1 Report on 500 MW Generator Stator Unloading , lifting and placement in TG Floor foundation at NTPC Kahalgaon - Stage-II for Unit # 5 & 6 ( 3 X 500 MW ) Team members : Shri P.K.Das , Sr.DGM (Team Leader ) Shri M.K.Majilya ,DGM Shri S.K.Mondal ,Manager Shri R.K.Srivastava,Chargeman Under the guidance of Shri D.Guha ,AGM,BHEL,Kahalgaon Site Report prepared and compiled by : M.K.Majilya BHEL:PSER:Kahalgaon Site Design & Execution by : M/s Fagioli PSC,Mumbai Review Consultant : M/s DCL,Kolkata Customer : NTPC
Transcript
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Report on 500 MW Generator Stator Unloading , lifting and placement in TG Floor foundation at NTPC Kahalgaon - Stage-II for Unit # 5 & 6 ( 3 X 500 MW )
Team members : Shri P.K.Das , Sr.DGM (Team Leader ) Shri M.K.Majilya ,DGM Shri S.K.Mondal ,Manager Shri R.K.Srivastava,Chargeman Under the guidance of Shri D.Guha ,AGM,BHEL,Kahalgaon Site Report prepared and compiled by : M.K.Majilya BHEL:PSER:Kahalgaon Site Design & Execution by : M/s Fagioli PSC,Mumbai Review Consultant : M/s DCL,Kolkata Customer : NTPC
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Brief History
As a standard practice followed earlier by BHEL-Power Sector Regions , the operation of
unloading , lifting and placement on TG Foundation for 500 MW Generator Stator
weighing around 265 MT for Thermal Power Stations used to be done with the help of
Portal Crane arrangement. At present 2 such Portal Crane sets are available with BHEL for
above type of jobs.
In case of Kahalgaon Stage –II ( 3 X 500 MW ) , Portal crane was not available as the both
the sets were pre-occupied for the projects under execution by PSSR & PSWR.
To come out with a solution ,BHEL/ PSER/Kahalgaon Site started exploring alternative
feasibility in lieu of Portal Crane for doing stator unloading , lifting from zero meter and
placement on TG Floor foundation at 17.00 meter elevation.
The idea of using strand jack method was thought as an alternative as Boiler Drum lifting
was done for Kahalgaon Unit #5 , 6 & 7 ( 3 X 500 MW ) by this method. The concerned
agencies M/s Fagioli PSC and M/s Freight Wings who have executed the job for 500 MW
Boiler Drum Lifting weighing around 244 MT at an elevation of around 78.00 meters
elevations were shown the details of the job. Both the parties have shown keen interest and
presentations were made by both the parties to NTPC and BHEL.
It was briefed to the interested executing agencies that they will be using existing 2
foundation footings outside TG Hall A Row adjacent to the rail line for transportation of
Generator Stator at zero meter and 2 foundation footings on TG Deck at 17.00 meter
elevation.
With the idea of existing Portal Crane system for Generator Stator Handling of 500 MW
Sets and Boiler drum lifting at NTPC Kahalgaon Unit # 5,6 & 7 ( 3 X 500 MW ) by strand
jack method , basic information for preparation of technical specifications was prepared by
BHEL, Kahalgaon Site.
In the beginning, certain design aspects were appearing as hindrances , as NTPC raised
doubt that certain loading and bending moment components by Strand Jack methods were
crossing design limit on the piles and rafts on the top of piles.
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The matter was referred to many corners of BHEL/Manufacturing Units , but no concrete
solutions came out. The matter was internally taken up by our Construction Manager Shri
D. Guha/AGM with BHEL/Trichy Boiler Engg. Group informally as they do design of the
Boiler Civil design aspects like heavy loading and moments coming on Boiler foundations
etc.
BHEL/Trichy design group after rechecking the available parameters gave us clearance
and they confirmed that the existing civil design of 6 nos. piles with raft can very well take
care of the combined load of Generator stator Handling Structure and Generator Stator.
