Restoration of Unit-I including SITC of Couplings of Unit-II at MHEP Pahalgam

Removal of the existing gearbox low-speed shaft, followed by precise dimensional checks using micrometres and dial indicators. Supply of a new low-speed shaft manufactured from OEM-approved material, adhering strictly to OEM specifications. Installation and assembly utilizing proper interference tolerances as per OEM guidelines. Provision of comprehensive drawings and formal handover of scrap/rejected (Red) material to the Subdivisional Store.

Precision repair and machining of the alternator rotor shaft journal and step collar to correct surface damage and out-of-round conditions. Restoration of the shaft to exact OEM dimensions and tolerances. Cutting of a fresh, properly aligned keyway. Precision machining and polishing of the rear shaft step collar to ensure optimal fit and performance.

Alternator Rotor Shift & Magnetic Centre Root Cause Analysis and its correction to restore concentricity. Investigate the root cause of the rotor shifting toward the rear side to check for magnetic centre mismatch and rotor levelling discrepancies against OEM recommendations, ensuring the prevention of recurring bearing failures

Supply and replace damaged oil seals of the Gearbox, Turbine Shaft and DE- NDE Bearings to permanently rectify the observed lubricating oil leakages.

Supply, installation, testing, and commissioning of high torque toothed geared Turbine couplings (double engagement type), forged from carbon steel as per ASTM A105 or higher grade alloy steels (as per actual Dia after dimensional checks at site). Scope includes precision boring and keyway cutting to match existing gearbox and Turbine shaft profiles, provision of high tensile keys, dynamic balancing to G2.5 grade (ISO 1940), and supply of drawings and all required high tensile fasteners and O ring seals.

Supply, installation, testing, and commissioning of high torque toothed geared Generator couplings (double engagement type), forged from carbon steel as per ASTM A105 or higher grade alloy steels (as per actual Dia after dimensional checks at site). Scope includes precision boring and keyway cutting to match existing gearbox and Generator shaft profiles, provision of high tensile keys, dynamic balancing to G2.5 grade (ISO 1940), and supply of drawings and all required high tensile fasteners and O ring seals.

Supply, installation, testing, and commissioning of DE & NDE Bearings High-grade Cast Iron or Cast Steel Split-type (two-part construction with flanged mating faces for secure bolting/clamping around the shaft as per sample, inner Lining (Babbitt metal) of high-grade Tin-based Alloy (Grade to match OEM specs) including oil groove cutting and final scraping to achieve 80% blue-match with the shaft journal.

Controlled dismantling of the existing Gearbox assembly and its accessories for Unit-II using overhead crane, chain pulley blocks/hydraulic jacks including decoupling from the turbine and generator shafts by way of removal of existing turbine and generator couplings (DE & NDE side) using hydraulic pullers; cleaning and inspection of shaft ends for any scoring or ovality and grinding of the journals if found deviated.