0-WD210-ER630-00553_Rev.2_ Steam Turbine Erection Procedure

Titolo

Identificativo

title

Rev.

document no.

STEAM TURBINE ERECTION PROCEDURE

rev.

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0408 TXMA*S553

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Volume N.

2

Prodotto/Struttura

volume no.

product/structure

DA901 Tipo doc.

Codice EmittenteTeamcenter

doc. type

Ente Emittente issued by

teamcenter issuer code

FSP Commessa

Progetto

job no.

POSCO E&C

Descrizione

rev.

kind of revision

First issue Revised paragraph: 1.3; 2.4; 3.2; 4; 6; 7; 8; 10.1; 10.2 Added dwg. missing

2

Montelatici

Beiso

Cagliani

Vacca

10/03/10

1

Montelatici

Beiso

Cagliani

Vacca

10/06/09 25/03/09

0

Rev rev.

Scopo

scope

Montelatici

Beiso

Cagliani

Vacca

TVP/VAVV

TVP/VAVV

TVP/CTEC

TVP/VAVV

Preparato

Controllato

Verificato

Approvato

prepared

Verificato

checked

verified

posco

verified

Approved

Data Date

HYUNDAI ENGINEERING CO.. LTD.

ANGAMOS

TITLE THERMOELECTRIC

STEAM TURBINE ERECTION PROCEDURE

POWER PLANT

PREPARED

Posco

ELECT.SIGN D:Montelatici C:Beiso A1:Cagliani A2:Vacca A3:- (11/03/2010)

rev.

ENG client

Rev.

0 1 2

Rev.

derived from

Cliente

ANGAMOS

0408T1/T2

Derivato da

language

TVP/VAVV

VPFO

project

Edizione in lingua

SIGNA TURE DATE

CHECKED

REVIEWED

APPROVED

Posco DWG no.

0-WD210-ER630-00553

Ansaldo Energia s.p.a. si riserva tutti i diritti su questo documento che non può essere riprodotto neppure parzialmente senza la sua autorizzazione scritta Ansaldo Energia s.p.a. reserves all rights on this document that can not be reproduced in any part without its written consent

Progetto / Titolo Project / title

0408 – ANGAMOS STEAM TURBINE ERECTION PROCEDURE

Identificativo document no.

0408 TXMA*S553

Rev. rev.

2

Pagina page

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50

Classe di Riservatezza confidential class

List of contents 0.

INTRODUCTION

1. 1.1 1.2 1.3

FOUNDATION INSERTS AND ANCHORS Installation and checks of the foundation inserts before and after concrete casting Installation of the foundation sole plates and anchors Oil tanks and other steam turbine auxiliary embedded parts

2. 2.1 2.2 2.3 2.4 2.5

LP SECTION Positioning the outer casing of the LP section Welding of the LP outer casing to the condenser neck Assembly of LP inner casing and gland seal casings Assembly of the LP rotor Alignment of the LP gland seal casings and closure of the LP section

3. 3.1 3.2 3.3 3.4

STEAM TURBINE SUPPORTS Installation of the pedestals Final assembly of the pedestals and assembly of the auxiliary bearings Bearing assembly and pedestal key final assembly Assembly of the upper parts of the pedestals

4.

IP SECTION

5.

HP SECTION

6.

CROSS OVER

7. 7.1 7.2 7.3

ASSEMBLY OF VALVE AND SERVOMOTORS Installation of main steam valves Hydrostatic test, acid cleaning and steam blowing Check of the valve cover tightness and coupling of the actuators to the valves

8.

MAIN STEAM AND EXTRACTION PIPING

9. 9.1 9.2

ASSEMBLY OF STEAM TURBINE AUXILIARIES AND RELATED PIPING Steam turbine auxiliaries Steam turbine related piping

10. 10.1 10.2

ROTOR ALIGNEMENT Rotor alignment and finish machining of the coupling bolt holes Final check of the alignment and final closure of the couplings

11.

INSTALLATION OF THE ELECTRIC COMPONENETS AND CABLING

12.

INSULATION

13.

CERTIFICATE LIST

APPENDIX A

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INTRODUCTION

This procedure refers to the field assembly of the steam turbine type RT rated 270 MW for Angamos Power Plant The instructions provided in this procedure are addressed only to skilled personnel with significant experience in steam turbine set assembly. Should the steam turbine assembly not be carried out directly by the manufacturer (Ansaldo Energia), the presence on site of Ansaldo Energia technical personnel is however deemed necessary for adequate assistance and supervision of the assembly work. The various phases of the assembly are given as separate activities and for each of them prerequisites are indicated so that the most practical assembly sequence and the planning of the assembly activities can be defined, considering as well delivery to site of main parts / components. For the various assembly activities / phases, the necessary documentation - such as part lists, assembly drawings, procedures, assembly and test certificates etc. - is listed. However the Ansaldo Energia representative(s) can have at his (their) disposal, further the documentation mentioned in this procedure, other Ansaldo Energia proprietary documentation, such as drawings and instructions. Further the reference documentation mentioned for each phase, the Steam Turbine Instruction manual 0408TXMA*O556 provides description of the parts / components and useful information regarding the various sections of the steam turbine and parts or components. Appendix A at the end of this instruction provides general information about nomenclature and terms used in this instruction as well general information applicable to all paragraph of this instruction. Note Part lists and manufacturing drawings mentioned in this procedure are and remain property of Ansaldo Energia: they are available, to whom having need and right, only for information The special tools required for each phase, i.e. specific tools designed and manufactured for the assembly of this turbine and within the scope of supply of Ansaldo Energia, are listed in each paragraph. Standard tools and standard measuring tools and instruments are not listed but mentioned in the procedure of each activity (paragraph). It is intended that standard tools, i.e. the tools necessary for assembly of heavy mechanical equipments and standard measuring tools normally available on the market are provided by whom is in charge of site assembly. Should doubts regarding the standard tools and standard measuring tools required / necessary arise, contact Ansaldo Energia head offices in advance of the assembly activities. The tests, measurements and checks carried out during the assembly of the unit are to be recorded in the test certificates listed in paragraph 13 of this instruction. The various test certificates are to be filled when the assembly or testing activity is carried out, indicating the effective date of the activity. Every test certificate, completely filled and signed, must be included in the assembly dossier. It is requested to send copies of the test certificates to Ansaldo Energia main office (Servizio Cantieri e Servizio Ingegneria) as soon as they have been issued.

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A “Non Conformance Report (RnC)” shall be issued by whom is in charge of site assembly for any relevant “non conformance” of components, parts or deviation of the same ones from the design requirements, indicated in this procedure or in the instructions, test certificates, drawings here mentioned or damage due to transportation or non proper protection and storage. The RnC, countersigned by the Ansaldo Energia representative, has to be sent to Ansaldo Energia main offices (Servizio Cantieri) for record and solution. Regarding materials, components or parts damaged or lost on site, it will be care of whom in charge of site assembly to replace or repair them: replaced or repaired materials, components, parts are required to be approved formally by the Ansaldo Energia representative on site. A Quality Control Plan (PCQ) for site assembly will be issued by whom in charge of site assembly. The PCQ for site assembly must include at least all the phases of assembly for which a Test Certificate is indicated by this procedure: refer to paragraph 13. where a complete list of Test Certificates is given. The PCQ has to be approved by Ansaldo Energia and attendance to the tests by Ansaldo Energia representative must be indicated at Ansaldo Energia care. Formal attendance or presence of the Customer to the various phases of site assembly, the type of surveillance and therefore approval of test results and signature of the various Test Certificates by the Customer, is to be defined at care of whom is in charge of the site assembly.. This procedure does NOT refer to generator assembly neither to parts, components out of the scope of supply of Ansaldo Energia, with the exception of what has or can have influence on the assembly or operation of the steam turbine

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1.

FOUNDATION INSERTS AND ANCHORS

1.1

Installation and checks of the foundation inserts before and after concrete casting

2

Reference documents o o o o

0408TXMA*M504 - Steam Turbine mechanical outline 0408TXMA*C505 - STG Floor line 0408TXMA*C506 - Steam turbine foundation inserts 0408TXMA*C507 – Foundation inserts details drawings

Test certificates o

613W745_0408T1/T2

Prerequisites: o o

Definition of the machine axis as per reference drawings by the civil engineer Definition of the height of the turbine floor (top surface of foundation) as per reference dwgs. by the civil engineer

Procedure Place the foundation inserts inside the reinforcement rods according to dwg. 0408TXMA*C506. The inserts to be placed in this phase are indicated as positions 200, 202, 203, 204, 208, 209, 210, 225, 227, 228, 229, 230, 231, 232, 233, 234, 235 in dwg. 0408TXMA*C506. The inserts are to be placed and secured inside the armour cage in order to obtain the requested position tolerances once the foundation has been completely casted. The required tolerances are given by Note 1 (Remarks) of dwg. 0408TXMA*C506: ± 10 mm regarding position, ± 3 mm regarding verticality. Record the measured values of insert positions before concrete casting on the relevant sheet of Test Certificate 613W745_0408T1/T2. Once the foundation casting has been completed, check again the position of the inserts and record the measured values on the relevant sheet of Test Certificate 613W745_0408T1/T2.

