Generator Erection Manual THW 210 2A 2B

POWER SECTOR – SOUTHERN REGION
Chennai
TECHNICAL SERVICES DEPARTMENT
Document Type : O & M Manual .
Project and Rating : .
Product Name : Turbo Generator .
Model Number/Type : 210MW – 2A/2B .
Title : Generator Erection Manual.

Contents in Brief : .
GENERATOR ERECTION
MANUAL
THW - 210 - 2A/2B
Bharat Heavy Electricais Limited

POWER SECTOR
TECHNICAL SERVICES/(H.Q)
NEW DELHI
GENERATOR ERECTION
MANUAL
Type : THW - 210 - 2A/2B
DOCUMENT NO : TS-G1-01
Bharat Heavy Electricals Limited

POWER SECTOR
TECHNICAL SERVICES/(H.Q)
NEW DELHI
GENERATOR ERECTION MANUAL
Type : THW - 210 - 2A/2B
Document No. Copy No. Ol Revision No. oo

TS-G1-01
NAME DESIGNATION/ADDRESS
Prepared by 1. S.C. Jain Sr. Manager TS-HQ/New Delhi
2. H.C. Madan Sr. Manager TS-HQ/New Delhi
3. J.S. Subramanian Sr. Manager PS-WR/Birsinghpur
4. K.V. Tandon Sr. Manager PS-NR/Dadri
5. Dev Raj Sr. Manager TGE-FES/Hardwar
6. Harsha Kayastha Manager FQA-New Delhi
Approved by S.L. Bhatia A.G.M. TS-HQ New Delhi
Date of Issue ol. 11. °lh. 1 rw f

i nntinllririniniiiWibim oupy
Issued by Head/TG •tu.v_^te

~r-
Issued t o : £.. D - P S - S R - Mdc#^ .
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR
TECHNICAL SERVICES (H.Q.)
NEW DELHI
FOREWORD
I am glad that Technical Services Head Quarters, New Delhi

has brought out t h i s Erection manual of main power station
equipments. This manual lays emphasis on site optimisation
techniques which aims at uniform erection practices,
improvement in quality, reduction in time cycle and saving
in cost.
I am sure, t h i s manual will form the basis for site

erection activities so that the organisation can derive
full benefit out of t h i s . It is needless to emphasise that
upgrading of technology is a continuous process and we have
to review our methods of working and make suitable changes,
wherever required. (jl
(K C Lahify
Director ( Power )
PREFACE
The Erection Manual for 200/210 MW Turbo - Generator has been prepared
by a team of BHEL engineers having long experience in Erection, Design and
Field Quality of Turbogenerator.
The scope of this erection manual is to bring out the recommended procedure
for erection along with the sequence of activity and various tools and plants
required to carry out this job. It also includes various logsheets required to
be filled in.
This manual is a broad based guideline for carrying out the job. Site
conditions availability of proper erection equipment and various facilities
influence the mode of erection. BHEL reserves the right to suggest alternative
procedure, if necessity arises.
P. N. BHARGAVA
General Manager (TS)
tJiTiwl
GENERATOR CODIFICATION FOR
Erection INSTRUCTION NUMBER
1.2 Type of Manual
1 - Erection
2 - Commissioning
3 - Service
1.3 Rating of Main Equipment
01 - 200/210 MW
02 - 120 MW
03 - 110 MW
04 - 60 MW
05 - 30 MW
06 - 100 MW
07 - 235 MW
08 - 500 MW - KWU Design
13 - Industrial Units
14 - 210 MW - tower Type Concrete Pylem
15 - 210 MW - Tower Type Steel Structure
16 - 500 MW - tower Type Once through
17 - 250 MW
18 - CCP
1.4 System Designation
01 - Main Generator
02 - Seal Oil System
03 - Gas System
04 - Stator Water System
05 - Excitation System

Rev. 00 10/93 2 of 3
tIZTtt GENERATOR CODIFICATION POR
Erection INSTRUCTION NUMBER
1.5 Type of Instruction
G General
T Technical
L Log Sheet
C Check List

Rev. 00 10/93 3 of 3
may GENERATOR
(^^J Erection C O N T E N T S
S.NO. T O P I C INSTN. NO.
1. Technical Parameters G1-01-0230G
2. General Description G1-01-0131G
3. Activity Sequence G1-01-0132G
4. SECTION I : ASSEMBLY INSTRUCTIONS

4 1 Preparation of Foundation G l - 0 1 -0101T
4 2 Stator Placement G l - 0 1 -0102T
4 3 Assembly of Bushing G l - - 0 1 - -0103T
4, 4 Gas Cooler Mounting G l - - 0 1 - -0104T
4. 5 Visual Inspection of Stator G l - - 0 1 - -0105T
4. 6 Visual Inspection of Rotor G l - - 0 1 - -0106T
4. 7 Rotor Insertion and withdrawl G l - - 0 1 - -0109T
4. 8 Bearing Assembly G l - - 0 1 - -0110T
4. 9 Rotor Alignment G l - - 0 1 - -0111T
4. 10 Reaming and Coupling G l - - 0 1 - -0112T
4. 11 Stator Centering G l - - 0 1 - -0113T
4. 12 Grouting of stator and G l - - 0 1 - -0114T
bearing pedestal
4.13 Assembly of fan Shield, G l - - 0 1 - -0115T
end Shield & fan Blades
4.14 Shaft seal Assembly G l - •01- -0116T
4.15 Brush Gear Assembly G l - - 0 1 - -0117T
4.16 Assembly of Extension Shaft, G l - - 0 1 - 0118T
Auxiliary bearing
4.17 Erection of TG Auxiliaries G l - 0 1 - 0136T
5. SECTION - II : TESTING INSTRUCTIONS
5.1 Rotor Purge Test G1-01-0107T

5.2 Gas Tightness Test of Rotor G1-01-0108T
5.3 Resistance Measuremeent of G2-01-0101T
Stator Winding
5.4 I.R. Measurement of Stator G2-01-0102T
Winding
5.5 Electrical Checking of G2-01-0103T
Stator R.T.D.
5.6 Pneumatic & Hydraulic test G1-01-0121T
of Stator Winding

X
Rev. 00 10/93 °£ 2
yUttgy GENERATOR
LUIH Erection C O N T E N T S
S.NO. T O P I C INSTN. NO.
5.7 Electrical Test of Rotor G2-01-0104T

Winding
5.8 Hydraulic Test of Gas Cooler G1-01-0126T
5.9 Air Leakage Test of Stator G1-01-0127T
5.10 Hot Water Circulation G1-01-0124T
5.11 IR Measurement of G1-01-0135T
Generator Rear Bearing
Pedestal & Seal Body
5.12 Slot wedge Tightness checking G3-01-0106T
6. SECTION - III : GENERAL INSTRUCTIONS

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

2
Rev. 00 10/93 °f 2
TECHNICAL PARAMETERS
The f o l l o w i n g c o d i f i c a t i o n system i s used f o r numbering of
i n s t r u c t i o n s and the c o d i f i c a t i o n of Log Sheets i s as per FQA
document.
xx x - xx xx xx x
Alpha Numeric Numeric Numeric Numeric Alpha
I I I I I I Type of
| | | I I I Instruction
| | | | | System I n s t r u c t i o n No.
| | | | System D e s i g n a t i o n
| | | R a t i n g of Main Equipment
| | Type of Manual
| Product Code
l.1 Product Code
B - Boiler
BA - Boiler Aux.
T - Turbine
TA - Turbine Aux.
G - Generator
GA - Generator Aux
P - Power Plant Piping
CI - C&I
harat Heavy Electricals Limited

Rev 00 in/cn 1 of 3
TECHNICAL PARAMETERS
ttZTJ^l GENERATOR
Erection TECHNICAL PARAMETERS
Turbogenerator Rating
Rated KW capacity 210,000 KW
Rated KVA capacity 247,000 KVA
Rated terminal voltage 15,750 V
Rated Power Factor 0.85 lag
Rated Stator Current 9050 A
Excitation Current at rated

power output and P.F. 2,600 A
Excitation voltage at rated

power output and P.F. 300 V
Rated frequency 50 cps
Rated speed 3000 R.P.M.
Direction of rotation when

viewed from Turbine end Anti clockwise
Rated H 2 Pressure 3.5 Kg/CM 2
Efficiency at M.C.R. conditions 98.55%
Short Circuit Ratio 0.49
TEMPERATURE RATING :
Class of insulation of Class 'B'
generator windings
Maximum temperature of Stator 105°C

Core (Measured by RTD)
Maximum temperature of stator 105°C

winding (Measured by RTD)
Maximum temperature of rotor 115°C

winding (Measured by resistance
method)
Bharat Heavy Electricals Limited G1-01-0230G/1 Of 3

Rev. 00 10/93
CftTjfta GENERATOR
Cooling System
Stator Core Direct Hydrogen
Stator winding Direct distillate

Rotor winding Direct Hydrogen
End terminals Direct distillate
Quantity of distillate for 27+3 M3/hr.
Cooling Stator winding
Temperature of distillate at 45°c
inlet of stator winding
Quantity of water required for 250 M3/hr.
hydrogen coolers
Temperature of cooling water 33°c
at inlet to gas cooler
Maximum allowable water pressure 4 Kg/CM2
in the gas cooler (gauge)
Minimum percentage purity of 97%
hydrogen inside the machine
OTHER PARTICLARS
Critical speed of generator 1370/3400 P.P.M.
rotor (Calculated)
Fly wheel moment of rotor 21.1 TM2
Ratio of S.C. torque to F.L. 8
Torque
Quantity of Oil required for 300 L/min.
generator per bearing
Oil pressure for lubrication 0.3-0.5 Kg/cm2.
of the bearing
Quantity of oil required for 160 L/min.
both the shaft seals
Rated pressure of the shaft eal 4.8.5.0 Kg/CM2
oil (Gauge)
1-0230G/2 of 3
Rev. 00 % / &
EiwHSl GENERATOR
Weights and overall dimensions of the main parts of the

Turbogenerator
Weight of Different Parts
Heaviest lift (wound stator with 175,000 Kg.

trunions)
Rotor 42,200 Kg.
Gas Cooler 1415 Kg.
Terminal buishing 85 Kg.
Shaft Seals 891 Kg.
End Shields 9300 Kg.
Bearing with brush gear and 270,000 Kg.

foundation plate
Total Weight of the generator 270,000 Kg.

(without exciter)
Overall Dimensions
Overall diameter of the stator 3960 mm
Total length of the stator 6580 mm
Outer Dia. of the rotor 1075 mm
Total length of the rotor 9770 mm
Overall length of the assembled 9770 mm

generator
Bharat Heavy Electncals Limited G1-01-0230G/3 of 3

Rev. 00 10/93
GENERAL DESCRIPTION
CilT^l GENERATOR
Erection GENERAL DESCRIPTION
The 210 MW turbogenerator type THW 210-2, employs direct hydrogen

cooling for the rotor and stator core and direct distillate water
cooling of stator winding. These modern cooling methods enable
high utilization of active materials and thus low value of
wight/kw ratio. The machine employs modern method of excitation
and control system to have a reliabile operation.
STATOR
The stator body is a gas tight fabricated structure designed to

withstand internal presure of hydrogen-air mixture explosion
without any residual deformation. The Stator core is built from
high alloy electro-technical steel segmental stampings which are
varnished on both sides. The stampings are assembled and pressed
on core bars in the form of packets which are separated from each
other by steel spacers of special profile to form ventilating
ducts for direct cooling of core by hydrogen.
The stator has a double layer lap winding connected in double

star. In all, 9 terminals, are brought out of the machine at the
exciter end out of which 3 are phase terminals and 6 are neutral.
The Stator winding is cooled by direct distillate. Each coil side
consists of solid and hollow conductors with the cooling water
passing through the latter. For circulating water through the
stator coils, ring type water headers, insulated from the body
are provided on turbine side. In the slot portion coil sides are
held in position by fibrous slot wedges to prevent any movement
during short circuits. The overhang portion of the winding is
securly lashed with glass cord to the bandage rings & special
brackets which in turn are fixed to the core pre springs. The
coils are insulated with mica tape and compounded with epoxy.
Bharat Heavy Electricals limited G1-01-0131G/1 of 6

Rev. 00 10/93
cjzrizi GENERATOR
ROTOR
The rotor is of cylindrical type, the shaft and rotor body being
forged in one piece from special alloy steel in accordance with
the most modern practice. The field winding is made of cold
rolled silver bearing electrical copper. Each conductor is wound
flat and consists of two parallel strips. The joints of the
winding are silver soldered. The main wall insulation to earth
(rotor body) of the winding is in the form of moulded troughts of
glass cloth impregnated with epoxy resins. The slot portion of
the winding are held against centrifugal forces by means by
duralumin wedge and overhang portion by retaininng rings of
special design. The retaining rings are made from high tensile
non-magnetic alloy steel forgings. The rotor winding is directly
cooled by hydrogen by gap-pick-up system of cooling. By adopting
this method of cooling, the uniform temperature distribution
along the length of rotor winding is achieved.
HYDROGEN COOLERS
For cooling hydrogen, 4 coolers of closed circulation type, with

sufficient surface area are provided. These coolers are mounted
longitudinally in the stator frame and are so designed that the
tubes may be cleaned without removing hydrogen from the machine.
Bearing
Generator bearing at the exciter end is of pedestal type with

high rigidity and is provided with spherically seated Self-
adjusting bush. The bearing bush is lined with anti-friction
metal and is lubricated by the oil supplied from the turbine oil
system. For checking the flow of oil, view windows are provided
on the drain pipes.
Bharat Heavy Electricals Limited TTTI T~~l
1 0131072
Rev. 00 ft/a - °f 6
GENERATOR
The circulation of shaft currents capable of damaging the bearing

surface is prevented by insulating the bearing body and the drain
pipes from the earth.
Generator bearing at the turbine end is supplied alongwith the

turbine and is housed in the L.P. casing of turbine.
Slip Rings and Brush Gear
The slip rings are steel forgings which are shrunk on to steel
hubs covered with mica, built up in position. They are arranged
side by side outside the generator bearing at the exciter end.
The surfaces of the slip rings are spirally grooved and the
brushes are staggered to increase the life of the slip rings and
brushes. The brushes are pressed on the slip rings by means of
spring loaded plungers. The tension of the springs is readily
adjustable. The slip rings and brush gear are designed to be self
ventilated with rotation. They are enclosed by perforated sheets.
Shaft Seals
The generator employs ring type shaft seals mounted in each of

the end shields. For improving the reliability during all regimes
of operation the shaft seal design incorporates high pressure oil
film around the rotor shaft.
In order to prevent the circulation of Shaft currents, body of

the shaft seal on the exciter side is insulated from the stator
end shields and connecting pipes.
GENERATOR
Temperature Control System
The generator is provided with an eloborate system for measuring

the temperature of stator winding, core iron, cooling gas,
cooling water, lubricating oil and babbit of bearinng and seal
liners (see table I)
The temperature of stator winding and core iron is measured by

means of resistance thermometers installed under slot wedges and
at the slot bottom under lower winding bar respectively.
Temperature of Cold and hot hydrogen is measured by means of

resistance thermometers located in the stator body and by mercury
thermometers mounted on the endshields and in the middle of
stator body.
Temperature of cold and hot distillate passing through the stator

winding is measured by means of resistance thermometer installed
in the distillate pipe lines. Temperature of gas cooler water is
measured by resistance thermometers as well as mercury
thermometers installed on cooling water pipe lines.
Babbit temperature are also measured by resistance thermometers

installed in the bushes of bearing.
Table - 1
Mercury Thermometers
SI. No. of Location To measure temp-

No. Thermometers erature of
1. Mx Generator stator body Hot gas

2. M2, M 3 Generator end Shields Cold gas
Bharat Heavy Electricals Limited "
0131074
Rev. 00 ft/*- °f6
ETiZIj^l GENERATOR
Table - l (continued)
Mercury Thermometers
SI. No. of Location To measure temp-

3. M4 Generator bearing drain Drain oil

pipe T.E.
4. M 15 , M l g Generator gas cooler Hot water

drain pipe
M
19 Main water piping Cold water
Resistance Thermometers
1 to 60 One of each slot Generator stator
wdg bar
2. 61 to 63 One of each slot Core iron end
1,21,41 packets
3. 64 to 69 One in each slot Core iron

2,22,42,1,21,41
4. 70 to 72 One in each slot Core iron end
1,21,41 packets
5. 73 to 76 Middl of stator Cold gas
77,78 body Hot gas
6. 79 to 80 Seal liner T.E. Babbit
(For Thrust Type Seals)
7. 81, 82 Seal liner E.E. Babbit
(For Thrust Type Seals)
8. 83, 84 Babbit
Bearing liner E.E.
9. 85 Drain oil
Bearing drain pipe E.E.
10. 86 Oil pipe after oil Oil to shaft
cooler seal
Bharat Heavy Electncals Limited

Rev. 00 %7^1"0131G/5 of 6
ciTijfn GENERATOR
Table - 1 (continued)
Resistance Thermometers
SI. NO. of Location To measure temp-

11. 87,88 Distilled water pipe to Distilled water

stator wdg. inlet
89 Outlet
12. 90 Water header to gas Water at inlet
cooler
13. 91 to 94 Water pipe from gas Drain water
coolers
Bharat Heavy Electncals Limited

Rev. 00 Cj^^l-0131G/6 of 6
ACTIVITY DETAILS
•a
nrnî GENERATOR
Erection MAJOR ACTIVITIES
Step No. Activity Dependency on

Step No.
1. Preparation of Foundation 0
2. Placement of Stator 1
3. Assembly of Terminal Bushing 2
4. Assembly of Gas Coolers 2
5. Tests on Stator 2
6. Tests on Rotor 2
7. Rotor Insertion 0
8. Rotor Alignment with LP Rotor 7
9. Reaming and Coupling 8
10. Stator Centering 8
11. Grouting of Stator and Bearing 10
Pedestal
12. Assembly of End Shield 11
13. Shaft Seal Assembly 12
14. Bearing Assembly 13
15. Brush Gear Assembly 11
16. Erection of TG Auxilliaries 0
17. Assembly of Extension Shaft 14
Bharat Heavy Electricals Limited . ,

Rev. 00 Cft/*1-01320/1 of 18
GENERATOR ASSEMBLY SEQUENCE PLAN
TIME IN WEEKS
ACTIVITY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Preparation of foundation
Stator Placement - .
Assembly of Terminal Bushing

•"• ••
Assembly of Gas Coolers
Tests on Stator
Tests on Rotor
£
JT-T •
Rotor Insertion
••
Rotor Alignment with LP rotor
-
Reaming and coupling ••
Stator centering
Grouting of stator and Bearing Pedestal
Assembly of End Shield
Shaft Seal Assembly
'
Bearing Assembly
Brush Gear Assembly
Erection of T.G. Auxiliaries

Assembly of Extension Shaft
FOR REFERENCE ONLY

CUM^l GENERATOR
STEP NO. ACTIVITY

1 PREPARATION OF FOUNDATION
SUB-ACTIVITY
Checking of foundation
Checking and matching of

Embedded plates
Mounting of foundation plates
DR6. REF. NO.

6030 029
6030 018
5066 008
5066 021
5066 022
5066, 023
5066. 018
LOG SHEET NO.

FQA-03-00-01-L01(Sheet 1 to 4)
TECH.INSTRUCTION NO.
Preparation of Foundation G1-01-0101T
REMARKS/PRECAUTIONS
Bharat Heavy Electricals Limited G1-01-0132G/2 of 18

Rev. 00 10/93
GENERATOR
Erection MAJOR A C T I V I T I E S
STEP NO. ACTIVITY

2 PLACEMENT OF STATOR
SUB-ACTIVITY
Matching and fixing of Trunion plates
Lifting of stator and placement on foundation
Preliminary centering of stator
DRG. REF. NO.

0311.016
0-5516.006
5478.007
LOG SHEET NO.
Stator Placement G1-01-0102T
REMARKS/PRECAUTIONS
- Ensure Reliability of EOT crane for
its operation
- Healthinecess of endless slings

Rev. 00 10/93
rizHî GENERATOR
STEP NO. ACTIVITY

3 ASSEMBLY OF TERMINAL BUSHING
SUB-ACTIVITY
Hydraulic test of terminal bushing
H.V. test of bushing insulator
Assembly of terminal bushing
Soldering of terminal bars
Insulation of terminal connections
DRG. REF. NO.

0311.016
0311.059
1255.001
LOG SHEET NO.

FQA-03-00-01-LO2 (Sheet 5/6, 6/6)
Assembly of terminal bushing G1-01-0103T
Resistance measurement of stator G2-01-0101T
winding.
REMARKS/PRECAUTIONS

Rev. 00 fo#- 0 1 3 2 G / 4 o f 18
enr^n GENERATOR
STEP NO. ACTIVITY

4 ASSEMBLY OF GAS COOLER
SUB-ACTIVITY
Hydraulic test of gas cooler
Insertion of coolers
Centering and Assembly
DRG. REF. NO.

0311.016
6392.032
LOG SHEET NO.

FQA-03-00-01-L02, Sheet 5/6 (Item No.23)
Assembly of Gas Cooler Gl-01-0104 T
Hydraulic Test of gas cooler Gl-01-0126 T
REMARKS/PRECAUTIONS

Rev. 00 10/93
CiZIXai GENERATOR
STEP NO. ACTIVITY

5 TESTS ON STATOR
SUB-ACTIVITY
Visual Inspection
Resistance Measurement of Stator Winding,RTD
IR Value measurement of Stator Winding, RTD's
& header
Pneumatic and hydraulic test of stator wdg.
Air tightness of stator without rotor.
DR6. REF. NO.

6020.025 2-5670.073
6020.026 6030 016
3-6060.00
LOG SHEET NO.

FQA-03-00-01-LO2
Visual Inspection of Stator Gl-02-0105 T
Resistance Measurement of stator winding G2-01-0101 T
IR measurement of stator winding G2-01-0102 T
Electrical checking of Gen. RTD G2-01-0103 T
Pneumatic & Hydraulic test of Gl-01-0121 T
Stator winding
Air leakage test of stator Gl-01-0127 T
Procedure for slot wedge tightening G3-01-0106 T
REMARKS/PRECAUTIONS

Rev. 00 10/93
CiiT^l GENERATOR
STEP NO. ACTIVITY

6 TEST ON ROTOR
SUB-ACTIVITY
Visual Inspection
DC Resistance, Impedance and IR measurement
of Rotor Winding
Purge Test
Gas Tightness Test
DRG. REF. NO.

5675.010
LOG SHEET NO.

FQA-03-00-01-L03
(Item No. 3.1 to 3.6)
Visual Inspection of Rotor Gl-01-0106 T
Electrical Test on rotor G2-01-0104 T
Rotor purge test Gl-01-0107 T
Gas Tightness test of rotor Gl-01-0108 T
REMARKS/PRECAUTIONS
Rotor having forced cooling arrangement of slip-ring
are not required to be checked for Gas tightness test

Rev. 00 10/93
CHTtt GENERATOR
STEP NO. ACTIVITY

7 ROTOR INSERTION
SUB-ACTIVITY
Kerosene Test of rear bearing pedestal
Bearing Matching with housing.
Rotor insertion.
DR6. REF. NO.

1-0344-001 8340.035
6771.002
6771.003
5260.001
LOG SHEET NO.
FQA-03-00-01-L04
Rotor insertion and withdrawl Gl-01-0109 T

REMARKS/PRECAUTIONS
Ensure that all ventilating plugs and sealing tapes have

been removed from ventilating holes.

Rev. 00 10/93
CiZHZl GENERATOR
STEP NO. ACTIVITY

8 ROTOR ALIGNMENT WITH L.P. ROTOR
SUB-ACTIVITY
Rotor alignment
DRG. REF. NO.
LOG SHEET NO.

FQA-03-00-01-L05
Rotor alignment Gl-01-0111 T
REMARKS/PRECAUTIONS
Bharat Heavy Electricals Limited G 1 - 0 1 - 0 1 3 2 G / 9 Of 18

Rev. 00 10/93
ci?H£i GENERATOR
STEP NO. ACTIVITY

9 REAMING AND COUPLING
SUB-ACTIVITY
Reaming and Coupling
DRG. REF. NO.
LOG SHEET NO.

FQA-03-00-01-L05
(Sheet 8/12)
Reaming and Coupling G1-01-0112T
REMARKS/PRECAUTIONS

Rev. 00 10/93
r-fiTjfî GENERATOR
STEP NO. ACTIVITY

10 STATOR CENTERING
SUB-ACTIVITY
Setting of Magnetic Axis
Setting of Air Gap
DRG. REF. NO.
LOG SHEET NO.

FQA-03-00-01-L05
(Sheet 3/12) (5.8 - 5.12)
Stator Centering G1-01-0113T
REMARKS/PRECAUTIONS

Rev. 00 10/93
rxmni GENERATOR
STEP NO. ACTIVITY

11 GROUTING OF STATOR & BEARING PEDESTAL
SUB-ACTIVITY
Fixing of Permanent Packers

Grouting And Curing
DRG. REF. NO.
FOA REF. NO.

