Capital Overhauling of Unit II of LJHP Baramulla

Dismantling

Dismantling of Chequered Plates of Generator Floor and their stacking in the Power House Service Bay.

Dismantling of Upper Dome assembly.

Dismantling of Slip Rings and the Bush Rocker Assembly, disconnecting and opening of Excitation Leads,Extension Shaft & Replacdement of old/degraded Carbon brushes with new one of Mersen Make (25 No).

Opening of all Oil, Water and Air and Grease Pipe lines of Turbine and Generator.

Jacking up of the Generator Rotor assembly and locking of all the Brake/ Jack units.

Dismantling of bearing oil coolers of all bearings, stator air coolers, vapour seal, etc.

Opening of Upper Guide Bearing (UGB) Pads followed by the dismantling of UGB cylinder as well.

Dismantling of Thrust Collar assembly, Thrust Mirror Disc and all the Thrust Bearing Pads.

Opening of the supporting plates of Regulating Rings after disengaging from the connecting rods of Guide Vane Servomotors.

Dismantling of the existing Shaft Sleeve assembly.

Dismantling of Runner Cone Assembly.

Dismantling of Runner Assembly.

Lifting of Runner Assembly and carriage of same to service bay.

Dismantling of Guide Vane Levers, Guide Vane Links etc.

Dismantling of all the Turbine Guide Bearing Pads and storing them safely.

Dismantling of Top Air Guide / Baffles assembly.

Dismantling of Bottom Air Guide/ Baffles, Vapour Seal, etc.

Dismantling of Radial Jacks of Upper Bracket Assembly followed by dismantling of the Upper Bracket Assembly

Decoupling of Turbine Shaft and the Generator Shaft assembly.

Lifting of Generator Rotor assembly safely and with due care from the Generator pit along with its Generator Shaft and placing it securely in the Service Bay.

Dismantling & Lifting of Lower Bracket assembly from the Unit pit followed by its placement in the Power House floor.

Dismantling of all the Guide Vanes and Guide Vane Servomotors, etc.

Dismantling of the Turbine Top Cover assembly including the Lower Fixed Labyrinth Ring.

Dismantling of the Turbine Shaft assembly.

Dismantling of MIV complete

Stacking and placement of dismantling parts at suitable safe place/service bay

POST-DISMANTLING INSPECTION & TESTING/MEASUREMENTS:

Ultrasonic testing of the primary Civil foundation at the Lower Bracket sole plates.

Non-Destructive Testing of the various dismantled unit assemblies including the welded portions on the Bracket arms & Turbine Top Cover including any other post dismantling tests as per applocable norms.

Liquid Penetrant tests shall be undertaken on the welded portions of the generator stator frame to assess their healthiness

Ultrasonic tests of all the bearing pads of

Thrust Bearing Assembly

Upper Guide Bearing Assembly

Lower Guide Bearing Assembly

Turbine Guide Bearing Assembly

Inspection and Measurement

Inspection of the secondary grouting and its bonding with the primary CiviI foundation at the Lower Bracket sole plates.

Inspection of the secondary grouting and its bonding with the primary civil foundation under all the Stator Sole Plates

Inspection of all the dismantled Studs, Dowels, Bolts/ Nuts, Pins to identify their replacement by new ones.

Measurement of thickness of Runner blades & Runner diameters at the Labyrinth Rings on both Suction side as well asthe Discharge side to check/determine the ovality/eccentricity besides the extent of erosion.

General Check-up of the profile of all the Runner Blades.

Measurement of the Diameters of both the Stationary Labyrinths engaged with Pivot Ring as well as the Turbine Top cover assemblies to check/ determine the ovality / eccentricity beside the extent of erosion.

Measurement of the dimensions including its top/ bottom Trunnion diameters as well as the feather heights of all the dismantled Guide Vanes.

Guide Vanes disassembly

Dismantling of all the Guide Vane bushes from the Pivot Ring assembly. However before their dismantling, diameters of all the pivot bushes shall be measured and recorded.

Dismantling of all the Guide Vane bushes from the Top Cover Bush Housings. However before their dismantling, diameters of all the pivot bushes shall be measured and recorded.

Carrying out physical inspection of MIV along with the seal and check list the works which shall be carried out at workshop in presence of the Site incharge .

Checklist of all parts which have to be replaced / repaired at workshop.

Transportation and Repair of dismantled assemblies at Workshop

All the dismantled 24 No. Guide Vanes if required.

All the dismantled Guide Vane bush Housings if required.

Dismantled Turbine Top Cover assembly along with Top

Stationary Labyrinth Ring assembly if required.

Dismantled Turbine Runner assembly along with its top as well as bottom moving labyrinth assembly if required.

Dismantled Pivot Ring Assembly if required.

