Htgg611728 Anb - 0軬軲ka 4510軪i - 02 en Field Assbly Instr. Wy23z
Htgg611728 Anb - 0軬軲ka 4510軪i - 02 en Field Assbly Instr. Wy23z
(2)
54 slots
72 slots
(1)
2015-06-16 EN Approved
(3)
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Rev. Released
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Type
DC
9470 HTGG611728
Dept. Document No.
G1036_C
(4)
Copyright
All rights reserved
© Copyright 2015 ALSTOM Power Systems SA
3 bis, avenue des 3 Chênes
90018 Belfort Cedex (France)
Prepared by STTG Engineering Belfort
This manual, including all content therein, is protected by copyright. No part of this publication
may be reproduced or translated in any form or by any means (electronic, photocopying,
microfilming, recording or otherwise) without prior written permission of:
ALSTOM Power Systems SA
Siège Social: 3, avenue André Malraux
92300 Levallois-Perret (France)
Disclaimer
The content in this manual does not constitute any legally binding assurance of certain
2015-06-16 EN Approved
Any work described in this manual must be carried out solely under the supervision of
personnel expressly authorized. Failure to comply with this requirement shall void any
warranties, guarantees, representations, or other types of liability, which ALSTOM Power
Rev. Released
Revision History
DC
DANGER indicates an
imminently hazardous DANGER
situation which, if not
avoided, will result in death Type/Source of Hazard
or serious injury. This signal What are the hazard consequences?
word is to be limited to the
most extreme situation Enter steps how to avoid the hazard.
WARNING indicates a
potentially hazardous WARNING
situation which, if not
avoided, could result in Type/Source of hazard
death or serious injury What are the hazard consequences?
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CAUTION indicates a
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Note
In addition to the safety instructions shown above, the manual contains safety
instructions with hazard-specific symbols similar to the symbols found on safety
labels and stickers on the Machine.
The information in this manual is compulsory reading matter for anyone working
with or at the Machine.
Information about 12
3 Note
references documents
Before starting any operation, read the references documents
in corresponding tables in the Field Assembly Documentation
List. (FAD)
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Type
DC
9470 HTGG611728
Dept. Document No.
List of Contents
1 General information ................................................................................................................. 9
1.1 Objective ................................................................................................................................... 9
1.2 Scope of Validity ...................................................................................................................... 9
1.3 Abbreviations and Terms used in this Instruction ............................................................... 9
1.4 Protection of Equipment ....................................................................................................... 10
1.4.1 General Information ................................................................................................................. 10
1.4.2 Precautions during unpacking turbo-generator components ................................................... 10
1.4.3 Preservation during the erection phase ................................................................................... 11
1.4.4 Monitoring during the erection phase ....................................................................................... 13
1.4.5 Clean working conditions during all work on the turbo-generator ............................................ 14
1.5 Preparation ............................................................................................................................. 15
1.5.1 Documentation ......................................................................................................................... 15
1.5.2 Checking .................................................................................................................................. 15
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List of Tables
Table 2-1: Mass of Generator different components ................................................................................... 24
List of Figures
Figure 1-1: Dewpoint as function of relative humidity and air temperature .................................................. 12
Figure 2-1: Basic Installation Sequence ...................................................................................................... 22
Figure 2-2: Pre-assembled Components & temporarily installed Transport Devices .................................. 23
Figure 2-3: Parts shipped separately ........................................................................................................... 26
Figure 3-1: Anchoring .................................................................................................................................. 28
Figure 3-2: Calculating the Elevation on the Sole Plates and Foundation Supports.................................... 30
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1 GENERAL INFORMATION
1.1 Objective
This instruction describes the Mechanical Field Installation of the Generator components
within the scope of supply of ALSTOM Power.
Read instructions!
The information in this manual is compulsory reading matter for anyone working with
or at the Machine. This means that everyone must understand what safety means.
ALSTOM Power declines all responsibility for personal injuries or material damages
occurring as a result of non-observance of the instructions and warnings in this
manual.
CAUTION
The following recommendations must be applied to avoid possible damage to the
machine.
condensation of water on the internal surfaces of the stator core and stator winding.
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Moisture formation on internal surfaces will result in rust on unprotected steel surfaces
and low winding insulation resistance. The rotor is similarly susceptible to these effects.
● Corrosion damage can require extensive efforts to return the components to their original
condition, and in many cases cannot be fully removed. Susceptible components will
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begin to show signs of rusting after exposure to moist air for only a short time (one day),
therefore only by strictly keeping to the requirements given in this document can such
problems be avoided.
-
Type
DC
● As a general rule unpacking of parts, removal of shipping covers and protective devices
Dept. Document No.
should preferably take place shortly before installation in order to protect parts and
components from damage, humidity and contamination for as long as possible.
● In particular the time between opening the generator stator transport / protection covers
and closing the stator again must be minimized. During this time the open stator must be
protected from moisture, particularly rain. This is of obvious concern when the power
plant is outdoors, but it can be overlooked on indoor installations where the permanent
building may not be completely finished or large doorways may be left open. Under these
conditions the building may not provide adequate protection and, as in the outdoor plant,
additional covers will be needed.
● Before removing the transport/protection covers, ensure that the stator structure is at the
same temperature as the ambient air or higher. If the structure is colder than the ambient
air then, depending on the dew point temperature, condensation could form on the stator
components. If the stator has been moved from a colder environment to a warmer
environment, e.g. from outside to inside the turbine hall, then time must be allowed for
the stator temperature to stabilize to the ambient air temperature before removing the
covers - this could take several days.
● Do not remove the covers if the stator internal air temperature is below the dew point of
the external, ambient air.