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Installation of the foundation sole plates and anchors

Reference documents o o o o o o o

0408TXMA*M504 - Steam Turbine mechanical outline 0408TXMA*C505 - STG Floor line 0408TXMA*C506 - Steam turbine foundation inserts 0408TXMA*C507 – Foundation inserts details drawings 203W243 - SIKADUR 42 – Technical Data Sheet 203W380 – Foundation supports for machine parts (Assembly instructions) 262W575 - Alignment diagram

Welding procedures o o

201W245 - Quality levels for weldings 201W165 - Liquid penetrant test inspection

Test certificates Refer to 201W165 Prerequisites o

Activities of paragraph 1.1 (“Installation and checks of the foundation inserts before and after concrete casting”) completed

Procedure Note Positions indicated herein refer to dwg. 0408TXMA*C506 Remove by chipping some material from the top surface of the foundation in the areas where foundation sole plates will be embedded. The sole plates to be placed during this phase are indicated by positions 1 / 2 / 3 / 7; dimensions of chipping are given by dwg. 0408TXMA*C506 sheet 2, sections E-4, E-8, E-12, H-4. Check that the concrete level inside the foundation inserts position 203 / 204 / 209, where plates positions 11 / 12 / 13 are to be welded, allows proper assembly of the plates and there is enough room to pour the bonding compound SIKADUR 42. Should it not be the case, chip the concrete in order to get the necessary room. Before proceeding to the assembly of the sole plates 1 / 2 / 3 / 7, check that there is at least a 60 % contact on the spherical seat between the nut and upper ring of each sub sole plate assembly. Cut the protection covers of the foundation inserts dwg. 204T584 Install the sole plates pos. 1 / 2 / 3 setting them with the setting screws

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Attention! Do not use the nut to get the required, with reference to the turbine hall floor, height of the sub sole plate assemblies: the nut of each sole plate has to be engaged for about a half of its setting run in order to maintain the maximum setting capacity for further assembly settings. It is useful for the definition of the height of the sole plate assemblies, to make reference to the Alignment Diagram dwg. 262W575. Bond the sole assemblies positions 1 / 2 / 3 to the foundation using the bonding compound P22 (SIKADUR 42). Characteristics of the bonding compound (synthetic resin mortar) SIKADUR 42 per specification 203W243, mixing ratios, preparation etc. according to instruction 203W380. Set the height of plates positions 11 / 12 / 13 using the setting screws position 14. Weld the plates to their inserts (positions 203 / 204 / 209 / 235) according to welding instruction P8A-AL-0001 and check the welds according to instruction 201W165. Weld the plates (in number of two) position 15 to inserts position 210. The inserts positions 203, 204, 209, 235 and plates positions 11, 12, 13 of sections P-4, P-8, P12 and T- 4 of dwg. 0408TXMA*C506 will be bonded to the foundation after welding of keys positions 8, 9, 10, 16 to the plates. The sole plates (positions 7) of section T-8 of dwg. 0408TXMA*C506 sheet 2 will be placed and bonded to the foundation after welding of keys position 9 when also insert position 204 will be bonded to the foundation. Regarding welder qualification and weld quality level, refer to instruction 201W245. Proceed to engage anchor bolts in their inserts.

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Oil tanks and other steam turbine auxiliary embedded parts

Reference documents o o o o o o o o o o

0408AXMA*M326 - Steam turbine generator oil tank - Input civil work 0408TXMAVM511 - Lube oil tank outline 252K538 - Oil tank embeddments 0408AXMA*M327 - Steam turbine generator Lube oil coolers - Input civil work 0408TXMAVM512 - Lube oil cooler outline 0408AXMA*M328 - Steam turbine generator lube oil purifier - Input civil work 0408TXMAVM513 - Lube oil purifier outline 0408AXMA*M329 - Gland steam condenser - Input civil work 0408TXMAVM514 - Gland steam condenser outline 0408AXMA*M332 - Embedded plates on pedestal for piping support

Procedure Install oil tank embeddments, lube oil coolers embeddments, lube oil purifier embeddments, gland steam condenser embeddments, piping supports embeddments as per reference documentation With reference to dwg. 252W538, weld the locking piece P2 to the embedments P1 of the oil tank. Regarding welder qualification and weld quality level, refer to instruction 201W245 (quality level Q3)

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LOW PRESSURE (LP) SECTION

2.1

Positioning the outer casing of the LP section

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Reference documents o o o o o o o

0408TXMA*M504 - Mechanical outline 0408TXMA*C506 - Foundation inserts 267H414 – LP turbine (complete) 0408TXMA*M510 – Heavy turbine parts 204H379 – LP cone mach. type 1 612W462 – Alignment of the LP outer casing on the foundation and welding of the transversal restrain 261N963 - Low pressure casing modifications

Welding procedures o

612W462 – Alignment of the LP outer casing on the foundation and welding of the transversal restrain

Test certificates None Prerequisites o o o

Definition of the machine axes Installation of the foundation inserts and foundation sole plates (activities of paragraphs 1.1 and 1.2) completed Turbine hall crane available

Procedure Install and secure the eight sliding plates (each in two halves) P33 dwg. to the foot of the LP outer casing lower half using the screws P34 dwg. 267H414. During assembly of the above said plates, apply on the screw threads a thread protective compound (Loctite® 561 is recommended) for the whole length of the thread. Place in position, on the foundation plates, the LP outer casing lower half: level it perfectly using water or spirit levels. Check the contact of the casing foot on the sole plates using a feeler gage; correct it eliminating any gap, acting on the sole plate nuts. Install the upper halves (both TE and GE) of the housings of the gland seal casings (shortly named “LP cones” hereinafter) P5 and P6 dwg 204H379. and tighten the horizontal joint screws M24x90 P11 dwg 204H379.

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Using an inside micrometer, check the roundness of the inside diameter (the diameter that mates with the gland seal casing) of the LP cones; record the measured values for each of them and transmit to Ansaldo Energia head office for approval. Centre longitudinally the LP outer casing with reference to the centreline of the condenser according to dwg. 0408TXMA*M504 Lay out a piano wire between two supports external to the turbine set: the piano wire is levelled and its height is according to steam turbine centreline, dwg. 0408TXMA*M504. of the LP outer casing with measurements taken with a micrometer head on a rod. Check the transversal centring on the cylindrical parts (inside diameter) of the LP cones: move LP outer casing in the transverse direction as necessary to centre it transversally. Act on the foundation sole plate nuts in order to get the required vertical centring. Tighten the foundation bolts P3 dwg. 0408TXMA*C506 of the LP outer casing without installing the expansion sleeves and weld the casing to the foundation inserts P15 (view P-17) of dwg. 0408TXMA*C506; welding according to procedure 612W462.

2.2

Welding of the LP outer casing to the condenser neck

Note Welding of the LP casing to the main condenser is outside the scope of supply of Ansaldo Energia: welding procedure is to be defined and qualified by the organization that is in charge of this activity. Testing of the welding is to be defined by the organization in charge of welding. Information and requirements regarding the steam turbine with reference to this activity are given herein. Reference documents o o o o

0408TXMA*M504 - Mechanical outline 0408TXMA*C506 - Foundation inserts 611W313 – Site welding of LP casing to condenser connection 254H273 – Steam turbine thermal isulation

Welding procedures Refer to “Note” above Test certificates 605W912_0408T1/T2 605W738_0408T1/T2 605W739_0408T1/T2 Refer to “Note” above

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Prerequisites Definitive placement of the LP outer casing (activity of paragraph 2.1) completed Procedure Note The connection of the LP outer casing to the condenser neck is made with an expansion bellow Assemble the upper half of the outer casing to the lower half and tighten the joint bolts. Weld eight temporary plates close to the four corners of the LP outer casing as indicated by Test Certificate 605W912_0408T1/T2 and use them as reference points in order to evidence possible distortions during the weld of the LP outer casing to the condenser neck. Take the required measurements before the welding and after the welding and record on Test Certificate 605W912_0408T1/T2. With reference to dwg. 0408TXMA*M504 partic.T-13, weld the LP outer casing to the condenser neck according to procedure 611W313. Once the welding has been completed and the measurements indicated above taken, loosen the foundation bolts and check again the contact of the casing foot on the sole plates using a feeler gage. With reference to dwg. 0408TXMA*C506 Sect. E-17, weld the bent plates P 5 and P 6 to the LP outer casing and the relevant foundation insert. After assembling of the expansion sleeves, tighten the foundation bolts P3 dwg. 0408TXMA*C506 of the LP outer casing according to requirements of Test Certificate 605W738_0408T1/T2 and record relevant data. Carry out the checks indicated by Test Certificate 605W739_0408T1/T2 and record on it the relevant data.

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Assembly of LP inner casing and gland seal casings

Reference documents o o o o

612W459 – Instruction for the definition of the radial and axial clearances for the LP inner casing of the unit type RT 602W330 - Assembly instructions – Tightening of separating flange bolts LP inner casing 204K385 – Temperature probe 204K827 – LP gland seal compl.