Guide Vanes repair

Repair of top ,middle and bottom journals by welding with suitable material as per IS standards and machining to achieve original size of guide vanes

Repair of feather portion of the guide vanes by welding, one layer of final welding to be done with haFd facing electrode before grinding in order to achieve original profile as far as possible. Height of the feather shall be made as per requirement based on the distance of top and bottom liners or as per drawings.

Weld build up sealing surface of each guide vane throughout the length is required to be carried out followed by their machining on planer machine. Sealing strips should be parallel to the guide vanes axis and horizontal feather surface should be perpendicular to the guide vane axis.

Weld repair of collar to be done with Stainless Steel 309 electrodes and its machining on suitable lathe for maintaining the seat for bush.

MIV Complete Overhauling of MIV along with repairs of moving and stationary parts

Dismantling of expansion joint, overhauling / repairing of S.S. sealing ring ( metal to metal). Maintenance sealing ring (metal to metal ) and fixed sealing ring , valve body drainage and air vent and rotor seal for term tightness

Overhauling / repairing of locking bolt of maintenance sealing ring along with cleaning of piston cylinder of servo motor and replacement of damaged/old cup seals

Supply & Replacement of old/deteriorated sliding bearing sleeve of shaft (rubber seal ) .

Supply & Replacement of old/deteriorated stem seal between valve shaft and body

Supply & Replacement of old/deteriorated MIV operating mech. Bushes linking servomotor

Overhauling of MIV operating mechanism including reconditioning of piston cylinder

Painting of MIV complete

Rebabitating of all Pads

Thrust bearing pads

Lower guide bearing pads

Upper guide bearing pads

Turbine guide bearing pads

REPAIR OF THE DISMANTLED ASSEMBLIES AT POWER HOUSE:

Replacement of Upper and Lower Labyrinth by new one available in the stores

Thorough Cleaning of MIV VTA and Turbine VTA, including Supply & Replacement of all Filters .

Repair of Bearing Bodies

Overhauling of all the Guide vane bush housings, as required.

General refurbishment of all Guide Vane Bearing Bodies by polishing etc. and assembly of Guide Vane Bushes in the Bearing body, Housing assemblies using proper fit including the new Cup Seals and ‘0’-Rings.

Replacement of 24 No. brass bushes by new one

Thrust Bearing Assembly:

Polishing of all the Thrust Bearing Pads and Blue-matching of rebabitated pads for checking quality of rebabitating with a surface plate.

Blue matching of the thrust collar bottom surface with the top insulation surface of thrust runner disc in the Service bay.

Supply & Replacement of all gaskets and damaged fasteners required for the assembly.

Upper Guide Bearing assembly

Polishing of all the Upper Guide Bearing Pads and Blue-matching of rebabitated pads with the corresponding journal surface on the Thrust Collar assembly.

Lower Guide Bearing Assembly

Polishing of all the Lower Guide Bearing Pads and Blue-matching of rebabitated pads with the corresponding journal surface on the Lower Bearing Journal on the Generator Shaft assembly.

Thorough cleaning of all Lower Guide Bearing Oil Coolers and pressure testing of the same and assembly.

Supply & Replacement of all gaskets and damaged fasteners required for the assembly

Turbine Guide Bearing Assembly

Polishing of all the Turbine Guide Bearing Pads and blue- matching them with the corresponding journal surface on the Turbine Bearing Journal on the Turbine Shaft assembly.

Thorough cleaning of all Turbine Guide Bearing Oil Coolers and pressure testing of the same and assembly.

Supply & Replacement of all gaskets and damaged fasteners required for the assembly

Replacement of eroded brass and bottom Pads by new ones.

Replacement of all Teflon Bushes by new ones.

Brake/ Jack Assembly:

Overhauling of Brake Jack assembly and its Pressure

All the old/deteriorated Cup-Seal to have been damaged shall be replaced.

Generator Stator Assembly

Thorough cleaning of the complete Generator Stator Core all along its periphery both inside as well as from its outside surface using a suitable cleaning agent.

Thorough cleaning of the complete Generator Stator Winding overhang portions all along its periphery on both its connection-end side as well as from its non-connection end side using a suitable cleaning agent.

Checking of Stator Slot Wedge tightening and its rectification. Checking for any looseness of whole top as well as bottom overhang insulation including packers and retightening of the same. Spare wedges and packers to be Supplied for undertaking this job.

Carrying out ELCID testing of the Generator Stator core assembly and minor repair, if required.

Application of Loctite-290 compound on the two top-most as well as bottom-most stator core packets all around the periphery of the generator core.

Spray painting of Generator Stator Winding top as well as bottom overhang portion by Epoxy Red Gel paint.

Spray painting of Generator Stator Core surface by Grey Becktol insulation paint using oxygen gas tO avOid any ingress of moisture in the Generator.

