generator erection manual thw 210 2a 2b (212)

POWER SECTOR – SOUTHERN REGION

Chennai

TECHNICAL SERVICES DEPARTMENT

Document Type : O & M Manual .

Project and Rating : . Product Name : Turbo Generator . Model Number/Type : 210MW – 2A/2B .

Title : Generator Erection Manual.

Contents in Brief : .

GENERATOR ERECTION M A N U A L

THW - 210 - 2A/2B

Bharat Heavy Electricais Limited POWER SECTOR

TECHNICAL SERVICES/(H.Q) NEW DELHI

GENERATOR ERECTION M A N U A L

Type : THW - 210 - 2A/2B

DOCUMENT NO : TS-G1-01

Bharat Heavy Electricals Limited POWER SECTOR

TECHNICAL SERVICES/(H.Q) NEW DELHI

GENERATOR ERECTION MANUAL

Type : THW - 210 - 2A/2B

Document No. TS-G1-01

Prepared by

Approved by

Date of Issue

Issued by

Copy No. O l

NAME

1. S.C. Jain

2. H.C. Madan

3. J.S. Subramanian

4. K.V. Tandon

5. Dev Raj

6. Harsha Kayastha

S.L. Bhatia

ol. 11. °lh.

Head/TG

Revision No. oo

DESIGNATION/ADDRESS

Sr. Manager TS-HQ/New Delhi

Sr. Manager TS-HQ/New Delhi

Sr. Manager PS-WR/Birsinghpur

Sr. Manager PS-NR/Dadri

Sr. Manager TGE-FES/Hardwar

Manager FQA-New Delhi

A.G.M. TS-HQ New Delhi

1 rw f

i nntinllririniniiiWibim oupy

~r-•tu.v_^te Issued t o : £ . . D - P S - S R - M d c # ^ .

BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR

TECHNICAL SERVICES (H.Q.) NEW DELHI

FOREWORD

I am glad that Technical Services Head Quarters, New Delhi

has brought out th i s Erection manual of main power station

equipments. This manual lays emphasis on site optimisation

techniques which aims at uniform erection pract ices ,

improvement in quali ty, reduction in time cycle and saving

in cost.

I am sure, th i s manual will form the basis for site

erection act ivi t ies so that the organisation can derive

full benefit out of t h i s . It is needless to emphasise that

upgrading of technology is a continuous process and we have

to review our methods of working and make suitable changes,

wherever required. (jl

(K C Lahify Director ( Power )

PREFACE

The Erection Manual for 200/210 MW Turbo - Generator has been prepared

by a team of BHEL engineers having long experience in Erection, Design and

Field Quality of Turbogenerator.

The scope of this erection manual is to bring out the recommended procedure

for erection along with the sequence of activity and various tools and plants

required to carry out this job. It also includes various logsheets required to

be filled in.

This manual is a broad based guideline for carrying out the job. Site

conditions availability of proper erection equipment and various facilities

influence the mode of erection. BHEL reserves the right to suggest alternative

procedure, if necessity arises.

Q

P. N. BHARGAVA General Manager (TS)

t J i T i w l GENERATOR CODIFICATION FOR

Erection INSTRUCTION NUMBER

1.2 Type of Manual

1 - Erection

2 - Commissioning

3 - Service

1.3 Rating of Main Equipment

01 - 200/210 MW

02 - 120 MW

03 - 110 MW

04 - 60 MW

05 - 30 MW

06 - 100 MW

07 - 235 MW

08 - 500 MW - KWU Design





13 - Industrial Units

14 - 210 MW - tower Type Concrete Pylem

15 - 210 MW - Tower Type Steel Structure

16 - 500 MW - tower Type Once through

17 - 250 MW

18 - CCP

1.4 System Designation

01 - Main Generator

02 - Seal Oil System

03 - Gas System

04 - Stator Water System

05 - Excitation System

Bharat Heavy Electricals Limited Rev. 00 10/93 2 of 3

tIZTtt GENERATOR CODIFICATION POR Erection INSTRUCTION NUMBER

1.5 Type of Instruction

G T

L

C

General Technical

Log Sheet

Check List

Bharat Heavy Electricals Limited Rev. 00 10/93 3 of 3

m a y GENERATOR ( ^ ^ J Erection C O N T E N T S

S.NO. T O P I C INSTN. NO.

1.

2.

3.

Technical Parameters

General Description

Activity Sequence

G1-01-0230G

G1-01-0131G

G1-01-0132G

4.

4 4 4 4, 4. 4. 4. 4. 4. 4. 4. 4.

SECTION I : ASSEMBLY INSTRUCTIONS

1 2 3 4 5 6 7 8 9 10 11 12

4.13

4.14 4.15 4.16

4.17

Preparation of Foundation Stator Placement Assembly of Bushing Gas Cooler Mounting Visual Inspection of Stator Visual Inspection of Rotor Rotor Insertion and withdrawl Bearing Assembly Rotor Alignment Reaming and Coupling Stator Centering Grouting of stator and bearing pedestal Assembly of fan Shield, end Shield & fan Blades Shaft seal Assembly Brush Gear Assembly Assembly of Extension Shaft, Auxiliary bearing Erection of TG Auxiliaries

G l G l Gl -Gl -Gl -G l -G l -G l -G l -G l -G l -G l -

G l -

G l -G l -G l -

G l -

- 0 1 - 0 1 -01--01--01--01--01--01--01--01--01--01-

-01-

•01--01--01-

0 1 -

-0101T -0102T -0103T -0104T -0105T -0106T -0109T -0110T -0111T -0112T -0113T -0114T

-0115T

-0116T -0117T 0118T

0136T

5. SECTION - II : TESTING INSTRUCTIONS

5.1 Rotor Purge Test 5.2 Gas Tightness Test of Rotor 5.3 Resistance Measuremeent of

Stator Winding 5.4 I.R. Measurement of Stator

Winding 5.5 Electrical Checking of

Stator R.T.D. 5.6 Pneumatic & Hydraulic test

of Stator Winding

G1-01-0107T G1-01-0108T G2-01-0101T

G2-01-0102T

G2-01-0103T

G1-01-0121T

Bharat Heavy Electricals Limited Rev. 00 10/93 X °£ 2

yUttgy GENERATOR LUIH Erection C O N T E N T S

S.NO. T O P I C INSTN. NO.

5.7 Electrical Test of Rotor G2-01-0104T Winding

5.8 Hydraulic Test of Gas Cooler G1-01-0126T 5.9 Air Leakage Test of Stator G1-01-0127T 5.10 Hot Water Circulation G1-01-0124T 5.11 IR Measurement of G1-01-0135T

Generator Rear Bearing Pedestal & Seal Body

5.12 Slot wedge Tightness checking G3-01-0106T

6. SECTION - III : GENERAL INSTRUCTIONS

6.1 Jointing of Rubber Gasket G1-01-0125G 6.2 Storage & Preservation G1-01-0122G 6.3 Sling Chart G1-01-0129G 6.4 Major T&P/Consumables G1-01-0133G 6.5 Erection Drawing G1-01-0134G 6.6 Dye Penetration Test G1-01-0137G

SECTION - IV : LOG SHEETS

Bharat Heavy Electricals Limited Rev. 00 10/93 2 ° f 2

TECHNICAL PARAMETERS

The fo l lowing c o d i f i c a t i o n system i s used for numbering of i n s t ruc t ions and the codi f ica t ion of Log Sheets i s as per FQA document.

xx x - xx xx xx x Alpha Numeric Numeric Numeric Numeric Alpha

I I I I I I Type of | | | I I I I n s t r u c t i o n

| | | | | System I n s t r u c t i o n No.

| | | | System Designat ion

| | | Rat ing of Main Equipment

| | Type of Manual

| Product Code

l.1 Product Code

B - Boiler

BA - Boiler Aux.

T - Turbine

TA - Turbine Aux.

G - Generator

GA - Generator Aux

P - Power Plant Piping

CI - C&I

harat Heavy Electricals Limited Rev 00 in/cn 1 of 3

TECHNICAL PARAMETERS

ttZTJ^l GENERATOR Erection TECHNICAL PARAMETERS

Turbogenerator Rating

Rated KW capacity

Rated KVA capacity

Rated terminal voltage

Rated Power Factor

Rated Stator Current

Excitation Current at rated power output and P.F.

Excitation voltage at rated power output and P.F.

Rated frequency

Rated speed

Direction of rotation when viewed from Turbine end

Rated H2 Pressure

Efficiency at M.C.R. conditions

Short Circuit Ratio

210,000 KW

247,000 KVA

15,750 V

0.85 lag

9050 A

2,600 A

300 V

50 cps

3000 R.P.M.

Anti clockwise

3.5 Kg/CM2

98.55%

0.49

TEMPERATURE RATING :

Class of insulation of generator windings

Maximum temperature of Stator Core (Measured by RTD)

Maximum temperature of stator winding (Measured by RTD)

Maximum temperature of rotor winding (Measured by resistance method)

Class 'B'

105°C

105°C

115°C

Bharat Heavy Electricals Limited Rev. 00

G1-01-0230G/1 Of 3 10/93

CftTjfta GENERATOR Erection TECHNICAL PARAMETERS

Cooling System

Stator Core

Stator winding

Rotor winding

End terminals

Quantity of distillate for Cooling Stator winding

Temperature of distillate at inlet of stator winding

Quantity of water required for hydrogen coolers

Temperature of cooling water at inlet to gas cooler

Maximum allowable water pressure in the gas cooler (gauge)

Minimum percentage purity of hydrogen inside the machine

OTHER PARTICLARS

Critical speed of generator rotor (Calculated)

Fly wheel moment of rotor

Ratio of S.C. torque to F.L. Torque

Quantity of Oil required for generator per bearing

Oil pressure for lubrication of the bearing

Quantity of oil required for both the shaft seals

Rated pressure of the shaft eal oil (Gauge)

Direct Hydrogen

Direct distillate

Direct Hydrogen

Direct distillate

27+3 M3/hr.

45°c

250 M3/hr.

33°c

4 Kg/CM2

97%

1370/3400 P.P.M.

21.1 TM2

8

300 L/min.

0.3-0.5 Kg/cm2.

160 L/min.

4.8.5.0 Kg/CM2

Bharat Heavy Electricals Limited Rev. 00 % / &

1-0230G/2 of 3

EiwHSl GENERATOR Erection TECHNICAL PARAMETERS

Weights and overall dimensions of the main parts of the Turbogenerator

Weight of Different Parts

Heaviest lift (wound stator with trunions)

Rotor

Gas Cooler

Terminal buishing

Shaft Seals

End Shields

Bearing with brush gear and foundation plate

Total Weight of the generator (without exciter)

Overall Dimensions

Overall diameter of the stator

Total length of the stator

Outer Dia. of the rotor

Total length of the rotor

Overall length of the assembled generator

175,000 Kg.

42,200 Kg.

1415 Kg.

85 Kg.

891 Kg.

9300 Kg.

270,000 Kg.

270,000 Kg.

3960 mm

6580 mm

1075 mm

9770 mm

9770 mm

Bharat Heavy Electncals Limited Rev. 00

G1-01-0230G/3 of 3 10/93

GENERAL DESCRIPTION

C i l T ^ l GENERATOR Erection GENERAL DESCRIPTION

The 210 MW turbogenerator type THW 210-2, employs direct hydrogen

cooling for the rotor and stator core and direct distillate water

cooling of stator winding. These modern cooling methods enable

high utilization of active materials and thus low value of

wight/kw ratio. The machine employs modern method of excitation

and control system to have a reliabile operation.

STATOR

The stator body is a gas tight fabricated structure designed to

withstand internal presure of hydrogen-air mixture explosion

without any residual deformation. The Stator core is built from

high alloy electro-technical steel segmental stampings which are

varnished on both sides. The stampings are assembled and pressed

on core bars in the form of packets which are separated from each

other by steel spacers of special profile to form ventilating

ducts for direct cooling of core by hydrogen.

The stator has a double layer lap winding connected in double

star. In all, 9 terminals, are brought out of the machine at the

exciter end out of which 3 are phase terminals and 6 are neutral.

The Stator winding is cooled by direct distillate. Each coil side

consists of solid and hollow conductors with the cooling water

passing through the latter. For circulating water through the

stator coils, ring type water headers, insulated from the body

are provided on turbine side. In the slot portion coil sides are

held in position by fibrous slot wedges to prevent any movement

during short circuits. The overhang portion of the winding is

securly lashed with glass cord to the bandage rings & special

brackets which in turn are fixed to the core pre springs. The

coils are insulated with mica tape and compounded with epoxy.

Bharat Heavy Electricals limited G1-01-0131G/1 of 6 Rev. 00 10/93

cjzrizi GENERATOR Erection GENERAL DESCRIPTION

ROTOR

The rotor is of cylindrical type, the shaft and rotor body being

forged in one piece from special alloy steel in accordance with

the most modern practice. The field winding is made of cold

rolled silver bearing electrical copper. Each conductor is wound

flat and consists of two parallel strips. The joints of the

winding are silver soldered. The main wall insulation to earth

(rotor body) of the winding is in the form of moulded troughts of

glass cloth impregnated with epoxy resins. The slot portion of

the winding are held against centrifugal forces by means by

duralumin wedge and overhang portion by retaininng rings of

special design. The retaining rings are made from high tensile

non-magnetic alloy steel forgings. The rotor winding is directly

cooled by hydrogen by gap-pick-up system of cooling. By adopting

this method of cooling, the uniform temperature distribution

along the length of rotor winding is achieved.

HYDROGEN COOLERS

For cooling hydrogen, 4 coolers of closed circulation type, with

sufficient surface area are provided. These coolers are mounted

longitudinally in the stator frame and are so designed that the

tubes may be cleaned without removing hydrogen from the machine.

Bearing

Generator bearing at the exciter end is of pedestal type with

high rigidity and is provided with spherically seated Self-

adjusting bush. The bearing bush is lined with anti-friction

metal and is lubricated by the oil supplied from the turbine oil

system. For checking the flow of oil, view windows are provided

on the drain pipes.

Bharat Heavy Electricals Limited T T T I T~~l Rev. 00 ft/a1-0131072 ° f 6

GENERATOR Erection GENERAL DESCRIPTION

The circulation of shaft currents capable of damaging the bearing

surface is prevented by insulating the bearing body and the drain

pipes from the earth.

Generator bearing at the turbine end is supplied alongwith the

turbine and is housed in the L.P. casing of turbine.

Slip Rings and Brush Gear

The slip rings are steel forgings which are shrunk on to steel

hubs covered with mica, built up in position. They are arranged

side by side outside the generator bearing at the exciter end.

The surfaces of the slip rings are spirally grooved and the

brushes are staggered to increase the life of the slip rings and

brushes. The brushes are pressed on the slip rings by means of

spring loaded plungers. The tension of the springs is readily

adjustable. The slip rings and brush gear are designed to be self

ventilated with rotation. They are enclosed by perforated sheets.

Shaft Seals

The generator employs ring type shaft seals mounted in each of

the end shields. For improving the reliability during all regimes

of operation the shaft seal design incorporates high pressure oil

film around the rotor shaft.

In order to prevent the circulation of Shaft currents, body of

the shaft seal on the exciter side is insulated from the stator

end shields and connecting pipes.

GENERATOR Erection GENERAL DESCRIPTION

Temperature Control System

The generator is provided with an eloborate system for measuring

the temperature of stator winding, core iron, cooling gas,

cooling water, lubricating oil and babbit of bearinng and seal

liners (see table I)

The temperature of stator winding and core iron is measured by

means of resistance thermometers installed under slot wedges and

at the slot bottom under lower winding bar respectively.

Temperature of Cold and hot hydrogen is measured by means of

resistance thermometers located in the stator body and by mercury

thermometers mounted on the endshields and in the middle of

stator body.

Temperature of cold and hot distillate passing through the stator

winding is measured by means of resistance thermometer installed

in the distillate pipe lines. Temperature of gas cooler water is

measured by resistance thermometers as well as mercury

thermometers installed on cooling water pipe lines.

Babbit temperature are also measured by resistance thermometers

installed in the bushes of bearing.

Table - 1

Mercury Thermometers

SI. No. of Location To measure temp-No. Thermometers erature of

1. Mx Generator stator body Hot gas

2. M2, M3 Generator end Shields Cold gas Bharat Heavy Electricals Limited "

Rev. 00 ft/*-0131074 ° f 6

ETiZI j^l GENERATOR Erection GENERAL DESCRIPTION

Table - l (continued)

Mercury Thermometers

SI. No. of No. Thermometers

Location To measure temperature of

3.

4.

M4

M15, Mlg

M19

Generator bearing drain Drain oil pipe T.E.

Generator gas cooler drain pipe

Main water piping

Hot water

Cold water

1 to 60

2. 61 to 63

3. 64 to 69

4. 70 to 72

5. 73 to 76 77,78

6. 79 to 80

7.

8.

9.

10.

81, 82

83, 84

85

86

Resistance Thermometers

One of each slot

One of each slot 1,21,41

One in each slot 2,22,42,1,21,41

One in each slot 1,21,41

Middl of stator body

Seal liner T.E. (For Thrust Type Seals)

Seal liner E.E.

(For Thrust Type Seals)

Bearing liner E.E.

Bearing drain pipe E.E. Oil pipe after oil cooler

Generator stator wdg bar

Core iron end packets

Core iron

Core iron end packets

Cold gas Hot gas

Babbit

Babbit

Babbit

Drain oil

Oil to shaft seal

Bharat Heavy Electncals Limited Rev. 00 %7^ 1 " 0 1 3 1 G / 5 o f 6

ciTijfn GENERATOR Erection GENERAL DESCRIPTION

Table - 1 (continued)

Resistance Thermometers

SI. No.

11.

12.

13.

NO. of Thermometers

87,88

89

90

91 to 94

Location

Distilled water stator wdg.

Water header to cooler

Water pipe from coolers

pipe

gas

gas

to

To measure temperature of

Distilled water inlet Outlet

Water at inlet

Drain water

Bharat Heavy Electncals Limited Rev. 00 Cj^^l-0131G/6 of 6

ACTIVITY DETAILS

•a

nrn^i GENERATOR Erection MAJOR ACTIVITIES

Step No. Activity Dependency on

Step No.

1. Preparation of Foundation 0

2. Placement of Stator 1

3. Assembly of Terminal Bushing 2

4. Assembly of Gas Coolers 2

5. Tests on Stator 2

6. Tests on Rotor 2

7. Rotor Insertion 0

8. Rotor Alignment with LP Rotor 7

9. Reaming and Coupling 8

10. Stator Centering 8 11. Grouting of Stator and Bearing 10

Pedestal

12. Assembly of End Shield 11

13. Shaft Seal Assembly 12

14. Bearing Assembly 13

15. Brush Gear Assembly 11

16. Erection of TG Auxilliaries 0

17. Assembly of Extension Shaft 14

Bharat Heavy Electricals Limited . , Rev. 00 C f t / * 1 - 0 1 3 2 0 / 1 o f 1 8

GENERATOR ASSEMBLY SEQUENCE PLAN

ACTIVITY

Preparation of foundation

Stator Placement

Assembly of Terminal Bushing

Assembly of Gas Coolers

Tests on Stator

Tests on Rotor

Rotor Insertion

Rotor Alignment with LP rotor

Reaming and coupling

Stator centering

Grouting of stator and Bearing Pedestal

Assembly of End Shield

Shaft Seal Assembly

Bearing Assembly

Brush Gear Assembly

Erection of T.G. Auxiliaries

Assembly of Extension Shaft

TIME IN WEEKS

1 2

- .

3

• " • £

4

JT-T

5

• •

•

6

• •

7 8

-

9

• •

FOR REFERENCE ONLY

10 11 12 13 14 15

'

16 17 18 19 20

CUM^l GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

1

ACTIVITY

PREPARATION OF FOUNDATION

SUB-ACTIVITY

Checking of foundation

Checking and matching of Embedded plates

Mounting of foundation plates

DR6. REF. NO.

6030 6030 5066 5066 5066 5066, 5066.

029 018 008 021 022 023 018

LOG SHEET NO.

FQA-03-00-01-L01(Sheet 1 to 4)

TECH.INSTRUCTION NO.

Preparation of Foundation G1-01-0101T

REMARKS/PRECAUTIONS


G1-01-0132G/2 of 18 10/93

GENERATOR Erection MAJOR ACTIVITIES

STEP NO. ACTIVITY

2 PLACEMENT OF STATOR

SUB-ACTIVITY

Matching and fixing of Trunion plates

Lifting of stator and placement on foundation

Preliminary centering of stator

DRG. REF. NO.

0311.016

0-5516.006

5478.007

LOG SHEET NO.


Stator Placement G1-01-0102T

REMARKS/PRECAUTIONS

- Ensure Reliability of EOT crane for its operation

- Healthinecess of endless slings

Bharat Heavy Electricals Limited G1-01-0132G/3 of 18 Rev. 00 10/93

rizH^i GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

3

ACTIVITY

ASSEMBLY OF TERMINAL BUSHING

SUB-ACTIVITY

Hydraulic test of terminal bushing

H.V. test of bushing insulator

Assembly of terminal bushing

Soldering of terminal bars

Insulation of terminal connections

DRG. REF. NO.

0311.016

0311.059

1255.001

LOG SHEET NO.

FQA-03-00-01-LO2 (Sheet 5/6, 6/6)


Assembly of terminal bushing G1-01-0103T

Resistance measurement of stator G2-01-0101T winding.

REMARKS/PRECAUTIONS

Bharat Heavy Electricals Limited Rev. 00 fo# -0132G/4 of 18

enr^n GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

4

ACTIVITY

ASSEMBLY OF GAS COOLER

SUB-ACTIVITY

Hydraulic test of gas cooler

Insertion of coolers

Centering and Assembly

DRG. REF. NO.

0311.016

6392.032

LOG SHEET NO.

FQA-03-00-01-L02, Sheet 5/6 (Item No.23)


Assembly of Gas Cooler Gl-01-0104 T

Hydraulic Test of gas cooler Gl-01-0126 T

REMARKS/PRECAUTIONS


G1-01-0132G/5 of 18 10/93

CiZIXai GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

5

ACTIVITY

TESTS ON STATOR

SUB-ACTIVITY

Visual Inspection

Resistance Measurement of Stator Winding,RTD

IR Value measurement of Stator Winding, RTD's & header

Pneumatic and hydraulic test of stator wdg.

Air tightness of stator without rotor.

DR6. REF. NO.

6020.025 6020.026 3-6060.00

2-5670.073 6030 016

LOG SHEET NO.

FQA-03-00-01-LO2


Visual Inspection of Stator Gl-02-0105 T Resistance Measurement of stator winding G2-01-0101 T IR measurement of stator winding G2-01-0102 T Electrical checking of Gen. RTD G2-01-0103 T Pneumatic & Hydraulic test of Gl-01-0121 T Stator winding Air leakage test of stator Gl-01-0127 T Procedure for slot wedge tightening G3-01-0106 T

REMARKS/PRECAUTIONS

Bharat Heavy Electricals limited Rev. 00

G1-01-0132G/6 of 18 10/93

C i i T ^ l GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

6

ACTIVITY

TEST ON ROTOR

SUB-ACTIVITY

DRG. REF. NO.

LOG SHEET NO.

Visual Inspection DC Resistance, Impedance and IR measurement of Rotor Winding Purge Test Gas Tightness Test

5675.010

FQA-03-00-01-L03 (Item No. 3.1 to 3.6)


Visual Inspection of Rotor

Electrical Test on rotor

Rotor purge test

Gas Tightness test of rotor

Gl-01-0106 T

G2-01-0104 T

Gl-01-0107 T

Gl-01-0108 T

REMARKS/PRECAUTIONS

Rotor having forced cooling arrangement of slip-ring

are not required to be checked for Gas tightness test


G1-01-0132G/7 of 18 10/93

CHTtt GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

7

ACTIVITY

ROTOR INSERTION

SUB-ACTIVITY

Kerosene Test of rear bearing pedestal

Bearing Matching with housing.

Rotor insertion.

DR6. REF. NO.

1-0344-001

6771.002

6771.003

5260.001

8340.035

LOG SHEET NO.

FQA-03-00-01-L04


Rotor insertion and withdrawl

REMARKS/PRECAUTIONS

Gl-01-0109 T

Ensure that all ventilating plugs and sealing tapes have

been removed from ventilating holes.


G1-01-0132G/8 of 18 10/93

CiZHZl GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

8

ACTIVITY

ROTOR ALIGNMENT WITH L.P. ROTOR

SUB-ACTIVITY

Rotor alignment

DRG. REF. NO.

LOG SHEET NO.

FQA-03-00-01-L05


Rotor alignment

REMARKS/PRECAUTIONS

G l - 0 1 - 0 1 1 1 T


G1-01-0132G/9 Of 18 10/93

ci?H£i GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

9

ACTIVITY

REAMING AND COUPLING

SUB-ACTIVITY

Reaming and Coupling

DRG. REF. NO.

LOG SHEET NO.

FQA-03-00-01-L05 (Sheet 8/12)


Reaming and Coupling G1-01-0112T

REMARKS/PRECAUTIONS

Bharat Heavy Electricals limited G1-01-0132G/10 of 18 Rev. 00 10/93

r-fiTjf^i GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

10

ACTIVITY

STATOR CENTERING

SUB-ACTIVITY

Setting of Magnetic Axis

Setting of Air Gap

DRG. REF. NO.

LOG SHEET NO.