This gave us confidence for using the Strand Jack Method for doing 500 MW Generator
Stator Handling and lifting. Finally the tender specifications were prepared jointly by
BHEL/Kahalgaon Site , Kolkata /FEX & PMX Department.
Finally the job was awarded to M/s Fagioli PSC,Mumbai.
Tendering went a long drawn process as many clarifications and doubts were raised by the
bidding parties and NTPC.
AA :: Important Features of the Strand Jack System
1. Right from the beginning BHEL:PSER informed all the concerned Units of BHEL to
participate in this job of Generator Stator lifting with strand jack method as this was
an MOU Project of BHEL with Govt.of India.
From BHEL , CPMG, New Delhi ,PS-TS/NOIDA alongwith our PSER Groups have
shown keen interest and they have taken all the pains to interact with NTPC-
Corporate Engg and execution Vendors for getting design clearance .BHEL/Hardwar
from time to time has given vital design information as per the queries raised by both
the vendors , BHEL-PSER , NTPC.
Our special thanks to Shri J.Kar,AGM/Project/NTPC/Kahalgaon who has
personally taken lot of initiatives and he himself was personally present at
NTPC – Engg Office Complex (EOC) / NOIDA during the final design
clearance from NTPC/ Corporate Engg.
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2. In the tender , a condition was included that the executing vendor should get the total
design to be vetted by a reputed 3rd party design consultant .This had to be done
because as per Contract condition of NTPC, BHEL was supposed to do Generator
Stator lifting by Portal Crane and that is why NTPC wanted that this type of job
being a new one for the first time being executed by BHEL , total design needs to be
vetted by a reputed 3rd party consultant.
As a result , the Executing agency M/s Fagioli engaged M/s DCL,Kolkata as design
consultant. Final concurrence was given by both M/s DCL and customer NTPC after
studying the detailed calculations and series of meetings had to be conducted for
clarification and approval.
3. Major components which were fabricated in Mumbai by M/s Fagioli were tested in
presence of our BHEL/Kolkata/FEX representative before arranging dispatch
clearance.
4. Major items dispatched were brought from different parts of India and abroad .The
details of the consignments received are as per following details.
3 Tower, Base beams, Tie Down beams,L300 Jack, MK4 Jack etc. Indian Lotus/ Achiver Road
4 Tower legs, Ladder set, Bracings, Ladder Platform, Stabbing Guides etc. Material lying At Anjar Site (Gujarat)
5 1 Office container + 1 bundle imported strands 1 bundle imported strands Material lying ready at Cochin
6 Swivel System U.K Airport to Kolkata Airport
5. While doing calculations on the TG Hall outside Column Foundation , M/s
Fagioli expressed difficulties as they opined that, the proposed 2 foundation
footings on the top of civil raft outside TG Hall can not take care of Generator
Stator and strand jack structural load and bending moments . Rather they
suggested that , they require 4 column types of strand jack system structure.
Accordingly they came out with a proposal of 4 nos. of foundation footings so that
they can go ahead with 4 columns structure instead of 2 foundation footings on
the top of raft. This called for major design changes on top of raft tops of the civil
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foundation. No change was done on the construction of sizes of 6 nos. piles and
raft. The proposed design conditions were reviewed by both NTPC and Design
Consultant M/s DCL and both the agencies confirmed that the existing raft can
accommodate 4 nos. of foundation footings with all the loads and moments
coming on to the foundation within design limits. NTPC was convinced and
arranged 4 no. foundation footings instead of the earlier designed 2 no.
foundation footings
BB :: Constructional features of Strand Jack System
The outside structure TG Hall has a feature of 4 columns of Tubular structure type (
Pipe size 457 mm OD X 16.00 mm thk ) with provision of flanges , attachments
,arrangement for bolting and other lugs to accommodate bracings and their
fasteners in between for assembly of modular types of structures of different
lengths to suit transportation and ease of assembly at site.
