed steam line piping and install all the permanent supports, without bolting the
bleed flange to the turbine, check the gap between the bleed flange and the turbine flange.
The gap should be less than 0.20mm variation all around the circumference.
 Also ensure that all the bolts can be installed freely without any difficulty.
 Sealing Steam pipeline to be connected with all the instrument and control valves installed in
position that were removed for steam blowing.
 After all the pipelines are finalized, check the high speed and low speed alignment to confirm
that no disturbance has occurred and remove shipping Yellow Bracket of the expansion bellow
and maintain holding down bolt clearance as per design recommendation.
 Refer O & M Manual chapter operation Page no 46 to 59 for complete turbine operation and
loading.
Documentation:
 Pre-commissioning and Commissioning record sheet.( ECD/FOR/207)
 Protocol for parallelity of Main stream/Extraction/Exhaust/Bleed Flanges. (ECD/FOR/292)
3.2 Coupled Running of the TG Set (Over speed test)
Procedure for starting and mechanical over speed test:
 Oil should be filled in the tank as specified.
 Check functioning of EOP cut in & cut off before starting of the set, correct it if not working.
 Run without circulation of cooling water & ensure the oil cooler outlet temperature around 35
Deg C is achieved before rolling the Turbine Generator set. If centrifuge is supplied take
centrifuge inline & heat the oil through the centrifuge to increase the temperature to 35 Deg C
 Before running barring Gear check and ensure oil level and quality of barring gear oil (Refer
O&M manual for oil grade) Run barring gear minimum for 8 hrs, record/check vibration and
sound level before starting warming up of the turbine.
 For warming up at barring gear speed please refer start up curves. If online vibration instrument
like Bentley Nevada/ Shin kava is not provided record vibration with IRD instrument.
 Ensure all the steam drains are open.
 Check for hot well level in condenser (maintain approx. 50%).
 Start cooling water circulating pump at cooling tower and check pressure and temperature with
respect to specified values in condenser/turbine coolers & to GVC cooler wherever applicable.
 Start CEP and check for discharge pressure to design values check for control valves operation
for its opening & closing as per specified settings.
 To warm up the turbine at barring gear speed, crack open the main steam valve. Before crack
opening the main steam valve, all steam piping/header should be fully warmed up and free
from water by steam flushing through vents.
 Start warming up of turbine and ensure all the drains are open, observe that all water particles
are completely drained & steam is visible from the drains.
 Steam inlet pressure and temperature should be close to rated pressure and temperature.
 Ensure casing is sufficiently heated up after allowing steam to casing before rolling the turbine
while barring gear is in operation
 Start GVC blower motor.
 Open motive steam supply to hogger ejector.
 Start sealing steam system and regulate the pressure as specified {approx. 0.1/0.3 kg/cm 2 (g)}.
Sealing steam should be opened only for about 20 minutes before rolling the turbine. Check for
designed vacuum to be achieved by hogger ejector.
 Reset solenoid and LP trip, check the safety trips and ensure free movement of SEV and TV and
their immediate closure on actuation of safety trips.
 Ensure EOP is in auto mode check interlocks between AOP, Barring gear and EOP as per logic
sheet. Check electrical OST rpm setting and raise it to 15% of the rated Rpm in order to
test/ensure the mechanical OST tripping.
Note: For 505 D governor keep Turbine speed very high relay as Over-speed relay, this will be
automatically bypassed after selecting external over-speed test.
 Start rolling of turbine as per the startup curve provided in the O&M manual and Design data
sheet.
 Ensure Auto cut off of barring gear as per Governor Program, and meanwhile ensure both
speed probes are reading speed in Governor (Analog Inputs).
 Throughout soaking period monitor the vibration levels, bearing temperature readings and any
unusual sound.
 Follow instruction according to start up curves as provided by design for further increasing of
speed/rpm, Ensure AOP auto cut off as per instrument (PS) setting/RPM interlock and ensure
MOP pressure as per design.
 Ensure once again that all the running parameters such as bearing temperatures, oil pressure’s,
vibration levels, CEP discharge pressure, hot well level, CEP vibrations, cooling water
temperature/pressure/flow, vacuum etc are within satisfactory limit.
 After attaining the nominal speed, the turbine should run for 10 minutes for stabilization of
bearing temperatures & vibrations. Exhaust temperature should be monitored
 Slowly raise the speed through governor/PB to the maximum governor speed.
 Press F2 button in the governor and raise the speed through governor/PB to the maximum. When
speed is in the band of 10 –15% above the nominal speed the mechanical over speed trip will
occur. S&E valve will trip & the throttle valve will also trip.
Note: for 505D Governor , raise the speed upto maximum governor speed ,enable the external over
speed trip and raise the speed up gradually till 10-15% above nominal speed and the mechanical
overs peed trip will occur.
 Recheck the AOP auto start with pressure interlock during coasting down period.
 Cut off the inlet steam supply by closing the line valve, open all the drains of the turbine and line,
ensure the turbine to come on barring speed.
 Note down the coasting down period of TG set from tripping speed to barring gear speed and
ensure OHT run down time is greater than TG coasting down period .
 Reset the electrical OST tripping rpm to 150 rpm lower than that of Mechanical OST and re-roll