FQA-03-00-01-L05 (Sheet 3/12) (5.8 - 5.12)


Stator Centering G1-01-0113T

REMARKS/PRECAUTIONS


G1-01-0132G/11 of 18 10/93

rxmni GENERATOR Erection MAJOR ACTIVITIES

STEP NO. ACTIVITY

11 GROUTING OF STATOR & BEARING PEDESTAL

SUB-ACTIVITY

Fixing of Permanent Packers

Grouting And Curing

DRG. REF. NO.

FOA REF. NO.

FQA-03-00-01-L05 (Sheet 4/12) (5.13)


Grouting of stator Gl-01-0114 T and bearing pedestal

REMARKS/PRECAUTIONS

Bharat Heavy Electricals Limited G1-01-0132G/12 of 18 Rev. 00 10/93

CJIT£Zi GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

12

ACTIVITY

ASSEMBLY OF END SHIELD

SUB-ACTIVITY

DRG. REF. NO.

Mounting of Fan Blades (Turbine End) Pre Assembly of Lower Halves of Fan Shields With End Shields Final Assembly of Bottom Halves of Fan Shields And End Shields Hot Water Circulation in Stator winding Final Assembly of Top Halves of Fan Shields and End Shields

0-5012.025 0-5013.005 5487.005 5487.006

LOG SHEET NO.

FQA-03-00-01-L05 (Sheet 4\12-5\12) (5.13, 5.15, 5.16, 5.17)


Assembly of Fan Shield, End Shield and Fan Blades

Gl-01-0115 T

Hot Water Circulation in Stator Winding Gl-01-0124 T

REMARKS/PRECAUTIONS


G1-01-0132G/13 Of 18 10/93

CIZFJ^t GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

13

ACTIVITY

SHAFT SEAL ASSEMBLY

SUB-ACTIVITY

Assembly of Oil Catcher (H2 Side) Assembly of Shaft Seal Assembly of Air Side Oil Catcher Assembly of Seal Cover.

DR6. REF. NO.

(FOR THRUST TYPE)

1-5372.010 2-5372.010 0-5371.002

(FOR RING TYPE)

LOG SHEET NO.

(FOR THRUST TYPE) FQA-03-00-01-L16

(FOR RING TYPE) FQA-03-00-01-L05

(5.18,5.19)

TECH. INSTRUCTION NO.

Shaft Seal Assembly

IR Measurement of Generator Rear Bearing Pedestal and Seal Body

REMARKS/PRECAUTIONS

G1-01-0116T

G1-01-0135T

FOR RING TYPE SEALS Initially assemble only EE components. Check IR value of rotor after decoupling. Assemble TE components - Recouple the rotor and elongate the coupling bolts.


G1-01-0132G/14 of 18 10/93

fTJZffifil GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

14

ACTIVITY

BEARING ASSEMBLY

SUB-ACTIVITY

Assembly of Front Bearing

Assembly of Rear Bearing

DR6. REP. NO.

5263.008

5264.002

LOG SHEET NO.

FQA-03-00-01-L05 (Sheet 9/12, 5.23)


Bearing Assembly

IR Measurement of Generator Rear Bearing Pedestal and Seal Body

G1-01-0110T

G1-01-0135T

REMARKS/PRECAUTIONS


G1-01-0132G/15 of 18 10/93

£izrm GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

15

ACTIVITY

BRUSH GEAR ASSEMBLY

SUB-ACTIVITY

Assembly of Brush Gear

Assembly of Brushes

DR6. REF. NO.

5264.002

LOG SHEET NO.

FQA-03-00-01-L05 (Sheet No.10/12, 5.27, 5.28, 5.29)


Brush Gear Assembly G1-01-0117T

REMARKS/PRECAUTIONS


G1-01-0132G/16 of 18 10/93

C i l T ^ l GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

16

ACTIVITY

ERECTION OF T.G. AUXILLIARY SYSTEM

SUB-ACTIVITY

DRG. REF. NO.

Panel Erection

Equipment Erection

Piping Erecttion

Cleaning of Seal Oil, Gas System, Stator Water

System Piping

Pressure Test Of Gas System Piping and Rack

LOG SHEET NO.


Erection of T.G. Auxiliaries G1-01-0136T

REMARKS/PRECAUTIONS


G1-01-0132G/17 of 18 10/93

CiTT^l GENERATOR CHECKING OF FOUNDATION & Erection MOUNTING OF FOUNDATION PLATE

Prior to starting the generator assembly, the entire foundation

should be thoroughly checked in detail for compliance with

foundation plan. This check ensures location of all embedded

parts as per drawing before mounting the equipment on foundation.

These foundations are designed for taking the total load of the

machine and various forces arising during its operation.

1.0 PRE-REQUISITE

After the foundations are cleared for its checking and

further assembly work, following jobs should be completed.

i) Ensure erection of temporary railings and covers to

prevent any accident due to fall.

ii) Remove all remaining construction materials lying

around and other obstacle materials to avoid any

accident.

iii) Cover all opening on TG floor.

2.0 CHECKS ON FOUNDATION

i) Check accuracy of site elevation and axillity of the

entire foundation as per drawing with the help of a

taut steel wire.

ii) Check all contact surfaces for burrs and dents

iii) Check all foundation openings, such as anchor bolt

holes, oil ducts, opening for pipe works and cables

etc. for its location and dimension.

Bharat Heavy Electrical* limited Qi-01-OlOlT/l of 3 Rev. 00 10/93

dCTJC^l GENERATOR Erection MAJOR ACTIVITIES

STEP NO.

17

ACTIVITY

ASSEMBLY OF EXTENSION SHAFT

SUB-ACTIVITY

Placement of a Pedestal

Coupling of Extension Shaft

Centering of Pedestal and Grouting

Assembly of Aux Bearing

DRG. REF. NO.

LOG SHEET NO.

FQA-03-00-01-L06 (Sheet 12/12)

TECH. INSTRUCTION NO.

Assembly of Extension Shaft and Auxiliary Brg.

G1-01-0118T

REMARKS/PRECAUTIONS

SECTION - I

ASSEMBLY INSTRUCTIONS

CitTjra GENERATOR CHECKING OF FOUNDATION & Erection MOUNTING OF FOUNDATION PLATE

Prior to starting the generator assembly, the entire foundation

should be thoroughly checked in detail for compliance with

foundation plan. This check ensures location of all embedded

parts as per drawing before mounting the equipment on foundation.

These foundations are designed for taking the total load of the

machine and various forces arising during its operation.

1.0 PREREQUISITE

After the foundations are cleared for its checking and

further assembly work, following jobs should be completed.

i) Ensure erection of temporary railings and covers to

prevent any accident due to fall.

ii) Remove all remaining construction materials lying

around and other obstacle materials to avoid any

accident.

iii) Cover all opening on TG floor.

2.0 CHECKS ON FOUNDATION

i) Check accuracy of site elevation and axillity of the

entire foundation as per drawing with the help of a

taut steel wire.

ii) Check all contact surfaces for burrs and dents

iii) Check all foundation openings, such as anchor bolt

holes, oil ducts, opening for pipe works and cables

etc. for its location and dimension.

Bharat Heavy Electrical* Limited Q1-01-0101T/1 of 3 Rev. 00 10/93

Eizrm GENERATOR CHECKING O FOUNDATION & Erection MOUNTING OF FOUNDATION PLATE

iv) Check, mark and record main referred point (Absolute

floor), level measuring points for height/elevation

against a foundation pillar. With reference to M s

point, check elevation of embedded parts and record

deviation.

Caution : Deviation on elevation should be strictly as per

logsheet.

3.0 CHECKS ON EMBEDDED PARTS

i) Check the location of embedded parts to longitudinal

and transverse axis of TG foundation and its elevationn

as per relevant drawing.

ii) Check the condition of embedded parts by knocking it by

a light hammer of 250 gms to ascertain that these form

monolythic structure with foundation. In case of any

voids or loose concrete layers, same should be

rectified as per civil recommendations.

Caution : Under no circumstances, there should be loose

concrete layers in the region where generator

rear bearing pedestal embedded parts are

installed.

iii) Check the inclination of embedded parts towards the

side where shims shall be inserted at a later stage for

its easy insertion. The inclination should be 4 to 5 mm

per meter.

Bharat Heavy Electricals Limited G1-01-0101T/2 of 3 Rev. 00 10/93

GENERATOR CHECKING OF FOUNDATION & Erection MOUNTING OF FOUNDATION PLATE

iv) Check the surface of embedded parts with the level and

blue paint. Contact area shall not be less than 80%.

The surface, on which shims are to be inserted, should

be free for any burrs/dents.

4.0 MOUNTING OF FOUNDATION PLATE

The generator foundation plates are laid as per longitudinal

and transverse axis. Final dimension are to be recorded.

The support surfaces of the foundation plate should be

colour matched with surface plate so that the contact area

of more than 80% is achieved by scrapping.

Initially, these plates are to be installed on temporary

shims (wedge type) placed in the space between adjacent

embedded parts steel packing shims of thickness 2 to 5 mm

should be kept on its foundation plates to facilitate

alignment after grouting in future.


CUTA^l GENERATOR Erection PLACEMENT OF STATOR

The stator body of 210 MW generator is supported on foundation

with the help of four trunion plates bolted to the stator casing.

PRE-REQUISITE

1. Ensure that foundation plates have been mounted properly on

foundation.

2. Ensure availability of two EOT cranes with main hook of the

capacity of 120 MT each and capability of operation of these

cranes in tandem operation.

3. Ensure availability of specially fabricated lifting beam

with two endless slings of 80 mm x 20 MTS each for lifting

the stator frame.

4. Ensure that foundation bolts/anchor bolts are wrapped with

polythene cover and inserted in their respective holes (pipe

shims) .

PROCEDURE

Before the stator is lifted, the trunion plates should be

assembled to stator casing as mentioned below:

1.0 Assembly of trunion foot plate

Check the punching marks on trunions and identify for its

stator casing location.

Check the contact surface of trunion foot plates and pads on

stator casing for any dents and burrs.

Bharat Heavy Electricals limited G1-01-0102T/1 of 3 Rev. 00 10/93

CIZIJO GENERATOR Erection PLACEMENT OF STATOR

Check levelling of all pads with the help of a straight

edge/scale.

Check the size of threads of trunion plates fixing bolts and

holes on the stator casing.

Check the contact surface between trunion plate and stator

casing mounting flange with blue plate and ensure contact

area of more than 80%.

Assemble the trunion plate at its respective location and

tighten it by fixing bolts.

Caution : A filler of 0.03 mm should not pass anywhere on

tightening the trunion foot plate bolts with

stator including the pads.

2.0 Placement of stator on foundation

Before moving the stator to foundation, ensure cleanliness

of contact surface of foundation plate and stator trunion

foot plate and these should be free from any dents and

burrs.

Lift the stator by placing endless string on trunions and

lifting beam (supplied by customer for 2 EOT cranes

operation)

Caution : Lifting of stator body by placing slings at any

other part is not allowed.


riiw^i GENERATOR Erection PLACEMENT OF STATOR

Place the stator on foundation plate with shims in between.

Carryout the centering of stator bore w.r.t. string (piano

wire) stretched along logitudinal axis of TG. This is only a

preliminary centering as the final centering is done only

after rotor is inserted and same has been aligned with L P

rotor.


CJTH^I GENERATOR ASSEMBLY OF TERMINAL

Erection BUSHING

In 200/210 MW TG Set, nine numbers of terminal bushings are

provided at the exciter end of stator casing in the terminal

chamber for taking electrical output connections to the bus duct.

Three numbers of terminal bushing are meant for phase side and

the six numbers for neutral side connection. These bushings are

direct water cooled and manufactured out of copper and insulated

with procelain insulators.

Pre-requisite

Check the physical condition of terminal bushing and insulator

for any damage during transportation.

Identify terminal bushing assembly for phase side and netural

side connections.

Dismantle the bushing assembly and separate terminal bar from

insulator.

Check all fasteners to be used for jointing the terminal bar to

stator winding for non-magnetic property.

Ensure availability of testing equipments like micro ohm meter,

meggar 1 kv, hydraulic test pump and HV test kit.

Ensure availability of soldering and insulating materials

required for terminal bar soldering to the winding and its

insulation.

Ensure availability of heating arrangement required for heating

the joints to be soldered.


Ei?n£i GENERATOR ASSEMBLY OF TERMINAL

Erection BUSHING

PROCEDURE

Before the terminal bars are bolted to the stator winding, it

should be hydraulically tested to detect any leakage point in the

terminal bar and porcelain insulator should be tested for high

voltage test.

1. Hydraulic test of terminal bar

Clean the terminal bar hollow portion by flushing it

thorougholy with/DM clarified water. Blank outlet nipple of

the bar and fill water from inlet nipple with the help of

hydraulic pump. Expell entrapped air by loosening the

blanking nut.

After ensuring the complete filling of water, raise water

pressure to 25 kg/cm2 and maintain it for 1/2 hour. Check

all weld seams for any water seepage. No visible water

seepage and pressure drop is allowed during this test.

Caution : Terminal bar water path should cleaned with

compressed air immediately after the test and

openings should be closed.

2 . HV TEST OF PORCELAIN INSULATOR

Clean the outer and inner surface of insulator thoroughly

and wrap a conductive foil along its entire outer surface.

Insert a cylinder like object made of copper/tin plate into

the bushing bore so that the cylinder is in contact with the

bushing liner surface throughout its entire length. The test

voltage of 25 kv (AC) for one minute (or 73 KV DC) should be

applied between bore cylinder and outer surface of bushing


• s

€ITTA^I GENERATOR ASSEMBLY OF TERMINAL

Erection BUSHING

and leakage current should be recorded. After application of

high voltage for one minute duration, the outer surface of

bushing should be carefully checked for any black marks.

Caution : Before and after HV test, the IR between cylinder

bore and outer surface of bushing should be

checked by 2.5 kv/1 kv meggar.

3 . Assembly of terminal bar.

Initially, the terminal bar alongwith the porcelain

insulator is trial assembled with the winding to check

proper centering of terminal bar w.r.to corresponding holes

in terminal chamber plate. Once the centering of terminal

bushing assembly is achieved, the terminal bars are fully

tightened with bolts and locking washers.

Caution : Ensure proper seating of tightening bolts and

washers on terminal bar mounting flange.

Remove the porcelain insulator after proper tightening of

terminal bar. The joints between bus bar and terminal bar

for all nine assemblies should be soldered as per procedure

mentioned as Annexure-I.

Caution : Check IR and DC resistance of stator winding

before connecting terminal bar, after bolting the

terminal bar and after soldering the joint.

Reassemble the porcelain insulator with sealing gaskets

after completing the soldering of joints and its thorough

cleaning. The fixing bolts of terminal bushing with stator

terminal plate should be locked properly.


CiZKO GENERATOR ASSEMBLY OF TERMINAL

Erection BUSHING

Assemble teflon tubes/copper tubes provided for water

circulation in terminal bar for each bar assembly. Carry out

the hydraulic test of stator winding as per instruction No.

Gl-01-012IT to detect any water seepage from the varous

joints in water path of terminal bar and connecting bus bar.

Insulate the terminal bar joints as per instructions

detailed in drawing No. 1255.001C.


ASSEMBLY OF TERMINAL BUSHING

Annexure - I

INSTRUCTIONS FOR SOLDERING OF TERMINAL

BAR WITH CONNECTING BUS BARS ON STATOR

WINDING AT SITE

1.0 INTRODUCTION

This instruction deals with the procedure of soldering of

terminal bushings with end terminals of stator winding at

site and various checks to be carried out before and after

soldering.

2.0 PREPARATORY WORKS BEFORE SOLDERING :

Remove procelain insulators from the terminal bushings.

Thoroughly clean joining surfaces of contact plates of

connecting bus bars of terminal bars taking utmost care not

to damage the tinning on their surface.

Measure d.c. resistance of stator winding between terminals

C4-1C1, C4-2C1, C5-1C, C5-2C2, C6-1C3, C6-2C3, which should

be identical.

Fix terminal bar with connecting bus bar using non-magnetic

bolts and nuts.

Repeat the D.C. resistance measurements as done earlier and

compare the two results. The difference between any two

measurements should not exceed 3%.


rizraa GENERATOR Erection

G1-01-0103T/5 of 7 10/93

CiZTi^l GENERATOR ASSEMBLY OF TERMINAL

Erection BUSHING

Ensure plugging of nipple connections of terminal bar and

connecting bus bar,

3.0 MATERIAL REQUIREMENT :

(As per packing list of package no 15T supplied by

manufacturing unit).

Solder (Sn 60) 60 Kg

IS 103-1966

Asbestos tape 400 meters

0.4x30 mm.

Asbestos cloth To be aranged at site.

Asbestos putty 40 Kg

4.0 SOLDERING PROCEDURE

Mix asbestos putty with water and apply in the viccinity of

joining surface followed by wrapping of two layers of

asbestos tape tightly over the same. Wrap the entire copper

bushing by asbestos cloth.

Heat the terminal bar using two gas torches from below i.e.

from the bushing projecting outside the stator body.

Feed solder wire from top keeping the same in touch with

joining surface. Once the solder starts melting, solder

should be continuously fed till it spills-over. Thereafter,

the heating should be stopped. Once heating is started, it

should not be stopped in between till soldering of one joint

is completed.


fr/ZEca GENERATOR ASSEMBLY OF TERMINAL

Erection BUSHING

Allow the soldered joints to cool before removing asbestos

putty/cloth/tape etc. and do thorough cleaning of terminal

bar.

5.0 CHECKS AFTER SOLDERING :

Measure the d.c. resistance of stator winding between

terminals C4-1C1, C4 - 2C1, C5 - 1C2, C5 - 2C2, C6 - 1C3, C6

- 2C3.

Compare these with the values obtained before soldering. For

good soldered joint, d.c. resistance after soldering should

come down.

The difference in value of d.c. resistance measured before

connecting the terminal bushing and after soldering should

generally not exceed 3%.

Note : 1. The D.C. resistance may be measured either by using

double Kelving bridge or by micro-ohm meter. It is,

however important that same set of instruments should

be used for all the measurements.

2. While soldering flexible type connection for terminal

bushings, the spaces between elementary strips of the

flexible links should be filled up with asbestos putty

to avoid penetration of solder & consequent loss of

flexibility.


S O I S R I N G nr Fl FXIRLE CONNECTON

TO BE SOLDERED

FIG.

6l-ol-0i0ST

-r*-f '-i£Kgc • •&•••*«? J*- /

fi*.^'

^

Z£-$

CiTH^l GENERATOR ASSEMBLY OF GAS

Erection COOLER

In 200/210 MW TG set, 4 Nos of gas coolers are mounted

horizontally inside the stator casing. These coolers are inserted

into the windows provided in the stator casing for housing the

coolers. The cooling water flows through the tube while the gas

passes over the finned tubes and gets cooled.

1.0 Pre-requisite

1. Ensure that gas coolers have been taken out of stator

casing, if sent in assembled condition with stator.

2. Ensure that hydraulic test on each cooler has been

completed as per Instruction No. G1-01-0126T.

3. Ensure that gas coolers have been properly cleaned by

air.

4. Ensure that cooler housing chamber in stator casing has

been thoroughly cleaned for any dirt/foreign materials.

5. Check the condition of each roller for all gas cooles

for its freeness and its straight axle.

6. Ensure availability of all sealing gaskets of

propersize required during assembly of gas coolers.

7. Check the tightening of all bolts provided on water

base cover (front & rear).


nrw^i GENERATOR ASSEMBLY OF GAS

Erection COOLER

2.0 PROCEDURE

Slowly insert the gas cooler one by one in horizontal

direction into the windows of stator from excitor end with

the help of E.O.T. crane. During insertion, care should be

taken that position of the longitudinal rubber gaskets

between gas cooler and stator angles should be as per

relevant drawing.

After insertions, centre the gas cooler w.r.t. windows by

means of levelling bolts provided. Assemble the fixing frame

with sealing gasket on stator body and gas cooler body and

ensure proper locking of all bolts. Connect the inlet/outlet

water pipes and vent pipes as per drawing.

Caution: Ensure cleanliness of inlet/outlet/vent pipes

before connecting it to the gas cooler.

The vent pipe should be properly laid and a vent cock should

be provided at other end with proper water draining

arrangement.


CJZFtt GENERATOR VISUAL INSPECTION

Erection OF STATOR

The Stator casign of 200/210 MW generator should be properly

checked before taking up the assembly of Stator and rotor. These

checks will ensure the healthiness of stator core, winding and

other components before it is finally assembled. Various checks

required to be carried out on stator are as follow:

1. Check presence of any foreign materials in :

(a) Gas Cooler Supporting Channels

(b) The Stator bore

(c) The space between stator core and casing.

2. Check for any visual damage to stator core.

3. Check that all the slot wedges are tight. If required

tightness them as per instructions for "T.G. Stator Slot

Wedging. No. G3-01-0106T".

4. Check for any damage to stator winding overhang and bus bar

connection visually. The terelyne cord bracing the bars with

binding ring and bars with one another, should not be broken

at any place and should have proper varnish applied on it.

5. There should not be any gap either between the layers at the

place of bracing or between the bracket and binding rings.

If any spacer has come out, it should be restored back after

putting proper packing and applying gluing material.

6: Check that no bolt of clamping arrangement of overhang

support is loose. The packing in between the support and

brackets should be well tight and should not have any gap in

between.


CiZXjfa GENERATOR VISUAL INSPECTION

Erection OF STATOR

7. Check that bolts for fixing the covers (Item 2,4,6 of Drg.

No. "5001, 027) which are used to block technological holes

in stator body are tack welded.

8. Inspect visually water headers, teflon tubes and insulation

of water headers.

9. Check the flanged connections of water header bushing with

intermediate and outer pipe line for proper tightness and

quality of sealing washers.

10. Check that washers are provided at connections of gas trap

line and main pipe line.

11. Check that the clamping of gas trap pipe with headers at

various places is alright and the same is no where

broken/missing.

12. Inspect the terminal bushings and their assembly visually.

(a) Check that the sealing washers provided are of proper

quality and the same are seating on the bushing face.

(b) The alignment of bushing should be correct so that the

sealing washer is pressed uniformly all over its

periphery.

(c) The bolts holding the bushing with stator casing should

be equally and well tightened.


tIZTtt GENERATOR VISUAL INSPECTION Erection OF STATOR

13. Ensure that following test on stator has been completed.

D.C. resistance and IR/PI of Winding.

Resistance and IR of RTD's.

14. Check that all technological bolts provided in core support

bars all around the periphery have been removed.


CUTtt GENERATOR VISUAL INSPECTION

Erection OF ROTOR

The rotor is visually inspected to check its healthiness before

its insertion into stator during erection/overhaul stage of the

machine. During this checking, following points should be

specifically checked apart from various points mentioned in O&M

manual.

CHECKS DURING PHYSICAL INSPECTION

1. Inspect fan hubs and retaining rings for any chipping of

metal, dents marks, crack etc.

2. Inspect journal for pitting and scratches.

3. Inspect seal collars for pitting ans scratches.(For Thrust

Type Seals).

4. Check for position of all balancing weights as per

manufacturers' report and its proper locking.

5. Check locking of all 10 Nos screws in centering ring.

6. Check whether any foreign material is lying in ventilating

holes. Ensure to remove all plugs from the ventilating

holes.

7. Check for any blocking of ventilating holes in slip rings.

8. Check up unevenness and any defect on the sliprings.

9. Ensure that phyusical dimension of rotor have been recorded

in the relevant logsheet.


riZTitw] GENERATOR VISUAL INSPECTION

Erection OF ROTOR

10. Ensure that following tests on the rotor have been

completed.

purge test and gas tightness test.

DC resistance, impedance and IR of rotor winding.

Bharat Heavy Electricals Limited G1-01 -0106T/2 of 2 Rev. 00 10/93

dEHSl GENERATOR Erection ROTOR INSERTION

The assembly of rotor into the stator casing is taken up after

thorough inspection of stator and rotor and completion of all

electrical and mechanical tests on stator and rotor. The assembly

of terminal bushing and its insulation should also have been

completed before taking up this activity. The rear bearing

pedestal including bottom half bearing and front bearing should

be made ready for its installation. Since, this activity involves

generator rotor lifting by the crane for its axial movement

inside the stator bore, following precautions should be taken

during handling of the rotor.

1. Protect all the machined surfaces from getting damaged.

2. Do not sling the bare surface. Cover the rotor with wooden

pieces (tied together) at the point of slinging. These are

supplied alongwith the rotor.

3. Keep the pole axis vertical.

4. Do not allow the rotor to rest on its slot wedges retaining

rings, sliprings or half coupling.

5. While inserting or removal of rotor, care should be taken

not to damage the stator overhang winding or rotor slot

wedges.

DEVICES REQUIRED FOR INSERTION AND REMOVAL OF ROTOR

All items necessary for threading in and removal of rotor are

suplied alongwith the set except item No. 14 (I-beam size 500 mm

x length 6 meters) . The list of items is given in the drawing

No.1-0344.001.


ciZTjfia GENERATOR Erection ROTOR INSERTION

PROCEDURE FOR INSERTION AND REMOVAL

There are six steps as shown in the drawing. The reverse sequence

has to be followd while taking out the rotor from the stator.

Step No. 1

1. Place card board item No. 19 and then item No. 3 into the

bottom of stator bore.

2. Install the rails item No. 6,7 & 8 on the slip ring side of

the foundation block as per sketch shown.

3. Mount the lower portion of the outer trolley item No. 9 on

the rails.

4. Connect the extension pipe item No. 16 to the half coupling.

5. Cover the shaft journals with card board item No. 11 and 13

and then with the aluminium sheet item 10 & 12.

6. Assemble the upper portion bracket of the trolley item No. 9

on the slipring side journal and trolley item no. 4 on the

turbine side j ournal.