Test certificates 602W654_0408T1/T2 612W460_0408T1/T2 Special tools o o o o

206T518P1 – Hydraulic jack 208L641P106 – Bolt tightening device M80x6 223W839P2 – Hydraulic torque tool DR 8,30 223W841P32 – Inner hexagonal insert SW55

Prerequisites Definitive placement of the LP outer casing (activity of paragraph 2.1) completed Welding of the LP casing to the condenser (activity of paragraph 2.2) completed Definitive placement of the turbine pedestals (activity of paragraph 3.2) completed Turbine hall crane available Procedure Assembly the adjusting devices P10 dwg. 267H414 in the supports of the lower half of the LP outer casing. Details of the adjusting devices are given by dwg. 204N373. Before assembly the LP inner casing, assembly on the LP inner casing the guide sleeve P13 and seal ring P29 dwg. 204K385 for the temperature probe P 14 dwg 267H414 Place the lower half of the inner casing on the adjusting devices already assembled in the LP outer casing and level the inner casing using a water or spirit level.

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Attention ! Any vertical movement of the LP inner casing must be carried out using hydraulic jacks in order to avoid stressing and damaging of the adjustment device threads. Centre longitudinally the LP inner casing with reference to the centreline of the condenser according to dwg. 0408TXMA*M504 Note The inner casing transversal axis is shifted 2,7 mm towards generator from the transversal axis of the outer casing, With reference to dwg 267H414., assemble the LP gland seal casings P5 to the pedestals adjacent to the LP section, both TE and GE: refer to LP gland seal casing assembly dwg 204K827.; LP gland casings are P3 and P4 of dwg 204K827. Carry out the top off / top on test as per instruction 612W459, paragraph 2 and record data on Test Certificate 612W460_0408T1/T2. 2.4

Assembly of the LP rotor

Reference documents o

204K827 – LP gland seal compl.

Special tools 264K293 – LP rotor support 264K267 – LP rotor lifting device 223W839P2 – Hydraulic torque tool DR 8,30 223W841P32 – Inner hexagonal insert SW55 Test certificates 238W878 238W880 238W879 238W881 Prerequisites o o o

Definitive alignment of bearings n. 3 and n. 4 (activity of paragraph 3.3) completed Assembly and preliminary alignment of LP lower inner casing (activity of paragraph 2.3) completed Turbine hall crane available

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Procedure Install the LP rotor, centre it in the LP inner casing and define the radial and axial clearances of the LP blading as well as the final position of the LP inner casing according to instruction 612W459 paragraph 3. Record the radial and axial clearances of the blading in the relevant Test Certificates. 2.5

Alignment of the LP gland seal casings and closure of the LP section

Reference documents o o o o o o o

602W330 - Assembly instructions – Tightening of separating flange bolts LP inner casing 602W233 - Assembly instructions – Sealing the LP outer casing 204N378 – Bellow assembly 217K657 – Vacuum breaker valve 204N373 – Regulating device TG71296 – Atmospheric relief diaphragm 615W128 – Assembly of seal packing casings and seal packing rings

Welding procedures o o

204N378 – Bellow assembly 201W245 – Quality levels for weldings

Special tools 223W839P2 – Hydraulic torque tool DR 8,30 223W841P32 – Inner hexagonal insert SW55 Test certificates o o o o o

602W654_0408T1/T2 602W652_0408T1/T2 606W530_0408T1/T2 608W537_0408T1/T2 605W737_0408T1/T2

Prerequisites o o

Final alignment of the LP inner casing completed and axial and radial clearances of the stationary and rotating parts of the LP blading definitely set (activity of paragraph 2.4 completed) Turbine hall crane available

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Procedure Remove the LP rotor from the casing and clean thoroughly it and the inner and outer casing. With reference to dwg. 204N373, lock the adjusting devices for the inner casing as herein indicated: lock the spherical seat washer P2 to the special screw P1, preparing the locking of the thread with Loctite; tighten the screw and then unscrew it of about half turn. Weld the lock plate so that it remains locked on one side of the hexagon of the screw in order to avoid the unlocking of the screw. Assemble the upper part of the LP inner casing and tighten the horizontal joint bolting as per Test Certificate 602W654_0408T1/T2 and per instruction 602W330. Record relevant data on the Test certificate. Check the data required by Test Certificate 608W537_0408T1/T2 and record them on the Test Certificate. Check the LP rotor position in the LP inner casing and record readings on Test Certificate 602W652_0408T1/T2. Record for future reference the position of the LP rotor in the n.3 and n. 4 pedestal (refer to Test Certificate 605W737_0408T1/T2). Install the bellow dwg. 204N377 for the cross over piping according to dwg. 204N378, maintaining in place the four shipping fixations and inserting the gasket between the bellow and the LP inner casing. Weld the bellow to the LP outer casing referring to 204N378 and to 201W245. Complete the assembly of the temperature probe P14 dwg. 267H414 as herein indicated. With reference to dwg. 204K385, weld the U shaped protective beam P20 for the thermocouple P 1 to the LP outer casing support; assemble the thermocouple P1 inside the threaded guide piece P 28 and then insert the thermocouple P1 inside the guide sleeve P13 previously assembled inside the LP inner casing (paragraph 2.3). Block the thermocouple cables on the U shaped protective beam P20. Finally assemble on the outside of the LP outer casing the threaded guide piece P28 with the seal ring P30 and then assemble on it the pipe union P27. Assemble the gland seal casings and packing rings according to spec. 615W128 and record relevant data on the Test Certificate 606W530_0408T1/T2. Assemble the upper half of each of the two cones (TE and GE) of the LP outer casing, P5 and P6 dwg. 204H379 and tighten the horizontal joint screws M24x90 P11 dwg. 204H379 definitively. Check that the piping of the LP casing sprayers is completely and correctly assembled in the LP outer casing, upper half: refer to dwg. 231K807; the nozzles P15 267H414 will be assembled only if the pipings an system feeding water to the nozzles has been already cleaned; elsewhere the nozzles will be assembled later, after the above said cleaning. Check that the pressure measurement piping and devices are completely and correctly assembled in the LP outer casing, lower half: refer to dwg. 217H455.

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Assemble the rotor covering, TE and GE, P17 dwg. 267H414: rotor covering details are given by dwg. 233K111. Assemble the upper half of the outer LP casing and tighten the bolts of the horizontal joint and of the vertical joints of the cones upper halves, both TE and GE. After the final assembly of the LP outer casing upper half, remove the four shipping fixations of the bellow. According to instruction 602W233, apply the sealing compound to the horizontal joint and to the joint between the outer upper casing and the upper halves of the housings of the gland casings, TE and GE.; assemble the angular shaped plates to protect the seal compound on the upper half of the horizontal flange. With reference to dwg. 267H414, complete the LP section, assembling the parts listed herein. P16 - Atmospheric relief diaphragm dwg. TG71296 on the upper part of the LP outer casing P11 - Steam pressure transmitters dwg. 216K315 P12 - Wells for thermocouples on the right side of the casing, GE P22 - Water spray valve DN 50 dwg. 204N837 P8 - Vacuum breaker valve dwg. 217K657

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STEAM TURBINE PEDESTAL ASSEMBLY

Herein the steam turbine pedestals will be indicated as pedestal n. 1 the type VL (MAD10), n.2 the type ALL1L (MAD20), n. 3 the type ZLL1L (MAD30), n. 4 the type NGL2L (MAD40). Notes Each steam turbine pedestal is shipped to site completely assembled. Each bearing has been centred in its pedestal during shop assembly, using a centring bar and the readings of the correct position of the axis are stamped on the housing of the oil deflectors of each pedestal: each pedestal must be aligned taking into account the above said values. 3.1

Installation of the pedestals

Reference documents o o o o o o o o o o o

231H404 – Bearing pedestal assembly (VL1) 242h835 – Bearing pedestal assembly (ALL1L) 238H806 – Bearing pedestal assembly (ZLL1L) 241K499 – Bearing pedestal (NGL2L) 206K546 – Foundation key 206K547 – Foundation key 0408TXMA*M504 Steam Turbine mechanical outline 0408TXMA*C506 Steam Turbine foundation inserts 203W243 - SIKADUR 42 – Technical Data Sheet 203W380 – Foundation supports for machine parts (Assembly instructions) 206W780 – Alignment of foundation chocks at site

Welding procedures o o

206W781 – Assembly instruction for welding foundation chocks 201W245 - Quality levels for weldings

Test certificates None Prerequisites o o o

Installation of the foundation inserts and foundation sole plates (activities of paragraphs 1.1 and 1.2) completed Positioning of the lower half of LP outer casing (activity of paragraph 2.1) completed Turbine hall crane available