FQA-03-00-01-L05
(Sheet 4/12) (5.13)
Grouting of stator Gl-01-0114 T
and bearing pedestal
REMARKS/PRECAUTIONS

Rev. 00 10/93
CJIT£Zi GENERATOR
STEP NO. ACTIVITY

12 ASSEMBLY OF END SHIELD
SUB-ACTIVITY
Mounting of Fan Blades (Turbine End)
Pre Assembly of Lower Halves of Fan Shields
With End Shields
Final Assembly of Bottom Halves of Fan Shields
And End Shields
Hot Water Circulation in Stator winding
Final Assembly of Top Halves of Fan Shields
and End Shields
DRG. REF. NO.

0-5012.025
0-5013.005
5487.005
5487.006
LOG SHEET NO.

FQA-03-00-01-L05
(Sheet 4\12-5\12) (5.13, 5.15, 5.16, 5.17)
Assembly of Fan Shield, End Shield Gl-01-0115 T

and Fan Blades
Hot Water Circulation in Stator Winding Gl-01-0124 T
REMARKS/PRECAUTIONS
Bharat Heavy Electricals Limited G 1 - 0 1 - 0 1 3 2 G / 1 3 Of 18

Rev. 00 10/93
CIZFJ^t GENERATOR
STEP NO. ACTIVITY

13 SHAFT SEAL ASSEMBLY
SUB-ACTIVITY
Assembly of Oil Catcher (H2 Side)
Assembly of Shaft Seal
Assembly of Air Side Oil Catcher
Assembly of Seal Cover.
DR6. REF. NO.

(FOR THRUST TYPE) (FOR RING TYPE)
1-5372.010
2-5372.010
0-5371.002
LOG SHEET NO.
(FOR THRUST TYPE) (FOR RING TYPE)

FQA-03-00-01-L16 FQA-03-00-01-L05
(5.18,5.19)
TECH. INSTRUCTION NO.
Shaft Seal Assembly G1-01-0116T
IR Measurement of Generator Rear Bearing

Pedestal and Seal Body G1-01-0135T
REMARKS/PRECAUTIONS
FOR RING TYPE SEALS

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

Rev. 00 10/93
fTJZffifil GENERATOR
STEP NO. ACTIVITY

14 BEARING ASSEMBLY
SUB-ACTIVITY
Assembly of Front Bearing
Assembly of Rear Bearing
DR6. REP. NO.
5263.008
5264.002
LOG SHEET NO.

FQA-03-00-01-L05
(Sheet 9/12, 5.23)
Bearing Assembly G1-01-0110T

IR Measurement of Generator Rear
Bearing Pedestal and Seal Body G1-01-0135T
REMARKS/PRECAUTIONS

Rev. 00 10/93
£izrm GENERATOR
STEP NO. ACTIVITY

15 BRUSH GEAR ASSEMBLY
SUB-ACTIVITY
Assembly of Brush Gear

Assembly of Brushes
DR6. REF. NO.
5264.002
LOG SHEET NO.
FQA-03-00-01-L05
(Sheet No.10/12, 5.27, 5.28, 5.29)
Brush Gear Assembly G1-01-0117T
REMARKS/PRECAUTIONS

Rev. 00 10/93
CilT^l GENERATOR
STEP NO. ACTIVITY

16 ERECTION OF T.G. AUXILLIARY SYSTEM
SUB-ACTIVITY
Panel Erection
Equipment Erection
Piping Erecttion
Cleaning of Seal Oil, Gas System, Stator Water
System Piping
Pressure Test Of Gas System Piping and Rack
DRG. REF. NO.
LOG SHEET NO.
Erection of T.G. Auxiliaries G1-01-0136T
REMARKS/PRECAUTIONS

Rev. 00 10/93
CiTT^l
GENERATOR CHECKING O F FOUNDATION &
Erection MOUNTING O F FOUNDATION PLATE
Prior to starting the generator assembly, the entire foundation

should be thoroughly checked in detail for compliance with
foundation plan. This check ensures location of all embedded
parts as per drawing before mounting the equipment on foundation.
These foundations are designed for taking the total load of the
machine and various forces arising during its operation.
1.0 PRE-REQUISITE
After the foundations are cleared for its checking and

further assembly work, following jobs should be completed.
i) Ensure erection of temporary railings and covers to

prevent any accident due to fall.
ii) Remove all remaining construction materials lying

around and other obstacle materials to avoid any
accident.
iii) Cover all opening on TG floor.
2.0 CHECKS ON FOUNDATION
i) Check accuracy of site elevation and axillity of the

entire foundation as per drawing with the help of a
taut steel wire.
ii) Check all contact surfaces for burrs and dents
iii) Check all foundation openings, such as anchor bolt

holes, oil ducts, opening for pipe works and cables
etc. for its location and dimension.
Bharat Heavy Electrical* limited Qi-01-OlOlT/l of 3

Rev. 00 10/93
dCTJC^l GENERATOR
STEP NO. ACTIVITY

17 ASSEMBLY OF EXTENSION SHAFT
SUB-ACTIVITY
Placement of a Pedestal
Coupling of Extension Shaft
Centering of Pedestal and Grouting
Assembly of Aux Bearing
DRG. REF. NO.
LOG SHEET NO.
FQA-03-00-01-L06
(Sheet 12/12)
TECH. INSTRUCTION NO.

Assembly of Extension G1-01-0118T
Shaft and Auxiliary Brg.
REMARKS/PRECAUTIONS
SECTION - I
ASSEMBLY INSTRUCTIONS
CitTjra
GENERATOR CHECKING O F FOUNDATION &
Erection MOUNTING O F FOUNDATION PLATE
Prior to starting the generator assembly, the entire foundation

should be thoroughly checked in detail for compliance with
foundation plan. This check ensures location of all embedded
parts as per drawing before mounting the equipment on foundation.
These foundations are designed for taking the total load of the
machine and various forces arising during its operation.
1.0 PREREQUISITE
After the foundations are cleared for its checking and

further assembly work, following jobs should be completed.
i) Ensure erection of temporary railings and covers to

prevent any accident due to fall.
ii) Remove all remaining construction materials lying

around and other obstacle materials to avoid any
accident.
iii) Cover all opening on TG floor.
2.0 CHECKS ON FOUNDATION
i) Check accuracy of site elevation and axillity of the

entire foundation as per drawing with the help of a
taut steel wire.
ii) Check all contact surfaces for burrs and dents
iii) Check all foundation openings, such as anchor bolt

holes, oil ducts, opening for pipe works and cables
etc. for its location and dimension.
Bharat Heavy Electrical* Limited Q1-01-0101T/1 of 3

Rev. 00 10/93
Eizrm GENERATOR CHECKING O FOUNDATION &
Erection MOUNTING OF FOUNDATION PLATE
iv) Check, mark and record main referred point (Absolute

floor), level measuring points for height/elevation
against a foundation pillar. With reference to M s
point, check elevation of embedded parts and record
deviation.
Caution : Deviation on elevation should be strictly as per

logsheet.
3.0 CHECKS ON EMBEDDED PARTS
i) Check the location of embedded parts to longitudinal

and transverse axis of TG foundation and its elevationn
as per relevant drawing.
ii) Check the condition of embedded parts by knocking it by

a light hammer of 250 gms to ascertain that these form
monolythic structure with foundation. In case of any
voids or loose concrete layers, same should be
rectified as per civil recommendations.
Caution : Under no circumstances, there should be loose

concrete layers in the region where generator
rear bearing pedestal embedded parts are
installed.
iii) Check the inclination of embedded parts towards the

side where shims shall be inserted at a later stage for
its easy insertion. The inclination should be 4 to 5 mm
per meter.
Bharat Heavy Electricals Limited G1-01-0101T/2 of 3

Rev. 00 10/93
GENERATOR CHECKING OF FOUNDATION &
Erection MOUNTING OF FOUNDATION PLATE
iv) Check the surface of embedded parts with the level and
blue paint. Contact area shall not be less than 80%.
The surface, on which shims are to be inserted, should
be free for any burrs/dents.
4.0 MOUNTING OF FOUNDATION PLATE
The generator foundation plates are laid as per longitudinal

and transverse axis. Final dimension are to be recorded.
The support surfaces of the foundation plate should be

colour matched with surface plate so that the contact area
of more than 80% is achieved by scrapping.
Initially, these plates are to be installed on temporary

shims (wedge type) placed in the space between adjacent
embedded parts steel packing shims of thickness 2 to 5 mm
should be kept on its foundation plates to facilitate
alignment after grouting in future.

Rev. 00 10/93
CUTA^l GENERATOR
Erection PLACEMENT O F STATOR
The stator body of 210 MW generator is supported on foundation

with the help of four trunion plates bolted to the stator casing.
PRE-REQUISITE
1. Ensure that foundation plates have been mounted properly on

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

capacity of 120 MT each and capability of operation of these
cranes in tandem operation.
3. Ensure availability of specially fabricated lifting beam

with two endless slings of 80 mm x 20 MTS each for lifting
the stator frame.
4. Ensure that foundation bolts/anchor bolts are wrapped with

polythene cover and inserted in their respective holes (pipe
shims) .
PROCEDURE
Before the stator is lifted, the trunion plates should be

assembled to stator casing as mentioned below:
1.0 Assembly of trunion foot plate
Check the punching marks on trunions and identify for its

stator casing location.
Check the contact surface of trunion foot plates and pads on

stator casing for any dents and burrs.
Bharat Heavy Electricals limited G1-01-0102T/1 of 3

Rev. 00 10/93
CIZIJO GENERATOR
Check levelling of all pads with the help of a straight

edge/scale.
Check the size of threads of trunion plates fixing bolts and

holes on the stator casing.
Check the contact surface between trunion plate and stator

casing mounting flange with blue plate and ensure contact
area of more than 80%.
Assemble the trunion plate at its respective location and

tighten it by fixing bolts.
Caution : A filler of 0.03 mm should not pass anywhere on

tightening the trunion foot plate bolts with
stator including the pads.
2.0 Placement of stator on foundation
Before moving the stator to foundation, ensure cleanliness

of contact surface of foundation plate and stator trunion
foot plate and these should be free from any dents and
burrs.
Lift the stator by placing endless string on trunions and

lifting beam (supplied by customer for 2 EOT cranes
operation)
Caution : Lifting of stator body by placing slings at any

other part is not allowed.

Rev. 00 10/93
riiwî GENERATOR
Place the stator on foundation plate with shims in between.

Carryout the centering of stator bore w.r.t. string (piano
wire) stretched along logitudinal axis of TG. This is only a
preliminary centering as the final centering is done only
after rotor is inserted and same has been aligned with L P
rotor.

Rev. 00 10/93
CJTHÎ GENERATOR A S S E M B L Y O F TERMINAL
Erection BUSHING
In 200/210 MW TG Set, nine numbers of terminal bushings are

provided at the exciter end of stator casing in the terminal
chamber for taking electrical output connections to the bus duct.
Three numbers of terminal bushing are meant for phase side and
the six numbers for neutral side connection. These bushings are
direct water cooled and manufactured out of copper and insulated
with procelain insulators.
Pre-requisite
Check the physical condition of terminal bushing and insulator

for any damage during transportation.
Identify terminal bushing assembly for phase side and netural

side connections.
Dismantle the bushing assembly and separate terminal bar from

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

stator winding for non-magnetic property.
Ensure availability of testing equipments like micro ohm meter,

meggar 1 kv, hydraulic test pump and HV test kit.
Ensure availability of soldering and insulating materials

required for terminal bar soldering to the winding and its
insulation.
Ensure availability of heating arrangement required for heating

the joints to be soldered.

Rev. 00 10/93
Ei?n£i GENERATOR ASSEMBLY OF TERMINAL
Erection BUSHING
PROCEDURE
Before the terminal bars are bolted to the stator winding, it

should be hydraulically tested to detect any leakage point in the
terminal bar and porcelain insulator should be tested for high
voltage test.
1. Hydraulic test of terminal bar
Clean the terminal bar hollow portion by flushing it

thorougholy with/DM clarified water. Blank outlet nipple of
the bar and fill water from inlet nipple with the help of
hydraulic pump. Expell entrapped air by loosening the
blanking nut.
After ensuring the complete filling of water, raise water

pressure to 25 kg/cm 2 and maintain it for 1/2 hour. Check
all weld seams for any water seepage. No visible water
seepage and pressure drop is allowed during this test.
Caution : Terminal bar water path should cleaned with

compressed air immediately after the test and
openings should be closed.
2. HV TEST OF PORCELAIN INSULATOR
Clean the outer and inner surface of insulator thoroughly

and wrap a conductive foil along its entire outer surface.
Insert a cylinder like object made of copper/tin plate into
the bushing bore so that the cylinder is in contact with the
bushing liner surface throughout its entire length. The test
voltage of 25 kv (AC) for one minute (or 73 KV DC) should be
applied between bore cylinder and outer surface of bushing

Rev. 00 10/93
•s
€ITTAÎ
GENERATOR ASSEMBLY O F TERMINAL
Erection BUSHING
and leakage current should be recorded. After application of

high voltage for one minute duration, the outer surface of
bushing should be carefully checked for any black marks.
Caution : Before and after HV test, the IR between cylinder

bore and outer surface of bushing should be
checked by 2.5 kv/1 kv meggar.
3. Assembly of terminal bar.
Initially, the terminal bar alongwith the porcelain

insulator is trial assembled with the winding to check
proper centering of terminal bar w.r.to corresponding holes
in terminal chamber plate. Once the centering of terminal
bushing assembly is achieved, the terminal bars are fully
tightened with bolts and locking washers.
Caution : Ensure proper seating of tightening bolts and

washers on terminal bar mounting flange.
Remove the porcelain insulator after proper tightening of

terminal bar. The joints between bus bar and terminal bar
for all nine assemblies should be soldered as per procedure
mentioned as Annexure-I.
Caution : Check IR and DC resistance of stator winding

before connecting terminal bar, after bolting the
terminal bar and after soldering the joint.
Reassemble the porcelain insulator with sealing gaskets

after completing the soldering of joints and its thorough
cleaning. The fixing bolts of terminal bushing with stator
terminal plate should be locked properly.

Rev. 00 10/93
CiZKO GENERATOR ASSEMBLY O F TERMINAL
Erection BUSHING
Assemble teflon tubes/copper tubes provided for water

circulation in terminal bar for each bar assembly. Carry out
the hydraulic test of stator winding as per instruction No.
Gl-01-012IT to detect any water seepage from the varous
joints in water path of terminal bar and connecting bus bar.
Insulate the terminal bar joints as per instructions
detailed in drawing No. 1255.001C.

Rev. 00 10/93
rizraa GENERATOR ASSEMBLY OF TERMINAL
Erection BUSHING
Annexure - I
INSTRUCTIONS FOR SOLDERING OF TERMINAL

BAR WITH CONNECTING BUS BARS ON STATOR
WINDING AT SITE
1.0 INTRODUCTION
This instruction deals with the procedure of soldering of

terminal bushings with end terminals of stator winding at
site and various checks to be carried out before and after
soldering.
2.0 PREPARATORY WORKS BEFORE SOLDERING :
Remove procelain insulators from the terminal bushings.
Thoroughly clean joining surfaces of contact plates of

connecting bus bars of terminal bars taking utmost care not
to damage the tinning on their surface.
Measure d.c. resistance of stator winding between terminals

C4-1C1, C4-2C1, C5-1C, C5-2C2, C6-1C3, C6-2C3, which should
be identical.
Fix terminal bar with connecting bus bar using non-magnetic

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

compare the two results. The difference between any two
measurements should not exceed 3%.

Rev. 00 10/93
CiZTi^l
GENERATOR ASSEMBLY O F TERMINAL
Erection BUSHING
Ensure plugging of nipple connections of terminal bar and

connecting bus bar,
3.0 MATERIAL REQUIREMENT :
(As per packing list of package no 15T supplied by

manufacturing unit).
Solder (Sn 60) 60 Kg

IS 103-1966
Asbestos tape 400 meters
0.4x30 mm.
Asbestos cloth To be aranged at site.
Asbestos putty 40 Kg
4.0 SOLDERING PROCEDURE

Mix asbestos putty with water and apply in the viccinity of
joining surface followed by wrapping of two layers of
asbestos tape tightly over the same. Wrap the entire copper
bushing by asbestos cloth.
Heat the terminal bar using two gas torches from below i.e.
from the bushing projecting outside the stator body.
Feed solder wire from top keeping the same in touch with
joining surface. Once the solder starts melting, solder
should be continuously fed till it spills-over. Thereafter,
the heating should be stopped. Once heating is started, it
should not be stopped in between till soldering of one joint
is completed.

Rev. 00 10/93
fr/ZEca GENERATOR ASSEMBLY O F TERMINAL
Erection BUSHING
Allow the soldered joints to cool before removing asbestos

putty/cloth/tape etc. and do thorough cleaning of terminal
bar.
5.0 CHECKS AFTER SOLDERING :
Measure the d.c. resistance of stator winding between

terminals C4-1C1, C 4 - 2C1, C 5 - 1C2, C 5 - 2C2, C 6 - 1C3, C6
- 2C3.
Compare these with the values obtained before soldering. For

good soldered joint, d.c. resistance after soldering should
come down.
The difference in value of d.c. resistance measured before

connecting the terminal bushing and after soldering should
generally not exceed 3%.
Note : 1. The D.C. resistance may be measured either by using

double Kelving bridge or by micro-ohm meter. It is,
however important that same set of instruments should
be used for all the measurements.
2. While soldering flexible type connection for terminal

bushings, the spaces between elementary strips of the
flexible links should be filled up with asbestos putty
to avoid penetration of solder & consequent loss of
flexibility.

Rev. 00 10/93
SOISRING nr Fl FXIRLE CONNECTON
TO BE SOLDERED
FIG.
6l-ol-0i0ST
• •&•••*«? J*- /
-r*-f '-i£Kgc fi*.^'
^
Z£-$
CiTH^l GENERATOR ASSEMBLY O F GAS
Erection COOLER
In 200/210 MW TG set, 4 Nos of gas coolers are mounted

horizontally inside the stator casing. These coolers are inserted
into the windows provided in the stator casing for housing the
coolers. The cooling water flows through the tube while the gas
passes over the finned tubes and gets cooled.
1.0 Pre-requisite
1. Ensure that gas coolers have been taken out of stator

casing, if sent in assembled condition with stator.
2. Ensure that hydraulic test on each cooler has been

completed as per Instruction No. G1-01-0126T.
3. Ensure that gas coolers have been properly cleaned by

air.
4. Ensure that cooler housing chamber in stator casing has

been thoroughly cleaned for any dirt/foreign materials.
5. Check the condition of each roller for all gas cooles

for its freeness and its straight axle.
6. Ensure availability of all sealing gaskets of

propersize required during assembly of gas coolers.
7. Check the tightening of all bolts provided on water

base cover (front & rear).

Rev. 00 10/93
nrwî GENERATOR ASSEMBLY OF GAS
Erection COOLER
2.0 PROCEDURE
Slowly insert the gas cooler one by one in horizontal

direction into the windows of stator from excitor end with
the help of E.O.T. crane. During insertion, care should be
taken that position of the longitudinal rubber gaskets
between gas cooler and stator angles should be as per
relevant drawing.
After insertions, centre the gas cooler w.r.t. windows by

means of levelling bolts provided. Assemble the fixing frame
with sealing gasket on stator body and gas cooler body and
ensure proper locking of all bolts. Connect the inlet/outlet
water pipes and vent pipes as per drawing.
Caution: Ensure cleanliness of inlet/outlet/vent pipes

before connecting it to the gas cooler.
The vent pipe should be properly laid and a vent cock should
be provided at other end with proper water draining
arrangement.

Rev. 00 10/93
CJZFtt GENERATOR VISUAL INSPECTION
Erection O F STATOR
The Stator casign of 200/210 MW generator should be properly

checked before taking up the assembly of Stator and rotor. These
checks will ensure the healthiness of stator core, winding and
other components before it is finally assembled. Various checks
required to be carried out on stator are as follow:
1. Check presence of any foreign materials in :
(a) Gas Cooler Supporting Channels

(b) The Stator bore
(c) The space between stator core and casing.
2. Check for any visual damage to stator core.
3. Check that a l l t h e slot wedges a r e t i g h t . If required

tightness them as p e r instructions for "T.G. Stator Slot
Wedging. N o . G3-01-0106T".
4. Check for any damage to stator winding overhang and bus bar
connection visually. The terelyne cord bracing the bars with
binding ring and bars with one another, should not be broken
at any place and should have proper varnish applied on it.
5. There should not be any gap either between the layers at the
place of bracing or between the bracket and binding rings.
If any spacer has come out, it should be restored back after
putting proper packing and applying gluing material.
6: Check that n o b o l t of c l a m p i n g a r r a n g e m e n t of o v e r h a n g
support is loose. The packing in between the support and
brackets should be well tight and should not have any gap in
between.

Rev. 00 10/93
CiZXjfa GENERATOR VISUAL INSPECTION
Erection OF STATOR
7. Check that bolts for fixing the covers (Item 2,4,6 of Drg.
No. "5001, 027) which are used to block technological holes
in stator body are tack welded.
8. Inspect visually water headers, teflon tubes and insulation

of water headers.
9. Check the flanged connections of water header bushing with

intermediate and outer pipe line for proper tightness and
quality of sealing washers.
10. Check that washers are provided at connections of gas trap

line and main pipe line.
11. Check that the clamping of gas trap pipe with headers at
various places is alright and the same is no where
broken/missing.
12. Inspect the terminal bushings and their assembly visually.
(a) Check that the sealing washers provided are of proper

quality and the same are seating on the bushing face.
(b) The alignment of bushing should be correct so that the

sealing washer is pressed uniformly all over its
periphery.
(c) The bolts holding the bushing with stator casing should
be equally and well tightened.

Rev. 00 10/93
tIZTtt GENERATOR VISUAL INSPECTION
Erection OF STATOR
13. Ensure that following test on stator has been completed.
D.C. resistance and IR/PI of Winding.

Resistance and IR of RTD's.
14. Check that all technological bolts provided in core support

bars all around the periphery have been removed.

Rev. 00 10/93
CUTtt GENERATOR VISUAL INSPECTION
Erection O F ROTOR
The rotor is visually inspected to check its healthiness before

its insertion into stator during erection/overhaul stage of the
machine. During this checking, following points should be
specifically checked apart from various points mentioned in O&M
manual.
CHECKS DURING PHYSICAL INSPECTION
1. Inspect fan hubs and retaining rings for any chipping of

metal, dents marks, crack etc.
2. Inspect journal for pitting and scratches.
3. Inspect seal collars for pitting ans scratches.(For Thrust

Type Seals).
4. Check for position of all balancing weights as per

manufacturers' report and its proper locking.
5. Check locking of all 10 Nos screws in centering ring.
6. Check whether any foreign material is lying in ventilating

holes. Ensure to remove all plugs from the ventilating
holes.
7. Check for any blocking of ventilating holes in slip rings.
8. Check up unevenness and any defect on the sliprings.
9. Ensure that phyusical dimension of rotor have been recorded

in the relevant logsheet.

Rev. 00 10/93
riZTitw] GENERATOR V I S U A L INSPECTION
Erection OF ROTOR
10. Ensure that following tests on the rotor have been

completed.
purge test and gas tightness test.
DC resistance, impedance and IR of rotor winding.
Bharat Heavy Electricals Limited G 1 - 0 1 - 0 1 0 6 T / 2 of 2

Rev. 00 10/93
dEHSl G E N E R A T O R
Erection ROTOR INSERTION
The assembly of rotor into the stator casing is taken up after

thorough inspection of stator and rotor and completion of all
electrical and mechanical tests on stator and rotor. The assembly
of terminal bushing and its insulation should also have been
completed before taking up this activity. The rear bearing
pedestal including bottom half bearing and front bearing should
be made ready for its installation. Since, this activity involves
generator rotor lifting by the crane for its axial movement
inside the stator bore, following precautions should be taken
during handling of the rotor.
1. Protect all the machined surfaces from getting damaged.
2. Do not sling the bare surface. Cover the rotor with wooden
pieces (tied together) at the point of slinging. These are
supplied alongwith the rotor.
3. Keep the pole axis vertical.
4. Do not allow the rotor to rest on its slot wedges retaining

rings, sliprings or half coupling.
5. While inserting or removal of rotor, care should be taken

not to damage the stator overhang winding or rotor slot
wedges.
DEVICES REQUIRED FOR INSERTION AND REMOVAL OF ROTOR
All items necessary for threading in and removal of rotor are

suplied alongwith the set except item No. 14 (I-beam size 500 mm
x length 6 meters) . The list of items is given in the drawing
No.1-0344.001.

Rev. 00 10/93
ciZTjfia GENERATOR
PROCEDURE FOR INSERTION AND REMOVAL
There are six steps as shown in the drawing. The reverse sequence
has to be followd while taking out the rotor from the stator.
Step No. 1
1. Place card board item No. 19 and then item No. 3 into the
bottom of stator bore.
2. Install the rails item No. 6,7 & 8 on the slip ring side of
the foundation block as per sketch shown.
3. Mount the lower portion of the outer trolley item No. 9 on

the rails.
4. Connect the extension pipe item No. 16 to the half coupling.
5. Cover the shaft journals with card board item No. 11 and 13
and then with the aluminium sheet item 10 & 12.
6. Assemble the upper portion bracket of the trolley item No. 9

on the slipring side journal and trolley item no. 4 on the
turbine side j ournal.
7. Remove the fan blades from the fan hubs on the turbine side.
It is also preferable to remove fan blades of excitor end
side.
8. Assemble the wooden pieces item no. 5 on rotor barrel as

shown in the sketch, sling at this place and hold by crane.
9. Insert rotor upto maximum possible position.

