Capital Overhaul and STG erection

TOSHIBA JSW AND TOSHIBA GLOBAL FOOTPRINTS FOR SERVICES

Overhaul Management

MAINTENANCE SERVICES FOR STEAM TURBINE

• Open, Clean, Close Services (Overhauling)
• Repair
• Replace Parts
• Parts Supply
• Engineering Services

OPEN, CLEAN, CLOSE SERVICES (OVERHAUL)

• Overhaul Planning
• Site Visit for Preparation (3 - 6 months ahead of overhaul)
• Mobilization of needful (T/A, Manpower, Tools, Instruments, Consumables, etc.)
• Disassembly
• Cleaning
• Inspection (VT / DT / NDE)
• Repair (*If necessary)
• Replace Parts (*If necessary)
• Re-assembly
• Re-commissioning
• Report Presentation

Repair / Replacement is decided based on inspection results and standardized criteria derived from the abundant field experiences and extensive knowledge of turbine design.

Repair

• Weld Repair of LP Inner Casing Horizontal Joint Surface (Erosion) (at site)
• Weld Repair of Gland Packing Casing Horizontal Joint Surface (Erosion) (at site)
• Weld Repair of Eroded Nozzle Partitions (at site)
• Machining of Dishing of Nozzle Diaphragm (at Chennai factory)
• Re-Babbiting of Damaged Bearing Metal (at Chennai factory)
• Machining of Damaged Rotor Journal (at site)
• Dressing of Damaged Blade (at site)
• Rotor Balancing (Low/High speed balancing) (Low speed balancing at site, high speed balancing at Chennai factory)
• Crack repair of HP turbine casing (at Chennai factory)

PARTS SUPPLY - CONCEPT OF CHENNAI FACTORY

Toshiba JSW Chennai factory has full-scale manufacturing of all parts and components of Turbines and Generators, completely manufactured in-house.

Parts Supply

• Blades (O-OEM design / Toshiba design)
• Diaphragms ( for O-OEM design / Toshiba design)
• Gasket / Packing
• Miscellaneous small parts (lock plate/bolt/nut /pin/shim/key, etc.)
• Tip fins
• Seal ring
• Casing stud / nut
• Bearing
• Packing ring (O-OEM design / Toshiba design)
• Others

Maintenance services of Generators

i. Overhauling of Generator

• De-coupling of LP - Gen
• Hydrogen Purge out and stator cooling water draining
• Leak test of Generator frame
• Leak test of coil (In-leak test, pressure and Vacuum decay test
• Hydrogen cooler removal and inspection
• Rotor Thread-out
• Inspection and Testing of stator, Rotor and other components
• Repair / Replacement of parts as desired
• Rotor thread in and re-assembly
• Lube oil, Seal oil system normalisation
• Generator frame leak test
• Stator cooling water system normalisation

ii. Rotor Maintenance / Modernization Services

• Complete rewinds-new or refurbished copper winding
• Retaining ring machining and replacement
• Winding and insulation inspection and repairs
• Main leads inspection, repairs and replacement
• Diagnostic inspection and evaluation
• Collector ring repairs and replacement
• Hydrogen seal repairs and replacement
• Bearing journal machining and repairs
• Cooling fan and other parts manufacturing
• Robotic inspection of the Generator Rotor without rotor thread out (by TESS)

iii. Stator Maintenance / Modernization Services

• Complete rewinds, including core restacking, if required
• Winding and insulation inspection and repairs
• Core inspection, repairs and tightening
• Frame and mechanical inspection and repairs
• Re-wedging
• End winding repairs and upgrades

iv. Rotor Testing & Inspection Services

• Electrical testing:
  • Insulation resistance and polarization index
  • DC resistance
  • AC impedance and pole-to-pole voltage drop testing
  • Pole Balance Test
  • RSO - Repetitive Surge Oscilloscope testing
• Collector lead stud seal leak testing
• Beneath retaining ring visual inspection with video-scope
• Retaining ring inspection and testing (rings on or rings off)
• Visual inspection and assessment
• Bearing journal and collector ring dimensional checks

v. Maintenance services of Generator - Solutions for Generator problems

• Stator
  • End winding vibration
  • Core melt
  • Stator winding water leak
  • Stator winding plugging
• Rotor
  • Inter turn short
  • Rotor coil overheating
  • Copper dusting
  • Cracking of pole to pole connector and main lead
  • Shaft crack of retaining ring shrink fit portion
  • SCC of coil retaining ring
  • Rotor vibration
  • Slot dovetail crack
  • Fan Blades / Bolts crack

MAINTENANCE SERVICES OF STEAM VALVES (MSV, CV, CRV, OLV)

Valve Repair & Upgrade Programs

• Complete de-scaling by pneumatic honing & NDE of valve components
• Reverse engineering & manufacture of replacement parts
• Re-establishment of appropriate clearances and restoration of internal alignment
• Engineering evaluation of valve condition and repair
• On-site valve seat replacement
• Sleeve repair
• New valve chests to replace those beyond repair
• Stellite overlay via Plasma Transfer Arc (PTA) welding

MAINTENANCE SERVICES FOR VALVE ACTUATOR HYDRAULIC CYLINDERS

Overhauling of Hydraulic cylinders

• Disassembly and inspection of the internals
• Replacement of the damaged parts
• Assembly with desired assembly CTQs
• Spare part supply by Toshiba

MAINTENANCE SERVICES FOR QCNRVS

Overhauling of QCNRVs

• Disassembly and inspection of the internals
• NDT and contact checks
• Assembly with desired assembly CTQs

MAINTENANCE SERVICES FOR BFP DRIVE TURBINE AND STEAM VALVES

Open, Clean, Close Services (Overhaul)

• Overhauling of BFP drive Turbine
  • Opening of the Turbine
  • Cleaning, inspection and NDT of the Turbine components
  • Re-assembly maintaining the assembly CTQs
• Overhauling of BFP Turbine valves:
  • Disassembly, inspection & overhauling of HP & LP stop valves, HP & LP control valves and re-assembly of all the valves.