Conducting the Dry-Out of the Generator Stator Winding assembly. The job includes providing/arranging of oven at site for conducting of dry-out.

Carrying out ultrasonic testing of stator core

Carrying out dye penetration test of stator core. IR and PI testing of stator core.

Carrying out Tan delta /power factor and capacitance measurement testing of stator core.

High Voltage testing of stator bars

Generator Rotor Assembly

Dismantling of all the 28 Rotor Poles from the Rotor assembly.

Dismantling of all the Rotor Pole Coils from their respective Pole assemblies.

Thorough cleaning of all the dismantled Pole Coils as well as their Pole Shoe assemblies using a suitable cleaning agent

Spray Painting of all the cleaned Pole Coils Epoxy Based Red Gel Paint using oxygen gas to avoid ingress of moisture.

Spray painting of all the pole shoe assemblies by Becktol Red insulation paint.

Reassembly of all the cleaned Pole Coils on their respective Pole Shoe assemblies and their packing up properly.

Reassembly of all the 28 No. Rotor Poles in their respective positions on the Rotor Rim assembly after driving their Pole Keys to the proper tightness.

Carrying out electrical testing (After Dismantling & before Assembly ) of all the assembled Generator Rotor Poles viz IR value,Impedance measurement, etc and comparing the results.

Conducting the Impedance measurement (After Dismantling & before Assembly ) of all the Rotor Pole Coils followed by their Polarity testing and comparing the results..

Completing the jointing of all the assembled/ tested Rotor Poles involving soldering and proper insulation.

Any other test required for Rotor Pole winding to check/Ensure its final healthiness as per relevant IS standards

Conducting the Dry-Out of the Generator Rotor assembly. The job includes providing/arranging of oven at site for conducting of dry-out.

Overhauling of H.S. Motor /Pump assembly and cleaning of its filters and replacement of its wornout gaskets of pipe line

Stator Coolers

Dismantling of Genrator hot air 8 No's , Thrust 6 No's , Upper guide 8 No's, and turbine coolers 2 No's from their respective positions and placing them over the service bay

Supply and Replacement of all gaskets and damaged fasteners required for the disassembly including its piping & Valves joints.

Retubing of Genrator hot air 8 no's , Thrust 6 No's , Upper guide 8 No's, and turbine coolers 2 no's by way of replacement of Ni-Cu tubes with new ones.

Pressure testing of all Cu-Ni tubes upto 12kgf/sq.cm as per IS Standard

Installation of retubed coolers over the machine. It includes the cost of neoprene rubber, gaskets, nuts and bolts etc.

Painting of all Stator Air Coolers using smoke grey Berger make synthetic super enamel paint.

Power Transformer

Thorough cleaning of all Oil Coolers along with water tubes and pressure testing of the same with assembly.

Replacement of all gaskets and damaged fasteners required for the assembly including pipeline and joints with new one

Replacement of worn out inlet and outlet valves of cooling system along with overhauling of other oil Inlet & Outlet valves with new one

Replacement of WTI (3 No),OTI (3 No),MOG (3 No) ,Water Flow Indicators (6 No),Oil Flow Indicators (6 No) & Silica Gel for breathers with new one

Supply & Replacement of existing Staters for oil pumps with contactors including necessary modification wherever required.

Replacement of old transformer oil with new transformer oil including its filtration in Unit-II Power Transformers

Supply & Replacement of 11 KV Cables of Unit-II Power Transformer to Bus Duct System.

Carrying out various tests on unit power transformers viz a Tandelta,Power factor and capacitance tests, D.C. winding resistance measurement , IR ,PI and short impedance test of all the three units of 14 MVA , 11/132 KV power transformers of Unit-II

Dissolved Gas analysis (DGA) and FURAAN Analysis Testing of the transformer oil of all the three units of 14 MVA , 11/132 KV power transformers of Unit-II

Turbine Assembly

Repair of Stay Vanes by welding & grinding.

Cleaning of Spiral casing, Stay Vanes and Discharge pipe with scrappers in order to remove rusting & other deposits to the maximum possible extent.

Painting of Spiral casing on its outer surface with one coat of primer and two coats of synthetic enamel paint of Berger make.

Cleaning of both the Draft Tube Cones as well as the Guide Plates with scrappers in order to remove rusting & other deposits to the maximum possible extent.

Painting of both the Draft Tube Cones as well as the Guide Plates with first coat of EpiIux-4 followed by two coats of Epilux- 5 paint.

Painting Works (Cleaning and Painting of Thrust Bearing housing, Upper Bracket assembly, Radial Jacks, Chequered Plates of the Stator & Rotor

Miscelaneous Power House Works

Renovation of Conference Hall and Allied Works inside Powerhouse, LJHP

Construction of Subdivisional offices including electrical fitting & supply of Furniture & fixture etc. As detailed in Scope of work

Trial Assembling

Trial assembly of Runner with Pivot ring and measurement of bottom labyrinths clearances to meet the design Value.