Rev. 00 10/93
GENERATOR
S t e p Ho. 2
1. Bring the lower portion of the trolley item No. 9 under the
brackets and tighten them by bolts.
2. Lower the rotor and make it rest on the trollies item No. 4
and item No. 9.
3. Check the concentricity of the rotor with stator bore and

release the sling. Place the beam item No. 14 on the turbine
side.
Step No. 3
1. Insert crow bar item No. 15 into the hole of the rollers of
the outer trolley.
2. Push the rotor into stator with the help of crow bar till
the extension pipe comes out at the turbine end and it is
possible to sling the rotor.
3. Put the sling under the extension pipe.
4. Lift the rotor by crane till there is no contact of the

trolley item No. 4 with sheet item No. 3 placed in the
stator.
Step No. 4
1. Bring the rotor to the position shown under stage IV.
2. Allow the rotor to rest on the beam item No. 14, taking care
that the rotor does not rest on the stator.

Rev. 00 10/93
GENERATOR
3. Remove the extension pipe.
4. Put the sling under the half coupling and hold the rotor.
5. Move the rotor to the position where it is convenient to

remove the inner trolley (item No. 4 ) .
Step No. 5
1. By means of crow bar and crane, move the rotor till the half
coupling of generator and turbine meet.
2. Mount the lower half of bearing liner on turbine side.
3. Lower and place the rotor on the liner.
4. Remove the beam item No. 14 from the turbine side.
Step No. 6
1. Lift the rotor slightly on excitor end side by crane.
2. Place the beam item No. 14 on excitor side.
3. Allow the rotor to rest on the beam with spacers in between.
4. Release the lower part of the trolley item No. 9 and take
out the trolley.
5. Remove the rails and sheet item No. 3 and 19.
6. Mount the generator bearing pedestal.

Rev. 00 10/93
EIZTtt GENERATOR
7. Mount the lower half of the bearing liner.
8. Lift the end of the rotor by crane and remove the beam item
No. 14.
9. Allow the rotor to rest on the bearing half liner.

Rev. 00 10/93
INSERTION OF ROTOR
INTO STATOR
UAORAM-NI OM3MMV
H- —jjMa
FOR DIAGRAM -IK FOR DtAQRAM-V
INSERT "HE CROW BARS INTO THE HOLES IN THE ROLLERS OF THE OUTER BY MEANS Of CROWBARS AND CRANE TAKE THE ROTOR TO THE POSflTON
TROLLP'. WITH THE HELP OF THESE CROW BARS PUSH THE ROTOR INTO THE WHERE THE HALF COUPLING OF TURBINE & GENERATOR MEET.
STATOR TILL IT OCCUPIES THE POSITION WHERE IT IS POSSIBLE TO PASS THE MOUNT THE LOWER HALF OF THE UNER ON THE TURBINE SIDE.
SUNG UNOER THE PROJECTING PART OF THE EXTENSION PIPE (ITEM 16) LOWER THE ROTOR ON TO THE LINER
PUT THE SUNG UNDER THE PROJECTING PART OF THE EXTENSION PIPE REMOVE THE BEAM (ITEM 14)
UFT THE ROTOR BY THE CRANE TILL THERE IS NO CONTACT Of THE TROLLEY
(ITEM «! WITH SHEET (ITEM 3).
SCHEME OF PLACING THE WOOOEN PIECES
DIAGRAM IV
FOftDUGRAM-l
PLACE CARD BOARD (ITEM 19) 4 THEN SHEET (ITEM 3) WTO THE STATOR BORE
INSTALL THE RAILS (ITEM «.7&8) ANO MOUNT THE LOWER PORTION OF THE TROLLEY (ITEM 9) ON THE RAiLS
CONNECTTHE EXTENSION PIPE (ITEM 151 TO HALF COUPLING OF ROTOR
ASSEMBLE THE TROLLEY (ITEM 4) ON THE SHAFT JOURNAL ON THE TURBINE SOE. REMOVE TURBINE SOE FAN BLAQFS
ASSEMBLE THE WOOOEN PIECES (ITEM 5! ON ROTOR BARREL AS SHOWN IN THE SCHEME
ASSEMBLE THE UPPER PORTION OF THE OUTER TROLLEY (ITEM 9 BRACKET) ON THE SHAFT AT EXOTER SOE FKING OUTER TROLLEY ITEM 9
LIFTTHE ROTOR BY CRANE. CHECK WHEATHER THE ROTOfi IS HORiZONTAL
CARRY THE ROTOR INTO STATOR BORE AS SHOWN IN DIAGRAM ! ! -, 1—i
1
•z- . 1
rr i 1
DIAGRAM-!!
1
"ii-if
1
\i •
-J
FORCMAGRAM-IV
BRING THE ROTOR TO THE POSITION SHOWN IN DIAGfl IV
MAKE THE ROTOR REST ON THE BEAM TAKING CARE SO THAT IT DOES NOT
REST ON THE STATOR (WOOD PACKING MAY BE PLACED OVER THE BEAM IF
RECUSED.
DIAGRAM VI DISCONMECTTHE EXTENSION PIPE (ITEM 16)
PASS THE SUNG UNDER THE HALF COUPLING
LIFT THE END OF ROTOR.
MOVE THE ROTOR TO THE POSTION WHERE IT IS CONVEN€NT TO REMOVE
THE TROLLEY.
REMOVE THE TROLLEY (ITEM 4.).
TECHNICAL REQUIREMENTS
FOB DIAGRAM A\ WHILE INSERTING ROTOR INTO STATOR CARE SHOULD BE TAKEN AGAINST
1 BRING THE LOWER PORTION OF THE TROLLEY rTEM 9 UNDER THE BRACKET THE DANGER OF DAMABE TO OVERHANG OF THE STATOR WINDING & SLOT
ANO JOIN THEM 6* BOLTS WEDGES OF THE ROTOR
FOR DtAGRAM-Vl
2. LOWER THE ROTOR ANO PLACE ON THE TROLLEYS (ITEM 4 & 8). RETAIWNG RINGS ANO FANS SHOULD NEVER BE USED AS SUPPORTS.
PLACE THE BEAM (ITEM 14) ON THE EXCITER SIDE.
3 REMOVE THE SUNG SHAFT JOURNAL OF THE ROTOR SHOULD BE COVERED WITH CARD BOARO ANO
REMOVE THE LOWER PART OF THE TROLLEY (ITEM 9).
4 PLACE THE BEAM (ITEM 14) ON THE TURBINE SOE ALUMINUM SHEETS BEFORE FIXING TROLLEYS
LIFT THE ROTOR END 8 * CRANE.
WHEN THE ROTOR IS HELD BY ITS BARREL BETWEEN THE SUNG ANO. BARREL
MAKE THE ROTOR REST ON THE BEAM WITH SPACERS IN BETWEEN
WOOOEN PIECES SHOULD BE INTRODUCED
TAKE OUT THE TROLLEY (ITEM 9)
ROTOR SHOULD NOT BE ALLOWED TO REST ON THE PROJECTING PARTS OF
REMOVE THE RMLS AND SHEET (ITEM 3)
MOUNT THE PEDESTAL OF THE BEARING. THE ROTOR WEDGES
MOUNT THE LOWER HALF OF THE BEARING UNER
INSERTION Of ROTOR INTO STATOR LFT THE END OF THE ROTOR BY CRANE.
REMOVE THE BEAM (OEM 14)
MAKE THE ROTOR REST ON THE HALF LINER OF THE BEARING
Gl-ol-olo$T
GENERATOR
Erection BEARING ASSEMBLY
The Rear end bearing of generator is assembled as per following

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

pedestal for 24 hours to ensure that there is no leakage
prior to rotor insertion.
2. Ensure that foundation plate is free from dents, burrs and

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

surface of the foundation plate.
4. Check the contact between foundation plate and bearing

pedestal (without insulating shim) and without tightening
the bolts. A feeler gauge of 0.05 mm should not pass
anywhere. If necessary, the contact surfaces are to be
carefully scrapped.
5. Check the contact surface between the bearing pedestal and

the cover when the bearing cover is freely placed on the
pedestal.
6. Check the contact surface between the bearing liner top half
and bottom half and ensure contact as per logsheet no. FQA-
03-00-01-L04.
7. Ensure the contact betwen the bearing pedestal and bottom

half bearing liner and top cover and top half liner by
rotating the liner in the pedestal and top cover
respectively.

Cjj^l-OllOT/1 of 3
Rev. 00
GENERATOR
8. Ensure cleanliness of the holes for the RTD's inside the

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

the sides (left and right) and at top should be maintained
as per FQA log sheet No. FQA-03-00-01-L-05 sheet 9/12 (SI.
No. 5.23)
10. After insertion of rotor into the stator, the position of

bearing pedestal is finally fixed as per the FQA log sheet
No. FQA-03--00-01-L-05 (Sheet 9/12).
11. The correctness of the bore of the liner is checked as per

shaft journal and the lower half of the liner should be
uniform and of equal width along the complete length of the
liner.
12. The oil gaps between the rotor journal and bearing liner at
sides (left and right) and top are maintained as per FQA log
sheet No. FQA-03-00-01-L-05 (sheet 9/12, SI. No. 5.23).
13. Before, finally lowering the rotor onto the bearing liner on
the excitor side, check the insulation resistance between
the bearing pedesal and the foundation frame and record.
14. Assemble the bearing liner and record the gaps.
15. Mount the bearing cover after completing the assembly of the
shaft seals.
Bharat Heavy Electricals Limited G1-01-0110T/2 Of 3

Rev. 00 10/93
CITFtt GENERATOR
16. Assemble oil catcher and maintain clearance as per FQA

log sheet No. FQA-03-00-01-L-05 (Sheet 9/12).
17. Assemble front bearing as per drawings and log Sheet No.
FQA-02-00-09-L04 of steam turbine check list.

Rev. 00 10/93
EITFtt GENERATOR ALIGNMENT O F GENERATOR
Erection ROTOR WITH L P ROTOR
Correct alignment of generator rotor with respect to turbine

rotor is most important for satisfactory operation of the turbo-
set. The two shafts are aligned along the line of their natural
deflection so that there is no break in the bending lines of the
individual rotors at the couplings. The criteria for the correct
alignment is
The identical radial position of associated coupling

and
Parallelism of the coupling flange faces at both

ends.
1.0 PRE-REQUISITE
Following should be ensured before alignment.
a) Ensure blue matching of babbit surface and rotor

journal of inboard and outboard bearing and blue
matching of spherical seating of bottom bearing half
of out board bearing and bearing housing and
bearings pads of in board bearing with bearing
housing.
b) Ensure minimum 2 mm shims alongwith insulation sheet

between pedestal and frame is provided.
c) Matching of foundation bolts anchor plate with

foundation block of rear bearing pedestal.
d) Blue matching of embedded plate with permanent

packers.
Bharat Heavy Electrical* Limited G i - Q l - O l l l T / 1 of 3

Rev. 00 10/93
tiTH^l GENERATOR ALIGNMENT OF GENERATOR
Erection ROTOR WITH LP ROTOR
e) Before joining the two coupling face required radial

gap between male and female spigot depth with male
spigot of projection should be checked.
f) Ensure condenser is filled up with water before

alignment in case of TG rotors coupled with LMW
turbines.
2.0 PROCEDURE
Prior to alignment work, the runout check of both half

couplings (turbine and generator) in radial and axial
direction is performed. By means of these checks, it is
possible to ascertain whether the outer circumferences of
two couplings donot feature any runout relative to the
shafts and whether the mating end faces are at right
angles to the shaft. Any minor manufacturing tolerances
measured should be taken into account accordingly while
numbering the coupling holes of both shafts to indicate
their final position relative to each other. The
alignment of both rotors should be carried out now in a
position in which they are to be coupled together.
The measurement of radial gaps is done by a dial gauge

and where a dial gauge cannot be used be cause of the
small clearnces in the bearing housing, a special
measuring device is fabricated and installed permitting
the gap measurement by means of a feeler gauge. Both
rotors are rotated by 90° and a four set of readings are
taken.
Bharat Heavy Electricals Limited 1-0111T/2 of 3

Rev. 00
rnxcTi GENERATOR ALIGNMENT OF GENERATOR
Erection ROTOR WITH LP ROTOR
The measurement of axial gap is also done at 4 positions

(90° apart) of rotors. 3 sets of reading (left, right and
Top) are taken between the two half couplings at each
position of rotor using feeler gauge. The 4th recording
(at bottom position) is normally calculated by using the
formula i.e. the sum of two measured values in the
horizontal plane must be equal to the sum of the
two measured values in the vertical plane.
A check for correctness of the entire measurement is

normally applied by bringing the device to the top
position again and checking the axial and radial gaps
once again in this position. Various readings are
recorded in the Log sheet No. FQA-03-00-01-L05 (point no.
5.2). The difference between average distances between
the end faces of the coupling in vertical and horizontal
plane and radial gaps in vertical and horizontal plane
should not exceed those specified in the log sheet.
However, if it is more, suitable adjustment of generator
bearings are carried out to obtain the desired results.
Bharat Heavy Electrical* Limited G1-Q1-0111T/3 of 3

Rev. 00 10/93
CiZEfal GENERATOR
Erection REAMING AND COUPLING
The generator rotor is coupled with LP rotor after aligning the

axis of both shafts. During alignment process, coupling faces of
both shafts are checked for parallelity of coupling faces and the
rotor axis are made concentric while coupling the shaft. It must
be properly ensured that maximum runout position of one coupling
face is coupled with min. runout position of other face and
aligned position of the shaft does not get disturbed.
1. 0 PROCEDURE
Check the coupling face for presence of any

dents/burrs and its cleanliness,
Bring the generator rotor closed to LP rotor and

match the holes concentricity to the extent
possible.
Tighten four diagonally opposite loose fit bolts.
Mount three dial indicators on «£fe coupling to check

any disturbance in the rotp.r alignment during
tightening process.
Ream the remaining holes with ifijitable fixture not

provided by BHEL).
Ensure the ovality and taper ®f finished holes are

with in 0.01 mm by honing proqsgs.
Check dia of finished holes mmo prepare the bolt

size with in 0.02 mm less th£tn finished hole size
and equal the weight of bolt£ j«th nut and washer
CJUTJC<1 GENERATOR
Erection REAMING AND COUPLING
for diagonally opposite holes and mark for hole

numbers and record as per Log sheet no. FQA-03-00-
01-L.05 (sheet. 8/12)
Fit these bolts in the reamed and corresponding

holes and tighten it by hand.
Remove the four loose bolts and ream these holes and
prepare the bolts for these holes also.
Fit all the bolts and tighten it.
Elogate all the bolts by tightening and record the

elongated length and elongation values as per log
heet no. FQA-03-00-01-L05 (Sheet 8/12)
Secure the coupling bolts by its proper caulking and

assemble the cover plate and pruck punch it. (For
sets coupled to KWV Turbine only.
Bharat Heavy Electricals limited

Rev. 00 ^Lj7^-0112T/2 Of 2
EIUJETl GENERATOR
Erection STATOR CENTERING
The stator of generator is required to be centered with respect

to rotor to have uniform air gap all around the rotor inside the
stator bore. This is done after finalising the position of rotor
after its alignment with LP rotor. During this process, three
main activities are required to be done:
(i) centering of stator with respect to generator rotor.
(ii) Measurement of air gap
(iii) Setting of magnetic off-set.
1.0 PROCEDURE
1.1 Centering of stator with respect to rotor:
After completion of generator rotor alignment with LP

rotor, measure the value of radial gaps between the rotor
and stator bore at four points 90° apart on turbine and
excitor sides. The gaps can be made uniform by moving the
stator radially with the help of four hydraulic jacks
placed between the casing and foundation. Its final
values should be recorded in the Logsheet No FQA-03-00-
01-L05 (Sheet 3/12).
1.2 Measurement of air gap
After centering stator w.r.to rotor, air gap should be

measured between rotor barrel and the stator core (1st
packet) radially at minimum four points 90° apart on
both side (i.e. Turbine and exciter end) with the help of

Rev. 00 10/93
CIZTtt GENERATOR
a suitable device (not supplied by BHEL) and should be

recorded in the Logsheet no FQA-03-00-01-L-05 (sheet
3/12)
l.3 Setting of Magnetic Axis
The centre axis of stator are kept at the off set from
rotor centre axis towards exciter end to compensate
thermal expansion of rotor while the machine is in
operation. For this, measurements should be taken between
stator end core packet and rotor retaining ring and as
shown in the Log sheet no FQA-03-00-01-L05 (sheet 3/12)
on both turbine and exciter ends. To achieve the required
value the stator should be shifted anially with the help
of two hydraulic jacks placed between stator casing and
foundation frame.
After finalising the position of stator w.r.to rotor

axially and radially, packer plates as per the gaps
between embedded plate and stator foundation plates are
prepared and inserted.
Note : The contact surface of the shims with embedded

plate and the foundation plates should not be less than
80% of the total surface area and packer thickness should
not be less than 25 mm.
Foundation both should be fully tightened keeping dial

indicators on stator frame to check any movement of
stator during tightening process. All the nuts should be
locked by tag welding.

Rev. 00 10/93
CiTT^l GENERATOR
Caution : Final rotor alignment should be again checked

before releasing it for grouting.
Anchor bolts should be tightened and locked by means of

tag-welding.
The stator body should be earthed by welding the earthing

contact assembly on the trunion foot plates and
connecting it to earthing grid of the station.
Bharat Heavy Electricals Limited <jj^gl-0113T/3 Of 3

Rev. 00
tJZFtt GENERATOR GROUTING O F STATOR,
Erection BEARING PEDESTAL
Grouting of stator foundation plates, bearing pedestal,

foundation frame with shrink-free grouting compound is intended
to ensure uniform transmission of the force and vibration of the
TG unit to the foundation.
Caution : Preparations for grouting, and grouting must be carried

out with great care as it is no longer possible to
check and rectify the parts once they have been
grouted.
CONBEXTRA GP-II should be used as grouting compound. Further

details on the grouting depths, mixing time, quantity of water to
be mixed, should be refered from the manufacturers brochures.
1.0 PROCEDURE
The foundation should be thoroughly cleaned. All foundation

bolt holes should be either filled with sand or pea-gravels
and covered at the top to avoid entry and sticking of
grouting materials with the bolts.
Note : Remove all rust preventive paints, grease etc from

surfaces by wire brushes to ensure proper adhesion of
the grouting compound.
1.1 SETTING UP OF SHUTTERING
Set up shuttering from suitable material in box like manner

around the foundation plates and secure it firmly.
Note : Shuttering must be sealed well to prevent the liquid

grouting compound from running out.

Rev. 00 10/93
ClZIJCl GENERATOR GROUTING O F STATOR,
As the grouting compound remains workable for a limited

time, to prevent air bubbles, it must be poured from one
side only. For this, a large size filling nozzle should be
used.
1.2 PREPARATION OF GROUT MIX
Following measure must be taken before commencing mixing and

grouting due to limited time that the grouting compound
remains workable.
Keep the foundation moist for at least 6 hours before the

grouting.
Set up mixers in the immediate vicinity of the

foundation plates. The capacity of the mixers, should
be adequate to cope with the quantity of mixed cement
required at a time. Two mixers are required for
grouting of bearing pedestal foundation frame.
Store the grouting compound next to mixer.
Ensure that the compound is well within its expiry

date.
Provide the water hose and measuring pans near the

mixers.
Ensure un-interrupted power supply to the mixers and

EOT Crane for handling the ready mix.
Provide adequate workmen for grouting.

Gl-01
Rev. 00 n>/93
filial GENERATOR GROUTING OF STATOR,
Complete alignment of stator and rotor is to be checked

and ensured before grouting.
Ensure six empty cubes for filling the grout for

strength testing.
Add water slowly to the mixtures or grouting compound in the

mixer (s) in exactly the quantities specified and mix
thoroughly for another 5 minutes atleast. Pour the mix with
buckets or with the help of a specially fabricated container
fitted with a hose through the filling nozzle until the
desired height is achieved at the opposite side. Flow may be
accelerated by moving the grout in the filling nozzles
underneath the plates with chains or material strips.
CAUTIONS
1. Do not use concrete vibrator
2. Pour grout from one side only so that no air bubbles

remains entrapped in the grouting compound.
3. Due to short workability times, never mix more grouting

compound at one time than is required for one plate or
volume to be grouted.
4. Pour in one continuous operation, without interruption.
5. Dox not install any woven steel fabric reinforcing mats

beneath the foundation plates.

Rev. 00 10/93
GENERATOR GROUTING OF STATOR,
2.0 GROUTING OF STATOR FOUNDATIONN PLATES
As the gap between stator foundation plate pads and embedded

plates is kept approx 50 mm, above method of grouting can be
followed straight away,, where the gaps are found to be more
than 70mm, pee-shaped gravels, collected from siever sand
are to be mixed in the required proportion to the grouting
mix while mixing.
Note : Sample mix must be filled up in cubes available

for the purpose of checking comprehensive strength
as per civil engineering norms and sent to the
laboratory (24 hrs), 3 days and 20 days tests).
3.0 GROUTING OF BEARING PEDESTAL FOUNDATION FRAME
The gap between the foundation frame and the embedded plates
is also 50 mm. Thereafter, filling the foundation frame
inner boix and its encasing from outside is carried out.
As such, grouting of the bearing pedestal foundation frame

can also be executed in two stages.
Stage - I
The front gap is filled up as mentioned above.
Stage - II
After approx 12 hours of stage - I grouting completion, when

the grouted material has become sufficiently hard, the
second stage grouting is carried out. In addition to grout

Rev. 00 10/93
Eiiffl^l GENERATOR GROUTING OF STATOR,
mix and requisite quantity of water, washed pea gravel 3-7

mm in size are also added upto 50% by weight and the mix is
prepared by thoroughly mixing in the mixer atleast for 5
minutes. Further, grouting is done as mentioned above.
Note : After atleast 24 hours hardening time, work may be

commenced on pre-tensioning of the foundation
studs to the values given in the logsheet No. FOA-
03-00-01-L-05 (sheet 4/12) .
After the grouting compound has dried out (approx 24 hours

after grouting), remove all shutterings and smooth off the
excess grout. Re-check the alignment of rotor and centering
of stator. The grouting compound is subjected to compressive
forces only. Resultant hair cracks are insignificant with
regard to TG stability provided these do not lead to
breaking of the grouting compound.

Rev. 00 10/93
CUKEI GENERATOR gô SHIELD AND FAN
Erection SHIELDS ASSEMBLY
GENERAL
The end shields are fabricated from mild steel and are made up in
two halves for convenience during erection and inspection. To
make the stator body gas tight at the two ends, two endshields
are 'fitted with the help of bolts and rubber sealing cord.
Aluminium alloy casting of fan shield is supported on end shield
to direct the gas flow from the propller fan. During the erecion
stage, end shields assembly is done twice, once before rotor
insertion for gas tightness test of stator and other after rotor
insertion. Final assembly of end shields is done together with
fan shields.
PRE-REQUISITE
1. Ensure blue matching of end shield parting plane joints.

2. Ensure proper size and freeness of end shield fixing bolts.
3. Ensure rubber sealing cord is free from cut marks, twist,
and is of proper quality and size.
4. Prepare rubber sealing cord joints as per Instruction No.
Gl-01-0125 T and fix them in position on the end shields.
5. Ensure cleaning of all drain pipes of generator casing by
blowing dry compressed air and cleaning of generator asing
bottom portion. It should be free from all foreign
particles/dust etc.
PROCEDURE
A. Assembly of end shield without rotor
A fixture is normally supplied to assemble end shield when

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

Rev. 00 10/93
GENERATOR gj^, SHIELD A N D FAN
be fabricated from stator dummy plate as per BHEL drawing.

Fix the end shield mounting device with stator in bottom
position with four bolts. Fix the bottom half end shield on
the fixture. On rotation, using crane, bring the bottom half
end shield slowly to the bottom position. Remove the above
fixture.
Fix rubber cord (12mm x 12mm) on horizontal portion (parting

plane) of end shield and place the top half end shield to
sit on jacking screws, which are to be projected 2/3 mm
above the rubber cord top level. Position top half fitting
dowel pin bolts of horizontal joints. Lower end shield top
on the bottom halfslowly by unscrewing jack screws, ensuring
rubber cord intact in its position. Tighten all the parting
plane bolts only after fully tightening the dowel pin bolts.
Cut the excess projected parting plane rubber cord on both
ends so as it projects out by 2 to 3 mm on either ends. Then
bolt the combined end shield to the stator.
B. Assembly of end shield with rotor in position
The bottom half end-shield is assembled temporarily using a

special fixture device received from BHEL Hardwar. Bottom
half fan shield is assembled and aligned in position to get
the required fan blade gaps and bolted tightly with bottom
half end shield using four bolts only. Then bottom half end
shield alongwith bottom half fan shield is taken out and fan
shield bottom is tightened fully with the remaining bolts
and locked after ensuring IR between end shield and fan
shield. Dowel holes between end shield and fan-shield bottom
halves to be re-reamed and dowel pins are fixed.

