Manual Final

TABLE OF CONTENTS
SECTION
No. Para DESCRIPTION PAGE
1 GENERATOR ASSEMBLY & ERECTION PRE-REQUISITES
1.1 Sub-assemblies 1.1
1.2 Auxiliaries 1.1
1.3 Erection pre-requisites 1.1
2 ERECTION SEQUENCE
2.1 General 2.1
2.2 Erection in service-bay 2.1
2.3 Erection in generator foundation pit 2.1
2.4 Slings 2.2
3 GENERATOR FOUNDATION 3.1
3.0 Reference drawings 3.1
3.1 Foundation: stator/bottom bracket 3.1
3.2 Sole plate and foundation bolts 3.1
3.3 Grouting
4 STATOR ASSEMBLY
4.1 General 4.2
4.2 Stator frame 4.2
4.3 Stator core 4.2
4.4 Stator winding 4.3
4.5 Lifting of wound stator and lowering 4.5
4.6 Air coolers 4.5
5 GENERATOR SHAFTS AND ROTOR ASSEMBLY
5.1 General 5.2
5.2 Spider and rim assembly 5.2
5.3 Mounting of poles 5.3
5.4 Fan assembly 5.4
5.5 Lowering of main shaft and rotor 5.5
5.6 Magnetic centering of stator and rotor 5.6
Fig. - 5.1 Developed view of rotor after pole mounting 5.8
Fig. - 5.2 Checking for magnetic centering 5.9
Fig. - 5.3 Greasing of rim keys and rim locking keys 5.10
Fig. - 5.4 Greasing of shaft and spider keys 5.11
SECTION
No. Para. DESCRIPTION PAGE
6 BOTTOM BRACKET, BEARINGS AND OTHER ASSEMBLIES
6.0 Reference drawings
6.1
6.1 General
6.1
6.2 Erection of bottom bracket
6.1
7 TOP BRACKET, BEARING AND OTHER ASSEMBLIES
7.1 General 7.1
7.2 Erection of top bracket and other assemblies 7.1
7.3 Guide bearing and insulation 7.2
8 LEVELS AND ALIGNMENT

(INCLUDING DOWELLING AND GROUTING)
8.1 Introduction 8.1
8.2 Starting check 8.1
8.3 Initial setting of bracket 8.1
8.4 Setting of thrust bearing elevation 8.2
8.5 Leveling of thrust bearing 8.2
8.6 Alignment 8.3
8.7 Rotational check on generator main shaft and top shaft 8.4
8.8 Combined rotational check on generator and turbine shaft 8.5
8.9 Alignment of collector 8.6
8.10 Stator and rotor form 8.7
8.11 Adjustment of bearing clearances 8.7
8.12 Dowelling 8.7
8.13 Grouting 8.7
9 STARTING, TESTING, COMMISSIONING AND TRIAL RUN
9.1 General
9.2 9.1
Pre-start checks 9.1
9.3 Bump start
9.4 9.1
First run 9.2
9.5 Setting of over speed device
9.6 9.2
Voltage build-up 9.3
9.7 Synchronising and loading
9.8 9.3
Putting into operation 9.3
9.9 Stopping
9.10 9.4
Handing over 9.4
ANNEXURES
ANNEXURE
NO. Para. DESCRIPTION PAGE
I HIGH VOLTAGE TESTS OFO WINDINGS
1.1 Schedule of HV tests on stator winding at site A-1.1
1.2 Schedule of HV tests on field winding at site A-1.1
II INSULATION RESISTANCE TESTING AND DRYOUT
2.0 General A-2.1
2.1 Insulation resistance testing A-2.1
2.2 Dryout A-2.2
2.3 Recommended minimum insulation resistance A-2.3
III STATOR FORM AND ROTOR FORM
3.1 General A-3.1
3.2 Stator form A-3.1
3.3 Rotor form A-3.2
3.4 Shifting of stator A-3.2
3.5 Example A-3.3
Fig. A-3.1 Stator form and rotor form (at upper end of core) A-3.5
Fig. A-3.2 Stator form and rotor form (at lower end of core) A-3.6
IV APPLICATION OF MOLYBDENUM DISULPHIDE A-4.1
V CHECKING ROUNDNESS OF ROTOR A-5.1
VI REPLACEMENT OF STATOR BAR AND FIELD COIL
6.1 Procedure for changing a faulty/damaged stator bar A-6.1
6.2 Assembly/removal of field coil A-6.1
VII DRAWING : 0 251 00 23501 : SECTIONAL ARRANGEMENT A-7.1
(GENERATOR)
SECTION - 1
GENERATOR ASSEMBLY AND ERECTION PRE-REQUISITES
The hydro generator mainly consists of following sub-assemblies and auxiliary equipment:
1.1 SUB-ASSEMBLIES
 Stator
 Rotor with main and top shafts, tubular shaft etc.
 Bottom bracket with a thrust and a guide bearing assemblies
 Top bracket with a guide bearing assembly
 Flooring, top casing, pit air seal, pit access door etc.
 Special instruments and wiring
1.2 AUXILIARIES.
 Hydrostatic lubrication system
 Brake-jack system
 Power pack
 Anti-condensation heaters
 Cooling water pipe lines for air/oil coolers
 Fire extinguishing system (CO2 type)
1.1 ERECTION PRE-REQUISITES

Ensure readiness of following inputs for starting assembly and erection of
generator.
 Power house roofing completed and sides, windows and entries are covered.
 Service-bay is concreted and embedding completed.
 Concreting and curing of generator barrel completed.
 Generator stator and bottom bracket foundations are checked, chipping
completed and pockets are clear.
 3-phase, 4 wire electric power supply for construction and the tapping points
are available in power house and general Illumination is provided.
 Ventilation and water supply arrangement.
 EOT cranes commissioned and tested for loads and tandem operation.
 Proper precautionary measures are ensured to avoid flooding of the power
house either from upstream or downstream of the POWER HOUSE.
1.1
SECTION – 2
ERECTION SEQUENCE
2.1 GENERAL
The erection procedure outlined below is a usual method adopted by BHEL. The
procedure is to be taken only as a guide and a preferred method of erection of
major component.
2.2 ERECTION IN SERVICE-BAY

2.2.1 Assemble the stator frame segments on level stools. Build the core as a continuous
ring and carry out the stator winding.
2.2.2 For building the rotor assembly, assemble spider with brake track, rim, poles, fans
etc.
2.2.3 Assemble bottom bracket center and arms. Remove two halves of the spring plate
from bottom bracket before its lowering.
2.2.4 Assemble top bracket center and arms.
2.3 ERECTION IN GENERATOR FOUNDTION PIT

2.3.1 Level the sole plates for bottom bracket in the generator barrel at correct elevation
using shims provided, as required. Refer clause 8.3, Section-8.
2.3.2 Level and center the stator sole plates in the generator barrel at correct elevation
with the use of shims, as required.
2.3.3 Lower the bottom bracket (without spring plate) on the sole plates. Level the
bottom bracket using seating surface of the spring plate as reference. Center the
bottom bracket by centering the ID of the guide bearing support ring with
reference to turbine axial centerline. Bolt up the bottom bracket to the sole plates.
2.3.4 Assemble all H.S. Lubrication oil piping and other items upto its starter panel. Also
complete brake/jack piping upto its starter panel.
APPLY A THIN COAT OF MOLIBDENUM - DI – SULPHIDE GREASE ON