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Procedure Clean thoroughly and check smoothness of the sole plates before placing the pedestals on them: the contact areas are required to be clean, smooth and without any dirt. Place pedestal n. 1 dwg. 231H404 and the foundation keys P2 dwg. 206K546 on its foundation sole plates. Assemble shims P. 3 dwg. 206K546 to restrain the pedestal to the foundation. Place pedestal n. 2 dwg. 242H835 (complete of the base plate P52) and the key P1 dwg. 206K547 on its foundation sole plates Assemble P2, P3, P4 dwg. 206K547 to restrain the pedestal to the foundation. Place pedestal n. 3 dwg. 238H806 and the foundation keys P1 and P2 dwg. 252K546 on its foundation sole plates Assembly shims pos. 3 dwg. 206K546 to restrain the pedestal to the foundation. Place pedestal n. 4 dwg. 241H499 and the foundation key P1 dwg. 206K546 on its foundation sole plates Assembly shims pos. 3 dwg. 206K546 to restrain the pedestal to the foundation. Note The above said shims are temporary; the exact thickness of the shims will be defined later with the check of the required clearances Using the LP outer casing as reference, place each pedestal in its correct position on the longitudinal axis according to dwg. 0408TXMA*M504. Using a piano wire centred on the conical supports of the LP outer casing, align transversally each pedestal. Once each pedestal has been aligned transversally, tighten the foundation bolts of the pedestals as indicated by Test Certificate 605W738_0408T1/T2; then restrain the foundation keys to the foundation plates with spot weldings. Remove each pedestal from the sole plates and weld the keys to the foundation plates – dwg. 0408TXMA*C506 section P-4, P-8, P-12, T-4, T-8 – according to 0408TXMA*C506, 206W780; welding per 206W781. Check the welds by dye penetrant test per instruction 201W165. Once the welds have been checked, cast the bonding compound SIKADUR 42 (reference: 203W243) as per instruction 203W380 and dwg. 0408TXMA*C506 sections P-4 / P-8 / P-12 / T-4 / T-8 3.2

Final assembly of the pedestals and assembly of temporary bearings

Reference documents o

0408TXMA*M504 - Steam Turbine mechanical outline

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262W575 – Alignment diagram

Prerequisites Pedestal installed on the turbine floor and keys welded (activity of paragraph 3.1 completed) Turbine hall crane available Special tools 244L101P8 – Manual pump ITH 244L101P9 – Flexible pipe (for high pressure application) ITH 244L101P10 – Elbow fitting (for high pressure) ITH 213K447 – Auxiliary bearing DN710 213K447 – Auxiliary bearing DN630 Test certificates 605W733_0408T1/T2 605W738_0408T1/T2 605W732_0408T1/T2 612W458_0408T1/T2 Procedure Place again each pedestal on its sole plates checking they are in their correct position along the longitudinal axis according to dwg. 0408TXMA*M504. Note The final axial position of pedestals n. 1 and n. 2 will be defined exactly after assembly of HP and IP casing (refer to paragraph 5. and 4. respectively). Verify that pedestal n. 2 can slide without restrains on its base plate freely of at least 15 mm towards the HP section Lay out a piano wire, perfectly levelled, and centre it on the cones of the LP outer casing both in the transversal and vertical direction. Acting on the nuts of the sole plates, move each pedestal centring it on the journal bearing to obtain the vertical position (elevation) and tilting of each pedestal as required by dwg. 262W575. The transverse alignment of each pedestal must be in agreement with the shop data stamped on the housing of the oil deflectors: should discrepancies occur between the shop data given by the referenced factory test certificates and the site transverse centring of one or more pedestals, contact Ansaldo Energia head office for instructions. Tighten the foundation bolts of the pedestals as per Test Certificate 605W738_0408T1/T2 and record the relevant data on the above said Test Certificate

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Check the clearances of the keys of the pedestal as required by Test Certificate 605W732_0408T1/T2 and record the readings on the Test Certificate. Check the thrust bearing (n. 2) pedestal hold down bar as per Test Certificate 605W733 and record the readings on the Test Certificate. Assembly the auxiliary bearing DN710 in the pedestal n. 2 and the auxiliary bearing DN630 in the pedestal n. 3: hereinafter the auxiliary bearing of pedestal n. 2 will be mentioned as “auxiliary bearing A” and the auxiliary bearing of pedestal n. 3 will be mentioned as “auxiliary bearing B”. 3.3

Bearing assembly and pedestal key final assembly

Reference documents: o o o o o

231H404 – Bearing pedestal assembly (VL1) 242h835 – Bearing pedestal assembly (ALL1L) 238H806 – Bearing pedestal assembly (ZLL1L) 241K499 – Bearing pedestal (NGL2L) 213H373 – Journal and thrust bearing DN280

Test certificates 605W429_0408T1/T2 605W734_0408T1/T2 605W735_0408T1/T2 605W430_0408T1/T2 605W644_0408T1/T2 Prerequisites Final assembly of pedestals (activities of paragraph 3.2) completed Rotor alignment (activity of paragraph 10.1) completed Positioning of HP and IP casings (activity of paragraphs 4. and 5. completed) Turbine hall crane available Procedure Pedestal n. 1 Assemble definitively the radial adjusting shims P18 dwg. 231H404; check and record the clearance as per Test Certificate 605W734_0408T1/T2 Assemble the oil inlet pipe to bearing n. 1, P6 dwg. 231H404 Assemble the hold down bars P9 dwg. 231H404, check the clearance of the keys P66 dwg. 251K480 per test certificate 605W735_0408T1/T2 and record relevant data.

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Assemble the main oil pump P8 dwg. 231H404, aligning it with the toothed wheel of the HP rotor; check it per Test Certificate 605W644_0408T1/T2. Once the alignment is completed, pin the main oil pump to the pedestal: refer to sect. F-F dwg. 231H404. Pedestal n. 2 Assemble definitively the radial adjusting shims P63 dwg. 242H835 and the axial adjusting shims P59 dwg. 242h835 and check the clearance as per Test Certificate 605W734_0408T1/T2 Assemble hold down bars P34 dwg. 238H875, check the clearance of the keys P67 dwg. 251K480 and P34 dwg. 232H895 per test certificate 605W735_0408T1/T2 and record relevant data. Assemble all the accessories, plates and spring rings, of the combined bearing according to dwg. 213H373; carry out checks required by Test Certificate 605W429_0408T1/T2 and record the readings Pedestal n. 3 Assemble definitively the radial adjusting shims P53 dwg. 238H806 and the axial adjusting shims P49 dwg. 238H806; check the clearance as per Test Certificate 605W734_0408T1/T2 Assemble the hold down bars P36 dwg. 238H806, check the clearance of the keys P34 dwg. 232H895 per test certificate 605W735_0408T1/T2 and record relevant data. Carry out the measurement of the radial clearance between rotor and journal bearings for each journal bearing using lead wires and record the readings on Test Certificate 605W430_0408T1/T2 Check the clearance of the outer casings as per Test Certificate 605W735_0408T1/T2 and record the readings 3.4

Assembly of the upper parts of the pedestals

Reference documents o o o o o o o

231H404 – Bearing pedestal assembly (VL1) 242h835 – Bearing pedestal assembly (ALL1L) 238H806 – Bearing pedestal assembly (ZLL1L) 241K499 – Bearing pedestal (NGL2L) 253W969 - Supervisory instrumentation 612W457 - Hydraulic prestress at 1.5 %0 of studs and bolts (stretch method) 201W814 – Check of the coupling between pedestal and bearing body

Test certificates 606W282_0408T1/T2 605W736_0408T1/T2 605W737_0408T1/T2 615W212_0408T1/T2 606W749_0408T1/T2

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Prerequisites Rotor alignment (activity of paragraph 10.1) completed Turbine hall crane available Special tools 208L641E01 – Bolt tightening device M42 Procedure Pedestal n. 1 Check the interference between the journal bearing body and the pedestal per instruction 201W814; record readings on Test Certificate 604W430_0408T1/T2 Assemble the lower part of the oil shield P3 dwg. 231H404 and centre it with reference to the rotor according to test certificate. Assemble the upper part of the pedestal and close the pedestal definitively tightening the joint bolts per 612W457 Check the axial and radial rotor position within the pedestal as per test certificate; record the readings Assemble the upper part of the oil shield P3 dwg. 231H404 and check the clearance as per test certificate; record the readings. Pedestal n. 2 Check the interference between the journal bearing and the pedestal per instruction 201W814; record readings on Test Certificate 604W430_0408T1/T2 Assemble the lower parts of the oil shields P13 and P14 dwg. 242H835 and centre them with reference to the rotor according to test certificate. Assemble the upper part of the pedestal, close the pedestal definitively tightening the joint bolts per 612W457 Check the axial and radial rotor position within the pedestal as per test certificate; record the readings Assemble the upper parts of the oil shields P13 and P14 dwg. 242H835 and check the clearance as per test certificate; record the readings. Assemble the turning gear P3 dwg. 242H835 and align it with the toothed wheel of the rotor: adjust to obtain the required backlash as per Test Certificate 606W282_0408T1/T2; record the final readings. After final adjustment, pin the turning gear to the pedestal as per Note 1 of dwg. 242H835.

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Assemble the speed sensors P15 dwg. 253W969 and check the data indicated by Test Certificate 606W282_0408T1/T2 Pedestal n. 3 Check the interference between the journal bearing and the pedestal per instruction 201W814; record readings on Test Certificate 604W430_0408T1/T2 Assemble the lower parts of the two (TE and GE) oil shields P5 dwg. 232H806 and centre them with reference to the rotor according to test certificate. Assemble the upper part of the pedestal and close the pedestal definitively tightening the joint bolts per 612W457 Check the axial and radial rotor position within the pedestal as per test certificate; record the readings Assemble the upper parts of the two oil shields P5 dwg. 232H806 and check the clearance as per test certificate; record the readings. Pedestal n. 4 Check the interference between the journal bearing and the pedestal per instruction 201W814; record readings on Test Certificate 604W430_0408T1/T2 Assemble the lower parts of the oil shields P5 and P6 dwg. 241K449 and centre them with reference to the rotor according to test certificate. Assemble the upper part of the pedestal, close the pedestal definitively tightening the joint bolts per 612W457 Check the axial and radial rotor position within the pedestal as per test certificate; record the readings Assemble the upper part of the oil shield P5 and P6 dwg. 241K449 and check the clearance as per test certificate; record the readings. Assemble the coupling shield P93 dwg. 241K449.