Rev. 00 10/93
CUTA^M GENERATOR END SHIELD AND FAN
Now, the bottom half end shield alongwith fan-shield is

assembled. Top half fan-shield is fixed to bottom half fan
shield ensuring required fan blade gaps and IR between two
halves of fan shield. Now, the top half end shield is
assembled as described earlier.
Precautions
1. Ensure proper fixing of the rubber sealing cord in its

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

flow test of teflon tubes of water header should be
completed as per Instructions No. G1-01-0124T
3. The dowel pin bolts on the horizontal joints of the two

halves of end shield should be fully tightened before
tightening of other bolts on the horizontal joints.
4. The fastners of end shield to stator should be tightened

sequentially as per log sheet no. FQA-03-00-01-L-05 (Sheet
5/12) .

Rev. 00 10/93
tJZFtt GENERATOR MOUNTING O F SHAFT SEAL
Erection (THRUST TYPE)
The Shaft seal is mounted after the generator rotor has been
inserted as well as the lower half of the bearing is in position
and after installation of the components to be accommodated in
the hydrogen space of the generator housing, e.g. fan shield, end
shield, etc.
Oil catcher & seal body on the exciter side are insulated from
the end shield to prevent the flow of shaft currents. Similarly
all pipes connected to the shaft seal body on the exciter side
are also insulated from earth. The insulation resistance should
be checked every time after assembly making sure that the
generator rotor has no connection to earth. This is to be checked
during the insulation check before generator rotor is coupled to
the turbine rotor. The value of the insulation resistance should
not be less than lM-ohm.
Before mounting the shaft seal, the contact surfaces between the
two halves of the seal body, seal liner and oil catchers are
checked. It should be ensured that for every cm square of the
surface threre are atleast three points of contacts and scraping
to achieve this should be adopted, if necessary.
1.0 GAS TIGHTNESS TEST OF SHAFT SEAL COMPONENT
Prior to assembling shaft seal, gas tightness of the seal

bodies is checked by joining them at their flanges of bigger
diameter with sealing gasket in between. Flanges of smaller
diameter and also flanges of feed and drain oil pipes are
closed with steel cover plates of thickness, not less than
16mm and rubber sealing gaskets. The leaks are detected by
soap solution. Seal bodies are considered to be gas tight if
Bharat Heavy Electncals Limited G1-01-0116T/1 of 6

Rev. 00 10/93 "
cizraa G E N E R A T O R MOUNTING OF SHAFT SEAL
Erection (THRUST T Y P E )
the pressure drop for a period of one hour is not more than
5mm of mercury column with the initial pressure of air at 3
atm gauge inside.
2.0 ASSEMBLY & FIXING OF OIL CATCHER
Before fitting the oil catcher ring in position, insulating

washer (of PVC sheet) is inserted over the rotor shaft and
placed on the end shield and joint is glued uniformly. Lower
half of the oil catcher is first taken in position and the
upper half is fixed on the split surface, by bolts and nuts.
The oil catcher is installed with oil outlet holes downwards
and fixed together with insulating washer on the end sheild,
maintaining uniform gap between oil catcher and rotor shaft.
3.0 FITTING THE SEAL BODY & LINER
To ensure proper performance of the shaft seals, the annular

gap of the seal liners must be concentric relative to the
shaft. For this purpose, the flange face of the seal body at
the stator end must be straight in itself, at right angles
to the shaft and exhibit no inadmissible joint displacement,
Otherwise, the result may be distortions or tilting of the
seal body and seal liner relative to the shaft with adverse
effect on the performance of the shaft seals.
Before separating the halves of seal body and liner for

further assembly operation, the matching diameters on both
of them are checked. After the insulating gasket is glued
over the end shield surface, the lower half seal body is
carefully inserted between the end shield and bearing
pedestal and preliminarily fixed to the end shield. The seal

Rev. 00 10/93
CIZTtt GENERATOR MOUNTING O F SHAFT SEAL
body is centered with respect to the rotor shaft with an

accuracy 0.1mm. Finally the lower half seal body is fixed to
the end shield by tightening the bolts fully.
In case any burrs or compression marks having been developed

due to improper storage the babbit surface of liner must be
scraped and checked with surface plate. There should not be
less than 10-12 spots per 25mm. square area. Then the colour
matching check between the shaft collar side and the liner
babbit surface should conducted. For this purpose after
applying of the dye on the shaft collar, lower shaft seal
liner is inserted first in the lower half seal body and the
upper half seal liner is then placed and fixed together. Now
the seal liner is pressed towards the shaft collar by
inserting wooden wedges between lower half body and seal
liner. The tightness of contact is checked by means of
feeler gauge inserted between the matching surfaces which
should not exceed a gap of 0.03 mm. After ensuring proper
contact, the shaft is rotated by 2-3 turns with the help of
crane or shaft turning gear. In case of necessity, the
babbit surface is rescrapped so that in every square of
surface area, there are at least four prints of contacts.
While scraping is carried out, two halves of the seal liner
are kept in assembled condition and cloth is placed between
the liner and seal body and also between the shaft and
liner. Then the shaft collar surface and seal liner are
washed in kerosene and cleaned properly.
The resistance thermometers and all deflecting rings are

fitted in position when the above operations are over. After
achieving the required gap between rotor shaft and all
deflecting ring, the screws are tightened finally to fix the
Bharat Heavy Electricals Limited „„ _ ^„ , . ^_

0116T/3 of 6
Rev. 00 %-M-
CiZUSl GENERATOR MOUNTING O F SHAFT SEAL
later. Now after fixing the sealing cords in respective

grooves, the lower seal liner is placed on the lower half
seal body. The upper half liner is then fixed together at
the split surface ensuring no relative displacement. The
free ends of the sealing cords are joined consequently.
Before mounting the upper half seal body, the split surfce
of the lower half is cleaned and sealing rubber cord is
placed and glued in the groove provided for it. It is to be
taken care that the rubber cord and the sealing gasket are
not damaged while fitting the upper half seal body at the
split surface and to the end shield in turn. A stopper screw
provides inter locking between seal liner and seal body to
prevent relative axial movement between the same in vertical
plane beyond the value specified. Now the RTD wires are
fixed on the seal body keeping sufficient loose length so as
to take into account the axial movement of liner with rotor
shaft.
Finally, one tapered hole is to be reamed together on seal

body and end shield to fit a conical set pin which helps in
locating correct position of seal body with respect to end
shield for satisfactory mounting.
4.0 INSTALLATION & FIXING OF SEALING RINGS
After successful completion of above mentioned stages, the

bearing pedestal and liner are cleaned for the absence of
foreign particles & dirt. Now the bearing cover is fitted
and the PVC sheet gasket for sealing ring is placed on the
bearing body and glued at joints uniformly. The lower half
sealing ring is preliminarily fixed with the bearing body
Bharat Heavy Electrical* Umhed Gj^-0116T/4 of 6

FiSXCTl GENERATOR MOUNTING O F SHAFT SEAL
through the gasket with two steel ring sectors, the steel
tape and sealing cord placed already in the groove provided.
The free ends of the sealing cord are then joined with the
help of steel. On the other hand the remaining two steel
ring sectors are placed in the groove of upper half sealing
ring and fixed in position by screwing through the side
holes. This upper half is now mounted, preliminarily fixing
it with the bearing cover and taking care of the sealing
cord and steel tape in position. The RTD wires are taken out
through the side hole provided. After final fixing of split
surface and with bearing cover in turn, the sealing cord is
to be pressed by 1.5 to 2 mm uniformly along the periphery
with bolts through the holes provided on the outer sealing
ring surface. Now the RTD wire outlet is sealed by placing
insulating washer, sealing washer and sealing gland
respectively and the wires are taken to the terminal box
mounted on the seal body.
5. 0 SALIENT PRECAUTIONS TO BE OBSERVED
5.1 Stopper screw:
Check the physical conditions of the stopper screw (item No.

31 of shaft seal Drg. No. 2-5372.010C) and its fitting holes
in seal liner/body for absence of any cut marks/foreign
particles, at each occasion when the shaft seals are
reassembled after disassembly of the same during a planned
shut down or other occasion. The absence of above screw
results in lowering of the thrust oil pressure and furhter
H 2 gas leakage from that end of the shaft seal.

Rev. 00 10/93
r/TiJO GENERATOR MOUNTING O F SHAFT SEAL
5.2 Interchange of turbine end and Exciter end and seal liners
Oil starvation in the seal may be caused by wrong assembly

of seal liners viz inter-change between turbine end and
exciter end seal liners having direction of the taper lands
on the seal face related to direction of rotation of rotor
shaft collar. This results in seal babbit temperature
reaching to a value more than 75°C.
Therefore, utmost care should be taken so as to avoid

intermixing of the seal liners of TG sets. The correct
direction of taper lands (on seal liner face) with reference
to direction of rotation of TG rotor is shown in Fig. l.A.
Close study of the disposition of taper lands on seal liner
faces of turbine and slipring end seal liners will help in
correct seal assemblies and their proper performance.

Rev. 00 10/93
EIEIiO GENERATOR MOUNTING O F SHAFT SEALS
Erection (RING TYPE)
The assembly sequence for mounting of shaft seals as mentioned

below may be considered as a guide, required measurement as
called on erection log sheets or elsewhere need to be done during
appropriate assembly stages as called for :
1.0 ASSEMBLY SEQUENCE
1. Mount lower half hydrogen side oil catcher, after

having glued in position, gasket between end shield and
the oil catcher.
2. Now assemble upper half hydrogen side oil catcher.
3. Assemble bottom and top half air side oil catchers.
4. Assemble lower half seal body.
5. Mount lower half seal ring and locate the stopper on

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

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

need to be taken to rotate the lower half from top to
bottom position so as not to interfere with hydrogen
side seal oil drain pipe flange.
8. Mount upper half seal cover on the lower half.
9. Finally assemble header.

Rev. 00 10/93 "
rizij£a GENERATOR MOUNTING OF SHAFT SEALS
2.0 GENERAL
When installed, the seal rings must be movable in both the

radial and axial direction. Check for the necessary-
clearances. If deviations are detected, reworking may be
necessary.
3.0 Assembly Checks
The annular gap of the seal rings must be concentric

relative to the shaft i.e. the face for the seal ring
carrier i.e. seal body at the end shield must be perfectly
flat, at right angles to the shaft and exhibit to
inadmisible joint displacement.
If these conditions are not obtained, the result may be

distortions or tilting of the seal ring carriers i.e. seal
bodies and seal rings relative to the shaft with adverse
effects on the performance of the shaft seals.
The maximum deviation from the correct annular position with

respect to the shaft must not exceed 0.2 mm.
While checking the flange surface make sure that the face is
not distorted in-spite of being at right angles to the
shaft. Such distortions shall not exceed 0.05 mm.
The joint displacement can be measured by checking joint

between the upper and lower seal body halves. The value
obtained must not exceed 0.03 mm if deviations are measured
which exceed the specified value, reworking will be
required.
Bharat Heavy Electricals Limited G ^ l - O l i e T / 2 of 4

Rev. 00
CiZHul
GENERATOR MOUNTING OF SHAFT SEALS
If any burrs or compression marks have developed due to

improper storage, rescrape only the affected portions.
After cleaning, checking and assembly insert the seal into

the chamber of the associated lower half carrier i.e. seal
body making sure that the locating pin is in correct
position. Put the upper half carrier (seal body), insert
taper pins and grub screws & tighten them. Measure the axial
clearane (chamber clearance) on the entire circumference
with a suitable feeler guage.
Nominal Ring Axial Clearance

size
400 mm 0.17 + 0.03 mm
Any raised portions in the seal ring carrier shall be

rescraped, keeping in view the tolerances specified on the
drawing.
4.0 FITTING OF SEAL RINGS
The seal rings which were bolted together to check the

chamber clearance, should be separated again at the joints.
Then place the half seal ring on the shaft at the bearing
saddle, obseving the "Hydrogen side" or "Air Side" marks
respectively. Bring the joints surface in vertical position
and fit the associated upper half to the lower half. Drive
in the reamed bolts and attach and tighten the circular
nuts. Then drive home the threaded locking pins of the
circular nuts. Turn the seal ring unit till locking pin is
supported in the recess of the seal ring carrier.
Bharat Heavy Electricals Limited (

Rev. 00 |fo$ 1 ~ 0 1 1 6 T / 3 ° f 4
tjiT^n GENERATOR MOUNTING OF SHAFT SEALS
MEASURING THE RADIAL RING CLEARANCES
Shift the ring on the shaft in the -axial direction until it

is approximately in its position for normal operation.
Measure the radial ring clearances (axial gap) with feeler
gauges. To do this, atleast three feeler gauges are
required.
Apply two feeler gauge simultaneously to obtain the gap at

each joint of the ring and use of the third feeler gauge to
measure to total gap at the highest point between ring and
shaft after first lifting the ring at the lower side of the
shaft until it touches the shaft.
Shaft diameter Ring Diameter Clearance

400mm 0.26mm + 0 . 04 mm
If there are insufficient gaps, rework the ring bore with a

scraper.
Bharat Heavy Electricals Limited ,

1 0116774
Rev. 00 ^M " °f 4
C-fiT^l GENERATOR
Erection ASSEMBLY OF BRUSH GEAR
GENERAL
The performance of brush gear and sliprings depends a lot on

quality of initial erection. Care should be taken to assemble the
brush gear properly.
1. PREPERATORY WORK
The alignment of generator rotor with respect to turbine

rotor and the assembly of auxiliary bearing must be done
prior to the assembly of brush gear. The brush gear should
be cleaned properly and inspected before assembly.
2. ASSEMBLY OF BRUSH GEAR
2.1 Before mounting the brush gear,• radial run out of slipring
should be checked at number of points along the width of
both the rings. Overall runout should not exceed 0.03 mm.
The radial run out for any sector of 30° should not exceed
0.015 mm. The surface of slipring should be free from any
scratch, rust, pitting marks etc.
2.2 The two halves of the brush gear should be fixed as per log
sheet. Centre the brush gear with respect to slipring. Refer
log sheet No. FQA-02-00-01-L-05 (Sheet 10/12).
2.3 The radial gap between brush holders and sliprings should be
uniformly set at 2.0 mm. For ensuring this, a packing of 2mm
thickness should be wrapped round the slipring and fixing of
the brush holder be done in such a way that the brush holder
touches the packing.
Bharat Heavy Electrical* limited G1-01-0117T/1 of 3

Rev. 00 10/93
GENERATOR
Erection ASSEMBLY O F BRUSH GEAR
2.4 It should be ensured that all the brushes being fitted are
of same grade HM6R/HM100 and have rubber top as per BHEL
specification. The brushes should also be graded according
to milliolt drop by passing approx 30 amps dc as per sketch
.1... Milliolt variation for grouping should be within 10%
of voltage drop across the brush.
2.5 The side clearance between brush and brush holder should be
checked. The side clearance between brush and brush holder,
with brush touching one side of the holder, should
preferably not exceed 0.25 mm.
2.6 It should be ensured that the contact between brush lead and
brush is not loose. Before fixing pig tail end cap to the
brush gear, it should be ensured that the surfaces of the
end cap and brush gear are cleaned and free from any
dust/greasy matter etc. Bolts for fixing end caps to brush
gear should be sufficiently tightened to ensure good
contact.
4.7 The pressure on all the brushes should be checked and it

should be ensured that it is uniform on all the brushes. The
spring force on each brush shoudl be within 0.9 to l. 0 kg
which can be adjusted by sliding supporting bracket over the
notches and check with the help of a spring balance having
range 0 to 2.0 kg. The above force is applicable for
HM6R/HM100 grade brushes.
2.8 New burshes must be bedded to have full contact over the
slipring surface. Bedding of brushes is done by wrapping
sand paper with glas abrasive around the sliprings and
rotating the rotor on barring gear. The use of emery cloth

Rev. 00 Gfa£l-0inT/2 of 3
ElZTjZTi GENERATOR
Erection ASSEMBLY O F BRUSH GEAR
is not permitted as emery may get embedded into the brush

surface and hence cause damage to slipring surface. After
completion of bedding, brush face should be scrapped with
sharp knife to remove the embedded abrasive and sliprings
should be thoroughly cleaned by compressed air and cotton
cloth to remove any traces of dust, dirt, oil etc,
2.9 Insulation resistance of both the brush gear stands should

be measured with respect to pedestal and also between two
stands, without the brushes in position. The value should
not be less than 1 mega ohm.

Rev. 00 10/93
£IZT£Zl
GENERATOR ASSEMBLY OF EXTENSION SHAFT
Erection AND AUXILIARY BEARINGS
GENERAL
Correct alignment of the extension shaft with respect to the

generator rotor is the most important pre-requisite for
satisfactory performance of slip rings and auxiliary bearings.
1. PREPARATORY WORK :
The alignment of generator rotor with respect to turbine

rotor must be done prior to alignment of extension shaft.
Remove the fitting pads of the bearing & keep it safely to
protect it from any damage.
2. EXTENSION SHAFT ALIGMENT
2.1 The extension shaft to be assembled to generator within

accuracy of 0.03 mm total indicated runout at journal. To
achieve this, the mating flange of extension shaft & end
face of generator rotor be scrapped, if required.
2.2 The castle nuts used for tightening the extension shaft
should be locked with the help of split pins.
3. ERECTION OF AUXILIARY BEARING
3.1 Insert the bearing pedestal under the extension shaft.

Insert the insulation liner under the bearing pedestal after
lifting it.
3.2 Axial Location : Centre line of auxiliary bearing should be

located axially as per erection drawing and log sheets.

Rev. 00 10/93
EIZTtt GFNFRATOR
ASSEMBLY OF EXTENSION SHAFT
Erection AND AUXILIARY BEARINGS
3.3 Lateral Location : Adjust the bearing body such that equal
gap is achieved at parting plane between bearing body and
extension shaft.
3.4 Inclination : The slope at parting plane of bearing body

should match with the slope of extension shaft.
Accuracy +0.1 mm
3.5 Elevation Location :

The height of auxiliary bearing is adjusted with the help of
steel shims (assorted thicknes) supplied. The height should
be such that when the tilting pads are inserted the
extension shaft gets lifted by 0.1 mm in the normal case.
This would load the bearing adequately.
3.6 The shim under the bearing pedestal should be of such size
that insulation liner should protrude outside the shim.
4. MEASUREMENT OF INSULATION RESISTANCE :
Insulation resistance (IR) of auxiliary bearing is to be

measured before insertion of tilting pads. But the
foundation bolts of the bearing pedestal should be fully
tight. The insulation resistance should be above 1 Mega Ohm
with 500 V megger.
5. PRECAUTIONS :
1. The drain pipe should have inclination for gravity flow

of drain oil.
2. Care must be exercised during assembly to protect the

bearing surface for any physical damage.
Bharat Heavy Electricals Limited G j j ^ l - O l l S T ^ of 2

Rev. 00
C1ZH£1
GENERATOR ERECTION OP TG AUXILIARIES
Erection
GENERAL
200/210 MW TG consists of various auxiliaries like seal oil

system, stator water system, gas system and static excitation
system. The components of these systems are normally mounted on a
rack. During erection of these systems, following activities are
required to be carried out:
Erection of control panels.

Erection of skid mounted racks.
Piping erection
Erection of loose components like valves, pump-motor
set, tanks, filters, coolers etc.
1.0 ERECTION OF CONTROL PANEL
The foundation details of the various control panel should

be checked as per drawing and foundation frame should be
placed in position. Proper opening in the foundation for
cable entry should also be ensured as per drawing. The
foundation frame should be levelled with the help of spirit
level and should be grouted. The panel should be placed on
foundation frame and its verticality should be checked. If
the antivibration pads are provided in the drawing same
should be mounted on the foundation frame before panel
placement. Proper earthing and locking of panel should be
ensured. All the unused cable entry points in the panel
should be properly sealed. No gas cutting in the bottom
plate should be done for making any extra cable entry holes.
All the transportation locking fixtures provided in the
panel should then be removed.
Bharat Heavy Electricals Limited C ^ £ - 0 1 3 6 T / 1 of 3

Rev. 00
CiUJCTl
GENERATOR ERECTION OF TG AUXILIARIES
Erection
2.0 ERECTION OF SKID MOUNTED RACKS
The dimension and position of pockets provided for

foundation bolts should be checked as per the details given
in the drawing. The various holes provided for anchoring
bolts should be checked as per foundation drawing. The
anchoring bolts should be placed in position and grouted.
The rack should then be placed in position, levelled,
aligned and foundation bolts should be tightened. While
doing levelling and alignment of the rack, its orientation
with respect to various piping connection should also be
checked. The frame should be finally grouted.
3.0 PIPING ERECTION
During erection of auxiliary systems, the piping erection

plays a vital role. Various pipings are supplied in pre-
fabricated manner and same have to be welded after its
proper laying. While laying the piping, following
precautions should be observed.
Lay the pipelines as per relevant drawing ensuring

proper slopes.
Ensure welding of piping joints as per recommendations

made on the relevant drawings.
Ensure freeness of piping and use of specified hangers

and supports as per drawings.
Ensure mechanical cleaning of the piping by air

blowing/cleaning by wire brush/by acid cleaning as the
case may be.
^-^1-0136^2 of 3
Rev. 00
ciir^n GENERATOR PURGE T E S T O F T . G . ROTOR
Erection
EQUIPMENTS REQUIRED TO CARRY OUT PURGE TEST
The following equipment/facilities are required for carrying

out the purge test of ventilation canals of TG rotor.
a. Source of compressed air to a pressure of not less than

3 atg.
b. Plug without nipples as per figure (a) - 6 Nos.
c. Plugs with measuring union nipple for manometer as per

figure (b) - 2 Nos.
d. Inlet adopter with removable nipple as per figure (c)

- 1 No.
e. Out let adopter with removable nipple as per figure (d)

- 1 No.
f. Spring type manometer which can measure upto 6 kg. per

Cm2 - 1 No.
g. Micro manometer with hoses which can measure upto 200

mm of water column - 2 Nos. (one as standard
manometer)).
h. Plug for closing the holes of slot wedges - 4536 Nos.
i. Plugs for closing ventilation slots in rotor poles - 4

Nos.
j. Supply hose (Rubber)
Bharat Heavy Electrical* Limited G1-01-0107T/1 of 4

Rev. 00 10/93
CiZH£l GENERATOR PURGE TEST OF T . G . ROTOR
Erection
2. PREPARATION FOR TESTING
a. Number the rotor slots serialwise in clockwise

direction, looking from slip ring end and starting from
that pole which is in the side of field lead connection
to inner slip ring.
b. Number the ventilation holes in wedges of each slot,

starting from retaining ring on slip ring end.
3. PROCEDURE FOR TESTING
3.1 SLOT PORTION
a. Close all the holes in slot wedges by plugs.
b. Remove the plugs from inlet and outlet holes of the

canal under test.
c. Place the nipple of inlet adopter in the inlet hole and

the nipple of outlet adopter with manometer connected
in the outlet hole as shown.
The hose from union nipple for total pressure should be

connected to " + " side and for static pressure to "-"
side of the micro manometer.
d. Supply compressed air at 3+0.1. atg through inlet

adopter.
e. Measure the velocity head at the outlet of the canal.
f. Enter the value of the pressure in relevant test chart.
Bharat Heavy Electricals Limited _ , „„ _„_„„,,_ £ .