THE TOP SEATING FACE OF STATOR SOLE PLATES.
2.3.5 Lower the wound stator on sole plates in generator barrel using lifting device.
Center the inner diameter of stator core with respect to turbine axis. Bolt up the
stator to the stator sole plate.
APPLY A THIN COAT OF MOLIBDENUM-DI–SULPHIDE GREASE ON
THE CONTACT FACE OF STATOR HOLDING DOWN BOLTS ALSO.
2.3.6 Check and ensure height of all thrust bearing springs as per drawing before their
assembly on spring plate. Assemble thrust bearing pads with a coat of molyb-
denum disulphide grease alongwith anchor plate, thrust pad stops etc. with the
spring plate around the shaft. However, oil retaining sleeve shall be bolted with
spring plate after alignment.
2.3.7 Lower the main shaft through bottom bracket with oil retaining sleeve and spring
plate assembled round the shaft. Fix the dowels and bolts to assemble spring plate
with the bottom bracket and while doing so, the shaft will remain suspended by the
crane.
2.1
2.3.7 Measure deflection of the bottom bracket due to the weight of the main shaft.
Deflection to be measured using two dial gauges 90 0 apart placed just at the I.D. of
the bottom plate of the bearing bracket.
NOTE : ENSURE THAT THE SPRINGS ARE FREE TO ROTATE AND DO NOT
FOUL WITH SURROUNDING SPRINGS.
2.3.8 Connect the piping of H.S. lubrication to the thrust pads.
2.3.9 Raise the brake-jack units mounted on the bottom bracket by about 10 mm. Check
their levels and lock them in position. Lower the rotor assembly on the raised
jacks. Pull-up the generator shaft to couple with spider. Main shaft and spider are
coupled together by radial keys and holding down bolts. Tighten main shaft and
spider coupling bolts using bolt tensioner.
Apply MOLIBDENUM-DI–SULPHIDE GREASE on the keys and bolts.
2.3.11 Lower the jacks slowly to enable load of rotor assembly to be taken on thrust pads.
2.3.12 Lower top shaft and assemble on main shaft.
2.3.13 Again measure the deflection of the bottom bracket.
2.3.14 Assemble top bracket in position and centralise the same with respect to the ID of
guide bearing support ring and top shaft.
2.3.15 Assemble collector shaft on generator top shaft.
2.3.16 Assemble four centralizing pads at 900 intervals.
2.3.17 Check the rotor level by rotating the rotor and taking measurements at all thrust
bearing arm positions. The level of rotor should be within one division of level
with an accuracy of 1 in 50,000.
2.3.18 Check alignment of generator main shaft and top shaft and correct it, as necessary.
2.3.19 Couple generator main shaft to turbine shaft and correct as necessary.
2.3.20 Check combined alignment of generator and turbine shafts & correct as necessary.
Re-check the rotor level.
2.3.21 Check alignment of collector and correct as necessary..
2.3.22 Measure the air gap at different locations to plot stator and rotor forms as per
Annexure-III. Based on these forms, centralise the stator with respect to rotor to
get minimum variation in air gap. Finally recheck stator and rotor forms.
2.3.23 Assemble top and bottom guide-bearing pads and set the guide pad clearances as
per drawings. Complete bearing housing assemblies.
2.3.24 Assemble top and bottom air guides and set fan tip clearances.
2.3.25 Assemble generator flooring, top casing etc.
2.3.26 Dowel stator, bottom bracket and top bracket. Before assembly of the dowels,
apply a thin coat of MOLIBDENUM DI- SULPHIDE grease in the reamed holes
and on the dowels.
2.3.27 Grout the sole plates using non-shrinking cement/compound.
2.3.28 All other assemblies like cooling water pipe work, inter pad cooling piping, brake
piping, vapour piping, OSD, SSG, pit air seal, DC connectors, instruments and
auxiliaries wiring can be taken up at appropriate stages of erection.
2.4 SLINGS
The steel wire slings are supplied for use as per the guidelines given in drawing,
‘Set of Slings’, 2 263 51 23504.
2.2
SECTION - 3
GENERATOR FOUNDATION
3.0 REFERENCE DRAWINGS
TITLE OF DRAWING DRAWING NO.

 Sectional arrangement 0 250 00 23504
GENERAL
 Generator foundation 0 250 00 23501
 Stator sole plate arrangement 1 251 02 23504
STATOR 2 251 02 23502
 Stator sole plate assembly
 Foundation Bolt Assembly 3 251 02 23504
 Bottom bracket sole plate arrangement 1 257 07 23501
BOTTOM 2 257 07 23502
 Bottom bracket sole plate assembly
BRACKET 3 257 07 23501
 Foundation Bolt Assembly
3.1 FOUNDATION : STATOR/BOTTOM BRACKET

 Fix horizontal and vertical foundation tubes of bottom bracket/stator sole plates
at appropriate stages. Record the dimensions in log sheets as per Quality Plan
for Installation, document no. QPX-HG-027.
 Check dimensions of cutouts/openings provided for sole plates in generator
foundation/barrel as per drawing.
 Chip off/grind the seating surfaces of the sole plates to remove loose concrete
and get hard and flat surface. Efforts to be made to obtain about 80% of
contact surface, evenly spread over the entire area.
3.2 SOLE PLATES AND FOUNDATION BOLTS

 Remove protective paint from sole plates and stud surfaces in the areas, to be
embedded in concrete.
 Check and prove threads of foundation bolts and nuts.
 Debur the packer plates to be used while assembling the sole plates in pit.
 Install sole plates and foundation bolts and position them to elevation specified
in drawing and centralize them to unit axis within ± 1 mm.
 Elevation of the sole plates shall be within ± 0.5 mm and level of individual
sole plate shall be within 0.1 mm.
 Record the dimensions in log sheets as per Quality Plan for Installation,
document no. QPX-HG-027.
3.3 GROUTING
. The grouting of the sole plates shall be taken-up only after final levelling, centering,
bolting and dowelling. It is necessary to use non-shrinking cement/ compound to
produce a monolithic mass capable of transmitting loads from sole plates to
generator foundation.
The method of grouting shall be decided by the customer.
3.1
SECTION – 4
STATOR ASSEMBLY
(a) Stator frame and core assembly
Description Drawing No.

Joint Bar Assembly 1 251 06 23502
Stator Frame Assembly (Fabrication) 0 251 06 23504
Stator Frame Assembly (Machining) 0 251 06 23505
Stator punching 0 251 06 23502
Stator Frame and Core Assembly 0 251 06 23503
BOM for Stator Frame & Core Assy. 2 251 06 23508
Arrangement for Intermediate Pressing of 1 251 51 23512
Stator core 1 251 51 23511
Items for Intermediate Pressing of stator core 2 251 06 23509
Glued Core Packet Assy. 3 251 06 01002
Core Stud Restrainer 3 251 06 23503
Stator Core Stud & Nut 3 251 06 23507
Key Bar 3 251 51 23517
Stator Core Building Tools 3 251 06 23518 (6 sheets)
Method of Building Stator Core in Ring form 4 251 01 01001
Washer (for stator core and rim building) 4 251 01 01007
Horse Shoe Plate 3 251 06 23513
Details of Stator Frame & Core Assy. 2 251 06 23511
Cover Plate 3 251 51 23508
Stator Stool Assembly
(b) Wound Stator
Stator Bar Layout 2 251 05 23501
Insulation Caps 1 251 05 23505
Packer for Insulation Cap 4 251 05 23508
Slot Wedge 1 251 05 23506
Separator 3 251 05 23511
Ripple Springs 3 251 05 23512
Stator Winding Connectors & Terminals 0 251 05 23506
Stator Winding Connection Diagram 0 251 05 23507
Wound stator 0 251 05 23501
Stator Winding Assembly (Bill of Material) 1 251 05 23507
Stator Bar Pressing Device 1 251 51 23518
Locking Plate (Strip) 4 251 01 01008
Clamp Plate 4 251 05 23502
4.1
Angle Bracket (Top) 4 251 05 23503
Clamp Plate Bottom 4 251 05 23505
Angle Bracket Bottom- 4 251 05 23506
Copper Clip (Series) 4 251 05 23507
Angle Bracket Bottom 4 251 05 84412
Support Ring Segment 2 251 05 23505
Packers 2 251 05 23506
Terminal Clamp M-16 Stud 3 251 05 01001
Support Block Top 3 251 05 23510
Insulating materials for complete stator winding 1 263 04 23501
(c) Stator lifting