The outside columns structure contains the following –
• Base plates assembly with shear lugs on all 4 foundations. The bottom portion
is square in construction and the top is of circular type. The height of stool is
400 mm. The plates are grouted with foundation. Foundation bolts size was
M36 X 1000 mm length with materials grade of 10.9 class. The weight of
these 4 plates and foundation bolts are 1.20 MT(approx.).
• On the top of it , 1st piece of modular structure of 12.00 meter length is
assembled with bracings with the help of both 100 MT Crane and 25 MT
Crane .The fasteners are of pin type with locking pins. The assembled weight
of this piece is 22 MT.
• On the top of the 1st piece , 2nd piece of modular structure of 4.0 meter length
is assembled with bracings with similar types of pin type fasteners and
locking pins. The assembled weight of this piece is 8.0 MT.
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• On the top of 2nd piece , 3rd piece of modular structure of 4.0 meter length
similar to the 2nd piece is assembled with bracings with similar types of pin
type fasteners and locking pins. The assembled weight of this item is 8.0 MT.
• On the top of it , 4th piece of modular structure of 2.0 meter length similar to
the 3rd piece is assembled with bracings with similar types of pin type
fasteners and locking pins. On the top of this 4th piece , a box type fabricated
assembly with beams is done .The combined weight of this 2 meter long
modular assembly and fabricated structure is 8.0 MT.
The assembly is shown in Annexure -1.
Over this piece , the girders are placed with one end at the top of outside
structure and other end at the top of inside 2 column structure on TG deck.
• On the top of TG Deck , 2 base plates of 20 mm thick MS Plates of approx.
500 x 500 mm size with shear lugs of 200 mm size below it is installed. The 2
columns structures are assembled on the top of the base plates and bolted with
base plates. There are 2 types of bracings in the 2 column structures.
First type is of diagonal bracings in 2 Column structures and assembled in 2
tiers.
Additionally 2 more diagonal beams with the Aux.Coulmns of TG Hall
towards B-Row in TG Hall to restrict movement of Generator during the
dragging process of Generator Stator.
On the top of it one fabricated box made out of beams is mounted on this
structure with the help of bolts. Secondary Grouting is done on the TG Deck
portion below base plates and similarly grouting was done below the 4
columns foundation footings outside TG Hall. This grouting was done by
BHEL. The combined weight of this structure is 8.0 MT. The assembly
details are shown in Annexure-2.
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• On the top of the outside Column structures outside TG Hall and inside TG
hall 2 girders are installed. The weight of individual girders are 36 MT. CR-
100 Rails are installed on the top of these girders for movement of trolleys.
• Each Girder is 34.700 meter long and dispatched in 2 pieces . Total no.of
girder pieces received are 4.The girders are of I-Section of built up beams 2.00
meter height and are assembled at site with splice plates assembled at the
flanges and webs with bolts. Around 1600 nos. of bolts are required and these
are tightened with electrically operated torque wrenches.
• The girders are assembled inside TG Hall alongside of TG axis and lifted on
the top of fabricated structures outside TG Hall and inside TG Hall with the
help of TG Hall EOT Crane main hook. The girders are rotated slowly and
taken outside for the portion projected outside TG Hall.
• The total assembly of the Strand Jack System structure is explained in
drawing no.HL1/F/004 of M/s Fagioli which was submitted to us after
approval of M/s DCL and NTPC. Railings and walkways are assembled
on the top of girders for working at height. The assembly details are shown in
Annexure-3.
• The moving trolley is mounted on top the Railline of the girders for moving
from outside TG Hall upto the CG of TG Central Line. The moving trolley
with the arrangement of L-300 Jacks are installed on the top of girders from
outside TG Hall with the help of 100 MT Mobile which is parked outside TG
Hall near A Row. The weight is around 8.0 MT.
Trolley can not be erected from inside TG Hall as the height available over the
top of the girders and highest position of the main hook of the EOT Crane
This is explained in Annexure - 4.