Trial assembly of Runner with Turbine Top Cover and measurement of top labyrinth clearances to meet the design Value.

Transportation of below mentioned repaired / refurbished components of Machine-II from workshop to the Power House for Reassembly of the Unit at Site

All the dismantled 24 No. Guide Vanes.

Dismantled Upper Draft TubeCone assembly along with Bottom Stationary Labyrinth Ring assembly.

Dismantled Turbine Top Cover assembly along with Top Stationary Labyrinth Ring assembly.

Dismantled Spare Turbine Runner assembly along with its top as well as bottom moving labyrinth assembly.

Dismantled Pivot Ring assembly.

All the dismantled Guide vane bush housings.

Box up/ Reassembly of the themachine aling with dynamic balancing of the machine

MIV Servomotor assembly.

Checking of stationary level of Turbine Speed Ring assembly.

Re-assembly of Pivot Ring assembly in position.

Re-assembly of all Guide Vanes in the Pivot Ring assembly.

Lowering of Turbine Shaft assembly in the turbine pit using the erection device.

Assemblies of the repaired Top Cover assembly in position with replacement of all its old fasteners by new ones which are to be procured.

Re-assembly of all the Guide Vane Bush Housings in the top cover and replacement of its damaged fasteners by new ones which are to be procured

Assembly of Regulating Ring along with Connecting Rods of the Guide Vane Servomotors in the unit.

Lowering of Lower Bracket assembly along with Brake Jack assembly in position with all its fasteners duly tightened.

Lowering of Generator Rotor assembly in the generator pit supporting on the jacking pads.

Lowering of Upper Bracket assembly in position with all its fasteners duly tightened.

Re-assembly of Thrust Collar assembly on the Generator Shaft by shrunk fitting method. Checking the vertical movement of Thrust Collar assembly.

Reassembly of Thrust Runner Disc assembly, Thrust Pads, H.S. Lubrication system, etc.

Checking of rotational level of Generator Shaft and correcting the same

Coupling of Generator and Turbine shaft flanges.

Re-assembly of the Francis Runner assembly and its coupling with Turbine Shaft using new Coupling Bolts & Nuts.

Assemblies of all associated turbine components viz Guide Vane Servomotors, Guide Vane Lever & Link Mechanism.

Carrying out the combined rotational checks of the Turbine & Generator Shafts and correcting the alignment, leveling & equal IOad sharing of the Thrust Pads.

Centering of the shaft and setting of Bearing clearances in UGB, LGB & TGB in a concentric manner.

Checking of all oil pipe lines & charging of Governor.

Bedding & setting of all Guide Vanes with respect to steel liner of Top Cover and Lower Ring to achieve proper clearances.

Boxing up all Bearings including their oil & water pipe lines.

Complete assembly of Adjusting Ring with full tightening of all the bolts.

Complete assembly of Shaft Sealing system including assembly of water pipelines

Overhauling/ Repair of Automatic Grease Lubrication System to make it functional & Assembly of grease pipeline of Upper Bushes and Lower Bushes and assembly of water pipe line of Lower Bushes.

Complete assembly of oil bath of Thrust Bearing with full tightening of bolts.

Measurement of Insulation Resistance value of Stator and Rotor winding & comparing with the initial reading.

Spinning of the machine, dry out and then synchronizing/ loading of the unit.

Carrying out the Dry-out of the Generator with windage loss method till the satisfactory levels of IR & the PI values is achieved.

Voltage build-up and subsequent synchronization of the unit followed by loading in steps and checking the unit vibrations at every step till the unit reached the rated load. Carrying out the balancing of the unit at load, if & as required.

Carrying out the measurement of unit vibrations & Dynamic balancing of the unit as required.

SITC Of Online Vibration Monitoring system in Unit-II including enabling its Successful operation from the existing scada system installed at the control room of LJHP Power House Vibration Monitoring System consists of the following major items: Vibration Monitoring System along with Analysis & Diagnostic Software shall comprise of the following items: 1. Relative Shaft Vibration Sensors in X and Y direction for TGB, LGB and UGB : 1 set 2. Bearing Casing Vibration Accelerometer Sensors in X and Y direction for TGB : 1 set 3. Phase Marker Sensor : 1 set 4.Panel :1 No.. 5. Server :1 No. 6. Mandatory Spares :1 Set. 7. Vibration Analysis plots.

MATERIALS REQUIRED (SPARES AND FASTENERS)

All general purpose consumables, D&H make Mo- 309 5S welding electrodes, 0-rings, general purpose fasteners, stainless steel shims, insulation paints, etc. required during the capital maintenance.

Transformer oil

SS Nuts and bolts

Turbine Oil Servo-57

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