Arrangement of Stator Lifting 0 251 51 23508
Stator Lifting Center Assy. 1 251 51 23509
Details of Stator Lifting Center Assy. 1251 51 23510
Stator Lifting Arm Assembly 1 251 51 23513
Stator Lifting Beam Center and Arm 1 251 51 23517
assembly Stator Lifting Trunnion Assembly 2 251 51 23512
Details of Stator Lifting Arm Assembly 2 251 51 23510
4.1 GENERAL
The stator frame, punching and winding materials are shipped loose for their
assembly at site. The stator core shall be built as continuous ring at site. The
consolidation of the core, laying of winding, bus bars etc. including stage wise and
final H.V. testing shall be carried at site.
4.2 STATOR FRAME

The stator frame is supplied in four segments. Transport stator segments to the
service bay of the powerhouse. Clean and debur stator joint flanges. Check all
threaded holes for any damage and retap them, if necessary.
Assemble two stator segments to form half of the stator frame. The fitted
bolts should be assembled first. Assemble all joint bolts and tighten uniformly.
Carry out assembly of remaining two segments as described above to form
another half of stator. Finally assemble two halves together by fixing the
fasteners. Tighten all the fitted and joint bolts fully and lock them.
4.3 STATOR CORE

Shift the complete stator frame on to the leveled stools in service bay.
Level the frame with the use of packers under the stator, as required. Install
temporary working platform round the inside periphery of the stator and adjust its
height, as necessary. Carry out core building as per drawings.
4.2
 The core building shall be carried out as per the drawing, method of
core building, 3 251 06 23518 (6 sheets).
 Weld the fingers on bottom plate of stator. Perform D.P. test to check
the welds. Check level of fingers and record the dimensions in log sheets
as per Quality Plan for Installation, document no. QPX-HG-027.
 Conduct D.P. test on welded joints between key-bars and horse shoe
plates. Straighten the key bars as necessary. Record the dimensions in log
sheets as per Quality Plan for Installation, document no. QPX-HG-027.
 The healthiness of RTDs shall be checked before and after their
installation in stator core/teeth and results shall be recorded in log
 The core consolidation and tightening shall be done as per drawing
and results shall be recorded in log sheet as per Quality Plan for Installation,
document no. QPX-HG-027.
 After the core consolidation and final tightening, fish plates to be
welded on the flanged joints of stator frame as per drawing 0 251 06
23503.
4.4 STATOR WINDING
4.4.1 General
The stator winding is class ‘F’ insulated with consolidated straight portion and flexible
overhang. It consists of a double layer, single turn bar, wave winding, wound in open
slots. All the bars have been formed, insulated and tested at works before dispatch.
The bars have been provided with a 3600 Roebel transposition in the slot portion to
eliminate circulating current losses
Before proceeding with the winding work, minutely examine the stator core slot at
the top and bottom ends particularly at the glued packets for projection of punching
into the slot. Failure to remove any projection in the slot will lead to damage to bar
insulation and ultimately failure during HV test. Clean the core with compressed dry
air and apply conducting paint inside the slots.
4.4.2 Setting of support rings and trial winding bars
Assemble a few bars to ascertain the locations of support brackets. Assemble support
brackets and support rings as per drawing. A gap of 2 to 3 mm shall be maintained
between trial bottom bars and support rings for adjustability. The gap shall be filled
with thin bakelite strips wrapped with treated glass tape in the open spiral form. A
layer of polyester filler felt shall be placed between bottom bars and packing strips
for cushioning effect. Remove the trial bars and complete the assembly of support
brackets and support rings above and below the stator core.
4.4.3 Assembly of bars
(i) Template
While assembling bars in slots, it is necessary that the straight portion of bars extend
by an equal amount at both ends of core. It is convenient to prepare a template made
of pressboard or PLC fabric sheet or wood. The template may be made as follows:
4.3
Measure core length over clamping fingers at several points round the periphery and
determine maximum over all length. Construct the template to fit into the angle of the
bar between the straight portion and the end winding so as to clear core clamping
fingers.
(ii) Assembly of bottom bars
Refer drawing 12510523507 for item wise distribution of bottom and top bars in the
slots. Before assembling the bottom bar, a conducting packer of epoxy glass shall
be fixed at slot bottom. Ensure that the projection of straight portion of the bars is
equalised at the top and bottom ends. After assembly of bars, side clearance
between bar and slot wall shall be packed with conducting sheets as per drawing.
The bar shall be secured tight with the support ring using glass fibre woven tape as
per drawing. Each pair of bottom bars shall be bound together as per drawing.
Conduct HV test on bottom bars as per Annexure-I. Record the results in log sheets
(iii) Assembly of top bars
Fix the separator in correct position before assembly of top bars. Assemble the top
bar following the same procedure as in the bottom bars. Use conducting glass
laminates as needed to make the bar tight in width.
Brace the end winding with glass fiber woven tape after placing necessary
packers of epoxy glass laminate and conformal packing. Each pair of top bars shall
be bound together with four turns of glass tape and two reverse turns, maintaining
uniform clearance in the end winding.
The mouth of slot packing blocks shall be assembled and bound in position
with varnish treated heat polyester shrink sleeve. Additional conformal packing
may be used to obtain a tight fit. Refer wound stator drawing: 0 251 05 23501.
(iv) Slot wedge assembly
In each slot, 15 pairs of slot wedges shall be assembled. Each pair comprises of a
parallel piece and a taper piece. Refer item 8 of wound stator drawing 0 251 05
23501. Top most and bottom most wedges have the groove at the ends for tying
them with the top bars. Packing under wedge of epoxy glass laminate are to be
used essentially while fixing the slot wedges. The ripple springs and slot wedges
shall be assembled as per the Tech. Requirement 8 of drawing, 1 251 05 23507.
For assembly of slot wedges, use bar pressing device to drawing 1 251 51 23518.
Conduct HV test on bottom bars as per Annexure-I. Record the results in log
(v) Brazing of winding bars, connectors and insulation
During stator winding, following types of brazed joints shall be made:
- Series joint between a top bars and a bottom bar using copper clips
- Jumper connection
- Winding bar to bus bar connection
- Bus bar to bus bar connection
Refer drawings: - Wound stator : 0 251 05 23501
- Insulating materials for complete stator winding : 1 263 04 23501
4.4
IMPORTANT : Neighbouring winding bars, connectors etc. should be protected from
heat while brazing by using asbestos putty/asbestos cloth.
(vi) Inspection of winding and HV test
It has been observed that generally the failure of winding in end winding region
during HV test or operation is due to mis-handling or presence of foreign materials
like nuts, bolts, metal chips, welding rods, tools, knife, blades, copper off cuts,
brazing material etc. etc. lodged in the cross over portion of bars during winding or
subsequent assembly and boxing-up. Therefore, best efforts must be made to
ensure removal of any foreign material before HV tests. Failure to do so result in
failure of winding during HV test or operation.
NOTE: The winding MUST be carried out in a clean and dust free atmosphere. If the
air is contaminated by cement dust etc. due to construction work in adjacent
locations, then it is necessary that the winding be carried out in an enclosed area.
DO NOT STEP ON WINDING.
4.4.4 Testing
The brazed joints after cleaning shall be subjected to ultrasonic test for joint
efficiency. Minimum acceptable joint efficiency is 50%. Record the results in log
 Check insulation resistance and carry out dry out of winding as per technical
instructions/standards.
Conduct stagewise H.V. tests on stator winding as called in Annexure-I. Record
the results in log sheet as per Quality Plan for Installation, document no. QPX-
HG-027. The stator winding insulation will be dried out before official H.V. test
and record the results in log sheet as per Quality Plan for Installation, document
no. QPX-HG-027.
4.5 LIFTING OF WOUND STATOR AND LOWERING
Lift compete stator as per the drawing, ‘Arrangement of stator lifting’, 0 251 51
23508 and lower it on leveled sole plates. Before lowering stator, apply thin coat of
molybdenum-disulphide grease on seating faces of sole plates. Refer Annexure-IV.
 Check magnetic axis of stator core with respect to turbine flange top.
Position piano wire with plumb bob at the center of stator bore. Using stick
micrometer, centralise the stator with respect to the center of turbine shaft bore.
Record the results in log sheets as per Quality Plan for Installation, document no.
QPX-HG-027.
 After alignment of rotor, centralise the stator again with respect to rotor on the
basis of stator form and rotor form (Refer Annexure-III). For this the weight of
stator can be taken on the crane without actually lifting it and using radial jacks to
move it in desired direction, as required.
4.6 AIR COOLERS
Carry out hydraulic testing of air coolers before their assembly on stator frame to
prove the healthiness of cooler tubes and joints. Record the results in log sheets
After lowering of stator assembly in generator pit, the air coolers shall be
installed on stator frame as per drawing, 1 251 04 23516.
4.5
SECTION – 5
GENERATOR SHAFTS AND ROTOR ASSEMBLY
(a) Rotor assembly
Rotor assembly 0 252 08 23509
Set of balance weights 3 252 51 23507
RIM assembly
Rim building instruction 3 252 03 01401
Rotor rim punching 0 252 03 23501
Rotor rim end plates 0 252 03 23503
Rim segment with spacer 1 252 03 23509
Rotor rim and spider stools 1 252 51 23508
Rotor rim stud and nut assembly 2 252 03 23502
Rotor rim building equipment 2 252 51 23506
Rotor rim assembly 0 252 03 23502
SPIDER
Spider center assembly (machining) 0 252 02 23504
Spider center and arm assembly 0 252 02 23505
Spider keys 2 252 02 23508
Spider cover assembly 1 252 08 23505
SPIDER and shaft
Fixing arrangement of generator shaft and spider 1 252 02 23511
Shaft and spider coupling stud and nut 3 252 02 23503
Set of items for coupling bolt tightening 2 252 08 23504
Spider, top shaft & main shaft tightening arrgt. 1 252 51 23516
BRAKE track, fan and collector
Arrgt. of brake track segments and spider assembly 1 252 07 23507
Fan segment and blade assembly 1 252 04 23512
Fan segment assembly 1 252 04 23513
Collector assembly (OD=1250 mm) 1 252 05 01003
ROTOR connections
Arrangement of rotor connection 0 252 06 23507
Shaft and lead assembly 1 252 06 23520
Rotor lead assembly (collector to shaft) 1 252 06 23521
(b) Pole and field coil
Fabricated field coil 0 253 02 23501
Details of fabricated field coil 1 253 02 23505
Wound pole assembly 1 253 02 23504
Pole keys 2 252 03 23501
Wound pole lifting gear assembly 1 253 51 23506
Pole fixing arrangement 1 253 03 23507
Pole key withdrawal gear 1 253 51 01001
5.1
(c) Generator shafts
Generator main shaft (machining) 0 254 01 23501
Top shaft (machining) 0 254 01 23502
Generator and turbine shaft tightening arrangement 0 254 51 23503
Top and main shaft fixing arrangement 1 254 01 23508
(d) Rotor lifting/turning
Rotor lifting Trunnion assembly 1 252 51 23522
Dummy shaft lifting arrangement 1 252 51 23523
Arrangement for rotor lifting 1 252 51 23524
Dummy shaft (machining) 1 252 51 23519
Arrangement of rotor turning 1 252 51 23517
5.1 GENERAL
The rotor spider is a fabricated assembly with detachable arms for their assemblies at
site. Generator has two forged shafts i.e. main shaft and top shaft. The main shaft has
integral thrust collar at top and a flange at the bottom for coupling with turbine shaft.
In this type of construction, rotor is assembled without main shaft in service-bay i.e.
spider, rim, fans, poles etc. are assembled. Generator main shaft and rotor spider are
coupled in the generator pit.
5.2 SPIDER AND RIM ASEMBLY