7. Remove the fan blades from the fan hubs on the turbine side.

It is also preferable to remove fan blades of excitor end

side.

8. Assemble the wooden pieces item no. 5 on rotor barrel as

shown in the sketch, sling at this place and hold by crane.

9. Insert rotor upto maximum possible position.


GENERATOR Erection ROTOR INSERTION

Step Ho. 2

1. Bring the lower portion of the trolley item No. 9 under the

brackets and tighten them by bolts.

2. Lower the rotor and make it rest on the trollies item No. 4

and item No. 9.

3. Check the concentricity of the rotor with stator bore and

release the sling. Place the beam item No. 14 on the turbine

side.

Step No. 3

1. Insert crow bar item No. 15 into the hole of the rollers of

the outer trolley.

2. Push the rotor into stator with the help of crow bar till

the extension pipe comes out at the turbine end and it is

possible to sling the rotor.

3. Put the sling under the extension pipe.

4. Lift the rotor by crane till there is no contact of the

trolley item No. 4 with sheet item No. 3 placed in the

stator.

Step No. 4

1. Bring the rotor to the position shown under stage IV.

2. Allow the rotor to rest on the beam item No. 14, taking care

that the rotor does not rest on the stator.

Bharat Heavy Electricals Limited G 1 - 0 1 - 0 1 0 9 T / 3 of 5 Rev. 00 10/93

GENERATOR Erection ROTOR INSERTION

3. Remove the extension pipe.

4. Put the sling under the half coupling and hold the rotor.

5. Move the rotor to the position where it is convenient to

remove the inner trolley (item No. 4).

Step No. 5

1. By means of crow bar and crane, move the rotor till the half

coupling of generator and turbine meet.

2. Mount the lower half of bearing liner on turbine side.

3. Lower and place the rotor on the liner.

4. Remove the beam item No. 14 from the turbine side.

Step No. 6

1. Lift the rotor slightly on excitor end side by crane.

2. Place the beam item No. 14 on excitor side.

3. Allow the rotor to rest on the beam with spacers in between.

4. Release the lower part of the trolley item No. 9 and take

out the trolley.

5. Remove the rails and sheet item No. 3 and 19.

6. Mount the generator bearing pedestal.


EIZTtt GENERATOR Erection ROTOR INSERTION

7. Mount the lower half of the bearing liner.

8. Lift the end of the rotor by crane and remove the beam item

No. 14.

9. Allow the rotor to rest on the bearing half liner.


INSERTION OF ROTOR INTO STATOR

UAORAM-NI OM3MMV

H- —jjMa

FOR DIAGRAM -IK INSERT "HE CROW BARS INTO THE HOLES IN THE ROLLERS OF THE OUTER TROLLP'. WITH THE HELP OF THESE CROW BARS PUSH THE ROTOR INTO THE STATOR TILL IT OCCUPIES THE POSITION WHERE IT IS POSSIBLE TO PASS THE SUNG UNOER THE PROJECTING PART OF THE EXTENSION PIPE (ITEM 16) PUT THE SUNG UNDER THE PROJECTING PART OF THE EXTENSION PIPE UFT THE ROTOR BY THE CRANE TILL THERE IS NO CONTACT Of THE TROLLEY (ITEM «! WITH SHEET (ITEM 3).

SCHEME OF PLACING THE WOOOEN PIECES

FOftDUGRAM-l PLACE CARD BOARD (ITEM 19) 4 THEN SHEET (ITEM 3) WTO THE STATOR BORE INSTALL THE RAILS (ITEM «.7&8) ANO MOUNT THE LOWER PORTION OF THE TROLLEY (ITEM 9) ON THE RAiLS CONNECTTHE EXTENSION PIPE (ITEM 151 TO HALF COUPLING OF ROTOR ASSEMBLE THE TROLLEY (ITEM 4) ON THE SHAFT JOURNAL ON THE TURBINE SOE. REMOVE TURBINE SOE FAN BLAQFS ASSEMBLE THE WOOOEN PIECES (ITEM 5! ON ROTOR BARREL AS SHOWN IN THE SCHEME ASSEMBLE THE UPPER PORTION OF THE OUTER TROLLEY (ITEM 9 BRACKET) ON THE SHAFT AT EXOTER SOE LIFTTHE ROTOR BY CRANE. CHECK WHEATHER THE ROTOfi IS HORiZONTAL

CARRY THE ROTOR INTO STATOR BORE AS SHOWN IN DIAGRAM !

DIAGRAM-!!

FKING OUTER TROLLEY ITEM 9

! -, •z- . rr

"ii-if 1 1 i

\i

1—i

1 1

•

1

-J

DIAGRAM VI

FOB DIAGRAM A\ 1 BRING THE LOWER PORTION OF THE TROLLEY rTEM 9 UNDER THE BRACKET

ANO JOIN THEM 6* BOLTS 2. LOWER THE ROTOR ANO PLACE ON THE TROLLEYS (ITEM 4 & 8). 3 REMOVE THE SUNG 4 PLACE THE BEAM (ITEM 14) ON THE TURBINE SOE

INSERTION Of ROTOR INTO STATOR

FOR DtAGRAM-Vl PLACE THE BEAM (ITEM 14) ON THE EXCITER SIDE. REMOVE THE LOWER PART OF THE TROLLEY (ITEM 9). LIFT THE ROTOR END 8* CRANE. MAKE THE ROTOR REST ON THE BEAM WITH SPACERS IN BETWEEN TAKE OUT THE TROLLEY (ITEM 9) REMOVE THE RMLS AND SHEET (ITEM 3) MOUNT THE PEDESTAL OF THE BEARING. MOUNT THE LOWER HALF OF THE BEARING UNER LFT THE END OF THE ROTOR BY CRANE. REMOVE THE BEAM (OEM 14) MAKE THE ROTOR REST ON THE HALF LINER OF THE BEARING

FOR DtAQRAM-V BY MEANS Of CROWBARS AND CRANE TAKE THE ROTOR TO THE POSflTON WHERE THE HALF COUPLING OF TURBINE & GENERATOR MEET. MOUNT THE LOWER HALF OF THE UNER ON THE TURBINE SIDE. LOWER THE ROTOR ON TO THE LINER REMOVE THE BEAM (ITEM 14)

DIAGRAM IV

FORCMAGRAM-IV BRING THE ROTOR TO THE POSITION SHOWN IN DIAGfl IV MAKE THE ROTOR REST ON THE BEAM TAKING CARE SO THAT IT DOES NOT REST ON THE STATOR (WOOD PACKING MAY BE PLACED OVER THE BEAM IF RECUSED. DISCONMECTTHE EXTENSION PIPE (ITEM 16) PASS THE SUNG UNDER THE HALF COUPLING LIFT THE END OF ROTOR. MOVE THE ROTOR TO THE POSTION WHERE IT IS CONVEN€NT TO REMOVE THE TROLLEY. REMOVE THE TROLLEY (ITEM 4.).

TECHNICAL REQUIREMENTS WHILE INSERTING ROTOR INTO STATOR CARE SHOULD BE TAKEN AGAINST THE DANGER OF DAMABE TO OVERHANG OF THE STATOR WINDING & SLOT WEDGES OF THE ROTOR RETAIWNG RINGS ANO FANS SHOULD NEVER BE USED AS SUPPORTS. SHAFT JOURNAL OF THE ROTOR SHOULD BE COVERED WITH CARD BOARO ANO ALUMINUM SHEETS BEFORE FIXING TROLLEYS WHEN THE ROTOR IS HELD BY ITS BARREL BETWEEN THE SUNG ANO. BARREL WOOOEN PIECES SHOULD BE INTRODUCED ROTOR SHOULD NOT BE ALLOWED TO REST ON THE PROJECTING PARTS OF THE ROTOR WEDGES

Gl-ol-olo$T

GENERATOR Erection BEARING ASSEMBLY

The Rear end bearing of generator is assembled as per following

procedures :

1. Carry out the kerosene test on the oil chamber of the

pedestal for 24 hours to ensure that there is no leakage

prior to rotor insertion.

2. Ensure that foundation plate is free from dents, burrs and

dust.

3. Remove all high points using a surface plate from the

surface of the foundation plate.

4. Check the contact between foundation plate and bearing

pedestal (without insulating shim) and without tightening

the bolts. A feeler gauge of 0.05 mm should not pass

anywhere. If necessary, the contact surfaces are to be

carefully scrapped.

5. Check the contact surface between the bearing pedestal and

the cover when the bearing cover is freely placed on the

pedestal.

6. Check the contact surface between the bearing liner top half

and bottom half and ensure contact as per logsheet no. FQA-

03-00-01-L04.

7. Ensure the contact betwen the bearing pedestal and bottom

half bearing liner and top cover and top half liner by

rotating the liner in the pedestal and top cover

respectively.


Cjj^l-OllOT/1 of 3

GENERATOR Erection BEARING ASSEMBLY

8. Ensure cleanliness of the holes for the RTD's inside the

liner before placing the liner inside the pedestal.

9. The gap between the bearing liner and the cover/pedestal at

the sides (left and right) and at top should be maintained

as per FQA log sheet No. FQA-03-00-01-L-05 sheet 9/12 (SI.

No. 5.23)

10. After insertion of rotor into the stator, the position of

bearing pedestal is finally fixed as per the FQA log sheet

No. FQA-03--00-01-L-05 (Sheet 9/12).

11. The correctness of the bore of the liner is checked as per

shaft journal and the lower half of the liner should be

uniform and of equal width along the complete length of the

liner.

12. The oil gaps between the rotor journal and bearing liner at

sides (left and right) and top are maintained as per FQA log

sheet No. FQA-03-00-01-L-05 (sheet 9/12, SI. No. 5.23).

13. Before, finally lowering the rotor onto the bearing liner on

the excitor side, check the insulation resistance between

the bearing pedesal and the foundation frame and record.

14. Assemble the bearing liner and record the gaps.

15. Mount the bearing cover after completing the assembly of the

shaft seals.


G1-01-0110T/2 Of 3 10/93

CITFtt GENERATOR Erection BEARING ASSEMBLY

16. Assemble oil catcher and maintain clearance as per FQA

log sheet No. FQA-03-00-01-L-05 (Sheet 9/12).

17. Assemble front bearing as per drawings and log Sheet No.

FQA-02-00-09-L04 of steam turbine check list.


EITFtt GENERATOR ALIGNMENT OF GENERATOR

Erection ROTOR WITH LP ROTOR

Correct alignment of generator rotor with respect to turbine

rotor is most important for satisfactory operation of the turbo-

set. The two shafts are aligned along the line of their natural

deflection so that there is no break in the bending lines of the

individual rotors at the couplings. The criteria for the correct

alignment is

The identical radial position of associated coupling

and

Parallelism of the coupling flange faces at both

ends.

1.0 PRE-REQUISITE

Following should be ensured before alignment.

a) Ensure blue matching of babbit surface and rotor

journal of inboard and outboard bearing and blue

matching of spherical seating of bottom bearing half

of out board bearing and bearing housing and

bearings pads of in board bearing with bearing

housing.

b) Ensure minimum 2 mm shims alongwith insulation sheet

between pedestal and frame is provided.

c) Matching of foundation bolts anchor plate with

foundation block of rear bearing pedestal.

d) Blue matching of embedded plate with permanent

packers.

Bharat Heavy Electrical* Limited Gi -Ql -Ol l lT /1 of 3 Rev. 00 10/93

ALIGNMENT OF GENERATOR ROTOR WITH LP ROTOR

e) Before joining the two coupling face required radial

gap between male and female spigot depth with male

spigot of projection should be checked.

f) Ensure condenser is filled up with water before

alignment in case of TG rotors coupled with LMW

turbines.

2.0 PROCEDURE

Prior to alignment work, the runout check of both half

couplings (turbine and generator) in radial and axial

direction is performed. By means of these checks, it is

possible to ascertain whether the outer circumferences of

two couplings donot feature any runout relative to the

shafts and whether the mating end faces are at right

angles to the shaft. Any minor manufacturing tolerances

measured should be taken into account accordingly while

numbering the coupling holes of both shafts to indicate

their final position relative to each other. The

alignment of both rotors should be carried out now in a

position in which they are to be coupled together.

The measurement of radial gaps is done by a dial gauge

and where a dial gauge cannot be used be cause of the

small clearnces in the bearing housing, a special

measuring device is fabricated and installed permitting

the gap measurement by means of a feeler gauge. Both

rotors are rotated by 90° and a four set of readings are

taken.

tiTH^l GENERATOR Erection


1-0111T/2 of 3

rnxcTi GENERATOR ALIGNMENT OF GENERATOR Erection ROTOR WITH LP ROTOR

The measurement of axial gap is also done at 4 positions

(90° apart) of rotors. 3 sets of reading (left, right and

Top) are taken between the two half couplings at each

position of rotor using feeler gauge. The 4th recording

(at bottom position) is normally calculated by using the

formula i.e. the sum of two measured values in the

horizontal plane must be equal to the sum of the

two measured values in the vertical plane.

A check for correctness of the entire measurement is

normally applied by bringing the device to the top

position again and checking the axial and radial gaps

once again in this position. Various readings are

recorded in the Log sheet No. FQA-03-00-01-L05 (point no.

5.2). The difference between average distances between

the end faces of the coupling in vertical and horizontal

plane and radial gaps in vertical and horizontal plane

should not exceed those specified in the log sheet.

However, if it is more, suitable adjustment of generator

bearings are carried out to obtain the desired results.

Bharat Heavy Electrical* Limited G1-Q1-0111T/3 of 3 Rev. 00 10/93

CiZEfal GENERATOR Erection REAMING AND COUPLING

The generator rotor is coupled with LP rotor after aligning the

axis of both shafts. During alignment process, coupling faces of

both shafts are checked for parallelity of coupling faces and the

rotor axis are made concentric while coupling the shaft. It must

be properly ensured that maximum runout position of one coupling

face is coupled with min. runout position of other face and

aligned position of the shaft does not get disturbed.

1. 0 PROCEDURE

Check the coupling face for presence of any

dents/burrs and its cleanliness,

Bring the generator rotor closed to LP rotor and

match the holes concentricity to the extent

possible.

Tighten four diagonally opposite loose fit bolts.

Mount three dial indicators on «£fe coupling to check

any disturbance in the rotp.r alignment during

tightening process.

Ream the remaining holes with ifijitable fixture not

provided by BHEL).

Ensure the ovality and taper ®f finished holes are

with in 0.01 mm by honing proqsgs.

Check dia of finished holes mmo prepare the bolt

size with in 0.02 mm less th£tn finished hole size

and equal the weight of bolt£ j«th nut and washer

CJUTJC<1 GENERATOR

Erection REAMING AND COUPLING

for diagonally opposite holes and mark for hole

numbers and record as per Log sheet no. FQA-03-00-

01-L.05 (sheet. 8/12)

Fit these bolts in the reamed and corresponding

holes and tighten it by hand.

Remove the four loose bolts and ream these holes and

prepare the bolts for these holes also.

Fit all the bolts and tighten it.

Elogate all the bolts by tightening and record the

elongated length and elongation values as per log

heet no. FQA-03-00-01-L05 (Sheet 8/12)

Secure the coupling bolts by its proper caulking and

assemble the cover plate and pruck punch it. (For

sets coupled to KWV Turbine only.

Bharat Heavy Electricals limited Rev. 00 ^ L j 7 ^ - 0 1 1 2 T / 2 Of 2

EIUJETl GENERATOR Erection STATOR CENTERING

The stator of generator is required to be centered with respect

to rotor to have uniform air gap all around the rotor inside the

stator bore. This is done after finalising the position of rotor

after its alignment with LP rotor. During this process, three

main activities are required to be done:

(i) centering of stator with respect to generator rotor.

(ii) Measurement of air gap

(iii) Setting of magnetic off-set.

1.0 PROCEDURE

1.1 Centering of stator with respect to rotor:

After completion of generator rotor alignment with LP

rotor, measure the value of radial gaps between the rotor

and stator bore at four points 90° apart on turbine and

excitor sides. The gaps can be made uniform by moving the

stator radially with the help of four hydraulic jacks

placed between the casing and foundation. Its final

values should be recorded in the Logsheet No FQA-03-00-

01-L05 (Sheet 3/12).

1.2 Measurement of air gap

After centering stator w.r.to rotor, air gap should be

measured between rotor barrel and the stator core (1st

packet) radially at minimum four points 90° apart on

both side (i.e. Turbine and exciter end) with the help of


CIZTtt GENERATOR Erection STATOR CENTERING

a suitable device (not supplied by BHEL) and should be

recorded in the Logsheet no FQA-03-00-01-L-05 (sheet

3/12)

l.3 Setting of Magnetic Axis

The centre axis of stator are kept at the off set from

rotor centre axis towards exciter end to compensate

thermal expansion of rotor while the machine is in

operation. For this, measurements should be taken between

stator end core packet and rotor retaining ring and as

shown in the Log sheet no FQA-03-00-01-L05 (sheet 3/12)

on both turbine and exciter ends. To achieve the required

value the stator should be shifted anially with the help

of two hydraulic jacks placed between stator casing and

foundation frame.

After finalising the position of stator w.r.to rotor

axially and radially, packer plates as per the gaps

between embedded plate and stator foundation plates are

prepared and inserted.

Note : The contact surface of the shims with embedded

plate and the foundation plates should not be less than

80% of the total surface area and packer thickness should

not be less than 25 mm.

Foundation both should be fully tightened keeping dial

indicators on stator frame to check any movement of

stator during tightening process. All the nuts should be

locked by tag welding.


CiTT^l GENERATOR Erection STATOR CENTERING

Caution : Final rotor alignment should be again checked

before releasing it for grouting.

Anchor bolts should be tightened and locked by means of

tag-welding.

The stator body should be earthed by welding the earthing

contact assembly on the trunion foot plates and

connecting it to earthing grid of the station.


<jj^gl-0113T/3 Of 3

tJZFtt GENERATOR GROUTING OF STATOR,

Erection BEARING PEDESTAL

Grouting of stator foundation plates, bearing pedestal,

foundation frame with shrink-free grouting compound is intended

to ensure uniform transmission of the force and vibration of the

TG unit to the foundation.

Caution : Preparations for grouting, and grouting must be carried

out with great care as it is no longer possible to

check and rectify the parts once they have been

grouted.

CONBEXTRA GP-II should be used as grouting compound. Further

details on the grouting depths, mixing time, quantity of water to

be mixed, should be refered from the manufacturers brochures.

1.0 PROCEDURE

The foundation should be thoroughly cleaned. All foundation

bolt holes should be either filled with sand or pea-gravels

and covered at the top to avoid entry and sticking of

grouting materials with the bolts.

Note : Remove all rust preventive paints, grease etc from

surfaces by wire brushes to ensure proper adhesion of

the grouting compound.

1.1 SETTING UP OF SHUTTERING

Set up shuttering from suitable material in box like manner

around the foundation plates and secure it firmly.

Note : Shuttering must be sealed well to prevent the liquid

grouting compound from running out.


ClZIJCl GENERATOR GROUTING OF STATOR,


As the grouting compound remains workable for a limited

time, to prevent air bubbles, it must be poured from one

side only. For this, a large size filling nozzle should be

used.

1.2 PREPARATION OF GROUT MIX

Following measure must be taken before commencing mixing and

grouting due to limited time that the grouting compound

remains workable.

Keep the foundation moist for at least 6 hours before the

grouting.

Set up mixers in the immediate vicinity of the

foundation plates. The capacity of the mixers, should

be adequate to cope with the quantity of mixed cement

required at a time. Two mixers are required for

grouting of bearing pedestal foundation frame.

Store the grouting compound next to mixer.

Ensure that the compound is well within its expiry

date.

Provide the water hose and measuring pans near the

mixers.

Ensure un-interrupted power supply to the mixers and

EOT Crane for handling the ready mix.

Provide adequate workmen for grouting.

Bharat Heavy Electricals Limited G1-01-0114T/2 of 5 Gl-01 Rev. 00 n>/93

f i l i a l GENERATOR GROUTING OF STATOR, Erection BEARING PEDESTAL

Complete alignment of stator and rotor is to be checked

and ensured before grouting.

Ensure six empty cubes for filling the grout for

strength testing.

Add water slowly to the mixtures or grouting compound in the

mixer (s) in exactly the quantities specified and mix

thoroughly for another 5 minutes atleast. Pour the mix with

buckets or with the help of a specially fabricated container

fitted with a hose through the filling nozzle until the

desired height is achieved at the opposite side. Flow may be

accelerated by moving the grout in the filling nozzles

underneath the plates with chains or material strips.

CAUTIONS

1. Do not use concrete vibrator

2. Pour grout from one side only so that no air bubbles

remains entrapped in the grouting compound.

3. Due to short workability times, never mix more grouting

compound at one time than is required for one plate or

volume to be grouted.

4. Pour in one continuous operation, without interruption.

5. Dox not install any woven steel fabric reinforcing mats

beneath the foundation plates.


GENERATOR GROUTING OF STATOR,


2.0 GROUTING OF STATOR FOUNDATIONN PLATES

As the gap between stator foundation plate pads and embedded

plates is kept approx 50 mm, above method of grouting can be

followed straight away,, where the gaps are found to be more

than 70mm, pee-shaped gravels, collected from siever sand

are to be mixed in the required proportion to the grouting

mix while mixing.

Note : Sample mix must be filled up in cubes available

for the purpose of checking comprehensive strength

as per civil engineering norms and sent to the

laboratory (24 hrs), 3 days and 20 days tests).

3.0 GROUTING OF BEARING PEDESTAL FOUNDATION FRAME

The gap between the foundation frame and the embedded plates

is also 50 mm. Thereafter, filling the foundation frame

inner boix and its encasing from outside is carried out.

As such, grouting of the bearing pedestal foundation frame

can also be executed in two stages.

Stage - I

The front gap is filled up as mentioned above.

Stage - II

After approx 12 hours of stage - I grouting completion, when

the grouted material has become sufficiently hard, the

second stage grouting is carried out. In addition to grout


GROUTING OF STATOR, BEARING PEDESTAL

mix and requisite quantity of water, washed pea gravel 3-7

mm in size are also added upto 50% by weight and the mix is

prepared by thoroughly mixing in the mixer atleast for 5

minutes. Further, grouting is done as mentioned above.

Note : After atleast 24 hours hardening time, work may be

commenced on pre-tensioning of the foundation

studs to the values given in the logsheet No. FOA-

03-00-01-L-05 (sheet 4/12) .

After the grouting compound has dried out (approx 24 hours

after grouting), remove all shutterings and smooth off the

excess grout. Re-check the alignment of rotor and centering

of stator. The grouting compound is subjected to compressive

forces only. Resultant hair cracks are insignificant with

regard to TG stability provided these do not lead to

breaking of the grouting compound.

Eiiffl^l GENERATOR Erection


G1-01-0114T/5 Of 5 10/93

CUKEI GENERATOR g^o SHIELD AND FAN

Erection SHIELDS ASSEMBLY

GENERAL

The end shields are fabricated from mild steel and are made up in

two halves for convenience during erection and inspection. To

make the stator body gas tight at the two ends, two endshields

are 'fitted with the help of bolts and rubber sealing cord.

Aluminium alloy casting of fan shield is supported on end shield

to direct the gas flow from the propller fan. During the erecion

stage, end shields assembly is done twice, once before rotor

insertion for gas tightness test of stator and other after rotor

insertion. Final assembly of end shields is done together with

fan shields.

PRE-REQUISITE

1. Ensure blue matching of end shield parting plane joints.

2. Ensure proper size and freeness of end shield fixing bolts.

3. Ensure rubber sealing cord is free from cut marks, twist,

and is of proper quality and size.

4. Prepare rubber sealing cord joints as per Instruction No.

Gl-01-0125 T and fix them in position on the end shields.

5. Ensure cleaning of all drain pipes of generator casing by

blowing dry compressed air and cleaning of generator asing

bottom portion. It should be free from all foreign

particles/dust etc.

PROCEDURE

A. Assembly of end shield without rotor

A fixture is normally supplied to assemble end shield when

rotor is not in position, if not available, the fixture can


GENERATOR gj^, SHIELD AND FAN Erection SHIELDS ASSEMBLY

be fabricated from stator dummy plate as per BHEL drawing.

Fix the end shield mounting device with stator in bottom

position with four bolts. Fix the bottom half end shield on

the fixture. On rotation, using crane, bring the bottom half

end shield slowly to the bottom position. Remove the above

fixture.

Fix rubber cord (12mm x 12mm) on horizontal portion (parting

plane) of end shield and place the top half end shield to

sit on jacking screws, which are to be projected 2/3 mm

above the rubber cord top level. Position top half fitting

dowel pin bolts of horizontal joints. Lower end shield top

on the bottom halfslowly by unscrewing jack screws, ensuring

rubber cord intact in its position. Tighten all the parting

plane bolts only after fully tightening the dowel pin bolts.

Cut the excess projected parting plane rubber cord on both

ends so as it projects out by 2 to 3 mm on either ends. Then

bolt the combined end shield to the stator.

B. Assembly of end shield with rotor in position

The bottom half end-shield is assembled temporarily using a

special fixture device received from BHEL Hardwar. Bottom

half fan shield is assembled and aligned in position to get

the required fan blade gaps and bolted tightly with bottom

half end shield using four bolts only. Then bottom half end

shield alongwith bottom half fan shield is taken out and fan

shield bottom is tightened fully with the remaining bolts

and locked after ensuring IR between end shield and fan

shield. Dowel holes between end shield and fan-shield bottom

halves to be re-reamed and dowel pins are fixed.