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INTERMEDIATE PRESSURE (IP) SECTION

Reference documents o o o o o o

232H895 – IP turbine (complete) 0408TXMA*M510 – Heavy turbine parts 262W575 – Alignment diagram 227H893 – Temperature probe 607W177 – Thermocouple assembly procedure 602W469_0408T1/T2 – Check of rotor in IP outer casing (Shop assembly data)

Test certificates 602W473_0408T1/T2 Prerequisites Final installation of bearing pedestals (activity of paragraph 3.2) completed Auxiliary bearings assembled in the pedestals N. 2 and N. 3 Turbine hall crane available Shop test certificate 602W469_0408T1/T2 available Procedure Note The IP turbine (section) is shipped to site completely assembled, included the IP rotor locked in its position during transportation by locking rings and axial spacers. Using the lifting device indicated by 0408TXMA*M510, lift the IP turbine (complete), taking care to maintain it horizontal. Place the IP turbine on temporary assembly shims. Take care that the IP rotor is NOT supported by the temporary bearings. Level transversally the IP casing, GE and TE according to shop data: proceed as indicated herein. Place a precision bar on the casing feet, GE, and therefore place a centesimal spirit level on the middle of the said bar. In accordance with the values stamped during shop assembly on the supporting feet of the outer casing, place the required shims, if any, between the bar and the casing. Then acting on the assembly shims move the HP turbine complete in order to zeroing the reading on the spirit level Repeat the procedure above for TE of the HP turbine. Attention ! Since this phase, any change of the vertical position of the IP turbine, must be carried out taking out or inserting the same amount of shims on the two supporting feet of each side of the IP casing.

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Check the radial position of the rotor in the casing: refer to the factory test certificate 602W469_0408T1/T2. Disassemble the upper halves of the locking rings pos. 100, dwg. 232H895, both TE and GE. With the IP rotor still supported by the lower halves of the locking rings, acting on the assembly shims of the casing, bring the two halves of the IP-LP coupling flanges concentric: the LP rotor position must remain unchanged and its flange is the reference for the alignment of the IP rotor flange. Transfer the IP rotor weight from the locking rings pos. 100 dwg. 232H895 to the auxiliary bearings: proceed as herein indicated. Place two centesimal dial gages, one for each side, between the outer upper casing and the rotor; then acting on the hydraulic jacks of the temporary bearings, bring the temporary bearings to come in contact with the rotor. As soon as the dial gages start to move, lock the temporary bearings in their vertical position. With the rotor supported by the auxiliary bearings, check that the two halves of the IP-LP coupling flanges are still concentric and that the opening of the flange halves is according to 262W575 point 3. Note This is a preliminary alignment of the IP and LP rotors: final alignment will be carried out later (refer to paragraph 9). Attention ! Do not change the rotor position with reference to the casing. After removal of the locking rings lower halves, the readings of the radial position of the rotor with reference to the inner parts, must be exactly the same as recorded during assembly in the shop as per factory test certificate 602W469_0408T1/T2. Measure the relevant dimensions (heights) of LB1 and LOB1 key slot and replace the temporary assembly shims with the keys LB1 and LOB1, dwg.232H895 pos.38: the required height of the keys LB1 and LOB1 is obtained using the shims part of the key assembly (details of the keys and shims are given by dwg. 203N389). Check again IP rotor position with reference to the casing. Push the IP casing complete towards the LP section and engage the rabbet fit (spigot) of the IP-LP coupling. Check that the axial position of IP casing (GE side) with reference to pedestal n. 3 is in agreement with the requirement of dwg. 0408TXMA*M504. Remove the shipping axial locking devices for the rotor, both TE and GE: refer to dwg. 231N400. Assemble the manhole covers P11 dwg. 231N400, both TE and GE.

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Check again the position of the IP rotor with reference to the inner parts: the readings of the radial position of the rotor with reference to the inner parts, must be exactly the same as recorded during assembly in the shop as per factory test certificate 602W469_0408T1/T2. Assemble the temperature probe dwg. 227H893 per assembly procedure 607W177; record relevant data in the referenced Test Certificate.

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HIGH PRESSURE (HP) SECTION

Reference documents o o o o o o o o

251K480 – HP turbine (complete) 0408TXMA*M510 – Heavy turbine parts 262W575 – Alignment diagram 227H893 – Temperature probe 607W177 – Thermocouple assembly procedure 231H404 – Bearing pedestal assembly (VL1) 213H373 – Journal and thrust bearing 606W391_0408T1/T2 – Check of rotor in HP casing (Shop assembly data)

Test certificates 602W473_0408T1/T2 Prerequisites Final installation of bearing pedestals (activity of paragraph 3.2) completed IP section installed with the IP rotor resting on the spigot of the IP – LP coupling (activity of paragraph 4. completed) Turbine hall crane available Shop test certificate 606W391_0408T1/T2 available Procedure Note The HP turbine (section) is shipped to site completely assembled, included the HP rotor, locked in its position during transportation by locking rings and axial spacers. Disassemble from the journal thrust bearing dwg. 213H373 the following parts: pads P6 and P7, spring ring P8. Lift the HP turbine (complete) taking care to maintain it horizontal. Place the HP turbine on temporary assembly shims, taking care that the HP rotor is NOT supported by its journal bearings. Level transversally the HP casing, GE and TE according to shop data; proceed as indicated herein. Place a precision bar on the casing feet, GE, and therefore place a centesimal spirit level on the middle of the said bar. In accordance with the values stamped during shop assembly on the supporting feet of the outer casing, place the required shims, if any, between the bar and the casing.

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Then acting on the temporary assembly shims move the HP turbine complete in order to zeroing the reading on the spirit level Repeat the procedure above for TE of the HP turbine. Attention ! Since this phase, any change of the vertical position of the HP turbine, must be carried out taking out or inserting the same amount of shims on the two supporting feet of each side of the HP casing . Check the radial position of the rotor in the casing: refer to the factory test certificate 606W391_0408T1/T2. Disassemble the upper halves of the locking rings positions 110, 112 dwg. 251K480. Transfer the HP rotor weigth from the locking rings pos. 110, 112 dwg. 251K480 to the journal bearings: proceed as herein indicated. Place two centesimal dial gages, one for each side, between the outer upper casing and the rotor and then, acting on the temporary assembly shims, bring the rotor to come in contact with their bearings: the shifting of the rotor to the journal bearing can be considered completed as soon as the dial gages start to move. Attention ! Do not change the rotor position with reference to the inner parts of the casing. After removal of the locking rings lower halves, the readings of the radial position of the rotor with reference to the inner parts, must be exactly the same as recorded during assembly in the shop as per shop test certificate 606W391_0408T1/T2. With the HP rotor supported by its bearings, check the alignment of the HP-IP coupling in uncoupled conditions: the two flange halves must be concentric. The position of the IP rotor must remain unchanged and its flange, turbine side, is the reference for the alignment of the HP rotor. Note This is a preliminary alignment of the HP and IP rotors: final alignment will be carried out later (refer to paragraph 9). However, should the alignment of the HP-IP coupling be not satisfactory, correct it acting on the nuts of pedestal n. 1 and n. 2. Measure the relevant dimensions (heights) of LB1 and LOB1 key slot and replace the temporary assembly shims with the keys LB1 and LOB1, dwg.251K480 P60 (TE) and P61 (GE): the required height of the keys LB1 and LOB1 is obtained using the shims part of the key assembly (details of the keys and shims are given by dwg. 203N389 (P1 for TE, P2 for GE). Check again HP rotor position with reference to the casing. Push the HP casing complete towards the IP section and engage completely the rabbet fit of the HP-IP coupling. Check that the axial position of HP casing, GE side, with reference to pedestal n. 2 is in agreement with the requirement of dwg. 0408TXMA*M504.

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Lower the temporary bearing A and remove it; remove the shipping axial locking devices for the rotor, both TE and GE: refer to dwg. 231N411. Assemble the manhole covers P101 dwg. 251K480, both TE and GE. Check that the axial position of pedestal n. 1 with reference to the HP casing (TE side) is in agreement with the requirement of dwg. 0408TXMA*M504. The journal - thrust bearing is shipped completely assembled with the pedestal n. 2. The adjusting shims P11 dwg. 213H373 are already set to provide the correct clearance for the thrust bearing. The shim plates P14 are already set and installed preliminary in equal amounts on the two sides of the male mating surfaces of the pedestal. Measure the distances between the thrust runner faces of the HP rotor and the faces of the thrust bearing; if necessary, move the journal thrust bearing body to obtain the right readings for the rotor position inside the thrust bearing and reset the amount of shim plates P14 for each side, TE and GE: the total (sum of the) thickness of the shims plates must remain the original one. Assemble the temperature probe dwg. 227H893 per assembly procedure 607W177; record relevant data on referenced Test Certificate.