Place spider center on levelled stools in service bay and assemble the arms on it.
Check the level of spider and record the results in log sheets as per Quality Plan for
Installation, document no. QPX-HG-027.
5.2.1 Rotor rim shall be built as per drawing no. 3 252 03 01401.
5.2.2 Following care should be taken during rim building in addition to those mentioned in
drawing no. 3 252 03 01401.
 Rim end plates should be levelled reasonably in circumferential and radial
direction.
 Molybdenum-di-sulphide grease should be applied on the seating surface of
spider key bars, coming in contact with rim end plates.
 The rim keys are sent match marked for generator of each unit separately.
Check if the match marked keys provided have corresponding width to suit the
pocket size in the rim. Apply molybdenum di-sulphide grease on the width of
master and static rim keys before assembly to facilitate free expansion and
contraction of rim during operation
 Rim punchings are assembled as per the sequence given in drawing of Rim
assembly, drawing no. 0 252 03 23502.
 Ensure that the gap between ID of rim punching and OD of spider key bar is
uniform.
 During rim building, keep on checking the verticality of T-slot and pole
seating faces
5.2
 Ensure that all rim building pins are free after stacking every 15 layers of rim
punchings.
 Also measure the width of pockets being formed on left hand and right hand of
master key at all key bar locations, except in one location where taper keys are
fitted. Minor variation in the width is expected, which can be taken care of by
the extra long rim keys.
 Rim shall be tightened in 6 stages (including final stage) to achieve rim stud
elongation as per rotor rim assembly drawing. Record the results in log sheets
Molybdenum di-sulphide grease shall also be applied on the rim locking keys
under surface coming in contact with the slot of spider key bar, before their
assembly. Refer Fig. 5.3 at the end of this section.
NOTE:
(i) Carryout intermediate pressing of the rim at the intervals specified in the
drawing of rim assembly and check the following in tightened condition:
- freeness of rim building pins
- height at ID and OD, at least at eight locations. The variation in the
heights measured at ID and OD shall be maintained within 2 to 3 mm.
(ii) During rim building, the verticality of all poles seating faces shall be checked
using plumb line. The permissible error in verticality of each pole seating face
shall be limited to 0.3 mm. If required, grind the pole seating face. Too much
difference in verticality would cause undue variation of air gap causing
unbalanced pull couple, which will be difficult to balance.
(iii) After grinding pole seating faces, check the A/F of the pole seating faces on
rim. This can be done by dropping a plumb wire to rim face by a inside
micrometer. Difference in A/F of opposite faces should be within 0.3-0.5 mm.
(iv) Check the rim height and ensure that it is uniform both from ID and OD around
the circumference.
5.3 MOUNTING OF POLES

5.3.1 Preparation for mounting the poles
Check IR value of the pole by 500 V megger. If it is found less than 50 M Ohm,
it is advisable to dry out the pole separately to get the required IR before
mounting them on rotor.
 To improve the IR, pole coils may be dried at a temperature of 80-85 0 C. Drying
process shall be slow and continued for 50-70 hours or till improvement. If the
IR does not improve, then the cause should be investigated.
 If drying of poles after mounting on rim becomes necessary, drying is done by
passing DC equivalent to 70% to 80% of the rated field current.
5.3.2 Check free movement of pole springs in the rim pocket.
5.3.3 Mount the poles with the help of pole lifting gear and crane. Weight of each pole is
punched on them at works and poles of equal weights should be placed
diametrically opposite, as far as possible. Record the results in log sheets as per
Quality Plan for Installation, document no. QPX-HG-027.
5.3
5.3.4 Measure D.C. resistance of field coils and winding. Record the results in log
5.3.5 Check AC impedance of wound pole and compare it with the value obtained
before. A lower value of impedance (less than 80 %) need to be investigated
which indicates turn fault in the coil. Record the results in log sheets as per
Quality Plan for Installation, document no. QPX-HG-027.
NOTE :(i) The pole body must be in tight contact with rim face, steel shim must not get
sand witched between pole body and rim.
(ii) During assembly of poles, the magnetic center of the poles has to be checked.
5.3.6 Apply a very thin coat of molybdenum-di-sulphide grease on taper face of pole key
and its opposite face.
Drive the pole key in their correct position taking care that taper surfaces are
properly matched. The drive key should project at least 2 to 3 mm beyond the
bottom rim end plate. Finally trim the keys to specified drawing dimension.
5.3.7 Record the verticality of pole as well as pole radius. If necessary, correct both
verticality and radius by grinding slightly the pole seating surface and rim. THE
VERTICALITY OF INDIVIDUAL POLE SHALL BE WITHIN 0.3 MM.
NOTE: Difference in radii of opposite poles shall be within 0.2 mm. Also refer Annexure
- V for rotor roundness check.
5.3.8 Again measure the impedance of pole and compare with the value obtained with
other pole. The impedance value of a pole shall not vary by more than 10 % of
average value of all poles. This value would be different from the impedance of the
pole when measured on ground. Record the results in a log sheet as per Quality
Plan for Installation, document no. QPX-HG-027.
5.3.9 Make pole-to-pole connection and assemble rotor leads on spider.
5.3.10 Conduct HV test on rotor winding & rotor leads as per Annex.-I. Record the results
in a log sheet as per Quality Plan for Installation, document no. QPX-HG-027.
5.4 FAN ASSEMBLY