● Remove one transport/protection/enclosure cover at a time (NDE then DE), immediately
replacing it by the temporary closure plates/covers to be used during the erection period,
i.e. do not have both ends of the stator open at the same time. This minimizes the
exchange of the dry air within the stator with the ambient air.
● The Generator should be kept closed directly until the lifting process. If the foundation
allows for leaving the transport/protection covers on the generator, then it should be lifted
with the covers on. Otherwise dehumidifiers must be prepared in advance and waiting on
the turbine block ready to use. These devices should be connected immediately after
putting (lifting) the generator on the foundation.
General
● Any openings on the generator need to be closed with plastic sheeting or wooden covers
and sealing tape to avoid excessive interchange between the dry air inside the generator
with the ambient air outside.
● The relative humidity of the air within the generator must be regularly monitored and
controlled to keep it at a low level. Generally relative humidity levels above 40% increase
the risk of rusting of unprotected steel surfaces.
● Additionally the steel temperature must always be kept at least 5K above the dew point
temperature of the air within the generator. The dew point can be obtained using the
2015-06-16 EN Approved
graph in Figure 1-1 from the measured air temperature and relative humidity, or directly
from the measuring equipment if a dedicated temperature/humidity detector is used.
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● The measurable steel temperatures within the generator depend on the specific design.
The stator core is common to all machine types and is normally the preferred
measurement since this has the greatest mass and will react more slowly to changes in
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For guidelines on monitoring the steel temperature, see section ‘Measurement and
control of generator steel temperature.
● The generator steel temperature, the air temperature and humidity inside the generator
9470 HTGG611728
Dept. Document No.
shall be measured daily and be part of the site report. Additionally the ambient
temperature and humidity in the turbine hall shall be measured and reported.
Unless local site conditions are particularly dry and stable, then it is recommended that
automatic, hourly logging of air relative humidity and temperature both inside and outside
the generator is carried out.
● When other generator parts are removed (such as cooler, enclosures, bearing covers,
shaft seals, brush-gear enclosures etc.), the exposed components must be covered with
a clean tarpaulin or dustsheet.
● If it is not feasible to use dehumidifiers during the day shift, then the humidity inside the
stator additionally needs to checked every two hours during the working time.
● If the relative humidity inside the generator exceeds 60%, or, due to a sudden inflow of
warm, humid air, condensation takes place on the generator, then the generator should
be closed and the dehumidifier applied until the relative humidity is again below 30%
before the stator can be opened for work and the dehumidifier stopped or disconnected.
Note
At certain times, the generator will be exposed to the station ambient air for
extended periods dependant on the generator type, e.g. during rotor insertion,
assembling the housing end closures/end housings, cooler pockets and terminal
box. It will be extremely difficult to avoid ingress of ambient station air into the
generator during these periods; therefore it is important that the local weather
conditions are checked in advance for any expected sudden increase in air
temperature and humidity during these periods.
CAUTION
2015-06-16 EN Approved
generator then condensation can occur extremely quickly on the colder generator
surfaces. If this occurs, then additional measures to dry out the generator may be
necessary (e.g. immediately wiping accessible surfaces to remove condensed
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outside the generator if the generator will be open for any reason.
If this criterion cannot be met, then there is a high risk of condensation occurring on the
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generator; even using high powered air heaters will require many hours. By far the most
effective way to avoid condensation in the generator is to control the relative humidity
(and therefore dew point) of the air inside the generator using a dehumidifier as
-
described above.
Type
DC
All loose objects in pockets of clothes are to be removed; remove jewellery (watches,
necklace etc.). Only carry tools and parts which are necessary to carry out the work.
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Make sure, nothing gets dropped or lost. After working inside the generator or bearing
pedestals, always make sure that all tools, parts and materials get removed again.
Frequently check for foreign objects and remove them. Clean-up possible debris
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periodically.
To ensure these requirements are met, strict inventory control of parts and tools entering
and leaving the stator housing shall be applied.
-
● Grinding, welding, chiseling in the immediate vicinity of the generator must be avoided.
Type
DC
CAUTION
Metallic or abrasive contamination on winding insulation, bearings, lube oil
systems, generator slip rings etc. may cause severe damage to the machine.
● Parts and components are to be set down on wooden blocks. Whereby machined
surfaces are to be protected additionally with plastic sheets, in order to prevent corrosion.
● Meticulous inspection of the stator windings and core shall be carried out at various
stages of assembly such as:
− Before inserting the rotor, when it is delivered separately.
− Before installation of the generator enclosures.
1.5 Preparation
1.5.1 Documentation
12
3 Note
Before starting any operation, read the references documents in table 03 of the
Field Assembly Documentation List (FAD).
1.5.2 Checking
● Perform incoming inspection of the generator components and prepare them either for
installation or storage.
● When unpacking components in preparation for installation, clean parts and remove
long-term corrosion-protection applied for shipping shortly before installation. Apply short-
term rust-protection (such as WD-40).
● Check unpacked parts for completeness and possible transportation damage.
● During installation, periodically check insulation resistance of stator and rotor windings in
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Note
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Note
It is absolutely recommended that the entire work on any parts of the facility is
carried out by or together with ALSTOM Power personnel.
WARNING
WARNING
-
Type
DC
CAUTION
When the generator is at a standstill for a short or long period of time,
various precautions should be taken, which have to be in accordance with
ALSTOM Power Instructions: refer to preservation recommendations!
It is absolutely important to keep the generator free of humidity: use a
desiccant and blow heated air through the generator.
CAUTION
Ensure absolute cleanliness and accuracy during maintenance of the
generator :
If dirt or foreign particles enter the casing, this can cause serious
irregularities or even destroy components.
A clean surrounding is also necessary for general maintenance work.