G1-01-0115T/2 of 3 10/93

END SHIELD AND FAN SHIELDS ASSEMBLY

Now, the bottom half end shield alongwith fan-shield is

assembled. Top half fan-shield is fixed to bottom half fan

shield ensuring required fan blade gaps and IR between two

halves of fan shield. Now, the top half end shield is

assembled as described earlier.

Precautions

1. Ensure proper fixing of the rubber sealing cord in its

position.

2. Before final assembly of turbine side end shield, hot water

flow test of teflon tubes of water header should be

completed as per Instructions No. G1-01-0124T

3. The dowel pin bolts on the horizontal joints of the two

halves of end shield should be fully tightened before

tightening of other bolts on the horizontal joints.

4. The fastners of end shield to stator should be tightened

sequentially as per log sheet no. FQA-03-00-01-L-05 (Sheet

5/12) .

CUTA^M GENERATOR Erection


G1-01-0115T/3 of 3 10/93

tJZFtt GENERATOR MOUNTING OF SHAFT SEAL

Erection (THRUST TYPE)

The Shaft seal is mounted after the generator rotor has been

inserted as well as the lower half of the bearing is in position

and after installation of the components to be accommodated in

the hydrogen space of the generator housing, e.g. fan shield, end

shield, etc.

Oil catcher & seal body on the exciter side are insulated from

the end shield to prevent the flow of shaft currents. Similarly

all pipes connected to the shaft seal body on the exciter side

are also insulated from earth. The insulation resistance should

be checked every time after assembly making sure that the

generator rotor has no connection to earth. This is to be checked

during the insulation check before generator rotor is coupled to

the turbine rotor. The value of the insulation resistance should

not be less than lM-ohm.

Before mounting the shaft seal, the contact surfaces between the

two halves of the seal body, seal liner and oil catchers are

checked. It should be ensured that for every cm square of the

surface threre are atleast three points of contacts and scraping

to achieve this should be adopted, if necessary.

1.0 GAS TIGHTNESS TEST OF SHAFT SEAL COMPONENT

Prior to assembling shaft seal, gas tightness of the seal

bodies is checked by joining them at their flanges of bigger

diameter with sealing gasket in between. Flanges of smaller

diameter and also flanges of feed and drain oil pipes are

closed with steel cover plates of thickness, not less than

16mm and rubber sealing gaskets. The leaks are detected by

soap solution. Seal bodies are considered to be gas tight if

Bharat Heavy Electncals Limited G1-01-0116T/1 of 6 Rev. 00 10/93 "

cizraa GENERATOR MOUNTING OF SHAFT SEAL


the pressure drop for a period of one hour is not more than

5mm of mercury column with the initial pressure of air at 3

atm gauge inside.

2.0 ASSEMBLY & FIXING OF OIL CATCHER

Before fitting the oil catcher ring in position, insulating

washer (of PVC sheet) is inserted over the rotor shaft and

placed on the end shield and joint is glued uniformly. Lower

half of the oil catcher is first taken in position and the

upper half is fixed on the split surface, by bolts and nuts.

The oil catcher is installed with oil outlet holes downwards

and fixed together with insulating washer on the end sheild,

maintaining uniform gap between oil catcher and rotor shaft.

3.0 FITTING THE SEAL BODY & LINER

To ensure proper performance of the shaft seals, the annular

gap of the seal liners must be concentric relative to the

shaft. For this purpose, the flange face of the seal body at

the stator end must be straight in itself, at right angles

to the shaft and exhibit no inadmissible joint displacement,

Otherwise, the result may be distortions or tilting of the

seal body and seal liner relative to the shaft with adverse

effect on the performance of the shaft seals.

Before separating the halves of seal body and liner for

further assembly operation, the matching diameters on both

of them are checked. After the insulating gasket is glued

over the end shield surface, the lower half seal body is

carefully inserted between the end shield and bearing

pedestal and preliminarily fixed to the end shield. The seal


CIZTtt GENERATOR MOUNTING OF SHAFT SEAL


body is centered with respect to the rotor shaft with an

accuracy 0.1mm. Finally the lower half seal body is fixed to

the end shield by tightening the bolts fully.

In case any burrs or compression marks having been developed

due to improper storage the babbit surface of liner must be

scraped and checked with surface plate. There should not be

less than 10-12 spots per 25mm. square area. Then the colour

matching check between the shaft collar side and the liner

babbit surface should conducted. For this purpose after

applying of the dye on the shaft collar, lower shaft seal

liner is inserted first in the lower half seal body and the

upper half seal liner is then placed and fixed together. Now

the seal liner is pressed towards the shaft collar by

inserting wooden wedges between lower half body and seal

liner. The tightness of contact is checked by means of

feeler gauge inserted between the matching surfaces which

should not exceed a gap of 0.03 mm. After ensuring proper

contact, the shaft is rotated by 2-3 turns with the help of

crane or shaft turning gear. In case of necessity, the

babbit surface is rescrapped so that in every square of

surface area, there are at least four prints of contacts.

While scraping is carried out, two halves of the seal liner

are kept in assembled condition and cloth is placed between

the liner and seal body and also between the shaft and

liner. Then the shaft collar surface and seal liner are

washed in kerosene and cleaned properly.

The resistance thermometers and all deflecting rings are

fitted in position when the above operations are over. After

achieving the required gap between rotor shaft and all

deflecting ring, the screws are tightened finally to fix the

Bharat Heavy Electricals Limited „„ _ ^„ , . ^ _ Rev. 00 %-M-0116T/3 o f 6

CiZUSl GENERATOR MOUNTING OF SHAFT SEAL


later. Now after fixing the sealing cords in respective

grooves, the lower seal liner is placed on the lower half

seal body. The upper half liner is then fixed together at

the split surface ensuring no relative displacement. The

free ends of the sealing cords are joined consequently.

Before mounting the upper half seal body, the split surfce

of the lower half is cleaned and sealing rubber cord is

placed and glued in the groove provided for it. It is to be

taken care that the rubber cord and the sealing gasket are

not damaged while fitting the upper half seal body at the

split surface and to the end shield in turn. A stopper screw

provides inter locking between seal liner and seal body to

prevent relative axial movement between the same in vertical

plane beyond the value specified. Now the RTD wires are

fixed on the seal body keeping sufficient loose length so as

to take into account the axial movement of liner with rotor

shaft.

Finally, one tapered hole is to be reamed together on seal

body and end shield to fit a conical set pin which helps in

locating correct position of seal body with respect to end

shield for satisfactory mounting.

4.0 INSTALLATION & FIXING OF SEALING RINGS

After successful completion of above mentioned stages, the

bearing pedestal and liner are cleaned for the absence of

foreign particles & dirt. Now the bearing cover is fitted

and the PVC sheet gasket for sealing ring is placed on the

bearing body and glued at joints uniformly. The lower half

sealing ring is preliminarily fixed with the bearing body

Bharat Heavy Electrical* Umhed Gj^-0116T/4 of 6

FiSXCTl GENERATOR MOUNTING OF SHAFT SEAL


through the gasket with two steel ring sectors, the steel

tape and sealing cord placed already in the groove provided.

The free ends of the sealing cord are then joined with the

help of steel. On the other hand the remaining two steel

ring sectors are placed in the groove of upper half sealing

ring and fixed in position by screwing through the side

holes. This upper half is now mounted, preliminarily fixing

it with the bearing cover and taking care of the sealing

cord and steel tape in position. The RTD wires are taken out

through the side hole provided. After final fixing of split

surface and with bearing cover in turn, the sealing cord is

to be pressed by 1.5 to 2 mm uniformly along the periphery

with bolts through the holes provided on the outer sealing

ring surface. Now the RTD wire outlet is sealed by placing

insulating washer, sealing washer and sealing gland

respectively and the wires are taken to the terminal box

mounted on the seal body.

5 . 0 SALIENT PRECAUTIONS TO BE OBSERVED

5.1 Stopper screw:

Check the physical conditions of the stopper screw (item No.

31 of shaft seal Drg. No. 2-5372.010C) and its fitting holes

in seal liner/body for absence of any cut marks/foreign

particles, at each occasion when the shaft seals are

reassembled after disassembly of the same during a planned

shut down or other occasion. The absence of above screw

results in lowering of the thrust oil pressure and furhter

H2 gas leakage from that end of the shaft seal.


r/TiJO GENERATOR MOUNTING OF SHAFT SEAL


5.2 Interchange of turbine end and Exciter end and seal liners

Oil starvation in the seal may be caused by wrong assembly

of seal liners viz inter-change between turbine end and

exciter end seal liners having direction of the taper lands

on the seal face related to direction of rotation of rotor

shaft collar. This results in seal babbit temperature

reaching to a value more than 75°C.

Therefore, utmost care should be taken so as to avoid

intermixing of the seal liners of TG sets. The correct

direction of taper lands (on seal liner face) with reference

to direction of rotation of TG rotor is shown in Fig. l.A.

Close study of the disposition of taper lands on seal liner

faces of turbine and slipring end seal liners will help in

correct seal assemblies and their proper performance.


EIEIiO GENERATOR MOUNTING OF SHAFT SEALS

Erection (RING TYPE)

The assembly sequence for mounting of shaft seals as mentioned

below may be considered as a guide, required measurement as

called on erection log sheets or elsewhere need to be done during

appropriate assembly stages as called for :

1.0 ASSEMBLY SEQUENCE

1. Mount lower half hydrogen side oil catcher, after

having glued in position, gasket between end shield and

the oil catcher.

2. Now assemble upper half hydrogen side oil catcher.

3. Assemble bottom and top half air side oil catchers.

4. Assemble lower half seal body.

5. Mount lower half seal ring and locate the stopper on

the ring.

6. Assemble upper half seal ring, followed by upper half

seal body.

7. Mount lower half seal cover in position. Specific care

need to be taken to rotate the lower half from top to

bottom position so as not to interfere with hydrogen

side seal oil drain pipe flange.

8. Mount upper half seal cover on the lower half.

9. Finally assemble header.

Bharat Heavy Electricals limited G1-01-0116T/1 of 4 Rev. 00 10/93 "

rizij£a GENERATOR MOUNTING OF SHAFT SEALS Erection (RING TYPE)

2.0 GENERAL

When installed, the seal rings must be movable in both the

radial and axial direction. Check for the necessary-

clearances. If deviations are detected, reworking may be

necessary.

3.0 Assembly Checks

The annular gap of the seal rings must be concentric

relative to the shaft i.e. the face for the seal ring

carrier i.e. seal body at the end shield must be perfectly

flat, at right angles to the shaft and exhibit to

inadmisible joint displacement.

If these conditions are not obtained, the result may be

distortions or tilting of the seal ring carriers i.e. seal

bodies and seal rings relative to the shaft with adverse

effects on the performance of the shaft seals.

The maximum deviation from the correct annular position with

respect to the shaft must not exceed 0.2 mm.

While checking the flange surface make sure that the face is

not distorted in-spite of being at right angles to the

shaft. Such distortions shall not exceed 0.05 mm.

The joint displacement can be measured by checking joint

between the upper and lower seal body halves. The value

obtained must not exceed 0.03 mm if deviations are measured

which exceed the specified value, reworking will be

required.


G ^ l - O l i e T / 2 of 4

CiZHul GENERATOR MOUNTING OF SHAFT SEALS Erection (RING TYPE)

If any burrs or compression marks have developed due to

improper storage, rescrape only the affected portions.

After cleaning, checking and assembly insert the seal into

the chamber of the associated lower half carrier i.e. seal

body making sure that the locating pin is in correct

position. Put the upper half carrier (seal body), insert

taper pins and grub screws & tighten them. Measure the axial

clearane (chamber clearance) on the entire circumference

with a suitable feeler guage.

Nominal Ring Axial Clearance

size

400 mm 0.17 + 0.03 mm

Any raised portions in the seal ring carrier shall be

rescraped, keeping in view the tolerances specified on the

drawing.

4.0 FITTING OF SEAL RINGS

The seal rings which were bolted together to check the

chamber clearance, should be separated again at the joints.

Then place the half seal ring on the shaft at the bearing

saddle, obseving the "Hydrogen side" or "Air Side" marks

respectively. Bring the joints surface in vertical position

and fit the associated upper half to the lower half. Drive

in the reamed bolts and attach and tighten the circular

nuts. Then drive home the threaded locking pins of the

circular nuts. Turn the seal ring unit till locking pin is

supported in the recess of the seal ring carrier.


( | fo$ 1 ~ 0 1 1 6 T / 3 ° f 4

t j i T ^ n GENERATOR MOUNTING OF SHAFT SEALS

Erection (RING TYPE)

MEASURING THE RADIAL RING CLEARANCES

Shift the ring on the shaft in the -axial direction until it

is approximately in its position for normal operation.

Measure the radial ring clearances (axial gap) with feeler

gauges. To do this, atleast three feeler gauges are

required.

Apply two feeler gauge simultaneously to obtain the gap at

each joint of the ring and use of the third feeler gauge to

measure to total gap at the highest point between ring and

shaft after first lifting the ring at the lower side of the

shaft until it touches the shaft.

Shaft diameter Ring Diameter Clearance

400mm 0.26mm + 0 . 04 mm

If there are insufficient gaps, rework the ring bore with a

scraper.

Bharat Heavy Electricals Limited , Rev. 00 ^ M 1 " 0 1 1 6 7 7 4 ° f 4

C-f iT^l GENERATOR Erection ASSEMBLY OF BRUSH GEAR

GENERAL

The performance of brush gear and sliprings depends a lot on

quality of initial erection. Care should be taken to assemble the

brush gear properly.

1. PREPERATORY WORK

The alignment of generator rotor with respect to turbine

rotor and the assembly of auxiliary bearing must be done

prior to the assembly of brush gear. The brush gear should

be cleaned properly and inspected before assembly.

2. ASSEMBLY OF BRUSH GEAR

2.1 Before mounting the brush gear,• radial run out of slipring

should be checked at number of points along the width of

both the rings. Overall runout should not exceed 0.03 mm.

The radial run out for any sector of 30° should not exceed

0.015 mm. The surface of slipring should be free from any

scratch, rust, pitting marks etc.

2.2 The two halves of the brush gear should be fixed as per log

sheet. Centre the brush gear with respect to slipring. Refer

log sheet No. FQA-02-00-01-L-05 (Sheet 10/12).

2.3 The radial gap between brush holders and sliprings should be

uniformly set at 2.0 mm. For ensuring this, a packing of 2mm

thickness should be wrapped round the slipring and fixing of

the brush holder be done in such a way that the brush holder

touches the packing.

Bharat Heavy Electrical* limited G1-01-0117T/1 of 3 Rev. 00 10/93

GENERATOR Erection ASSEMBLY OF BRUSH GEAR

2.4 It should be ensured that all the brushes being fitted are

of same grade HM6R/HM100 and have rubber top as per BHEL

specification. The brushes should also be graded according

to milliolt drop by passing approx 30 amps dc as per sketch

.1... Milliolt variation for grouping should be within 10%

of voltage drop across the brush.

2.5 The side clearance between brush and brush holder should be

checked. The side clearance between brush and brush holder,

with brush touching one side of the holder, should

preferably not exceed 0.25 mm.

2.6 It should be ensured that the contact between brush lead and

brush is not loose. Before fixing pig tail end cap to the

brush gear, it should be ensured that the surfaces of the

end cap and brush gear are cleaned and free from any

dust/greasy matter etc. Bolts for fixing end caps to brush

gear should be sufficiently tightened to ensure good

contact.

4.7 The pressure on all the brushes should be checked and it

should be ensured that it is uniform on all the brushes. The

spring force on each brush shoudl be within 0.9 to l. 0 kg

which can be adjusted by sliding supporting bracket over the

notches and check with the help of a spring balance having

range 0 to 2.0 kg. The above force is applicable for

HM6R/HM100 grade brushes.

2.8 New burshes must be bedded to have full contact over the

slipring surface. Bedding of brushes is done by wrapping

sand paper with glas abrasive around the sliprings and

rotating the rotor on barring gear. The use of emery cloth

Bharat Heavy Electricals Limited Rev. 00 Gfa£l-0inT/2 of 3

ElZTjZTi GENERATOR Erection ASSEMBLY OF BRUSH GEAR

is not permitted as emery may get embedded into the brush

surface and hence cause damage to slipring surface. After

completion of bedding, brush face should be scrapped with

sharp knife to remove the embedded abrasive and sliprings

should be thoroughly cleaned by compressed air and cotton

cloth to remove any traces of dust, dirt, oil etc,

2.9 Insulation resistance of both the brush gear stands should

be measured with respect to pedestal and also between two

stands, without the brushes in position. The value should

not be less than 1 mega ohm.


£IZT£Zl GENERATOR ASSEMBLY OF EXTENSION SHAFT

Erection AND AUXILIARY BEARINGS

GENERAL

Correct alignment of the extension shaft with respect to the

generator rotor is the most important pre-requisite for

satisfactory performance of slip rings and auxiliary bearings.

1. PREPARATORY WORK :

The alignment of generator rotor with respect to turbine

rotor must be done prior to alignment of extension shaft.

Remove the fitting pads of the bearing & keep it safely to

protect it from any damage.

2 . EXTENSION SHAFT ALIGMENT

2.1 The extension shaft to be assembled to generator within

accuracy of 0.03 mm total indicated runout at journal. To

achieve this, the mating flange of extension shaft & end

face of generator rotor be scrapped, if required.

2.2 The castle nuts used for tightening the extension shaft

should be locked with the help of split pins.

3 . ERECTION OF AUXILIARY BEARING

3.1 Insert the bearing pedestal under the extension shaft.

Insert the insulation liner under the bearing pedestal after

lifting it.

3.2 Axial Location : Centre line of auxiliary bearing should be

located axially as per erection drawing and log sheets.


EIZTtt GFNFRATOR ASSEMBLY OF EXTENSION SHAFT

Erection AND AUXILIARY BEARINGS

3.3 Lateral Location : Adjust the bearing body such that equal

gap is achieved at parting plane between bearing body and

extension shaft.

3.4 Inclination : The slope at parting plane of bearing body

should match with the slope of extension shaft.

Accuracy +0.1 mm

3.5 Elevation Location :

The height of auxiliary bearing is adjusted with the help of

steel shims (assorted thicknes) supplied. The height should

be such that when the tilting pads are inserted the

extension shaft gets lifted by 0.1 mm in the normal case.

This would load the bearing adequately.

3.6 The shim under the bearing pedestal should be of such size

that insulation liner should protrude outside the shim.

4. MEASUREMENT OF INSULATION RESISTANCE :

Insulation resistance (IR) of auxiliary bearing is to be

measured before insertion of tilting pads. But the

foundation bolts of the bearing pedestal should be fully

tight. The insulation resistance should be above 1 Mega Ohm

with 500 V megger.

5. PRECAUTIONS :

1. The drain pipe should have inclination for gravity flow

of drain oil.

2. Care must be exercised during assembly to protect the

bearing surface for any physical damage.


G j j ^ l - O l l S T ^ of 2

C1ZH£1 GENERATOR ERECTION OP TG AUXILIARIES

Erection

GENERAL

200/210 MW TG consists of various auxiliaries like seal oil

system, stator water system, gas system and static excitation

system. The components of these systems are normally mounted on a

rack. During erection of these systems, following activities are

required to be carried out:

Erection of control panels.

Erection of skid mounted racks.

Piping erection

Erection of loose components like valves, pump-motor

set, tanks, filters, coolers etc.

1.0 ERECTION OF CONTROL PANEL

The foundation details of the various control panel should

be checked as per drawing and foundation frame should be

placed in position. Proper opening in the foundation for

cable entry should also be ensured as per drawing. The

foundation frame should be levelled with the help of spirit

level and should be grouted. The panel should be placed on

foundation frame and its verticality should be checked. If

the antivibration pads are provided in the drawing same

should be mounted on the foundation frame before panel

placement. Proper earthing and locking of panel should be

ensured. All the unused cable entry points in the panel

should be properly sealed. No gas cutting in the bottom

plate should be done for making any extra cable entry holes.

All the transportation locking fixtures provided in the

panel should then be removed.


C ^ £ - 0 1 3 6 T / 1 of 3

CiUJCTl GENERATOR ERECTION OF TG AUXILIARIES

Erection

2.0 ERECTION OF SKID MOUNTED RACKS

The dimension and position of pockets provided for

foundation bolts should be checked as per the details given

in the drawing. The various holes provided for anchoring

bolts should be checked as per foundation drawing. The

anchoring bolts should be placed in position and grouted.

The rack should then be placed in position, levelled,

aligned and foundation bolts should be tightened. While

doing levelling and alignment of the rack, its orientation

with respect to various piping connection should also be

checked. The frame should be finally grouted.

3.0 PIPING ERECTION

During erection of auxiliary systems, the piping erection

plays a vital role. Various pipings are supplied in pre

fabricated manner and same have to be welded after its

proper laying. While laying the piping, following

precautions should be observed.

Lay the pipelines as per relevant drawing ensuring

proper slopes.

Ensure welding of piping joints as per recommendations

made on the relevant drawings.

Ensure freeness of piping and use of specified hangers

and supports as per drawings.

Ensure mechanical cleaning of the piping by air

blowing/cleaning by wire brush/by acid cleaning as the

case may be.


^ - ^ 1 - 0 1 3 6 ^ 2 of 3

ciir^n GENERATOR PURGE T E S T OF T . G . ROTOR Erection

EQUIPMENTS REQUIRED TO CARRY OUT PURGE TEST

The following equipment/facilities are required for carrying

out the purge test of ventilation canals of TG rotor.

a. Source of compressed air to a pressure of not less than

3 atg.

b. Plug without nipples as per figure (a) - 6 Nos.

c. Plugs with measuring union nipple for manometer as per

figure (b) - 2 Nos.

d. Inlet adopter with removable nipple as per figure (c)

- 1 No.

e. Out let adopter with removable nipple as per figure (d)

- 1 No.

f. Spring type manometer which can measure upto 6 kg. per

Cm2 - 1 No.

g. Micro manometer with hoses which can measure upto 200

mm of water column - 2 Nos. (one as standard

manometer)).

h. Plug for closing the holes of slot wedges - 4536 Nos.

i. Plugs for closing ventilation slots in rotor poles - 4

Nos.

j . Supply hose (Rubber)

Bharat Heavy Electrical* Limited G1-01-0107T/1 of 4 Rev. 00 10/93

CiZH£l GENERATOR PURGE TEST OF T . G . ROTOR Erection

2 . PREPARATION FOR TESTING

a. Number the rotor slots serialwise in clockwise

direction, looking from slip ring end and starting from

that pole which is in the side of field lead connection

to inner slip ring.

b. Number the ventilation holes in wedges of each slot,

starting from retaining ring on slip ring end.

3. PROCEDURE FOR TESTING

3.1 SLOT PORTION

a. Close all the holes in slot wedges by plugs.

b. Remove the plugs from inlet and outlet holes of the

canal under test.

c. Place the nipple of inlet adopter in the inlet hole and

the nipple of outlet adopter with manometer connected

in the outlet hole as shown.

The hose from union nipple for total pressure should be

connected to " + " side and for static pressure to "-"

side of the micro manometer.

d. Supply compressed air at 3+0.1. atg through inlet

adopter.

e. Measure the velocity head at the outlet of the canal.

f. Enter the value of the pressure in relevant test chart.

Bharat Heavy Electricals Limited _ , „„ _„_„„, ,_ £ . Rev. 00 GA7,&l-0107T/2 of 4

vjciNXiivrt.i wiv PURGE TEST OF T .G. ROTOR Erection

g. After taking the reading, the plugs removed earlier for

test of this canal are kept back in position.

h. Repeat the test for other canals.

i. Determine the average velocity and pressure for each

zone and for each slot.

3.2 OVER HANG PORTION

a. Purge test for the canals of overhang portion of rotor

winding should be done immediately after the test of

slot portion as shown.

b. Close the ventilation slots on the rotor shaft,

ventilation slots in the poles, space under centering

ring and holes in the end zone of slot portion on slip

ring end by plugs.

c. Supply compressed air at 3.5 atg. to the plugs and

connect the hose of the micro-manometer to the

measuring nipple of the plug. Gauge static pressure

under the retaining ring must be maintained constant

and equal to 50 mm of water column.

d. Take out the plug from the canal under test.

e. Insert the nipple of outlet adopter into the outlet

hole of the canal under test after making sure by

feeling that there is flow of air coming out of the

canal.

f. Connect the hose from the union nipple of static

pressure of the outlet adopter to the micro-manometer


G1-01-0107T/3 Of 4 10/93

CIZTJCTI GENERATOR mn„ _ o m n„ „ „ nfWm PURGE TEST OF T.G. ROTOR

Erection

and measure the static pressure of air. During this

measurement, the hole at the other end of the outlet

adopter and union nipple for total pressure should be

closed.

g. Measure the static pressure at the outlet of canal.

h. Enter the values of pressure in the purge test chart.

i. Repeat the test for all other holes connected to the

overhang portion.

j . Carry out the purge test for overhang portion of rotor

winding on turbine end in a similar manner.

4. ACCEPTED NORMS

a. The average value of velocity head in the canal of slot

portion of rotor winding should not be less than 15 mm

of water column for each zone and 21 mm of water column

for each slot.

b. The minimum static pressure in each canal of overhang

portion of rotor winding should not be less than 15 mm

of water column.

c. The number of fully closed canals should not be more

than 6 in the slot portion of rotor winding at the same

time there should not be more than one closed canal in

any one slot.

d. Fully closed canals are not allowed in the overhang

portions of the rotor windings.