The fan segment assemblies at top and bottom of rotor are fixed to the rim end
plates by means of four extra rim nuts, including two collared rim nuts, for taking
centrifugal force of fan assembly. It is important that the collars and reamed holes
of the fans do not have clearance of more than 0.05 to 0.08 mm.
5.4
5.4.1 Assemble fan segment as per drawing. Very light grinding of holes in fan
segments can be done for seating on rim nuts, if required.
5.5 LOWERING OF MAIN SHAFT AND ROTOR

Lowering of main shaft rotor assembly shall be done as described below:
5.5.1 Lowering of bottom bracket and main shaft

(i) Assemble bottom bracket centre and arms in service-bay. Remove spring plate
from bottom bracket. Lower bottom bracket in the pit on levelled sole plates.
(ii) The generator main shaft is supplied with oil retaining sleeve assembled round it.
Assemble spring plate around the shaft. Assemble springs, thrust pads, pad stops,
anchor plates etc. Lower main shaft (with assembled oil-retaining sleeve and
spring plate). After passing the flange of the main shaft through the bottom
bracket, keep the shaft in hanging position by the overhead crane, till spring plate
is assembled on to the bottom bracket.
.
(iii) Lower generator main shaft on thrust bearing.
NOTE : WHILE ASSEMBLING THE SPRINGS, ENSURE THAT THE SPRINGS ARE
FREE TO ROTATE AND DO NOT FOUL WITH SURROUNDING
SPRINGS.
5.5.2 Lowering of rotor assembly

(i) The rotor is now ready for the lowering on the jack units of bottom bracket. For
this raise the jacks by 10-15 mm and lock them in position by moving the helical
sleeve provided on the jacks.
(ii) Lift the rotor by using two cranes as per lifting arrangement drawing and lower it
on the raised jacks. While lowering the rotor, following precautions shall be
observed:
a) Rotor is reasonably level
b) Rotor is central to the stator bore
c) Rotor should be clear of any part of a wound stator
(iii) Pull-up the main shaft with crane for coupling it with spider, taking guidance from
location dowels. Fit the bolts in positions and tighten using hydraulic bolt
tensioner provided.
(iv) Assemble the taper keys to suit the shaft and spider slots adjacent to the master
keys. Normally they will be match marked. Apply a thin coat of MOLYBDENUM-
DI-SULPHIDE GREASE on taper face and its opposite face.
(v) Assemble key retaining plates.
5.5
IMPORTANT : The stator core/winding must be protected while lowering the rotor
through stator bore. For this purpose. atleast eight persons should stand equally
spaced on stator. While lowering the rotor, they should position planks (75 mm
x 2 m) on inner diameter of core.
5.5.3 Lowering of generator top shaft
(i) Bring top shaft in the service bay and remove temporary rusts preventive coating
and clean it up for assembly.
(ii) Make top shaft vertical using the lifting device provided and lower it on the main
shaft.
(iii) Bolt-up the top shaft with main shaft as per, ‘Top and main shaft fixing
arrangement’, drawing 1 254 01 23508.
5.6 MAGNETIC CENTERING OF STATOR AND ROTOR

For magnetic centering, the centreline of rotor and stator shall be at the same
elevation during operation. In order to achieve proper magnetic centering,
following precautions shall be observed during erection at site:
5.6.1 Rotor Pole Mounting
During assembly of poles on the rotor rim, it must be ensured that centrelines of
all the poles are at the same elevation and at the centreline of rotor rim. To achieve
this, following method is recommended:
(i) Decide the location of the pole on the rim on the basis of its type and
weight.
(ii) Measure the pole body length (Refer Fig. 5.1 – dimension ‘P’)
(iii) Measure the stacked rim height on the corresponding pole seating face (at
the center of this face – refer Fig. 5.1 – dimension ‘R’).
(iv) The pole stop height shall be equal to dimension (R-P)/2. If required the
height of the supplied pole stops shall be reduced by machining or increased
by weld deposit and subsequent machining so that centre line of all poles is
within 0.5 mm.
(v) Mark the centre line of the pole with white paint on the pole face.
(vi) Assemble the poles using modified pole stop, wherever necessary.
(vii) Assemble all the poles adopting the method given above and complete the
rotor assembly.
(viii) The above procedure ensures all the poles lie on the same centre line.
5.6.2 After rotor lowering : Rotor form
After lowering the rotor in the pit, the magnetic centre of the stator and rotor shall
be checked. For this purpose, some additional measurements shall be taken while
taking readings of rotor form. For checking rotor form, all the poles are brought
one by one, in front of a reference point marked on the stator and air gaps are
measured at top and bottom. While measuring the air gap, following shall also be
measured with reference to Fig. 5.2:
- dimension ‘T’ = distance between pole end plate and stator core at top
- dimension ‘B’ = distance between pole end plate and stator core at bottom
5.6
For evaluation, average value of ‘T’ and ‘B’ shall be separately computed. Since
during erection, the rotor elevation is set higher to cater for the thrust bearing
deflection due to turbine runner and hydraulic thrust, the values of T&B will not be
equal. However half the difference of ‘B’ and ‘T’, i.e. (T - B) / 2 shall be equal to
the thrust bearing bracket and spring deflection. Refer clause 8.4.4, Section – 8 of
this manual. A variation of about 2 mm is permitted on this dimension.
5.6.3 Method of correction

