Section No. para Description 1 Generator Assembly & Erection Pre-Requisites

TABLE OF CONTENTS
SECTION
SECTION
No. Para DESCRIPTION PAGE
1
1.1
1.2
1.3
GENERATOR ASSEMBLY & ERECTION PRE-REQUISITES
Sub-assemblies
Auxiliaries
Erection pre-requisites
1.1
1.1
1.1
2
2.1
2.2
2.3
2.4
ERECTION SEQUENCE
General
Erection in service-bay
Erection in generator founation pit
Slings
2.1
2.1
2.1
2.2
3
3.!
3.1
3.2
3.3
GENERATOR FOUNDATION
"eference ra#ings
$ounation% stator&bottom brac'et
Sole plate an founation bolts
Grouting
3.1
3.1
3.1
3.1
4
4.!
4.1
4.2
4.3
4.4
4.(
4.)
STATOR ASSEMBLY
"eference ra#ings
General
Stator frame
Stator core
Stator #ining
*ifting of #oun stator an lo#ering
Air coolers
4.1
4.2
4.2
4.2
4.3
4.(
4.(
5
(.!
(.1
(.2
(.3
(.4
(.(
(.)
GENERATOR SAFTS AND ROTOR ASSEMBLY
"eference ra#ings
General
Spier an rim assembly
+ounting of poles
$an assembly
*o#ering of main s,aft an rotor
+agnetic centering of stator an rotor
(.1
(.2
(.2
(.3
(.4
(.(
(.)
F!". - 5.1
F!". - 5.2
F!". - 5.3
F!". - 5.4
-evelope vie# of rotor after pole mounting
.,ec'ing for magnetic centering
Greasing of rim 'eys an rim loc'ing 'eys
Greasing of s,aft an spier 'eys
(./
(.0
(.1!
(.11
No. Para. DESCRIPTION PAGE
#
).!
).1
).2
BOTTOM BRAC$ET% BEARINGS AND OTER ASSEMBLIES
"eference ra#ings
General
Erection of bottom brac'et
).1
).1
).1
&
1.!
1.1
1.2
1.3
TOP BRAC$ET% BEARING AND OTER ASSEMBLIES
"eference ra#ings
General
Erection of top brac'et an ot,er assemblies
Guie bearing an insulation
1.1
1.1
1.1
1.2
'
/.1
/.2
/.3
/.4
/.(
/.)
/.1
/./
/.0
/.1!
/.11
/.12
/.13
LE(ELS AND ALIGNMENT
)INCLUDING DO*ELLING AND GROUTING+
2ntrouction
Starting c,ec'
2nitial setting of brac'et
Setting of t,rust bearing elevation
*eveling of t,rust bearing
Alignment
"otational c,ec' on generator main s,aft an top s,aft
.ombine rotational c,ec' on generator an turbine s,aft
Alignment of collector
Stator an rotor form
A3ustment of bearing clearances
-o#elling
Grouting
/.1
/.1
/.1
/.2
/.2
/.3
/.4
/.(
/.)
/.1
/.1
/.1
/.1
,
0.1
0.2
0.3
0.4
0.(
0.)
0.1
0./
0.0
0.1!
STARTING% TESTING% COMMISSIONING AND TRIAL RUN
General
4re-start c,ec's
5ump start
$irst run
Setting of over spee evice
6oltage buil-up
Sync,ronising an loaing
4utting into operation
Stopping
7aning over
0.1
0.1
0.1
0.2
0.2
0.3
0.3
0.3
0.4
0.4
ANNE-URES
ANNE-URE
NO. Para. DESCRIPTION PAGE
I
1.1
1.2
IG (OLTAGE TESTS OFO *INDINGS
Sc,eule of 76 tests on stator #ining at site
Sc,eule of 76 tests on fiel #ining at site
A-1.1
A-1.1
II
2.!
2.1
2.2
2.3
INSULATION RESISTANCE TESTING AND DRYOUT
General
2nsulation resistance testing
-ryout
"ecommene minimum insulation resistance
A-2.1
A-2.1
A-2.2
A-2.3
III
3.1
3.2
3.3
3.4
3.(
STATOR FORM AND ROTOR FORM
General
Stator form
"otor form
S,ifting of stator
Example
A-3.1
A-3.1
A-3.2
A-3.2
A-3.3
F!". A-3.1
F!". A-3.2
Stator form an rotor form 8at upper en of core9
Stator form an rotor form 8at lo#er en of core9
A-3.(
A-3.)
I( APPLICATION OF MOLYBDENUM DISULPIDE A-4.1
( CEC$ING ROUNDNESS OF ROTOR A-(.1
(I
).1
).2
REPLACEMENT OF STATOR BAR AND FIELD COIL
4roceure for c,anging a faulty&amage stator bar
Assembly&removal of fiel coil
A-).1
A-).1
(II
DRA*ING . / 251 // 235/1 % SECTIONAL ARRANGEMENT
)GENERATOR+
A-1.1
SECTION - 1
GENERATOR ASSEMBLY AND ERECTION PRE-REQUISITES
:,e ,yro generator mainly consists of follo#ing sub-assemblies an auxiliary equipment%
1.1 SUB-ASSEMBLIES
Stator
"otor #it, main an top s,afts; tubular s,aft etc.
5ottom brac'et #it, a t,rust an a guie bearing assemblies
:op brac'et #it, a guie bearing assembly
$looring; top casing; pit air seal; pit access oor etc.
Special instruments an #iring
1.2 AU-ILIARIES.
7yrostatic lubrication system
5ra'e-3ac' system
4o#er pac'
Anti-conensation ,eaters
.ooling #ater pipe lines for air&oil coolers
$ire extinguis,ing system 8.<
2
type9

1.1 ERECTION PRE-REQUISITES
Ensure reainess of follo#ing inputs for starting assembly an erection of
generator.

4o#er ,ouse roofing complete an sies; #ino#s an entries are covere.
Service-bay is concrete an embeing complete.
.oncreting an curing of generator barrel complete.
Generator stator an bottom brac'et founations are c,ec'e; c,ipping
complete an poc'ets are clear.
3-p,ase; 4 #ire electric po#er supply for construction an t,e tapping points
are available in po#er ,ouse an general 2llumination is provie.
6entilation an #ater supply arrangement.
E<: cranes commissione an teste for loas an tanem operation.
4roper precautionary measures are ensure to avoi flooing of t,e po#er
,ouse eit,er from upstream or o#nstream of t,e 4<=E" 7<>SE.
1.1
SECTION 0 2
ERECTION SEQUENCE
2.1 GENERAL
:,e erection proceure outline belo# is a usual met,o aopte by 57E*. :,e
proceure is to be ta'en only as a guie an a preferre met,o of erection of
ma3or component.
2.2 ERECTION IN SER(ICE-BAY
2.2.1 Assemble t,e stator frame segments on level stools. 5uil t,e core as a continuous
ring an carry out t,e stator #ining.
2.2.2 $or builing t,e rotor assembly; assemble spier #it, bra'e trac'; rim; poles; fans
etc.
2.2.3 Assemble bottom brac'et center an arms. "emove t#o ,alves of t,e spring plate
from bottom brac'et before its lo#ering.
2.2.4 Assemble top brac'et center an arms.
2.3 ERECTION IN GENERATOR FOUNDTION PIT
2.3.1 *evel t,e sole plates for bottom brac'et in t,e generator barrel at correct elevation
using s,ims provie; as require. "efer clause /.3; Section-/.
2.3.2 *evel an center t,e stator sole plates in t,e generator barrel at correct elevation
#it, t,e use of s,ims; as require.
2.3.3 *o#er t,e bottom brac'et 8#it,out spring plate9 on t,e sole plates. *evel t,e
bottom brac'et using seating surface of t,e spring plate as reference. .enter t,e
bottom brac'et by centering t,e 2- of t,e guie bearing support ring #it,
reference to turbine axial centerline. 5olt up t,e bottom brac'et to t,e sole plates.
2.3.4 Assemble all 7.S. *ubrication oil piping an ot,er items upto its starter panel. Also
complete bra'e&3ac' piping upto its starter panel.
APPLY A TIN COAT OF MOLIBDENUM - DI 0 SULPIDE GREASE ON
TE TOP SEATING FACE OF STATOR SOLE PLATES.
2.3.( *o#er t,e #oun stator on sole plates in generator barrel using lifting evice.
.enter t,e inner iameter of stator core #it, respect to turbine axis. 5olt up t,e
stator to t,e stator sole plate.
APPLY A TIN COAT OF MOLIBDENUM-DI0SULPIDE GREASE ON
TE CONTACT FACE OF STATOR OLDING DO*N BOLTS ALSO.
2.3.) .,ec' an ensure ,eig,t of all t,rust bearing springs as per ra#ing before t,eir
assembly on spring plate. Assemble t,rust bearing pas #it, a coat of molyb-
enum isulp,ie grease along#it, anc,or plate; t,rust pa stops etc. #it, t,e
spring plate aroun t,e s,aft. 7o#ever; oil retaining sleeve s,all be bolte #it,
spring plate after alignment.
2.3.1 *o#er t,e main s,aft t,roug, bottom brac'et #it, oil retaining sleeve an spring
plate assemble roun t,e s,aft. $ix t,e o#els an bolts to assemble spring plate
#it, t,e bottom brac'et an #,ile oing so; t,e s,aft #ill remain suspene by t,e
crane.
2.1
2.3.1 +easure eflection of t,e bottom brac'et ue to t,e #eig,t of t,e main s,aft.
-eflection to be measure using t#o ial gauges 0!
!
apart place 3ust at t,e 2.-. of
t,e bottom plate of t,e bearing brac'et.
NOTE . E?S>"E :7A: :7E S4"2?GS A"E $"EE :< "<:A:E A?- -< ?<:
$<>* =2:7 S>""<>?-2?G S4"2?GS.
2.3./ .onnect t,e piping of 7.S. lubrication to t,e t,rust pas.
2.3.0 "aise t,e bra'e-3ac' units mounte on t,e bottom brac'et by about 1! mm. .,ec'
t,eir levels an loc' t,em in position. *o#er t,e rotor assembly on t,e raise
3ac's. 4ull-up t,e generator s,aft to couple #it, spier. +ain s,aft an spier are
couple toget,er by raial 'eys an ,oling o#n bolts. :ig,ten main s,aft an
spier coupling bolts using bolt tensioner.
Apply +<*25-E?>+--2@S>*472-E G"EASE on t,e 'eys an bolts.
2.3.11*o#er t,e 3ac's slo#ly to enable loa of rotor assembly to be ta'en on t,rust pas.
2.3.12 *o#er top s,aft an assemble on main s,aft.
2.3.13 Again measure t,e eflection of t,e bottom brac'et.
2.3.14 Assemble top brac'et in position an centralise t,e same #it, respect to t,e 2- of
guie bearing support ring an top s,aft.
2.3.1( Assemble collector s,aft on generator top s,aft.
2.3.1) Assemble four centraliAing pas at 0!
!
intervals.
2.3.11 .,ec' t,e rotor level by rotating t,e rotor an ta'ing measurements at all t,rust
bearing arm positions. :,e level of rotor s,oul be #it,in one ivision of level
#it, an accuracy of 1 in (!;!!!.
2.3.1/ .,ec' alignment of generator main s,aft an top s,aft an correct it; as necessary.
2.3.10 .ouple generator main s,aft to turbine s,aft an correct as necessary.
2.3.2! .,ec' combine alignment of generator an turbine s,afts B correct as necessary.
"e-c,ec' t,e rotor level.
2.3.21 .,ec' alignment of collector an correct as necessary..
2.3.22 +easure t,e air gap at ifferent locations to plot stator an rotor forms as per
Annexure-222. 5ase on t,ese forms; centralise t,e stator #it, respect to rotor to
get minimum variation in air gap. $inally rec,ec' stator an rotor forms.
2.3.23 Assemble top an bottom guie-bearing pas an set t,e guie pa clearances as
per ra#ings. .omplete bearing ,ousing assemblies.
2.3.24 Assemble top an bottom air guies an set fan tip clearances.
2.3.2( Assemble generator flooring; top casing etc.
2.3.2) -o#el stator; bottom brac'et an top brac'et. 5efore assembly of t,e o#els;
apply a t,in coat of +<*25-E?>+ -2- S>*472-E grease in t,e reame ,oles
an on t,e o#els.
2.3.21 Grout t,e sole plates using non-s,rin'ing cement&compoun.
2.3.2/ All ot,er assemblies li'e cooling #ater pipe #or'; inter pa cooling piping; bra'e
piping; vapour piping; <S-; SSG; pit air seal; -. connectors; instruments an
auxiliaries #iring can be ta'en up at appropriate stages of erection.
2.4 SLINGS
:,e steel #ire slings are supplie for use as per t,e guielines given in ra#ing;
CSet of SlingsD; 2 2)3 (1 23(!4.
2.2
SECTION - 3
GENERATOR FOUNDATION
3./ REFERENCE DRA*INGS
TITLE OF DRA*ING DRA*ING NO.
GENERAL
Sectional arrangement
Generator founation
! 2(! !! 23(!4
! 2(! !! 23(!1
STATOR
Stator sole plate arrangement
Stator sole plate assembly
$ounation 5olt Assembly
1 2(1 !2 23(!4
2 2(1 !2 23(!2
3 2(1 !2 23(!4
BOTTOM
BRAC$ET
5ottom brac'et sole plate arrangement
5ottom brac'et sole plate assembly
$ounation 5olt Assembly
1 2(1 !1 23(!1
2 2(1 !1 23(!2
3 2(1 !1 23(!1