the turbine following same instruction as mentioned above to check electrical OST.
Documentation:
 Pre-commissioning and Commissioning record sheet.( ECD/FOR/207).
 Condensing system pre-commissioning/commissioning record.( ECD/FOR/208).
 Protocol for CEP pump commissioning (ECD/FOR/291)
3.3 Voltage build up, synchronization and loading of the TG set
Procedure:
 Refer O & M Manual chapter operation for complete turbine operation and loading. Once the
nominal speed is attained, check the bearing temperatures and vibrations are normal.
 During running record all the parameters in “Log Book” at regular intervals i.e. after every half an
hour.
 Important parameters to be observed on regular basis during running are listed below:
a) Bearing temperature’s
b) Lube oil and control oil pressure/temperature
c) Vibration levels.
d) CEP discharge pressure
e) Hotwel level.
f) Cooling water temperature/pressure/flow.
g) Inlet steam pressure/temperature.
h) Extraction & Bleed pressure.
i) Exhaust temperature and pressure.
j) DP across lube oil filter.
k) DP across condenser cooling water
Voltage Build up procedure:
 Check the residual voltage of the Alternator in relay panel, MSC panel and AVR panel.
 This also ensures the continuity of the signal. Record the values as this can be used as a future
reference.
 Ensure that all the interlocks are in line for the excitation control and are not active ex 86G/T is
not tripped, 90 % speed relay in TCP is picked up.
 Switch on all the required MCB’s in all the panels. Ensure that all the panels are powered up.
 Check all the MCB’s are on in the AVR Panel. Check the PMG voltage. Ensure the required
voltage (225V, 3 Phase) is available.
 Select remote through the local remote selector switch.
 Select the manual mode through mode selection on the Excitation control panel. Press the
excitation on slowly increases the voltage by set point raise in steps of 1 KV until the nominal
voltage is attained. During the buildup if any abnormality is observed press Excitation OFF.
 Once nominal voltage is attained record the no load excitation voltage and current. Check
voltages of all three phases on the voltmeter by rotating the voltage selector switch.
 Ensure that the all the three phases are balance. Slowly bring down the voltage by pressing the
set point lower. Once the voltage is Zero press the excitation OFF.
 Select the auto mode through. Press excitation ON. Voltage should build up to 90% of the
nominal voltage. Slowly raise the voltage to nominal by set point raise PB. Check the no load
excitation voltage & current. Press the excitation OFF PB.
 Change over to AVR 2 and check for the above functions.
 During the voltage build up time the vibrations & bearing temperatures are to be observed for
any abnormality. Should be same as it was in nominal speed operation.
 Build up the voltage again in auto mode (either of the two channels), check the secondary
voltages in all the panels.
 Check phase sequence in all synchronizing PT’s as well as on terminals of respective panels and
note down the same. This sequence should match with that of the sequence checked with
Incoming voltage. It should be Typically RYB.
 Check the voltmeter in metering panel is displaying the nominal voltage. GPR in relay panel is
also displaying the nominal voltages.
 Proceed for synchronization. Ensure that the TG incomer VCB panel control supplies are on.
Breaker is in test position.
Synchronization in Manual Mode
Procedure:
 Select the appropriate switches for manual synchronization in synchronizing panel. Put the
local/remote switch in remote position in the Excitation control panel for synchronization.
 Check the double voltmeter and double frequency meters are displaying the bus and
generator parameters for synchronization.
 Adjust the generator voltage and frequency w.r.t the bus voltage by the speed raise/lower and
voltage raise/lower PB’s as applicable. Once both frequency & voltages are matched.
 Check the rotation of the synchronoscope, it should be clock wise (Red LED’s will lit up) which
ensures that the TG Frequency is little higher than the bus. If not adjust the frequency and
voltage such that the rotation of the synchronoscope is clock wise and very slow. When the 12
O’clock position is reached the synchronoscope LED will become green and at the same time
Check synchronization relay should give permission for breaker closure. This signal can be seen
on the front panel when the LED SKE acted is lit up. Once the rotation has crossed the 12
O’clock position this LED will get OFF.
 Allow one cycle of rotation of the synchronoscope just to ensure that the system is working Ok
and to tune the response of the governor & AVR if required.
 In the Next cycle try to close the breaker in test position if the provision is available in the breaker.
This ensures that the closing circuit is OK.
 Rack in the breaker to service position start synchronization activity, close the breaker through
the breaker TNC Switch when SKE permitted. Return all the switches to off position except the
auto manual switch.
Synchronization in Auto Mode
Procedure
 Select the appropriate switches for auto synchronization in synchronizing panel. Put the
local/remote switch S8 in remote position in the Excitation control panel for synchronization.
 Observe the system as the auto synchronizer takes control of the system and starts adjusting the
speed and voltage to match the bus parameters. Once the parameters are matched the Auto
synchronizer will give the breaker close command.
 In TTL system the check synchronization relay will be in series with the auto closing command. For
breaker closing, both commands should come at a time. If not tune the auto synchronizer to
achieve the same.
 After breaker closing the loading pattern will be same as above.
Dead Bus Closing
Procedure