In case, the variation in centre line elevation of the stator and rotor is more than
the desired value, than corrective action shall be taken. In case the rotor pole
mounting is done as per procedure given above and setting of thrust bearing
elevation is correct, then correction is required only on stator. Appropriate shims
shall be added or remove from the bottom of each stator sole plate to raise or lower
the stator center line, as desired. After correction, magnetic centering shall be
checked again.
The center line of stator and rotor shall match during normal operation. However
during standstill condition the rotor elevation is set a little higher than running
elevation, taken into account the thrust bearing bracket deflection and thrust
bearing spring deflection. This fact must be kept in mind while checking or
adjusting magnetic centre.
5.7
SECTION-6
BOTTOM BRACKET, BEARINGS AND OTHER ASSEMBLIES
Bottom guide bearing arrangement 0 257 02 23501
Bottom bracket centre and arm assembly 0 257 01 23504
Bottom bracket centre assembly 0 257 01 23505
Arrangement of air and oil vapour piping 0 257 02 23507
Arrangement of brake piping and conduit 0 257 08 23509
Arrangement of air guide and air baffle 0 257 05 23510
Air guide fixing support assembly 2 257 05 23510
Arrangement of pit air seal 0 257 06 23511
Baffle assembly 1 257 05 23506
Bottom guide pad 2 257 02 23503
Pivot bar (bottom) 2 257 02 23508
Pad stop 3 257 02 23505
Arrgt. of bottom bearing instruments & oil level switch 0 259 03 23503
6.1 GENERAL
The bottom bracket is supplied with detachable arms for their assembly at site. The
bottom bracket assembly comprising of thrust bearing, guide bearing, oil coolers
etc. rests on sole plates. The brake-jack units, oil vapour seal, pit air seal etc. are
assembled on bottom bracket.
6.2 ERECTION OF BOTTOM BRACKET
6.2.1 Lower bottom bracket and centralize it with respect to turbine shaft and also
check elevation. Refer clause 8.4.
6.2.2 Lower main shaft and measure bottom bracket deflection as per Section - 8.
6.2.3 Assemble interpad cooling piping inside the bottom bracket and outside piping
upto oil pump and motor unit provided for interpad cooling.
6.2.4 Commission brake-jack control panel and H.S. lubrication unit.
6.2.5 Lower the rotor and measure bottom bracket deflection as per Section-8.
6.2.6 Bedding of guide pads : Rub babbitt surface of a guide pad on respective
journal surface of generator shaft. Continue scraping of shining points of babbited
surface, which represent high points, till 80% contact area of the babbited surface
is achieved.
6.2.7 Assemble guide bearing pads. Set guide bearing clearances as per drawing and
record the clearances in log sheets as per Quality Plan for Installation, document
no. QPX-HG-027.
6.2.8 Assemble oil retaining sleeve on spring plate assembly and set it concentric to the
journal surface of main shaft.
6.2.9 Carry out hydraulic testing of oil coolers as per drawing and assemble them on
bottom bracket. Assemble oil vapour seal/pipes, bottom bearing instruments etc.
NOTE: Oil vapour seal should be assembled carefully for its effective functioning.
6.2.10 Clean the bearing housing thoroughly. Fill a few drums of oil and flush 2 to 3
times. Do not fill oil at this stage.
6.1
SECTION – 7
TOP BRACKET, BEARING AND OTHER ASSEMBLIES
DESCRIPTION DRAWING
Top bracket center assembly 0 256 01 23503
Top bracket center and arm assembly 0 256 01 23504
Arrangement of stator and top bracket fixing 2 256 01 23508
Top guide bearing arrangement 0 256 02 23501
Top oil vapour seal assembly 0 256 02 23505
Arrangement of air and oil vapour piping 0 256 02 23506 (2 sheets)
Top air guide and baffle arrangement 0 256 02 23507
Oil leakage collector assembly 1 256 02 23503
Guide bearing pad 2 256 02 23501
Pivot bar 2 256 02 23505
BOM for bearing protection brush arrangement 3 256 02 23511
Arrangement of floor plates 0 256 05 23510
Air guide assembly (top and bottom) 0 256 06 23508
Air baffle assembly 2 256 06 23510
Arrangement of D.C. connections 0 256 10 23509
Connector for D.C. connection 2 256 10 23512
Brushgear assembly 1 256 10 23505
Method of setting spring load for brushes 3 256 10 01401
Top oil cooler withdrawal arrangement 1 256 51 23507
Arrgt. of top bearing instruments and oil level switch 0 259 03 23501
7.1 GENERAL
The top bracket is supplied with detachable arms for their assembly at site. It
accommodates the guide bearing assembly, oil coolers etc. It provides support for
generator flooring, top casing, brushgear etc.
7.2 ERECTION OF TOP BRACKET AND OTHER ASSEMBLIES

7.2.1 Unload top bracket and its arms in service-bay. Remove temporary rust preventive
and clean up for assembly. Bolt up top bracket arms with center assembly as per
drawing.
7.2.2 Lower top bracket on stator frame and centralize it with reference to top shaft and
level. Bolt up top bracket with stator.
7.2.3 Assemble oil-retaining sleeve to the top bracket. Clean the bracket thoroughly. Do
not fill oil at this stage.
7.2.4 After final alignment, assemble guide bearing pads. Set guide bearing clearances
as per drawing and record the clearances in a log sheet as per Quality Plan for
7.1
7.2.5 Assemble guide pads and other components and complete top guide bearing
assembly as per drawing.
7.2.6 Set oil retaining sleeve concentric to the journal surface of shaft.
7.2.7 Assemble oil leakage collector assembly underneath oil retaining sleeve.
7.2.8 Carry out hydraulic testing of oil coolers as per drawing to check healthiness of
cooler tubes and joints. Assemble oil coolers, oil vapour seal, instruments &
covers.
7.2.9 Complete laying, tack welding of cooling water and air pipe lines. Dismantle pipes
for final welding, cleaning and hydraulic testing as called in drawing. Install
cooling water pipes with supports and clamping arrangement as per drawing.
7.2.10 Assemble tubular shaft assembly and assemble collector, over speed device and
toothed wheel of SSG on it.
7.2.11 Check alignment of collector as given in Section - 8.
7.2.12 Fill up oil upto the specified oil level and close bearing housing.
7.2.13 Conduct High Voltage test on collector and rotor leads and record the results in log
7.2.14 Assemble brushgear, OSD, SSG and DC connections on top bracket.
7.3 GUIDE BEARING AND INSULATION

Bedding of guide pads: Rub babbit surface of a guide pad on respective journal
surface of generator shaft. Continue scraping of shining points of babbited surface,
which represent high points. After each operation of scraping, rubbing process of
pads over journal shall be continued, till atleast 80% contact area of the babbited
surface is achieved.
Assemble guide pads, oil vapour seal assembly, oil leakage collector assembly and
bearing protection brush. Measure IR values of following and record.
(i) Each guide pad to pivot bar before assembly in bearing housing
(ii) Guide pad to top bracket (earth)
(iii) Top oil vapour seal with respect to top bracket (earth)
(iv) Bearing protection (insulated) brush with respect to top bracket (earth)
(v) Oil leakage collector assembly with respect to top bracket (earth)
NOTE: Ensure that capillaries of RTDs, DTTs and thermostats do not touch the bearing
pads, keep plate etc. till they come on to the guide bearing support ring. For this
purpose capillary length inside top bearing housing should be insulated as per
drawing, 0259 03 23501.
7.2
SECTION – 8
LEVELS, CENTERING AND ALIGNMENT
(INCLUDING DOWELLING AND GROUTING)
8.1 INTRODUCTION
Levelling and alignment along with centralizing are the most important operation
in the erection of a Hydrogenerator. Trouble free operation of a machine depends
on satisfactory achievement of level, alignment and centralizing of rotor. These
operations must ensure that:
 The thrust bearing is horizontal
 The thrust bearing elevation is set to give correct turbine runner elevation during
normal operation
 The axis of turbine shaft, generator main shaft, top shaft and collector shaft are in
one vertical line.
 The turbine runner centre and generator rotor center coincide with centre line of
stay ring and stator bore respectively during normal operation.
 The guide bearing clearances are set as per drawing.
8.2 STARTING CHECK

The turbine shaft will be set truly vertical and central to the stay ring during
turbine erection. The turbine shaft however will be set lower than its normal
running position to clear the coupling spigot when generator shaft is lowered. It is
presumed that the stator frame has been positioned and bolted down with the
stator sole plates supported on packers but not grouted in position.
8.3 INITIAL SETTING OF BRACKET

8.3.1 Place the sole plate for bottom bracket in position over the foundation bolts and
adjust to a position at approximately the concrete level.
8.3.2 Level the sole plates in position. Adjust the bottom bracket elevation by adjusting
the shims and then tighten the foundation bolts.
NOTE: Shims are to be used below sole plates as shown in the drawing. Minimum
number of shims are to be used for adjustment i.e. thicker shims are to be used,
wherever possible. It is suggested that after elevation setting is completed using
graded shims, the total thickness of packers used may be measured and replaced
by new packer with larger thickness at site.
8.3.3 Lower the bottom bracket on the sole plates. Centralise the bracket by setting a
plumb line passing through center of turbine shaft. Adjust the radial position of the
bracket. Rough adjustment may be made by station crane and final adjustment by
jacking screws. The center of bore of the guide bearing support ring should
coincide with plumb line within ± 0.1 mm. Tighten the holding down bolts of sole
plates.
8.1
8.4 SETTING OF THRUST BEARING ELEVATION
8.4.1 Check that the sole plates and bottom bracket holding down bolts are tightened.
8.4.2 After transferring load of rotor on thrust bearing, measure difference in magnetic
center of stator and rotor. Adjust the difference such that rotor axis, coincides
with that of stator, while the unit is under operation under full load.
8.4.3 Allowance must be made for deflection of the bottom bracket and thrust bearing
springs under full load i.e. weight of rotating parts and hydraulic thrust as
below:
a) Bracket deflection at full load (1015 T) 2.3 mm
b) Bracket deflection with generator rotor & gen. shafts (405 T) 0.92 mm
c) Spring deflection at full load (1015 T) 2.0 mm
d) Spring deflection with generator rotor & gen. shafts (405 T) 0.4 mm
8.4.4 It is to be ensured that the turbine runner will be at the desired level under
running condition on load. The turbine erector will advise the amount (T) by
which the turbine coupling is below the normal running position. The generator
shaft must then be set at a height above the turbine coupling by an amount equal
to T plus additional deflection of thrust bearing at full load. This equals to :
T + (2.3 – 0.92) + (2.0 – 0.4) = T + 2.98 mm.
8.4.5 It is essential that any adjustment of the bearing bracket shims provided to
obtain the correct coupling gap must be precisely the same (by micrometer
Measurement) at each bracket foot, otherwise the bracket will be thrown out of
level.
8.5 LEVELLING OF THRUST BEARING