3.1 FOUNDATION . STATOR1BOTTOM BRAC$ET
$ix ,oriAontal an vertical founation tubes of bottom brac'et&stator sole plates
at appropriate stages. "ecor t,e imensions in log s,eets as per Euality 4lan
for 2nstallation; ocument no. E4F-7G-!21.
.,ec' imensions of cutouts&openings provie for sole plates in generator
founation&barrel as per ra#ing.
.,ip off&grin t,e seating surfaces of t,e sole plates to remove loose concrete
an get ,ar an flat surface. Efforts to be mae to obtain about /!G of
contact surface; evenly sprea over t,e entire area.
3.2 SOLE PLATES AND FOUNDATION BOLTS
"emove protective paint from sole plates an stu surfaces in t,e areas; to be
embee in concrete.
.,ec' an prove t,reas of founation bolts an nuts.
-ebur t,e pac'er plates to be use #,ile assembling t,e sole plates in pit.
2nstall sole plates an founation bolts an position t,em to elevation specifie
in ra#ing an centraliAe t,em to unit axis #it,in H 1 mm.
Elevation of t,e sole plates s,all be #it,in H !.( mm an level of iniviual
sole plate s,all be #it,in !.1 mm.
"ecor t,e imensions in log s,eets as per Euality 4lan for 2nstallation;
ocument no. E4F-7G-!21.
3.3 GROUTING
. :,e grouting of t,e sole plates s,all be ta'en-up only after final levelling; centering;
bolting an o#elling. 2t is necessary to use non-s,rin'ing cement& compoun to
prouce a monolit,ic mass capable of transmitting loas from sole plates to
generator founation.
:,e met,o of grouting s,all be ecie by t,e customer.
3.1
SECTION 0 4
STATOR ASSEMBLY
)a+ S2a2or 3ra45 a67 8or5 a9954:;<
D598r!=2!o6 Dra>!6" No.
Ioint 5ar Assembly
Stator $rame Assembly 8$abrication9
Stator $rame Assembly 8+ac,ining9
Stator punc,ing
Stator $rame an .ore Assembly
5<+ for Stator $rame B .ore Assy.
Arrgt. for 2ntermeiate 4ressing of stator core
2tems for 2ntermeiate 4ressing of stator core
Glue .ore 4ac'et Assy.
.ore Stu "estrainer
Stator .ore Stu B ?ut
Jey 5ar
Stator .ore 5uiling :ools
+et,o of 5uiling Stator .ore in "ing form
=as,er 8for stator core an rim builing9
7orse S,oe 4late
-etails of Stator $rame B .ore Assy.
.over 4late
Stator Stool Assembly
1 2(1 !) 23(!2
! 2(1 !) 23(!4
! 2(1 !) 23(!(
! 2(1 !) 23(!2
! 2(1 !) 23(!3
2 2(1 !) 23(!/
1 2(1 (1 23(12
1 2(1 (1 23(11
2 2(1 !) 23(!0
3 2(1 !) !1!!2
3 2(1 !) 23(!3
3 2(1 !) 23(!1
3 2(1 (1 23(11
3 2(1 !) 23(1/ 8) s,eets9
4 2(1 !1 !1!!1
4 2(1 !1 !1!!1
3 2(1 !) 23(13
2 2(1 !) 23(11
3 2(1 (1 23(!/
):+ *o?67 S2a2or
D598r!=2!o6 Dra>!6" No.
Stator 5ar *ayout
2nsulation .aps
4ac'er for 2nsulation .ap
Slot =ege
Separator
"ipple Springs
Stator =ining .onnectors B :erminals
Stator =ining .onnection -iagram
=oun stator
Stator =ining Assembly 85ill of +aterial9
Stator 5ar 4ressing -evice
*oc'ing 4late 8Strip9
.lamp 4late
2 2(1 !( 23(!1
1 2(1 !( 23(!(
4 2(1 !( 23(!/
1 2(1 !( 23(!)
3 2(1 !( 23(11
3 2(1 !( 23(12
! 2(1 !( 23(!)
! 2(1 !( 23(!1
! 2(1 !( 23(!1
1 2(1 !( 23(!1
1 2(1 (1 23(1/
4 2(1 !1 !1!!/
4 2(1 !( 23(!2
4.1
Angle 5rac'et 8:op9
.lamp 4late 5ottom
Angle 5rac'et 5ottom-
.opper .lip 8Series9
Angle 5rac'et 5ottom
Support "ing Segment
4ac'ers
:erminal .lamp +-1) Stu
Support 5loc' :op
2nsulating materials for complete stator #ining
4 2(1 !( 23(!3
4 2(1 !( 23(!(
4 2(1 !( 23(!)
4 2(1 !( 23(!1
4 2(1 !( /4412
2 2(1 !( 23(!(
2 2(1 !( 23(!)
3 2(1 !( !1!!1
3 2(1 !( 23(1!
1 2)3 !4 23(!1
)8+ S2a2or ;!32!6"
D598r!=2!o6 Dra>!6" No.
Arrangement of Stator *ifting
Stator *ifting .enter Assy.
-etails of Stator *ifting .enter Assy.
Stator *ifting Arm Assembly
Stator *ifting 5eam .enter an Arm
assembly Stator *ifting :runnion Assembly
-etails of Stator *ifting Arm Assembly
! 2(1 (1 23(!/
1 2(1 (1 23(!0
12(1 (1 23(1!
1 2(1 (1 23(13
1 2(1 (1 23(11
2 2(1 (1 23(12
2 2(1 (1 23(1!

4.1 GENERAL
:,e stator frame; punc,ing an #ining materials are s,ippe loose for t,eir
assembly at site. :,e stator core s,all be built as continuous ring at site. :,e
consoliation of t,e core; laying of #ining; bus bars etc. incluing stage #ise
an final 7.6. testing s,all be carrie at site.
4.2 STATOR FRAME
:,e stator frame is supplie in four segments. :ransport stator segments to t,e
service bay of t,e po#er ,ouse. .lean an ebur stator 3oint flanges. .,ec' all
t,reae ,oles for any amage an retap t,em; if necessary.
Assemble t#o stator segments to form ,alf of t,e stator frame. :,e fitte
bolts s,oul be assemble first. Assemble all 3oint bolts an tig,ten uniformly.
.arry out assembly of remaining t#o segments as escribe above to form
anot,er ,alf of stator. $inally assemble t#o ,alves toget,er by fixing t,e
fasteners. :ig,ten all t,e fitte an 3oint bolts fully an loc' t,em.
4.3 STATOR CORE
S,ift t,e complete stator frame on to t,e levele stools in service bay.
*evel t,e frame #it, t,e use of pac'ers uner t,e stator; as require. 2nstall
temporary #or'ing platform roun t,e insie perip,ery of t,e stator an a3ust its
,eig,t; as necessary. .arry out core builing as per ra#ings.
4.2
:,e core builing s,all be carrie out as per t,e ra#ing; met,o of
core builing; 3 2(1 !) 23(1/ 8) s,eets9.
=el t,e fingers on bottom plate of stator. 4erform -.4. test to c,ec'
t,e #els. .,ec' level of fingers an recor t,e imensions in log s,eets
as per Euality 4lan for 2nstallation; ocument no. E4F-7G-!21.
.onuct -.4. test on #ele 3oints bet#een 'ey-bars an ,orse s,oe
plates. Straig,ten t,e 'ey bars as necessary. "ecor t,e imensions in log
s,eets as per Euality 4lan for 2nstallation; ocument no. E4F-7G-!21.
:,e ,ealt,iness of ":-s s,all be c,ec'e before an after t,eir
installation in stator core&teet, an results s,all be recore in log
:,e core consoliation an tig,tening s,all be one as per ra#ing
an results s,all be recore in log s,eet as per Euality 4lan for 2nstallation;
ocument no. E4F-7G-!21.
After t,e core consoliation an final tig,tening; fis, plates to be
#ele on t,e flange 3oints of stator frame as per ra#ing ! 2(1 !)
23(!3.
4.4 STATOR *INDING
4.4.1 G565ra;
:,e stator #ining is class C$D insulate #it, consoliate straig,t portion an flexible
over,ang. 2t consists of a ouble layer; single turn bar; #ave #ining; #oun in open
slots. All t,e bars ,ave been forme; insulate an teste at #or's before ispatc,.
:,e bars ,ave been provie #it, a 3)!
!
"oebel transposition in t,e slot portion to
eliminate circulating current losses
5efore proceeing #it, t,e #ining #or'; minutely examine t,e stator core slot at
t,e top an bottom ens particularly at t,e glue pac'ets for pro3ection of punc,ing
into t,e slot. $ailure to remove any pro3ection in t,e slot #ill lea to amage to bar
insulation an ultimately failure uring 76 test. .lean t,e core #it, compresse ry
air an apply conucting paint insie t,e slots.
4.4.2 S522!6" o3 9?==or2 r!6"9 a67 2r!a; >!67!6" :ar9
Assemble a fe# bars to ascertain t,e locations of support brac'ets. Assemble support
brac'ets an support rings as per ra#ing. A gap of 2 to 3 mm s,all be maintaine
bet#een trial bottom bars an support rings for a3ustability. :,e gap s,all be fille
#it, t,in ba'elite strips #rappe #it, treate glass tape in t,e open spiral form. A
layer of polyester filler felt s,all be place bet#een bottom bars an pac'ing strips
for cus,ioning effect. "emove t,e trial bars an complete t,e assembly of support
brac'ets an support rings above an belo# t,e stator core.
4.4.3 A9954:;< o3 :ar9
)!+ T54=;a25
=,ile assembling bars in slots; it is necessary t,at t,e straig,t portion of bars exten
by an equal amount at bot, ens of core. 2t is convenient to prepare a template mae
of pressboar or 4*. fabric s,eet or #oo. :,e template may be mae as follo#s%
4.3
+easure core lengt, over clamping fingers at several points roun t,e perip,ery an
etermine maximum over all lengt,. .onstruct t,e template to fit into t,e angle of t,e
bar bet#een t,e straig,t portion an t,e en #ining so as to clear core clamping
fingers.
)!!+ A9954:;< o3 :o22o4 :ar9
"efer ra#ing 12(1!(23(!1 for item #ise istribution of bottom an top bars in t,e
slots. 5efore assembling t,e bottom bar; a conucting pac'er of epoxy glass s,all
be fixe at slot bottom. Ensure t,at t,e pro3ection of straig,t portion of t,e bars is
equalise at t,e top an bottom ens. After assembly of bars; sie clearance
bet#een bar an slot #all s,all be pac'e #it, conucting s,eets as per ra#ing.
:,e bar s,all be secure tig,t #it, t,e support ring using glass fibre #oven tape as
per ra#ing. Eac, pair of bottom bars s,all be boun toget,er as per ra#ing.
.onuct 76 test on bottom bars as per Annexure-2. "ecor t,e results in log s,eets
)!!!+ A9954:;< o3 2o= :ar9
$ix t,e separator in correct position before assembly of top bars. Assemble t,e top
bar follo#ing t,e same proceure as in t,e bottom bars. >se conucting glass
laminates as neee to ma'e t,e bar tig,t in #it,.
5race t,e en #ining #it, glass fiber #oven tape after placing necessary
pac'ers of epoxy glass laminate an conformal pac'ing. Eac, pair of top bars s,all
be boun toget,er #it, four turns of glass tape an t#o reverse turns; maintaining
uniform clearance in t,e en #ining.
:,e mout, of slot pac'ing bloc's s,all be assemble an boun in position
#it, varnis, treate ,eat polyester s,rin' sleeve. Aitional conformal pac'ing
may be use to obtain a tig,t fit. "efer #oun stator ra#ing% ! 2(1 !( 23(!1.
)!@+ S;o2 >57"5 a9954:;<
2n eac, slot; 1( pairs of slot #eges s,all be assemble. Eac, pair comprises of a
parallel piece an a taper piece. "efer item / of #oun stator ra#ing ! 2(1 !(
23(!1. :op most an bottom most #eges ,ave t,e groove at t,e ens for tying
t,em #it, t,e top bars. 4ac'ing uner #ege of epoxy glass laminate are to be
use essentially #,ile fixing t,e slot #eges. :,e ripple springs an slot #eges
s,all be assemble as per t,e :ec,. "equirement / of ra#ing; 1 2(1 !( 23(!1.
$or assembly of slot #eges; use bar pressing evice to ra#ing 1 2(1 (1 23(1/.
.onuct 76 test on bottom bars as per Annexure-2. "ecor t,e results in log
)@+ BraA!6" o3 >!67!6" :ar9% 8o66582or9 a67 !69?;a2!o6
-uring stator #ining; follo#ing types of braAe 3oints s,all be mae%
- Series 3oint bet#een a top bars an a bottom bar using copper clips
- Iumper connection
- =ining bar to bus bar connection
- 5us bar to bus bar connection
R535r 7ra>!6"9. - =oun stator % ! 2(1 !( 23(!1
- 2nsulating materials for complete stator #ining % 1 2)3 !4 23(!1
4.4
IMPORTANT . ?eig,bouring #ining bars; connectors etc. s,oul be protecte from
,eat #,ile braAing by using asbestos putty&asbestos clot,.
)@!+ I69=582!o6 o3 >!67!6" a67 ( 2592
2t ,as been observe t,at generally t,e failure of #ining in en #ining region
uring 76 test or operation is ue to mis-,anling or presence of foreign materials
li'e nuts; bolts; metal c,ips; #eling ros; tools; 'nife; blaes; copper off cuts;
braAing material etc. etc. loge in t,e cross over portion of bars uring #ining or
subsequent assembly an boxing-up. :,erefore; best efforts must be mae to
ensure removal of any foreign material before 76 tests. $ailure to o so result in
failure of #ining uring 76 test or operation.
?OTE. TB5 >!67!6" MUST :5 8arr!57 o?2 !6 a 8;5a6 a67 7?92 3r55 a24o9=B5r5. 2f t,e
air is contaminate by cement ust etc. ue to construction #or' in a3acent
locations; t,en it is necessary t,at t,e #ining be carrie out in an enclose area.
-< ?<: S:E4 <? =2?-2?G.
4.4.4 T592!6"
:,e braAe 3oints after cleaning s,all be sub3ecte to ultrasonic test for 3oint
efficiency. +inimum acceptable 3oint efficiency is (!G. "ecor t,e results in log
.,ec' insulation resistance an carry out ry out of #ining as per tec,nical
instructions&stanars.
.onuct stage#ise 7.6. tests on stator #ining as calle in Annexure-2. "ecor
t,e results in log s,eet as per Euality 4lan for 2nstallation; ocument no. E4F-
7G-!21. :,e stator #ining insulation #ill be rie out before official 7.6. test
an recor t,e results in log s,eet as per Euality 4lan for 2nstallation; ocument
no. E4F-7G-!21.
4.5 LIFTING OF *OUND STATOR AND LO*ERING
*ift compete stator as per t,e ra#ing; CArrangement of stator liftingD; ! 2(1 (1
23(!/ an lo#er it on levele sole plates. 5efore lo#ering stator; apply t,in coat of
molybenum-isulp,ie grease on seating faces of sole plates. "efer Annexure-26.
.,ec' magnetic axis of stator core #it, respect to turbine flange top.
4osition piano #ire #it, plumb bob at t,e center of stator bore. >sing stic'
micrometer; centralise t,e stator #it, respect to t,e center of turbine s,aft bore.
"ecor t,e results in log s,eets as per Euality 4lan for 2nstallation; ocument no.
E4F-7G-!21.
After alignment of rotor; centralise t,e stator again #it, respect to rotor on t,e
basis of stator form an rotor form 8"efer Annexure-2229. $or t,is t,e #eig,t of
stator can be ta'en on t,e crane #it,out actually lifting it an using raial 3ac's to
move it in esire irection; as require.
4.# AIR COOLERS
.arry out ,yraulic testing of air coolers before t,eir assembly on stator frame to
prove t,e ,ealt,iness of cooler tubes an 3oints. "ecor t,e results in log s,eets
After lo#ering of stator assembly in generator pit; t,e air coolers s,all be
installe on stator frame as per ra#ing; 1 2(1 !4 23(1).
4.(
SECTION 0 5
GENERATOR SAFTS AND ROTOR ASSEMBLY
)a+ Ro2or a9954:;<
"otor assembly
Set of balance #eig,ts
! 2(2 !/ 23(!0
3 2(2 (1 23(!1
RIM a9954:;<
"im builing instruction
"otor rim punc,ing
"otor rim en plates
"im segment #it, spacer
"otor rim an spier stools
"otor rim stu an nut assembly
"otor rim builing equipment
"otor rim assembly
3 2(2 !3 !14!1
! 2(2 !3 23(!1
! 2(2 !3 23(!3
1 2(2 !3 23(!0
1 2(2 (1 23(!/
2 2(2 !3 23(!2
2 2(2 (1 23(!)
! 2(2 !3 23(!2
SPIDER
Spier center assembly 8mac,ining9
Spier center an arm assembly
Spier 'eys
Spier cover assembly
! 2(2 !2 23(!4
! 2(2 !2 23(!(
2 2(2 !2 23(!/
1 2(2 !/ 23(!(
SPIDER a67 9Ba32
$ixing arrangement of generator s,aft an spier
S,aft an spier coupling stu an nut
Set of items for coupling bolt tig,tening
Spier; top s,aft B main s,aft tig,tening arrgt.
1 2(2 !2 23(11
3 2(2 !2 23(!3
2 2(2 !/ 23(!4
1 2(2 (1 23(1)
BRA$E 2ra8C% 3a6 a67 8o;;582or
Arrgt. of bra'e trac' segments an spier assembly
$an segment an blae assembly
$an segment assembly
.ollector assembly 8<-K12(! mm9
1 2(2 !1 23(!1
1 2(2 !4 23(12
1 2(2 !4 23(13
1 2(2 !( !1!!3
ROTOR 8o66582!o69
Arrangement of rotor connection
S,aft an lea assembly
"otor lea assembly 8collector to s,aft9
! 2(2 !) 23(!1
1 2(2 !) 23(2!
1 2(2 !) 23(21
):+ Po;5 a67 3!5;7 8o!;
$abricate fiel coil
-etails of fabricate fiel coil
=oun pole assembly
4ole 'eys
=oun pole lifting gear assembly
! 2(3 !2 23(!1
1 2(3 !2 23(!(
1 2(3 !2 23(!4
2 2(2 !3 23(!1
1 2(3 (1 23(!)
4ole fixing arrangement
4ole 'ey #it,ra#al gear
1 2(3 !3 23(!1
1 2(3 (1 !1!!1
(.1
)8+ G565ra2or 9Ba329
Generator main s,aft 8mac,ining9
:op s,aft 8mac,ining9
Generator an turbine s,aft tig,tening arrangement
:op an main s,aft fixing arrangement
! 2(4 !1 23(!1
! 2(4 !1 23(!2
! 2(4 (1 23(!3
1 2(4 !1 23(!/
)7+ Ro2or ;!32!6"12?r6!6"
"otor lifting :runnion assembly
-ummy s,aft lifting arrangement
Arrangement for rotor lifting
-ummy s,aft 8mac,ining9
Arrangement of rotor turning
1 2(2 (1 23(22
1 2(2 (1 23(23
1 2(2 (1 23(24
1 2(2 (1 23(10
1 2(2 (1 23(11
5.1 GENERAL
:,e rotor spier is a fabricate assembly #it, etac,able arms for t,eir assemblies at
site. Generator ,as t#o forge s,afts i.e. main s,aft an top s,aft. :,e main s,aft ,as
integral t,rust collar at top an a flange at t,e bottom for coupling #it, turbine s,aft.
2n t,is type of construction; rotor is assemble #it,out main s,aft in service-bay i.e.
spier; rim; fans; poles etc. are assemble. Generator main s,aft an rotor spier are
couple in t,e generator pit.
5.2 SPIDER AND RIM ASEMBLY
4lace spier center on levelle stools in service bay an assemble t,e arms on it.
.,ec' t,e level of spier an recor t,e results in log s,eets as per Euality 4lan for
2nstallation; ocument no. E4F-7G-!21.
5.2.1 "otor rim s,all be built as per ra#ing no. 3 2(2 !3 !14!1.
5.2.2 $ollo#ing care s,oul be ta'en uring rim builing in aition to t,ose mentione in
ra#ing no. 3 2(2 !3 !14!1.
"im en plates s,oul be levelle reasonably in circumferential an raial
irection.
+olybenum-i-sulp,ie grease s,oul be applie on t,e seating surface of
spier 'ey bars; coming in contact #it, rim en plates.
:,e rim 'eys are sent matc, mar'e for generator of eac, unit separately.
.,ec' if t,e matc, mar'e 'eys provie ,ave corresponing #it, to suit t,e
poc'et siAe in t,e rim. Apply molybenum i-sulp,ie grease on t,e #it, of
master an static rim 'eys before assembly to facilitate free expansion an
contraction of rim uring operation
"im punc,ings are assemble as per t,e sequence given in ra#ing of "im
assembly; ra#ing no. ! 2(2 !3 23(!2.
Ensure t,at t,e gap bet#een 2- of rim punc,ing an <- of spier 'ey bar is
uniform.
-uring rim builing; 'eep on c,ec'ing t,e verticality of :-slot an pole
seating faces