Rev. 00 GA 7 ,&l-0107T/2 of 4
vjciNXiivrt.i wiv PURGE TEST OF T . G . ROTOR
Erection
g. After taking the reading, the plugs removed earlier for

test of this canal are kept back in position.
h. Repeat the test for other canals.
i. Determine the average velocity and pressure for each

zone and for each slot.
3.2 OVER HANG PORTION
a. Purge test for the canals of overhang portion of rotor

winding should be done immediately after the test of
slot portion as shown.
b. Close the ventilation slots on the rotor shaft,

ventilation slots in the poles, space under centering
ring and holes in the end zone of slot portion on slip
ring end by plugs.
c. Supply compressed air at 3.5 atg. to the plugs and

connect the hose of the micro-manometer to the
measuring nipple of the plug. Gauge static pressure
under the retaining ring must be maintained constant
and equal to 50 mm of water column.
d. Take out the plug from the canal under test.
e. Insert the nipple of outlet adopter into the outlet

hole of the canal under test after making sure by
feeling that there is flow of air coming out of the
canal.
f. Connect the hose from the union nipple of static

pressure of the outlet adopter to the micro-manometer

Rev. 00 10/93
CIZTJCTI
GENERATOR mn„ _om n„ „ „ nfWm
PURGE TEST OF T.G. ROTOR
Erection
and measure the static pressure of air. During this

measurement, the hole at the other end of the outlet
adopter and union nipple for total pressure should be
closed.
g. Measure the static pressure at the outlet of canal.
h. Enter the values of pressure in the purge test chart.
i. Repeat the test for all other holes connected to the

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

winding on turbine end in a similar manner.
4. ACCEPTED NORMS
a. The average value of velocity head in the canal of slot

portion of rotor winding should not be less than 15 mm
of water column for each zone and 21 mm of water column
for each slot.
b. The minimum static pressure in each canal of overhang

portion of rotor winding should not be less than 15 mm
of water column.
c. The number of fully closed canals should not be more

than 6 in the slot portion of rotor winding at the same
time there should not be more than one closed canal in
any one slot.
d. Fully closed canals are not allowed in the overhang

portions of the rotor windings.
Bharat Heavy Electricals Limited „„„„,/„ ^ ,

Rev. 00 < f t $ L - 0 1 0 7 T / 4 of 4
PIPE JOEL MEASURING UNION
/ NIPPLE
s
RUBBER B O D Y ^ RUBBER BODY
OF PLUG OF PLUG ;
fa)
FOR SPRING TYPE
MANOMETER
REMOVABLE NIPPLE
NUT
EE MOVABLE
NIPPLE
UNION NIPPLE „
UNION NIPPLE FOR
FOR TOTAL PRESSURE
STATIC PRESSURE
(d)
NIPPLES & FITTtNGS FOR PURGE TEST
a l- Oi-OiOlT
INLET ADAPTER OUTLET
' * /ADAPTER MEASURING
r-H IMICROMANOMETER
SPR.ING JU
CANAL
B€ 2 DIAGRAM FOR THE PURGE TEST OF

VENTILATION CANALS SLOT PORTION
G t~ol- ol&7T
:ASUBIU£
OUTLET ADAPTER
PLUG WITH
MEASURING
UNION NIPPLE
'MEASURING
MICROMANO-
METER
HG. § DIAGRAM FOR THE PURGE TEST OF VENTI

LATION CANALS OVERHANG PORTION
ei/ot'**077"
VJ^Î^JUI\ Q^g TIG HTNESS TEST OF ROTOR
Erection
Rotor is tested for gas tightness before its insertion into

stator. During this test sealing provided at the following places
is checked.
i. Slipring end of the central hole of Rotor.
ii. Turbine end of the central hole of Rotor.
iii. Current carrying bolts connecting windings to the field lead

core bar in the central hole of the rotor shaft.
iv. Current carrying bolt connecting the slip rings to the field
lead core bar in the central hole of the rotor shaft.
PROCEDURE FOR CARRYING OUT GAS TIGHTNESS TEST
The scheme of testing is given showing the details of equipment

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

the rotor shaft at slip ring end. Plug is removed and a
compressed air pipe line with manometer is connected to this.
With the pressure of compressed air of 3.0 to 4.0 atmospheres in
the central hole the leakage is checked. First leakage at the end
of central hole is detected by applying soap solution. For
preventing the leakage, if any, the bolts are tightened and if
required the sealing gaskets at the ends are replaced. If
manometer still shows fast reduction of pressure, sealing gaskets
provided for current carrying bolts are checked first at slip
rings and then under the over-hang portion of rotor windings. To
check at these places the brackets and insulating details over
the current carrying bolts are taken out and then connecting

Rev. 00 10/93
€IZT£Zl
GAS TIGHTNESS TEST OF ROTOR
Erection
copper flexibles are disconnected. To detect leakage white spirit

is applied around the current carrying bolts. In case of leakage,
air bubbles are formed. Nuts pressing the sealing gaskets are
tightened and if necessary sealing gaskets are replaced.
While testing leakage at the current carrying bolts the rotor

should be placed in a way that the bolts under test are in
vertical plane.
Gas tightness of the rotor is considered satisfactory if the

pressure drop for a period of 6 hours does not exceed 10% of the
initial pressure. Initial pressure being 4.0 atmosphere.
Bharat Heavy Electricals Limited „ «,„„„,/„ J= -,

Rev. 00 G ^ - O l O S T / 2 of 2
CJZTtt GENERATOR RESISTANCE MEASUREMENT O P
Erection STATOR WINDING
Measurement of DC Ohmic resistance of stator winding is

carried out during assembly of terminal bushing,
commissioning and subsequent overhaul of generator. During
assembly of terminal bushing, it is to ensure the proper
quality of tightening/soldering of flexible connection with
phase leads and terminal bushings. This is done at three
stages of assembly work.
Stage-I : DC resistance of stator winding before

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

bushing.
During commissioning and subsequent checking, it is done

before making electrical connection to the bus duct.
1.0 PRE-REQUISITE :
i) Ensure the proper cleanliness of the contact used for

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

electrical connections with the measuring cable.
iii) Ensure that generator is in cold condition at the time

of measurement, if necessary, temperature correction
may be carried out.

Rev. 00 10/93
rizraa GENERATOR RESISTANCE MEASUREMENT OF
2.0 INSTRUMENT REQUIRED :
Micro Ohm Meter - l No.
3.0 PROCEDURE :
The measurement of DC resistance of stator winding per phase

per parallel path is done by connecting the micro ohm meter
across the terminals of the concerned winding.
The readings should be recorded as per log sheet No. FQA-03-

00-01-L07.
4.0 ACCEPTANCE CRITERIA
i) Maximum permissible variation in winding resistance

value between Stage-I and Stage-Ill is 3%.
ii) Value measured in Stage-I should match with test

certificate value (within 3%).

Rev. 00 10/93
C£UF£iI» GENERATOR „™™ ™ ™ ,^„
m m w P m
MEASUREMENT OF INSULATION
Erection RESISTANCE O F STATOR WINDING
The insulation resistance value of stator winding is taken to

assess the conditions of insulation during various stages of
erection/commissioning and overhaul of the machine. The value may
sometime deteriorate due to moisture absorption during storage
and transportation of stator. The insulation resistance should,
therefore, be measured prior to the first commissioning, after
any prolonged shutdown and after any work on windings. If
required, the generator should be dried until a sufficient
insulation resistance has been obtained.
1.0 PRE-REQUISITE
1. Prior to measuring the insulation resistance of stator

winding, it must be ensured that, there was no water
ingress during storage, transit and erection and
winding is clean from dust etc.
2. Water should be drained off from the winding and

winding should be dried by blowing dry instrument air.
3. Water header and gas trap pipe line should be

disconnected from the external piping system and ensure
minimum IR value of water headers with respect to
stator casing to 5 M.ohm by 500 V meggar.
4. The generator terminals should be electrically

disconnected from the bus duct at its terminal on both
sides (phase and neutral).
5. Ensure earthing of stator casing at two places.

Rev. 00 q f o g l - 0 1 0 3 T / l of 4
CitTiCl
MEASUREMENT OF INSOLATION
Erection RESISTANCE OF STATOR WINDING
2.0 EQUIPMENT USED
Motorised meggar (l KV) - l No.
3.0 PROCEDURE
The insulation resistance of stator winding is measured in

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

stator casing (other two phases should be
grounded).
Step-II : IR value between two phases (remaining phase

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

earthed casing.
During checking the insulation resistance of each phase with

reference to earthed casing, the phase winding should be
connected to LIVE terminal of meggar and casing to EARTH
terminal and water header which is isolated from external
cooling circuit should be connected to Guard terminal of
meggar. The remaining two phases should be connected to
earth. The readings should be taken at interval of 15
seconds, 60 seconds and 10 minutes duration after switching
ON the instrument. This should be repeated for all other
phases.
For checking the insulation resistance values between phase

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

Gg^.-0103T/2 Of 4
Rev. 00
CJTijETI
GENERATOR MEASUREMENT O F INSULATION
should be connected to LIVE terminal and other phase should

be connected to EARTH terminal and GUARD terminal should be
connected to isolated water header and the remaining phase.
Readings in this case should be taken at 15 seconds and 60
seconds interval after switching ON the meggar.
The recommended minimum insulation resistance of stator

winding can be determined by formula
R60 = KV + 1
Where R60 = recommended minimum insulation resistance in

mega ohms of the entire winding at 40°C after 60 seconds.
KV = Rated voltage of the machine in kilovolts.
For 200/210 MW generator, the recommended one minute value

of insulation resistance for stator winding is 16.75 M Ohms
at 40°C with 1 KV meggar.
Also, the values of absorption co-efficient and Polarisation

Index are taken to access the degree of dryness of winding.
IR measured at 60 Sec.
Absorption Co-efft =
IR measured at 15 Sec.
IR measured at 10 Min.
Polarisation Index =
IR measured at 1 Min.
The minimum recommended value of Absorption Co-efficient and
Po

Rev. 00 10/93
CiTT^Tl GENERATOR MEASUREMENT O F INSULATION
in good condition, insulation resistance readings at 60 Sec.

are normally observed to be 10 to 100 times the minimum
recommended values.
If the windings are not at 40°C temp., the temp, correction

should be made in IR values by multiplying with temp, co-
efficient of insulation resistance. K40°C as given in Fig.
1. The corrected insulation resistance at 40°C is calculated
by the formula :
R40°C = Rt x K40°C
Where Rt = measured insulation resistance in M.Ohm at t°C.
5. 0 PRECAUTIONS
On completion of IR measurement, the winding should be

properly discharged to earth with the help of earthing rod
before disconnecting the measuring leads from winding.
NOTE
During initial commissioning stage, the IR value should be
recorded at each minute interval from 1 minute to 10 minutes
duration for future reference.

G^-^L-0103T/4 Of 4
Rev. 00
CIZT1Z*
GENERATOR ELECTRICAL C H E C K I N G O F
Erection GENERATOR R T D S
The temperature rise of stator winding, core and H2 gas (cold and
hot) in a 200/210 MW generator are monitored by way of providing
embedded RTDs in these components. These RTDs are terminated to a
terminal box for its external electrical connection to the
measuring circuits. These RTDs are required to be checked for
healthiness interms of IR and DC resistance values before
connecting it to the external measuring circuit.
1.0 PRE-REQUISITE :
i) Ensure that no external connections are made to the

RTDs terminals.
ii) The generator casing should be at the cold condition.
iii) The terminal box should be cleaned by compressed air.
iv) Ensure that screen of all RTDs are properly earthed at

terminal box.
2. 0 EQUIPMENT USED :
Digital Multimeter - 1 No.

Meggar 250V - 1 No.
3.0 PROCEDURE
a) D . C Resistance Measurement
The resistance of each RTD should be checked with the
help of digital multimeter by connecting it across both
ends of RTD at terminal box. The resistance values
should be recorded as per log sheet No. FQA-03-00-01-L-
11.
Bharat Heavy Electricals Limited ]
Rev. 00 < % ^ - 0 1 0 2 T / l of 3
CfiTjt^l
GENERATOR ELECTRICAL CHECKING O F
Erection GENERATOR RTDS
b) IR Measurement
The insulation resistance of each RTD should be

measured with the help of a 250V meggar. The meggar
terminal should be connected across one end of RTD and
earth potential of stator casing. The insulation
resistance value at 15 second should be recorded as per
log Sheet No. FQA-03-00-01-L-11.
4.0 ACCEPTANCE CRITERIA :
In case of DC resistance, the obtained value should not

differ by more than 2% as computed from Resistance vS Temp.
- chart. For IR values a minimum value of 0.5 M ohm should
be obtained for an healthy RTD.

Rev. 00 ( f t $ L - 0 1 0 2 T / 2 of 3
riiTfTi GENERATOR
p . ELECTRICAL CHECKING OF
Erection GENERATOR RTDS
RESISTANCE Vs TEMPERATURE FOR

PRT (RO=100 Ohms)
Temperature in (°C) Resistance in (Ohms)
0 100.00
2 100.78
4 101.56
6 102.34
8 103.12
10 103.90
12 104.68
14 105.46
16 106.24
18 107.02
20 107.79
22 108.57
24 109.35
26 110.12
28 110.90
30 111.67
32 112.45
36 113.99
38 114.77
40 115.54
42 116.31
44 117.08
46 117.85
48 118.62
50 119.40
52 120.16
54 120.93
56 121.70
58 122.47
60 123.24

Rev. 00 ^ 7 ^ . - 0 1 0 2 7 / 3 of 3
CJZF£Zi GENERATOR HYDRAULIC T E S T O F STATOR
Erection WINDING
The stator winding of water cooled generator is having hollow

conductors for circulation of DM water in the winding for its
cooling. This water path along with its header and teflon tube
connection should be hydraulically tested to ensure its
tightness for any water leakage inside the stator casing.
1.0 PRE REQUISITE
To carry out the hydraulic test of stator winding including

the terminal bushing, following preprations should be
done: -
i. The terminal bars along with the bushing should be

mounted and its electrical and water connections to
the main winding should be established.
ii. Insulated pipes at inlet and outlet of water header

should be properly assembled and its vent pipe
connection should also be established.
iii. End shields of generator on both side should be kept

open.
iv. A temporary blank at the outlet header of water

connection should be provided and the inlet header
should be connected to a manual operated hydraulic
pump.
v. Vent pipe provided at both water header should be

temporarily blanked with a proper device.

Qj^L-0121T/l Of 3
Rev. 00
W wîv™v/w HYDRAULIC TEST OF STATOR
Erection WINDING
vi. A proper arrangement for DM water should be made near

the hydraulic pump.
2.0 PROCEDURE
Initially the winding should be filled with DM water with

the help of hydraulic pump and air venting from the winding
should be done by loosening the temporary blanks provided
at both vent lines and outlet header. While venting the
air, it must be ensured that no air is coming out of the
vents and water wihtout any bubble is coming out.
After ensuring that complete winding is full of water, the

water pressure should be raised with the help of hydraulic
pump upto 8 Kg/cm2 and same should be maintained for 24
hours after closing the isolating valve at outlet of
hydraulic pump.
Hourly reading of water pressure should be recorded and

complete system should be thoroughly inspected for any
water seepage from any of the joints in the water path.
A drop of 5% may be allowed to compensate the temperature

variation throughout the test. No signs of moisture on the
windings, headers, flexible hoses, and their connections
should be observed during the test.
NOTE :
1. It is recommended to conduct an "AIR LEAK TEST" of

stator winding with dry compressed air at 4 Kg/cm2

Rev. 00 10/93
tizraa GENERATOR HYDRAULIC T E S T O F STATOR
Erection WINDING
prior to Hydraulic test for easy detection of leakage

points, if any.
2. IR value of stator winding should be checked before

and after the test.

Rev. 00 10/93
ttZrtZm GENERATOR ELECTRICAL TESTS O F ROTOR
Erection WINDING
The field winding of generator rotor should be checked for its

D.C. resistance, impedance and insulation resistance values to
ensure it's healthiness at various stages of erection,
commissioning and subsequent during overhauls.
1.0 PRE-REQUISITE
i. During any measurement, the rotor winding should be

electrically disconnected from external circuit.
ii. During checking of DC resistance and impedance values

of winding, it must be ensured that electrical
connections made at both slip ring for measurement are
perfectly tight.
iii. While doing measurement on the rotor, its condition

like outside/inside the generator casing, temperature
should be properly recorded.
iv. The areas around slip ring surface should be cleaned

properly before carrying out any checks on the
winding.
v. During impedance checking of winding, the frequency of

supply to the winding should also be recorded.
2.0 INSTRUMENT REQUIRED
Micro Ohm meter 1 No.

Meggar (500 V) 1 No.
Voltmeter (0-300V) AC 1 No.
Ammeter (0-100A) AC 1 No.
Single Phase 1 No.
Variac (0-250V/100A)

Rev. 00 10/93
ExTHiH GENERATOR ELECTRICAL TESTS OP ROTOR
Erection WINDING
3.3 INSULATION RESISTANCE MEASUREMENT
The insulation resistance of field winding should be

checked with the help of 500V megger at one of the slip
ring with respect to shaft surface. Since the rotor is a
moving part of generator, the insulation resistance should
be measured at different speed to see the effect of speed
on the insulation resistance value. Normally, this value is
taken at standstill, barring gear and 3000 rpm of
generator.
For DC resistance and impedance values of rotor winding,

the obtained results should be compared with the values
obtained at test bed/previous reference. In no case, these
values should differ from the previously measured values by
more than 2% under similar test condition.
In case of insulation resistance values, this value should

not be less than 1.3 Mohm at 40°C at any test condition. If
this is observed to be less than min. recommended value,
same should be improved by heating before proceeding to
next stage of operation.
NOTE
If testing facility exists at site, oto winding impedance

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

Rev. 00 10/93
CI3T*il GENERATOR HYDRAULIC TEST OF GAS COOLER
Erection
Note : (For Coolers showing Leakage during Operation).
If it is not possible to detect the leaking area with cold

water, hot water at a temperature of 65-70°C can be used to
detect the leakage point.

Rev. 00 10/93
rjzijui GFNFRATOR
vji.i>iE,ivniwi\ g^ T I G H T N E S S TEST OF STATOR
Erection
Stator is usually tested for gas tightness during erection once

before inserting the rotor and again on completely assembled
generator alongwith all the auxiliary system piping. This test
is carried out during overhauls also. This test is carried out
mainly to ensure that :
a. There is no damage to weldseams during transportation and

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

etc. are gas tight.
c. The whole assembly of the generator and the systems is

correct and gas tight.
The good gas tightness test ensure minimum consumption of

hydrogen.
1.0 PROCEDURE
The test envisages in filling the stator or the whole

machine as the case may be with air at a pressure of
4.0/3.5 atg. and checking the leakage at the possible
places by soap solution. This test is usually carried out
without any water in the gas coolers and stator winding.
The major leakages in coller and stator winding are however
detected and eliminated by carrying out pneumatic test at
4.5 atg. with air prior to this test.
Generator is considered to be gastight if the leakage of

air in 24 hours referred to atmospheric pressure is not
Bharat Heavy Electricals Limited ^ ^ „„„„„,,., __

Rev. 00 G^l-O^T/l of 2
£IlTtt GENERATOR
GAS TIGHTNESS TEST OF STATOR
Erection
more than 1% of internal gas volume in case of stator alone

and 5% in case of completely assembled generator alongwith
pipings. The quantity of air leakage is determined by
finding out the drop in pressure taking into account the
temperature corrections.
2 .0 METHOD OF CALCULATION OF HYDROGEN LEAKAGE FROM THE

GENERATOR
Leakage of gas may be calculated from the formula.
925 PI P2
So =
T 2 73 + tl 273 + t2
Where So = Leakage of gas in 24 hours, referred to atmos-
pheric pressure (760 mm of mercury) and temperature
of 20oC as a percentage gas volume of the generator
PI & P2 Absolute pressure of air in mm of mercury at begin-

ing and end of test respectively.
tl & t2 Temperature of air inside the generator at begining

and end of test respectively in oC.
T = Duration of test in hours.
Absolute leakage of gas from the generator in M J can be

calculated from the formula :
SO X V
Vo
100

1 - 0 1 2 7 T / 2 of 2
Rev. 00 «
CIXTJCI
GENERATOR g^ T I GHTNESS TEST OF STATOR
Erection
Where:V = gas volume of generator stator which is 56 M3 with

rotor and 60 M 3 without Rotor.
Although the generator is tested for gas tightness with air

medium it is desirable to determine the expected leakage of
hydrogen in actual working conditions. In fact the gas tightness
test is done with air due to the risk involved in filling the
generator with hydrogen until its gas tightness is ensured and
also because of the difficulties and expenses involved. Leakage
of hydrogen can be calculated by using the formula.
Vo(Hydrogen) Density of air at 20oC Temp.

Vo(Air) Density of H2 at 20oC temp.
1.18
0.1138
Bharat Heavy Electricals Limited Gl-01 0127T/3 of 2

Rev. 00 10/93 "
EICTiO CJENERATOR HOT WATER CIRCULATION I N
4. Check the Temp, rise of each teflon tube by its

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

surface. Such tubes should be checked for any blockage
after opening it from the header.

Rev. 00 10/93 ~
EXPANSION
TANK STEAM SUPPLY LINE
OP
ELECTRICAL IMMERSION HEATER:
LI
it
>
z
STATOR WINDING
V FILTER
<
0
«
'z
e STATOR WATER
SYSTEM PUMP
JXh-O—Cxi
c
z FIG. 1 SCHEME OF HOT WATER CIRCULATION THROUGH

STATOR WINDING
- * $ •
GL-Oi - OL2UT
CJHTÎ
GENERATOR INSULATION RESISTANCE MEASUREMENT OF
Erection GENERATOR REAR BEARING PEDESTAL AND SEAL BODY
INTRODUCTION
During operation of a generator, voltages are set up along the

rotor shaft due to magnetic unbalances. This shaft voltage would
cause a destructive current to flow through the bearing shaft
seal and other components if the rotor shaft were not insulated
from ground at least at the excitor end. In 200/210 Mtf TG all
the stator components coming into contact with generator rotor
shaft at slip ring end i.e. bearing pedestal, Oil catcher, Seal
body and all pipings connected to seal body and bearing pedestal
are insulated with the help of a textolite liner, insulating
sleeve, washer and gaskets. The healthiness of insulation is
ensured by checking of IR value during erection stage as follows:
1.0 CHECKS DURING ERECTION STAGE
During assembly of each component at slip ring end, IR is

measured at every stage of assembly as mentioned below •. -
1.1 BEARING PEDESTAL ASSEMBLY
Slip ring end bearing pedestal is insulated from foundation

bed plate by means of a thick glass textolite liner
interposed between the pedestal and the bed plate. The IR
of this insulation sheet is checked at different erection
stages. c
After placing the pedestal on bed plate.

Before and after tightening of pedestal fixing bolt.
Bharat Heavy Electrical* Limite<£K~ 1717117! f ,

R.V. 00 ( ^ £ 1 - 0 1 3 5 1 / 1 of 3
CiZHSl
INSULATION RESISTANCE MEASUREMENT OF
After placing the rotor on bearing pedestal (not

coupled to LP rotor).
After assembly of piping with pedestal.
With satisfactory insulation, a value in excess of 3-5
Megaohm is expected after placing the rotor on bearing
pedestal.
1.2 OIL CATCHER
Oil Catcher is insulated from end shield. The IR

measurement should be done after tightening the fixing
bolt.
CAUTION
During IR measurement it must be ensured that oil catcher

fins do not come in contact with rotor surface. Same can be
insulated by providing an insulating-paper between fins and
rotor shaft.
1.3 SHAFT SEAL BODY
Shaft seal body is insulated from end shield by means of

insulating sheet. The fixing bolts of seal body are
insulated from seal body with the help of insulating sleeve
and washers. During its assembly, the IR measurement should
be done after fixing each bolt. After fully tightening of -
all fixing bolt, joint IR value of seal body should be
checked.
Bharat Heavy Electricals Limited ,

135T
Rev. 00 %7#-° /2 °f 3
GFNFRATOR
INSULATION RESISTANCE MEASUREMENT OF
1.4 VARIOUS PIPING CONNECTIONS TO BEARING PEDESTAL AND SEAL

BODY
All pipings connected to bearing pedestal and seal body are
insulated by means of insulating sleeve, washer and
insulating gaskets. During assembly of these pipings, the
IR should be measured after each piping connection before
proceeding to next. During piping assembly, it must be
ensured that insulating gaskets provided between piping
flanges are projecting over the pipe flanges and also the
insulating washers should project out side the tightening
bolt head. It will avoid lowering of IR value due to dust
settling in the gaps between pipe flanges and bolt heads.
NOTE :
1. Insulation resistance measurement should be carried out
with the help of a 500V megger.
2. Final IR value of rotor shaft after assembly of bearing

pedestal and seal body connected with piping should be
measured and same should not be less than 1 Mohm.
3. All insulating components like sleeves, washers, liners

should be cleaned properly and checked for any physical
damage during storage before its use.
4. After getting good IR value across the bearing pedestal

insulating liner, same can be maintained by covering the
exposed surface of the textolite liner and adjoining
surface of steel sheet pedestal and bed plate by applying
epoxy insulating varnish after thoroughly cleaning the
surface.

Rev. 00 G^7^.-0135T/3 of 3
rizraa GENERATOR
_ SLOT WEDGE TIGHTNESS CHECKING
Erection
The function of slot wedges in stator is to ensure that winding

bars remain tightly secured in the slots and they are permanently
protected from possible vibrations in order to avoid damage to
the insulation of bars. Two types of slot wedging system are used
in 210 MW turbogenerators manufactured by BHEL.
a) Slot wedging system without top ripple spring.

b) Slot wedging system with top ripple springs.
In the first system (without top ripple springs), sufficient

thickness of plain insulating packing is provided under the slot
wedges to ensure that wedges are tight enough to stop the winding
bar from bouncing under electro-magnetic forces.
In second system, corrugated ripple springs are provided between

slot wedge and winding bar. The required force on the bar for
counteracting the electromagnetic bar bouncing force is provided
during wedging by compressing the springs. The initial spring
compression also compensate for shrinkage of slot contents
and hence there are lesser chances of wedges getting loose
(See Fig-2).
1.0 TEST PROCEDURE & NORMS
1.1 Testing of Slot Wedge System without top Ripple Springs :
1.1.1 Procedure
The extent of tightness of slot wedges is judged by knock

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

G
Rev. 00 ft)7& L -° 1 0 6 T / 1 ° f 7
yi.i^.vîun SLQT WEDGE TIGHTNESS CHECKING
Erection
i) Mark the slot nos. on the bars at slot exit by paint.

The slot no. 1 is at 9'0' clock position looking from
exciter end and the numbering is done clockwise. Then
mark the wedge numbers along the length of slot
starting from exciter end i.e. the end wedge on
exciter end is marked no. 1.
ii) Check each and every wedge for tightness by knocking

at the centre and ends of wedge by a 400 gms.
metallic hammer and enter the degree of tighteness in
chart given in Annexure-I. The degree of tightness is
determined as follows :
Category-1 : Under this category, the wedge gives

uniform metallic sound all along length without any
vibration in wedge.
Category-2 : Wedge gives slight hollowness and some

vibration is felt on upto 50% length of the wedge
when it is knocked by hammer.
Category-3 : Wedge gives hollow sound on more than

50% length of the wedge.
1.1.2 Norms for Allowable Wedge Looseness
There should not be more than 5 wedges loose

(Category-2&3) per slot.
First five wedges from each end of the slot should

be of Category-1 tightness.

