FIELD OF INVENTION:
The present invention relates to a reusable steel structure for locating
anchor rods at turbine-generator (TG) deck casting for large size thermal
power plants, or more particularly relates to steel structure which is
capable of holding all the templates firmly at their desired location
during TG deck casting.
Further, the present subject matter also relates to a method of locating of
anchor rods templates by using reusable steel structure.
BACKGROUND OF THE INVENTION:
Steam turbine extracts thermal energy from pressurized steam and uses
it to do mechanical work on a rotating output shaft to drive an electrical
generator for generating electricity.
In a typical larger power stations, the steam turbines are split into three
separate stages, the first stage being the High Pressure (HP), the second
stage the intermediate Pressure (IP) and the third the Low Pressure (LP)
stage where high, intermediate and low describe the pressure of the
steam. The High Pressure (HP) turbine module is the first turbine to
receive steam from the main steam system, while Low Pressure (LP)
turbine module is the last. The turbine in between the HP and LP is an
intermediate Pressure (IP) Turbine module. These turbines are designed
to efficiently extract work out of high pressure of the steam as steam
passes through all the modules and converts thermal energy (high
pressure and high temperature) of working fluid in to mechanical energy
(as shown in Fig. 6).
Anchor bolts are used in all manner of construction projects, commercial
as well as residential, Anchor bolts are used to secure a structural
element or member to concrete. Anchor bolts are of two types, namely

those installed in concrete that has already cured (drilled and installed in
a drilled hole) and those that are set into concrete while the concrete is
still "wet".
Fig 6 illustrates a thermal power plant basically consists of number of
turbine modules i.e. High Pressure (HP), Intermediate Pressure (IP) and
Low Pressure (LP) Turbines. These turbines are placed on the foundation
above pedestals. For a 4 module turbine there are total of 5 nos; pedestal
i.e. Front pedestal, HP-IP pedestal, IP-LP pedestal, LP-LP and LP-Gen
pedestal. The pedestals supports the Turbine casing and the rotors are
supported on the bearings placed inside the pedestal. The static and
dynamic loads generated during operation are transferred to the
foundation through the pedestals. Hence the fixing/placement of
pedestals on foundation is a critical activity and has to be done precisely.
Steam Turbine Foundation casting is a critical activity in the complete
Power plant construction. The Foundation is subjected to severe dynamic
loading during the start, stop, base load and peak load operation of
machines.
In the past, during Turbine-Generator (TG) Deck casting at thermal
power plant sites, the templates are located at their location using by
spot welding with the steel reinforcements bars. The templates are
supported at their locations using small pieces of steel reinforcement's
bars. Actually, as per engineering practice it is not advised to weld the
steel reinforcement's bars with anything. Also, fixing of templates at the
desired centerline distances is a cumbersome and time consuming job.
There is always a high possibility of templates getting disturbed from
their location during cement pouring.
Figure 9, 10 and 11 describes the present practice at sites.

The Turbine pedestals are placed on the Foundation after initial chipping
of the top surface of foundation. An initial gap of around 60-70 mm is
kept between the pedestal and the foundation. The gap is maintained by
use of packers and lift bolts. All the pedestals are aligned with the
desired centerline using the piano wire. The elevation of the pedestals
with respect to each other is maintained by water pot levelling. Once the
pedestals are aligned as per drawing requirements, anchor bolts are
installed between the embedded anchor box and pedestal. The anchor
bolts fix the location of the pedestals as per the drawing requirement.
After fixing the location a secondary grout of non-shrinking cement is
poured between the pedestal and foundation avoiding the flow to enter
the anchor box tops by using thermocol spacers. The secondary grout
helps the pedestal to transfer all the static and dynamic loading to
foundation without disturbing the position (horizontal as well as vertical)
of the pedestal (as shown in Fig. 7 and 8).
The above paragraph explains the criticality of the exact location of the
embedded anchor boxes. The anchor boxes are placed in their location by
the anchor rods which are fixed in their drawing location using the
individual templates. The anchor rods are fixed in their location during
the first phase of casting and once the location of anchor rods for all
anchor boxes are found correct after initial curing of concrete completes,
anchor boxes are placed and locked using the anchor rods and nuts.
After placement of anchor boxes at their respective location second phase
of concreting takes place which embeds the complete anchor box inside
the concrete. As a common practice, during TG Deck casting at sites the
templates are located at their location using spot welding with the steel
reinforcement’s bars. The templates are supported at their locations
using small pieces of steel reinforcement's bars. As per engineering