Lowering of generator main shaft
8.5.1 Lower generator main shaft (Refer Section-5).
8.5.2 Lower rotor assembly (Refer Section-5). Couple rotor and top shaft with main
shaft. Measure bottom bracket deflection when rotor rests on thrust bearing.
8.5.3 Assemble the items for shaft centralising as per Technical Requirement given in
drawing 0 257 02 23501. Centralise the shaft.
8.5.4 Lower generator top shaft and assemble it with the main shaft.
8.5.5 FOR CHECKING THE LEVELLING OF THRUST BEARING AND ALL
ROTATIONAL CHECKS, FIT FOUR SHAFT CENTRALISING BLOCKS AT
900 INTERVAL AND CLOSE UP THE CLEARANCE TO A MINIMUM, YET
ALLOWING THE ROTOR TO ROTATE. SHAFT CENTRALISING BLOCKS
SHOULD BE COATED WITH MOLYBDENUM-DI-SULPHIDE.
8.5.6 Check that the thrust bearing is horizontal by placing a level on top of the thrust
Block and rotating the shaft. Use a level gauge of 0.025 mm in 1 meter accuracy.
Level the bracket by modifying shims below the bracket feet, if required.
8.5.7 Place the precision level gauge (mentioned above) on the top of rim end plate and
secure it firmly to avoid jerks when rotated.
8.2
NOTE: The level gauge must be checked for zero error before use. H.S. lubrication should
be switched ON before giving any rotation to the rotor / shaft.
8.5.8 Rotate the rotor and note the level gauge readings at regular interval. It must be
ensured that the rotor is stationary, freely suspended, H.S. lubrication system is
OFF and no person or foreign material is on the rotor while taking the readings
8.5.9 While checking the level variation, H.S. lubrication pump should be switched off.
Adjust the bracket shims as necessary to get the resultant level reading within 1
division of level of 0.025 mm in 1 meter accuracy.
8.5.10 To obtain the required accuracy of the level, the shims under bottom bracket
feet are adjusted. The adjustment in the shims should be graded as far as
ispracticable to maintain an even loading on sole plates. Minimum number of
shims for a given adjustment should be used i.e. thicker shims are used wherever
possible
NOTE:
(1) It is advisable to measure total thickness of the shims used under each bracket
foot and then use a thick machined plate of same thickness as measured by
micrometer in place of many shims.
(2) All level gauge readings are to be taken after fully tightening the holding down
bolts after each adjustment of shims.
8.6 ALIGNMENT
IMPORTANT : DURING ALIGNMENT CHECKS, FOLLOWING POINTS
MUST BE ENSURDED:
(i) THE RETAINING PLATES OF THRUST PADS ARE NOT FOULING
WITH THRUST PADS PREVENTING FREE ROTATION OF ROTOR AND
SHAFT.
(ii) THE MOVEMENT OF DIAL GAUGE AT THE REFERENCE GUIDE
BEARING SHALL NOT EXCEED 1 TO 2 DIVISIONS.
(III) CLOSING ERROR SHALL NOT EXCEED 2 DIVISIONS AT THE
POINT OF MEASUREMENT OF THROW
(IV) THE FINAL ALIGNMENT READINGS SHALL BE TAKEN ONLY
AFTER FULL TIGHTENING OF THE BOLTS OF TURBINE AND
GENERATOR SHAFT COUPLING.
(v) TWO CONSECUTIVE FINAL THROW CIRCLE DIAMETERS
SHOULD BE
EQUAL IN MAGNITUDE AND DIRECTION.
IF ABOVE POINTS ARE NOT SATISFACTORY, THE ALIGNMENT READINGS

ARE SUSPECT AND NOT ACCEPTABLE.
8.3
8.7 ROTATIONAL CHECK ON GENERATOR MAIN WITH ROTOR AND
TOP SHAFT
8.7.1 Fully tighten the main shaft and top shaft coupling bolts.
8.7.2 Fit dial gauges at top and bottom, generator guide bearing journals in X and Y axis.
8.7.3 Rotate the rotor through 450, 900, 1350, 1800, 2250, 2700 , 3150 and 3600. Record the
dial gauge readings in a tabular form (as given below for ready reference) in line
with log sheet as per Quality Plan for Installation, document no. QPX-HG-027.
Location of X-axis Y-axis

dial gauge
Rotation in 0 45 90 135 180 225 270 315 360 0 90 135 180 225 270 315 360
degrees
Generator
bottom
guide
bearing (a)
Generator
Top guide
bearing (b)
c = b-a
NOTE : The reading of 00 and 3600 should be the same within the tolerance of reading
accuracy. If these readings constantly show a difference, there is a possibility that the
shaft may not be rotating freely. The oil retaining sleeve or some such other component
may be touching the rotor. It is to be checked whether any jerk is produced while
rotating the rotor, which affects the initial readings. If so, the initial reading should be
taken after the cause of jerk is investigated and rotor made to rotate smoothly.
8.7.4 Plot the co-ordinates of ‘c’ on a graph paper to a suitable scale. Draw a circle with
minimum radius passing through any three points whereas enclosing remaining points.
THE THROW CIRCLE DIAMETER AT TOP GUIDE BEARING SHOULD BE
LIMITED TO 0.06 MM MAXIMUM.
8.7.5 The throw at the top guide-bearing journal shall be corrected, if it exceeds the
permissible limits defined above. In this case, the correction is possible by providing
shims between top shaft and main shaft.
8.7.6 Following points should be observed for shims:
(i) The shims should be graded in thickness and in steps of 200 to 250 mm i.e., if a shim
of 0.1 mm be needed at one end, thinner shims (say 0.08, 0.06, 0.04, 0.02 mm etc.)
shall be introduced additionally upto the diametrically opposite end as far as possible,
to maintain constant taper.
(ii) The shims shall be free from kinks etc. and must cover the full diameter of the flange.
(iii) Each piece of shim shall have at least one cutout for one fastener, i.e. bolts, dowels,
etc. ‘U’ cuts shall be provided for the purpose.
(iv) Shims shall be of stainless steel.
8.4
8.8 COMBINED ROTATIONAL CHECK ON GENERATOR & TURBINE SHAFTS

8.8.1 Pull the turbine shaft towards the generator shaft and join the flanges by coupling
bolts. The bolts should be tightened to give extension within the value mentioned on
drawing. The diametrically opposite bolts should be tightened progressively.
8.8.2 Remove the turbine guide pads, seals and turbine support so that the turbine shaft is
suspended freely from the thrust bearing.
8.8.3 The gap between the turbine runner and stay ring should agree with the setting
obtained during turbine erection while centralizing the shaft. For centralization,
bottom guide bearing is to be adjusted, as necessary. If this centralizing affects the
bracket centering by more than  0.25 mm, the bracket will also have to be
centralized.
8.8.4 Fit dial gauges on turbine guide bearing journal, generator bottom and top guide
bearing journals in X and Y axis.
8.8.5 Rotate the rotor through 450, 900, 1350, 1800, 2250, 2700 , 3150 and 3600. Record the
dial gauge readings in a tabular form (as given below for ready reference) in line with
log sheet as per Quality Plan for Installation, document no. QPX-HG-027.