Bharat Heavy Electricals Limited „ „ „ „ , / „ ^ , Rev. 00 < f t $ L - 0 1 0 7 T / 4 of 4

PIPE

s RUBBER B O D Y ^ OF PLUG

JOEL

RUBBER BODY OF PLUG ;

fa)

REMOVABLE NIPPLE

MEASURING UNION / NIPPLE

FOR SPRING TYPE MANOMETER

NUT

EE MOVABLE NIPPLE

UNION NIPPLE „ FOR TOTAL PRESSURE

UNION NIPPLE FOR STATIC PRESSURE

(d)

NIPPLES & FITTtNGS FOR PURGE TEST

a l- Oi-OiOlT

INLET ADAPTER OUTLET ' * /ADAPTER MEASURING

r-H IMICROMANOMETER

SPR.ING JU

CANAL

B€ 2 DIAGRAM FOR THE PURGE TEST OF VENTILATION CANALS SLOT PORTION

G t~ol- ol&7T

:ASUBIU£

PLUG WITH MEASURING UNION NIPPLE

OUTLET ADAPTER

'MEASURING MICROMANO-METER

HG. § DIAGRAM FOR THE PURGE TEST OF VENTI LATION CANALS OVERHANG PORTION

ei/ot'**077"

V J ^ ^ I ^ J U I \ Q^g TIGHTNESS TEST OF ROTOR Erection

Rotor is tested for gas tightness before its insertion into

stator. During this test sealing provided at the following places

is checked.

i. Slipring end of the central hole of Rotor.

ii. Turbine end of the central hole of Rotor.

iii. Current carrying bolts connecting windings to the field lead

core bar in the central hole of the rotor shaft.

iv. Current carrying bolt connecting the slip rings to the field

lead core bar in the central hole of the rotor shaft.

PROCEDURE FOR CARRYING OUT GAS TIGHTNESS TEST

The scheme of testing is given showing the details of equipment

required.

A plug is provided on the cover plate closing the central hole of

the rotor shaft at slip ring end. Plug is removed and a

compressed air pipe line with manometer is connected to this.

With the pressure of compressed air of 3.0 to 4.0 atmospheres in

the central hole the leakage is checked. First leakage at the end

of central hole is detected by applying soap solution. For

preventing the leakage, if any, the bolts are tightened and if

required the sealing gaskets at the ends are replaced. If

manometer still shows fast reduction of pressure, sealing gaskets

provided for current carrying bolts are checked first at slip

rings and then under the over-hang portion of rotor windings. To

check at these places the brackets and insulating details over

the current carrying bolts are taken out and then connecting


G1-01-0108T/1 of 2 10/93

€IZT£Zl GAS TIGHTNESS TEST OF ROTOR

Erection

copper flexibles are disconnected. To detect leakage white spirit

is applied around the current carrying bolts. In case of leakage,

air bubbles are formed. Nuts pressing the sealing gaskets are

tightened and if necessary sealing gaskets are replaced.

While testing leakage at the current carrying bolts the rotor

should be placed in a way that the bolts under test are in

vertical plane.

Gas tightness of the rotor is considered satisfactory if the

pressure drop for a period of 6 hours does not exceed 10% of the

initial pressure. Initial pressure being 4.0 atmosphere.

Bharat Heavy Electricals Limited „ « ,„„„, /„ J= -, Rev. 00 G ^ - O l O S T / 2 of 2

CJZTtt GENERATOR RESISTANCE MEASUREMENT OP

Erection STATOR WINDING

Measurement of DC Ohmic resistance of stator winding is

carried out during assembly of terminal bushing,

commissioning and subsequent overhaul of generator. During

assembly of terminal bushing, it is to ensure the proper

quality of tightening/soldering of flexible connection with

phase leads and terminal bushings. This is done at three

stages of assembly work.

Stage-I : DC resistance of stator winding before

connecting the terminal bushing.

Stage-II : DC resistance after bolting the terminal bushing.

Stage-Ill: DC resistance after soldering the terminal

bushing.

During commissioning and subsequent checking, it is done

before making electrical connection to the bus duct.

1.0 PRE-REQUISITE :

i) Ensure the proper cleanliness of the contact used for

resistance measurement.

ii) A proper clamping device should be used to make the

electrical connections with the measuring cable.

iii) Ensure that generator is in cold condition at the time

of measurement, if necessary, temperature correction

may be carried out.


rizraa GENERATOR RESISTANCE MEASUREMENT OF

Erection STATOR WINDING

2.0 INSTRUMENT REQUIRED :

Micro Ohm Meter - l No.

3.0 PROCEDURE :

The measurement of DC resistance of stator winding per phase

per parallel path is done by connecting the micro ohm meter

across the terminals of the concerned winding.

The readings should be recorded as per log sheet No. FQA-03-

00-01-L07.

4.0 ACCEPTANCE CRITERIA

i) Maximum permissible variation in winding resistance

value between Stage-I and Stage-Ill is 3%.

ii) Value measured in Stage-I should match with test

certificate value (within 3%).


C£UF£iI» GENERATOR m „ ™ ™ m w ™ ™ P m , ^ „ MEASUREMENT OF INSULATION

Erection RESISTANCE OF STATOR WINDING

The insulation resistance value of stator winding is taken to

assess the conditions of insulation during various stages of

erection/commissioning and overhaul of the machine. The value may

sometime deteriorate due to moisture absorption during storage

and transportation of stator. The insulation resistance should,

therefore, be measured prior to the first commissioning, after

any prolonged shutdown and after any work on windings. If

required, the generator should be dried until a sufficient

insulation resistance has been obtained.

1.0 PRE-REQUISITE

1. Prior to measuring the insulation resistance of stator

winding, it must be ensured that, there was no water

ingress during storage, transit and erection and

winding is clean from dust etc.

2. Water should be drained off from the winding and

winding should be dried by blowing dry instrument air.

3. Water header and gas trap pipe line should be

disconnected from the external piping system and ensure

minimum IR value of water headers with respect to

stator casing to 5 M.ohm by 500 V meggar.

4. The generator terminals should be electrically

disconnected from the bus duct at its terminal on both

sides (phase and neutral).

5. Ensure earthing of stator casing at two places.

Bharat Heavy Electricals limited Rev. 00 qfog l -0103T/ l of 4

CitTiCl MEASUREMENT OF INSOLATION


2.0 EQUIPMENT USED

Motorised meggar (l KV) - l No.

3.0 PROCEDURE

The insulation resistance of stator winding is measured in

three steps.

Step-1 : IR value of each phase with respect to earthed

stator casing (other two phases should be

grounded).

Step-II : IR value between two phases (remaining phase

shorted to earth).

Step-Ill: IR value of all 3 phases shorted together w.r.t.

earthed casing.

During checking the insulation resistance of each phase with

reference to earthed casing, the phase winding should be

connected to LIVE terminal of meggar and casing to EARTH

terminal and water header which is isolated from external

cooling circuit should be connected to Guard terminal of

meggar. The remaining two phases should be connected to

earth. The readings should be taken at interval of 15

seconds, 60 seconds and 10 minutes duration after switching

ON the instrument. This should be repeated for all other

phases.

For checking the insulation resistance values between phase

to phase of the winding, out of two phases under test, one

Bharat Heavy Electricals Limited Rev. 00 G g ^ . - 0 1 0 3 T / 2 Of 4

CJTijETI GENERATOR MEASUREMENT OF INSULATION


should be connected to LIVE terminal and other phase should

be connected to EARTH terminal and GUARD terminal should be

connected to isolated water header and the remaining phase.

Readings in this case should be taken at 15 seconds and 60

seconds interval after switching ON the meggar.


The recommended minimum insulation resistance of stator

winding can be determined by formula

R60 = KV + 1

Where R60 = recommended minimum insulation resistance in

mega ohms of the entire winding at 40°C after 60 seconds.

KV = Rated voltage of the machine in kilovolts.

For 200/210 MW generator, the recommended one minute value

of insulation resistance for stator winding is 16.75 M Ohms

at 40°C with 1 KV meggar.

Also, the values of absorption co-efficient and Polarisation

Index are taken to access the degree of dryness of winding.

IR measured at 60 Sec. Absorption Co-efft =

IR measured at 15 Sec.

IR measured at 10 Min. Polarisation Index =

IR measured at 1 Min.

The minimum recommended value of Absorption Co-efficient and

Po

Bharat Heavy Electricals Limited Rev. 00 10/93

CiTT^Tl GENERATOR MEASUREMENT OF INSULATION


in good condition, insulation resistance readings at 60 Sec.

are normally observed to be 10 to 100 times the minimum

recommended values.

If the windings are not at 40°C temp., the temp, correction

should be made in IR values by multiplying with temp, co

efficient of insulation resistance. K40°C as given in Fig.

1. The corrected insulation resistance at 40°C is calculated

by the formula :

R40°C = Rt x K40°C

Where Rt = measured insulation resistance in M.Ohm at t°C.

5 . 0 PRECAUTIONS

On completion of IR measurement, the winding should be

properly discharged to earth with the help of earthing rod

before disconnecting the measuring leads from winding.

NOTE

During initial commissioning stage, the IR value should be

recorded at each minute interval from 1 minute to 10 minutes

duration for future reference.


G^-^L-0103T/4 Of 4

CIZT1Z* GENERATOR ELECTRICAL CHECKING OF

Erection GENERATOR RTDS

The temperature rise of stator winding, core and H2 gas (cold and

hot) in a 200/210 MW generator are monitored by way of providing

embedded RTDs in these components. These RTDs are terminated to a

terminal box for its external electrical connection to the

measuring circuits. These RTDs are required to be checked for

healthiness interms of IR and DC resistance values before

connecting it to the external measuring circuit.

1.0 PRE-REQUISITE :

i) Ensure that no external connections are made to the

RTDs terminals.

ii) The generator casing should be at the cold condition.

iii) The terminal box should be cleaned by compressed air.

iv) Ensure that screen of all RTDs are properly earthed at

terminal box.

2 . 0 EQUIPMENT USED :

Digital Multimeter - 1 No.

Meggar 250V - 1 No.

3.0 PROCEDURE

a) D.C Resistance Measurement

The resistance of each RTD should be checked with the

help of digital multimeter by connecting it across both

ends of RTD at terminal box. The resistance values

should be recorded as per log sheet No. FQA-03-00-01-L-

11.

Bharat Heavy Electricals Limited ] Rev. 00 < % ^ - 0 1 0 2 T / l of 3

CfiTjt^l GENERATOR ELECTRICAL CHECKING OF

Erection GENERATOR RTDS

b) IR Measurement

The insulation resistance of each RTD should be

measured with the help of a 250V meggar. The meggar

terminal should be connected across one end of RTD and

earth potential of stator casing. The insulation

resistance value at 15 second should be recorded as per

log Sheet No. FQA-03-00-01-L-11.

4.0 ACCEPTANCE CRITERIA :

In case of DC resistance, the obtained value should not

differ by more than 2% as computed from Resistance vS Temp.

- chart. For IR values a minimum value of 0.5 M ohm should

be obtained for an healthy RTD.

Bharat Heavy Electricals Limited Rev. 00 ( f t$L-0102T/2 of 3

riiTfTi GENERATOR p . ELECTRICAL CHECKING OF Erection GENERATOR RTDS

RESISTANCE Vs TEMPERATURE FOR

PRT (RO=100 Ohms)

Temperature in (°C) Resistance in (Ohms)

0 100.00

2 100.78

4 101.56

6 102.34

8 103.12

10 103.90

12 104.68

14 105.46

16 106.24

18 107.02

20 107.79

22 108.57

24 109.35

26 110.12

28 110.90

30 111.67

32 112.45

36 113.99

38 114.77

40 115.54

42 116.31

44 117.08

46 117.85

48 118.62

50 119.40

52 120.16

54 120.93

56 121.70

58 122.47

60 123.24

Bharat Heavy Electricals Limited Rev. 00 ^ 7 ^ . - 0 1 0 2 7 / 3 of 3

CJZF£Zi GENERATOR HYDRAULIC TEST OF STATOR

Erection WINDING

The stator winding of water cooled generator is having hollow

conductors for circulation of DM water in the winding for its

cooling. This water path along with its header and teflon tube

connection should be hydraulically tested to ensure its

tightness for any water leakage inside the stator casing.

1.0 PRE REQUISITE

To carry out the hydraulic test of stator winding including

the terminal bushing, following preprations should be

done: -

i. The terminal bars along with the bushing should be

mounted and its electrical and water connections to

the main winding should be established.

ii. Insulated pipes at inlet and outlet of water header

should be properly assembled and its vent pipe

connection should also be established.

iii. End shields of generator on both side should be kept

open.

iv. A temporary blank at the outlet header of water

connection should be provided and the inlet header

should be connected to a manual operated hydraulic

pump.

v. Vent pipe provided at both water header should be

temporarily blanked with a proper device.


Q j ^ L - 0 1 2 1 T / l Of 3

W w ^ i v ™ v / w HYDRAULIC TEST OF STATOR Erection WINDING

vi. A proper arrangement for DM water should be made near

the hydraulic pump.

2.0 PROCEDURE

Initially the winding should be filled with DM water with

the help of hydraulic pump and air venting from the winding

should be done by loosening the temporary blanks provided

at both vent lines and outlet header. While venting the

air, it must be ensured that no air is coming out of the

vents and water wihtout any bubble is coming out.

After ensuring that complete winding is full of water, the

water pressure should be raised with the help of hydraulic

pump upto 8 Kg/cm2 and same should be maintained for 24

hours after closing the isolating valve at outlet of

hydraulic pump.

Hourly reading of water pressure should be recorded and

complete system should be thoroughly inspected for any

water seepage from any of the joints in the water path.


A drop of 5% may be allowed to compensate the temperature

variation throughout the test. No signs of moisture on the

windings, headers, flexible hoses, and their connections

should be observed during the test.

NOTE :

1. It is recommended to conduct an "AIR LEAK TEST" of

stator winding with dry compressed air at 4 Kg/cm2


G1-01-0121T/2 of 3 10/93

tizraa GENERATOR HYDRAULIC TEST OF STATOR

Erection WINDING

prior to Hydraulic test for easy detection of leakage

points, if any.

2. IR value of stator winding should be checked before

and after the test.


ttZrtZm GENERATOR ELECTRICAL TESTS OF ROTOR

Erection WINDING

The field winding of generator rotor should be checked for its

D.C. resistance, impedance and insulation resistance values to

ensure it's healthiness at various stages of erection,

commissioning and subsequent during overhauls.

1.0 PRE-REQUISITE

i. During any measurement, the rotor winding should be

electrically disconnected from external circuit.

ii. During checking of DC resistance and impedance values

of winding, it must be ensured that electrical

connections made at both slip ring for measurement are

perfectly tight.

iii. While doing measurement on the rotor, its condition

like outside/inside the generator casing, temperature

should be properly recorded.

iv. The areas around slip ring surface should be cleaned

properly before carrying out any checks on the

winding.

v. During impedance checking of winding, the frequency of

supply to the winding should also be recorded.

2.0 INSTRUMENT REQUIRED

Micro Ohm meter 1 No.

Meggar (500 V) 1 No.

Voltmeter (0-300V) AC 1 No.

Ammeter (0-100A) AC 1 No.

Single Phase 1 No.

Variac (0-250V/100A)


ExTHiH GENERATOR ELECTRICAL TESTS OP ROTOR Erection WINDING

3.3 INSULATION RESISTANCE MEASUREMENT

The insulation resistance of field winding should be

checked with the help of 500V megger at one of the slip

ring with respect to shaft surface. Since the rotor is a

moving part of generator, the insulation resistance should

be measured at different speed to see the effect of speed

on the insulation resistance value. Normally, this value is

taken at standstill, barring gear and 3000 rpm of

generator.


For DC resistance and impedance values of rotor winding,

the obtained results should be compared with the values

obtained at test bed/previous reference. In no case, these

values should differ from the previously measured values by

more than 2% under similar test condition.

In case of insulation resistance values, this value should

not be less than 1.3 Mohm at 40°C at any test condition. If

this is observed to be less than min. recommended value,

same should be improved by heating before proceeding to

next stage of operation.

NOTE

If testing facility exists at site, oto winding impedance

value can also be taken at 378 V A.C.


CI3T*il GENERATOR HYDRAULIC TEST OF GAS COOLER

Erection

Note : (For Coolers showing Leakage during Operation).

If it is not possible to detect the leaking area with cold

water, hot water at a temperature of 65-70°C can be used to

detect the leakage point.


r j z i j u i GFNFRATOR vji.i>iE,ivniwi\ g ^ T I G H T N E S S TEST OF STATOR Erection

Stator is usually tested for gas tightness during erection once

before inserting the rotor and again on completely assembled

generator alongwith all the auxiliary system piping. This test

is carried out during overhauls also. This test is carried out

mainly to ensure that :

a. There is no damage to weldseams during transportation and

further handling.

b. The various pipe lines, flanged and welded joints, valves

etc. are gas tight.

c. The whole assembly of the generator and the systems is

correct and gas tight.

The good gas tightness test ensure minimum consumption of

hydrogen.

1.0 PROCEDURE

The test envisages in filling the stator or the whole

machine as the case may be with air at a pressure of

4.0/3.5 atg. and checking the leakage at the possible

places by soap solution. This test is usually carried out

without any water in the gas coolers and stator winding.

The major leakages in coller and stator winding are however

detected and eliminated by carrying out pneumatic test at

4.5 atg. with air prior to this test.

Generator is considered to be gastight if the leakage of

air in 24 hours referred to atmospheric pressure is not

Bharat Heavy Electricals Limited ^ ^ „„„„„, , . , _ _ Rev. 00 G^l-O^T/l of 2

£IlTtt GENERATOR Erection

GAS TIGHTNESS TEST OF STATOR

more than 1% of internal gas volume in case of stator alone

and 5% in case of completely assembled generator alongwith

pipings. The quantity of air leakage is determined by

finding out the drop in pressure taking into account the

temperature corrections.

2 .0 METHOD OF CALCULATION OF HYDROGEN LEAKAGE FROM THE

GENERATOR

Leakage of gas may be calculated from the formula.

So =

Where So =

925

T

PI

2 73 + tl

P2

273 + t2

Leakage of gas in 24 hours, referred to atmos

pheric pressure (760 mm of mercury) and temperature

of 20oC as a percentage gas volume of the generator

PI & P2 Absolute pressure of air in mm of mercury at begin-

ing and end of test respectively.

tl & t2 Temperature of air inside the generator at begining

and end of test respectively in oC.

T = Duration of test in hours.

Absolute leakage of gas from the generator in MJ can be

calculated from the formula :

Vo

SO X V

100

Bharat Heavy Electricals Limited Rev. 00 «

1-0127T/2 of 2

C I X T J C I GENERATOR g ^ T IGHTNESS TEST OF STATOR Erection

Where:V = gas volume of generator stator which is 56 M3 with

rotor and 60 M3 without Rotor.

Although the generator is tested for gas tightness with air

medium it is desirable to determine the expected leakage of

hydrogen in actual working conditions. In fact the gas tightness

test is done with air due to the risk involved in filling the

generator with hydrogen until its gas tightness is ensured and

also because of the difficulties and expenses involved. Leakage

of hydrogen can be calculated by using the formula.

Vo(Hydrogen) Density of air at 20oC Temp.

Vo(Air) Density of H2 at 20oC temp. 1.18

0.1138

Bharat Heavy Electricals Limited Gl-01 0127T/3 of 2 Rev. 00 10/93 "

EICTiO CJENERATOR H O T W A T E R CIRCULATION IN Erection STATOR WINDING

4. Check the Temp, rise of each teflon tube by its

physical touching.

5. Mark the teflon tube indicating no Temp, rise on its

surface. Such tubes should be checked for any blockage

after opening it from the header.

Bharat Heavy Electricals Limited G1-01-0124T/2 of 2 Rev. 00 10/93 ~

LI

it > z

V

< 0 «

' z e

c

z

EXPANSION TANK STEAM SUPPLY LINE

OP ELECTRICAL IMMERSION HEATER:

STATOR WINDING

FILTER

STATOR WATER SYSTEM PUMP

JXh-O—Cxi

- * $ •

FIG. 1 SCHEME OF HOT WATER CIRCULATION THROUGH STATOR WINDING

GL-Oi - OL2UT

C J H T ^ I GENERATOR INSULATION RESISTANCE MEASUREMENT OF Erection GENERATOR REAR BEARING PEDESTAL AND SEAL BODY

INTRODUCTION

During operation of a generator, voltages are set up along the

rotor shaft due to magnetic unbalances. This shaft voltage would

cause a destructive current to flow through the bearing shaft

seal and other components if the rotor shaft were not insulated

from ground at least at the excitor end. In 200/210 Mtf TG all

the stator components coming into contact with generator rotor

shaft at slip ring end i.e. bearing pedestal, Oil catcher, Seal

body and all pipings connected to seal body and bearing pedestal

are insulated with the help of a textolite liner, insulating

sleeve, washer and gaskets. The healthiness of insulation is

ensured by checking of IR value during erection stage as follows:

1.0 CHECKS DURING ERECTION STAGE

During assembly of each component at slip ring end, IR is

measured at every stage of assembly as mentioned below •. -

1.1 BEARING PEDESTAL ASSEMBLY

Slip ring end bearing pedestal is insulated from foundation

bed plate by means of a thick glass textolite liner

interposed between the pedestal and the bed plate. The IR

of this insulation sheet is checked at different erection

stages. c

After placing the pedestal on bed plate.

Before and after tightening of pedestal fixing bolt.

Bharat Heavy Electrical* Limite<£K~ 1717117! f , R.V. 00 ( ^ £ 1 - 0 1 3 5 1 / 1 of 3

CiZHSl INSULATION RESISTANCE MEASUREMENT OF

Erection GENERATOR REAR BEARING PEDESTAL AND SEAL BODY

After placing the rotor on bearing pedestal (not

coupled to LP rotor).

After assembly of piping with pedestal.

With satisfactory insulation, a value in excess of 3-5

Megaohm is expected after placing the rotor on bearing

pedestal.

1.2 OIL CATCHER

Oil Catcher is insulated from end shield. The IR

measurement should be done after tightening the fixing

bolt.

CAUTION

During IR measurement it must be ensured that oil catcher

fins do not come in contact with rotor surface. Same can be

insulated by providing an insulating-paper between fins and

rotor shaft.

1.3 SHAFT SEAL BODY

Shaft seal body is insulated from end shield by means of

insulating sheet. The fixing bolts of seal body are

insulated from seal body with the help of insulating sleeve

and washers. During its assembly, the IR measurement should

be done after fixing each bolt. After fully tightening of -

all fixing bolt, joint IR value of seal body should be

checked.

Bharat Heavy Electricals Limited , Rev. 00 % 7 # - ° 1 3 5 T / 2 ° f 3

GFNFRATOR INSULATION RESISTANCE MEASUREMENT OF

Erection GENERATOR REAR BEARING PEDESTAL AND SEAL BODY

1.4 VARIOUS PIPING CONNECTIONS TO BEARING PEDESTAL AND SEAL

BODY

All pipings connected to bearing pedestal and seal body are

insulated by means of insulating sleeve, washer and

insulating gaskets. During assembly of these pipings, the

IR should be measured after each piping connection before

proceeding to next. During piping assembly, it must be

ensured that insulating gaskets provided between piping

flanges are projecting over the pipe flanges and also the

insulating washers should project out side the tightening

bolt head. It will avoid lowering of IR value due to dust

settling in the gaps between pipe flanges and bolt heads.

NOTE :

1. Insulation resistance measurement should be carried out

with the help of a 500V megger.

2. Final IR value of rotor shaft after assembly of bearing

pedestal and seal body connected with piping should be

measured and same should not be less than 1 Mohm.

3. All insulating components like sleeves, washers, liners

should be cleaned properly and checked for any physical

damage during storage before its use.

4. After getting good IR value across the bearing pedestal

insulating liner, same can be maintained by covering the

exposed surface of the textolite liner and adjoining

surface of steel sheet pedestal and bed plate by applying

epoxy insulating varnish after thoroughly cleaning the

surface.

Bharat Heavy Electricals Limited Rev. 00 G^ 7 ^. -0135T/3 o f 3

rizraa GENERATOR _ SLOT WEDGE TIGHTNESS CHECKING Erection

The function of slot wedges in stator is to ensure that winding

bars remain tightly secured in the slots and they are permanently

protected from possible vibrations in order to avoid damage to

the insulation of bars. Two types of slot wedging system are used

in 210 MW turbogenerators manufactured by BHEL.

a) Slot wedging system without top ripple spring.

b) Slot wedging system with top ripple springs.

In the first system (without top ripple springs), sufficient

thickness of plain insulating packing is provided under the slot

wedges to ensure that wedges are tight enough to stop the winding

bar from bouncing under electro-magnetic forces.

In second system, corrugated ripple springs are provided between

slot wedge and winding bar. The required force on the bar for

counteracting the electromagnetic bar bouncing force is provided

during wedging by compressing the springs. The initial spring

compression also compensate for shrinkage of slot contents

and hence there are lesser chances of wedges getting loose

(See Fig-2).

1.0 TEST PROCEDURE & NORMS

1.1 Testing of Slot Wedge System without top Ripple Springs :

1.1.1 Procedure

The extent of tightness of slot wedges is judged by knock

test with the help of a hammer. The procedure is as

follows :

Bharat Heavy Electricals Limited Rev. 00 Gft)7&L-°106T/1 ° f 7

yi.i^.v^iun S L Q T WEDGE TIGHTNESS CHECKING Erection

i) Mark the slot nos. on the bars at slot exit by paint.