practice it is not advised to weld the steel reinforcements bars with
anything Also fixing of templates at the desired centerline distances is a
cumbersome and time consuming job. There is always a high possibility
of templates getting disturbed from their location during cement pouring,
A slight tilting of anchor rods from bottom can result into unacceptable
deviation at the top of the anchor rod due to the longer length. As a
common civil construction practice vibrators are used for better concrete
compaction. The vibrators produce harmonic vibrations and is kept
inside the concrete at a particular location for around 10-20 seconds.
During the use of the vibrators there is always a chance that the
vibrators touch the reinforcements and start transferring the vibrations
to steel reinforcements. These vibrations can result into dislocation of
anchor rods due to improper fixing.
To resolve the above technical problem and for time and cost saving
during foundation casting an innovative reusable structural template has
been invented which can be used to locate all the anchor rods of a
particular pedestal at once.
Hence, the present invention fulfills the need by providing a steel
structure and its width is designed in such a manner that it does not
produce any hindrance to the steel reinforcements for the pedestal.
OBJECTS OF THE INVENTION:
It is therefore, the principal object of the present invention to provide a
reusable steel structure for locating anchor rods templates as well as for
fixing the templates at their designated location firmly.
Another object of the present invention is to provide a reusable steel
structure which can be used for TG deck casting.

Further object of the present invention is to provide a reusable steel
structure which will reduce time by fixing the individual templates at
their location.
Yet another object of the present invention is to provide a reusable steel
structure which will hold the templates firmly in their location during
cement pouring.
Further object of the present invention is to provide a reusable steel
structure which can be used repetitively without dismantling as the
same is placed on a wooden shuttering and its width is designed in such
a manner that it does not produce any hindrance to the steel
reinforcements for the pedestal.
Another object of the present invention is to provide a reusable steel
structure which is cost effective and leads to huge time savings as well.
SUMMARY OF THE INVENTION:
A reusable steel structure assembly for locating anchor rod templates
comprises: i) multiple numbers of first channel or vertical members (1)
for taking the vertical load of the upper structure; (ii) second channel (2)
used on upper structure of the composite template fixed with the help of
spot welding; (iii) composite templates further comprised of individual
templates (3); (iv) a plurality of anchor rods (4) being inserted into the
upper structure through the template holes and locked by anchor rod
nuts (5) for fastening the said anchor rod at desired location;
characterized in that the vertical members (1) are disposed at the steel
structure which facilitate holding the concrete during wet condition so
that the templates can be fixed at their location firmly which eventually
checks the friction with steel reinforcement; and an additional floor, is
placed for installation of the said structure.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:
It is to be noted, however, that the appended drawings illustrate only
typical embodiments of the present subject matter and are therefore not
to be considered for limiting of its scope, for the invention may admit to
other equally effective embodiments. The detailed description is
described with reference to the accompanying figures. In the figures, the
left-most digit(s) of a reference number identifies the figure in which the
reference number first appears. The same numbers are used throughout
the figures to reference like features and components. Some
embodiments of system or methods in accordance with embodiments of
the present subject matter are now described, by way of example, and
with reference to the accompanying figures, in which:
Figure 1 illustrates the arrangement of template with anchor rods during
casting along with invented steel structure.
Figure 2 illustrates the arrangement of anchor box with anchor rods
during casting.
Figure 3 illustrates the top view of invented steel structure to support
templates of pedestal no. 1 during casting.
Figure 4 illustrates the top view of invented steel structure to support
templates of pedestal no. 2 during casting.
Figure 5 illustrates the side view of invented steel structure to support
templates of during casting.
Figure 6 illustrates the cross-sectional arrangement of a steam turbine
set.
Figure 7 illustrates photographic view of turbine bearing pedestal
placement over anchor box after final casting.