(.2
Ensure t,at all rim builing pins are free after stac'ing every 1( layers of rim
punc,ings.
Also measure t,e #it, of poc'ets being forme on left ,an an rig,t ,an of
master 'ey at all 'ey bar locations; except in one location #,ere taper 'eys are
fitte. +inor variation in t,e #it, is expecte; #,ic, can be ta'en care of by
t,e extra long rim 'eys.
"im s,all be tig,tene in ) stages 8incluing final stage9 to ac,ieve rim stu
elongation as per rotor rim assembly ra#ing. "ecor t,e results in log s,eets
+olybenum i-sulp,ie grease s,all also be applie on t,e rim loc'ing 'eys
uner surface coming in contact #it, t,e slot of spier 'ey bar; before t,eir
assembly. "efer $ig. (.3 at t,e en of t,is section.
NOTE.
8i9 .arryout intermeiate pressing of t,e rim at t,e intervals specifie in t,e
ra#ing of rim assembly an c,ec' t,e follo#ing in tig,tene conition%
- freeness of rim builing pins
- ,eig,t at 2- an <-; at least at eig,t locations. :,e variation in t,e
,eig,ts measure at 2- an <- s,all be maintaine #it,in 2 to 3 mm.
8ii9 -uring rim builing; t,e verticality of all poles seating faces s,all be c,ec'e
using plumb line. :,e permissible error in verticality of eac, pole seating face
s,all be limite to !.3 mm. 2f require; grin t,e pole seating face. :oo muc,
ifference in verticality #oul cause unue variation of air gap causing
unbalance pull couple; #,ic, #ill be ifficult to balance.
8iii9 After grining pole seating faces; c,ec' t,e A&$ of t,e pole seating faces on
rim. :,is can be one by ropping a plumb #ire to rim face by a insie
micrometer. -ifference in A&$ of opposite faces s,oul be #it,in !.3-!.( mm.
8iv9 .,ec' t,e rim ,eig,t an ensure t,at it is uniform bot, from 2- an <- aroun
t,e circumference.
5.3 MOUNTING OF POLES
5.3.1 Pr5=ara2!o6 3or 4o?62!6" 2B5 =o;59
.,ec' 2" value of t,e pole by (!! 6 megger. 2f it is foun less t,an (! + <,m;
it is avisable to ry out t,e pole separately to get t,e require 2" before
mounting t,em on rotor.
:o improve t,e 2"; pole coils may be rie at a temperature of /!-/(
!
.. -rying
process s,all be slo# an continue for (!-1! ,ours or till improvement. 2f t,e
2" oes not improve; t,en t,e cause s,oul be investigate.
2f rying of poles after mounting on rim becomes necessary; rying is one by
passing -. equivalent to 1!G to /!G of t,e rate fiel current.
5.3.2 .,ec' free movement of pole springs in t,e rim poc'et.
5.3.3 +ount t,e poles #it, t,e ,elp of pole lifting gear an crane. =eig,t of eac, pole is
punc,e on t,em at #or's an poles of equal #eig,ts s,oul be place
iametrically opposite; as far as possible. "ecor t,e results in log s,eets as per
Euality 4lan for 2nstallation; ocument no. E4F-7G-!21.
(.3
5.3.4 +easure -... resistance of fiel coils an #ining. "ecor t,e results in log
5.3.5 .,ec' A. impeance of #oun pole an compare it #it, t,e value obtaine
before. A lo#er value of impeance 8less t,an /! G9 nee to be investigate
#,ic, inicates turn fault in t,e coil. "ecor t,e results in log s,eets as per
Euality 4lan for 2nstallation; ocument no. E4F-7G-!21.
NOTE .8i9 :,e pole boy must be in tig,t contact #it, rim face; steel s,im must not get
san #itc,e bet#een pole boy an rim.
8ii+ -uring assembly of poles; t,e magnetic center of t,e poles ,as to be c,ec'e.
5.3.# Apply a very t,in coat of molybenum-i-sulp,ie grease on taper face of pole 'ey
an its opposite face.
-rive t,e pole 'ey in t,eir correct position ta'ing care t,at taper surfaces are
properly matc,e. :,e rive 'ey s,oul pro3ect at least 2 to 3 mm beyon t,e
bottom rim en plate. $inally trim t,e 'eys to specifie ra#ing imension.
5.3.& "ecor t,e verticality of pole as #ell as pole raius. 2f necessary; correct bot,
verticality an raius by grining slig,tly t,e pole seating surface an rim. :7E
6E":2.A*2:L <$ 2?-262->A* 4<*E S7A** 5E =2:72? !.3 ++.
NOTE. -ifference in raii of opposite poles s,all be #it,in !.2 mm. Also refer Annexure
- 6 for rotor rounness c,ec'.
5.3.' Again measure t,e impeance of pole an compare #it, t,e value obtaine #it,
ot,er pole. :,e impeance value of a pole s,all not vary by more t,an 1! G of
average value of all poles. :,is value #oul be ifferent from t,e impeance of t,e
pole #,en measure on groun. "ecor t,e results in a log s,eet as per Euality
4lan for 2nstallation; ocument no. E4F-7G-!21.
5.3., +a'e pole-to-pole connection an assemble rotor leas on spier.
5.3.1/ .onuct 76 test on rotor #ining B rotor leas as per Annex.-2. "ecor t,e results
in a log s,eet as per Euality 4lan for 2nstallation; ocument no. E4F-7G-!21.
5.4 FAN ASSEMBLY
:,e fan segment assemblies at top an bottom of rotor are fixe to t,e rim en
plates by means of four extra rim nuts; incluing t#o collare rim nuts; for ta'ing
centrifugal force of fan assembly. 2t is important t,at t,e collars an reame ,oles
of t,e fans o not ,ave clearance of more t,an !.!( to !.!/ mm.
(.4
(.4.1 Assemble fan segment as per ra#ing. 6ery lig,t grining of ,oles in fan
segments can be one for seating on rim nuts; if require.
5.5 LO*ERING OF MAIN SAFT AND ROTOR
*o#ering of main s,aft rotor assembly s,all be one as escribe belo#%

5.5.1 Lo>5r!6" o3 :o22o4 :ra8C52 a67 4a!6 9Ba32
8i9 Assemble bottom brac'et centre an arms in service-bay. "emove spring plate
from bottom brac'et. *o#er bottom brac'et in t,e pit on levelle sole plates.