The slot no. 1 is at 9'0' clock position looking from

exciter end and the numbering is done clockwise. Then

mark the wedge numbers along the length of slot

starting from exciter end i.e. the end wedge on

exciter end is marked no. 1.

ii) Check each and every wedge for tightness by knocking

at the centre and ends of wedge by a 400 gms.

metallic hammer and enter the degree of tighteness in

chart given in Annexure-I. The degree of tightness is

determined as follows :

Category-1 : Under this category, the wedge gives

uniform metallic sound all along length without any

vibration in wedge.

Category-2 : Wedge gives slight hollowness and some

vibration is felt on upto 50% length of the wedge

when it is knocked by hammer.

Category-3 : Wedge gives hollow sound on more than

50% length of the wedge.

1.1.2 Norms for Allowable Wedge Looseness

There should not be more than 5 wedges loose

(Category-2&3) per slot.

First five wedges from each end of the slot should

be of Category-1 tightness.


G3-01-0106T/2 of 7 10/93

riiw^i GFNFRATOR vj^iNcivrvi wiv S L 0 T WEDQE TIGHTNESS CHECKING Erection

Two wedges of category-2 tightness on RTDs are

allowed in each slot.

Two consequtive loose wedges (Category-2&3) in the

middle of each slot are allowed. These consequtive

loose wedges sholuld not be within 10 wedges from

each end.

In general, there should be minimum gap of 5 wedges

between any two loose wedges subjected to above

conditions.

1.2 Testing of Slot Wedge System having Top Ripple Springs

1.2.1 Testing Equipment

Please see Figure-1, The test equipment includes the

following:

i) Hydraulic test device with thrust piston in the

stator bore.

ii) Interchangeable pressure bars.

iii) Pressure manometer.

iv) Dial guages with magnetic mounting.

The test medium shall be Hydraulic oil.

1.2.2 Test Procedure

The test device is so positioned in the stator bore that

the pressure bar comes in contact with only one partial

slot wedge at a time (Please see Fig. 1).


ciznzi GFNFR ATOR vjci>iE,ivn.i wrv. S L Q T ,^1X38 TIGHTNESS CHECKING Erection

Dimensions of pressing piece shall be as per Fig.l. The

wedges on which measurements to be made are selected as

explained in para 2.2.3. The slot wedge movements are

read on two dial gauges provided for the purpose. The

mean value of the two is entered in the test record data

in unit of one hundredth mm.

2.2.3 Measuring Points

To permit an assessment of spring force on bars and

wedges, it will normally not be necessary to check all

slot wedges, but the check should cover not less than 20%

of the total number of slot wedges. The measuring points

should be distributed over the slot length so that they

are staggered from slot to slot as given in Table-I.

Bharat Heavy Electricals Limited __ . , TTTTZTM I ~ 7 Rev. 00 <flj#-0106T/4 of 7

y^^^iv/n g L O T VEDGE TIGHTNESS CHECKING

Erection

Table - I

S lo t Wedges on which Measurements are made

SLOT NO.

1

2

3

4

5

6

7

8

9

10

EE

1 2

X

X

X

X

X

X

X

X

X

X

3

X

X

X

X

X

X

X

X

X

X

4

X

X

X

X

X

X

X

X

X

X

5

X

X

X

X

X

X

X

X

X

X

6

X

7

X

X

8

X

X

9

X

X

STATOR SLOT

10 11 12 13 14 15 16

X

X

X

X X

X X

X

X

X

X

X X

17 18

X

X

X

X

19

X

X

20

X

X

X

X

X

X

X

X

X

X

21

X

X

X

X

X

X

X

X

X

X

22

X

X

X

X

X

X

X

X

X

X

23

X

X

X

X

X

X

X

X

X

X

TE

24

60

No. Of Slots : 60 No.of wedges per slot : 24 Total wedges : 1440 Measuring points : 2x4x60 + 20% of 840 = 648

X - Measuring Point

Note 1. End wedges i.e. 1 and 24 are rigidly fixed and hence no measurements are made on them.

2. Wedge Nos. 21, 22, 23 are not provided with top ripple springs as they are comning over the RTDs. Therefore their tightness is to be checked by knock test.

Bharat Heavy Electricals Limited Rev. 00 %

01-0106T/5 of 7

EirrrTt frFNFR ATOR vjci>civrvi v^iv S L 0 T VfEDGE TIGHTNESS CHECKING Erection

1.2.4 Test Pressure

The test pressure to be applied to a particular slot wedge

depends on the thickness, number and compressed area of the

springs (approx. slot width x length of slot wedge). In 210

MW THW Generator, single spring of 0.9 mm thickness are used

under each wedge. In this case, following requirement will

be applicable.

Specific test pressure =1.8 N/mm2

10. Pp

Required Manometer Pr. = . lN.bN bar Fk

Where 1N = Slot wedge length in cm.

b N = Slot width in cm. ,2 Pp = Specific test pressure in N/mm''

F^ = Piston surface area in cnr

Therefore requried Manometer pressure = 73.84 bar.

1.2.5 Test Records

The results of tests should be tabulated as per performa

given in Table - I.

1.2.6 Allowable Wedge Deflection

< 0.90 mm for not less than 60% of measuring points.

< 1.10 for remaining measuring points (40% max.) .

Bharat Heavy Electricals Limited „„ „ „ „, . _ „ Rev. 00 Gfo^-OlOST/e of 7

GENERATOR „ SLOT WEDGE TIGHTNESS CHECKING Erection

If a wedge movement of more than 1.10 mm is measured in any

slot, the number of measuring points in this slot should be

doubled. If the value is exceeded at two points, all wedges

in this slot should be checked to ensure that not more than

two points are having wedge movement more than abvoe

specified value.

Note : If the above guiding values are exceeded, consult

FES/TGE department of BHEL Hardwar for advice, who will then

issue recommendation regarding need for rewedging.

2.2.7 Permissible Slot Wedge Deflection after Rewedging

During rewedging operation, the compression of ripple

spring is restored by inserting packing strips of

required thickness. To enable easier and more reliable

determination of the thickness of the filler strips, it

is recommended to measure the movement of all wedges

prior to rewedging. After rewedging of the complete

winding, following slot wedge deflections are

permissible.

o Slot wedge deflection shal not be less than 0.1 mm but

not more than 0.3 mm for not less than 75% of all

measuring points.

o Slot wedge movement at remaining 25% of measuring

points shall not exceed 0.45 mm.

Bharat Heavy Electricals Limited Rev. 00 CJtogL-OlOST/V of 7

C i T T ^ l GENERATOR Erection

JOINTING OF RUBBER GASKETS

INTRODUCTION :

The necessity of having leak proof joint at End Shields of

generator makes it essential to take proper care during storage,

erection/assembly of rubber components. As such a proper

procedures should be followed which is recommended as follows

during storage and assembly of rubber components.

1.0 PRECAUTIONS TO BE TAKEN DURING STORAGE OF RUBBER COMPONENTS

It is a fact that if rubber components are not stored

properly, these will age quickly thus becoming hard and

brittle and sometimes developing cracks under stressed

conditions. Accordingly, these components need care during

storage as per the following recommendations :

TEMPERATURE Storage should be preferably below

15°C but should not exceed 25°C.

If the rubber components are kept in

store, at temperatures exceeding 25°C

these will harden at a faster rate

and would become unfit for use later.

LIGHT Rubber components should be protected

from direct sunlight and strong

artificial light having high

ultraviolet content.

DEFORMATION Rubber components should be stored

fully supported and free from

tension, compression or deformation.

Bharat Heavy Electricals Limited Rev. 00 <M 1-0125G/1 Of 4

ClZTtt GENERATOR Erection

JOINTING OF RUBBER GASKETS

Hanging of these items from hooks,

nails or by some other method should

be avoided.

CONTACT WITH

LIQUIDS, METALS

Contact with liquid or semi-solid

materials such as solvents, oil and

greases should be avoided. Similarly

contact with metals particularly

copper, manganese and iron should be

avoided as these affect some rubbers.

EFFECT OF OZONE Atmospheric ozone has a particularly

severe cracking effect on many

rubbers. If possible, the rubber/PVC

items should be protected from

circulating air by wrapping, storage

in air-tight containers or by any

other suitable method.

ROTATION OF STOCKS The rubber/PVC component should

remain in stock for as short a time

as possible. Therefore the components

should be issued from stores on

strictly first in, first out

principle.

2.0 PRECAUTIONS TO BE TAKEN DURING ASSEMBLY OF RUBBER CORDS FOR

END SHIELDS :

While assembling the rubber cords in the End shields,

following sequence to be followed :


G1-01-0125G/2 of 4 10/93

SECTION - III

GENERAL INSTRUCTIONS

JOINTING OF RUBBER GASKETS Erection

2.1 Examine the square rubber cord 12x12 mm for any

deformation, cut marks or cracks, if found damaged replace

the same.

2.2 Before fixing the square rubber cord, examine the end

shield groove and the matching surface of side wall on

stator body - sharp edges if any to be rounded off so as to

prevent damage to the cord.

2.3 Degrease the groove thoroughly with petrol/white spirit, do

not allow rubber cord to come in contact with any of the

solvents.

2.4 Apply a thin layer of chemistick adhesive (Chemistick S-75

supplied by Chemisol Industries, Shamdas Gandhi Marg,

Bombay 400 002) or suitable equivalent at the bottom of

grooves and allow the solvent to evaporate before placing

the cord.

2.5 Place the square rubber cord size 12x12 ram centrally in

side the groove and keep it for about 4 hours suitably

pressed. The cord in the lower half shield should be left

unpasted for a length of 40 to 50 mm from the joining

surface.

2.6 On both the ends of the lower half end shield groove, the

rubber cord should project over the joining surface by 35

mm and the rubber cord of upper half end shield should end

at 10 mm before the joining surface. Both the cords should

be joined by a taper (scarf) joint for a length of 25 mm in

such a way that there is no squeezing of rubber cord near

parting plane (PI. see sketch 1).


0 ^ 1 - 0 1 2 5 0 / 3 Of 4

£JZT£Z* GENERATOR JOINTING OF RUBBER GASKETS Erection

2.7 The round cord of dia 10 mm should be pasted in the

corresponding groove on the inner part of the end shield.

2.8 During assembly of lower half, the press out bolts M20x70

must be assembled in such a way that they project by at

least 8 mm so that the rubber cord glued in the groove do

not come in contact with stator body while rotating the End

shield. The above requirements are also specified in the

drg. No. 5487.005 "Mounting of End Shields".

2.9 In any case, it must be ensured that the rubber cord during

assembly, does not come out of the slot while bolting and

does not get crushed. Particular attention must be given to

the top half circumferential joint.

Bharat Heavy Electrical* limited G1-01-0125G/4 of 4 Rev. 00 10/93

mt :MP

•I

i 1

m

- F I R S T ^ A N G L E P R O J E C T I O N ( ALL DIMENSIONS ARE IN mm) Form D6-4$

m •$Z

i - f c ALTERED

1 ; « i ! '*';

CHECKED

;>£ 8

p.*

xS (_ c < p

m « ^ • o o >

a c o a o.c a >.

TJtJ

•.a e £••6 0 I 11 I* c o

s5 ? E

' - £ * * . > • / • ' ; ••••*• v "

II

(0 Q

I

REV °m ALTERED

CHECKED

G M S HO./an. SP. NO.

AGREED DEPT. NAME SIGN

• T A T U 4 OPDPtO

DATE

AT CIRCUMFERENCE TECHNICAL REQUIREMENTS

1. - SHARP CORNERS OF THE GROOVES MUST BE ROUNDEd OFF.

2 . - DEGREASE THE GROOVES THOROUGHLY WITH

PETROL. APPLY A THIN LAYER OF ADHESIVE

AT THE BOTTOM OF GROOVES AND ALLOW THE SOLVENT TO EVAPORATE BEFORE PLACING THE CORD.

3. - SEALING RUBBER CORDS MUST BE LOCATED CENTRAL]

TO GROOVES. NO FOREIGN MATTER TO BE LEFT IN SIDE THE GROOVE.

A. -

AT PARTING PLANE 5. -

RUBBER CORDS MUST BE INI TIALLY GLUED SLIGHT TENSION.

UNDER A

20*0.5

AT THE TWO ENDS OF LOWER HALF END SHIELD GROOVE THE CORD SHOULD PROJECT BY 35MM AND \H<%%$&-\JP HALFBND SHIELD THE CORD MUST END AT10M.MFROM PARTING PLANE AND SHOULD BE JOINED BY A PROPER (SCARP ) JOINT FOR A LENGTH OF 25 M M IN SUCHA WAY THAT THERE IS NO SQUEEZING OF RUBBER CORD NEAR PARTING PLANE.

DURING ASSY OF LOWER H A L F , THE PRE SS OUT BOLTS M 20X70 MUST BE ASSEMBLED IN SUCH AWAY THAT THEY PROJECT BY AT LEAST 8 M M SO THAT THE RUBBER CORD GLUED IN GROOVE DONOT COME IN CONTACT WITH STATOR BODY WHILE END SHIELD ROTATES.

UPPER HALF_SHIELD

LOWER HALF SHIELD

VIEW ON THE JOINT OF SEALING RUBBER CORD (SEE 7.R.5)

REMARKS

8 8 7 5

CARD TYPE- S

ITEM NO .

23 27

20 —*•

DESCRIPTION

2 9

20 CARD TYPE-1

Esa BHARAT HEAVY ELECTRICAIS [ID. H A R D W A R

29 31

VAR 32 S3

MATERIAL CODE 34 45 MATERIAL SPECN 46 94

1 CAHO TYPE 2

I I I I

U N I T WEIGHT

fi6 71

nr?N.

CMP.

DEPT . TGE

CODE 4233

GRADE OF

U N T O L O I M .

C / M / F

£?] •SCALE

1.1

APPD

WEIGHT i K C l

TITLE .. V

SEALINGCORD ASSEMBLY (UNPRESSED) IN GROOVES OF END SHIELD.

I 3 <:. A r> u CODE

NAME PN MOURYA

R K BABBAR

A.S.SIDHU

REF. TO ASSY PRO

SIGN DATE

ITEM NO

NO.OF VAR

73 74

NO. O F ITEMS

7S 77

DRAWING NO

TGE-0871 _1 L

REV.

' i I I I I I I ' I I I I * 1 ' " I Z*

JHFF r NO. 1 I' OF SHEETS. \

CUTJTTM GENERATOR STORAGE AND RECONSERVATION Erection

1 STORAGE

1.1 The equipment should be accommodated in permanent places

of storage within 5 days after their arrival at

destination, taking into account the order of

requirement of details at the erection site.

1.2 Storing conditions fall into the following categories :-

Category I - Storing indoors: in dry store house.

Category II - Storing indoors: in unheated store houses.

Category III- Storing under a shed.

1.3 The platforms and store-houses should be built up in

conformity with the fire prevention rules and standards.

1.4 The platforms (near the railway and in other places),

intended for storing of articles, should be grouted with

concrete or the like, besides, draining of sub-soil and

surface water from the store houses site is to be

ensured.

1.5 Store houses should be provided with reliable

ventilation system.

1.6 The store house should be equipped with proper lifting

devices which ensure normal handling of articles.

1.7 Enclosed - type heated store houses should have fore-

rooms in front of the gateway and should be provided

with a reliable ventilation system. Temperature

fluctuations in the heated store - houses must not

exceed 10°C (as far as possible).

Bharat Heavy Electncals Limited „„ „„ „„_. w , / ' .. „ ,_ 3 „ G1-01-0122G/1 of 15

Rev. 00 10/93

C I S T A S I GENERATOR STORAGE AND RECONSERVATION Erection

1.8 Floors out of earth in the enclosed - type stores houses

are forbidden.

1.9 If the manufacturer's packing cases which are to - be

used during the storage time are damaged, they should be

completely repaired. In case the rust preventive coating

is faulty, the coating should be applied again.

1.10 In order to choose a proper category of stores for

articles, as well as for their assemblies and

individuals parts use Table - 1 as a guide.

Table - 1

Description Category of Storage

1. Turbogenerator assemblies and parts :.

Rotor I

Stator II

Outer end Shields II

Foundation plates III

Stator end parts II

Exciter I

Large parts of assembling devices II

Studs II

Bearings II

Fan Baffles II

Terminal bushings II

Seal bodies I

Insulators II

Terminal boxes II

Emergency lubrication tanks II

Bharat Heavy Electrical* Limited G1-Q1-0122G/2 of 15 Rev. 00 10/93

OOi(£ l GENERATOR Erection

STORAGE AND RECONSERVATION

Description Category of Storage

Stator winding bars

Gas coolers

Small parts of turbogenerators

Thermal control apparatus

Erection materials

I

II

I

I

I

Apparatus & Control gear

3. Spare Parts :

Bearing liner

Coils and winding bars

Oil rings

Brushes

Fastenings and packings

Tools

I

I

I

I

I

I

1.10.1 The articles not specified in Table - I, should be

stored like equipment, similar in design, size and

application given in Table - 1.

1.10.2 The articles referring to category III are to be stored

in packed condition.

1.11 All the articles, additionally packed into film jackets

or the like envelope materials, should be stored without

opening this packing. In this case the middle - and

large size machines are to be stored without taking them

off from the bottom parts of wooden case.


G1-01-0122G/3 of 15 10/93

CiZTjRjl G b R STORAGE AND RECONSERVATION Erection

1.12 To prevent distortion, stator, its end portions, the

rotor and other large asemblies should be laid down upon

even platforms. While arranging the parts and assemblies

for storage, try to place them in the operating

position.

1.1.13 Small and middle size spare parts and articles are

recommended to be stored on shelves. The middle-size

articles weighting notover 10 Tonnes (in packed

condition) can be piled up to 2.5 m high; when doing

this, care should be taken to see that the lighter

articles be laid upon the heavier ones, and not vice

versa,- otherwise the lower articles will be damaged by

upper ones.

1.14 The articles weighing 10 tonnes or above are to be

arranged in a single tier.

1.15 While handling the equipment, strictly observe the

warning indicated by markings and inscriptions such as

"HANDLE WITH CARE" "TOP", "NOT TO PUT LOAD UPON THE

TOP". SLING HERE" etc.

2. Removal of Preservation Coatings

2.1 The removal of preservation coatings is to be carried

out in the following cases:

a) During routine inspection in order to check the

condition of the parts with regards to corrosion.

b) When preparing the assemblies and parts for

erection.

Bharat Heavy Electrical* Limited G1-01-0122G/4 of 15 Rev. 00 10/93

CJMTMSM* GENERATOR Erection


c) When commissioning the machines applied with

protective coatings for a long term shutdown;

d) For re-application of preservation coatings after

the expiry of guarantee term.

2.2 The articles should be freed of all the preservation

measures at a relative humidity of above 70% and at a

temperature not less than +12°C. While doing this the

open articles should be protected against atmospheric

precipitation, dust and dirt.

1.2.3 The personnel entrusted with this work should wear

cotton gloves.

The articles should be freed of preservation coatings

as recommended in Table 2.

Table - 2

Description Scope & Sequence of removing all the preservation coatings

Shaft journals of

dismantled machine;

couplings flanges

and half couplings,

Joining surfaces.

a) Remove protective film and

paraffin paper.

b) By means of a wooden spatula

remove the basic layer of

grease and remove the rest of

the grease by means of rags

wetted in white spirit (item

1 of section 5).


G1-01-0122G/5 Of 15 10/93

n^rrw) GENERATOR Erection



c) Wash of N.C. protective

coatings (as per item 4 of

section 5) with the

corresponding thinner (Item 5

of section 5) and wipe off

the cleaned surface with dry

clean calico.

2 . Slip Rings a) Take off the wrapping paper.

b) Remove the layer of grease by

wiping the slip rings with

rags wetted in white spirit

(Item l of section 5).

c) Wipe with clean dry calico.

Fastenings, rotation a) Wash with white spirit.

indicators, name , plates, (item 1 of section 5)

foundation bolts, small

parts.

Shaft journals of machines

transported in assembled

condition^:

a) If applied with grease a) Thoroughly wash the shaft

journal bearing liner, oil

chamber, labyrinth packings,


G1-01-0122G/6 of 15 10/93

CIZF£ZM GENERATOR Erection



the bearing cap, using white

spirit or hydro carbon

solvent or Aviation Gasoline

(Item 1 of section 5) till

the grease is completely

removed.

b) If applied with liquid b)

lubricants.

Pour Oil light (Item 8 of

section 5) preheated upto +

105 - 110 C into the bearing,

Crank the shaft for 4 to 5

times. Drain off the rest of

oil.

CONSERVATION

3.1 Conservation should be carried out on assembled

machines and their parts in the following cases :-

a) After removing the preservation coatings of the

equipment after the expiry of the guaratnee term

stated for preservation coatings.

b) When the machine is shut down for a long period

exceeding one month).

3.2 All the surfaces to be conserved should be degreased by

applying white spirt (item No. 1 of section 5).

Bharat Heavy Electricals Limited Rev. 00 fi/9? -Q1-0122G/7 Of 15

CiTiJfll GENERATOR Erection


3.2.1 Rust any should be remvoed by rubbing with emerge cloth

mnoistened with rust removing solution 9 item no. 2

section 5).

3.2.2 The surface of non-ferrous metal components should be

dressed with fine gained sand paper, wetted with IOC,

DTE oil light (as per item 8 of section 5).

3.2.3 The surfaces should be air-dried at normal temperature

or wiped dry with clean rags, gauze or calico.

3.2.4 Preservation coatings should be applied to machine

assemblies and parts at a temperataure of not less than

+ 12° C and humidity of not over 70%. (at a temperature

of 25°C) requirements stated in Table - 3) .

TABLE

Description Scope and sequence of Conservation procedures

Shaft journals, shaft

ends, couplings.

a) Coat with N.C. protective

(item 4 of section on 5).

b) Dry the coating for 8 hours

at a temperature of +18 -

23°C.

c) Coat the dry painted surface

with Mobilex grease no.

2 (Item 3 of section 1.5)

preheated upto +

C.

110 - 120*


G1-01-0122G/8 of 15 10/93

riEHTTi GENERATOR Erection



d) Wrap up with paraffin paper.

e) Enclose the article into a

film jacket.

Slip rings a) Coat the ground surface of

rings with mobilex grease No.

2 (item 3 of section 5)

heated upto 110 to 120° C.

b) Wrap up with paraffin paper.

c) Wrap up with polyethylene

film and tie around with

adhesive PVC tape.

Bearing Liners a) Coat the babbited surface

with Mobilex grease No. 2

(item 3 of section 5)

preheated upto + 110

C.

120 0

b) Coat the' surfaces of the

steel parts with two layers

of N.C. protective coating

(item 4 of section 5) dry

each layer for 8 hours.


G1-01-0122G/9 of 15 10/93

fTiZTjCl GENERATOR Erection



Coat the dry painted surface

with Mobilex grease No. 2

(item 3 of section 1.5)

preheated upto 110 - 120° C.

Wrap up with paraffin paper,

enclose in a film jacket and

tie around with adhesive PVC

tape.

Plated steel and

cast-iron parts.

a) Apply Mobilex grease No. 2


preheaated upto 110

C.

120c

b) Wrap with paraffin paper.

c) Enclose in a polythylene

jacket.

Brush rocker a) Take the brushes out of brush

boxes.

b) Wrap the brushes

paraffin paper.

w i t h

c) Put t h e b r u s h e s upon t h e

b r u s h b o x e s and clamp them

wi th b rush h o l d e r l e v e r . Wrap

t h e b r u s h r o c k e r w i t h

p a r a f f i n p a p e r .


GJL-$1-0122G/10 of 15

CiZECTI GENERATOR Erection



6. Name plates Coat with Mobilex grease No

2 (Item 3 of section 5)

preheated upto + 110 120°C,

Paste paraffin paper upon the

greased surface.

7. Free threaded holes

(blind and through holes)

Apply Mobilex grease No. 2

(Item No. 3 of section 5)

8. Surfaces at split joints a)

of magnet system and those

of bearing bodies, and

shielding.

Coat with a continuous layer

of N.C. protective coating

(item 4 of section 5).

b) Dry the coating at room

temperature.

c) Apply Mobilex grease No. 2

(Item 2 of section 5 to the

dry painted surface).

d) Paste paraffin paper.

3.3 Machine parts and assemblies not specified in Table -3

should be preserved like details of similar type and

purpose given in this table.

3.4 The assemblies and parts of machine (when assembled)

should be conserved during long term shut-downs

according to table - 4.

Bharat Heavy Electricals Limited Rev. 00 C^^L-0122G/11 Of 15

cisxcni GENERATOR Erection


ITEM - 4

Description Scope and sequence of conservation procedures.

Bearing assembly, drain off the working oil

from the bearing oil chambers,

b) While rotating the shaft pour

Anti-Rust solution APS 22J or

Esso Rust TOP. PT (Item 6 of

section 5) into the hole

under the oil rings till a

continuous protective oil

film is formed on the shaft

journal, oil rings and

bearing liners.

c) Drain off the rest of Anti-

rust solution (item No. 6 of

section 5) throught the drain

hole.

Slip Rings a) Wipe with calico soaked with

rectified spirit.

b) By means of a paint-brush

apply Mobilex grease No. 2


preheated upto + 120°C.

c) Wrap up with paraffin paper.


G1-01-0122G/12 of 15 10/93

CIZTJCH GENERATOR Erection


Description Scope and sequence of conservation procedures.

d) Wrap into polythylene film

and tie around with adhesive

tape.

3. Brush Rocker a) Take the brushes out of brush

boxes.

b) Wrap up with paraffin paper.

c) Put the brushes upon the

brush boxes and clamp them

with brush holder levers.