 After build up of voltage in auto mode (nominal voltage), select appropriate switches for dead
bus selection in the synchronizing panel, ensure voltage & frequency at nominal, confirm that
the generator voltage and frequency is only present and the bus voltage & frequency are not
getting displayed on the double voltmeter & frequency meter. Close the respective breaker
through TNC switch.
 Switch on the load feeder one by one as per load curve, if vibration & temperatures are found
within limit.
Loading of the TG Set
Procedure:
 Slightly increase the speed through the speed raise PB to take KW load on the machine around
500-700 KW. Observe the PF of the TG set. To adjust the PF to the desired value, voltage
raise/lower PB can be used to decrease/increase the PF. Ideally the PF should be maintained
around 0.8 –0.9 lag. Note the vibration readings and bearing temperatures.
 Bearing Vibrations and Temperatures should be stable within the limits.
 Alternator cooling water can be kept closed for this operation, as the temperature raise will help
in removing any moisture content left out in the alternator. Ensure space heaters in Alternator,
Bus Duct and exciter are off after breaker closing as per interlock.
 After observing for few minutes go to load control mode in the governor/droop mode & after
load is increased to above 15% auto PF control can be taken in to line by pressing PF control ON
PB on the Excitation control panel. Ensure the local/remote switch is in local mode. To adjust the
PF set point, Set point raise or lower PB should be used.
 Check all the operating electrical parameters like voltage, current, power etc are displayed on
the respective meters in the metering panel and also the parameters are being displayed on
the GPR in the relay panel and are within specified limits.
 When the winding temperatures reach around 65 – 70 Deg C open the cooling water for
alternator
 Slowly raise the load in accordance with the loading curve submitted by M/s TTL and in
consultation with the Boiler operating personnel.
Ensure the following points:
a) During loading ensure response of actuator and AVR, in case response is not proper tuning is
required.
b) Ensure working logic of CEP, Control Valves, LP actuator etc. during trail.
c) Ensure P.F is showing Lag at all the meters i.e: Synchronization panel and AVR panel.
d) Ensure all 3 Phase Voltages and currents are balanced, and check for differential and Earth Fault
current at low loads.
e) Enable Auxiliary load control if KW feedback is showing correctly in Governor. (In case TG is
synchronized with grid.)
f) Re-ensure bellow clearances and expansion due to flow of steam in exhaust pipe.
g) Ensure all flow transmitters and other devices are working satisfactorily and showing correct value.
h) Ensure no leakage from Oil and steam system and well as all parameters are within specified limits.
Note: The loading of the TG set should be done with strict adherence to the loading curves submitted by
M/s TTL and with consultation of the boiler operating personnel. This is to avoid any unnecessary stress
on the boiler and TG set due to impact loading.
a) Pre-commissioning & Commissioning Record: Completion of first coupled run and voltage
buildup (ECD/FOR/285).
b) Pre-commissioning & Commissioning Record: Completion of 1 st synchronization & 1st Load Trial
(ECD/FOR/286).
c) Protocol for operational training (ECD/FOR/295, ECD/FOR/295-M & ECD/FOR/295-E).
d) Protocol for handover (ECD/FOR/296).
e) 72 hours running log sheet /PLC, DCS log sheet print to be recorded and maintained.
SPECIAL CONDITIONS:
This Installation & commissioning manual has been prepared as an aid to supplement the experience and
ability of well qualified persons who have already carried out such installation & commissioning jobs of Steam
Turbogen Set with associated auxiliaries and controls.
These procedures do not claim to cover every detail / aspect involved in the installation & commissioning of the
STG, nor does it ensure instructions for every possible contingency which can be faced during installation &
commissioning of the STG and its auxiliaries.
Therefore, it is recommended that all these jobs to be done under skilled supervision from Triveni only to avoid
any re-work and to provide safe and reliable commissioning.
The proprietary information published in this Service Information Manual is offered to you by Triveni Turbine
Limited in consideration of its ongoing sales and service relationship with your organization. However, since the
operation of your equipment involves many factors not within our knowledge, and since operation of the
equipment is in your control and ultimate responsibility for its continuing successful operation rests with you,
Triveni Turbine Limited specifically disclaims any responsibility for liability based on claims for damage of any
type, i.e. direct, consequential or special that may be alleged to have been incurred as result of applying this
information regardless of whether it is claimed that Triveni Turbine Limited is strictly liable, in breach of contract,
in breach of warranty, negligent, or is in other respects responsible for any alleged injury or damage sustained
by your organization as a result of applying this information.
This Service Information Manual contains proprietary information of the Triveni Turbine Limited, India and is
furnished to its customer solely to assist that customer in the installation, testing, operation and/or maintenance
of the equipment described. This document shall not be reproduced or distributed in whole or in part nor shall its
contents be disclosed to any third party without the written approval of Triveni Turbine Limited. All rights
reserved.
Special care to be taken to ensure that working team/ contractor shall comply with all health, safety &
environmental legislation as applicable to the site / or the work.
Thank you…………………………………………….