Generally, the open parts of the generator housing, which are not worked
on are to be covered. This applies also during work interruptions regardless
to their length
Only clean, lint-free cloth can be used for cleaning the components.
CAUTION
Oil leakage is to be immediately blanked off and removed or collected.
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Some fixations are secured by spot-welding. Remove them before assembling. During
cutting-off and welding operations, put on suitable clothes and the required personal
protective equipment!
Mandatory Action
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Always wear tested protective glasses, facemasks, gloves, safety shoes and
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WARNING
9470 HTGG611728
Dept. Document No.
DANGER
Heavy load
documentation).
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Visual inspection of handling equipment after (and also prior to) every
usage must be performed. In case of any discontinuities, cracks, etc.
further utilization of the equipment is not allowed.
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Do never stand under suspended loads. Make sure that persons not
involved in the work are outside the danger area.
-
Type
DC
WARNING
9470 HTGG611728
WARNING
Slippery
Danger of slip or fall due to oil leakage on the surface caused by incorrect
using of hydraulic tools.
Make a correct using of the hydraulic tools to avoid oil leakage.
WARNING
Slippery
Danger of loss of health because of ejected oil from the bearing block.
Risk of slip due to oiled components and fall due to components placed
around bearing pedestal. (lateral guides, cabling, piping)
Keep cleanness around bearing blocks.
Use shoes with good adhesion to the floor.
DANGER
High voltage/Electrical shock
Danger of life by electrical shock under high voltage
Be sure that the excitation cannot be switched on while the machine is at
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standstill.
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WARNING
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Rotating parts
- Fan Blades
WARNING
Pressurized air
Danger of personal injury by high pressure air flow!
In case of pressurized unit, ensure in addition that the housing
pressurization system is switched off and the housing is at atmospheric
pressure.
WARNING
Danger of drawing-in or trapping due to contact with rotating surfaces that
are not covered by protection device.
Always keep safe distance from machine.
CAUTION
Harmful materials
Personal injury by contact or inhalation with glass components during
handling/machining processes.
The generator contains many components manufactured from glass fibre bound in
epoxy and polyester resins.
Risk of abrasion when handling / machining.
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No Step name
Prepare the foundation to receive the
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1
generator
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5 Remove desiccants
Remove transport cover & install stat.
6
-
Casing top-cover
Type
DC
8
wedges
Check 3rd bearing (end-bearing)
9
alignment (for 60Hz generators)
10 Check brush gear alignment
11 Final installation of the seal frame
12 Weld cross and longitudinal guides
Install inner & outer enclosures DE &
13
NDE
14 Close generator bearings
15 Tighten turbine / generator coupling
16 Install generator accessories
17 Finalize generator installation
11
10 4 4 5 14
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3
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2 1 9 6, 7
-
8(*) 13 12 G1037_C
Type
DC
60WY23Z – 60WY23Z –
2015-06-16 EN Approved
rd
3 bearing / / / 1.8 To 1.8 To
Brush gear 1.6 To 1.6 To 1.6 To 1.5 To 1.5 To
9470 HTGG611728
11 Stator casing transportation cover Various blind flanges on oil and water
piping
12 Sheet metal shipping covers bolted to Desiccant bags (placed inside bearing
the brush gear air filter area pedestals and stator casing)
1 Stator housing top-cover with main 10 Standstill-heaters & sub junction box
terminals & connecting parts
2 Lifting brackets (if applicable) 11 Leak detectors & sub junction box
3 Foundation anchor bolts with nuts & 12 Cross / longitudinal guides
washers
4 Foundation supports and sole Plates
Instrument wiring from standstill-
5 Foundation seal-frame parts heaters & leak-detectors to sub junction
box & main junction box
6 Brush-gear cooling air filter box Special tools for rotor and bearing
installation
Brush-gear cooling air silencers (if Special assembly consumables such
7 option) as thread lubricant, sealant, thread
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8 Make-up filter (replaced by a Spare seals for casing top cover and
pressurization unit if pressurized) outer enclosures (end shields)
Parts of shaft-grounding equipment (DE Flexible connections and assembly
9 Grounding in the scope of Turbine in material must be shipped separately
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detail design
(***): 4 coolers for 50/60WY23Z-090-109 generators; 5 coolers for 50WY23Z-124 generators
9470 HTGG611728
Dept. Document No.
(**)
1 54 slots
72 slots
9
(*)
D D-D
7 6
H D
12 2 (***) 11 12 10 8 11 3
H-H
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4
J 11
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J
5 J-J
-
Type
DC
G1038_C
9470 HTGG611728
Note
Foundation/anchoring parts which are directly embedded into the foundation
concrete are usually supplied by the civil contractor and/or the turbine
manufacturer.
Accessory-hardware to the generator rotor coupling(s), its documentation and
overall shaft-line issues generally fall in to the scope of supply of the turbine
manufacturer.
3.1.2 Preparation
● Foundation fully cured, checked and turned over from civil-department.
● Dimension check on anchor boxes and embedded anchor plates complete.
● All necessary elevation-bench marks set and machine centrelines (longitudinal and
transverse axis) laid out.
● Foundation surface cleaned and free of dirt and dust.
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● Cooling air ducts and chambers checked for required surface finish and required slope
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CAUTION
-
Type
DC
Fall risk
Personal injury
9470 HTGG611728
A-A 40,400
32
27
50WY23Z-090-109
20
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A
A A
9 11,402
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A
60WY23Z-109
11,402
-
Type
DC
3
A
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Dept. Document No.
A A
4
A
50WY23Z-124
A
A A
40,400 5 A S1109_A
9 Base plate (sole plate) 400 Coat threads & sliding surfaces with
item 40
11 Epoxy grout 402 Chipped off concrete
20 Foundation support (“elephant foot”)
Note
Due to the shaft bending line (natural sag of the rotors) the generator will have to
be set in a certain slope. The generator frame must form a straight line, within that
slope!