Wrap the brush rocker with

paraffin paper and tie it

around with glass tape.

4. Threaded Holes Apply Mobilex grease No. 2

(Item No. 3 of section 1.5)

heated upto 110UC 120°C.

Name Plates Rotation

Indicators.

b)

c)

a) By means of a paint-brush

apply Mobilex grease No. 2

(Item 3 of section 5)

preheated upto 100-120°C.

Wrap up with paraffin paper.

Tie around with adhesive

glass tape.

6. Joining, Surfaces Cast with Anti-Rust solution

(Item 6 of section 5).

Bharat Heavy Electricals Limited Rev. 00 itaff 1-0122G/13 Of 15

OZiiTCl GENERATOR Erection


3.5 The scope of conservation work should be recorded in the

inspection certificates to be prepared for each article

specifying the nature and quality of procedures adopted.

INSTRUCTIONS FOR SAFETY DURING CONSERVATION.

4.1 Removal of preservation coatings and reconservation

should be carried on the platform prepared before hand

and kept free from stray objects, dust, refuse etc.

4.2 When using volatile material (white spirit or Hydro

Carbon Solvent or Aviation Gasoline as per item 1 of

section 5) regularly check the purity of air in the

premises.

4.3 In the zone where the conservation work is carried out,

it is forbidden to keep and to take food, to smoke and

to perform any operations connected with fire.

4.4 Upon completion of conservation work, the rest of

material should be returned to a special store house.

MATERIALS REQUIRED FOR RECONSERVATION WORK

Item No.

1.

Specification of material

White spirit of Hydro carbon

solvent of corresponding grade as

per IS: 1745 or Aviation gasoline

IS : 1604.

2. Rust solvent X

Industries Ltd

equivalent.

50 of Ashok

Bombay or

Bharat Heavy Electricals Limited Rev. 00 Gj^7^L-0122G/l4 Of 15

CIUJCIl GENERATOR Erection


Item No. Specification of material

3. Mobilex grease No. 2 of Indian

Oil Corpn. or any equivalent

Lithium Hydroxide grease.

Nitro cellulose protective

coating (Red.) of Shalimar Paints

Ltd. or equivalent.

Thinner for item No. 4 above.

Anti rust solution ARS-22 J of

Plastipeel Chemical Corpn. or

equivalent.

Rectified Spirit.

DTE oil light of Indian Oil

Corpn.

Paraffin paper 0.06 mm thick.

10 Polyethene film 0.15 mm thick.

11 Adhesive glass tape or adhesive

0.1 x 25 PVC tape.

12 Emery paper 100 GNT and 180 GNT.


G1-01-0122G/15 Of 15 10/93

CiiEHCl GENERATOR MAJOR T&P CONSUMABLES Erection

LIST OF MAJOR T&P / CONSUMABLES REQUIRED

S.No. Item Quantity

1. Hydraulic Jack 100 MT 4 Nos.

2. Hot Air Blower

3. Hydraulic Test Pump (Hand Operated 15 Kg/Cm2) 1 No.

4. Heavy Duty Vaccum Cleaner l No.

5. 3 Leg Inside Micrometer or Box Dial Indicator 1 No. 50 - 70 mm

6. HV Test Kit(52 Kv AC or 73 Kv DC) 1 No.

7. Micro ohm meter 1 No.

8. Motor Operated Meggar (0-5Kv) 1 No.

9. 250 & 500 V hand Operated Meggar 1 No.

10. Single Phase Auto Tr. (0-240 V AC, 70 A) 1 No.

11. Compressor 1 No.

12. Hylomer or Shellac

13. CTC

14. White Spirit

15. Paraffin Paper

16. Silica Gel Approx. 25 Kg.

17. Instant setting Adhesive solution Approx. 250 ml. (Anabond/Fevicol)

18. Non Corrosive Protective Paint

19. Mercury

20. Conbextra GP-2 6 Tons

21. Purge Test Kit

22. Dial Indicators


G j ^ l - 0 1 3 3 0 / 1 of 2

EiUJGn GENERATOR MAJOR T&P CONSUMABLES Erection

S.No. Item Quantity

23. Feeler gauge sets

24. Varnier Calipers

25. Inside micrometer set (upto 1mm)

26. Outside micrometer set (upto 400 mm)

27. Multimeter (Digital and Analog) 2 Nos.

28. Surface place upto 1 Meter size.

29. Torque Wrinch (upto 150 Kg-M).

Bharat Heavy Electrical* Limited G1-01-0133G/2 of 2 Rev. 00 H**J*

aeefioj GENERATOR Erection

ERECTION DRAWINGS

LIST OF TURBOGENERATOR DRAWINGS

SI.No. Drawing No, Description

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

1255.001c

0311.016C

0311.059C

6020.025C

2-5670.073C

6020.026C

0-5012.025C

0-5013.005C

6392.032C

2-5372.010C

1-5372.010C

0-5371.002C

6030.016C

Turbogenerator (General view)

Erection drawing (Gen.)

Terminal details

Temperature control diagram

Wound Stator

Installation of resistance thermometers

End Shield

Fan Shield

Gas Cooler

Shaft Seal (T.E.)

Shaft Seal (E.E.)

Seal Liner

Mounting of headers

Description SI.No. Drawing No.

14.

15.

16.

17.

18.

19.

20.

5675.010C

5675.012C

5264.002C

5263.008C

0-5516.006C

5478.007C

6030.049C

Rotor

Wound rotor

Bearing with brush gear

Bearing liner

Trunion foot plate

Trunion foot plate

Mountinmg of casing


<JJ^gl-0134G/l Of 3

GENERATOR Erection

ERECTION DRAWINGS

SI.No. Drawing No. Description

21.

22 .

23 .

24.

25.

26.

27.

28.

29.

30.

6030.029C

6030.018C

5066.008C

5066.021C

5066.022C

5066.023C

0-5150.008C

5150.013C

5066.018

3-5060.000

Fixing of foundation plate

Mounting of embedded plate

Embedded plate

Embedded plate

Embedded plate

Embedded plate

Shim

Shim

Foundation plate (Bearing)

Terminal box with equalising Coil

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

1-0344.001C

6771.003C

6771.002C

5260.000C

5260.001C

8340. 035C

5487.005C

5487.006C

5487.035C

5487.061C

5487.008C

B. ERECTION DEVICES & TOOLS

Insertion of rotor into stator

Outer trolley

Inner trolley-

Rail

Rail

Sheet

Mounting of end shield

Device for mounting of end shield

Device for removing and fixing of Retaining Ring.

Device for screwing and removing of nut.

Device for removing fan hub.

Bharat Heavy Electricals Limited Rev. 00 % * •

0134G/2 of 3

ElErMkMa GENERATOR

Erection ERECTION DRAWINGS

SI

12.

13.

14.

15.

16.

No. Drawing No.

5487.009C

5484.001C

5484.100C

5484.000C

8921.006C

Description

Device for removing slip ring with brush

Erection tools

Spanner

Wrench

Jack screw


(JJ^gl-0134G/3 Of 3

CISTACI GENERATOR Erection DYE PENETRATION TEST

Dye penetration test is carried out for detecting surface cracks

and some other abnormalities on the rotor retaining ring surface

and other critical machined components.

1.0 MATERIAL & TOOLS EMPLOYED

1. Dye Solution in Spray type container

2. Developer

3. Cleaner/Thinner

4. Cotton Cloth

2.0 TEST PROCEDURE

i) Clean the surface under test till it becomes bright.

Rough scratches should be removed as they may effect

the results.

ii) Degrease the surface just before test.

iii) Apply dye solution and wait for 15 minutes.

iv) Clean the surface with thinner jet and wipe off with

the help off clean soft rag till dye is completely

removed.

v) Now quickly coat the surface with developer and

observe its drying for 2 to 3 minutes. Appearance of

red lines on the surface as the halk solution dries

indicates the presence of cracks and flaws.

Bharat Heavy Electricals Limited „ „ - , „ „ , ^ , Rev. 00 %/W-°1 3 7 G / 1 ° f X

FIELD QUALITY ASSURANCE

1.0 Test results for placementof stator on foundation

SI. No. Description Design

Value Actual Value Remarks

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

Soundness of bondage of stator embedded plates with the concrete by means of harmrBr test.

Centering and elevation readings of embedded plates.

Centering readings of pipe sleeves.

Matching of embedded plates to obtain required contact and slopes in the direction of insertion (sloping away frcm TG centre line)

Percentage of contact surface of bottom side of foundation of stator.

Checking of top surface of foundation plates with straight edge.

Percentage of contact surface of anchor plates with foundation.

Percentage of contact surface of pads of trunion foot plates with pads of stator.

Feeler gauge check at pads and vertical face during assembly of trunion foot plates to stator.

Vibration of sand not allowed

Contact ̂ 80% slope 3-4 mm per metre.

contact ̂ 80%

0.50rrm f e e l e r gauge shou ld not pass Contact/C80%

Contac t -^ 90%

0.03 mm f e e l e r gauge should not pass

Readings obtained to be entered in sheet 2/4 & 3 / 4 of this logsheet.

Readings obtain ed to be entered in sheet 4/4 of this logsheet.

PROJECT ERECTION

NAME & SIG. REVISION ^-8/92

UNIT NO. CUSTOMER SHEET 1 / 4

RATING FQA F Q A - 0 3 - 0 0 - 0 1 - L - 0 1


SLOPES OF GENERATOR EMBEDDED PLATES

\u p r 1 |o n

DURING MATCHING ENSURE THERE IS NO SLOPE TRANSVERSE TO THE DIRECTION OF INSERTION OF PACKERS .

CL OF GENERATOR

S L O P E S O B T A I N E D A F T E R M A T C H I N G (_ TO BE ENTERED I N BOXES SHOWN. °

ID

' ID "

U

Dl t t

Dl , . . 1

LM o

"C

0 u

0 Q

a o

o a 4 4

n t J-, J,i SLOPES AS PER DRAWING I N DIRECTION

OF INSERTION OF PACKERS 3-4mm/M

PROJECT: ERECTION:

NAME SIGNATURE DATE R E V I S I O N : R 2 - 8 / 9 2

UNIT NO: FQA: SHEET: 4 / 4

RATING: CUSTOMER: F Q A - 0 3 - O Q - 0 1 - L - 0 1

n No. of

Thermometer

1

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

PROJECT

UNIT NO.

RATING

No. of Thermometer-

lead

2

17A

17B ' 18A 18R 19A 19B 20A 20R 21A 21B 22A 22B 23A 23B 24A 24B 25A 25B 26A 26B 27A 27B 28A 28B 29A 29B 30A 30B 31A 31B 32A 32B 33A 33B 34A 34B 35A 35B 36A 3fiR

- 37A 37B 38A 38B 39A 39B


Location

3

S l o t 17

S l o t 18

S l o t 19

S l o t 20

S l o t 21

S l o t 22

S l o t 23

S l o t 24

S l o t 25

S l o t 26

S l o t 27

S l o t 28

S l o t 29

S l o t 30

S l o t 31

S l o t 32

S l o t 33

S l o t 34

S l o t 35

S l o t 36

S l o t 37

S l o t 38

S l o t 39

Parameter Measured

4

W i n d i n g t e m p .

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

ERECTION

CUSTOMER

FQA

DC resistance

n

5

IR Value M G

6

NAME & SIG.

Ambient Temperature

•c

7

Remarks

8

REVISION R ? - 8 / 9 2

SHEET 2 / 6

F Q A - 0 3 - 0 0 - 0 1 - L - 0 2

M No. of

Thermometer

1

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

PROJECT

UNIT NO.

RATING

No. of Thermometer-

lead

2

40A 40B 41A 41B 42A 42B 43A 43B 44A 44B 45A 45B 46A 46B 47A 47B 48A 48B 49A 49R

50A 50B 51A 51B 52A 52B 53A 53B 54A 54B 55A 55B 56A 56B 57A 57R 58A 58B 59A 59B 60A 60B 61A 61B 62A 62B


Location

3

S l o t 40

S l o t 41

S l o t 42

S l o t 43

S l o t 44

S l o t 45

S l o t 46

S l o t 47

S l o t 4 8

S l o t 49

S l o t 50

S l o t 51

S l o t 52

S l o t 53

51o t 54

S l o t 55

S l o t 56

S l o t 57

S l o t 5 8

S l o t 5 9

51o t 6 0

51ot 1

s l o t 21

Parameter Measured

4

W i n d i n g t e r r p .

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d O T

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

Co re i r o n t e r r p .

- d o -

ERECTION

CUSTOMER

FQA

DC resistance

O

5

>

IR Value M f i

6

NAME & SIG.

Ambient Temperature

•c

7

Remarks

8

-

REVISION R 2 - 8 / 9 2

SHEET 3 / 6

F Q A - 0 3 - 0 0 - 0 1 - L - 0 2

[ 7/1 VU y {TrfJ

Ea No. of

Thermometer

1

63

61S

62S

63S

64

65

66

64S

65S

66S

67

68

69

67S

68S

69S

70

71

72

70S

71S

72S

73

74

PROJECT

UNIT NO.

RATING

No. of Thermometer-

lead

2

63A

63B 61AS 61BS 62AS 62BS 63AS 63BS 6 i A 64B 65A 65B 66A 66B 64AS 64BS 65AS 65BS 66AS 66BS 67A 67B 68A 68B 69A 69B 67AS 67BS 68AS 68BS 69AS 69BS 70A 7 OB 71A 71B 72A 72B 70AS 70BS 71AS 71BS 72AS 72BS 73A 73B 74A 74B


Location

3

S l o t 41

S l o t 2

S lo t 22

S l o t 42

S l o t 1

S l o t 21

S l o t 41

S l o t 2

S lo t 22

S l o t 42

S l o t 1

S l o t 21

S l o t 41

S l o t 2

S l o t 22

S l o t 42

S l o t 1

S l o t 21

S l o t 41

S l o t 2

S l o t 22

S l o t 42

M i d d l e o f stator body

- d o -

Parameter Measured

4

C o r e i r o n

t e r m . - d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

- d o -

C o l d gas

- d o -

ERECTION

CUSTOMER

FQA

DC resistance

n

5

IR Value M Q

6

NAME & SIG.

Ambient Temperature

•C

7

Remarks

8

REVISION R 2 ~ 8 / 9 2

SHEET 4 / 6

F O A - 0 3 - 0 0 - 0 1 - L - 0 2


si. No.

No. of Thermometer

No. of Thermometer-

lead Location

Parameter Measured

DC resistance

a

IR Value Mfi

Ambient Temperature Remarks

75 75A 75B

M idd le of stater booV

Cold gas

76 76A - d o - -do-76B

77 77A - d o - - d o -_77B_

78 78A -do- -do-78B

Description Design Value

Actual Value Remarks

2.3

2.4

2.5

2.6

Hydraulic test of Hydrogen coolers. Test pressure Duration

Hydraulic test of terminal bars before assembling on the stator terminals.

Test pressure Duration

5Kg/cm

30 min.

25Kg/cm 30 min.

Non magnetic property of bolts/nuts connecting the terminal bars with connecting bus bars inside the stator. MEASUREMENT OF DC RESISTANCE k IMPEDANCE OF STATOR WINDING

Non

magnetic

C -1C1 C -2C1

r - i c 2 C-2C2

C - E -r - i c 3 C-2C3

C - C

C 5- C 6

C -C 4 6

DC Resistance

IR Value

DC Resistance

iH Value

DC Resistance

IR Value

IR Value

Before connecting Terminal bushing ' Value Temp.

After bolting rt\ Terminal Bushing Value Temp

After soldering /-.•» Terminal Bushing Value Temp.

V a r i a t i o n i n r e s i s t a n c e ^ 3% between ' ( a ) , (b )6 (c)

Jse 1000 V meggar

I R ^ t (KV+1) a t 40°C.

PROJECT ERECTION

NAME & SIG. REVISION R 2 - 8 / 9 2


RATING FQA FOA-03-00 -01 -L -02

m SI. No.

2 . 7

2 .8

2 . 9

2 . 1 0

2 . 1 1

2 .12


Description

HV t e s t on p o r c e l a i n i n s u l a t o r s of the bushings

I n s u l a t o r Nunber

HV Test volts Duration - 1 minute Leakage current IR Before Test IR After Test

i z 3

i ) C o n d i t i o n of the water pa th d e t a i l s of s t a t o r w i n d i n g , t e f l o n hoses, vent p i p e s , genera l c o n d i t i o n o f s t a t o r w i n d i n g .

i i ) L o c k i n g of f a s t e n e r s p rov ided on i n s u l a t i n g b racke ts f o r s t a t o r w ind ing overhang.

IR between water headers and s t a t o r body. I n l e t Header O u t l e t Header

i ) Pneumatic p ressure t e s t of s t a t o r w i n d i n g .

Pressure o f a i r a p p l i e d Per iod of a p p l i c a t i o n .

i i ) H y d r a u l i c p ressure a p p l i e d on s t a t o r

w i n d i n g .

Per iod o f a p p l i c a t i o n Permiss ib le p ressure drop

IR va lue of w ind ing w i t h w a t e r . (cor responding t o DM water c o n d u c t i v i t y of 5 micro-semen)

A i r t i g h t n e s s t es t o f S t a t o r .

Pressure o f a i r a p p l i e d Perm iss ib le leakage o f a i r i n rtm Hg a f t e r temperature c o r r e c t i o n .

PROJECT

UNIT NO.

RATING

ERECTION

CUSTOMER

FQA

Design Value

52 KV AC f o r / 1min .or 73KV DC f o r 1 m i n .

4 5

5M ohm

3.5 A t g . 4 h r s .

8 .0 A t g .

24 h r s 0 .4 A t g .

• 100 K ohm

4 . 0 A t g .

8

Actual Value

6 7

NAME & SIG. REVISION R

SHEET 6

F Q A - 0 3 - 0 0

Remarks

8 9

Use 500 V meggar

Use only d r y i n s t r i m e n t a i r No leakage p e r m i s s i b l e .

Use on ly D/M w a t e r . No leakage p e r m i s s i b l e

Use 1000 V meggar

2 - 8 / 9 2

/ 6

- 0 1 - L - 0 2


3. Tests on rotor prior to rotor insertion

SI. No.



3 . 1

3 . 2

3 . 3

1) Diameter of journals

a) Front brg. journal b) Front seal journal c) Rear brg. journal d) Rear seal journal

2) Spigot of coupling:-

a) Diameter b) Projection

Gas tightness test Pressure of N applied Permissible leakage of N in mm of Hg. column.

in 6 hrs,

4.0 Atg

260

Purge test of ventilating canals: Technical requirements:

1) Inlet pressure of air at the ventilating canals of slot through the inlet adapter.

2) Static pressure to be maintained under retaining ring during test on overhang portion.

3) Required average velocity pressure for each zone in the canals of slot portion.

Required average velocity pressure for each slot.

4) Required value of static pressure in individual canals of overhang port ion.

5) Fully closed canals are not allowed in the overhang portion of rotor winding.

6) Ensure sealing of all ventilation canals/ducts after purge test and their removal only at the time of rotor insertion.

3.0+0.1 A t g .

50 rrtn of H O column

^ . 1 5 mn o f H„0 column

-£.21 rrm of H„0 column

^C.15 nrm of H„0 column

Not a p p l i c a b l e f o r THW-210-2B Genera tor .

F i l l sheet 3 6 A of ' t h i s l ogshee t .

PROJECT ERECTION


UNIT NO. CUSTOMER SHEET 1 / A

RATING FQA FQA-03 -00 -01 -L -03

mmitAVgM

aun

PROJECT:

UNIT NO:

RATING:

CHART FOR PURGE TEST OF ROTOR VENTILATION CANALS •• • In le t air pressure In slot portion :

S L O T P O R T I O N OF ROTOR . Static pressure under retalnlnq rlnq :

I N L E T HOLES Overhang portion on IE

o

s 1 2 3. 4

4_ IT 7 8-9

10 11

12 13 14

15 16 17 18 19 20 21 22 2.3 _ 24 25

%-> 27 28 29

39-5i 32 33 34 IS 36

71 |73 |75 |77 |79 le i |83 IAVERAGE 72 74 76 178 8 0 I 8 2 J 8 4 /

FOR

58 60 6?

1

64 66 68 70 SECTION 05

ERECTION:'

FQA:

CUSTOMER:

87 19 91 93 95 97

—

WERAGE 1 FOR 0

ECTION

,•

NAME

39 | lOl | l03| l05J07 109 111}

UTLET MOLES

36 88 90

1

92 94 96 98

.

(VERAGE 1

FOR

SECTION

00 102,04 106 1 0 8 1 1 0 1 1 ; '

J i 15H?

,

LL2 U1

SIGNATURE

23 25

IVERAGE

FOR

>ECT!0N

DATE

AVERAGE

FOR

SLOT

M U M LLt H i Llfl lifl 121

—

—

—

—

— —

24 J&

—

REVISION: R 2 - 8 / 9 2

SHEET: h I i*

F Q A - 0 3 - 0 0 - 0 1 - L - 0 3

|M2t£tJffrl]

am

PROJECT:

U N I T N O :

R A T I N G :

CHART FOR PURGE T E S T OF ROTOR V E N T I L A T I O N C A N A L S

OVERHANG PORTION ON EXCITER SIDE

o X 1-o —1

1

2 3

ft s 6 7 8

T 10 11 12 13

T T

TT 16 17

42-i9 20 21 22 Z3 2*

I f 26 27 28

"77 I f f -JT

"5? 33 34 35 36

„

I I I I I 1517

r^-r- •-.».-.-rr <-...• nr- ^T-^ .1- . I n l e t a i r pressure in s to t por t ion : S L O T P O R T I O N OF ROTOR S ta t i c pressure under re ta in ing r i ng :

119 21 |23 |25 |27

T

i

3

—

5 7 9

i

11

—

—

—

13 |2 4

_ -

E R E C T I O N

FQA:

C U S T O M E

6 8 10

—

12

—

—

14

—

J AVERAGE

FOR SECTION

I N L E T H O L E S 16

29 )

.

8 20

1 33

—

22

35"

—

—

24

37

?6 [28

)9 41

N A M E

R:

|AVERAGE

FOR

SECTION

4 3 | 4 5 | 4 7 | 4 9 | 5 1 |53 |55

30 32

—

—

—

34

—

—

36

—

38 40

—

S I G N A T U R E

42

—

—

AVERAGE

FOR

SECTION

D A T E

44 I 46j 181 50 152 | 51 |56

57 59

—

61

—

63

—

65 67 69

JAVERAGE

FOR

SECTION

R E V I S I O N : R - 8 / 9 2

S H E E T : 3 / A

F Q A - 0 3 - 0 0 - 0 1 - L - 0 3

m SI. No.

5 . 3

5 . 4

5 . 5

5 . 6

5 . 7


Description

P e r c e n t a g e c o n t a c t o f p e r m a n e n t p a c k e r s w i t h embedded p l a t e s and f o u n d a t i o n f r a m e o f r e a r b e a r i n g p e d e s t a i .

T h i c k n e s s o f p e r m a n e n t p a c k e r s .

T i g h t e n i n g t o r q u e o f f o u n d a t i o n s t u d s .

A v e r a g e v a l u e o f c o m p r e s s i v e s t r e n g t h o f t e s t c u b e s 21 d a y s a f t e r g r o u t i n g o f r e a r b e a r i n g p e d e s t a 1 .

A l i g n m e n t r e a d i n g s o f G e n e r a t o r r o t o r w i t h LP r o t o r a f t e r g r o u t i n g .

Pe ga

Pe ga ! !

I n c mm/

tora* [AS

e*

St'

t*>*

170*

AlV*A*t

r m i s s i b l e p s .

r m i s s i b l e ps - i . e .

" ! 3 a n C

1 i n a t i o n 1000 met*

r i n "—

Design Value

^ 8 0 %

<£ 25mm

110 k g - M

2 2 0 0 k g / c m

TO*

r,

%

5

*

"

d i

> d i

ab ; J 2

o f

Vs * Y/\

PROJECT

UNIT NO.

RATING

n,

f f e r e

f f e r e 5 o l u t

" \ sh

4L- -l l i_U_ -

aorroff

4

*

*

**

*

Z i f r r

A

/ /

J-3

*+

/

n c e s i n a x i a l

T - B L-R

n c e s i n r a d i a l e v a l u e s o f

a f t j o u r n a l i n

1 1

4 Y' 7]

*»>r>

yi ;—r

/r/s#r

*,

4

is

**

*

+ 0.02 ±0.02

C

i

ERECTION

CUSTOMER

FQA

Actual Value

I 1

J,

t>

Ju

1

. - 0.03 - 0.03

mm

.03nrm

1 1*

1

if.

' X/YA

NAME & SIG.

Remarks


SHEET 2 / 1 2

F O A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.

5 . 8

5 . 9

5 . 1 0

Description

Centering of stator w.r.t. Rotor. SECTION-XX x r

Design Value


I

1

r \

i

\T \

V

— \ k i

\ 1* \ | J\ y

1 D

c t

r s •

N

/

\ \

\

/

<

—1

d -=lh> Sj|_i>

[ /

x h— — H x THE DISTANCE A.B.C.D SHOULD HOT DIFFER FROM EACH OTHER BT MORE THAN O S mm

Permissible difference A-B C-D

±0.5 mm

Adjustment of magnetic axis, §2 51:2

TURBINE END

Dimension A and B shouLd be adjusted such that A-B

Note: Offset of axis 18 mm is only for reference.

,> . s,:< .