MAINTENANCE SERVICES FOR BFP AND BP

Overhauling of BFP and BP

• Threading-out of the pump cartridge assembly, stage wise disassembly of the impellers.
• Inspection of all internal components.
• Checking of clearances.
• Re-assembly of all internals, rotary components stage wise with correct clearances.
• Threading-in of repaired cartridge.
• Centering check and setting of radial gaps & axial floats of the cartridge assembly etc.
• Reassembly of seals, bearings, oil pipe lines & other connected lines.

MAINTENANCE SERVICES FOR REDUCTION GEAR AND HYD COUPLING

Overhauling of Reduction Gear

• Disassembly of the gear box. Cleaning, checking of gears. Performing contact checks, backlash check etc. of gear teeth
• Re-assembly of the gear box.
• Alignment of R/G with Turbine & Booster pump
• Overhauling of Hyd coupling
• Dismantling of Hyd coupling
• Cleaning, inspection and re-assembly of the Hyd coupling

AVR & DCS

AVR and DCS services

• Upgradation of the AVR
• Trouble shooting

TOSHIBA JSW SERVICES CAPABILITY

Spare parts supply

• Supply of the spares of Turbine, Generator and steam valves for all the Indian projects for which all the drawings are available with Toshiba JSW under technology transfer commitment.
• For non-Indian projects, Toshiba JSW can supply the spares with the support of Toshiba Energy Systems & Solutions Corporation (TESS) and technology transfer.
• O-OEM spares supply is through reverse engineering and validation by TESS.
• Material equivalent support from TESS in case the materials are not available with Toshiba JSW, applicable both for OEM old machines and O-OEM machines.
• Repair specification / drawings from TESS in case of repair of the parts.

STG Parts Manufacturing & Spare Parts Supply from Toshiba JSW Chennai

Supply of components at competitive price with Japanese Quality for Customers

• Toshiba JSW has complete capabilities to supply self-manufactured or outsourced items as per customer’s needs.
• Efforts are made to procure raw materials locally from Toshiba-approved suppliers.

Parts for STG

• Blades
• Nozzle Diaphragm & Spare parts
• Casings & accessories
• Rotors & accessories
• Control devices & accessories
• Generator & accessories

OOEM Spare parts

OOEM spares supplied by Toshiba JSW

Parts supplied

• Fasteners for Turbine Nozzle
• HP,IP,TG Inlet flange bolts
• IP STG 1 to 5 NOZ DPH
• IP Inlet flange bolts
• Parting plane bolts
• Throttle Valve Assembly
• ST Bolts & Nuts
• Supply of Fan Guard
• Replacement of Brush gear assembly
• High Speed Balancing of LP rotor
• ST Rotor refurbishment & HSB
• Repair of 500 MW LP Rotor
• Repair and HSB of 500 MW LP Rotor
• Repair of 150 MW ST Rotor
• IP STG 1 to 5 NOZ DPH

TA (TECHNICAL ADVISOR) SERVICES

With abundant experience in TG erection and overhauling, Toshiba JSW has developed the TA in the following areas and supporting the global companies

• Turbine disassembly and assembly
• Major steam valves disassembly and assembly
• Generator disassembly and assembly
• Measurement
• AVR
• DCS
• TSI
• Turbine start up
• Generator leak test and start up
• Generator rotor coil inspection
• Generator stator coil inspection

Toshiba JSW offers the following services

• Generator in-situ re-winding
• Generator electrical testing
  • All the testing equipment can be shipped to site
• Generator epoxy injection
• Low speed balancing of TG rotors
  • In-house Portable machine packed in a container can be shipped to site.
  • Expert balancing team
• Reaming and Honing of the coupling holes in case of rotor replacement
  • In-house Reaming machine can be dispatched to site
  • Experienced specialist
• Steam valves fine mesh removal
• Honing of the Steam valve bushes to maintain the desired clearance
  • Honing machine with the experienced specialist can be dispatched to site

ENGINEERING SERVICES (SUPPORTED BY TESS JAPAN)

• Steam path audit
• Risk Based Assessment of Steam Turbine
• Condition assessment
• Reverse Engineering
• Life assessment
• Field balancing
• Trouble shooting
• Recommendation of repair / replace parts
• Provision of spare parts list for maintenance and overhaul
• Reverse Engineering for spares supply
• TESS has services for manufacturing and supplying of parts by 3D scanning measurement.
• Residual Life Assessment

SUMMARY OF TOSHIBA JSW ELECTRICAL CAPABILITIES

• Design, Engineering, Testing, Supply, Erection and Commissioning for Generator Stator Cooling Water System (SCWU), Seal Oil System (SOU), AVR, GACP, Excitation Transformer, Auto Synch and Generator & Transformer Protection System.
• Supplied and Commissioned SOU, SCWU, AVR/GACP and Excitation Transformer for 4 projects of 660 MW and 800 MW capacity in India.
• Supplied and Commissioned Generator & Transformer Protection panels for Anpara U#5 (500 MW) and Harduaganj (660 MW) in India.
• Troubleshooting and System Upgradation (for R&M job). Currently executing an R&M order for replacement of Generator & Transformer Protection Panel of NN2HP Hydro Project in Laos.

ADVANTAGE OF Toshiba JSW

• Global offices hold a good chance to win the bid due to competitive cost of SOU, SCWU, AVR/GCP, Excitation Tx and Tx protection system from India.
• Toshiba JSW complies to quality standards of TESS for all its products and services.