3. Measure the elevation of the concrete at the base plate’s locations, using an optical
levelling instrument. Compare the elevation readings to the calculated requirements.
4. Determine the amount of concrete needed to be chipped off (at least 10 mm) in order to:
− Clean off the soft concrete skin.
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− Expose clean and “healthy” concrete, required for the epoxy grout to properly bond.
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CL
2
7
8
9
11
10
12
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7
8
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3
Elevation at
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shaft-train 0
“Zero”
-
2 3
Type
DC
9470 HTGG611728
Dept. Document No.
Turbine Generator
4 5 6
S1123
Figure 3-2: Calculating the Elevation on the Sole Plates and Foundation Supports
3.2.3 Set and grout the foundation base plates (sole plates)
1. Grind or chip off the concrete in the soleplate areas by the amount determined in the
previous section.
2. Prepare and clean the soleplates :
− Grind off any rust or loose surface skin. Degrease surface of soleplates.
CAUTION
All plate surfaces which come in contact with epoxy grout must be absolutely clean
from rust, dust, paint, grease, oil, scale etc.!
The machined surface of the sole plates must be on top.
3. Place the sole plates on setscrews onto the cleaned concrete. Align them to the
longitudinal and transverse axes and level them.
4. Using the optical levelling instrument, adjust the soleplate on the setscrews to the
required elevation calculated in the previous section.
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6. Prepare and install wooden frames around the sole-plates in preparation for grouting with
none shrinking grout. Plug foundation bolt holes temporarily.
7. Grout foundation base plates (sole plates).
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-
CAUTION
Type
DC
While pouring self-levelling epoxy grout, make sure that no air gets entrapped into
the mortar.
9470 HTGG611728
At high ambient temperatures, very sunny conditions, or strong winds, make sure
Dept. Document No.
8. After the none shrinking grout has cured, remove wooden frames, clean foundation and
sole plates.
9. Protect all plates and supports against dust, water and other ambient influences until
setting of components.
Note
Final installation and alignment of the seal-frame and welding of the separation
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baffle will be done after the generator has been set and aligned.
-
Type
1. Clean the threads of the foundation bolts and coat them with MoS2 lubricant. Install
eyebolts on the top end of the foundation bolts.
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Dept. Document No.
2. Lower the foundation bolts into the anchor boxes and screw them into the anchor-box
nuts.
3. Prepare means to pull-up the foundation bolts from the lowered position once the
generator is set on the foundation.
− Insert an eye-bolt on the top-side of the anchor bolts and pull a rope through it.
− Or remove the eyebolts and prepare a long threaded-rod with a hook or an eye-nut
on one end.
WARNING
1. Layout and drill the holes into the foundation for the bolting of the heaters, leak-detectors
and sub junction boxes.
2. Install standstill-heaters, leak-detectors and junction boxes in the proper locations
according to the KKS numbering (MKA13 xx xxx).
3. Layout and drill the holes into the foundation and stator casing for the cable-conduit clips.
Install the cable-conduits and clips.
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CAUTION
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Distance between cable-conduit clips must not be larger than 300 mm.
Holes for cable-conduit clips in the stator casing must not be drilled through.
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4. Pull the power and signal wiring and terminate the wiring in the junction boxes according
to the GENERATOR TERMINAL PLAN.
-
Type
DC
Note
The signal wiring of the leak-detectors between sub-junction box and main junction
box must be finished after the generator is set on the foundation.
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Dept. Document No.
CAUTION
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While grinding off the shipping cover welds, cover-up and seal-off the area towards
the coolers and stator-windings.
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4. Lay out centreline marks on the generator frame in preparation for alignment to the
centreline marks on the foundation.
-
section 3.2.7
6. Remove the rotor-locking device.
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Dept. Document No.
CAUTION
Removal of the rotor locking device should be done as late as possible :
At a stage of installation, when axial shifting has been completed or
reduced to a few millimetres for pre- and final alignment.
To avoid collision with the turbine, if already set
7. Clean coupling face and check for scratches, dents, high spots. Carefully clean
irregularities with a fine honing stone.
8. Lightly coat coupling-recess with MoS2 lubricant, while the front face of the coupling must
remain dry and free from oil and lubricants.
9. Temporarily cover coupling face with protective mats (rubber, gasket, cardboard or
similar) preferably under an additional sheet metal cover.
Note
Method and sequence of generator lift vary; depending on transportation
arrangement and lifting equipment used and will not be described in detail in this
instruction.
2. Lift the generator above the turbine-deck elevation and move it over towards the
generator foundation.
3. Set the generator down onto the foundation supports, as close as possible to the
previously established centreline marks on generator foot and foundation.
4. Assure that stator casing, rotor, stator windings, bearing pedestals of generator and
exciter are grounded and properly connected to plant earth. Use temporary grounding
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WARNING
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tool.
Take special care when working with hydraulic tools.
9470 HTGG611728
Always work in accordance with the user manual of the hydraulic device.
Do not exceed maximum pressure.
WARNING
Slippery
Danger of slip or fall due to oil leakage on the surface caused by incorrect
using of hydraulic tools.
Make a correct using of the hydraulic tools to avoid oil leakage.
DANGER
Heavy load
See the weight and size in the documentation, or on Table 2-1 page 24
Wrong use of lifting tools could lead to serious accident!
Do never stand under suspended loads. Make sure that persons not
involved in the work are outside the danger area.