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CROSS OVER ASSEMBLY

Reference documents o o

263K927 – Cross over assembly 204N378 – Bellow assembly

Welding procedures o o

263K927 – Cross over assembly 201W245 – Quality levels for weldings

Test certificates None Prerequisites o o

IP section installed (activity of paragraph 4. completed) LP section closed (activity of paragraph 2.5 completed)

Procedure Note The cross over is supplied only partially fabricated and the fabrication will be completed on site. Some loose parts are supplied with adequate extra stock on the relevant mating surfaces Before starting the fabrication on site of the cross over, protect the steam turbine (IP and LP sections) by placing adequate temporary covers / plugs on the IP and LP turbine cross over flanges. Herein reference is made to dwg. 263K927. Assemble temporary the IP cross over pipe P51 to the IP cross over flange: do not use the gasket P2, but insert shim(s) of the same thickness of the gasket. Tack weld the pipe P51 to the bellow P54 and the elbow P50 to the bellow P54 as per dwg.. Disassemble the pieces above from the turbine and weld P51 to P54 and P54 to P50 as per dwg.. ND testing of the welds as required by 201W245. Re - assemble temporary parts P51, P54, P50 welded together to the IP cross over flange: do not use the gasket P2, but insert shim(s) of the same thickness of the gasket. Remove the four shipping fixations of the bellow dwg. 204N378 installed on the LP section and assemble temporary the LP cross over pipe P53 to the LP bellow already assembled on the LP inner casing: do not use the gasket P10 but insert shim(s) of the same thickness of the gasket.

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With the above said parts, IP and LP side, temporary installed on the IP and LP sections, take the dimensions necessary to machine off the extra stock at the IP side end of P52 (made by P5 and P6 sent to site already welded together) and at the upper end of P53. Disassemble P53 from the turbine, machine to the proper dimensions the IP side of P52 and the upper side of P53; then machine the weld preparations on P52 (IP side end) and P53 (upper end) according to Part. D. Assemble P53 to the LP cross over flange and the welded assembly of P51 / P54 / P50 to the IP cross over flange and weld P52 to the mating parts according to dwg.. Disassemble the cross over completely fabricated and ND test as required by 201W254. Clean thoroughly the internals of the cross over and assemble definitively the cross over to the IP and LP flanges using the gasket P2 and P10 as per dwg. tighten the flange bolts according to 602W454.

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ASSEMBLY OF VALVES AND VALVE ACTUATORS

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Reference documents o o o o o o o o o o o o o o o

0408TXMA*M504 – Steam turbine mechanical outline 0408TXMA*C506 – Steam turbine foundation inserts 213N260 – Suspension 226T729 – Valve assembly (HP valves) 228H127 – Stop valve actuator (HP valves) 206K738 – Emergency valve inner parts (HP valves) 228H128 – Control valve actuator (HP valves) 224H751 – Control valve inner parts (HP valves) 208K718 – Suspension 232N111 – Valve block compl. (IP valves) 228H129 – Stop valve actuator (IP valves) 229H162 – Stop / control valve (internal parts - IP valves) 228H130 – Control valve actuator (IP valves) 206W779 – Manufacturing instruction for the alignment and welding of swing arm supporting valves of the RT series 231K963 – Inlet piping RH

Welding procedures o o

0408TXMA*C506 – Steam turbine foundation inserts 206W779 – Manufacturing instruction for the alignment and welding of swing arm supporting valves of the RT series

Special tools O o o

208L641E05 – Bolt tightening device M72 223W839P2 – Hydraulic torque tool 8,30 223W841P29 – Inner hex. insert

Test certificates o o

606W210_0408T1/T2 606W630_0408T1/T2

Prerequisites o o

Assembly of HP casing (section) completed (activity of paragraph 5.) Assembly of IP casing (section) completed (activity of paragraph 4.)

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Procedure Note The main valve assemblies (both for HP and IP section) are shipped with the internal parts assembled included the temporary fine mesh strainers, but without the actuators that are shipped separately. Assemble the bodies of the HP stop and control valves dwgs. 226T729 Check that the contact between the valve assembly and the HP casing is complete and tighten the flange bolts per 606W630; record relevant data on the Test Certificate. Install the swing arm supports 213N260 and weld their support base to the foundation base plates sections S-18 and P-22 of dwg. 0408TXMA*C506 per instruction 206W779. Remove the transportation devices restraining the valve stem and assemble temporary the actuators to the HP valves in order to allow the installation of the oil pipings to the actuators (do not couple the actuators to the valve stems) Note One bolt, indicated on the flange of the valve casing with “L366”, must be assembled before of the corresponding opposite bolt. Assemble the inlet pipings 231K963 to the IP casing and then assemble the bodies of the IP (RH) stop and control valves dwgs. 232N111 to the above said inlet pipings. Check that the contact between the valve assembly and the inlet pipngs and between the inlet piping and the casing are complete and tighten the flange bolts per 606W210; record relevant data on Test Certificate Install the swing arm supports 208K718 and weld their support base to the foundation base plates sections L-22 and P-22 of dwg. 0408TXMA*C506 per instruction 206W779. Assemble temporary the actuators to the valves in order to allow the installation of the oil pipings to the actuators (do not couple the actuators to the valve stems)

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Hydrostatic test, acid cleaning and steam blowing

Notes Herein it is intended that steam blowing of the main steam lines is carried out through the main valves. Design, fabrication, erection and removal of the temporary piping for steam blowing of the main steam lines is out of Ansaldo Energia scope of supply Reference documents o o o

206K738 – Emergency valve inner parts (HP valves) 224H751 – Control valve inner parts (HP valves) 229H162 – Stop / control valve (internal parts - IP valves)

Special tools o o o o o

216K951 - Blow out, hydrostatic test, and acid cleaning device (HP valves) 233N198 – Blow out and acid cleaning device (IP valves) 233N209 - Hydrostatic test device (IP valves) 215N933 – Device for assembly – disassembly HP valves 229N174 – Stop/control valve assembling device (IP valves)

Test certificates None Prerequisites o o

Main steam valves assembled to the steam turbine casings (activity of paragraph 7.1 completed) Main steam lines welded to the steam turbine main HP and IP steam valves (activity of paragraph 8. completed)

Procedure Disassemble the actuators of the stop and control valves, of both the HP valves and IP valves. Then disassemble the internal parts of HP stop valves and of the IP valves (both stop and control).using the referenced special tools. Install the tools for the hydraulic test on the HP and IP valves. After the hydraulic test of the main steam piping has been carried out, remove the devices for hydraulic testing and install the devices for the acid cleaning and steam blowing, both for HP and IP valves. Completed the chemical cleaning and the blow out of the main steam piping, remove the devices for the blow out of the main steam pipe.

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Reassembly of valves internals and coupling of the actuators to the valves

Reference documents o o o o o o o o o o o o o o o

213N260 – Suspension 226T729 – Valve assembly (HP valves) 228H127 – Stop valve actuator (HP valves) 206K738 – Emergency valve inner parts (HP valves) 228H128 – Control valve actuator (HP valves) 224H751 – Control valve inner parts (HP valves) 208K718 – Suspension 232N111 – Valve block compl. (IP valves) 228H129 – Stop valve actuator (IP valves) 229H162 – Stop / control valve (internal parts - IP valves) 228H130 – Control valve actuator (IP valves) 605W127 – Coupling of SSA actuator and valve 606W936 – Coupling of STAE actuator and valve 612W316 – Coupling of SSAK 200125 actuator and valve 602W454 - Prestress values and tightening torques for metric threads

Special tools o o o o

215N933 – Device for assembly – disassembly HP valves 229N174 – Stop/control valve assembling device (IP valves) 253T336 – Assembly device (STAE 315071) 213T567 – Fixture for loading (STAE 200050)

Test certificates o o

612W333_0408T1/T2 606W211_0408T1/T2

Prerequisites o o

Main steam piping chemical cleaning and blowing completed successfully Turbine hall crane available

Procedure Clean thoroughly the valve casings and re-assembly the internal parts of the HP and IP valves using the relevant special tools. Prestress the Belleville springs of the swing arm supports per Test certificate 606W211 and record relevant data.

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Couple the actuators SSA250070 dwg. 228H127 to the HP stop valves according to instruction 606W937. Record the relevant data on the test certificate Couple the actuators STAE315071 dwg. 229H128 to the HP control valves according to instruction 606W936. Record the relevant data on the test certificate Couple the actuators SSAK2000125 dwg. 228H129 to the IP stop valves according to instruction 612W316. Record the relevant data on the test certificate Couple the actuators STAE 8000 dwg. 228H130 to the IP control valves according to instruction 606W936. Record the relevant data on the test certificate

Note The strainer installed on the valves are the temporary ones (fine mesh). The permanent strainers (large mesh) will be installed, after removal of the temporary ones, after operation at full load of the unit.