8ii9 :,e generator main s,aft is supplie #it, oil retaining sleeve assemble roun it.
Assemble spring plate aroun t,e s,aft. Assemble springs; t,rust pas; pa stops;
anc,or plates etc. *o#er main s,aft 8#it, assemble oil-retaining sleeve an
spring plate9. After passing t,e flange of t,e main s,aft t,roug, t,e bottom
brac'et; 'eep t,e s,aft in ,anging position by t,e over,ea crane; till spring plate
is assemble on to t,e bottom brac'et.
.
8iii9 *o#er generator main s,aft on t,rust bearing.
NOTE . =72*E ASSE+5*2?G :7E S4"2?GS; E?S>"E :7A: :7E S4"2?GS A"E
$"EE :< "<:A:E A?- -< ?<: $<>* =2:7 S>""<>?-2?G
S4"2?GS.
5.5.2 Lo>5r!6" o3 ro2or a9954:;<
8i9 :,e rotor is no# reay for t,e lo#ering on t,e 3ac' units of bottom brac'et. $or
t,is raise t,e 3ac's by 1!-1( mm an loc' t,em in position by moving t,e ,elical
sleeve provie on t,e 3ac's.
8ii9 *ift t,e rotor by using t#o cranes as per lifting arrangement ra#ing an lo#er it
on t,e raise 3ac's. =,ile lo#ering t,e rotor; follo#ing precautions s,all be
observe%
a9 "otor is reasonably level
b9 "otor is central to t,e stator bore
c9 "otor s,oul be clear of any part of a #oun stator
8iii9 4ull-up t,e main s,aft #it, crane for coupling it #it, spier; ta'ing guiance from
location o#els. $it t,e bolts in positions an tig,ten using ,yraulic bolt
tensioner provie.
8iv9 Assemble t,e taper 'eys to suit t,e s,aft an spier slots a3acent to t,e master
'eys. ?ormally t,ey #ill be matc, mar'e. Apply a t,in coat of +<*L5-E?>+-
-2-S>*472-E G"EASE on taper face an its opposite face.
8v9 Assemble 'ey retaining plates.
(.(
IMPORTANT . :,e stator core&#ining must be protecte #,ile lo#ering t,e rotor
t,roug, stator bore. $or t,is purpose. atleast eig,t persons s,oul stan equally
space on stator. =,ile lo#ering t,e rotor; t,ey s,oul position plan's 81( mm
x 2 m9 on inner iameter of core.
5.5.3 Lo>5r!6" o3 "565ra2or 2o= 9Ba32
8i9 5ring top s,aft in t,e service bay an remove temporary rusts preventive coating
an clean it up for assembly.
8ii9 +a'e top s,aft vertical using t,e lifting evice provie an lo#er it on t,e main
s,aft.
8iii9 5olt-up t,e top s,aft #it, main s,aft as per; C:op an main s,aft fixing
arrangementD; ra#ing 1 2(4 !1 23(!/.
5.# MAGNETIC CENTERING OF STATOR AND ROTOR
$or magnetic centering; t,e centreline of rotor an stator s,all be at t,e same
elevation uring operation. 2n orer to ac,ieve proper magnetic centering;
follo#ing precautions s,all be observe uring erection at site%
5.#.1 Ro2or Po;5 Mo?62!6"
-uring assembly of poles on t,e rotor rim; it must be ensure t,at centrelines of
all t,e poles are at t,e same elevation an at t,e centreline of rotor rim. :o ac,ieve
t,is; follo#ing met,o is recommene%
8i9 -ecie t,e location of t,e pole on t,e rim on t,e basis of its type an
#eig,t.
8ii9 +easure t,e pole boy lengt, 8"efer $ig. (.1 @ imension C4D9
8iii9 +easure t,e stac'e rim ,eig,t on t,e corresponing pole seating face 8at
t,e center of t,is face @ refer $ig. (.1 @ imension C"D9.
8iv9 :,e pole stop ,eig,t s,all be equal to imension 8"-49&2. 2f require t,e
,eig,t of t,e supplie pole stops s,all be reuce by mac,ining or increase
by #el eposit an subsequent mac,ining so t,at centre line of all poles is
#it,in !.( mm.
8v9 +ar' t,e centre line of t,e pole #it, #,ite paint on t,e pole face.
8vi9 Assemble t,e poles using moifie pole stop; #,erever necessary.
8vii9 Assemble all t,e poles aopting t,e met,o given above an complete t,e
rotor assembly.
8viii9 :,e above proceure ensures all t,e poles lie on t,e same centre line.
5.#.2 A325r ro2or ;o>5r!6" . Ro2or 3or4
After lo#ering t,e rotor in t,e pit; t,e magnetic centre of t,e stator an rotor s,all
be c,ec'e. $or t,is purpose; some aitional measurements s,all be ta'en #,ile
ta'ing reaings of rotor form. $or c,ec'ing rotor form; all t,e poles are broug,t
one by one; in front of a reference point mar'e on t,e stator an air gaps are
measure at top an bottom. =,ile measuring t,e air gap; follo#ing s,all also be
measure #it, reference to $ig. (.2%
- imension C:D K istance bet#een pole en plate an stator core at top
- imension C5D K istance bet#een pole en plate an stator core at bottom
(.)
$or evaluation; average value of C:D an C5D s,all be separately compute. Since
uring erection; t,e rotor elevation is set ,ig,er to cater for t,e t,rust bearing
eflection ue to turbine runner an ,yraulic t,rust; t,e values of :B5 #ill not be
equal. 7o#ever ,alf t,e ifference of C5D an C:D; i.e. 8: - 59 & 2 s,all be equal to
t,e t,rust bearing brac'et an spring eflection. "efer clause /.4.4; Section @ / of
t,is manual. A variation of about 2 mm is permitte on t,is imension.
5.#.3 M52Bo7 o3 8orr582!o6
2n case; t,e variation in centre line elevation of t,e stator an rotor is more t,an
t,e esire value; t,an corrective action s,all be ta'en. 2n case t,e rotor pole
mounting is one as per proceure given above an setting of t,rust bearing
elevation is correct; t,en correction is require only on stator. Appropriate s,ims
s,all be ae or remove from t,e bottom of eac, stator sole plate to raise or lo#er
t,e stator center line; as esire. After correction; magnetic centering s,all be
c,ec'e again.
:,e center line of stator an rotor s,all matc, uring normal operation. 7o#ever
uring stanstill conition t,e rotor elevation is set a little ,ig,er t,an running
elevation; ta'en into account t,e t,rust bearing brac'et eflection an t,rust
bearing spring eflection. :,is fact must be 'ept in min #,ile c,ec'ing or
a3usting magnetic centre.
(.1
SECTION-#
BOTTOM BRAC$ET% BEARINGS AND OTER ASSEMBLIES
#./ REFERENCE DRA*INGS
5ottom guie bearing arrangement
5ottom brac'et centre an arm assembly
5ottom brac'et centre assembly
Arrangement of air an oil vapour piping
Arrangement of bra'e piping an conuit
Arrangement of air guie an air baffle
Air guie fixing support assembly
Arrangement of pit air seal
5affle assembly
5ottom guie pa
4ivot bar 8bottom9
4a stop
Arrgt. of bottom bearing instruments B oil level s#itc,
! 2(1 !2 23(!1
! 2(1 !1 23(!4
! 2(1 !1 23(!(
! 2(1 !2 23(!1
! 2(1 !/ 23(!0
! 2(1 !( 23(1!
2 2(1 !( 23(1!
! 2(1 !) 23(11
1 2(1 !( 23(!)
2 2(1 !2 23(!3
2 2(1 !2 23(!/
3 2(1 !2 23(!(
! 2(0 !3 23(!3
#.1 GENERAL
:,e bottom brac'et is supplie #it, etac,able arms for t,eir assembly at site. :,e
bottom brac'et assembly comprising of t,rust bearing; guie bearing; oil coolers
etc. rests on sole plates. :,e bra'e-3ac' units; oil vapour seal; pit air seal etc. are
assemble on bottom brac'et.
#.2 ERECTION OF BOTTOM BRAC$ET
).2.1 *o#er bottom brac'et an centraliAe it #it, respect to turbine s,aft an also
c,ec' elevation. "efer clause /.4.
).2.2 *o#er main s,aft an measure bottom brac'et eflection as per Section - /.
).2.3 Assemble interpa cooling piping insie t,e bottom brac'et an outsie piping
upto oil pump an motor unit provie for interpa cooling.
).2.4 .ommission bra'e-3ac' control panel an 7.S. lubrication unit.
).2.( *o#er t,e rotor an measure bottom brac'et eflection as per Section-/.
).2.) B577!6" o3 "?!75 =a79 . "ub babbitt surface of a guie pa on respective
3ournal surface of generator s,aft. .ontinue scraping of s,ining points of babbite
surface; #,ic, represent ,ig, points; till /!G contact area of t,e babbite surface
is ac,ieve.
).2.1 Assemble guie bearing pas. Set guie bearing clearances as per ra#ing an
recor t,e clearances in log s,eets as per Euality 4lan for 2nstallation; ocument
no. E4F-7G-!21.
).2./ Assemble oil retaining sleeve on spring plate assembly an set it concentric to t,e
3ournal surface of main s,aft.
).2.0 .arry out ,yraulic testing of oil coolers as per ra#ing an assemble t,em on
bottom brac'et. Assemble oil vapour seal&pipes; bottom bearing instruments etc.
NOTE. <il vapour seal s,oul be assemble carefully for its effective functioning.
).2.1! .lean t,e bearing ,ousing t,oroug,ly. $ill a fe# rums of oil an flus, 2 to 3
times. -o not fill oil at t,is stage.
).1
SECTION 0 &
TOP BRAC$ET% BEARING AND OTER ASSEMBLIES
&./ REFERENCE DRA*INGS
DESCRIPTION DRA*ING
:op brac'et center assembly
:op brac'et center an arm assembly
Arrangement of stator an top brac'et fixing
:op guie bearing arrangement
:op oil vapour seal assembly
Arrangement of air an oil vapour piping
:op air guie an baffle arrangement
<il lea'age collector assembly
Guie bearing pa
4ivot bar
5<+ for bearing protection brus, arrangement
Arrangement of floor plates
Air guie assembly 8top an bottom9
Air baffle assembly
Arrangement of -... connections
.onnector for -... connection
5rus,gear assembly
+et,o of setting spring loa for brus,es
:op oil cooler #it,ra#al arrangement
Arrgt. of top bearing instruments an oil level s#itc,
! 2() !1 23(!3
! 2() !1 23(!4
2 2() !1 23(!/
! 2() !2 23(!1
! 2() !2 23(!(
! 2() !2 23(!) 82 s,eets9
! 2() !2 23(!1
1 2() !2 23(!3
2 2() !2 23(!1
2 2() !2 23(!(
3 2() !2 23(11
! 2() !( 23(1!
! 2() !) 23(!/
2 2() !) 23(1!
! 2() 1! 23(!0
2 2() 1! 23(12
1 2() 1! 23(!(
3 2() 1! !14!1
1 2() (1 23(!1
! 2(0 !3 23(!1
&.1 GENERAL
:,e top brac'et is supplie #it, etac,able arms for t,eir assembly at site. 2t
accommoates t,e guie bearing assembly; oil coolers etc. 2t provies support for
generator flooring; top casing; brus,gear etc.
&.2 ERECTION OF TOP BRAC$ET AND OTER ASSEMBLIES
1.2.1 >nloa top brac'et an its arms in service-bay. "emove temporary rust preventive
an clean up for assembly. 5olt up top brac'et arms #it, center assembly as per
ra#ing.
1.2.2 *o#er top brac'et on stator frame an centraliAe it #it, reference to top s,aft an
level. 5olt up top brac'et #it, stator.
1.2.3 Assemble oil-retaining sleeve to t,e top brac'et. .lean t,e brac'et t,oroug,ly. -o
not fill oil at t,is stage.
1.2.4 After final alignment; assemble guie bearing pas. Set guie bearing clearances
as per ra#ing an recor t,e clearances in a log s,eet as per Euality 4lan for
1.1
1.2.( Assemble guie pas an ot,er components an complete top guie bearing
assembly as per ra#ing.
1.2.) Set oil retaining sleeve concentric to t,e 3ournal surface of s,aft.
1.2.1 Assemble oil lea'age collector assembly unerneat, oil retaining sleeve.
1.2./ .arry out ,yraulic testing of oil coolers as per ra#ing to c,ec' ,ealt,iness of
cooler tubes an 3oints. Assemble oil coolers; oil vapour seal; instruments B
covers.
1.2.0 .omplete laying; tac' #eling of cooling #ater an air pipe lines. -ismantle pipes
for final #eling; cleaning an ,yraulic testing as calle in ra#ing. 2nstall
cooling #ater pipes #it, supports an clamping arrangement as per ra#ing.
1.2.1! Assemble tubular s,aft assembly an assemble collector; over spee evice an
toot,e #,eel of SSG on it.
1.2.11 .,ec' alignment of collector as given in Section - /.
1.2.12 $ill up oil upto t,e specifie oil level an close bearing ,ousing.
1.2.13 .onuct 7ig, 6oltage test on collector an rotor leas an recor t,e results in log
1.2.14 Assemble brus,gear; <S-; SSG an -. connections on top brac'et.

&.3 GUIDE BEARING AND INSULATION
B577!6" o3 "?!75 =a79. "ub babbit surface of a guie pa on respective 3ournal
surface of generator s,aft. .ontinue scraping of s,ining points of babbite surface;
#,ic, represent ,ig, points. After eac, operation of scraping; rubbing process of
pas over 3ournal s,all be continue; till atleast /!G contact area of t,e babbite
surface is ac,ieve.
Assemble guie pas; oil vapour seal assembly; oil lea'age collector assembly an
bearing protection brus,. +easure 2" values of follo#ing an recor.
8i9 Eac, guie pa to pivot bar before assembly in bearing ,ousing
8ii9 Guie pa to top brac'et 8eart,9
8iii9 :op oil vapour seal #it, respect to top brac'et 8eart,9
8iv9 5earing protection 8insulate9 brus, #it, respect to top brac'et 8eart,9
8v9 <il lea'age collector assembly #it, respect to top brac'et 8eart,9

NOTE. Ensure t,at capillaries of ":-s; -::s an t,ermostats o not touc, t,e bearing
pas; 'eep plate etc. till t,ey come on to t,e guie bearing support ring. $or t,is
purpose capillary lengt, insie top bearing ,ousing s,oul be insulate as per
ra#ing; !2(0 !3 23(!1.
1.2
SE.:2<? @ /
LE(ELS% CENTERING AND ALIGNMENT
)INCLUDING DO*ELLING AND GROUTING+
'.1 INTRODUCTION
*evelling an alignment along #it, centraliAing are t,e most important operation
in t,e erection of a 7yrogenerator. :rouble free operation of a mac,ine epens
on satisfactory ac,ievement of level; alignment an centraliAing of rotor. :,ese
operations must ensure t,at%
:,e t,rust bearing is ,oriAontal
:,e t,rust bearing elevation is set to give correct turbine runner elevation uring
normal operation
:,e axis of turbine s,aft; generator main s,aft; top s,aft an collector s,aft are in
one vertical line.
:,e turbine runner centre an generator rotor center coincie #it, centre line of
stay ring an stator bore respectively uring normal operation.
:,e guie bearing clearances are set as per ra#ing.
'.2 STARTING CEC$
:,e turbine s,aft #ill be set truly vertical an central to t,e stay ring uring
turbine erection. :,e turbine s,aft ,o#ever #ill be set lo#er t,an its normal
running position to clear t,e coupling spigot #,en generator s,aft is lo#ere. 2t is
presume t,at t,e stator frame ,as been positione an bolte o#n #it, t,e
stator sole plates supporte on pac'ers but not groute in position.
'.3 INITIAL SETTING OF BRAC$ET
/.3.1 4lace t,e sole plate for bottom brac'et in position over t,e founation bolts an
a3ust to a position at approximately t,e concrete level.
/.3.2 *evel t,e sole plates in position. A3ust t,e bottom brac'et elevation by a3usting
t,e s,ims an t,en tig,ten t,e founation bolts.
NOTE. S,ims are to be use belo# sole plates as s,o#n in t,e ra#ing. +inimum
number of s,ims are to be use for a3ustment i.e. t,ic'er s,ims are to be use;
#,erever possible. 2t is suggeste t,at after elevation setting is complete using
grae s,ims; t,e total t,ic'ness of pac'ers use may be measure an replace
by ne# pac'er #it, larger t,ic'ness at site.
/.3.3 *o#er t,e bottom brac'et on t,e sole plates. .entralise t,e brac'et by setting a
plumb line passing t,roug, center of turbine s,aft. A3ust t,e raial position of t,e
brac'et. "oug, a3ustment may be mae by station crane an final a3ustment by
3ac'ing scre#s. :,e center of bore of t,e guie bearing support ring s,oul
coincie #it, plumb line #it,in H !.1 mm. :ig,ten t,e ,oling o#n bolts of sole
plates.
/.1
'.4 SETTING OF TRUST BEARING ELE(ATION
/.4.1 .,ec' t,at t,e sole plates an bottom brac'et ,oling o#n bolts are tig,tene.
/.4.2 After transferring loa of rotor on t,rust bearing; measure ifference in magnetic
center of stator an rotor. A3ust t,e ifference suc, t,at rotor axis; coincies
#it, t,at of stator; #,ile t,e unit is uner operation uner full loa.
/.4.3 Allo#ance must be mae for eflection of t,e bottom brac'et an t,rust bearing
springs uner full loa i.e. #eig,t of rotating parts an ,yraulic t,rust as
belo#%
a9 5rac'et eflection at full loa 81!1( :9 2.3 mm
b9 5rac'et eflection #it, generator rotor B gen. s,afts 84!( :9 !.02 mm
c9 Spring eflection at full loa 81!1( :9 2.! mm
9 Spring eflection #it, generator rotor B gen. s,afts 84!( :9 !.4 mm
/.4.4 2t is to be ensure t,at t,e turbine runner #ill be at t,e esire level uner
running conition on loa. :,e turbine erector #ill avise t,e amount 8:9 by
#,ic, t,e turbine coupling is belo# t,e normal running position. :,e generator
s,aft must t,en be set at a ,eig,t above t,e turbine coupling by an amount equal
to : plus aitional eflection of t,rust bearing at full loa. :,is equals to %
: M 82.3 @ !.029 M 82.! @ !.49 K : M 2.0/ mm.
/.4.( 2t is essential t,at any a3ustment of t,e bearing brac'et s,ims provie to
obtain t,e correct coupling gap must be precisely t,e same 8by micrometer
+easurement9 at eac, brac'et foot; ot,er#ise t,e brac'et #ill be t,ro#n out of
level.
'.5 LE(ELLING OF TRUST BEARING
Lo>5r!6" o3 "565ra2or 4a!6 9Ba32
/.(.1 *o#er generator main s,aft 8"efer Section-(9.
/.(.2 *o#er rotor assembly 8"efer Section-(9. .ouple rotor an top s,aft #it, main
s,aft. +easure bottom brac'et eflection #,en rotor rests on t,rust bearing.
/.(.3 Assemble t,e items for s,aft centralising as per :ec,nical "equirement given in
ra#ing ! 2(1 !2 23(!1. .entralise t,e s,aft.
/.(.4 *o#er generator top s,aft an assemble it #it, t,e main s,aft.
/.(.( $<" .7E.J2?G :7E *E6E**2?G <$ :7">S: 5EA"2?G A?- A**
"<:A:2<?A* .7E.JS; $2: $<>" S7A$: .E?:"A*2S2?G 5*<.JS A:
0!
!
2?:E"6A* A?- .*<SE >4 :7E .*EA"A?.E :< A +2?2+>+; LE:
A**<=2?G :7E "<:<" :< "<:A:E. S7A$: .E?:"A*2S2?G 5*<.JS
S7<>*- 5E .<A:E- =2:7 +<*L5-E?>+--2-S>*472-E.
/.(.) .,ec' t,at t,e t,rust bearing is ,oriAontal by placing a level on top of t,e t,rust
5loc' an rotating t,e s,aft. >se a level gauge of !.!2( mm in 1 meter accuracy.
*evel t,e brac'et by moifying s,ims belo# t,e brac'et feet; if require.
/.(.1 4lace t,e precision level gauge 8mentione above9 on t,e top of rim en plate an
secure it firmly to avoi 3er's #,en rotate.
/.2
NOTE. :,e level gauge must be c,ec'e for Aero error before use. 7.S. lubrication s,oul
be s#itc,e <? before giving any rotation to t,e rotor & s,aft.