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1. Measure axial position of the bearings to the rotor. See Dimensions e & f and remark 2)
Type
DC
on the Assembly Plan Generator. Compare to the current gap between turbine and
generator coupling face and calculate the generators axial misalignment.
2. Using a spirit level, check lateral level of the generator on the DE & NDE bearing
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Dept. Document No.
pedestal half-joints.
Note
For rough alignment measurements, it is not required to rotate the shaft for radial
axis displacement and coupling parallelism measurements.
3. Using a straight edge and feeler gauge, measure radial axis displacement between
turbine and generator on the coupling circumference on four points.
4. Using parallel-blocks (or snap-gauges), check the coupling parallelism on four points.
5. Calculate the required correction values (radial axis displacement and coupling
parallelism) for horizontal and vertical correction.
6. Calculate the required correction values (radial axis displacement and coupling
parallelism) for vertical correction for each individual foundation support pair (left &
right).
• With a thread pitch on the foundation support bushing of 4 mm and 10 notches on
the circumference :
One full turn equals 4.0 mm
One notch equals 0.4 mm
S1082
S1118
Figure 3-4: Stretched tight wire along the footplate cross mark level
t < 1mm
S1119
CAUTION
This is a rough-alignment only. The positioning of the generator towards the
turbine may still be off some ways. But it is important, that the generator now sits
straight and square on the foundation. The generator must not be bent nor twisted.
5. The transport bolts that provide contact between the stator core and housing must be
wound back from outside
− Remove cover on both sides by grinding off spot welds
− Wind back bolt approx. 10mm
− Re secure by welding cover back on
Note
Fill the test certificate LOOSENING TRANSPORT BOLTS.
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X W
G1091
905 a 1 4
A-A
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901
b
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1
906
903
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A s A
-
2 902
Type
DC
S1113
8. Screw the hydraulic – jack down on the foundation bolt thread, all the way down to the
support-ring. Press the hydraulic jack together by tightening the piston with a hook-
spanner until it bottoms out in the cylinder. Then back it off again and leave a clearance s
of 1 to 1.5 mm between the jack and the support ring.
WARNING
Danger of limbs crushing due to incorrect using of hydraulic tools.
Danger of high pressure oil ejection due to failure of hydraulic tools.
Risk of causing serious injury due to incorrect use or defect in hydraulic
tool.
Take special care when working with hydraulic tools.
Check all parts for wear/damage prior to assembly.
Always work in accordance with the user manual of the hydraulic device.
Do not exceed maximum pressure.
WARNING
Slippery
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Lng. Status
Danger of slip or fall due to oil leakage on the surface caused by incorrect
using of hydraulic tools.
Make a correct using of the hydraulic tools to avoid oil leakage.
Rev. Released
9. Attach the pressure-oil connection to the hydraulic-jack at (a) and connect to the oil
-
pump.
Type
DC
10. Vent the system by applying some oil-pressure and loosening the pressure-oil connection
on the cylinder.
11. Re-tighten all connections and re-check the clearances s = 1 - 1.5 mm between the
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Dept. Document No.
Note
While increasing the oil-pressure, keep tightening the foundation bolt-nut,
otherwise it may jam against the bottom of the jack.
CAUTION
Oil ejection
Personal injury, tool damage.
The maximum stroke on the hydraulic-jack is marked with a groove (laid-
out red) around the circumference of the piston. When this groove
becomes visible, stop increasing the oil pressure.
13. When the maximum stroke of the hydraulic jack is reached, stop increasing the oil
pressure and stretching the foundation bolt. Tighten the foundation bolt-nut and repeat
previous steps starting at step (8).
14. Increase the oil-pressure in the jack to the value specified in the test certificate. Maintain
the specified oil pressure in the jack and tighten the nut with the handle 902/903 solidly
by hand.
Note
Fill the test certificate HYDRAULIC PRE-STRESS OF FDT.BOLTS.
Note
Do not use extensions on the tightening handle!
15. Release the oil pressure down to zero, remove the pressure oil line, remove the
hydraulic-jack and disassemble the tightening device.
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3.5 Remove Outer and Inner Enclosures Upper Halves, DE & NDE
3.5.1 Documentation
12
3 Note
Before starting any operation, read the references documents in table 10 of the
Field Assembly Documentation List (FAD).
aside.
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G1040
6. Loosen and remove the inner enclosure upper and lower halves bolts to the stator casing
7. Attach the hoist to the lifting device (3, Figure 3-9) and turn round inner enclosure around
the rotor and set the half-joint in horizontal position
2
1
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G1041
CAUTION
9470 HTGG611728
Dept. Document No.
Harmful materials
Personal injury due to contact with glass components during
handling/machining processes.
The generator contains many components manufactured from glass fibre bound in
epoxy and polyester resins.
Risk of abrasion when handling / machining.
Risk of dust inhalation when handling or machining and in operation : some
mechanical wear can result in traces of glass/resin dust in the machine.
Appropriate measures should be taken to avoid inhalation of any such dust.
CAUTION
All desiccant units placed inside the stator casing on DE and NDE, and in the
bearing pedestals must be removed.
Reinstall the blind flanges, if the permanent lube-oil piping is not immediately installed
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yet.
2. Remove all desiccants inside the brush gear console.
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Note
-
3.7.2 Prerequisites
● Generator must be aligned and straightened.
● Outer and inner enclosures must be removed.
2. Hoist the transportation cover from the stator casing and set it aside.
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3. Cover the exposed core and windings with plastic sheets or tarpaulins until the top-cover
is installed.
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CAUTION
9470 HTGG611728
Dept. Document No.
Harmful materials
Personal injury due to contact with glass components during
handling/machining processes.
The generator contains many components manufactured from glass fibre bound in
epoxy and polyester resins.
Risk of abrasion when handling / machining.