• Swiveling beam is assembled in the A-row of TG Hall and strands of 18 mm
dia and 29 meters long are inserted from the bottom of the swiveling beam
and pulled with chain pulley blocks from the moving pulley top .These strands
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are passed through the moving trolley jacks strand holders. A strand guide is
made at the top of the moving trolley. This is explained in Annexure - 5.
CC :: Activities involved in the process
(i) Unloading of Generator Stator from the Generator Special Wagon on Aux.
Pedestals with the help of Hydraulic Jacks (Pictorial view is as per Annexure-6) .
(ii) Removal of the Load carrying beam from inside Generator Stator and taking it
out completely from the Generator Stator (Pictorial view is as per Annexure - 7).
(iii) Lifting of Generator stator from Aux. Pedestals with the help of Strand Jack
method (Pictorial view is as per Annexure - 8).
(iv) Rotation of the Generator Stator to suit insertion of the stator inside A Row as the
position of the Stator on the Rail track is 500 mm offset.
For Unit # 5 , the rotation was done after crossing TG Floor elevation as the
operating floors at 17.00 meter was ready (Pictorial view is as per Annexure - 9).
In case of Unit # 6 , the rotation was done at zero meter as there was no operating
floor either at 8.5 meters and 17.0 meters elevation at TG Building towards A-Row
adjacent to TG Deck (Pictorial view is as per Annexure - 10).
(v) The dragging operation is started with the help of 2 nos. hydraulically operated
jacks of 15 MT Capacity each towards B-row from A-row. Further to readjust the
movement of generator stator from other side is done with the help of 2 manually
operated Maxpullers of Capacity 5.0 MT each and to give breaking action in case
of emergency. Although , requirement of Maxpullers was not required ( Pictorial
view is as per Annexure- 11)
This is an unique feature which is not required during boiler drum lifting.
(vi) Once the above rotation is complete , the Stator is further rotated to make parallel
to TG Axis and slowly it is made almost in line with TG Axis with the help of
swiveling beam assembly (Pictorial view is as per Annexure - 12).
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(vii) Placement of Generator Stator on TG Hall foundation (Pictorial view is as per
Annexure - 13).
(viii) Joining of the 2 parts of Special wagons of Generator for dispatching of the
Generator Special wagon for arranging departure to BHEL/Hardwar (Pictorial
view is as per Annexure - 14).
DD :: Chronological events of Unit # 5 & 6
Duration Sl.No. Description of the activity
Unit # 5 Unit # 6
01 Arrival of Generator Stator at Site 15.04.2006 29.04.2006
02 First time No Load Run of Engine on rail track 22.04.2006 Not required
03 Generator Stator placed on rail-track 26.04.2006 17.06.2006
04 Stator unloading on Aux. Pedestals 04.05.2006 26.06.2006
05 Strand jack system dismantling from
Unit # 5 for installation in Unit # 6
Not applicable 11 to 16.06.2006
06 Strand jack system assembly and
erection
04.05.2006 to
09.06.2006
17 to 24.06.2006
07 Stator lifting and placement on TG Fdn. 10.06.2006 27.06.2006
EE :: Generator Stator Package details : Pkg No. 501 of BHEL/Hardwar .
Net weight-265 MT, Gr. Wt.- 275 MT, Size – 8830 x 4100 x 4120 mm.
Pkg .No. 580 becomes redundant with Strand Jack method.
Generator Transportation
Generator stators are transported from Hardwar to Kahalgaon site on a special wagon either by
Kailash-I or II which have been designed by M/s. RDSO. The wagon consists of 24 axles i.e. 8
bogies (4 on each side) of 3 axles each with facility by a carrier beam and the beam is pivoted to
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the bogies. Pictorial view is enclosed in Annexure-2. Necessary Railway clearances were
obtained by BHEL/PSER in consultation with BHE/ROD Kolkata Office.
FF :: Job description
The scope of the vendor was
(i) Supervision of Unloading of Generator and arranging all necessary logistics
and this includes design of the required fixtures and accessories ,
(ii) Design , Supply , Erection of Strand Jack System for lifting of Generartor
Stator from Rail line alongside A-row and placement on TG Floor foundation.