Rev. 00 10/93
riiwî G F N F R A T O R
vjîNcivrvi wiv SL0T WEDQE TIGHTNESS CHECKING
Erection
Two wedges of category-2 tightness on RTDs are

allowed in each slot.
Two consequtive loose wedges (Category-2&3) in the

middle of each slot are allowed. These consequtive
loose wedges sholuld not be within 10 wedges from
each end.
In general, there should be minimum gap of 5 wedges

between any two loose wedges subjected to above
conditions.
1.2 Testing of Slot Wedge System having Top Ripple Springs
1.2.1 Testing Equipment
Please see Figure-1, The test equipment includes the

following:
i) Hydraulic test device with thrust piston in the

stator bore.
ii) Interchangeable pressure bars.
iii) Pressure manometer.
iv) Dial guages with magnetic mounting.
The test medium shall be Hydraulic oil.
1.2.2 Test Procedure
The test device is so positioned in the stator bore that

the pressure bar comes in contact with only one partial
slot wedge at a time (Please see Fig. 1 ) .

Rev. 00 10/93
ciznzi G F N F R ATOR
vjci>iE,ivn.i wrv. SLQT ,^1X38 TIGHTNESS CHECKING
Erection
Dimensions of pressing piece shall be as per Fig.l. The

wedges on which measurements to be made are selected as
explained in para 2.2.3. The slot wedge movements are
read on two dial gauges provided for the purpose. The
mean value of the two is entered in the test record data
in unit of one hundredth mm.
2.2.3 Measuring Points
To permit an assessment of spring force on bars and

wedges, it will normally not be necessary to check all
slot wedges, but the check should cover not less than 20%
of the total number of slot wedges. The measuring points
should be distributed over the slot length so that they
are staggered from slot to slot as given in Table-I.
Bharat Heavy Electricals Limited __ . , TTTTZTM I~7

Rev. 00 <flj#-0106T/4 of 7
y^^îv/n g L O T VEDGE TIGHTNESS CHECKING
Erection
Table - I
S l o t Wedges on which Measurements are made
SLOT EE STATOR SLOT TE

NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1 X X X X X X X X X X X
4 X X X X X X X X X X
60
No. Of Slots : 60
No.of wedges per slot : 24
Total wedges : 1440
Measuring points : 2x4x60 + 20% of 840 = 648
X - Measuring Point
Note 1. End wedges i.e. 1 and 24 are rigidly fixed and hence no
measurements are made on them.
2. Wedge Nos. 21, 22, 23 are not provided with top ripple
springs as they are comning over the RTDs. Therefore
their tightness is to be checked by knock test.

01-0106T/5 of 7
Rev. 00 %
EirrrTt frFNFR ATOR
vjci>civrvi vîv S L 0 T VfEDGE T I GHTNESS CHECKING
Erection
1.2.4 Test Pressure
The test pressure to be applied to a particular slot wedge

depends on the thickness, number and compressed area of the
springs (approx. slot width x length of slot wedge). In 210
MW THW Generator, single spring of 0.9 mm thickness are used
under each wedge. In this case, following requirement will
be applicable.
Specific test pressure =1.8 N/mm2
10. P p
Required Manometer Pr. = . l N .b N bar
F
k
Where 1 N = Slot wedge length in cm.

bN = Slot width in cm.
Pp = ,2
Specific test pressure in N/mm''
F^ = Piston surface area in cnr
Therefore requried Manometer pressure = 73.84 bar.
1.2.5 Test Records
The results of tests should be tabulated as per performa

given in Table - I.
1.2.6 Allowable Wedge Deflection
< 0.90 mm for not less than 60% of measuring points.
< 1.10 for remaining measuring points (40% max.) .
Bharat Heavy Electricals Limited „„ „ „ „, . _ „

Rev. 00 Gfo^-OlOST/e of 7
GENERATOR
„ SLOT WEDGE TIGHTNESS CHECKING
Erection
If a wedge movement of more than 1.10 mm is measured in any

slot, the number of measuring points in this slot should be
doubled. If the value is exceeded at two points, all wedges
in this slot should be checked to ensure that not more than
two points are having wedge movement more than abvoe
specified value.
Note : If the above guiding values are exceeded, consult

FES/TGE department of BHEL Hardwar for advice, who will then
issue recommendation regarding need for rewedging.
2.2.7 Permissible Slot Wedge Deflection after Rewedging
During rewedging operation, the compression of ripple

spring is restored by inserting packing strips of
required thickness. To enable easier and more reliable
determination of the thickness of the filler strips, it
is recommended to measure the movement of all wedges
prior to rewedging. After rewedging of the complete
winding, following slot wedge deflections are
permissible.
o Slot wedge deflection shal not be less than 0.1 mm but

not more than 0.3 mm for not less than 75% of all
measuring points.
o Slot wedge movement at remaining 25% of measuring

points shall not exceed 0.45 mm.

Rev. 00 CJtogL-OlOST/V of 7
CiTT^l GENERATOR JOINTING OF RUBBER GASKETS
Erection
INTRODUCTION :
The necessity of having leak proof joint at End Shields of

generator makes it essential to take proper care during storage,
erection/assembly of rubber components. As such a proper
procedures should be followed which is recommended as follows
during storage and assembly of rubber components.
1.0 PRECAUTIONS TO BE TAKEN DURING STORAGE OF RUBBER COMPONENTS
It is a fact that if rubber components are not stored

properly, these will age quickly thus becoming hard and
brittle and sometimes developing cracks under stressed
conditions. Accordingly, these components need care during
storage as per the following recommendations :
TEMPERATURE Storage should be preferably below

15°C but should not exceed 25°C.
If the rubber components are kept in

store, at temperatures exceeding 25°C
these will harden at a faster rate
and would become unfit for use later.
LIGHT Rubber components should be protected

from direct sunlight and strong
artificial light having high
ultraviolet content.
DEFORMATION Rubber components should be stored

fully supported and free from
tension, compression or deformation.

Rev. 00 <M1 - 0 1 2 5 G / 1 Of 4
ClZTtt GENERATOR JOINTING OF RUBBER GASKETS
Erection
Hanging of these items from hooks,

nails or by some other method should
be avoided.
CONTACT WITH Contact with liquid or semi-solid

LIQUIDS, METALS materials such as solvents, oil and
greases should be avoided. Similarly
contact with metals particularly
copper, manganese and iron should be
avoided as these affect some rubbers.
EFFECT OF OZONE Atmospheric ozone has a particularly

severe cracking effect on many
rubbers. If possible, the rubber/PVC
items should be protected from
circulating air by wrapping, storage
in air-tight containers or by any
other suitable method.
ROTATION OF STOCKS The rubber/PVC component should

remain in stock for as short a time
as possible. Therefore the components
should be issued from stores on
strictly first in, first out
principle.
2.0 PRECAUTIONS TO BE TAKEN DURING ASSEMBLY OF RUBBER CORDS FOR

END SHIELDS :
While assembling the rubber cords in the End shields,

following sequence to be followed :

Rev. 00 10/93
SECTION - III
GENERAL INSTRUCTIONS
JOINTING OF RUBBER GASKETS
Erection
2.1 Examine the square rubber cord 12x12 mm for any

deformation, cut marks or cracks, if found damaged replace
the same.
2.2 Before fixing the square rubber cord, examine the end
shield groove and the matching surface of side wall on
stator body - sharp edges if any to be rounded off so as to
prevent damage to the cord.
2.3 Degrease the groove thoroughly with petrol/white spirit, do

not allow rubber cord to come in contact with any of the
solvents.
2.4 Apply a thin layer of chemistick adhesive (Chemistick S-75

supplied by Chemisol Industries, Shamdas Gandhi Marg,
Bombay 400 002) or suitable equivalent at the bottom of
grooves and allow the solvent to evaporate before placing
the cord.
2.5 Place the square rubber cord size 12x12 ram centrally in
side the groove and keep it for about 4 hours suitably
pressed. The cord in the lower half shield should be left
unpasted for a length of 40 to 50 mm from the joining
surface.
2.6 On both the ends of the lower half end shield groove, the
rubber cord should project over the joining surface by 35
mm and the rubber cord of upper half end shield should end
at 10 mm before the joining surface. Both the cords should
be joined by a taper (scarf) joint for a length of 25 mm in
such a way that there is no squeezing of rubber cord near
parting plane (PI. see sketch 1).

0^1-01250/3 Of 4
Rev. 00
£JZT£Z* GENERATOR JOINTING OF RUBBER GASKETS
Erection
2.7 The round cord of dia 10 mm should be pasted in the

corresponding groove on the inner part of the end shield.
2.8 During assembly of lower half, the press out bolts M20x70
must be assembled in such a way that they project by at
least 8 mm so that the rubber cord glued in the groove do
not come in contact with stator body while rotating the End
shield. The above requirements are also specified in the
drg. No. 5487.005 "Mounting of End Shields".
2.9 In any case, it must be ensured that the rubber cord during
assembly, does not come out of the slot while bolting and
does not get crushed. Particular attention must be given to
the top half circumferential joint.
Bharat Heavy Electrical* limited G1-01-0125G/4 of 4

Rev. 00 10/93
:
mt MP - F I R S T ^ A N G L E P R O J E C T I O N ( ALL DIMENSIONS ARE IN mm) Form D6-4$
i-fc
ALTERED
1 ;
«i! '*'; REV
°m ALTERED G M S HO./an. SP. NO. •TATU4
OPDPtO
m m
•$Z
' - £ * * . > • / • ' ;

CHECKED
••••*• v "
CHECKED
AGREED
DEPT. NAME SIGN DATE
;>£ 8
•I
AT CIRCUMFERENCE TECHNICAL REQUIREMENTS
1. - SHARP CORNERS OF THE GROOVES MUST BE ROUNDEd

i 1 p.* OFF.
2. - DEGREASE THE GROOVES THOROUGHLY WITH
PETROL. APPLY A THIN LAYER OF ADHESIVE
xS AT THE BOTTOM OF GROOVES AND ALLOW THE
(_ c SOLVENT TO EVAPORATE BEFORE PLACING THE CORD.
<p
3. - SEALING RUBBER CORDS MUST BE LOCATED CENTRAL]
m « TO GROOVES. NO FOREIGN MATTER TO BE LEFT IN
^•o
o > SIDE THE GROOVE.
A. - RUBBER CORDS MUST BE INI TIALLY GLUED UNDER A
a c SLIGHT TENSION.
o a
o.c
a >. AT PARTING PLANE 5. - AT THE TWO ENDS OF LOWER HALF END SHIELD GROOVE
II THE CORD SHOULD PROJECT BY 3 5 M M AND \H<%%$&-\JP
20*0.5
HALFBND SHIELD THE CORD MUST END AT10M.MFROM
PARTING PLANE AND SHOULD BE JOINED BY A PROPER
(SCARP ) JOINT FOR A LENGTH OF 25 M M IN SUCHA
WAY THAT THERE IS NO SQUEEZING OF RUBBER
TJtJ CORD NEAR PARTING PLANE.
•.a e
£••6 DURING ASSY OF LOWER H A L F , THE PRE SS OUT BOLTS
0 M 20X70 MUST BE ASSEMBLED IN SUCH AWAY THAT
I
11 THEY PROJECT BY AT LEAST 8 M M SO THAT THE RUBBER
I*
c o CORD GLUED IN GROOVE DONOT COME IN CONTACT
WITH STATOR BODY WHILE END SHIELD ROTATES.
s5
?E UPPER HALF_SHIELD
LOWER HALF SHIELD
VIEW ON THE JOINT OF SEALING RUBBER CORD (SEE 7.R.5)

I I I I
29 31 M A T E R I A L CODE UNIT WEIGHT

ITEM 34 45
REMARKS DESCRIPTION
NO. VAR M A T E R I A L SPECN
88 7 5 23 27 2 9 32 S3 46 94 fi6 71
CARD TYPE- S 20 —*• 20 CARD TYPE-1 1 C A H O TYPE 2
NAME SIGN DATE NO.OF
Esa
(0 VAR
nr?N. PN MOURYA
Q
BHARAT HEAVY ELECTRICAIS [ID. CMP. R K BABBAR
HARDWAR
APPD A.S.SIDHU 73 74
DEPT. GRADE OF •SCALE WEIGHT i K C l REF. TO ASSY P R O ITEM NO. O F
TGE NO ITEMS
CODE
UNTOLOIM.
£?] 1.1
4233 7S 77
C/M/F
I 3 D R A W I N G NO REV.
TITLE .. V
<:. A r> u
SEALINGCORD ASSEMBLY CODE
TGE-0871
(UNPRESSED) IN GROOVES OF END _1 L ' i I I I I I I ' I I I I* 1
'" I Z
*
SHIELD. JHFF r NO. 1 I' OF SHEETS. \
I
CUTJTTM
GENERATOR STORAGE AND RECONSERVATION
Erection
1 STORAGE
1.1 The equipment should be accommodated in permanent places

of storage within 5 days after their arrival at
destination, taking into account the order of
requirement of details at the erection site.
1.2 Storing conditions fall into the following categories :-
Category I - Storing indoors: in dry store house.

Category II - Storing indoors: in unheated store houses.
Category III- Storing under a shed.
1.3 The platforms and store-houses should be built up in

conformity with the fire prevention rules and standards.
1.4 The platforms (near the railway and in other places),

intended for storing of articles, should be grouted with
concrete or the like, besides, draining of sub-soil and
surface water from the store houses site is to be
ensured.
1.5 Store houses should be provided with reliable

ventilation system.
1.6 The store house should be equipped with proper lifting

devices which ensure normal handling of articles.
1.7 Enclosed - type heated store houses should have fore-

rooms in front of the gateway and should be provided
with a reliable ventilation system. Temperature
fluctuations in the heated store - houses must not
exceed 10°C (as far as possible).
Bharat Heavy Electncals Limited „„ „„ „ „ _ . w , / ' .. „ ,_

3
„ G1-01-0122G/1 of 15
Rev. 00 10/93
CISTASI
Erection
1.8 Floors out of earth in the enclosed - type stores houses

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

used during the storage time are damaged, they should be
completely repaired. In case the rust preventive coating
is faulty, the coating should be applied again.
1.10 In order to choose a proper category of stores for

articles, as well as for their assemblies and
individuals parts use Table - 1 as a guide.
Table - 1
Description Category of Storage
1. Turbogenerator assemblies and parts :.

Rotor I
Stator II
Outer end Shields II
Foundation plates III
Stator end parts II
Exciter I
Large parts of assembling devices II
Studs II
Bearings II
Fan Baffles II
Terminal bushings II
Seal bodies I
Insulators II
Terminal boxes II
Emergency lubrication tanks II
Bharat Heavy Electrical* Limited G1-Q1-0122G/2 of 15

Rev. 00 10/93
OOi(£l GENERATOR STORAGE AND RECONSERVATION
Erection
Description Category of Storage
Stator winding bars I

Gas coolers II
Small parts of turbogenerators I
Thermal control apparatus I
Erection materials I
Apparatus & Control gear
3. Spare Parts :
Bearing liner I
Coils and winding bars I
Oil rings I
Brushes I
Fastenings and packings I
Tools I
1.10.1 The articles not specified in Table - I, should be

stored like equipment, similar in design, size and
application given in Table - 1.
1.10.2 The articles referring to category III are to be stored

in packed condition.
1.11 All the articles, additionally packed into film jackets

or the like envelope materials, should be stored without
opening this packing. In this case the middle - and
large size machines are to be stored without taking them
off from the bottom parts of wooden case.

Rev. 00 10/93
CiZTjRjl
G b R STORAGE AND RECONSERVATION
Erection
1.12 To prevent distortion, stator, its end portions, the

rotor and other large asemblies should be laid down upon
even platforms. While arranging the parts and assemblies
for storage, try to place them in the operating
position.
1.1.13 Small and middle size spare parts and articles are
recommended to be stored on shelves. The middle-size
articles weighting notover 10 Tonnes (in packed
condition) can be piled up to 2.5 m high; when doing
this, care should be taken to see that the lighter
articles be laid upon the heavier ones, and not vice
versa,- otherwise the lower articles will be damaged by
upper ones.
1.14 The articles weighing 10 tonnes or above are to be

arranged in a single tier.
1.15 While handling the equipment, strictly observe the

warning indicated by markings and inscriptions such as
"HANDLE WITH CARE" "TOP", "NOT TO PUT LOAD UPON THE
TOP". SLING HERE" etc.
2. Removal of Preservation Coatings
2.1 The removal of preservation coatings is to be carried

out in the following cases:
a) During routine inspection in order to check the

condition of the parts with regards to corrosion.
b) When preparing the assemblies and parts for

erection.
Bharat Heavy Electrical* Limited G 1 - 0 1 - 0 1 2 2 G / 4 of 15

Rev. 00 10/93
CJMTMSM* GENERATOR STORAGE AND RECONSERVATION
Erection
c) When commissioning the machines applied with

protective coatings for a long term shutdown;
d) For re-application of preservation coatings after

the expiry of guarantee term.
2.2 The articles should be freed of all the preservation

measures at a relative humidity of above 70% and at a
temperature not less than +12°C. While doing this the
open articles should be protected against atmospheric
precipitation, dust and dirt.
1.2.3 The personnel entrusted with this work should wear

cotton gloves.
The articles should be freed of preservation coatings

as recommended in Table 2.
Table - 2
Description Scope & Sequence of removing all

the preservation coatings
Shaft journals of a) Remove protective film and

dismantled machine; paraffin paper.
couplings flanges
and half couplings, b) By means of a wooden spatula
Joining surfaces. remove the basic layer of
grease and remove the rest of
the grease by means of rags
wetted in white spirit (item
1 of section 5 ) .
Bharat Heavy Electricals Limited G 1 - 0 1 - 0 1 2 2 G / 5 Of 15

Rev. 00 10/93
n^rrw) GENERATOR STORAGE AND RECONSERVATION
Erection

c) Wash of N.C. protective

coatings (as per item 4 of
section 5) with the
corresponding thinner (Item 5
of section 5) and wipe off
the cleaned surface with dry
clean calico.
2. Slip Rings a) Take off the wrapping paper.
b) Remove the layer of grease by

wiping the slip rings with
rags wetted in white spirit
(Item l of section 5 ) .
c) Wipe with clean dry calico.
Fastenings, rotation a) Wash with white spirit.

indicators, name , plates, (item 1 of section 5)
foundation bolts, small
parts.
Shaft journals of machines

transported in assembled
condition^:
a) If applied with grease a) Thoroughly wash the shaft

journal bearing liner, oil
chamber, labyrinth packings,
Bharat Heavy Electricals Limited G 1 - 0 1 - 0 1 2 2 G / 6 of 15

Rev. 00 10/93
CIZF£ZM GENERATOR STORAGE AND RECONSERVATION
Erection

the bearing cap, using white

spirit or hydro carbon
solvent or Aviation Gasoline
(Item 1 of section 5) till
the grease is completely
removed.
b) If applied with liquid b) Pour Oil light (Item 8 of

lubricants. section 5) preheated upto +
105 - 110 C into the bearing,
Crank the shaft for 4 to 5
times. Drain off the rest of
oil.
CONSERVATION
3.1 Conservation should be carried out on assembled

machines and their parts in the following cases :-
a) After removing the preservation coatings of the

equipment after the expiry of the guaratnee term
stated for preservation coatings.
b) When the machine is shut down for a long period

exceeding one month).
3.2 All the surfaces to be conserved should be degreased by

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

-Q1-0122G/7 Of 15
Rev. 00 fi/9?
CiTiJfll GENERATOR STORAGE AND RECONSERVATION
Erection
3.2.1 Rust any should be remvoed by rubbing with emerge cloth

mnoistened with rust removing solution 9 item no. 2
section 5 ) .
3.2.2 The surface of non-ferrous metal components should be

dressed with fine gained sand paper, wetted with IOC,
DTE oil light (as per item 8 of section 5 ) .
3.2.3 The surfaces should be air-dried at normal temperature

or wiped dry with clean rags, gauze or calico.
3.2.4 Preservation coatings should be applied to machine

assemblies and parts at a temperataure of not less than
+ 12° C and humidity of not over 70%. (at a temperature
of 25°C) requirements stated in Table - 3) .
TABLE
Description Scope and sequence of

Conservation procedures
Shaft journals, shaft a) Coat with N.C. protective
ends, couplings. (item 4 of section on 5).
b) Dry the coating for 8 hours

at a temperature of +18 -
23°C.
c) Coat the dry painted surface

with Mobilex grease no.
2 (Item 3 of section 1.5)
preheated upto + 1 1 0 - 120*
C.

Rev. 00 10/93
riEHTTi GENERATOR STORAGE AND RECONSERVATION
Erection

d) Wrap up with paraffin paper.
e) Enclose the article into a

film jacket.
Slip rings a) Coat the ground surface of

rings with mobilex grease No.
2 (item 3 of section 5)
heated upto 110 to 120° C.
b) Wrap up with paraffin paper.
c) Wrap up with polyethylene

film and tie around with
adhesive PVC tape.
Bearing Liners a) Coat the babbited surface

with Mobilex grease No. 2
(item 3 of section 5)
preheated upto + 110 1200
C.
b) Coat the' surfaces of the

steel parts with two layers
of N.C. protective coating
(item 4 of section 5) dry
each layer for 8 hours.

Rev. 00 10/93
fTiZTjCl GENERATOR
STORAGE AND RECONSERVATION
Erection

Coat the dry painted surface

with Mobilex grease No. 2
(item 3 of section 1.5)
preheated upto 110 - 120° C.
Wrap up with paraffin paper,

enclose in a film jacket and
tie around with adhesive PVC
tape.
Plated steel and a) Apply Mobilex grease No. 2

cast-iron parts. (item 3 of section 5)
preheaated upto 110 120c
C.
b) Wrap with paraffin paper.

c) Enclose in a polythylene
jacket.
Brush rocker a) Take the brushes out of brush

boxes.
b) Wrap the brushes with

paraffin paper.
c) Put the brushes upon the

brush boxes and clamp them
with brush holder lever. Wrap
the brush rocker with
paraffin paper.

GJL-$1-0122G/10 of 15
Rev. 00
CiZECTI GENERATOR
Erection

6. Name plates Coat with Mobilex grease No

2 (Item 3 of section 5)
preheated upto + 110 120°C,
Paste paraffin paper upon the

greased surface.
7. Free threaded holes Apply Mobilex grease No. 2

(blind and through holes) (Item No. 3 of section 5)
8. Surfaces at split joints a) Coat with a continuous layer

of magnet system and those of N.C. protective coating
of bearing bodies, and (item 4 of section 5 ) .
shielding.
b) Dry the coating at room

temperature.
c) Apply Mobilex grease No. 2

(Item 2 of section 5 to the
dry painted surface).
d) Paste paraffin paper.
3.3 Machine parts and assemblies not specified in Table -3

should be preserved like details of similar type and
purpose given in this table.
3.4 The assemblies and parts of machine (when assembled)

should be conserved during long term shut-downs
according to table - 4.

Rev. 00 C ^ ^ L - 0 1 2 2 G / 1 1 Of 15
cisxcni GENERATOR STORAGE AND RECONSERVATION
Erection
ITEM - 4

conservation procedures.
Bearing assembly, drain off the working oil

from the bearing oil chambers,
b) While rotating the shaft pour

Anti-Rust solution APS 22J or
Esso Rust TOP. PT (Item 6 of
section 5) into the hole
under the oil rings till a
continuous protective oil
film is formed on the shaft
journal, oil rings and
bearing liners.
c) Drain off the rest of Anti-

rust solution (item No. 6 of
section 5) throught the drain
hole.
Slip Rings a) Wipe with calico soaked with

rectified spirit.
b) By means of a paint-brush
apply Mobilex grease No. 2
(item 3 of section 5)
preheated upto + 120°C.
c) Wrap up with paraffin paper.

Rev. 00 10/93
CIZTJCH
Erection

conservation procedures.
d) Wrap into polythylene film

and tie around with adhesive
tape.
3. Brush Rocker a) Take the brushes out of brush

boxes.
c) Put the brushes upon the

brush boxes and clamp them
with brush holder levers.
Wrap the brush rocker with
paraffin paper and tie it
around with glass tape.
4. Threaded Holes Apply Mobilex grease No. 2

(Item No. 3 of section 1.5)
heated upto 110 U C 120°C.
Name Plates Rotation a) By means of a paint-brush

Indicators. apply Mobilex grease No. 2
(Item 3 of section 5)
preheated upto 100-120°C.
c) Tie around with adhesive
glass tape.
6. Joining, Surfaces Cast with Anti-Rust solution

(Item 6 of section 5 ) .