Risk of dust inhalation when handling or machining and in operation : some
mechanical wear can result in traces of glass/resin dust in the machine.
Appropriate measures should be taken to avoid inhalation of any such dust
2. Clean and prepare the bolts, nut, washers, dowel-pins, thread-studs etc. for the top-cover
joint, coat threads with MoS2 lubricant.
3. Insert and tighten two thread-studs diagonally in two corners as guides for the top-cover
installation.
4. Clean stator windings, stator core and the exposed insides of the stator casing with
vacuum cleaners and clean rags. Perform a thorough visual inspection of the stator core
and stator windings. Make sure the stator windings and core are free of dust, dirt, any
kind of foreign objects and metal particles.
5. Hoist the top-cover and align it leveled and centered above the stator casing. Lower the
top-cover and insert the dowel pins just before the top-cover touches down on the casing
joint.
CAUTION
While lowering the top-cover down to the casing, make sure the seal-rubber
profiles seat properly on the outside diameter of the stator core.
6. Before cutting the top-cover loose from the hoist, insert all flange bolts. Insert all thread-
studs and tighten them. Drive-in the dowel-pins until they seat solidly.
7. Remove hoist from the top-cover.
8. Tighten all thread-stud nuts and flange bolts according to separate procedure Assembly
of Stator Frame Top Half to the required torque.
9. Install the two grounding straps between stator casing and top-cover on NDE.
10. Install the flexible connection according to the procedure “Process specification for
assembly of flexible connection”.
centre.
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to the thread and re-tighten the bolts, one bolt after another to the required torque.
-
1. Install the flexible links, cooper spacers, bolts, nuts and washers according to the
drawing Terminal Part Assembling and process specification for assembly of flexible
connection, apply resin mixture to the thread and tighten the bolts to the required torque.
9470 HTGG611728
Dept. Document No.
After 15-20 minutes installation, re-torque the bolts with the required torque.
2. Install cooper spacers, bolts, nuts and washers on the winding side of the flex.-links
according to the drawing Terminal Part Assembling and tighten the bolts to the required
torque. After 15 - 20 minutes, re-torque the bolts.
3. Clean the terminal parts and the stator windings below, with vacuum cleaners and clean
rags. Perform a thorough visual inspection. Make sure the stator windings and terminal
parts are free of dust, dirt, any kind of foreign objects and metal particles.
4. Measure insulation resistance according to the separate procedure Measurement of
Insulation Resistance of the stator winding with the now connected terminals.
Note
Fill the test certificate INSULATION RESISTANCE MEASUREMENT.
3.8.1 Documentation
12
3 Note
Before starting any operation, read the references documents in table 13 of the
Field Assembly Documentation List (FAD).
1. Measure axial position of the bearings to the rotor. Dimensions e & f and remark 2) on
the ASSEMBLY PLAN GENERATOR. Compare to the current gap between turbine and
-
2. Using a spirit level, check lateral level of the generator on the DE & NDE bearing
pedestal half-joints. Must be within 0.08 mm/m.
3. Carry out rotational measurement of the radial axis displacement between turbine and
9470 HTGG611728
Dept. Document No.
Note
Always run jacking oil when rotating and / or shifting rotors.
Shut-down jacking oil during alignment measurements on the rotors.
6. Calculate the required correction values (radial axis displacement and coupling
parallelism) for vertical correction for each individual foundation support pair (left &
right).
● With a thread pitch on the foundation support bushing of 4 mm and 10 notches on the
circumference :
One full turn equals 4.0 mm
One notch equals 0.4 mm
Note
Fill the test certificate AXIAL POSITION OF THE ROTOR.
2015-06-16 EN Approved
Lng. Status
2. Check the straightness of the final aligned generator either on the horizontal axis cross
marks (+) on both sides of the stator housing, using an optical levelling instrument. Or
check the straightness on the cross marks on both sides (+) at the footplate level with the
tight wire method. The straightness t must be < 1.0 mm.
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b) Back off jack-bolts on lifting brackets away from the generator side-wall.
Dept. Document No.
c) Loosen and remove bolts, fastening the bracket to the generator foot.
d) Pick-up lifting bracket with hoist and set aside.
WARNING
Danger of limbs crushing due to incorrect using of hydraulic tools.
Danger of high pressure oil ejection due to failure of hydraulic tools.
Risk of causing serious injury due to incorrect use or defect in hydraulic
tool.
Take special care when working with hydraulic tools.
Check all parts for wear/damage prior to assembly.
Always work in accordance with the user manual of the hydraulic device.
Do not exceed maximum pressure.
WARNING
Slippery
Danger of slip or fall due to oil leakage on the surface caused by incorrect
using of hydraulic tools.
Make a correct using of the hydraulic tools to avoid oil leakage.
Note
Fill the test certificate HYDRAULIC PRE-STRESS OF FDT.BOLTS.
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CAUTION
2015-06-16 EN Approved
Make sure to remove all cable ties from the working area.
3. Measure the torque on the four unlocked wedge bolts on both ends according to the
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WARNING
Dept. Document No.
Note
Fill the test certificate END WINDING, TIGHTENING THE WEDGES.
CAUTION
Avoid to drop any cable tie inside the Generator.
CAUTION
Harmful materials
Personal injury due to contact with glass components during
handling/machining processes.
The generator contains many components manufactured from glass fibre bound in
epoxy and polyester resins.
Risk of abrasion when handling / machining.
Risk of dust inhalation when handling or machining and in operation : some
mechanical wear can result in traces of glass/resin dust in the machine.
Appropriate measures should be taken to avoid inhalation of any such dust
2
LG
L2
Z
4
5
6
2015-06-16 EN Approved
7
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Z A
2
-
Type
DC
4 2
5 A
9470 HTGG611728
Dept. Document No.