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MAIN STEAM AND EXTRACTION PIPING

Note Welding of the main steam pipings and extraction pipings is outside the scope of supply of Ansaldo Energia: welding procedures are to be defined and qualified by the organization that is in charge of this activity with reference to the information given herein Reference documents o o o o o o o o o o o o o

0408TXMA*M504 – Steam turbine mechanical outline 0408TXMA*S535 – Steam turbine mechanical interface list 0408TXMA*P515 – Dimensions of connections to steam turbine 251T939 – MAW01AA041 (shut off) valve 259T484 - LBQ20AA061 (NR) valve 259T485 – LBD10AA041 (shut off) valve 259T486 – LBD10AA061/062 (NR) valve 259T487 – LBQ10AA041 (shut off) valve 259T488 – LBQ10AA061/062 (NR) valve 259T489 – LBS20AA041 (shut off) valve 259T490 - LBS20AA061 (NR) valve 259T491 – LBS30AA041 (shut off) valve 259T492 – LBS30AA061 (NR) valve

Welding procedures Refer to “Note” above Test certificates Refer to “Note” above Prerequisites o o o

Main steam valves installed (activity of paragraph 7.1 completed) HP section installed (activity of paragraph 5. completed) IP section installed (activity of paragraph 4. completed)

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Procedure

Note Welding of the main steam pipings is required to be carried out before final alignment of the rotors and closure of the couplings in order to take into account also the effects of the loadings due to the pipings. Weld preparations, dimensions and materials of the steam turbine side connections are given by dwg. 0408TXMA*P515. Data regarding the connections of the extraction check valves and extraction shut off valves (loose supply within the Ansaldo scope of supply) are given by dwg. 0408TXMA*S535 After completion of welding, remove the temporary supports and hangings of the main steam pipings and extraction piping, if any, and set the permanent supports and hangings to the design values (the supports and hangings are out of the Ansaldo Energia scope of supply).

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ASSEMBLY OF STEAM TURBINE AUXILARIES AND RELATED PIPING

Note Assembly of steam turbine auxiliaries and related piping is carried out in parallel to the steam turbine assembly. 9.1

Steam turbine auxiliaries

Reference documents o o o o o o o o

0408AXMA*P302 – Steam turbine – generator and auxiliaries arrangement 0408AXMA*M326 - Steam turbine generator oil tank – Input civil work 0408TXMAVM511 – Lube oil tank outline 0408AXMA*M327 - Steam turbine generator Lube oil coolers – Input civil work 0408TXMAVM512 – Lube oil cooler outline 0408AXMA*M328 - Steam turbine generator lube oil purifier – Input civil work 0408TXMAVM513 – Lube oil purifier outline 0408AXMA*M329 – Gland steam condenser – Input civil work

Test certificates None Prerequisites o

Embeddments for the auxiliaries installed (activity of paragraph 1.3 completed)

Procedure Install the lube oil tank dwg. 0408TXMAVM511, the lube oil coolers 0408TXMAVM512, the gland steam condenser 0408TXMAVM514, the lube oil purifier 0408TXMAVM513 as per dwg. 0408TXMA*P302.

9.2

Steam turbine related piping

Note For lines with with a diameter larger than 50 mm (2”) and to “hot” lines with diameter < 50 mm only both a ”Piping lay out” dwg. and a isometric dwg. are provided as well as a “Piping support dwg. collection”. Not hot lines smaller than 50 mm diameter are indicated only in the “Piping lay out dwg” such as the “Oil system piping composite dwg.” etc. For both types of piping, materials are provided raw (i.e. not pre fabricated) and MTO (Material Take Off) lists are provided. MTO are indicated as well for insulation and painting materials and manual valves.

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Reference documents o o o o o o o o o o o o o o o o o o o o o o

0408TXMA*P606 – Steam turbine pipe connection lay out 0408TXMA*P607 – Pipe connection list 0408AXMA*M332 – Embedded plates on pedestal for piping support 0408AXMA*P301 – Piping specification 0408AXMA*P606 – Steam turbine pipe connection lay out 0408AXMA*P305 – Oil system piping composite dwg. 0408AXMA*P306 – Gland steam system piping composite dwg 0408AXMA*P308 – Steam turbine oil system piping isometric drawing 0408AXMA*P309 – Gland steam system piping isometric drawing 0408AXMA*P310 – Drain system piping isometric drawing 0408AXMA*P311 – Piping supports drawing collection 0408AXMA*P332 – Steam turbine lube oil system connection parts 0408AXMA*P337 – STG lube oil control and protection system connection pieces 602W936 – Flared tube fitting – Triple lok 0408AXMA*P338 – STG steam seal and drain system connection pieces 255T755 – Desuperheater 0408AXMA*P312 – Thermal insulation specification 0408AXMA*P313 – Painting specification 0408AXMA*S347 - MTO - Piping and fittings 0408AXMA*S334 – MTO - Manual valves 0408AXMA*S345 – MTO – Insulating material 0408AXMA*S346 – MTO – Painting material

Welding procedures STD30004A Test certificates Refer to STD30004A Prerequisites o

Steam turbine main components and auxiliaries installed

Procedure Before assembly of the piping, inspect the pipings and the various parts of the pipings to verify their cleanliness and preservation conditions. Pipes made of stailesss steel – class AG – must be at any rate clean and without rust, oxidation, scales, chips, and welding slugs or any other foreign material.

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Note Cleaning of the lube oil piping by sand blasting is NOT allowed Fabricate and install lube oil pipings, gland steam pipings, drain pipings according referenced documentation. Assembly instructions for flared tube fitting used in the lube oil control and protection system connection pieces are provided by 602W936. Painting and thermal insulation per reference documents. For flushing of the lube and control oil system refer to 0408TXMA*S547 where preparatory work for the flushing and restoring work are indicated. For cleaning (blowing) of the steam seal system pipings refer to 0408TXMAWS552 where preparatory work for the flushing and restoring work are indicated.

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10. ROTOR ALIGNMENT 10.1

Rotor alignment and finish machining of the coupling bolt holes

Reference documents o o o

262W575 - Alignment diagram 606W289 – Expansion sleeve coupling standard 80 606W298 – Honing the expansion sleeve couplings

Test certificates o o

606W386_0408T1/T2 612W757_0408T1/T2

Prerequisites o o o

All the components are installed on the turbine floor of the foundation. Main steam piping and extraction piping welded, temporary piping supports removed, permanent supports and hangings of the piping set to their design values (activity of paragraph 8. completed) Oil lifting system commissioned and available 1

Procedure Note HP – IP coupling is of type DN315 K, IP – LP coupling is of type DN400, LP – generator coupling is of type DN400. The HP-IP coupling and the IP – LP coupling are coupled together only on the rabbet fits (spigots) and each coupling flange is open about 2. mm; the LP – generator flange is open (spigot not engaged).. The auxiliary bearings, should they be still installed in the pedestals during these activities, are not in contact with the rotors. Check that the HP – IP, IP – LP, LP – generator coupling flanges are as per requirements of dwg. 262W575; if necessary correct the alignment, moving the pedestal n. 1 and n. 2 and the generator. Attention ! 1 Should the lifting oil system be not yet available, it is possible to rotate the rotors for the alignment checks, as herein

indicated Disassemble the oil pipings of the lifting oil system from the flow control valves of the lifting oil of each pedestal. Connect the a hydraulic pump to the above said flow control valve (the pump must be able to deliver a pressure of 400 bar) Lift the rotors with the hydraulic pump.

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Do not change the position of the LP rotor to correct the HP-IP, IP-LP and LP- generator coupling alignment and do not change the tilting of the pedestals set previously Close the couplings bringing the faces of the coupling flanges into contact.. Attention! All rotor zero marks (hole 4 mm diameter drilled radially at the GE coupling flange), must be at the same circumferential angle when the rotors are coupled for honing of the bolt holes of the coupling flanges. The bolts and the holes of each flange are requested to be identified by a number Assembly the couplings per instruction 606W289, honing of the bolt holes per 606W298: record the relevant data on Test certificate 606W386_0408T1/T2 and 612W757_0408T1/T2 (data regarding coupling alignment and runouts, bolt tensioning pressure will be filled in the certificate after final alignment check, paragraph 10.2). Attention ! Measure the bolt diameter before and after final machining with the same instrument. After final machining of the bolt holes, all the coupling must be opened and thoroughly cleaned, in particular by any machining debris. 10.2

Final check of the alignment and final closure of the couplings

Reference documents o

262W575 - Alignment diagram

Special tools o o

216W347P2 – Coupling DN315K tightening device 2 216W347P5 – Coupling DN400STD tightening device 3

Test certificates o o o o o

606W386_0408T1/T2 612W757_0408T1/T2 605W736_0408T1/T2 606W391_0408T1/T2 602W496_0408T1/T2

2 Dwg. not available 3 Dwg not available

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Prerequisites o o o o

All the components are installed on the turbine floor of the foundation. Main steam piping and extraction piping welded, temporary piping supports removed, permanent supports and hangings of the piping set to their design values (activity of paragraph 8. completed) Final alignment of the rotors and coupling of the rotor (activity of paragraph 10.1) completed Oil lifting system commissioned and available 4

Procedure Open the turbine (HP-IP, IP-LP) couplings of about 2 mm maintaining the rabbet fits engaged, and disassemble completely the LP – generator coupling: check the alignment of all the couplings: the required coupling alignment is provided by dwg 249W244 Record the final alignment data on test certificates 606W386_0408T1/T2 and 612W757_0408T1/T2 Close the HP-IP and IP-LP couplings and tighten definitively their bolts; record the relevant final data on the referenced test certificate 606W386_0408T1/T2 Couple again the LP-generator coupling and tighten definitively their bolts, record the relevant final data on the referenced test certificate 612W757_0408T1/T2 With all the couplings closed definitively, check the run out of each coupling and record the measured values on the test certificates 606W386_0408T1/T2 and 612W757_0408T1/T2. Check again the rotor positions with reference to the oil deflectors at each pedestal; record the final readings on Test Certificate 605W736_0408T1/T2. Check again the HP and IP rotor positions in their casings and record this final position filling the Test Certificates 606W391_0408T1/T2 and 602W469_0408T1/T2.