Rev. 00 itaff1-0122G/13 Of 15
OZiiTCl GENERATOR
Erection
3.5 The scope of conservation work should be recorded in the

inspection certificates to be prepared for each article
specifying the nature and quality of procedures adopted.
INSTRUCTIONS FOR SAFETY DURING CONSERVATION.
4.1 Removal of preservation coatings and reconservation

should be carried on the platform prepared before hand
and kept free from stray objects, dust, refuse etc.
4.2 When using volatile material (white spirit or Hydro

Carbon Solvent or Aviation Gasoline as per item 1 of
section 5) regularly check the purity of air in the
premises.
4.3 In the zone where the conservation work is carried out,

it is forbidden to keep and to take food, to smoke and
to perform any operations connected with fire.
4.4 Upon completion of conservation work, the rest of

material should be returned to a special store house.
MATERIALS REQUIRED FOR RECONSERVATION WORK
Item No. Specification of material

1. White spirit of Hydro carbon
solvent of corresponding grade as
per IS: 1745 or Aviation gasoline
IS : 1604.
2. Rust solvent X 50 of Ashok

Industries Ltd Bombay or
equivalent.
Rev. 00 Gj^7^L-0122G/l4 Of 15
CIUJCIl GENERATOR
Erection
Item No. Specification of material
3. Mobilex grease No. 2 of Indian

Oil Corpn. or any equivalent
Lithium Hydroxide grease.
Nitro cellulose protective

coating (Red.) of Shalimar Paints
Ltd. or equivalent.
Thinner for item No. 4 above.
Anti rust solution ARS-22 J of

Plastipeel Chemical Corpn. or
equivalent.
Rectified Spirit.
DTE oil light of Indian Oil

Corpn.
Paraffin paper 0.06 mm thick.
10 Polyethene film 0.15 mm thick.
11 Adhesive glass tape or adhesive

0.1 x 25 PVC tape.
12 Emery paper 100 GNT and 180 GNT.
Bharat Heavy Electricals Limited G1-01-0122G/15 Of 15

Rev. 00 10/93
CiiEHCl GENERATOR MAJOR T&P CONSUMABLES
Erection
LIST OF MAJOR T&P / CONSUMABLES REQUIRED
S.No. Item Quantity

1. Hydraulic Jack 100 MT 4 Nos.
2. Hot Air Blower
3. Hydraulic Test Pump (Hand Operated 15 Kg/Cm2) 1 No.
4. Heavy Duty Vaccum Cleaner l No.
5. 3 Leg Inside Micrometer or Box Dial Indicator 1 No.
50 - 70 mm
6. HV Test Kit(52 Kv AC or 73 Kv DC) 1 No.
7. Micro ohm meter 1 No.
8. Motor Operated Meggar (0-5Kv) 1 No.
9. 250 & 500 V hand Operated Meggar 1 No.
10. Single Phase Auto Tr. (0-240 V AC, 70 A) 1 No.
11. Compressor 1 No.
12. Hylomer or Shellac
13. CTC
14. White Spirit
15. Paraffin Paper
16. Silica Gel Approx. 25 Kg.
17. Instant setting Adhesive solution Approx. 250 ml.
(Anabond/Fevicol)
18. Non Corrosive Protective Paint
19. Mercury
20. Conbextra GP-2 6 Tons
21. Purge Test Kit
22. Dial Indicators

Gj^l-01330/1 of 2
Rev. 00
EiUJGn GENERATOR MAJOR T&P CONSUMABLES
Erection
S.No. Item Quantity

23. Feeler gauge sets
24. Varnier Calipers
25. Inside micrometer set (upto 1mm)
26. Outside micrometer set (upto 400 mm)
27. Multimeter (Digital and Analog) 2 Nos.
28. Surface place upto 1 Meter size.
29. Torque Wrinch (upto 150 Kg-M).
Bharat Heavy Electrical* Limited G1-01-0133G/2 of 2

Rev. 00 H**J*
aeefioj GENERATOR
ERECTION DRAWINGS
Erection
LIST OF TURBOGENERATOR DRAWINGS
SI.No. Drawing No, Description
1. 1255.001c Turbogenerator (General view)

2. 0311.016C Erection drawing (Gen.)
3. 0311.059C Terminal details
4. 6020.025C Temperature control diagram
5. 2-5670.073C Wound Stator
6. 6020.026C Installation of resistance thermometers
7. 0-5012.025C End Shield
8. 0-5013.005C Fan Shield
9. 6392.032C Gas Cooler
10. 2-5372.010C Shaft Seal (T.E.)
11. 1-5372.010C Shaft Seal (E.E.)
12. 0-5371.002C Seal Liner
13. 6030.016C Mounting of headers
SI.No. Drawing No. Description
14. 5675.010C Rotor

15. 5675.012C Wound rotor
16. 5264.002C Bearing with brush gear
17. 5263.008C Bearing liner
18. 0-5516.006C Trunion foot plate
19. 5478.007C Trunion foot plate
20. 6030.049C Mountinmg of casing
Bharat Heavy Electricals Limited <JJ^gl-0134G/l Of 3

Rev. 00
GENERATOR
ERECTION DRAWINGS
Erection
SI.No. Drawing No. Description
21. 6030.029C Fixing of foundation plate

22 . 6030.018C Mounting of embedded plate
23 . 5066.008C Embedded plate
24. 5066.021C Embedded plate
27. 0-5150.008C Shim
28. 5150.013C Shim
29. 5066.018 Foundation plate (Bearing)
30. 3-5060.000 Terminal box with equalising Coil
B. ERECTION DEVICES & TOOLS

1. 1-0344.001C Insertion of rotor into stator
2. 6771.003C Outer trolley
3. 6771.002C Inner trolley-
4. 5260.000C Rail
5. 5260.001C Rail
6. 8340. 035C Sheet
7. 5487.005C Mounting of end shield
8. 5487.006C Device for mounting of end shield
9. 5487.035C Device for removing and fixing of
Retaining Ring.
10. 5487.061C Device for screwing and removing of nut.
11. 5487.008C Device for removing fan hub.

0134G/2 of 3
Rev. 00 % * •
ElErMkMa GENERATOR
ERECTION DRAWINGS
Erection
SI No. Drawing No. Description
12. 5487.009C Device for removing slip ring with brush
13. 5484.001C Erection tools
14. 5484.100C Spanner
15. 5484.000C Wrench
16. 8921.006C Jack screw

(JJ^gl-0134G/3 Of 3
Rev. 00
CISTACI GENERATOR
Erection DYE PENETRATION TEST
Dye penetration test is carried out for detecting surface cracks

and some other abnormalities on the rotor retaining ring surface
and other critical machined components.
1.0 MATERIAL & TOOLS EMPLOYED
1. Dye Solution in Spray type container

2. Developer
3. Cleaner/Thinner
4. Cotton Cloth
2.0 TEST PROCEDURE
i) Clean the surface under test till it becomes bright.

Rough scratches should be removed as they may effect
the results.
ii) Degrease the surface just before test.
iii) Apply dye solution and wait for 15 minutes.
iv) Clean the surface with thinner jet and wipe off with
the help off clean soft rag till dye is completely
removed.
v) Now quickly coat the surface with developer and

observe its drying for 2 to 3 minutes. Appearance of
red lines on the surface as the halk solution dries
indicates the presence of cracks and flaws.
Bharat Heavy Electricals Limited „ „-,„„, ^ ,

137G/1
Rev. 00 %/W-° °f X
FIELD QUALITY ASSURANCE
1.0 Test results for placementof stator on foundation
SI. Design Actual

No. Description Remarks
Value Value
1.1 Soundness of bondage of stator embedded Vibration of
plates with the concrete by means of harmrBr sand not
test. allowed
1.2 Centering and elevation readings of Readings obtain-

embedded plates. ed to be entered
in sheet 2/4 &
Centering readings of pipe sleeves. 3 / 4 of this
logsheet.
1.3 Matching of embedded plates to obtain Contact ^ 8 0 % Readings obtain
required contact and slopes in the slope 3-4 mm ed to be entered
direction of insertion (sloping away frcm per metre. in sheet
TG centre line) 4/4 of this
logsheet.
1.4 Percentage of contact surface of bottom contact ^ 8 0 %
side of foundation of stator.
1.5 Checking of top surface of foundation plates 0.50rrm f e e l e r

with straight edge. gauge s h o u l d
not pass
1.6 Percentage of contact surface of anchor Contact/C80%
plates with foundation.
1.7 Percentage of contact surface of pads of C o n t a c t - ^ 90%

trunion foot plates with pads of stator.
1.8 Feeler gauge check at pads and vertical 0.03 mm

face during assembly of trunion foot plates f e e l e r gauge
to stator. s h o u l d not
pass
NAME & SIG.

REVISION ^-8/92
PROJECT ERECTION
UNIT NO. CUSTOMER SHEET 1 / 4
RATING FQA FQA-03-00-01-L-01
SLOPES OF GENERATOR EMBEDDED PLATES
\u p r1 |o n
DURING MATCHING ENSURE THERE
IS NO S L O P E T R A N S V E R S E TO T H E
D I R E C T I O N OF I N S E R T I O N OF
0 u
PACKERS .
0 Q
CL O F GENERATOR
SLOPES OBTAINED AFTER M A T C H I N G (_ "C

TO BE ENTERED I N BOXES SHOWN. °
ID
a o
' ID "
o a
U 4 4
Dl Dl LM o n
t t ,. .1
t J-, J,i SLOPES AS PER DRAWING I N D I R E C T I O N

OF I N S E R T I O N OF PACKERS 3-4mm/M
NAME SIGNATURE DATE

REVISION: R2-8/92
PROJECT: ERECTION:
UNIT NO: FQA: SHEET: 4/4
RATING: CUSTOMER: FQA-03-OQ-01-L-01
n FIELD QUALITY ASSURANCE
No. of No. of Parameter DC IR Value Ambient

Thermometer Thermometer- Location Measured resistance MG Temperature Remarks
lead n •c
1 2 3 4 5 6 7 8
17 17A S l o t 17 Winding
17B ' temp.
18 18A S l o t 18 -do-
18R
19 19A S l o t 19 -do-
19B
20 20A S l o t 20 -do-
20R
21 21A S l o t 21 -do-
21B
22 22A S l o t 22 -do-
22B
23 23A S l o t 23 -do-
23B
24 24A S l o t 24 -do-
24B
25 25A S l o t 25 -do-
25B
26 26A S l o t 26 -do-
26B
27 27A S l o t 27 -do-
27B
28 28A S l o t 28 -do-
28B
29 29A S l o t 29 -do-
29B
30 30A S l o t 30 -do-
30B
31 31A S l o t 31 -do-
31B
32 32A S l o t 32 -do-
32B
33 33A S l o t 33 -do-
33B
34 34A S l o t 34 -do-
34B
35 35A S l o t 35 -do-
35B
36 36A S l o t 36 -do-
3fiR
37 - 37A S l o t 37 -do-
37B
38 38A S l o t 38 -do-
38B
39 39A S l o t 39 -do-
39B
NAME & SIG.

REVISION R?-8/92
PROJECT ERECTION

M

Thermometer Thermometer- Location Measured resistance Mfi Temperature Remarks
lead O •c
1 2 3 4 5 6 7 8
-
40 40A Slot 40 Winding
40B terrp.
41 41A Slot 41 -do-
41B
42 42A Slot 42 -do-
42B
43 43A Slot 43 -do-
43B
44 44A Slot 44 -do-
44B
45 45A Slot 45 -do-
45B
46 46A Slot 46 -do-
46B
47 47A Slot 47 -do-
47B
48 48A Slot 48 -do-
48B
49 49A Slot 49 -do-
49R
50 50A Slot 50 -do-
50B
51 51A Slot 51 -do-
51B
52 52A Slot 52 -do- >
52B
53 53A Slot 53 -dOT
53B
54 54A 51ot 54 -do-
54B
55 55A Slot 55 -do-
55B
56 56A Slot 56 -do-
56B
57 57A Slot 57 -do-
57R
58 58A Slot 58 -do-
58B
59 59A Slot 59 -do-
59B
60 60A 51ot 60 -do-
60B
61 61A 51ot 1 Core i r o n
61B terrp.
62 62A slot 21 -do-
62B
NAME & SIG.

REVISION R2-8/92
PROJECT ERECTION
UNIT N O . CUSTOMER SHEET 3 / 6

[ 7/1 VU y {TrfJ
Ea
Thermometer Thermometer- Location Measured resistance MQ Temperature Remarks
lead n •C
1 2 3 4 5 6 7 8
63 63A Slot 41 Core i r o n

63B term.
61S 61AS Slot 2 -do-
61BS
62S 62AS S l o t 22 -do-
62BS
63BS
64 6iA Slot 1 -do-
64B
65 65A Slot 21 -do-
65B
66 66A Slot 41 -do-
66B
64BS
65S 65AS S l o t 22 -do-
65BS
66BS
67 67A Slot 1 -do-
67B
68 68A Slot 21 -do-
68B
69 69A Slot 41 -do-
69B
67BS
68BS
69BS
70 70A Slot 1 -do-
7 OB
71 71A Slot 21 -do-
71B
72 72A Slot 41 -do-
72B
70BS
71BS
72BS
73 73A Middle of C o l d gas
73B stator body
74 74A -do- -do-
74B
NAME & SIG.

REVISION R2~8/92
PROJECT ERECTION
RATING FQA FOA-03-00-01-L-02

si. No. of No. of Parameter DC IR Value Ambient

No. Thermometer Thermometer- Measured resistance Mfi Temperature
Location Remarks
lead a
75 75A M i d d l e of C o l d gas
75B stater booV
76 76A -do- -do-
76B
77 77A -do- -do-
_77B_
78 78A -do- -do-
78B
Design Actual
Description Value Value Remarks
2.3 Hydraulic test of Hydrogen coolers. 5Kg/cm

Test pressure
Duration 30 min.
2.4 Hydraulic test of terminal bars before

assembling on the stator terminals.
Test pressure 25Kg/cm
Duration 30 min.
2.5 Non magnetic property of bolts/nuts Non-

connecting the terminal bars with magnetic
connecting bus bars inside the stator.
2.6 MEASUREMENT OF DC RESISTANCE k IMPEDANCE OF STATOR WINDING
Before connecting After bolting rt\ After soldering /-.•» V a r i a t i o n i n
Terminal bushing ' Terminal Bushing Terminal Bushing resistance^
Value Temp. Value Temp Value Temp. 3% b e t w e e n '
C -1C1 (a), (b)6
DC Resistance (c)
C -2C1
IR Value
r-ic2
DC Resistance
C-2C2
C iH Value
- E -
r - i c 3 DC Resistance
C-2C3 Jse 1000 V
IR Value meggar
I R ^ t (KV+1)
C -C a t 40°C.
C IR Value
5-C6
C -C
4 6
NAME & SIG.
REVISION R2-8/92
PROJECT ERECTION
m FIELD QUALITY ASSURANCE
SI. Design Actual

Description Remarks
No. Value Value
2.7 HV t e s t on porcelain insulators of t h e 52 KV AC f o r /

bushings 1 m i n . o r 73KV
DC f o r 1 m i n .
Insulator Nunber i z 3 4 5 6 7 8 9
HV Test volts
Duration - 1 minute
Leakage current
IR Before Test
IR After Test
2.8 i ) C o n d i t i o n of t h e w a t e r p a t h d e t a i l s of
stator winding, teflon hoses, vent
pipes, general condition of stator
winding.
ii)Locking of fasteners provided on

insulating brackets for s t a t o r winding
overhang.
2.9 IR between water headers and s t a t o r body.

I n l e t Header 5M ohm Use 500 V
Outlet Header meggar
2.10 i ) Pneumatic pressure test of stator

winding.
Pressure of a i r a p p l i e d 3.5 A t g . Use o n l y d r y

P e r i o d of a p p l i c a t i o n . 4 hrs. instriment air
No leakage
permissible.
ii)Hydraulic pressure applied on stator 8.0 A t g .
winding. Use o n l y D/M
w a t e r . No
Period of a p p l i c a t i o n 24 h r s leakage
Permissible pressure drop 0.4 A t g . permissible
2.11 IR v a l u e of w i n d i n g w i t h w a t e r . • 100 K ohm Use 1000 V

( c o r r e s p o n d i n g t o DM w a t e r c o n d u c t i v i t y meggar
of 5 micro-semen)
2.12 Air tightness test of Stator. 4.0 Atg.
Pressure o f a i r a p p l i e d 8
P e r m i s s i b l e leakage o f a i r i n rtm Hg
a f t e r temperature c o r r e c t i o n .
NAME & SIG.
REVISION R2 - 8 / 9 2
PROJECT ERECTION
RATING FQA FQA-03-00 - 0 1 - L - 0 2

3. Tests on rotor prior to rotor insertion
SI. Design Actual

Description Remarks
No. Value Value
3 .1 1) Diameter of journals
a) Front brg. journal

b) Front seal journal
c) Rear brg. journal
d) Rear seal journal
2) Spigot of coupling:-
a) Diameter
b) Projection
3.2 Gas tightness test 4.0 Atg Not a p p l i c a -

Pressure of N applied b l e f o r THW-
Permissible leakage of N in 6 hrs, 260 210-2B
in mm of Hg. column. Generator.
3.3 Purge test of ventilating canals: F i l l sheet 3

Technical requirements: 6 A of ' t h i s
logsheet.
1) Inlet pressure of air at the 3 . 0 + 0 . 1 A t g .
ventilating canals of slot
through the inlet adapter.
2) Static pressure to be maintained 50 rrtn of H O

under retaining ring during test column
on overhang portion.
3) Required average velocity ^ . 1 5 mn o f

pressure for each zone in the H„0 column
canals of slot portion.
Required average velocity -£.21 rrm of

pressure for each slot. H„0 column
4) Required value of static pressure ^C.15 nrm of

in individual canals of overhang H„0 column
port ion.
5) Fully closed canals are not

allowed in the overhang portion
of rotor winding.
6) Ensure sealing of all ventilation

canals/ducts after purge test and
their removal only at the time of
rotor insertion.
NAME & SIG.

REVISION R2-8/92
PROJECT ERECTION
UNIT NO. CUSTOMER SHEET 1 / A
mmitAVgM
CHART FOR PURGE TEST OF ROTOR VENTILATION CANALS
aun •• •
SLOT P O R T I O N O F ROTOR
INLET HOLES
.
I n l e t a i r pressure In slot portion
Static pressure under retalnlnq rlnq
:
:
Overhang portion on IE
o 74 76 178 8 0 I 8 2 J 8 4 /WERAGE 139 | l O l | l 0 3 | l 0 5 J 0 7 109 111}(VERAGE 1 00 102,04 106 1 0 8 1 1 0 1 1 ; 'IVERAGE AVERAGE
71 | 7 3 |75 |77 | 7 9 l e i |83 I A V E R A G E 72
M U M
s FOR FOR 0 U T L E T MOLES FOR FOR FOR
58 60 6? 64 66 68 70 SECTION 05 87 19 91 93 95 97 ECTION 36 88 90 92 94 96 98 SECTION J i 15H? LL2 U1 23 25 >ECT!0N SLOT LLt H i Llfl lifl 121 24 J&
1
2
3. ——
4
4_
IT
7
8-
9
10 —
11
12
13
14
15
16
17 — ,• ——
18
— —
19
20
21
22
2.3 _
24
25
%->
27
28
29
39-
5i ,
32
33
34
IS 1
36
1 .
NAME SIGNATURE DATE
REVISION: R2-8/92
PROJECT: ERECTION:'
UNIT NO: FQA: SHEET: h I i*
RATING: CUSTOMER: FQA-03-00-0 1-L-03

|M2t£tJffrl] CHART FOR PURGE TEST OF ROTOR VENTILATION CANALS
am o
X
1-
o
—1
T
OVERHANG PORTION
ON EXCITER SIDE
I I I
3 5 7 9
I I 1 5 1 7 119
11 13 |2 4 6 8 10 12 14 SECTION
r^-r- •-.».-.-rr <-...• nr-
SLOT P O R T I O N OF
2 1 | 2 3 | 2 5 | 2 7J AVERAGE
FOR
I N L E T HOLES
^T-^.1-.
ROTOR
16 8 20 22 24 ?6 [28 |AVERAGE
29 ) 1 33 35" 37 )9 41 SECTION
FOR
I n l e t a i r pressure i n s t o t p o r t i o n
S t a t i c pressure under r e t a i n i n g r i n g
4 3 | 4 5 | 4 7 | 4 9 | 5 1 |53 |55 AVERAGE
30 32 34 36 38 40 42 SECTION
FOR
44
57 59 61 63 65 67 69 SECTION
:
:
I 46j 181 50 152 | 51 |56 JAVERAGE

FOR
1
2
3 i
fts
6
7 i
—
8
T
10
11
12
13
TT
TT
16
17
42-
i9
20
21
22
Z3
2*
I f
— — — —
26
—
27
— —— —— — —— —— —
28
"77
Iff
——
-JT
"5?
33
34
35
—_ - — — —
36 .
NAME SIGNATURE DATE
REVISION: R - 8 / 9 2
PROJECT: ERECTION
UNIT NO: FQA: SHEET: 3 / A
RATING: CUSTOME R: F Q A - 0 3 - 0 0 - 0 1 - L - 0 3
m FIELD QUALITY ASSURANCE
SI. Design Actual

Description Remarks
No. Value Value
5.3 Percentage contact of permanent ^80%

packers with embedded plates and
foundation frame of rear bearing
pedes ta i .
Thickness of permanent packers. <£ 25mm
5.4 Tightening torque of foundation 110 kg-M

studs .
2
5.5 Average value of compressive 200kg/cm
strength of test cubes 21 days
after grouting of rear bearing
pedesta1.
Alignment readings of Generator

rotor with LP r o t o r a f t e r grouting.
tora* [AS
TO* aorroff Zifrr /r/s#r
e* r, 4 A *, I
1
St' % * // 4 J
,
t*>*
5 * J-3 is t>
170* J
* ** *+ ** u
AlV*A*t * / * 1
"
5.6 Pe r m i s s i b l e d i f f erences in axial
ga p s .
T-B + 0.02. - 0.03
L-R ±0.02 - 0.03
mm
Pe r m i s s i b l e > d i f f e r e n c e s i n radial
ga p s - i . e . a b ;5 o l u t e v a l u e s of
C .03nrm
!
! "
!
3 a n C J2 " \
Inc 1 i n a t i o n of sh a f t journal in
mm/ 1 0 0 0 met*
r 1 1
*»>r>
1 1*if.
i 4L- -
n ll 1
"— Vs *n, i_U_ - 7]
Y/\ 4 ; r ' X/YA
Y' yi —
i
NAME & SIG.
REVISION R2-8/92
PROJECT ERECTION
UNIT NO. CUSTOMER SHEET 2 / 1 2
5.7
si. Design Actual

No. Description Remarks
Value Value
5.8 Centering of stator w.r.t. Rotor.

SECTION-XX xr
k
i —1
\
i
—\
d
r
\
\T
\
J\
y
\ \ 1|*
t
c r
s •
N /
-
=lh>
Sj|_i>
I
1 V 1
D
/ <
[
\\ /
x h— —Hx
THE DISTANCE A.B.C.D SHOULD HOT DIFFER FROM EACH OTHER BT MORE THAN O S mm
Permissible difference
A-B ±0.5 mm
C-D
5.9 Adjustment of magnetic axis, §2
51:2
,>. s,:< . B
IliU) • i
il |!.,|ill!il| 1
TURBINE END <~ H EXCITER END
iL
J -J l_p
, !j 1BMM
Dimension A and B shouLd be

adjusted such that A-B 36 mm
Note: Offset of axis 18 mm is only

for reference.
5.10 Air gap reading,
EXCITER END EXCITER END
TURBINE END TURBINE END
EXCITER END
TURBINE ENO
X^J EXCITER END
TURBINE ENO
CALCULATED VALUE OF GAP i 1 0 mm
ACTUAL AIR SAP SHOULD BE WITHIN 70 • 1.75

_J J L
NAME & SIG.
REVISION R2-8/92
PROJECT ERECTION
A. Test results on EE bearing and pedestal prior to rotor insertion,
SI. Design Actual

Description Value Value
Remarks
No.
A. 1 Soundness of bondaae of pedestal V i b r a t i o n o f

embedded plates with the concrete sand not
by means of hammer test. allowed.
A.2 Centering and elevation readings Sheet No.2/4

of embedded plates. 5, 3/4 of L-01 to
Centering readings of pipe be f i l l e d .
sleeves .
A.3 Matching of embedded plates to C o n t a c t ^ ' 8 0 % Sheet No. 4/4
obtain required contact and slopes s l o p e 3-A rrm of L-01 to be
in the direction of insertion. per m e t e r .
filled.
A.A Percentage of contact anchor Contac t ^ 7 0 %

plates with foundat ion.
A.5 Kerosene test of oil chamber of No l e a k a g e /
rear bearing pedestal. seepage
Period of application. 2A h r s . allowed.
Contact between foundation frame
A.6 and rear bearing pedestal.
Clearance at joint should not 0.05 mm
exceed.
A.7
Percentage of contact of •ft 80%
foundation frame bottom at seating
surface with permanent packers.
A) Percentag e of contact of -JC 80%
spher icat seat ing of rear
bear ing liner with pedestal.
B) Percentage of contact of - £ 80%

rear bearing liner parting
plane .
C) Percentage of contact of - £ 80%
rear bearing pedestal
parting plane.
d) Percentage of contact -ft 80%
between journal and bearing
liner lower half along a
uniform band of A5°-55°.
NAME & SIG.