GG :: Major T&P arranged by BHEL
• EOT Crane in TG Hall.
• 8/10/12 MT Hydra for Transportation and erection of materials.
• 18/25 MT Mobile Crane for pre-assembly of modular column structures and assembly .
• 20 MT Truck for transportation of materials inside plant premises. Majority of the big
consignments were unloaded at site.
• 100 MT Mobile Crane with boom length of 70 meters for Pre-assembly and erection of
Strand Jack System Outside TG Hall alongside A-Row.
HH :: Methodology adopted by M/S Fagioli is briefly explained below.
1.0 DESIGN CRITERIA
The engineering for installation operations were developed considering the following
criteria:
The structural calculation is carried with the reference to Indian Standard I.S. Code
800 and British Code for Steel Design (BS 5950-2000).
For structural check of each single component is used a Dynamic Amplification
Factor DAF = 1.05.
The load transfer between upper and lower anchor blocks can give rise to a small
amount of load bounce resulting in a effective additional load of up to 5% of the
lifted load. For this reason a factor of 1.05 on load was considered.
Horizontal load F = 3 % of the maximum vertical load was considered for the tower
and for the columns. In this load the effect of wind load was also included
(considering wind velocity of 16 m/s) and any other effect due to the motion of
the generator during the operation.
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2.0 EQUIPMENT USED BY M/S FAGIOLI PSC The main equipment used are as follows:
1 no. L300 strand jack with Standard Fagioli PSC Strand dia. 18 mm of 29 meters
length ( total 19 nos. strands were used).
1 no. Power Pack with total hydraulic systems of high pressure armoured hoses with
needle valves was designed to suit the load condition for connecting to different points
as per load requirement.
1 number L300 fixed anchor swivel
1 Trolley with 4 Nos. Skate Rollers (50 t capacity and part of the moving trolley)
2 Hydraulic Pullers of 15MT Capacity each to drag the Generator from A row side to
B-row Side and 2 Mechanical Max pullers of 5.0 MT Capacity to move the Generator
towards A-row from B-row.
Each and every Equipment was subjected to periodic inspections, moreover prior to
commencement of the operation the equipment was checked according to the daily
inspection checking list.
Standard rigging hardware (as slings, grommets, shackles etc.) were selected to work within
the manufacturer’s Safe Working Load and were subsequently provided with Manufacturer
Test /Fitness Certificates and were inspected before the use.
3.0 OPERATIONS Before starting the operation, the following checks were carried out under the supervision of
BHEL and M/s Fagioli Design Engineer and Lifting Engineer.
3.0.1 Checking before Unloading of the Stator & equipment used • Unloading Area in and around Railway Track is clear from the other working contractors.
Unloading Area is checked for lateral / overhead obstructions, over head power lines,
distance. Transverse centre line of TG stator should be transferred onto Rail track and
marked and it is ensured that the Centre Line of Strand Jack system when transferred
onto the rail track, coincides with the above said transverse centre line.
• The weight of TG Stator was considered as 275 T & the CG of the Stator was taken as same as the centre line of the stator bore as per confirmation of BHEL/Hardwar/TGE.
• Installation of the Auxiliary and the Bottom Pedestal alongside the generator unloading foundation area.
• Installation of 4 Point Lift System’s 480T (Total Capacity ) Hydraulic Jacks of Enerpac make ( 4 nos.Jacks Capacity 120T each) with its accessories alongside the Generator Stator for unloading of Generator Stator on Auxiliary Pedestals.
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• The packer sizes were 20 mm thk – 6 nos. on 4 Aux. pedestals of sizes 750x150 mm. 30 mm thk – 18 nos. on each pedestals of size 150 x 100 mm 10 mm thk – 18 nos. on each pedestals of size 150 x 100 mm and other sizes plus condenser packer plates as per requirement.