S1115
3.10.1 Documentation
12
3 Note
Before starting any operation, read the references documents in table 15 of the
Field Assembly Documentation List (FAD).
Note
The term ∆h used in these sections refers to the difference of the vertical shaft-end
position within the end-bearing pedestal, between free hanging and end-bearing in
place. The required value for ∆h is found on the ASSEMBLY PLAN GENERATOR
2015-06-16 EN Approved
•
Type
CAUTION
While raising the rotor at the NDE-bearing (attempting to free the lower end-
bearing shell, observe the clearances on the shaft seal of the NDE outer
enclosure.
5. Coat the bearing journal with turbine oil. Roll the end-bearing shell lower-half out, to the
top of the shaft. Pick-up the bearing shell with a hoist and set it aside.
6. While observing the air gaps and clearances in the brush-gear, lower the shaft with the
shaft lifting device all the way down until the rotor sits back down in the NDE bearing.
CAUTION
The free hanging shaft-end must not touch any part of the brush-gear/exciter!
Make sure, the shaft lifting device is completely loose.
7. Measure and note the shaft position within the end-bearing pedestal, front and rear,
using an inside micrometre. Note dial indicator readings.
2015-06-16 EN Approved
11. Adjust the half joints of the bearing shell to the half joint of the pedestal.
12. Lower the shaft lifting device and let the rotor sit down into the bearings. Note the dial
indicator readings.
13. Measure and note the shaft position within the end-bearing pedestal, front and rear,
using an inside micrometre.
14. Calculate ∆h on test certificate ADJUSTMENT OF THE END BEARING.
Note
Fill the test certificate ADJUSTMENT OF THE END BEARING.
20. Reinstall thermocouples and jacking-oil line to the lower half of the bearing shell.
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Note
2015-06-16 EN Approved
3. Check brush holder clearance to the slip-rings and adjust if necessary. Check/secure
lock-plates on the brush-holders.
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Note
Type
DC
Note
Fill the test certificate INSULATION RESISTANCES, BRUSH GEAR.
5. Clean brush-gear interior with vacuum cleaners. Check insides of the brush-gear for
debris, contamination and any kind of foreign objects and clean as necessary. Install
access doors on the brush-gear.
6. After the brush holder clearance to the slip ring is set, unlock and remove the plug-in
brush holder assemblies and install the carbon brushes. Check that the carbon brush
quality is according drawing specification. Check that each brush can move freely without
restriction inside there brush holder cage. Connect and fasten the carbon brush cable
lugs at the specified location with the fastening screw. Install the coil spring supports and
assure that it snapped into place correctly.
7. To prevent stand-still corrosion, the plug-in brush holder assemblies with the installed
carbon brushes are inserted at the numbered location only hours before start up. After
the final installation ensure that each plug-in brush holder assembly is locked into place
correctly by pulling on the handle towards the outside.
Note
Do not install the carbon brushes until shortly before start-up. Carbon brushes
must not be left sitting on the slip rings at standstill or extended periods of time on
turning-gear.
8. After the plug-in brush holder is installed, straighten the carbon brush cable as per
drawing specification. Each carbon brush must be lifted up by pulling at the brush cable
approximately 5-20 mm against the force of the spring support coil spring. The brush is
then slowly released towards the slip ring. Repeat this procedure 2-3 times to make sure
that the carbon brush is pushed back correctly and the brush can move freely inside their
holder cage with slight clearance.
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3.12.2 Prerequisites
● Final alignment of the generator must be complete.
CAUTION
Suffocation
Be aware of confined space hazards when working in the air-ducts
underneath the generator!
2015-06-16 EN Approved
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● For reasons of better ventilation of the working space, the welding of the separating
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baffle to the underside of the generator should preferably be done while outer / inner
enclosures and transportation cover are removed.
-
● Protect coolers and stator windings from contamination that may be caused by welding,
Type
DC
grinding, chiselling.
9470 HTGG611728
CAUTION
Dept. Document No.
Harmful materials
Personal injury due to contact with glass components during
handling/machining processes.
The generator contains many components manufactured from glass fibre bound in
epoxy and polyester resins.
Risk of abrasion when handling / machining.
Risk of dust inhalation when handling or machining and in operation: some
mechanical wear can result in traces of glass/resin dust in the machine.
Appropriate measures should be taken to avoid inhalation of any such dust
3.13.2 Preparations
● Prepare and clean the embedded steel-plates, guide-blocks and angle brackets. In the
weld areas, grind off any rust or loose surface skin down to the blank metal.
2. Place the guide-blocks on the embedded steel plate. Align them to the generator-foot
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1. Prepare and clean the embedded steel-plates and angle brackets. In the weld areas,
grind off any rust or loose surface skin down to the blank metal.
2. Place the angle brackets on the embedded steel plates. Align it to the generator feet and
9470 HTGG611728
tack-weld.
Dept. Document No.
3. Weld angle brackets to the embedded steel plate and to the generator feet.
4. After the welds have cooled-down, touch up welds with GK131/132 paint.
CAUTION
2015-06-16 EN Approved
All bolts and nuts on the inside of the generator behind the outer enclosure (cold-
Lng. Status
air side), are to be secured with DB136. If bolts had to be loosened for any reason,
be sure to re-apply DB136.
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3. Check the gaskets on the enclosure flanges and half-joints. Repair/replace as necessary.
-
Type
CAUTION
9470 HTGG611728
Dept. Document No.
Harmful materials
Personal injury due to contact with glass components during
handling/machining processes.
The generator contains many components manufactured from glass fibre bound in
epoxy and polyester resins.
Risk of abrasion when handling / machining.