/.(./ "otate t,e rotor an note t,e level gauge reaings at regular interval. 2t must be
ensure t,at t,e rotor is stationary; freely suspene; 7.S. lubrication system is
<$$ an no person or foreign material is on t,e rotor #,ile ta'ing t,e reaings
/.(.0 =,ile c,ec'ing t,e level variation; 7.S. lubrication pump s,oul be s#itc,e off.
A3ust t,e brac'et s,ims as necessary to get t,e resultant level reaing #it,in 1
ivision of level of !.!2( mm in 1 meter accuracy.
/.(.1! :o obtain t,e require accuracy of t,e level; t,e s,ims uner bottom brac'et
feet are a3uste. :,e a3ustment in t,e s,ims s,oul be grae as far as
ispracticable to maintain an even loaing on sole plates. +inimum number of
s,ims for a given a3ustment s,oul be use i.e. t,ic'er s,ims are use #,erever
possible
NOTE.
819 2t is avisable to measure total t,ic'ness of t,e s,ims use uner eac, brac'et
foot an t,en use a t,ic' mac,ine plate of same t,ic'ness as measure by
micrometer in place of many s,ims.
829 All level gauge reaings are to be ta'en after fully tig,tening t,e ,oling o#n
bolts after eac, a3ustment of s,ims.
'.# ALIGNMENT
IMPORTANT % ->"2?G A*2G?+E?: .7E.JS; $<**<=2?G 4<2?:S
+>S: 5E E?S>"-E-%
8i9 :7E "E:A2?2?G 4*A:ES <$ :7">S: 4A-S A"E ?<: $<>*2?G
=2:7 :7">S: 4A-S 4"E6E?:2?G $"EE "<:A:2<? <$ "<:<" A?-
S7A$:.
8ii9 :7E +<6E+E?: <$ -2A* GA>GE A: :7E "E$E"E?.E G>2-E
5EA"2?G S7A** ?<: EF.EE- 1 :< 2 -262S2<?S.
82229 .*<S2?G E""<" S7A** ?<: EF.EE- 2 -262S2<?S A: :7E
4<2?: <$ +EAS>"E+E?: <$ :7"<=
8269 :7E $2?A* A*2G?+E?: "EA-2?GS S7A** 5E :AJE? <?*L
A$:E" $>** :2G7:E?2?G <$ :7E 5<*:S <$ :>"52?E A?-
GE?E"A:<" S7A$: .<>4*2?G.
8v9 :=< .<?SE.>:26E $2?A* :7"<= .2".*E -2A+E:E"S
S7<>*- 5E
EE>A* 2? +AG?2:>-E A?- -2"E.:2<?.
2$ A5<6E 4<2?:S A"E ?<: SA:2S$A.:<"L; :7E A*2G?+E?: "EA-2?GS
A"E S>S4E.: A?- ?<: A..E4:A5*E.
/.3
'.& ROTATIONAL CEC$ ON GENERATOR MAIN *IT ROTOR AND
TOP SAFT
/.1.1 $ully tig,ten t,e main s,aft an top s,aft coupling bolts.
/.1.2 $it ial gauges at top an bottom; generator guie bearing 3ournals in F an L axis.
/.1.3 "otate t,e rotor t,roug, 4(
!
; 0!
!
; 13(
!
; 1/!
!
; 22(
!
; 21!
!
; 31(
!
an 3)!
!
. "ecor t,e
ial gauge reaings in a tabular form 8as given belo# for reay reference9 in line
#it, log s,eet as per Euality 4lan for 2nstallation; ocument no. E4F-7G-!21.
*ocation of
ial gauge
--aD!9 Y-aD!9
"otation in
egrees
! 4( 0! 13( 1/! 22( 21! 31( 3)! ! 0! 13( 1/! 22( 21! 31( 3)!
Generator
bottom
guie
bearing 8a9
Generator
:op guie
bearing 8b9
c K b-a
NOTE . :,e reaing of !
!
an 3)!
!
s,oul be t,e same #it,in t,e tolerance of reaing
accuracy. 2f t,ese reaings constantly s,o# a ifference; t,ere is a possibility t,at t,e
s,aft may not be rotating freely. :,e oil retaining sleeve or some suc, ot,er component
may be touc,ing t,e rotor. 2t is to be c,ec'e #,et,er any 3er' is prouce #,ile
rotating t,e rotor; #,ic, affects t,e initial reaings. 2f so; t,e initial reaing s,oul be
ta'en after t,e cause of 3er' is investigate an rotor mae to rotate smoot,ly.
/.1.4 4lot t,e co-orinates of CcD on a grap, paper to a suitable scale. -ra# a circle #it,
minimum raius passing t,roug, any t,ree points #,ereas enclosing remaining points.
:7E :7"<= .2".*E -2A+E:E" A: :<4 G>2-E 5EA"2?G S7<>*- 5E
*2+2:E- :< !.!) ++ +AF2+>+.
/.1.( :,e t,ro# at t,e top guie-bearing 3ournal s,all be correcte; if it excees t,e
permissible limits efine above. 2n t,is case; t,e correction is possible by proviing
s,ims bet#een top s,aft an main s,aft.
/.1.) $ollo#ing points s,oul be observe for s,ims%
8i9 :,e s,ims s,oul be grae in t,ic'ness an in steps of 2!! to 2(! mm i.e.; if a s,im
of !.1 mm be neee at one en; t,inner s,ims 8say !.!/; !.!); !.!4; !.!2 mm etc.9
s,all be introuce aitionally upto t,e iametrically opposite en as far as possible;
to maintain constant taper.
8ii9 :,e s,ims s,all be free from 'in's etc. an must cover t,e full iameter of t,e flange.
8iii9 Eac, piece of s,im s,all ,ave at least one cutout for one fastener; i.e. bolts; o#els;
etc. C>D cuts s,all be provie for t,e purpose.
8iv9 S,ims s,all be of stainless steel.
/.4
'.' COMBINED ROTATIONAL CEC$ ON GENERATOR & TURBINE SAFTS
/./.1 4ull t,e turbine s,aft to#ars t,e generator s,aft an 3oin t,e flanges by coupling
bolts. :,e bolts s,oul be tig,tene to give extension #it,in t,e value mentione on
ra#ing. :,e iametrically opposite bolts s,oul be tig,tene progressively.
/./.2 "emove t,e turbine guie pas; seals an turbine support so t,at t,e turbine s,aft is
suspene freely from t,e t,rust bearing.
/./.3 :,e gap bet#een t,e turbine runner an stay ring s,oul agree #it, t,e setting
obtaine uring turbine erection #,ile centraliAing t,e s,aft. $or centraliAation;
bottom guie bearing is to be a3uste; as necessary. 2f t,is centraliAing affects t,e
brac'et centering by more t,an !.2( mm; t,e brac'et #ill also ,ave to be
centraliAe.
/./.4 $it ial gauges on turbine guie bearing 3ournal; generator bottom an top guie
bearing 3ournals in F an L axis.
/./.( "otate t,e rotor t,roug, 4(
!
; 0!
!
; 13(
!
; 1/!
!
; 22(
!
; 21!
!
; 31(
!
an 3)!
!
. "ecor t,e
ial gauge reaings in a tabular form 8as given belo# for reay reference9 in line #it,
log s,eet as per Euality 4lan for 2nstallation; ocument no. E4F-7G-!21.
*ocation of
ial gauge
--aD!9

Y-aD!9
"otation in
egrees
! 4( 0! 13( 1/! 22( 21! 31( 3)! ! 0! 13( 1/! 22( 21! 31( 3)!
Generator
bottom guie
bearing 8a9
Generator
:op guie
bearing 8b9
:urbine
guie
bearing 8c9
K b-a
e K c-a
NOTE. :,e reaing of !
!
an 3)!
!
s,oul be same #it,in t,e tolerance of reaing
accuracy. 2f t,ese reaings constantly s,o# a ifference; t,ere is possibility t,at
a s,aft is not rotating freely. :,e oil retaining sleeve or some suc, ot,er
component may be touc,ing t,e rotor. 2t is to be c,ec'e #,et,er any 3er' is
prouce #,ile rotating t,e rotor; #,ic, affects t,e initial reaings. 2f so; t,e
initial reaing s,oul be ta'en after t,e cause of 3er' is investigate an rotor
mae to rotate smoot,ly.
/.(
/./.) 4lot t,e co-orinates of CD an CeD on a grap, paper to a suitable scale. -ra# a circle
#it, minimum raius passing t,roug, any t,ree points #,ereas enclosing remaining
points. :7E :7"<= .2".*E -2A+E:E" A: :>"52?E G>2-E 5EA"2?G
S7<>*- 5E *2+2:E- :< !.!/ ++ +AF2+>+.
:,e t,ro# at t,e top guie bearing s,oul agree #it, t,e previous reaing ta'en in
para /.1.
/./.1 :,e t,ro# at t,e turbine-bearing 3ournal s,oul be correcte if it excees t,e
permissible limits efine above. :,e t,ro# can be correcte by scrapping of en
surface of turbine or generator s,aft or by placing stainless steel s,ims bet#een
flanges. $or s,imming; t,e points mentione in clause /.1.) s,all be strictly follo#e.

'., ALIGNMENT OF COLLECTOR
/.0.1 Assemble t,e collector s,aft on top of t,e generator top s,aft an t,en assemble
collector.
/.0.2 $it ial gauges at any one collector ring an at generator bottom guie bearing 3ournal
in F an L axis. "otate t,e rotor t,roug, 4(
!
; 0!
!
; 13(
!
; 1/!
!
; 22(
!
; 21!
!
; 31(
!
an
3)!
!
. "ecor t,e ial gauge reaings in a tabular form 8given belo# for reay
reference9 in line #it, log s,eet as per Euality 4lan for 2nstallation; ocument no.
E4F-7G-!21.
/.0.3
4lot t,e co-orinates of CcD on a grap, paper. :,e t,ro# circle iameter as efine earlier
s,oul be limite to !.1 mm.
'.1/ STATOR AND ROTOR FORM
After completion of generator alignment but before setting guie bearing clearances;
air gaps s,all be measure an recore in log s,eets as per Euality 4lan for
*ocation of
ial gauge
--aD!9 Y-aD!9
"otation in
egrees
! 4( 0! 13( 1/! 22( 21! 31( 3)! ! 0! 13( 1/! 22( 21! 31( 3)!
Generator
bottom
guie
bearing 8a9
.ollector
ring 8b9
c K b-a
<n t,e basis of air gap measurements; t,e stator form an rotor form s,all be plotte
an necessary correction #ill be mae as per Annexure @ 222.
/.)
'.11 ADEUSTMENT OF BEARING CLEARANCES
Set t,e turbine guie bearing clearances as per ra#ing. 5efore setting generator top
an bottom guie bearing clearances; guie pas s,all be bee #it, 3ournal. S,ims
S,all be fitte bet#een guie pas an pivot bars. Ensure t,at t,e pivot bars; #,ic, is
offset; is properly assemble #it, respect to t,e irection of rotation as per ra#ing.
4us, t,e guie pas against 3ournal an measure t,e clearance bet#een t,e bac' of
pivot bar an guie bearing support ring by inserting feeler gauge. :,is raial
clearance s,all be set at bottom an top guie bearings by aing or removing t,e
s,ims.