REVISION R2-8/92
PROJECT ERECTION
RATING FQA FQA-03-00-01-L-0A
r nwufc-w •
SHEET 1 / 12
UNIT NO. CUSTOMER
FQA-03-00-01-L-05
RATING FQA
Bun-out readings of r o t o r .
x _* ha 1 f -coup 1 i n 9 •
A. Axial run out of halt
Radial run-outs
0.03
0.03
0.03
0.03
0.03
E/E b e a r i n g ,- 0.03
E/E seal journal 0.03
Inner slip r i n g . 0.03
O u t e r slip ring- 0.03
Balancing disc.
2 Alignment readings of generator

rotor with LP rotor.
J !
TOP narrow \ ±/rsr \ #/6f/r
St'
,»'
v*\ \«\
t70*
fil/CMA** \9
s in axial
ible difference
Permiss
gaps. 1.0.02 - 0 . 0 3
T-B ±0.02 - 0 . 0 3
L-R rrm
n radial
differences i
p is s b e
.
gaps
! ™ - ' , rt.;T«« v.i»..« 0.03rrm
jnd I.
REVISION R2-8/92
ERECTION SHEET 1 / 1 2
PROJECT
CUSTOMER
UNtT NO.
FQA
[RATING
si. Description Design Actual

Remarks
No. Value Value
5.3 Percentage contact of permanent ^80%

packers with embedded plates and
foundation frame of rear bearing
pedes ta 1.
Thickness of permanent packers. «£ 25mm
5.A Tightening torque of foundation 110 kg-M

studs.
5.5 Average value of compressive 200kg/crr/

after grouting of rear bearing
pedesta1.
5.6 Alignment readings of Generator

rotor with LP rotor after grouting.
Mfrar [AS
J?AJ>/JIL a A P.
TO* BOTTOM *.esr #/6#r
r,
Je' It
fM' is
170'
ADffAat
Permissible differences in axial

gaps.
T-B + 0 . 0 2 - 0.03
L-R ±0.02 - 0.03
nm
Permissible differences in radial
gaps - i.e. absolute values of
I 0.03nm
X
! ~ X 3 a n d l2
5.7 Inclination, of shaft journal in
mm/1000 meter
J>»*.
-B SB m ~\—
%
J_
NAME & SIG.
REVISION R2-8/92
PROJECT ERECTION
si. Description
Design Actual
Remarks
No. Value Value
5.8 Centering of stator w.r.t. Rotor.

SEC7I0N-XX xi —H X
/
r^ ' ^ \ ) "li
\ •» s /
A
\ i ^r •*
^ H s 1-1
~tZ l
J il-"
^ y
I
V j D
^
\
/ s
r
\\ /
x f— —Hx
THE OISTAMCE A.B.C.D SHOULD NOT DIFFER FROM EACH OTHER BT MORE THAN O S mm
Permissible difference
A-B ±0.5 mm
C-D
5.9 Adjustment of magnetic axis.
I I M : , . . ( ! . . 1111 f i i |
TURBINE ENO EXCITER END
III""!:"''''!!)!
, !'_,18MM
Dimension A and B should be

adjusted such that A-B 36 mm
Note: Offset of axis 18 mm is only

for reference.
5.10 Air gap reading.
EXCITER END EXCITER END
1 1 1
TURBINE END TURBINE END
1 1
EXCITER END
TURBINE END
W' EXCITER END
TURBINE ENO
1
CALCULATED VALUE OF GAP «10 mm
ACTUAL AIR GAP SHOULD BE WITHIN 70 • 1.75 m

__J 1Z L
NAME & SIG.
REVISION R2-8/92
PROJECT ERECTION
si. Design Actual

No.
Calculated value of gap. 70mm
Permissible differences in measured ^3.5 mm

values of top and bottom readings
and left and right readings.
5. 1 1Percentage of contact surface of ft 80%

permanent packers with embedded
plates of stator.
Thickness of permanent packers. •jt 25mm
5. 12 Elongation of foundation studs of 0.38mm

stator during tightening
or
Tightening torque of foundation 105Kg-M
stud.
5. 13 Average value of compressive 200Kg/cm"

after grouting of stator foundation
plates.
5. 14 Hot water flushing of stator water Wa t e r Iemp. A l i the t e f -

system including winding prior to about 60-70°C l o n hoses
boxing up of Generator. s h o u l d be
hand felt
f o r warmness
5. 15 Clearance between fan and fan to detect
shield . blockage of
an w a t e r
Gap 'A' to be adjusted at site to obtain path.
the following readings:
Gap 'A' to be adjusted at site to obtain

xne following readings:
E/E 7s 4Qrm
T/E < IQrm
Required values of gap B 2-2.98rmi
T/E 2-2.98mn
P e r m i s s i b l e d i f f e r e n c e i n measured values
of gap ' B ' i n h o r i z o n t a l 6 v e r t i c a l planes ^ 0.07mm
NAME & SIG.

REVISION R?-8/92
PROJECT ERECTION
si. Design Actual

No.
5.16 IR value between fan -

Shield and end -shield E/E ft 5M Ohms Use 500V
meggar
5.17 End-shield fixing
Tightening torque for bolts:

a) Parting plane bolts (item 2) 95 Kg-m
b) Bolts for fixing end-shield 45 Kg-m
with stator body litem 1)
Note: Locking of bolts for fixing
upper naif fan shield to end
shield to be ensured -.prior
to closing of Inspection
windows.
5 . 18 Axial run out measurement on end
shield (seal body seating surface)
MEASUREMENT AXIAL RUN OUT I MEASUREMENT I AXIAL RUN CUT
VIEW- A 01 02 ID1-021/2I VIEW- B ! 01 I 02 EVO:W
01 I I
02
03
01 0(
as
06
09
_LL 12
13
Permissible axial run-out

Axial run-out exceeding 0-2 mm t o be ^ 0-2/nm
neutralised by s u i t a b l e machining of seal
body flange.
Note: Location nurbers are counted while locking from TE U EE respectiv s l y
NAME & SIG.

REVISION R2-8/92
PROJECT ERECTION

si. Design Actual

No.
5.19|Shaft seal 6 oil catcher adjustment

CNO SHIELD EXCITER SOE | TURBINE SIDE
NOUTION
' NOMINAL MEASURED NOMINAL MEASURED
VALUES VALUES VALUES VALUES
A
(SO • 5S ) I m - JO)
•COS
B W -«)
t5 - 10)
C
OS •<:o*
(35-3« U-S )
D O-17-0-2J6 O47-0-3?*
Note: Ensure absence of contact of seal body with

rotor step radius, for this 2XA5 chamfer can
be done on the seal body edge facing rotor
step.
NOMINAL MEASURED VALUE I

S-NO
VALUE IEX-SI0E |TUR-SI0E i
| TOP | 0-3 -0-4 I
I 0-17-O-3SI
BOTTOM 1005-0-101
LEFT 10-17-035!
I 01 I TOP ^BOTTOM* 0-26-0-30 I IDIAMETRICAL
"i02ILEFT4RIGHT! 0-25- 3-30 I 'CLEARANCE
| 01I II TOP 50
1021 SIGHT
'*! 03 I BOTTOM 5-0 I
iotl LEFT
1011 TOP '0-3 -0-6 J^
J02| RIGHT iQ-17-0-351
"J03I BOTTOM iQ-Ot-3-IQI
i 0 4 l LEFT | 0-17-3-35!
OIL SELECTING SING 5.1 01_ I TOP |0-3 -0-5 j
02 SIGHT
10-17-0-35 I
1. Joining surfaces of seal bodies should

be matched so that 0.03 . feeler gauge
does not pass. Ensure that no undue
ovality in bore dia is created at the
time of matching.
2. Centering of lower half seal body with

respect to rotor be done within 0.10 rrm.
NAME & SIG.

REVISION R2-8/92
PROJECT ERECTION
RATING FQA FOA-03-0O-O1-L-05
VLlimt-MtJiM I FIELD QUALITY ASSURANCE
\njju
SI. Design Actual
No. Description Value Remarks
Value
3 . R o t a t e t h e seal r i n g and check free

movement on r o t o r and i n s i d e the seal
body.
A. No s c r a p i n g s h o u l d be c b n e o n p a r t i n g p l a n e
o r i n s i d e d i a of s e a l r i n g i n any case
5 . Check t h a t the. l o c a t i o n o f t h e s l o t ( f o r
s e a l r i n g s t o p p e r ) a t lower h a l f j o i n i n g
. p l a n e of s e a l body i s on l e f t s i d e f o r
b o t h T / E and E/E s e a l s when viewed f r o m
T/E.
6 . Check t h a t the l o c a t i o n o f t h e s e a l r i n g
. i o i n i n g plane viewed f r o m T/E i s on t h e
l e f t s i d e f o r b o t h T / E and E/E seals
when t h e stopper p i n r e s t s i n t h e s e a l
body s l o t .
-
7 . Check t h e s t o p p e r o f seal ring for

absence of any n o t c h o r crack.
8 . Ensure t h a t the s t o p p e r i s p r o t r u d i n g a t
l e a s t 10 mm i n t o t h e s e a l body g r o o v e .
5 . For p r o p e r f l o a t of s e a l r i n g , check gap

between s e a l body s l o t and s t o p p e r p i n -
d e s i g n v a l u e 0.5 rrm.
10. I n case stopper p i n i s t o be r e p l a c e d

ensure t h a t l o c a l l y made p i n i s not used
5.20 IR v a l u e of e n d - s h i e l d o i l c a t c h e r a t EE <£ 5 Mohm Use 500V

meggar
5.21 IR value, of g e n e r a t o r r e a r end a f t e r EE "i£. 5 Mohm -do-
s h a f t s e g l assembly by l i f t i n g t h e r o t o r on
TE and w i t h an a x i a l gap between LP and
Generator r o t o r s
1 NAME & SIG.

REVISION R, - 8 / 9 2 -
PROJECT ERECTION 2
RATING FQA FQA-03-00 - 0 1 - L - 0 5
si. Design Actual

No.
5-22 Reaming/Coupling of generator and LP
rotor half couplings
w. _rr
| 170 I
JO.
11
12
13
14
15
16
17
18
1« BOtTS ITSO WITH 0 - O i - 0 - 0 3 mm

CLEARANCE FITTED At SITE
Elongation of coupling bolts achieved after 0.43 0.47

coupling LP and TG rotors. rrm
Permissible change in coupling radial run- 0.01 0.02

outs after fitment of coupling bolts. mm
Data on Reaming/Coupl ing of LP-TG rotors
COUPLING COUPLING HOLE DIMENSIONS COUPLING BOLT DIMENSIONS

s.
NO- HOLE NO. INITIAL FINISHED OVALITY TAPER COUPLING WALL FINISHED OVALITY WEIGHT OF BOLT
DIA DIA THICKNESS DIA AND NUT
5.
6-
f.
8.
».
10.
II.
II.
IS.
14.
IS.
I*.
a.
18.
NAME & S1G.

REVISION R2-8/92
PROJECT ERECTION
si. Design Actual

No.
5.23 Bearing adjustment (Exciter side)
ALONG t-t ALONG C-C ALONG 0 - 0
C A L C U L I ACTUM CALCULA- ACIUAL CALCULA- ACTUAL

TE TE P
0-7- 0-9 O.A-0-* O-ta-0-40
0-35-O-A5 0-1-S-4S O-ll-O-l
O-IO-O-IS
DIAPHRAGM IN OIL PIPE
DESIGN VALUE 10MN\
ACTUAL VALUE.
DC resistance of bearing RTDs 79 A

79 B
80 A
80 B
Note: For 2B type of generators the value of E i s 27mm
5.24 Insulation resistance of all oil piping|3E)
A. Lub o i l inlet sfc 5 Mohms'
B. Lub o i l d r a i n -do-
C. Jacking oil inlet - - d o - _.
D. Seal o i l i n l e t -do-
E. Ring r e l i e f inlet -do-
F. Seal o i l drain (H,side) -do-
G. Seal o i l drain ( a i r s i d e ' -do-
H. Aux.bearing inlet -do-
I. A u x . b e a r i n g outlet"- -do-
5.25 A i r t i g h t e n e s s t e s t o f asserrbled g e n e r a t o r
w i t h gas and o i l s y s t e m
Pressure of a i r a p p l i e d 4.0 atg
P e r m i s s i b l e leakage o f a i r i n 24 Hrs 38
( i n nrm of Hg c o l u m n ) a f t e r teTperattre
correction.
526 IR & PI values of each phase of stator wdg PI Value=

Phase R ' IR.n . IRfOMiVv.
*>2
..p.10 min . IR
1 min I Min
PI value PI Value of less
than 2 is to be
Phase Y improved before
IR 10min
1 min synchronisation.
PI value
Phase B IR.n .
I R 10min
1 nun
PI value
NAME & SIG.
REVISION R2-8/92
PROJECT ERECTION
si. Design Actual

No.
5.27 Centering 8 offset setting of Brush-
Gear for THW-210-2A generators BRUSH GEAR SLIP RING
BRUSH HOLDER
BRUSH GEAR
SLIP RING
THE DIFFERENCE BETWEEN

t ^ . t ^
VVV*« NOT MORE
THAN 1 m n .
CALCULATED V A L U E ACTUAL
NOTATION FOR BRUSH GEAF FOR BRUSH GEAF
VALUE
WITH I D * 0 " 4 8 0 WITH 1 0 1 7 4 68
t 1 9-5 - 10-4 3-4 • 41
t2 9- 5 - 1 0 - 4 34 - 4-1
t3 9 - 5 - 10-4 yi - 41
t4 9- 5 - 10-4 >4 - 41
A 0 0
B 18 TO JO 16 T 20
c 32 TO 36 32 .- 3 6
! ° SO TO S4 50 - 54
5.28 Centering & o f f s e t s e t t i n g of brush-

g e a r f o r THW-210-2B g e n e r a t o r s
RIB
VARIATION IN t ON Al I THE Rl°^ «;nnni n
NOT BE MORE THAN 2 mm
FREE END GENERATOR END

SUPRING
MEASURED
VALUE
BRUSH
t
BDDD L
DDDD
SUP RING
18mm
/
Check IR value a) Each limb 'h 5Mohms
b) Between Hmbs T^T 5Mohms
NAME & SIG.

REVISION R -8/92
PROJECT ERECTION
SL Design Actual
Description Remarks
No. Value Value
5.29 Fixing of Brush Holder 6 Brushes for

THW-210-2A/2B generators.
BRUSH KXOEW , _ *
! --Â> BRUSH <-
SUP RING
a)
NOTATION DESIGN VALUE ACTUAL VALUE
S 2 TO 25MM
II 0-1 TO 030
t2 01 X) 030
b)For measuring t & t brush s h o u l d be

p r e s s e d a g a i n s t one s i d e o f b r u s h h o l d e r .
c ) A x i s o f b r u s h h o l d e r s h o u l d be r a d i a l t o
slip ring surface. Variation ±2 d e g .
d) F i x i n g b o l t s o f b r u s h holder s h o u l d be
properly locked.
e) B e d d i n g o f b r u s h e s s h o u l d be done w i t h
t h e h e l p o f g l a s s a b r a s i v e c l o t h t o achievi
80S area of contact.
f ) Ensure that i n t e r n a l surface of brush holder is

free from any i r r e g u l a r i t y .
g) Adjust spring tension to 0.9 - 1.0 Kg.
5.30 C e n t e r i n g of Brush-gear enclosure

with fan for THW-210-2B generator
Actual
Pos i t ion Value
0°
90°
180°
270°
VALUE OF 't'SHOULD NOT DIFFER BY MORE THAN 1 nm AROUND THE PERIPHERY
N A M E & SIG.
REVISION R?_8/92
PROJECT ERECTION

si. Description
Design Actual
Remarks
No. Value Value
5.31 Extension shaft alignment for

THW-210-2B g e n e r a t o r s
COUPLED RUNOUTS
BALANCING
DISC
& 0.03
^ 0.03
>75
5.32 Auxiliary bearing adjustment for

THW-210-2B generators.
Bearing without
Free end pads
x Gen end.
«-»
•Si.!-i *1
R
TH
C 'S\ B -*
X=325 mm
Along A-A Along B-B Along C-C

REMARKS
Designed Actual Designed Actual Designed Actual
Value Value Value Value Value Value
p.15-
0.20
0.05-
NOTE : -0.10
The height of the bearing is 0.10-
-0.15
is adjusted such that when
0.10-
tilting pads are insered the -0.15
T-B + 0.10 +0.10 Slope of shaft &
extension shaft gets lifted bearing should
by 0 .10 m m . l-R not differ by
+0.02 ±0.02 more than 0.01mm
per metre.
NAME & SIG.
REVISION R -8/92
PROJECT ERECTION
6.0 Test results on equipments of Generator Auxiliary Systems
SI. Design Actual

Description Remarks
No. Value Value
6.1 Seal oil system
Hydraulic pressure applied in Atg. 20

(Piping)
30 min
Period of application
6.2
Gas system
a) Hydrogen drier 4.5

Pneumatic pressure applied(atg) 1 hour
Period of application 3heck absence
b) Assembled CO- control stand Df p a s s i n g o f
Pneumatic pressure applied(atg) 4.5 /aIves S cali-
Period of application 4 hrs . bration of
safety v a l v e .
c) A s s e m b l e d H c o n t r o l s t a n d (upto
>ieck absence
isolating valve after pr.regjlators en gas
}f passing o f
unit)
/alves 6 set
Pneumatic pressure applied(atg) 6.0 regulator Pr.
Period of application 4 hrs ,
d) Valves
Pneumatic pressure applied(atg) 4.5
Period of application 10 m i n
el Hydraulic pressure applied (atg)J 6.0

6.3 Stator water cooling system

a) Water Expansion Tank
Hydraulic pressure applied(atg) 1 .3
b) Stator water coolers

Hydraulic pressure appl ied(a tg)|
Shell side 8
Tube side 10
c) Valves
Hydraulic pressure applied(atg) 12
d) Piping
Hydraulic pressure applied(atg) 12
P e r i o d of application 30 m i n
NAME & S1G.
REVISION R2-8/92
PROJECT ERECTION
RATING FQA FQA-03-00-O1-L-06
6.4 D.C.resistance and IR value of following RTDs
No. of No. of DC IR Value Ambient

Thermometer Thermometer- Location resistance MQ Temperature Remarks
lead a •C
81 81A Brg. drain pipe E/E

B1R
82 82A Sreft seal K side drain
82B PtoT/E
83 83A 9-aft seal sicfe drain
83 pipe E/E.
84 84A O i l pipe before seal o i l
84B cooler.
85 85A Oil pipe after seal
85B oil cooler.
86 86A DVM water inlet to
86B stator winding.
87 87A -do-
87B
88 88A D/M water outlet
88B from stator wdg.
89 89A Waterheader inlet
89B to gas coolers
90 90A Water pipe outlet
90B from gas cooler.
91 91A -do-
91B
92 92A -do-
92B
93 93A -do-
93B
"54" "54A" Cooling water inlet
94B pipe to St.vater coolers.
9o "5BX Cooling water .outlet
95B f ran St. water coolers
96 96A Shaft seal corrmon
96B- a i r sice dr-ain pipeline,
NAME & SIG.

R _ 8 / 9 2
REVISION 2
PROJECT ERECTION

m 6.5
t-ltL-U U U A L I 1 Y A b b U K A r J U C
Protocol/Log sheet for Pumps 6 Motor sets during erection
^—.^__^ System Stator water (Booster Pump)

^~~~^--^_^ cooling Seal oil Hydrogen
Cooler wa ter
Description ^*~~-~^___^ No. 1 No. 2 AC DC No. 1 No.2
Mo tor:
Make
Type
Frame size
Ra t ing
Insulat ion class
Direction of rotation
KW/HP
Ful1 load amps.
Voltage
R P M
Supply voltage.
Machine No.
Temp, rise
Checks:
Free mov ement of rotor

I R of Motor winding
(Between phases and
between phases S earth)
Bearing
Lubricant
Earthing of motor body
Pump:
Make
Type
Mach ine- No.
Head
Discharge
Speed
Input
Direction of rotation
NAME & SIG.

REVISION R 2 -8/92
PROJECT ERECTION
UNIT NO. CUSTOMER SHEET 3/4
RATING FQA FQA-03-00-01-L-06 j
Protocol/Log sheet for Pumps 8 Motor sets during erection
System ( B o o s t e r Pump)
Stator Water-
Hydrogen
cool i ng Sea 1 o i l Cooler water
Descr ipt i on No. 1 No. 2 AC DC No. 1 No.
Checks:
Free movement of the

shaft
Bearing condition
Lubr icant
Impeller condition
Gl and
Impeller clearance
Axial Radial
Front
Rear
Gasket thickness
Alignment checks:
Half coupling condition
Run out :
Radial Axial
Alignment reading:
Radial • Axial
NAME & SIG.

R 2
REVISION 2 -8/9
PROJECT ERECTION
RATING FQA FQA-03-00-01-L-C6
FIELD QUALITY ASSURANCE HW DOCUMENT NO:
0492-003
1 .SHAFT SEAL ADJUSTMENT
EXCITER SIDE TURBINE SIDE

NOTATION
CALCULATED ACTUAL CALCULATED ACTUAL
M 0 . 4 TO 0 . 5 4 0.4 TOO.54
D ^f- 10 < j t 20
A ^C- 20 <=£ 10
B <j=L 1 0 <^P- 20
LI -=fC 25 4 1 10
L2 ^ 1 0 *4^ 20
L3 41.10 ^ - 20
T 1 TO 1 . 2 5 1 TO 1 . 2 5
••-
Y 1 TO 1 . 2 9 J TO 1 . 9 Q
S 38.62T045.16 28.62T035.16
E 1 TO 1 . 5 \ TO 1 . 5
cHEckEb BY D*T6
Project Site: Rev:01-Aug'8] Sheet 1 / 3 Sheets
1
FIELD QUALITY ASSURANCE Hit DOCUMENT MO I
III TECHNICAL REQUIREMENTS OF SHAFT SEAL 0492-003

ASSEMBLY
1. ALL JOINING SURFACES OF SEAL BODY & SEAL LINER SHOULD BE MATCHED
SO THAT 0 . 0 3 FEELER GAUGE SHOULD NOT PASS ANY WHERE.
2. CENTERING OF SEAL BODY TO BE DONE WITH RESPECT TO HOTOR WITHIN

0 . 0 5 MM.
• 3. MATCHING OF SEAL LINER BABBIT SURFACES TO BE DONE WITH ROTOR

4 COLLAR. CONTACT AREA SHOULD NOT BE LESS THAN 8 0 *
4. TAPER OF ROTOR SEAL COLLAR SHOULD NOT BE MORE THAN 0 . 0 3 MM.
CUEXKED &V
t)ATE
Project Site: Rev:03 Sheet 3 / 3 Sheets

U n i t No:
d$fc: fS?
>iQ-roA~003-00.-0! - v l 6

Generator Erection Manual THW 210 2A 2B

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Generator Erection Manual THW 210 2A 2B

Загружено:

Авторское право:

Доступные форматы

POWER SECTOR – SOUTHERN REGION

TECHNICAL SERVICES DEPARTMENT

Document Type : O & M Manual .

Project and Rating : .

Product Name : Turbo Generator .

Model Number/Type : 210MW – 2A/2B .

Title : Generator Erection Manual.

THW - 210 - 2A/2B

Bharat Heavy Electricais Limited

Type : THW - 210 - 2A/2B

Bharat Heavy Electricals Limited

Document No. Copy No. Ol Revision No. oo

Prepared by 1. S.C. Jain Sr. Manager TS-HQ/New Delhi

2. H.C. Madan Sr. Manager TS-HQ/New Delhi

3. J.S. Subramanian Sr. Manager PS-WR/Birsinghpur

4. K.V. Tandon Sr. Manager PS-NR/Dadri

5. Dev Raj Sr. Manager TGE-FES/Hardwar

6. Harsha Kayastha Manager FQA-New Delhi

Approved by S.L. Bhatia A.G.M. TS-HQ New Delhi

Date of Issue ol. 11. °lh. 1 rw f

Issued by Head/TG •tu.v_^te

Issued t o : £.. D - P S - S R - Mdc#^ .

BHARAT HEAVY ELECTRICALS LIMITED

I am glad that Technical Services Head Quarters, New Delhi

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

1.2 Type of Manual

1.3 Rating of Main Equipment

1.4 System Designation

Bharat Heavy Electricals Limited

1.5 Type of Instruction

Bharat Heavy Electricals Limited

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

1. Technical Parameters G1-01-0230G

2. General Description G1-01-0131G

3. Activity Sequence G1-01-0132G

4. SECTION I : ASSEMBLY INSTRUCTIONS

5. SECTION - II : TESTING INSTRUCTIONS

5.1 Rotor Purge Test G1-01-0107T

Bharat Heavy Electricals Limited

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

5.7 Electrical Test of Rotor G2-01-0104T

6. SECTION - III : GENERAL INSTRUCTIONS

SECTION - IV : LOG SHEETS

Bharat Heavy Electricals Limited

l.1 Product Code

harat Heavy Electricals Limited

Rated KW capacity 210,000 KW

Rated KVA capacity 247,000 KVA

Rated terminal voltage 15,750 V

Rated Power Factor 0.85 lag

Rated Stator Current 9050 A

Excitation Current at rated

Excitation voltage at rated

Rated frequency 50 cps

Rated speed 3000 R.P.M.

Direction of rotation when

Rated H 2 Pressure 3.5 Kg/CM 2

Efficiency at M.C.R. conditions 98.55%

Short Circuit Ratio 0.49

Maximum temperature of Stator 105°C

Maximum temperature of stator 105°C

Maximum temperature of rotor 115°C

Bharat Heavy Electricals Limited G1-01-0230G/1 Of 3