Figure 8 illustrates photographic view of fixed turbine casing over
bearing pedestal anchored with foundation.
Figure 9 illustrates the old practice of fixing of anchor rods by using
templates
Figure 10 and 11 illustrates the fixing of templates using local steel bars
temporarily.
Figure 12 illustrates the photographic view of anchor box.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
The subject matter disclosed herein relates to a reusable steel structure
to locate anchor rods templates and also capable for holding all the
templates firmly at their desired location during TG deck casting.
According to an implementation of the present subject matter, a novel
steel structure is specifically designed as per the foundation
requirements of individual pedestal.
The steel structures comprises of following structural members:
i) a multiple numbers of first channel or vertical members (1) (150mm x
75 mm) for taking the vertical load of the upper structure including the
templates;
(ii) second channel (75mm x 40mm) (2) to design the upper structure of
the composite template on which the individual templates (3) are fixed
with help of spot welding;
(iii) templates (3) fixed on the lower side of the upper structure formed by
second channel (2);
(iv) anchor rods (4) which has inserted into the template holes (as shown
in Fig 2);

(v) anchor rods nut (5) which is used for locking of anchor rod (4) and
also helps fastening each desired location;
vi) a steel reinforcement (6); a wooden shuttering (7) for providing
support to the multiple numbers of vertical members (1).
The width and height of the upper structure is designed in such a
manner that there is no clashing with the steel reinforcement.
It should be noted that the description and figures merely illustrate the
principles of the present subject matter. It should be appreciated by
those skilled in the art that conception and specific embodiment
disclosed may be readily utilized as a basis for modifying or designing
other structures for carrying out the same purposes of the present
subject matter. It should also be appreciated by those skilled in the art
that by devising various arrangements that, although not explicitly
described or shown herein, embody the principles of the present subject
matter and are included within its spirit and scope. Furthermore, all
examples recited herein are principally intended expressly to be for
pedagogical purposes to aid the reader in understanding the principles of
the present subject matter and the concepts contributed by the
inventor(s) to furthering the art, and are to be construed as being
without limitation to such specifically recited examples and conditions.
The novel features which are believed to be characteristic of the present
subject matter, both as to its organization and method of operation,
together with further objects and advantages will be better understood
from the following description when considered in connection with the
accompanying figures.
Fig 1 illustrates the design of upper structure considering the location
and load of the individual template (3).

In one implementation of the present subject matter, the vertical
members (1) has been supported at the bottom on the wooden shuttering
(7) (as shown in Fig. 1). The number of vertical members has been
decided based upon the vertical load of the upper structure. The load of
the upper structure increase with the increase in length and width of the
individual pedestal. Item 1 has been installed on both side of the upper
structure. The width and height of the upper structure is designed in
such a manner that there is no clashing with the steel reinforcement.
The second channel (2) has been used to design the upper structure of
the composite template on which individual templates has been fixed
using spot welding. The upper structure design has been done
considering the location and load of the individual template (3). The
templates (3) are fixed on the lower side of the upper structure formed by
using second channel (2). The height of the templates is kept 150mm
more than the top level of concreting in phase 1. The upper structure
formed by second channel has been formed by stitch welding among
individuals Pieces.
The vertical members (1) has been welded using electrode E7018 to Item
2. Once the complete structure is fabricated the complete structure is
lifted and placed on the wooden shuttering protruding outside of pedestal
area.
Fig 3 and 4 illustrates the longitudinal and latitudinal centerline of
structure which matched with the pedestal centerline. The whole
structure is locked at this location.
The longitudinal and latitudinal centerline of structure is matched with
the pedestal centerline as per foundation drawing. The whole structure is
locked out at this location.

The anchor rods (4) are inserted into the template holes (8) (shown in Fig
11 and 12). The top of the anchor rod (4) has been locked in the vertical
direction using also fastened in each anchor rods (4) to fix the location
(as shown in Fig 2).
Once the above procedure is completed for all pedestals, cement pouring
takes place.
The four turbine casings are positioned on five bearing Pedestals. The
pedestal is fixed with the foundation using anchor bolts and nuts (Refer
to Figure 7 and 8). The anchor bolts are tightened into the anchor box
(embedded in foundation) at one end and other hold the pedestal using a
torque nut. The anchor box is located at its designed location using
anchor rods beneath it (as shown in Fig. 2).
In another embodiment of the present subject matter, the method of
locating anchor rod templates by using novel steel structures comprises
the following steps:
once the complete structure is fabricated the complete structure is lifted
and placed on the wooden shuttering protruding outside of pedestal area.
The longitudinal and latitudinal centerline of structure is matched with
the pedestal centerline as per foundation drawing' The whole structure is
locked at this location.
anchor rods (4) has now been inserted into the templates holes;
the top of the anchor rod is kept at a height as per drawing requirement;
anchor rod (4) has been locked in the vertical direction using the Anchor
rod nuts (5).
The Elevation of Turbine centerline decides the elevation to which the
Turbine foundation column is to be raised from zero-meter level. The