'.12 DO*ELLING
<nly after completion of above operation; o#elling #or' s,all be ta'en up. :,e
reame ,oles s,all be smoot, an parallel to t,eir axis. :,e ,ole iameter s,all be
measure at top; mile an bottom. -o#el s,all be mac,ine an groun to give
clearance of !.!2 to !.!4 mm on actual measure iameters of ,oles.
All o#els 8bet#een bottom brac'et an sole plates; stator an sole plates; top brac'et
an stator etc.9 s,all be coate #it, molybenum i-sulp,ie grease before putting in
place.
'.13 GROUTING
8i9 .oncrete surface for sole plate seating s,oul be c,ippe&groun to get a levelle
an ,ar surface; before lo#ering sole plates on concrete.
8ii9 A$:E" $2?A* *E6E**2?G; .E?:E"2?G; 5<*:2?G A?- -<=E**2?G <$
:7E S<*E 4*A:ES A"E <6E"; t,e sole plates s,all be groute to t,e founation
using non-s,rin'ing cement&compoun to prouce a monolit,ic mass capable of
transmitting loas from sole plates to generator founation. 8"efer ra#ing 1 2(1
!2 23(!2 for Arrangement of stator sole plates an ra#ing 1 2(1 !1 23(!1 for
arrangement of bottom brac'et sole plates9.
8iii9 :,e met,o of grouting s,all be ecie by t,e customer.
/.1
SECTION - ,
STARTING% TESTING AND COMMISSIONING
,.1 GENERAL
.lean t,e ,yrogenerator of ust an irt #it, t,e ,elp of ry compresse air an
vacuum cleaner. "ub #it, clot, to clean internal surfaces of frame an air baffles
#it, clot,.
"emove foreign ob3ects; if any from inner parts of ,yro generator; specially t,e core
ucts; air gaps; inter polar gaps etc.
.,ec' installation of o#els an tig,tening of fixing bolts of stator; bottom brac'et;
top brac'et; bra'e-3ac' assemblies etc. .,ec' t,e loc'ing of all t,e nuts; particularly
in rotating parts of generator an air baffles.
.,ec' air guies an air baffles to ensure t,at t,ey o not touc, t,e rotating parts of
generator an t,e variation in airguie&baffle clearances are #it,in limits specifie in
t,e ra#ings.
.,ec' t,at all cover plates are close tig,tly.
:,e oil pot an pipelines are to be flus,e by circulating oil for t#elve ,ours. :,e
bearing ,ousing s,all t,en be fille #it, fres, oil up to t,e level s,o#n in t,e
ra#ing. Again use t,e oil purifier for t#enty-four ,ours for purification. .,ec' for
any oil lea'age.
2n orer to prevent entry of irt an ust into t,e oil bat, uring first starting;
isconnect air piping from air baffle to vapour seal. 7<=E6E"; :7E A2" 424E*2?E
+>S: 5E .<??E?.:E- 5A.J A$:E" $E= -ALS <$ ">??2?G.
,.2 PRE-START CEC$S
.,ec' t,at cooling #ater circulation is normal t,roug, t,e air coolers an bearing
oil coolers. <pen t,e valves of t,e coolers for releasing t,e trappe air.
<il circulation t,roug, inter pa cooling system s,all be c,ec'e.
:,e fire extinguis,ing system of generator s,oul be c,ec'e for operational
reainess.
:,e bra'e s,all be applie an release a number of times #it, compresse air to
c,ec' t,eir performance to ensure t,at t,ey are not stic'ing.
-isconnect t,e generator excitation system an isconnect t,e generator main
terminals from bus bars. Start 2nterpa .ooling System an 7yrostatic
*ubrication System.
.,ec' t,at all t,e t,ermal inicators are installe at t,e require places an t,e
instruments are functioning normally.
.,ec' t,at fire extinguis,ing system for generator functions normally.
,.3 BUMP START
:,e mac,ine is given a start an allo#e to rotate so t,at it ma'es fe# rotations. :,e
aim is to ensure t,at rotor rotates freely #it,out any fouling or abnormal noise.
0.1
,.4 FIRST RUN
2n t,e first run; t,e mac,ine is run #it,out excitation an ,ence ensure t,at generator
excitation system is s#itc,e off. Start t,e ,yro set an run it at lo# spee an ma'e
sure t,at t,ere is no 3amming; un#ante noise&run-out of s,aft an collector. 2f any
abnormal vibration is notice at lo#er spee; balancing s,all be one at t,at spee
before ta'ing t,e mac,ine to t,e next ,ig,er spee an upto finally rate spee.
<:7E"=2SE :7E S7A$: +AL ">5 :7E <2* 6A4<>" SEA* A?- 4<SS25*L
-A+AGE :7E SEA*.
4rovision is mae on t,e rotor spier for fixing of t,e balance #eig,t. 5y c,oosing t,e
proper siAe an location of balance #eig,ts; as require; t,e generator s,oul be
balance #it,in allo#able limits. :,e allo#able brac'et vibrations an s,aft vibrations
8ouble amplitue9 are as uner%
P; P;a85 o3 45a9?r54562 A;;o>a:;5 @!:ra2!o69 )4aD.+% 44
Guie bearing brac'et !.1(
S,aft; near to guie bearing (!G of iametral clearance of guie bearing
,.4.1 A325r 3!r92 92ar2
After t,e first start; t,e mac,ine is to be s,ut o#n for inspection. :,e generator s,all be
t,oroug,ly inspecte an mec,anical fastenings s,all be c,ec'e for looseness. .,ec'
#,et,er t,e brus,es are properly bee on t,e collector.
,.4.2 B5ar!6" r?6
"un t,e mac,ine at rate spee 8at no loa9. :,e t,rust an guie bearing temperatures
are to be carefully observe #,en t,e set is spun. :,e temperature s,oul increase
graually #it,out s,arp 'ic's; #it, uniform increment an #it,in 2-3 ,ours of operation;
it s,oul practically stabiliAe. 2f t,e temperature inicate by any t,ermometer in t,rust
an guie bearings increases s,arply even if t,e absolute temp. is not very ,ig,; t,e
mac,ine s,oul be stoppe an t,e reason for t,e same is ascertaine. :,e bearing run
can be continue for about 12 ,ours.
<bserve t,e oil level in t,rust bearing oil bat,. After starting; t,e oil level rises ue to
centrifugal forces; ,eating an aeration. .,ec' t,at t,e oil oes not lea' t,roug, t,e
bearing ,ousing an oil retaining sleeves.
,.5 SETTING OF O(ERSPEED DE(ICE
.7E.J :7E SE::2?G <$ <6E"S4EE- -E62.E 5L S4EE-2?G->4 :7E >?2:
:< S4E.2$2E- <6E"S4EE- SE::2?G. 2: S7<>*- 5E *2::*E 72G7E" :7A?
+AF2+>+ *<A- :7"<=-<$$ S4EE-. JEE4 A =A:.7 <? A5?<"+A*
0.2
J?<.J2?G A?- ?<2SE ->"2?G S4EE-2?G >4. >?2: S7A** ?<: 5E
+A2?:A2?E- A: <6E" S4EE- $<" A *<?G :2+E. 2?4E.: GE?E"A:<"
.<+4<?E?:S A$:E" <6E"S4EE- :ES:; 2?.*>-2?G :2G7:E?2?G <$ A**
7A"-=A"ES; 4<*E&"2+ JELS E:..
,.# (OLTAGE BUILD-UP
5efore builing-up t,e voltage; generator s,all be run for ry out of #inings by s,ort
circuiting t,e t,ree-p,ase terminals an by circulating t,e current t,roug, #inings. $or
supplying excitation to t,e generator fiel #inings; t,e static excitation equipment can
be use uner manual control; by giving 11 '6 station supply to t,e 76 terminals of
excitation transformer.
:,e voltage s,all be built-up only after satisfactory conition of #ining insulation
ac,ieve by ry out. 2n orer to buil-up t,e voltage in stator #ining; s#itc, on t,e
excitation system an increase fiel current. Generator terminal voltage s,all be
increase in steps of 2 '6 an t,e unit s,all be allo#e to run for about ( minutes every
time before increasing t,e voltage. .,ec' t,e brus,es for any spar'ing. <ver voltage
protection c,ec' can also be one at t,is stage.
-uring t,e process of voltage buil-up; monitor t,e vibration of s,aft an bearing
brac'ets an if necessary; rebalance t,e mac,ine before proceeing to t,e next ,ig,er
voltage. 2n t,is #ay; balance t,e mac,ine uner excite conition upto rate voltage.
,.& SYNCRONISATION AND LOADING
Stop t,e unit an connect t,e generator terminals to transformer terminals t,roug, bus
bars. "estart t,e unit an buil-up voltage as explaine above. Sync,roniAe an loa t,e
unit. *oa s,all be increase in steps of 1! += an sufficient time s,all be allo#e at
every stage to #atc, t,e performance. .,ec' for abnormal noise; vibration etc. an 'eep
a #atc, on #ining; core an bearing temperatures. .ollector brus,es s,all also be
c,ec'e for smoot, function.
+easure t,e vibration of t,e brac'et an t,e s,aft at top brac'et an bottom brac'et #it,
an #it,out excitation an no loa. 2f necessary; rebalance t,e mac,ine before
proceeing to t,e next ,ig,er loa. 2n t,is #ay; balance t,e mac,ine uner excite
conition upto rate loa.
.onuct partial; full loa an max. loa t,ro# off tests an c,ec' for satisfactory voltage
an spee rise.
,.' PUTTING INTO OPERATION
5efore putting t,e generator on commercial loa; follo#ing final c,ec's s,oul be
mae%
0.3
8a9 All balance #eig,ts are permanently #ele&loc'e as per ra#ing; after removal of
temporary loc'ing provie uring balancing of a unit.
8b9 .,ec' carefully t,e tig,tness of fixing etails of poles an 'eys; fan; rotor; air baffles;
stator; brac'ets; cover plates etc.
8c9 .,ec' carefully t,e stator #ining for absence of any bulging of insulation or flo# of
varnis,.
89 .,ec' t,e interpolar 3oints of t,e rotor fiel #ining. 2f necessary; tig,ten t,e ,oling
o#n nuts etc.
8e9 .,ec' t,e sealing of oil bat,s an vapour seal clearances.
8f9 .,ec' #ater an oil pipe lines for any lea'age.
8g9 .,ec' #or'ing of bra'ing system.
8,9 .,ec' t,e connections of current carrying leas an cables.
8i9 +easure t,e insulation resistance of all t,e #inings of t,e generator an compare t,em
#it, t,e measurements carrie out earlier.
839 .,ec' t,e #eling of rotor spier; top an bottom brac'ets; stator an ot,er etails.
8'9 5lo# t,e collector #it, ry compresse air as uring starting perio t,e most sensitive
#ear of t,e brus,es is observe.
8l9 .,ec' t,e oil levels in t,e bearing ,ousings.
,., STOPPING
$ollo#ing sequence s,all be follo#e for stopping t,e unit #,en running on loa.
8a9 "euce t,e output of generator till it is almost Aero.
8b9 :rip line circuit brea'er.
8c9 "euce t,e fiel current till t,e terminal voltage is almost Aero.
89 :rip fiel circuit brea'er.
8e9 Allo# t,e mac,ine to ecelerate to bra'ing spee an apply bra'es.
8f9 S,ut off cooling #ater supply to air&oil coolers; after mac,ine comes to stan still. .
8g9 S,ut off 7.S. *ubrication system an interpa cooling system.
8,9 "elease an reset bra'es.
,.1/ ANDING O(ER
After successful running of t,e mac,ine as per contractual requirement; same #ill be
,ane over to customer for operation as per gri eman.
0.4
ANNE-URE 0 I
IG (OLTAGE TEST ON *INDINGS
1.1 SCEDULE OF ( TESTS ON STATOR *INDING AT SITE
S.No. S2a"5 o3 2592!6" T592 @o;2a"5 )r49 @a;?5+
1
2
3
Bo22o4 :ar9 % After placing t,e bottom bars in
position in stator slots; test bottom bars at
To= :ar9 % After placing top bars in stator
slots; test top bars an bottom bars toget,er at
O33!8!a; ( 2592 % test separately #it, ot,er
t#o p,ases eart,e after completing #ining;
braAing an stringing etc.
2& C(
25 C(
23 C(
1.2 SCEDULE OF ( TEST ON FIELD *INDING AT SITE
S.No. S2a"5 o3 2592!6" T592 @o;2a"5 )r49 @a;?5+
1
2
A325r 4o?62!6" 2B5 >o?67 =o;5 on rotor an
riving t,e pole 'eys ,ar but before
interconnection; test bet#een eac, fiel coil
an pole boy
O33!8!a; ( 2592 bet#een collector an eart,
after ma'ing all connections bet#een fiel
coils an upto collector
5.5/ C(
4.&5 C(
NOTES.
819 7.6. tests specifie are A.; rms voltage at (! 7A for a uration of )! secons.
829 2" value s,all be recore before an after eac, 76 test.
839 2n case of failure uring 76 test; testing at any stage; t,e subsequent tests s,all be
at t,e specifie voltage; for )! secons uration irrespective of t,e uration of
application of voltage uring failure.
849 2mpeance test of #oun poles to at )! to 1!! 6 A. before conucting 76 test%
8i9 5efore mounting t,e #oun poles on rotor
8ii9 After mounting t,e poles on rotor; but before connections
8(9 :#o terminals of eac, p,ase to be c,ec'e for electrical isolation by continuity test.
A - 1.1
A??EF>"E - 22
INSULATION RESISTANCE TESTING AND DRYOUT
2./ GENERAL
:,e insulation resistance of a #ining is a function of t,e type an assembly of
insulating material. 2n general it varies irectly #it, t,e t,ic'ness of insulation an
inversely #it, t,e conuctor surface area. :,e value of insulation resistance also varies
inversely #it, t,e amount of moisture in t,e insulation an t,e amount of solvent left in
t,e boning varnis, of t,e #ining connections. 2nsulation tests are carrie out normally
using a megger. =,ere polariAation inex values are require; t,e megger must be
capable of supplying a steay voltage for 1! minutes. :,e results obtaine using -...
test met,os are affecte by t,e general conitions of t,e surface of t,e #inings as #ell
as by t,e lea'age t,roug, t,e main insulation. 2nterpretation of t,e results may be
ifficult if contamination is presentN for t,is reason before carrying out t,e test; t,e
surface of t,e #ining s,oul be examine to ma'e sure t,at t,ey are clean an ry; an
not contaminate by moisture; oil; salt; carbon ust or ot,er foreign matter.
2.1 INSULATION RESISTANCE TESTING
2.1.1 SAFETY PRECAUTIONS FOR TESTING
5efore attempting any insulation resistance test; it is essential to eart, t,e frame of t,e
mac,ine an parts of t,e #ining not being teste. -ry insulation resistance is capable
of ,oling an electrical c,arge for several ,ours after t,e removal of t,e applie
voltage. $or reasons of bot, safety an accuracy; it is essential t,at t,e #ining; or
section uner test is aequately eart,e bot, before an after t,e application of t,e test
potential. $or large mac,ines a perio of 3! minutes s,oul be allo#e.
2.1.2 METOD OF TEST
2nitial test may be carrie out #it,out isconnecting t,e supply cables; but if
unsatisfactory result is obtaine; t,en t,e #inings s,oul be isolate from all
externals cables an connections before repeating t,e measurement of insulation
resistance. 2nsulation resistance s,oul be measure bet#een eac, iniviual p,ase
an eart, #it, t,e remaining p,ase eart,e. :,e insulation resistance 8"
p,
9 of one
p,ase to eart, on a 3-p,ase #ining is approximately t#ice t,at of t,e complete
#iningN t,erefore; t,e measure value must be ivie by t#o to obtain a value for
comparison #it, t,e value recommene. 2n practice eac, test is carrie out by
conuctor or terminal of t,e #ining uner test an t,e ot,er lea to t,e frame. :,e
instrument is t,en s#itc,e on an t,e test voltage maintaine for one minute at #,ic,
stage t,e insulation resistance reaing 8"19 is note. :,e test is continue an an
aitional reaing 8"1!9 after 1! minutes is note for calculation of t,e 42-value.
2.1.3 POLARISATION INDE-
:,e measure insulation resistance of a #ining normally increases #it, t,e time of
application of t,e -... test voltage. :,e increase is usually rapi for t,e first one to
A - 2.1
t#o minutes an t,ereafter t,e slope of t,e curve steaies of #it, timeN for t,e next 1!
to 3! minutes; t,e increase is a function of t,e absorption c,aracteristics of t,e
insulation an ,ence of its general conition. <n ma3ority of t,e #ining; t,e value
reac,e in 1! minutes #ill be greater t,an 0!G of t,e final steay state reaing. :,e
polarisation inex of a #ining is efine as t,e ratio of t,e insulation resistance after
1! minutes 8"1!9 to t,e insulation resistance after 1 minute 8"19 i.e.
Po;ar!9a2!o6 I675D )P.I.+ F R1/1R1
<n a clean ry #ining; t,e polarisation inex value s,oul not be less t,an 2.!. 2f a
value belo# t,is is obtaine; t,en a ry out s,oul be carrie out .
2.2 DRY OUT
2.2.1 M52Bo79 o3 7r< o?2
)a+ S=a85 5a25r9
Electric space ,eaters may be use for rying #inings #,ere t,e moisture is on or
close to t,e surface of t,e outer layer of insulation. 7o#ever; if t,e moisture ,as
penetrate t,e #ining insulation; t,en t,e met,o is unli'ely to be successful on its
o#n. 2f use in con3unction #it, irect ,eating; it can prove useful in 'eeping t,e
overall temperature upto t,e specifie ry out value.
):+ SBor2 C!r8?!2 R?66!6"
:,e stator terminals s,oul be s,ort circuite by connecting t,e t,ree main terminals
toget,er. .onnections must be mae #it, cable or copper strip of aequate section to
carry t,e full loa current of t,e mac,ine. Approximately equal current s,oul flo# in
eac, p,ase uring t,e ry out. :,e stator frame must be solily eart,e. :,e mac,ine
s,oul be run up using t,e prime mover. As a first part of t,e ry out sc,eule; t,e
mac,ine s,oul be run #it,out excitation as t,e #inage losses #ill generate
sufficient ,eat to raise t,e temperature of t,e #ining to an acceptable rate. 2nitially
excitation s,oul be applie to cause approximately 1(G of t,e full loa current to
flo#. As t,e temperature goes up; t,e excitation s,oul be varie to follo# t,e ,eating
rate specifie in 4ara 2.4. 2n general t,e circulating current must not be allo#e to
excee t,e full rate value; ot,er#ise over,eating of t,e stator may occur.
)8+ D!r582 8?rr562 B5a2!6"
=,ere t,e controllable lo# voltage irect current supply is available from a motor
generator set or rectifier equipment; t,en t,is may be use for ry out of t,e A... stator
#inings 8#it, or #it,out t,e rotor in position9 an -. fiel .ircuit.
2.2.2 A.C. S2a2or
All t,e p,ases s,oul be connecte in series using copper strip or cable of aequate
section to carry t,e full loa current. 2nitially t,e value of current s,oul be set at
approximately 1(G of t,e full loa rating an a3uste as t,e temperature rises to
follo# t,e ,eating sc,eule. :,e irect current supply an any external cables must be
isconnecte before any insulation resistance reaing are ta'en. >sually; about (!-)!G
of rate current may be sufficient to maintain ry out temperature. :,e en #inings
A - 2.2
must be properly covere by suitable non ,ygroscopic covers to contain t,e ,eat
#it,in; an t,e irect ,eating can be supplemente by use of space ,eaters locate
belo# t,e #ining for quic' results. Asbestos s,eets are not recommene for
covering t,e en #inings as t,ese are ,ygroscopic an may ,iner satisfactory ry
out.
2.2.3 DC F!5;7 8!r8?!29
$or rying out t,e -. fiel #inings all t,e coils s,oul be connecte in series an
current passe t,roug, t,e circuit so as to follo# t,e rate of temperature rise specifie
belo#. 2n general t,e value of current use s,oul not excee t,e maximum value
specifie for t,e mac,ine fiel circuit. As fiel circuits are inuctive; it is essential
#,en brea'ing t,e circuit 8to ta'e insulation reaings9 t,at t,e current is broug,t o#n
to a lo# value by eit,er ,aving a resistance in series #it, t,e supply or by reucing t,e
voltage to as near Aero as practicable.
2.2.4 Dr< o?2 254=5ra2?r5
2n general #,en using irect ,eating of t,e #ining by passing current t,e
temperature s,oul be raise to approximate /!
!
. as measure by t,ermometers
attac,e to t,e en #inings are 0!
!
. #,en measure by embee temperature
etectors 8E:-DS9. :,e rate of temperature rise for a #ining #,ic, ,as been allo#e
to get amp ue to moisture pic' up from ,ig,ly ,umi atmosp,ere s,oul be limite
to ( to )
!
. per ,our; #,ere a #ining ,as been soa'e #it, #ater t,an t,e rate of
temperature rise s,oul be limite to 2 to 3
!
. per ,our; ot,er#ise amage to t,e
insulation is li'ely to occur. <nce t,e maximum temperature is reac,e it s,oul be
maintaine t,roug, out t,e ry out perio. :o ensure t,at t,e moisture is effectively
remove t,ere must be free circulation of air aroun t,e #inings. :,e generators
covers must be opene occasionally to allo# continuous interc,ange of air as
ot,er#ise t,e air may become saturate an t,ere by slo# o#n t,e rate at #itc,
moisture comes out from t,e #inings. A convenient met,o of follo#ing t,e
progress of ry out is to ta'e insulation resistance reaing 8"
1
B "
1!
9 at regular
intervals of say ) ,our an to plot t,em; along #it, t,e calculate value of
polariAation inex an #ining temperature. $or amp #inings reaings s,oul be
ta'en every 1 to 2 ,ours. <n grossly contaminate #inings t,e ry out #ill be slo#er
an t,e intervals may be increase to 4 to / ,ours. -uring t,e initial perio of t,e ry
out t,e insulation values ten to ecrease appreciable as t,e temperature rises but over
a perio of time t,ey #ill rise again. <nce t,e maximum temperature ,as been
reac,e; it s,oul be maintaine as constant as practicable so t,at t,e measure
c,anges in insulation resistance reflect accurately t,e progress of t,e ry out. :,e ry
out process s,oul be continue beyon t,e time at #,ic, t,e insulation resistance ,as
starte to increase an ,eat s,oul be maintaine until t,e insulation resistance is
above t,e minimum acceptable value. 4olariAation inex is not substantially affecte
by temperature an ,ence a value of minimum to s,oul be ac,ieve. Since t,e
#ining #ill cool off slig,tly uring t,e time t,at t,e insulation resistance an
polariAation inex tests are carrie out; t#o points s,oul be observe.
A - 2.3
8a9 =,en iniviual p,ases are being c,ec'e; t,e orer in #,ic, reaings are ta'en
s,oul be 'ept t,e same uring eac, test perio.
A?-
8b9 2f t,e cooling is significant 8e.g. on small mac,ines9 t,en t,e polarisation inex
value #ill be slig,tly optimistic unless t,e insulation resistance values are relate
to t,e same temperature.
2.2.5 Co4=;52!o6 o3 7r< o?2
:,e ry out s,oul be terminate; an t,e source of ,eat remove; after t,e minimum
levels of insulation resistance an nearly constant 8but not less t,an t#o9 polarisation
inex ,ave been reac,e an maintaine for at least anot,er 24 ,ours base on )
,ourly reaings.
NOTE . I3 PI @a;?5 25679 2o !68r5a95 >!2B 9?88599!@5 r5a7!6"9 2B5 7r< o?2 9Bo?;7
:5 8o62!6?57 2!;; 65ar;< 8o692a62 @a;?5 !9 r5a8B57.
2.3 RECOMMENDED MINIMUM INSULATION RESISTANCE
2.3.1 S2a2or >!67!6"
8i9 2nsulation resistance of stator #ining varies consierable for ifferent insulation
systems; atmosp,eric conition an service life; but for practical purposes a
recommene minimum one minute value for eac, p,ase of t,e #ining may be
obtaine from t,e follo#ing equation%
IR 4!6 F 2.F2 )2C( G 1+ M5"a oB49
>B5r5 C( F ;!65 @o;2a"5 !6 $!;o@o;29.
C$tD is a factor epenent on #ining conition an #ining temperature at #,ic, t,e
test is carrie out. 6alues of $t are given belo#%