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TRIVENI TURBINE LIMITED

INSTALLATION, PRE-COMMISSIONING & COMMISSIONING PROCEDURE

12-A Peenya Industrial Area

DOCUMENTS REQUIRED FOR ERECTION, PRE-COMMISSIONING & COMMISSIONING

SL.NO. Description of Drawing / Document

3 Power House & Equipment layout

4 Auxiliary Equipment Foundation Details

5 P & I diagram for Lube & Control Oil system

8 P & I diagram for Turbo visory system

9 Cut out Insert Plate Details

11 G.A. of Lube oil System, Isometric drawings

12 G.A drawings of all equipments

13 G.A. of Over Head Tank

15 Data Sheet of Alignment/ MRT Report

17 Protocol for OIL flushing, Protocol for Alignment

Sl. No. Activity Remarks

3 Positioning and Leveling of Surface Condenser

Final leveling & checking of HS/LS Alignment prior to

10 Cleaning of pipelines and refitting. Triveni Engineer Required

13 Commissioning activities Triveni Engineer Required

This procedure is applicable to only Triveni make Turbines

 Details of mechanical & electrical contractor (if applicable)

 Details of Mechanical & electrical activities

 Project schedule/ Planning

 GUIDELINES FOR SITE MOBILIZATION

 Meet the concerned customer representative.

 Make site survey.

 TG foundations as well as other equipment foundations are ready for installation.

 Availability of space for storage of equipment and site office.

 Arrangement of gate-pass for TTL engineers and if any sub-contractors.

 Completion of statutory formalities by sub-contractor (legal, safety etc).

 Discussion with sub-contractor about the project schedule.

 Receipt and shifting of materials.

 Verification of received materials and reporting of damaged/missing items if any.

 Prepare and send the progress report to respective TTL office.

 Protocol for Storage ECD/FOR/288,

 Protocol for Site handing over meeting ECD/FOR/297

 Site Report ECD/FOR/200

 Weekly progress report cum Time Sheet (ECD/FOR/201).

 Pre-casting/Post casting Foundation Inspection

 Unloading and Safe storage

 Leveling & Grouting of Packer plates(Check availability of Sikador-42)

 Positioning and Leveling of Surface Condenser.

 Shrink Fitting of Coupling Hub on Alternator Shaft(If applicable)

 Lifting and Placing of Turbine and Alternator.

 Make sure Alternator Magnetic center.

 Half Grouting of Turbine & Alternator foundation bolts.

 Clean Turbine oil tank before oil filling.

 Oil temperature to be obtained as per protocol ECD/FOR/219 60degC to 65 degC.

 Condenser flushing, Condensate pipeline cleaning and CEP Commissioning

 Condenser Commissioning & Vacuum Build Up

 Interlocks and Logic check

 Barring Gear Trial

 Steam line flange parallelism

 STG rolling & No Load Trial

SL.NO. Description of Drawing / Document

1 Purchase order copy of E&C sub-contractor

2 All applicable Protocols & Check Lists (Latest revision)

3 All Check list for Toll gate reviews (If applicable)