4 Should the lifting oil system be not yet available, it is possible to rotate the rotors for the alignment checks, as herein indicated. Disassemble the oil pipings of the lifting oil system from the flow control valves of the lifting oil of each pedestal. Connect the a hydraulic pump to the above said flow control valve (the pump must be able to deliver a pressure of 400 bar) Lift the rotors with the hydraulic pump.

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INSTALLATION OF THE ELECTRIC COMPONENTS AND CABLING

Reference documents o o o o o o o o o o o o o o o

0408TXMA*E530 – Steam turbine junction boxes arrangement 248W300E01 – Miscellaneous steam turbine instrumentation 0408TXMA*M544 – Steam turbine instrument panels 252W825E01 – Turbine electrical conduits arrangement 252H824 – Turbine instruments, electrical connections and conduits layout 0408TXMA*E531 – Steam turbine wiring diagrams 0408TXMA*S538 – S(team) T(urbine) instrument set-up list 253W969 - Supervisory instruments 233K680 – Arrangement of differential expansion detectors 231K775 – Arrangement of rotor vibration probes 215T688 – Arrangement of absolute expansion detector (VL pedestal) 231N774 – Arrangement of thrust bearing wear detectors 215N692 – Arrangement of absolute expansion detector (AL pedestal) 207N580 – Arrangement of speed detectors 231N387 – Arrangement of phase detector

Test certificates None Prerequisites This activity can be carried out after the various mechanical components have been definitively installed Procedure Note The referenced part lists 252W825E01 and 248W300E01 provides references for the various parts / components required and typical arrangements of instrumentation, cabling, etc.; therefore the various detail dwgs. are not indicated in this procedure. With reference to dwg. 0408TXMA*E530, install the junction boxes EA, EB, TA, TB listed by 252W825E01 according to dwg. 252H824. Junction boxes LA, LB for instruments located on the oil tank and power terminal boxes for the lube oil purifier, the vacuum breaker valve and the turning gear electrical motor have been shipped already installed and pre wired on each of the above said components. Install the instruments panels listed by 248W300E01 according to dwg. 0408TXMA*M544. Assemble on each pedestal the brackets for the differential expansion probes dwg. 233K680.

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Install the supervisory instrumention listed by dwg. 253W969 5 according to the referenced arrangements and dwg. 252H824; final setting of the probe will be carried out during commissioning of the T(urbine) S(upervisory) I(nstrumentation) system. Carry out the cabling of the instrumentation and electric devices to the junction boxes according to dwg. 252H824 using materials / components listed by 252W825E01 and per wiring diagrams 0408TXMA*E531.

5 Speed sensors have been already installed: refer to paragraph 3.4

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HEAT INSULATION

Reference documents o

611W323

Test certificates None Prerequisites o

All the activities of the previous paragraphs completed

Procedure Install and assembly the insulation according to reference documents. Attention ! The man holes for access to the balancing provisions of the HP and IP outer casings, are required to be insulated with removable covers to allow access to the balance provisions of the rotors.

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TEST CERTIFICATE LIST

NUMBER: 262W274_T1/T2 262W275_T1/T2 262W285_T1/T2 262W286_T1/T2 602W469_0408T1/T2 602W473_0408T1/T2 602W652_0408T1/T2 602W654_0408T1/T2 605W429_0408T1/T2 605W430_0408T1/T2 605W644_0408T1/T2 605W732_0408T1/T2 605W733_0408T1/T2 605W734_0408T1/T2 605W735_0408T1/T2 605W736_0408T1/T2 605W737_0408T1/T2 605W738_0408T1/T2 605W739_0408T1/T2 605W912_0408T1/T2 606W210_0408T1/T2 606W211_0408T1/T2 606W282_0408T1/T2 606W386_0408T1/T2 606W391_0408T1/T2 606W530_0408T1/T2 606W630_0408T1/T2 606W749_0408T1/T2 608W537_0408T1/T2 612W333_0408T1/T2 612W458_0408T1/T2 612W460_0408T1/T2 612W757_0408T1/T2 613W745_0408T1/T2 615W172_0408T1/T2 615W212_0408T1/T2

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DESCRIPTION Rotating and stationary blades clearances Rotating and stationary blades clearances Rotating and stationary blades clearances Rotating and stationary blades clearances Check of rotor in IP uoter casing Temperature sensor check of position in turbine Position of LP inner casing relative to rotor LP inner casing checking the bolt prestress Thrust Journal bearing Pocket type journal bearing Main oil pump and overspeed device Foundation splines,bearing supports Bearing pedestal Hold –down bar Vertical keyway bearing pedestal /outer casing Clearances of outer casings at pedestals Clearances of oil shields RT Rotor position in bearing pedestal Foundation bolt tightening Support of – LP – outer casing Warping test connection of lp turbine /condendenser. IP steam duct checking the bolt prestress Swing arm support Test of the turning gear speed sensor Expansion sleeves coupling Check of rotor in HP outer casing LP Gland seal HP steam duct checking the bolt prestress Foundation leveling points Position of LP inner casing relative to outer casing Coupling actuator – valve -stroke Check support lifting and inclination Moving test of low pressure internal casing (ABB type LP / Gen coupling Fondation slab position check Casing position to pedestal Check of connection between LP gland seals and supports

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APPENDIX A Nomenclature and terms Turbine centreline: is the rotation axis of the steam turbine and generator. Reference point: is a point of the turbine centreline, indicated on the Steam Turbine Mechanical Outline dwg. . Typically the reference point is the point of intersection of the turbine centreline and of the condenser centreline Turbine floor: is the top surface of the foundation table. The turbine centreline is located at a height over the turbine floor indicated on the Steam Turbine Mechanical Outline dwg.. Longitudinal axis: is any axis parallel to the turbine centreline Longitudinal direction: is a direction according the longitudinal axis Transversal axis: is any axis perpendicular to the longitudinal axis in a plane parallel to the turbine floor Transversal direction: is a direction according to the transversal axis Condenser centreline: is a transversal axis, laying in the horizontal plane, perpendicular to the turbine centreline indicating the midspan of the condenser. Right side: as right side, it is always intended the right side looking from the steam turbine (pedestal n. 1) towards the generator along the turbine centreline Left side: as left side, it is always intended the left side looking from the steam turbine (pedestal n. 1) towards the generator along the turbine centreline Turbine side (shortly indicated as TE): it is always intended, for each turbine section, with reference to the transversal direction, the side towards pedestal n. 1 of the steam turbine Generator side (shortly indicated as GE): it is always intended, for each turbine section, with reference to the transversal direction, the side towards the generator To centre longitudinally: means to give the correct position to a component or part in the longitudinal direction with reference to the transversal direction. In order to centre longitudinally a component or part, it will be moved along the longitudinal axis. To centre transversally: means to give the correct position to a component or part in the transversal direction with reference to the right and left sides. In order to centre transversally a component or part, it will be moved along the transversal direction, typically to make equal the right and left dimensions or distances from the longitudinal axis.

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To centre vertically: means to give the correct position to a component or part in the vertical direction. In order to centre vertically a component or part it will be moved along the vertical direction. General notes 1 – Prerequisites It is intended, for each activity, that clearance of any Non Conformance Reports regarding the activities that are included in the prerequisites is mandatory in order to start the activity and therefore it must be considered a prerequisite for any activity, even if it is normally not indicated in the prerequisites 2 – Welding procedures For the activities requiring welds, the welding procedure(s) is (are) indicated separately in a dedicated section of the paragraph Where specific welding procedures are required, they are indicated for each paragraph / activity. For the other welds reference is made to the relevant dwg., where the characteristics of the weld, the preparation and the required quality level are indicated, and to instruction 201W245. The above said instruction also indicates the ND testing method, the ND testing instruction and the defect acceptance criteria (201W939) to be used. It is intended that the ND testing instruction and the defect acceptance criteria instruction are to be applied even if they are usually not mentioned 3. – Special tools For the activities requiring special tools, the required special tools are indicated separately in a dedicated section of the paragraph 4. – Test certificates Test certificates for each activity where a specific test certificates is required to be filled in are indicated separately in a dedicated section of the paragraph. When a Test certificate is used as reference because it indicates some requirement or information necessary to carry out the activity or part of the activity, it is mentioned only in the section of the paragraph regarding the procedure 5 - Bolt tightening torques The required bolt tightening torques are indicated on the test certificates relevant to the flange / bolts as tightening torques or, where a tightening device has to be used, as required hydraulic pressure of the tightening tool. . If a specific bolt or screw tightening torque is not indicated, it is intended that the bolts are to be tightened according to 602W454.