*!67!6"
T54=5ra2?r5
/
C
(a;?59 o3 HF2I
N5> 4a8B!65
Dr<% ?6a"57
a67 8;5a6
Ma8B!65 a325r
S5r@!85% 8;5a6
a67
?68o62a4!6a257
Ma8B!65 a325r 95r@!85 3or
S5@5ra; <5ar9 >!2B 6or4a;
I67?92r!a; Co62a4!6a2!o6
1/
2/
3/
4/
5/
#/
&/
'/
32
1#
'
4
2
1
/.5
/.25
1#
'
4
2
1
/.5
/.25
/.125
'
4
2
1
/.5
/.25
/.125
/./#25
A - 2.4
)!!+ Po;ar!9a2!o6 I675D
:,e 42 value s,all be recore in aition to 2". 2t is not uncommon on a clean; ry
#ining to ac,ieve a 42 value of 2.! B more after proper ry out. 7o#ever; t,is may
not be ac,ievable in some cases ue to averse atmosp,eric conitions suc, as
presence of moisture; irt or ust etc. :,e minimum 42 value acceptable for
satisfactory operation in suc, cases s,all be ta'en as 1.(.
NOTE . I2 !9 r58o4456757 2Ba2 a 7r< o?2 9Ba;; :5 8arr!57 o?2 !rr59=582!@5 o3
IR1PI @a;?5 :53or5 .(. 2592 or :?!;7!6" ?= @o;2a"5 7?r!6"
8o44!99!o6!6".
2.3.2 ROTOR *INDING
)!+ I69?;a2!o6 R59!92a685
:,e values normally ac,ieve for a ne# an clean iniviual pole assembly is 2!!
+.<,m at room temperature. :,e minimum acceptable limit for satisfactory
operation is (! +.<,m belo# #,ic, ry out is recommene. 2t is expecte t,at on a
ne#ly assemble mac,ine #it, clean; ry an uncontaminate #ining; t,e 2" value
s,all not be less t,an 2 +.<,m; measure bet#een collector an eart,. 7o#ever;
for satisfactory operation uner any conition; minimum 2" value of total rotor
#ining measure bet#een collector an eart, s,all be not less t,an 1+.<,m.
7o#ever; in suc, cases; it is recommene t,at t,e generator be run for several ,ours
on lig,t loa to improve t,e 2" value suc, t,at mal-operation of eart, fault relay
cause by lo# 2" is avoie.
)!!+ Po;ar!9a2!o6 0 I675D
42 value is not require or recommene for rotor #ining circuits.
2.5 COLLECTOR ASSEMBLY AND BRUSGEAR
?ormal expecte value for a ne# mac,ine is ( +-<,m; but minimum acceptable
value for satisfactory operation is 2 +-<,m.
G565ra; No25.
:,e 2" values recommene are for guiance. As state in 2EEE-43; it is impractical
to specify a efinite minimum value of 2" or 42 of a rotating mac,ine belo# #,ic,
t,e mac,ine cannot be operate. 2t is recogniAe t,at it is sometimes possible to
operate a mac,ine #it, value lo#er t,an t,e recommene minimum value; but it is
not consiere a goo practice in t,e ma3ority of t,e cases.
A - 2.(
ANNE-URE 0 III
STATOR FORM AND ROTOR FORM
3.1 GENERAL
:,e purpose of c,ec'ing stator an rotor forms is to minimiAe t,e inequalities in t,e
air gap all-roun t,e circumference. :,is #ill ensure minimum possible unbalance
magnetic pull #it, t,e built up stator an rotor; #,ic, #ill ,ave a beneficial effect on
vibration performance of generator.
:,e stator an rotor must be built as circularly as possible; ensuring t,at t,e
ifference in raius of iametrically opposite poles is #it,in !.2 mm. :,is can be
ac,ieve by builing t,e rim concentric to t,e spier 8i.e. ensuring uniform gap on all
'ey bars9 an properly grining t,e pole seating surface an :-Slot groove in rim
#,ile assembling t,e rotor poles.
NOTE. 5E$<"E :AJ2?G S:A:<" A?- "<:<" $<"+S +EAS>"E+E?:S; 2: 2S
?E.ESSA"L :< .E?:"A*2SE :7E GE?E"A:<" S7A$: =2:7 "ES4E.:
:< 2??E" -2A.+E:E" <$ G>2-E 5EA"2?G S>44<": "2?G. ?EF:; $2:
$<>" -2A+E:"2.A**L <44<S2:E .E?:"A*2S2?G 5*<.JS =2:7 I>S:
S>$$2.2E?: .*EA"A?.E 8!.!2 :< !.!3 ++9 :< E?A5*E "<:A:2<? <$
"<:<". :7E "<:<" S7<>*- "E+A2? 2? :72S 4<S2:2<? :7"<>G7<>:
:72S 47ASE <$ =<"J.
3.2 STATOR FORM
3.2.1 +ar' equivalent perip,eral position; equal to no of poles; on t,e stator bore 2.-.
3.2.2 >sing any one pole as a atumN bring centerline of t,is pole tip opposite to t,e mar'
point on stator bore.
3.2.3 +easure t,e air gap at top an bottom ens of stator bore; approximately 2!! mms
from t,e ens.
3.2.4 "otate t,e atum pole successively to remaining mar'e position on stator bore an
ta'e reaings.
3.2.( -ra# a reference circle of 'no#n iameter on a grap,. 2ts iameter s,all be 'ept a
little smaller t,an t,e air gap reaings.
3.2.) +ar' t,e points as per air gap reaings. out sie t,e reference circle an 3oin t,em to
obtain stator form. :,is plot represent t,e profile of stator bore an is inicative of
its circularity. "efer $ig. A 3 1.
3.3 ROTOR FORM
3.3.1 +ar' a atum point on stator bore; #,ic, can correspon to t,e erection mar'
location on stator frame.
3.3.2 5ring center of eac, pole successively opposite t,is atum mar' on stator bore.
3.3.3 +easure t,e air gap at top an bottom ens; approximately 2!! mms from t,e ens
of stator core.
3.3.4 Stuy t,e air gap reaings ta'en for rotor form an orient so as to obtain t,e
position of largest ifference in air gap bet#een stator an rotor. 4lot air gap
A - 3.1
reaings of rotor form to t,e same scale on a ifferent transparent paper; but insie
t,e reference circle. :,is represents t,e profile of pole tip.
3.3.( :,e air gap variation bet#een stator an rotor form represent t,e inequality in built
up generator. :,e purpose of t,is exercise is to reuce t,is inequality.
3.4 SIFTING OF STATOR
3.4.1 Examine t,e stator an rotor form plotte for top an bottom ens of generator.
Superimpose t,e t#o forms; an by rotating t,e rotor form; ientify t,e pole
corresponing to maximum air gap variation.
3.4.2 :a'e t,e ifference of air gap reaings on t,e stator form corresponing to
maximum air gap an t,e opposite pole. 7alf of t,is ifference is t,e s,ift of t,e
stator require.
3.4.3 :,e s,ifting of stator #ill be in a irection opposite to t,e maximum air gap "ef.
$ig. A 3.1. $or t,is fine s,ifting of statorN raial scre# 3ac's are to be use an fine
movement of stator along #it, its lateral s,ifting; if any s,all be monitore by
means of four ial gauges fixe at 0!
!
.
After above a3ustment; stator form an rotor form are to be c,ec'e again. 2f
require; furt,er a3ustment of t,e stator position ,as to be one. Since; t,e core is
long; separate plots are to be ra#n for top air gap reaings an bottom air gap
reaings. 2t ,as to be c,ec'e t,at t,ere is not muc, ifference bet#een top an
bottom air gap reaings corresponing to eac, pole. 2f t,e ifference bet#een top
an bottom air gap reaings at any pole is large; t,e mounting of pole ,as to be
c,ec'e.
3.5 E-AMPLE
An example ,as been enclose to illustrate t,e plotting of stator form; rotor form;
irection an extant of stator s,ift.
:,e stator an rotor forms ,ave been plotte base on follo#ing air gap reaings.
STATOR FORM 4ole ?o. 1 ,as been ta'en as atum
Lo8a2!o6 =o!62 o6 92a2or A!r "a= )To=+% 44 A!r "a= )Bo22o4+% 44
1
2
3
4
(
)
1
/
0
1!
11
12
13
14
1(
1)
20.0!
20.1!
20.4
20.0!
20.1(
20.)!
20.(!
2/.0!
20./!
20.)!
20.)(
3!.3(
3!.0!
3!./!
3!.!!
20.1(
20.2!
2/.)!
2/.4(
2/.1!
2/.(!
2/.(!
2/.2(
2/.)!
20.!!
20.((
20.)(
3!.3(
3!.2(
3!.1(
20.0(
20.((
A 3.2
ROTOR FORM Da2?4-U=92r5a4 4arC
Po;5 No. A!r "a= )To=+% 44 A!r "a= )Bo22o4+% 44
1
2
3
4
(
)
1
/
0
1!
11
12
13
14
1(
1)
3!.)!
20.)(
3!.)!
3!.)(
20.0(
20.)!
20./(
3!.1(
3!.1(
3!./!
3!.)!
3!.(!
3!.2!
3!.0!
3!.(!
3!.1!
3!.1!
3!.1!
3!.)(
3!.2(
20.1(
20.1(
20.4(
20.1(
3!.4!
31.!!
31.!!
3!.1!
3!.)!
3!.0(
31.!!
3!.1!
:,e minimum air gap ,as been mar'e as A5 in $ig. A 3.1. As explaine above t,e
irection of stator s,ift is opposite to t,e maximum air gap i.e. in t,e irection 5 to
A as s,o#n in $ig. A 3.1.
:,e ecision regaring t,e amount of stator s,ift s,all be ta'en only after carefully
analyAing t,e stator t,e stator form an rotor form reaing. As mentione above in
4.2 above ,alf t,e ifference of appositive air gap stator form reaing; at location of
maximum air gap 8i.e. 4ole 14 B pole ) in fig. A /.19 is t,e amount of stator s,ift.
Since bot, t,e stator an rotor form are not truly circular t,e effect of stator s,ift on
air gap at a3acent pole may be ifferent. .onsiering t,is factor an to get
optimum air gap reaing; t,e average of ,alf t,e ifference of air gap reaings of
a3acent poles are ta'en to ecie t,e amount of stator s,ift; as explaine in t,e
table belo#%
A-3.3
S.NO. AIR GAPS DIFFERENCE ALF TE
DIFFERENCE
A(ERAGE
SIFT
AMOUNT
OF STATOR
SIFT
819 829 839 849 8(9 8)9
:op
5ott.
4ole 1(
2.(
2.0(
4ole 1
1.3(
!.3!
1.1(
3.2(
!.(1(
1.)2(
1.2(!
1.42(
:op
5ott.
4ole 14
3.1
3.1
4ole )
1.2!
!.2(
2.(!
2./(
!.012(
1.(2(
!.01(
1.3)2
O !.0 mm
O 1.! mm
:op
5ott.
4ole 13
3.1
2./(
4ole (
1.1!
!.2(
1.4!
2.)!
!.1!!
1.3!!
NOTE.
819 :,e reaings given in column 819 B 829 are t,e ifference in
"otor form an stator form e.g. lengt, of line A5 for pole no. 14 in $ig. A 3.1 is
3.1 mm.
829 :,e value is .ol. 4 inicates t,e amount of stator s,ift
require as escribe in 4ara 3.4.
839 :,e column ( inicates t,e average of reaings in column 4
for 4ole nos. 1( B 14 an set of 4ole 14 B 13. $rom t,e above it can be seen t,at
t,e stator ,as to be s,ifte by !.0 mm 8i.e. rouning off !.01(9 to 1 mm 8i.e.
rouning off !.01(9 to ac,ieve optimum air gap reaings. :,is is ecie after
careful stuy of complete set of reaings. :,e bottom average air gap reaings
1.(2( an 1.32) ,ave been ignore because s,ifting t,e stator by t,is amount
#oul ,ave eteriorate t,e top air gap reaings.
A 3.4
A??EF>"E - 26
APPLICATION OF MOLYBDENUM-DI-SULPIDE GREASE
Application of +<*L5-E?>+--2-S>*472-E G"EASE to t,e critical
components&surfaces allo#s free expansion an facilitates easy removal&assembly
of generator components.
As is #ell 'no#n; uring normal operation of generator; some of t,e generator
components expan an contract eit,er ue to t,ermal cycling or ue to centrifugal
forces.
Similarly; uring maintenance; some components require ismantling an
reassembly for #,ic, certain items li'e 'eys; o#els; bolts etc. are require to be
opene an refitte properly.
2n t,e main boy of t,is +A?>A*; t,e location for greasing ,ave been inicate in
respective sections. :,e follo#ing; ,o#ever; summarises t,e locations #,ere
+<*L5-E?>+--2-S>*472-E G"EASE ,as to be applie%
8i9 a t,in coat on top seating surface of stator sole plates before lo#ering t,e
stator. :,e grease s,oul also be applie on t,e contact faces of ,oling o#n
bolts an o#els.
8ii9 on <- of 'ey bar to facilitate assembly of rim punc,ing.
8iii9 on rim 'eys before t,eir assembly an seating surface of 'ey-bar.
8iv9 on rim loc'ing 'ey uner surfaces coming in contact #it, top rim en plates.
"efer $ig. (.3.
8v9 on t,e raial 'eys for s,aft an spier coupling. "efer $ig. (.4; Section - (.
8vi9 on all o#els 8e.g. top brac'et an stator frame9 before putting t,em in place.
8vii9 on taper mating faces of pole 'eys.