Risk of dust inhalation when handling or machining and in operation : some
mechanical wear can result in traces of glass/resin dust in the machine.
Appropriate measures should be taken to avoid inhalation of any such dust
1. Pick-up the inner enclosure upper half with a hoist and lifting device and set them in
position, lined-up to the half-joint of the lower half and the guide sleeves in the casing
flange.
2. Insert half-joint bolts with washers and nuts and tighten them.
3. Turn round inner enclosure around the rotor and set it in vertical position, refer to Figure
3-8.
4. Insert all flange bolts to inner enclosure upper and lower half to the stator casing and
tighten them.
5. Measure and record the fan blade clearances.
Note
Fill the test certificate RADIAL CLEARANCES OF ROTOR.
6. Disassembly of rotating specific tool (1, Figure 3-8) and lifting device (3)
7. Secure all bolts and nuts on the inner enclosure with DB136
− Remove the bolt, apply DB136 to the thread and re-tighten the bolt to the required
torque; one bolt after another.
1. Pick-up the outer enclosure upper half with a hoist and set it in position, lined-up to the
bolt holes.
CAUTION
2015-06-16 EN Approved
While positioning the outer enclosure upper half, make sure that the gaskets do
Lng. Status
2. Insert all bolts in the outer enclosure and tighten them to the required torque.
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Note
Fill the test certificate RADIAL CLEARANCES OF ROTOR.
9470 HTGG611728
Dept. Document No.
bearing covers.
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WARNING
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DANGER
Heavy load
See the weight and size in the documentation, or on Table 2-1 page 24
Wrong use of lifting tools could lead to serious accident!
Note
2015-06-16 EN Approved
1. Apply a light coat of sealing compound DB202 to the oil-deflector half-joints and on their
edges to the flange gasket.
-
2. Install lower and upper oil deflector-halves. Insert a few flange bolts to hold the oil
Type
DC
deflector in place.
3. Align the lower and upper oil deflector-halves to each other and tighten the half-joint
bolts.
9470 HTGG611728
4. Insert all flange bolts and align the oil deflector assembly to the shaft. Tighten all flange
Dept. Document No.
bolts.
5. On the outboard side of the DE bearing pedestal (towards the shaft grounding), install
and align the additional oil deflector.
Note
Fill the test certificate SHAFT SEAL AND BEARING PEDESTAL.
3.16.1 Documentation
12
3 Note
Before starting any operation, read the references documents in table 21 of the
Field Assembly Documentation List (FAD).
Note
-
CAUTION
Friction force of the rotating shaft must pull the grounding-strip downwards
2015-06-16 EN Approved
Lng. Status
2. Install adapter plate to the bearing cover and install grounding strips.
3. Connect the connecting cables between grounding strips and DE-module.
4. Temporarily place insulating material (such as gasket-material, rubber-mat etc.) between
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Note
Fill the test certificate INSULATION TEST (DE SHAFT GROUNDING).
9470 HTGG611728
Dept. Document No.
6 2 A-A
9 2 8
A
7
1
A 3 1 5 4
I1082
6 2 A-A
8 2 9
A
7
1
A 3 1 5 4
I1083
2015-06-16 EN Approved
5 Rotor Shaft
Type
DC
Note
Friction force of the rotating shaft must push the carbon-brush towards the brush-
holder clamp.
3. Install the RC grounding device to the backside of the brush gear (in case of 50Hz
generator) or to the backside of the end bearing (in case of 60Hz generators), centred in
the bolt-holes.
4. Adjust the brush-holders to the required clearance to the stub-shaft.
5. Connect connecting cables between brush-holders and RC-module.
6. Measure insulation resistance between carrier plate and casing (ground).
Note
Fill the test certificate INSULATION TEST (RC SHAFT GROUNDING).
A-A
B
3
4
2 1
5
1
A
2
6
A
B
12 1
2015-06-16 EN Approved
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6 11
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10
9
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12
Type
8
DC
7 2 I1090
9470 HTGG611728
3.17.4 Install the Make-up Filter with Silencer (not applicable if Pressurization
Unit)
• Drill the holes for the anchor bolts in the foundation wall.
• Place the make-up filter assembly in the correct position.
• Assemble and tighten anchor bolts.
• Make sure that the assembly fits tightly to the foundation wall and that the gasket is not
damaged during installation.
Z
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Z
9470 HTGG611728
Dept. Document No.
S1053
Item Description
1 Make-up Filter with Silencer
CAUTION
Damages can be incurred by changes, modifications as well as the use of non-
original parts, defective installations and lacking or deficient inspection, as well as
change of the filters (insertion of objects through the opening into the generator
etc.).
CAUTION
Lifting eyes are provided to carry out any transport operations. Lifting using only
one lifting eye is not permitted.
6
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C
5
4
2
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1 B
-
Type
DC
2
1
9470 HTGG611728
Dept. Document No.
2
9
B C
5 8 5 8
6 6
9 9
E1029
2 7 2 7
Note
Fill the tests certificates PAMOS SENSOR INSTALLATION CHECK PART 1 & 2.
2015-06-16 EN Approved
Lng. Status
Note
2015-06-16 EN Approved
● Complete signal wiring of leak-detectors between sub junction box and main junction
box.
-
Type
DC
WARNING
Slippery
Danger of loss of health because of ejected oil from the bearing block.
Risk of slip due to oiled components and fall due to components placed
around bearing pedestal. (lateral guides, cabling, piping)
Keep cleanness around bearing blocks.
Use shoes with good adhesion to the floor.
Note
Fill the test certificates :
COMPLETENESS OF Q-RECORDS
IDENTIFICATION OF COMPONENTS
2015-06-16 EN Approved
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9470 HTGG611728
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