3.0.2 :: UNLOADING OF GENERATOR STATOR FROM SPL WAGON & POSITIONING ON AUX. PEDESTALS AND PACKERS.
• The Stator comes in hanging condition over the Carrier Beam, Which passes through the inside void portion of the Stator and remains supported from the temporary end shield bearings of Stator at both ends, while the Beam ends are mounted on the top of the two end segments of the special carrier wagon and the whole unit is pulled by Railway engine.
• Once the 500 MW Generator Stator weighing 275MT is received at site, the same is brought on to the Railway track alongside the TG Building A-row.
• Stator is to be lifted by around 300 mm. with 4 no Jacks of 120 MT Capacity each.
Saddles/Trunnions available on the sides of the Stator Body are used for this purpose . One Motor operated Hydraulic operated high pressure pumping unit for controlling movement of all 4 above jacks is used for unloading of Stator on Aux. Pedestals and packers. Slowly the load is released from the temporary end-shield bearings so that the carrier beam becomes free and rests only at the ends on the top of wagon segments. During this time , the total load of the Stator and Carrier beam i.e. 275 + 90 = 365 T is to be handled by the lifting arrangement, and the Jacks are to be of that capacity.
• One Fabricated moving Trolley structurally suitable to bear the self load of about 100T of the carrier beam with a hydraulic Telescopic jack of at least 150 T capacity( Since the weight of carrier beam is approximately 90 MT) is placed between the stator and Powered end of the wagon. This temporary support is required to take the load of carrier beam when it comes out of stator, so that free end of the beam does not strike and damage the stator core.
• The trailing end of the beam is made free from the wagon and the carrier beam is pulled out of the stator with the help of the powered wagon very slowly. The operation continues till the beam comes out fully from inside the stator.
• Stator is to be rested on Jacks and Pedestals for about 24 hours with minimum ground clearance of 500mm at the stator bottom to facilitate blue matching of the bottom terminal box and re-threading and re-tapping for final placement.
3.0.3 GENERATOR STATOR LIFTING AND PLACEMENT ON TG FOUNDATION
□ The four Slings at the ends of the swivel beam are properly tied with the Lifting Lugs of
the Generator.
□ The strands of the Strand Jacks are tightened by operating the power pack of the strand
jack.
□ Verticality of lifting wires is continuously maintained during the lifting at +/- 1°.
□ The strands are slowly raised to lift the stator from the supports so that there is a clear
gap of about 100mm between the carrier / supports and the stator and the total load is
transferred on the 4 nos. slings.
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□ Overall vertical dimension of the system is checked that , these are within the tolerance
limit as the access over T.G. deck is very narrow.
□ The transverse centre line of the Stator is marked at its location on the TG deck.
□ Proper checking & ensuring of the longitudinal centre line is marked on the Stator body.
This is done just to facilitate matching with the Centre line of the skid Trolley.
□ In the next step , pulling is done with the Trolley/Strand Jacks together with the
Generator, along the skid tracks by using the L15 MT capacity pulling jacks, restrained at
the end of the skidding beam.
□ The Rotation of the generator is done with the help of Slings and the shackles connected
to the lifting beam assembly or on the generator body at the ground. This is done
manually. The Stator is rotated to the required angle. Once the generator is rotated it is
pulled with the help of strand jack until it clear the Column along grid line A.
□ On completion of the above activities , the Generator is made parallel to column line A
after it clears the Column A/6.
□ The Generator stator is further pulled and lifted with the help of the strands using the
strand jack up to an elevation of 17m (bottom of generator stator). The generator should
be lifted to a clearance of 500mm above the TG Deck top.
□ The Two main Skid Beams over which the Stator lifting trolley is going to skid has to be
properly braced together for stability.
□ At the time of skidding care should be taken that only four brace between the two skid
beams is removed while longitudinal movement for access & the same shall be braced
again to the position after the stator is passed. This is important for stability of the main
Skid beams.
□ The above procedure is continued till the stator reaches above the exact foundation on
T.G deck
□ Skiding of the Generator is continued so that it exactly reaches over its foundation.