A - 4.1
ANNE-URE 0 (
CEC$ING ROUNDNESS OF ROTOR
(.1 2t is necessary to c,ec' t,e rounness of t,e rotor in orer to minimise t,e
variation in air gap. $or t,is; raius of pole face s,all be measure an it s,oul be
ensure t,at t,e ifference in t,e raii bet#een any t#o iametrically opposite
poles is in t,e range of !.2 to !.3 mm.
(.2 :,e c,ec'ing of rotor iameter s,all be one on bot, rim A&$ an pole <.-.
#,ere t,e ifference in raii is beyon permissible limits; t,e relevant poles s,all
be ta'en out an rim-seating surface s,all be groun to remove t,e ,ig,
spots&protruing punc,ing an t,e poles re-assemble.
(.3 :,e measurement of pole face raius can also be carrie out #it, t,e ,elp of
stic' micrometer. "eaings are ta'en bet#een t,e centraliAe piano #ire an a
straig,t ege #,ic, is firmly presse against t,e pole face at its tip center.
(.4 +inimiAing t,e raii ifference to reuce t,e air gap variation #ill reuce t,e
>?5A*A?.E- +AG?E:2. 4>** in operation an #ill result in lo# vibration
of t,e rotor s,aft system an bearing brac'ets.
(.( =,ile re-assembling t,e poles on t,e rotor after correcting t,e rounness; it is
necessary to ensure t,at t,e centre lines of all poles are matc,ing for proper
c,ec'ing of t,e magnetic center of t,e unit at a later stage. $or t,is purpose; refer
to t,e etaile proceure on magnetic .entering.
(.) After grining operations are over; utmost care must be ta'en to clean all
surfaces free of iron filings; irt an ust. <t,er#ise t,is may lea to a possible
eart, fault at a later ate.
NOTE .
I2 !9 658599ar< 2o 8B58C 2B5 =o;5 3a85 ra7!?9 a2 2o= a67 :o22o4 o3 5a8B =o;5.
TB5 @5r2!8a;!2< o3 5a8B !67!@!7?a; =o;5 9Ba;; :5 >!2B!6 /.3 44% >B56 45a9?r57 a325r
a9954:;< o6 r!4. A6< ;ar"5 @ar!a2!o6 8o?;7 :5 7?5 2o
)!+ R!4 3a85 6o2 :5!6" @5r2!8a;%
)!!+ 95a2!6" 9?r3a85 o3 =o;5 o6 r!4 6o2 :5!6" 3;a2% a67
)!!!+ =ro2r?9!o6 o3 r!4 =?68B!6"9 or =o;5 =?68B!6"9.
:,e verticality can be correcte by grining of t,e rim surface an&or seating surface of
pole boy #,ic, #ill be in contact #,ic, rim.
A - (.1
ANNE-URE (I
REPLACEMENT OF STATOR BAR AND FIELD COIL
#.1 PROCEDURE FOR CANGING A FAULTY1 DAMAGED STATOR BAR
#.1.1 Fa?;2 ;o8a2!o6
2n many of t,e cases; t,e fault can be locate by visual inspection after opening t,e air
guies. <t,er#ise; t,e fault can be locate by using 2.( '6 megger by sectionalising
t,e faulty branc,.
#.1.2 R54o@a; o3 !69?;a2!o6 a67 75:raA!6" 2B5 Jo!629
?o local repair is recommene in case of a fault in t,e straig,t portion of a bar. 2f t,e
fault &amage ios #ell a#ay from t,e core an beyon t,e first ben; it can be repaire
after ascertaining t,at t,e amage is confine to fe# top layers of insulation. 2n all
ot,er circumferences t,e faulty bar s,oul be replace #it, a ne# bar.
A s,arp tool s,all be use to cut open t,e insulation of t,e 3oints. .are s,oul be
ta'en uring t,is operation not to transfer t,e mec,anical strain to t,e ,ealt,y bars.
:,e en #ining bracing #it, spacers s,oul not be opene before removing t,e
insulation an ebraAing t,e 3oints. After removing t,e insulation; t,e 3oints s,all
be ebraAe by using oxy-acetylene. :,e surrouning area s,all be protecte #it,
#et asbestos putty.
After ebraAing all t,e require 3oints; t,e corresponing slots #eges s,all be
remove an t,e en #ining #eging #it, spacer&mout, slot pac'ers s,all be
remove. Sie fillers of conucting laminates s,all be carefully remove an t,e
top bars s,all be ta'en out. :,e slot #,ic, ,ouses t,e faulty bars s,all be
t,oroug,ly inspecte an any carbon eposits ue to fault current s,all b e cleane
#it, a clot, #et #it, carbon tetra c,lorie.
:,e faulty bar after removal s,all be replace by a spare bar 8t,e item number
punc,e on t,e bar s,oul be c,ec'e #it, t,e boun stator assembly ra#ing9.
:,e proceure given in clause s,all b e follo#e for reassembly.
:,e bars s,all be rebraAe an reinsulate as per ra#ing 1 2)3 !4 23(!1.
A supplementary 76 test is avisable after ma3or repairs&replacement of bars.
.onsult esigner; 57E*; 5,opal.
#.2 REMO(AL OF FIELD COIL
"eplacement of fiel coil is a specialiAe operation an s,oul be carrie out only by
a s'ille an experience person. :o replace a fiel coil; it is necessary to remove t,e
pole from t,e rotor. 4lace t,e pole assembly upsie o#n 8:-,eas on top9 on a firm
groun level. "emove t,e steel pac'ing #as,ers an t,e insulation flange carefully.
:,in long nose pliers may be foun useful for easily gripping t,e pole boy insulation
pac'ers initially. ?ext raise t,e fiel coil to a sufficient ,eig,t to enable manila rope
A ).1
slings to be passe uner bot, ens of t,e coil. :,is can be one by riving #ooen
#eges bet#een t,e pole tips an insulation flange at intervals along#it, sie of t,e
coil. :,e coil can no# be lifte out by passing manila rope 8not steel9 slings over t,e
ens of t,e coil; care being ta'en to prevent amage to t,e copper turns from t,e
slings by interposing a t,ic' s,eet of press boar. :,oroug,ly clean all eposits of
ust from t,e pole boy an insulation pac'ers by a clean clot, moistene #it, #,ite
spirit or *ectraclean an ry by blo#ing compresse air. "etain t,e springs uner t,e
fiel coils or reuse uring reassembly.
Assemble t,e spare coil on t,e pole boy after cutting of t,e un#ante leas;
flus, to copper turns. :,e spare coil can be t,en be use in any position. Ensure t,at
t,e clearance is uniform on all four sies. :,e existing pole boy insulation can be
use; if unamage; ot,er#ise ne# pole boy insulation is to be use. $irst assemble
t,e corner angle an t,en epoxy glass laminate s,eets. 2f any clearance is foun
bet#een pole boy an fiel coil; t,is is to be fille epoxy glass fibre s,eets. ?o
slac'ness is permitte bet#een fiel coil an pole boy. Assemble t,e steel #as,ers
an t,e insulation flange of t,e coil. .,ec' t,at t,e ,eig,t t,at t,e ,eig,t of t,e coil
assembly is as per ra#ing. ?ever lift t,e coil by slinging aroun pro3ecting fiel
turns; as t,is may result in e- lamination of turns.
.,ec' t,e 2" value of t,e fiel coil an also measure its A. impeance.
.onuct 76 test as per Annexure-2 bet#een t,e coil an t,e pole boy. ?ext
assemble t,e pole on to t,e rotor. +easure t,e A. impeance of t,e coil again if
satisfactory; conuct 76 test as per Annexure-2 bet#een t,e coil an pole boy.
$inally; connect t,e pole leas to t,e a3acent pole an soler t,e 3oints using soler.
2f a fiel coil is replace at any p time; care s,oul be ta'en to ensure t,at
t,e pole is polle ,ar o#n on t,e rotor rim. =,en t,e pole 'eys are riven in. :,is
can be c,ec'e by seeing t,at t,ere is no gap bet#een t,e pole boy an t,e rim
seating surface. 7o#ever; t,e spring allo#ance bet#een t,e steel pac'ers an rim
surface must be available aroun.

A ).2

Section No. para Description 1 Generator Assembly & Erection Pre-Requisites

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Section No. para Description 1 Generator Assembly & Erection Pre-Requisites

Hochgeladen von

Copyright:

Verfügbare Formate

TABLE OF CONTENTS

Das könnte Ihnen auch gefallen