<~ iL

I l i U )

il | ! . , | i l l ! i l |

H

B • i

1

J -J l _ p EXCITER END

, !j 1BMM

Air gap reading,

36 mm

EXCITER END

TURBINE END

EXCITER END

EXCITER END

X^J TURBINE ENO

TURBINE END

EXCITER END

TURBINE ENO

CALCULATED VALUE OF GAP i 1 0 mm

ACTUAL AIR SAP SHOULD BE WITHIN 70 • 1.75

_ J J L

PROJECT ERECTION


UNIT NO. CUSTOMER SHEET 3 / 1 2

RATING FQA F O A - 0 3 - 0 0 - 0 1 - L - 0 5


A. Test results on EE bearing and pedestal prior to rotor insertion,

SI. No. Description

Design Value


A. 1

A.2

A.3

A.A

A.5

A.6

A.7

Soundness of bondaae of pedestal embedded plates with the concrete by means of hammer test.

Centering and elevation readings of embedded plates. Centering readings of pipe sleeves .

Matching of embedded plates to obtain required contact and slopes in the direction of insertion.

Percentage plates with

of contact foundat ion.

anchor

Kerosene test of oil rear bearing pedestal. Period of application.

chamber of

Contact between foundation frame and rear bearing pedestal. Clearance at joint should not exceed.

Percentage of contact of foundation frame bottom at seating surface with permanent packers.

A) Percentag spher icat bear ing

e of contact of seat ing of rear

liner with pedestal.

B) Percentage of contact of rear bearing liner parting plane .

C) Percentage of contact of rear bearing pedestal parting plane.

d) Percentage of contact between journal and bearing liner lower half along a uniform band of A5°-55°.

PROJECT

UNIT NO.

RATING

ERECTION

CUSTOMER

FQA

V i b r a t i o n o f sand not a l l o w e d .

Contact^ '80% slope 3-A rrm per me te r .

Contac t ^ 7 0 %

2A h r s .

0.05 mm

•ft 80%

-JC 80%

- £ 80%

-£ 80%

-ft 80%

NAME & SIG.

Sheet No.2/4 5, 3/4 of L-01 to be f i l l e d .

Sheet No. 4/4 of L-01 to be f i l l e d .

No leakage/ seepage allowed.


SHEET 1 / 1

F Q A - 0 3 - 0 0 - 0 1 - L - 0 A

r nwufc-w •

UNIT NO.

RATING

CUSTOMER

FQA

SHEET 1 / 12

F Q A - 0 3 - 0 0 - 0 1 - L - 0 5

Bun-out readings of rotor.

x _* ha 1 f -coup 1 i n 9 • A. Axial run out of halt

Radial run-outs

E/E bearing ,-E/E seal journal Inner slip ring. Outer slip ring-Balancing disc.

0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03

2 Alignment readings of generator rotor with LP rotor.

J TOP ! narrow \ ±/rsr \ #/6f/r

St'

,»'

t70*

v*\ \«\

fil/CMA**

Permiss gaps .

\9

i b l e d i f f e r e n c e s in a x i a l

T-B L-R

d i f f e r e n c e s i n r a d i a l

p . ! ™ i s - s ' b , e rt.;T«« v . i » . . « gaps

j n d I .

PROJECT

UNtT NO.

[RATING

ERECTION

CUSTOMER

FQA

1.0.02 - 0.03 ±0.02 - 0.03

rrm

0.03rrm


SHEET 1 / 1 2


si. No.



5.3

5.A

5.5

5.6

Percentage contact of permanent packers with embedded plates and foundation frame of rear bearing pedes ta 1.

Thickness of permanent packers.

Tightening torque of foundation studs.

Average value of compressive strength of test cubes 21 days after grouting of rear bearing pedesta1.

Alignment readings of Generator rotor with LP rotor after grouting.

^ 8 0 %

«£ 25mm

110 kg-M

200kg/crr/

Mfrar [AS

Je'

fM'

170'

ADffAat

TO*

r,

BOTTOM

It

*.esr

Permissible differences in axial gaps.

T-B L-R

Permissible differences in radial gaps - i.e. absolute values of X! ~ X3 a n d l2 I

5.7 Inclination, of shaft journal in mm/1000 meter

#/6#r

is

J?AJ>/JIL a A P.

+0.02 - 0.03 ±0.02 - 0.03

nm

0.03nm

J>»*.

-B SB m %

~\—

J_

PROJECT ERECTION



RATING FQA F Q A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.

5 . 8

5 . 9

5 . 1 0

Description

Centering of stator w.r.t. Rotor.

Design Value


SEC7I0N-XX x

I

r^ '

^ ^

V

^ \

i

/ )

\ •» \ i

A y

j J

D

H ~tZ

r̂ sl

^

s

/

\ \ \

—H X

"li /

s

•* 1-1 il-"

r /

x f— — H x THE OISTAMCE A.B.C.D SHOULD NOT DIFFER FROM EACH OTHER BT MORE THAN O S mm

Permissible difference A-B C-D

±0.5 mm

Adjustment of magnetic axis.

TURBINE ENO

Dimension A and B should be adjusted such that A-B

Note: Offset of axis 18 mm is only for reference.

I I M : , . . ( ! . . 1111 f i i |

EXCITER END

I I I""! :" ' ' ' ' ! ! ) !

, !'_,18MM

A i r g a p r e a d i n g .

36 mm

EXCITER END

1 1 TURBINE END

EXCITER END W' TURBINE END

EXCITER END

1 TURBINE END

1 1

EXCITER END

1 TURBINE ENO

CALCULATED VALUE OF GAP «10 mm

ACTUAL AIR GAP SHOULD BE WITHIN 70 • 1.75 m

__J 1Z L

PROJECT ERECTION



RATING FQA F O A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.



5. 1 1

5. 12

5. 13

5. 14

5. 15

Calculated value of gap.

Permissible differences in measured values of top and bottom readings and left and right readings.

Percentage of contact surface of permanent packers with embedded plates of stator.

Thickness of permanent packers.

Elongation of foundation studs of stator during tightening

or

Tightening torque of foundation stud.

Average value of compressive strength of test cubes 21 days after grouting of stator foundation plates.

Hot water flushing of stator water system including winding prior to boxing up of Generator.

70mm

^ 3 . 5 mm

ft 80%

•jt 25mm

0.38mm

105Kg-M

200Kg/cm"

Wa t e r Iemp. about 60-70°C

Clearance shield .

between fan and fan

Gap 'A' to be adjusted at site to obtain the following readings:

Gap 'A' to be adjusted at site to obtain xne following readings:

Required values of gap B

E/E T/E

T/E Pe rm iss ib l e d i f f e r e n c e i n measured values of gap ' B ' i n h o r i z o n t a l 6 v e r t i c a l planes

7s 4Qrm < IQrm

2-2.98rmi 2-2.98mn

^ 0.07mm

A l i the t e f l on hoses shou ld be hand f e l t f o r warmness t o d e t e c t b lockage o f an wa te r p a t h .

PROJECT ERECTION

NAME & SIG. REVISION R ? - 8 / 9 2


RATING FQA F Q A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.



5 .16

5 .17

5. 18

IR value between fan -Shield and end -shield

E n d - s h i e l d f i x i n g

E/E ft 5M Ohms Use 500V meggar

Tightening torque for bolts:

a) Parting plane bolts (item 2)

b) Bolts for fixing end-shield with stator body litem 1)

Note: Locking of bolts for fixing upper naif fan shield to end shield to be ensured -.prior to closing of Inspection windows.

Axial run out measurement on end shield (seal body seating surface)

95 Kg-m

45 Kg-m

MEASUREMENT VIEW- A

01

AXIAL RUN OUT I MEASUREMENT I AXIAL RUN CUT

01

_LL 13

02 ID1-021/2I VIEW- B ! 01 I 02 EVO:W 01 I I 02 03 0 (

as 06

09

12

Permissible axial run-out Axial run-out exceeding 0-2 mm t o be ^ 0-2/nm neutral ised by su i tab le machining of seal body f lange. Note: Location nurbers are counted whi le locking from TE U EE respect iv

PROJECT ERECTION

NAME & SIG.

s l y



RATING FQA F Q A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.



5.19|Shaft seal 6 oil catcher adjustment CNO SHIELD

NOUTION

A

B

C

D

EXCITER SOE | TURBINE SIDE

' NOMINAL VALUES

MEASURED VALUES

(SO • 5S ) I •COS

t5 - 10) O S

( 3 5 - 3 «

O-17-0-2J6

NOMINAL VALUES

m - JO)

W - « ) •<:o*

U - S )

O47-0-3?*

MEASURED VALUES

Note: Ensure absence of contact of seal body with rotor step radius, for this 2XA5 chamfer can be done on the seal body edge facing rotor step.

OIL SELECTING SING

1. Joining surfaces of seal bodies should be matched so that 0.03 . feeler gauge does not pass. Ensure that no undue ovality in bore dia is created at the time of matching.

2. Centering of lower half seal body with respect to rotor be done within 0.10 rrm.

S-NO NOMINAL VALUE

MEASURED VALUE I

IEX-SI0E |TUR-SI0E i

| TOP | 0-3 -0-4 I I 0-17-O-3SI

BOTTOM 1005-0-101 LEFT 10-17-035!

I 01 I TOP ̂ BOTTOM* 0-26-0-30 I "i02ILEFT4RIGHT! 0-25- 3-30 I

I I TOP | 01 I 1021 SIGHT

'*! 03 I BOTTOM i o t l LEFT

5 0

5-0 I

TOP '0-3 -0-6 J^ 1011 J02| RIGHT iQ-17-0-351

"J03I BOTTOM iQ-Ot-3-IQI i04 l LEFT | 0-17-3-35!

5.1 01_

02 I TOP |0-3 -0-5 j

SIGHT

IDIAMETRICAL 'CLEARANCE

10-17-0-35 I

PROJECT ERECTION



RATING FQA FOA-03-0O-O1-L-05

VLlimt-MtJiM

\njju SI. No.

.

5.20

5.21

I FIELD QUALITY ASSURANCE

Description

3 . Ro ta te the seal r i n g and check f r e e movement on r o t o r and i n s i d e the seal body.

A. No sc rap ing should be cbneonpar t ing p lane or i n s i d e d i a of sea l r i n g i n any case

5. Check t h a t the. l o c a t i o n o f the s l o t ( f o r sea l r i n g s topper) a t lower h a l f j o i n i n g p lane of seal body i s on l e f t s i de f o r bo th T/E and E/E sea l s when viewed f rom T / E .

6 . Check tha t the l o c a t i o n o f the seal r i n g . i o in ing plane viewed f rom T/E i s on the l e f t s i de f o r both T/E and E/E sea ls when the stopper p i n r e s t s i n the seal body s l o t .

7 . Check the stopper o f sea l r i n g f o r absence of any notch or c r a c k .

8 . Ensure t ha t the s topper i s p r o t r u d i n g a t l eas t 10 mm i n t o the sea l body groove.

5 . For proper f l o a t of sea l r i n g , check gap between seal body s l o t and stopper p i n -des ign va lue 0.5 rrm.

10. I n case stopper p i n i s to be rep laced ensure tha t l o c a l l y made p i n i s not used

IR va lue of e n d - s h i e l d o i l ca tcher a t EE

IR value, of generator rea r end a f t e r EE sha f t segl assembly by l i f t i n g the r o t o r on TE and w i t h an a x i a l gap between LP and Generator r o t o r s

1 PROJECT

UNIT NO.

RATING

ERECTION

CUSTOMER

FQA

Design Value

<£ 5 Mohm

"i£. 5 Mohm

Actual Value


SHEET 7

F Q A - 0 3 - 0 0

Remarks

-

Use 500V meggar

- d o -

, - 8 / 9 2 -2

/ 12

- 0 1 - L - 0 5


si. No.


Actual Value

w. _rr Remarks

5-22 Reaming/Coupling of generator and LP rotor half couplings

| 170 I

JO. 11 12 13 14 15

16 17 18

1« BOtTS ITSO WITH 0-Oi - 0 - 0 3 mm CLEARANCE FITTED At SITE

Elongation of coupling bolts achieved after coupling LP and TG rotors.

Permissible change in coupling radial runouts after fitment of coupling bolts.

0.43

0.01

0.47 rrm

0.02 mm

Data on Reaming/Coupl ing of LP-TG rotors

s. NO-

COUPLING HOLE NO.

COUPLING HOLE DIMENSIONS

INITIAL DIA

FINISHED DIA

OVALITY TAPER COUPLING WALL THICKNESS

COUPLING BOLT DIMENSIONS FINISHED

DIA OVALITY WEIGHT OF BOLT

AND NUT

5.

6-

f.

8.

».

10. I I .

II .

IS. 14.

IS. I*.

a. 18.

PROJECT ERECTION

NAME & S1G. REVISION R 2 - 8 / 9 2


RATING FQA F Q A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.



5.23 Bearing adjustment (Exciter side)

ALONG t - t

CALCULI ACTUM

0-7- 0-9

0-35-O-A5

ALONG C-C

CALCULAT E

ACIUAL

O . A - 0 - *

0-1-S-4S

O-IO-O-IS

ALONG 0 - 0

CALCULATE P

O-ta-0-40

O-ll-O-l

ACTUAL

DC resistance of bearing RTDs

Note: For 2B type of generators the

5.24

5.25

79 A 79 B 80 A 80 B

value of

526

Insulation resistance of all oil piping|3E) A. Lub o i l i n l e t B . Lub o i l d r a i n C . J a c k i n g o i l i n l e t D . S e a l o i l i n l e t E . R i n g r e l i e f i n l e t F . S e a l o i l d r a i n ( H , s i d e ) G. S e a l o i l d r a i n ( a i r s i d e ' H. A u x . b e a r i n g i n l e t I . A u x . b e a r i n g o u t l e t " -

A i r t ighteness tes t o f asserrbled genera to r with gas and o i l system

Pressure o f a i r a p p l i e d P e r m i s s i b l e leakage of a i r i n 24 Hrs ( i n nrm of Hg co l umn)a f t e r teTperattre correction.

IR & PI values of each phase of stator wdg

Phase R ' IR.n . ..p.10 min .

1 min PI value

Phase Y IR10min

1 min PI value

DIAPHRAGM IN OIL PIPE

DESIGN VALUE

ACTUAL VALUE.

E i s 27mm

sfc 5 Mohms' - d o -

- - d o - _. - d o -- d o -- d o -- d o -- d o -- d o -

4 . 0 38

a t g

Phase B I R . n . IR10min

1 nun P I va lue

1 0 M N \

* > 2

PI Value= IRfOMiVv. I R I Min

PI Value of less than 2 is to be improved before synchronisation.

PROJECT ERECTION



RATING FQA F Q A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.



5.27 Centering 8 offset setting of Brush-Gear for THW-210-2A generators BRUSH GEAR SLIP RING

BRUSH HOLDER

BRUSH GEAR

SLIP RING

THE DIFFERENCE BETWEEN

VVV*« THAN 1 m n . t ^ . t ^ NOT MORE

5 . 2 8

NOTATION

t 1

t2

t 3

t 4

A

B

c

! °

CALCULATED VALUE

FOR BRUSH GEAF WITH ID*0"480

9 - 5 - 10-4

9- 5 - 10-4

9 - 5 - 10-4

9 - 5 - 10-4

0

18 TO JO

32 TO 36

SO TO S4

FOR BRUSH GEAF WITH 10174 68

3-4 • 41

34 - 4-1

yi - 41

>4 - 41

0

16 T 20

32 .- 36

50 - 54

ACTUAL

VALUE

C e n t e r i n g & o f f s e t s e t t i n g o f b rush gear f o r THW-210-2B g e n e r a t o r s

RIB

VARIATION IN t ON Al I THE Rl°^ «;nnni n NOT BE MORE THAN 2 mm

SUPRING FREE END

BRUSH

SUP RING

B D D D DDDD

GENERATOR END

18mm

t

L

MEASURED VALUE

/

Check IR value a) Each limb b) Between Hmbs

'h 5Mohms T̂T 5Mohms

PROJECT ERECTION

NAME & SIG. REVISION R - 8 / 9 2


RATING FQA F O A - 0 3 - 0 0 - 0 1 - L - 0 5


SL No. Description

Design Value

Actual Value

Remarks

5.29 F i x i n g o f B r u s h H o l d e r 6 B r u s h e s f o r

T H W - 2 1 0 - 2 A / 2 B g e n e r a t o r s . BRUSH KXOEW , _ *

! - - ^ A > BRUSH <-SUP RING

a)

5 . 3 0

NOTATION

S

I I

t2

DESIGN VALUE

2 TO 25MM

0-1 TO 030

01 X) 030

ACTUAL VALUE

b ) F o r m e a s u r i n g t & t b r u s h s h o u l d be

p ressed a g a i n s t one s i d e o f b rush h o l d e r . c ) A x i s o f b rush h o l d e r s h o u l d be r a d i a l t o

s l i p r i n g s u r f a c e . V a r i a t i o n ±2 deg .

d) F i x i n g b o l t s o f b r u s h h o l d e r s h o u l d be p r o p e r l y l o c k e d .

e) Bedd ing o f b r u s h e s s h o u l d be done w i t h t h e h e l p o f g l a s s a b r a s i v e c l o t h t o achievi 80S area of contact.

f ) Ensure that internal surface of brush holder is free from any i r r e g u l a r i t y .

g) Adjust spring tension to 0.9 - 1.0 Kg.

C e n t e r i n g o f B r u s h - g e a r e n c l o s u r e w i t h f a n f o r T H W - 2 1 0 - 2 B g e n e r a t o r

Pos i t ion

0 °

9 0 °

180°

270°

Ac tua l Value

VALUE OF 't'SHOULD NOT DIFFER BY MORE THAN 1 nm AROUND THE PERIPHERY

PROJECT ERECTION

NAME & SIG. REVISION R ? _ 8 / 9 2


RATING FQA F Q A - 0 3 - 0 0 - 0 1 - L - 0 5


si. No.



5 .31 Extens ion s h a f t a l ignment f o r THW-210-2B g e n e r a t o r s

BALANCING DISC

COUPLED RUNOUTS

& 0.03 ^ 0.03

>75

5.32 Auxiliary bearing adjustment for THW-210-2B generators.

Bearing without pads Free end

•Si.!-i *1

x Gen end. «-»

TH S\ -* C ' B

X=325 mm

R

NOTE :

The height of the bearing is

is adjusted such that when

tilting pads are insered the

extension shaft gets lifted

by 0 .10 mm.

p.15-0.20

T-B

l-R

Along A-A Along B-B Along C-C

Designed Value

0.05--0.10

0.10--0.15

0.10--0.15

Actual Value

Designed Value

+ 0.10

+0.02

Actual Value

Designed Value

+0.10

±0.02

Actual Value

REMARKS

Slope of shaft & bearing should not differ by more than 0.01mm per metre.

PROJECT ERECTION

NAME & SIG. REVISION R - 8 / 9 2


RATING FQA FQA-03-00-01-L-05


6.0 Test results on equipments of Generator Auxiliary Systems

SI. No. Description Design

Value Actual Value Remarks

6.1

6.2

6.3

Seal oil system

Hydraulic pressure applied in Atg. (Piping)

Period of application

Gas system

a) Hydrogen drier Pneumatic pressure applied(atg) Period of application

b) Assembled CO- control stand Pneumatic pressure applied(atg) Period of application

c ) A s s e m b l e d H c o n t r o l s t a n d (upto isolating valve af ter pr.regjlators en gas unit) Pneumatic pressure applied(atg) Period of application

d) Valves Pneumatic pressure applied(atg) Period of application

el Hydraulic pressure applied (atg)J Period of application

Stator water cooling system

a) Water Expansion Tank Hydraulic pressure applied(atg) Period of application

b) Stator water coolers Hydraulic pressure appl ied(a tg)|

Shell side Tube side

Period of application

c) Valves Hydraulic pressure applied(atg) Period of application

d) Piping H y d r a u l i c p r e s s u r e a p p l i e d ( a t g ) P e r i o d o f a p p l i c a t i o n

20

30 m i n

4 . 5 1 h o u r

4 . 5 4 h r s .

6 . 0 4 h r s ,

4 . 5 10 m i n

6 . 0 10 m i n

1 . 3 10 m i n

8 10 30 m i n

12 10 m i n

12 30 m i n

3heck absence Df pass ing o f / a I ves S c a l i b r a t i o n o f s a f e t y v a l v e .

>ieck absence } f pass ing o f / a l ves 6 se t r e g u l a t o r P r .

PROJECT ERECTION

NAME & S1G. REVISION R 2 - 8 / 9 2


RATING FQA F Q A - 0 3 - 0 0 - O 1 - L - 0 6


6.4 D.C.resistance and IR value of following RTDs

No. of Thermometer

No. of Thermometer-

lead Location

DC resistance

a

IR Value MQ

Ambient Temperature

•C Remarks

81 81A Brg. drain pipe E/E B1R

82 82A 82B

Sreft seal K side drain

PtoT/E 83

84

85

86

87

88

89

90

91

92

93

"54"

83A 83 84A

9-aft seal pipe E/E.

sicfe drain

84B Oi l pipe before seal o i l cooler.

85A 85B 86A

Oil pipe after oil cooler.

seal

86B 87A 87B 88A 88B 89A 89B 90A 90B 91A 91B 92A 92B 93A 93B

DVM water inlet to stator winding.

-do-

D/M water outlet from stator wdg. Waterheader inlet to gas coolers Water pipe outlet from gas cooler.

- do -

-do-

- d o -

"54A" Coo l i ng water i n l e t pipe to St.vater coolers.

9o

96

94B "5BX 95B

Coo l ing water . o u t l e t f ran St. water coolers

96A 96B-

Shaf t sea l corrmon a i r sice dr-ain pipeline,

PROJECT

UNIT NO.

RATING

ERECTION

CUSTOMER

FQA

NAME & SIG. REVISION R 2 _ 8 / 9 2

SHEET 2 / 4

F Q A - 0 3 - 0 0 - 0 1 - L - 0 6

m t-ltL-U U U A L I 1 Y A b b U K A r J U C

6.5 Protocol/Log sheet for Pumps 6 Motor sets during erection

^—.^__^ System ^~~~^--^_^

Description *̂~~-~̂ ___̂

Mo tor:

Make Type Frame size Ra t ing Insulat ion class Direction of rotation KW/HP Ful1 load amps. Voltage R P M Supply voltage. Machine No. Temp, rise

Checks:

Free mov ement of rotor I R of Motor winding (Between phases and between phases S earth)

Bearing

Lubricant

Earthing of motor body

Pump:

Make

Type

Mach ine- No.

Head

Discharge

Speed

Input

Direction of rotation

PROJECT

UNIT NO.

RATING

Stator water cooling

No. 1 No. 2

ERECTION

CUSTOMER

FQA

Seal oil

AC DC

NAME & SIG.

(Booster Pump)

Hydrogen Cooler wa ter No. 1 No.2

REVISION R2-8/92

SHEET 3 / 4

FQA-03-00-01-L-06 j


Protocol/Log sheet for Pumps 8 Motor sets during erection

System

Descr ipt i on

Checks:

Free movement of the shaft

Bearing condition

Lubr icant

Impeller condition

Gl and

Impeller clearance

Axial Radial

Front

Rear

Gasket thickness

Alignment checks:

Half coupling condition

Run out :

Radial Axial

Alignment reading:

Radial • Axial

Stator Water-

cool i ng

N o . 1 N o . 2

Sea 1 o i l

AC DC

( B o o s t e r Pump) H y d r o g e n

C o o l e r w a t e r

N o . 1 No.

PROJECT ERECTION


2 - 8 / 9 2


RATING FQA FQA-03-00-01-L -C6


1 .SHAFT SEAL ADJUSTMENT

HW DOCUMENT NO:

0492-003

NOTATION

M

D

A

B

LI

L2

L3

T

Y

S

E

EXCITER SIDE

CALCULATED

0 . 4 TO 0 . 5 4

^f- 1 0

^C- 20 <j=L 1 0

-=fC 25

^ 1 0

41.10

1 TO 1 . 2 5

1 TO 1 . 2 9

3 8 . 6 2 T 0 4 5 . 1 6

1 TO 1 . 5

ACTUAL

••-

TURBINE SIDE

CALCULATED

0 . 4 TOO.54

< j t 20

< = £ 1 0

<̂ P- 20 4 1 10

*4^ 20 ^ - 20

1 TO 1 . 2 5

J TO 1.9Q

2 8 . 6 2 T 0 3 5 . 1 6

\ TO 1 . 5

ACTUAL

cHEckEb BY

1 Project Site:

D*T6 Rev:01-Aug'8] Sheet 1 / 3 Sheets


III TECHNICAL REQUIREMENTS OF SHAFT SEAL ASSEMBLY

Hit DOCUMENT MO I

0 4 9 2 - 0 0 3

1 . ALL JOINING SURFACES OF SEAL BODY & SEAL LINER SHOULD BE MATCHED SO THAT 0 . 0 3 FEELER GAUGE SHOULD NOT PASS ANY WHERE.

2 . CENTERING OF SEAL BODY TO BE DONE WITH RESPECT TO HOTOR WITHIN

0 . 0 5 MM.

• 3 . MATCHING OF SEAL LINER BABBIT SURFACES TO BE DONE WITH ROTOR 4 COLLAR. CONTACT AREA SHOULD NOT BE LESS THAN 8 0 *

4 . TAPER OF ROTOR SEAL COLLAR SHOULD NOT BE MORE THAN 0 . 0 3 MM.

CUEXKED &V

t)ATE

P r o j e c t S i t e :

U n i t No:

R e v : 0 3 d$fc: fS?

S h e e t 3 / 3 S h e e t s

>iQ-roA~003-00.-0! - v l 6

generator erection manual thw 210 2a 2b (212)

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