□ Lowering of the Generator Stator is done on to its foundation and MS packer plates are
inserted underneath Stator body on both sides of the anchor bolt location.
□ The Strands are slowly lowered so that Stator is aligned properly on its foundation.
□ After all the dimensional check the Stator load is released onto the foundation & the
Strands are released.
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JJ :: Comparison between Strand Jack method and Portal Crane.
Sl.No. Description Portal Crane method Strand Jack Method
01. Foundation on
TG Deck
2 Raised foundation of
around 500 mm height with
packer plates and foundation
of 580 Package.
2 base plates of 500 x 500 mm
size with shear lugs and M36
Foundation bolts. The base plate
level is almost on TG Floor.
02. Foundation on
Outside TG Hall
alongside A-row
2 Raised foundation of
around 250 mm height with
packer plates and foundation
of 580 Package.
4 base plates of 500 x 500 mm
size with shear lugs and M36
Foundation bolts. The base plate
level is almost on TG Floor.
03. Package No.580 Used Not required and this leads to savings of around Rs.2.0 lakhs approx. per 500 MW Unit.
04. Erection Time 3 weeks For 1st Unit – 25 days including
11 Strands Not applicable 19 Nos. of 18 mm dia. Of 29.00 meters length
12. Lifting Capacity 365 MT 400 MT
Annexure –1 ( 1) Assembly of Base plates and 1st Set of Stools
4 Nos, Base plates with Shear lugs levelled and grouted
4 Base Stools bolted with base plates
Annexure – I ( 2 ) Outside Structure Assembly
Assembly of 1st Modullar Column set with bracings ( length 12 meters and weight 22 MT)
Base Stools – 4 Nos.
Annexure-1( 3 ) 1st Modular Column is being lifted for erection in position
Annexure-1 ( 4 ) Assembly of Outside TG Hall Structure Assembly
1st Modular Columsassembly 12 mt length
2nd Modular Colums assembly 4.0 mt length
3rd Modular Columsassembly 4.0 mt length
4th Modular Column Assembly of 2.0 mt.length
Fabricated box assembly
Annexure- 2 ( 1 ) Assembly of Inside 2 Column Strcture inside TG Hall
Diagonal bracings in between columns
Annexure – 2 ( 2 ) Diagonal bracings taken from 2 coulmn structure with TG Hall Aux.Columns and beams
Bracings weldded and bolted with columns and strctures for arresting movement of Strand Jack structure towards B-row during Dragging of the Stator from A to B Row.
Annexure – 3 ( 1 ) Girders pieces unloaded in TG Hall for joining with splice plates and bolts and assessment is being done
Annexure – 3 ( 2 ) Girders are joined with splice plates and bolts
Annexure – 3 ( 3) Girders lifting with TG Hall EOT Crane
Walkways , railing are ready
Annexure – 3 ( 4 ) Lifting of Girders .The lifting lugs angles are so set , that minimum clearance between below hook of main hoist of TG Hall EOT Crane is maintained and girders are placed on top of strand jack strucrures (both outside TG Hall & inside TG Hall )
Annexure – 4 ( 1 ) Moving Trolley alongwith Powerpack ready for lifting on Girders top
Annexure – 4 ( 2 ) Moving Trolley being lifted on Girders by 100 MT Mobile Crane from outside TG Hall
Annexure – 4 ( 3 ) Moving trolley on top of the Girders with strand arrangement
Rails are welded on top of the girders and welded at regular intervals
Rollers are fixed below trolley for reducing friction during dragging of Stator
Annexure – 5 ( 1 ) Swivelling beam with strands and lifting slings
Annexure – 5 ( 2 ) Strands Guide coming out from top of the powerpack
Annexure – 6 ( 1) Hydraulic Jacks – 4 nos. of 120 MT Capacity each for Unloading of Generator Stator on Aux. Pedestals
Annexure – 6 ( 2 ) Generator Stator unloaded on Aux.Pedestals with the help of Hyd.jacks
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