elevation of centerlines is derived from the sizing of the water-cooled
condenser' The Strength of foundation is governed by the sizing of the
reinforcement and the grade of concrete.
The usable structural template can be removed after the concert pouring
and curing, keeping the anchor rods fixed at their drawing location, it is
apparent that the embodiment of the invention, as described
hereinabove, shall provide an extremely critical reusable steel structure
with provisions that the same templates can be further used for
foundation casting for other power plant units with the similar
foundation design. The innovation results into cost effectiveness by
reducing manpower deploy ability to locate the individual templates at
their location w.r.t turbine centerline and by reducing requirement of
new templates for each new foundation casting (as the old one are not
damaged by spot welding), providing an even further versatile scope of
use.
Although embodiments for the present subject matter have been
described in language specific to structural features, it is to be
understood that the present subject matter is not necessarily limited to
the specific features described. Rather, the specific features and methods
are disclosed as embodiments for the present subject matter. Numerous
modifications and adaptations of the system/device of the present
invention will be apparent to those skilled in the art, and thus it is
intended by the appended claims to cover all such modifications and
adaptations which fall within the scope of the present subject matter.

WE CLAIM:
1. A reusable steel structure assembly for locating anchor rod templates
comprises:
i) multiple numbers of first channel or vertical members (1) for
taking the vertical load of the upper structure;
(ii) second channel (2) used on upper structure of the composite
template fixed with the help of spot welding;
(iii) composite templates further comprised of individual templates;
(iv) a plurality of anchor rods (4) being inserted into the upper
structure through the template holes and locked by anchor rod nuts (5)
for fastening the said anchor rod nut at desired location;
characterized in that the vertical members (1) are disposed at the wooden
shuttering which facilitate holding the concrete during wet condition so
that the templates can be fixed at their location firmly which eventually
checks the friction with steel reinforcement; and
an additional floor, is placed for installation of the said shuttering.
2. The reusable steel structure as claimed in claim 1, wherein the
dimensions of first channel (1) and second channel (2) are (150mm x
75mm) and (75mm x 40mm) respectively.
3. The reusable steel structure as claimed in claim 1, wherein said
additional floor is made up of wooden and/or metal sheets.
4. The reusable steel structure as claimed in claim 1, wherein the
member of vertical members (1) has been decided based on the vertical
load of the upper structure.

5. The reusable steel structure as claimed in claim 1, wherein said
templates are fixed on the lower side of upper structure formed by using
the second channel (2).
6. The reusable steel structure as claimed in claim 1, wherein the height
of the templates (3) is kept 150mm more than the top level of concreting
in phase 1.
7. The reusable steel structure as claimed in claim 1, wherein said
anchor rod (4) is locked in the vertical direction using said anchor rod
nuts.
8. The reusable steel structure as claimed in claim 1, wherein said
templates are fixed on the lower side of said upper structure, which is
formed by welding of second channel (2) with vertical members (1) by
using an electrode.
9. The reusable steel structure as claimed in claim 1, wherein said
wooden shuttering is produces outside of the pedestal area.
10. A method for locating rod template by using the steel structure as
claimed in claim 1 comprises the steps of:
i) lifting and placing of the complete structure after fabrication on
the wooden shuttering;
ii) matching of longitudinal and latitudinal centerline of structure
with pedestal centerline;
iii) locking of whole structure insertion of anchor rods (4) into the
template holes;
iv) keeping the top of the anchor rod (4) at a substantial height;
v) locking of anchor rod (4) in the vertical direction using the
anchor rod nuts;

vi) fastening of anchor rod nuts to each anchor rods for fixing the
location, pouring of cement.