dial gauge
Rotation in 0 45 90 135 180 225 270 315 360 0 90 135 180 225 270 315 360
degrees
Generator
bottom guide
bearing (a)
Generator
Top guide
bearing (b)
Turbine
guide
bearing (c)
d = b-a
e = c-a
NOTE: The reading of 00 and 3600 should be same within the tolerance of reading
accuracy. If these readings constantly show a difference, there is possibility that
a shaft is not rotating freely. The oil retaining sleeve or some such other
component may be touching the rotor. It is to be checked whether any jerk is
produced while rotating the rotor, which affects the initial readings. If so, the
initial reading should be taken after the cause of jerk is investigated and rotor
made to rotate smoothly.
8.5
8.8.6 Plot the co-ordinates of ‘d’ and ‘e’ on a graph paper to a suitable scale. Draw a circle
with minimum radius passing through any three points whereas enclosing remaining
points. THE THROW CIRCLE DIAMETER AT TURBINE GUIDE BEARING
SHOULD BE LIMITED TO 0.08 MM MAXIMUM.
The throw at the top guide bearing should agree with the previous reading taken in
para 8.7.
8.8.7 The throw at the turbine-bearing journal should be corrected if it exceeds the
permissible limits defined above. The throw can be corrected by scrapping of end
surface of turbine or generator shaft or by placing stainless steel shims between
flanges. For shimming, the points mentioned in clause 8.7.6 shall be strictly followed.
8.9 ALIGNMENT OF COLLECTOR

8.9.1 Assemble the collector shaft on top of the generator top shaft and then assemble
collector.
8.9.2 Fit dial gauges at any one collector ring and at generator bottom guide bearing journal
in X and Y axis. Rotate the rotor through 45 0, 900, 1350, 1800, 2250, 2700 , 3150 and
3600. Record the dial gauge readings in a tabular form (given below for ready
reference) in line with log sheet as per Quality Plan for Installation, document no.
QPX-HG-027.

8.9.3
dial gauge
Rotation in 0 45 90 135 180 225 270 315 360 0 90 135 180 225 270 315 360
degrees
Generator
bottom
guide
bearing (a)
Collector
ring (b)
c = b-a
Plot the co-ordinates of ‘c’ on a graph paper. The throw circle diameter as defined earlier
should be limited to 0.1 mm.
8.10 STATOR AND ROTOR FORM

After completion of generator alignment but before setting guide bearing clearances,
air gaps shall be measured and recorded in log sheets as per Quality Plan for
On the basis of air gap measurements, the stator form and rotor form shall be plotted
and necessary correction will be made as per Annexure – III.
8.6
8.11 ADJUSTMENT OF BEARING CLEARANCES
Set the turbine guide bearing clearances as per drawing. Before setting generator top
and bottom guide bearing clearances, guide pads shall be bedded with journal. Shims
Shall be fitted between guide pads and pivot bars. Ensure that the pivot bars, which is
offset, is properly assembled with respect to the direction of rotation as per drawing.
Push the guide pads against journal and measure the clearance between the back of
pivot bar and guide bearing support ring by inserting feeler gauge. This radial
clearance shall be set at bottom and top guide bearings by adding or removing the
shims.
8.12 DOWELLING
Only after completion of above operation, dowelling work shall be taken up. The
reamed holes shall be smooth and parallel to their axis. The hole diameter shall be
measured at top, middle and bottom. Dowel shall be machined and ground to give
clearance of 0.02 to 0.04 mm on actual measured diameters of holes.
All dowels (between bottom bracket and sole plates, stator and sole plates, top bracket
and stator etc.) shall be coated with molybdenum di-sulphide grease before putting in
place.
8.13 GROUTING
(i) Concrete surface for sole plate seating should be chipped/ground to get a levelled
and hard surface, before lowering sole plates on concrete.
(ii) AFTER FINAL LEVELLING, CENTERING, BOLTING AND DOWELLING OF
THE SOLE PLATES ARE OVER, the sole plates shall be grouted to the foundation
using non-shrinking cement/compound to produce a monolithic mass capable of
transmitting loads from sole plates to generator foundation. (Refer drawing 1 251
02 23502 for Arrangement of stator sole plates and drawing 1 257 07 23501 for
arrangement of bottom bracket sole plates).
(iii) The method of grouting shall be decided by the customer.
8.7
SECTION - 9
STARTING, TESTING AND COMMISSIONING
9.1 GENERAL
 Clean the hydrogenerator of dust and dirt with the help of dry compressed air and
vacuum cleaner. Rub with cloth to clean internal surfaces of frame and air baffles
with cloth.
 Remove foreign objects, if any from inner parts of hydro generator, specially the core
ducts, air gaps, inter polar gaps etc.
 Check installation of dowels and tightening of fixing bolts of stator, bottom bracket,
top bracket, brake-jack assemblies etc. Check the locking of all the nuts, particularly
in rotating parts of generator and air baffles.
 Check air guides and air baffles to ensure that they do not touch the rotating parts of
generator and the variation in airguide/baffle clearances are within limits specified in
the drawings.
 Check that all cover plates are closed tightly.
 The oil pot and pipelines are to be flushed by circulating oil for twelve hours. The
bearing housing shall then be filled with fresh oil up to the level shown in the
drawing. Again use the oil purifier for twenty-four hours for purification. Check for
any oil leakage.
 In order to prevent entry of dirt and dust into the oil bath during first starting,
disconnect air piping from air baffle to vapour seal. HOWEVER, THE AIR PIPELINE
MUST BE CONNENCTED BACK AFTER FEW DAYS OF RUNNING.
9.2 PRE-START CHECKS

 Check that cooling water circulation is normal through the air coolers and bearing
oil coolers. Open the valves of the coolers for releasing the trapped air.
 Oil circulation through inter pad cooling system shall be checked.
 The fire extinguishing system of generator should be checked for operational
readiness.
 The brake shall be applied and released a number of times with compressed air to
check their performance to ensure that they are not sticking.
 Disconnect the generator excitation system and disconnect the generator main
terminals from bus bars. Start Interpad Cooling System and Hydrostatic
Lubrication System.
 Check that all the thermal indicators are installed at the required places and the
instruments are functioning normally.
 Check that fire extinguishing system for generator functions normally.
9.3 BUMP START

The machine is given a start and allowed to rotate so that it makes few rotations. The
aim is to ensure that rotor rotates freely without any fouling or abnormal noise.
9.1
9.4 FIRST RUN
In the first run, the machine is run without excitation and hence ensure that generator
excitation system is switched off. Start the hydro set and run it at low speed and make
sure that there is no jamming, unwanted noise/run-out of shaft and collector. If any
abnormal vibration is noticed at lower speed, balancing shall be done at that speed
before taking the machine to the next higher speed and upto finally rated speed.
OTHERWISE THE SHAFT MAY RUB THE OIL VAPOUR SEAL AND POSSIBLY
DAMAGE THE SEAL.
Provision is made on the rotor spider for fixing of the balance weight. By choosing the
proper size and location of balance weights, as required, the generator should be
balanced within allowable limits. The allowable bracket vibrations and shaft vibrations
(double amplitude) are as under:
Pl Place of measurement Allowable vibrations (max.), mm

Guide bearing bracket 0.15
Shaft, near to guide bearing 50% of diametral clearance of guide bearing
9.4.1 After first start

After the first start, the machine is to be shut down for inspection. The generator shall be
thoroughly inspected and mechanical fastenings shall be checked for looseness. Check
whether the brushes are properly bedded on the collector.
9.4.2 Bearing run

Run the machine at rated speed (at no load). The thrust and guide bearing temperatures
are to be carefully observed when the set is spun. The temperature should increase
gradually without sharp kicks, with uniform increment and within 2-3 hours of operation,
it should practically stabilize. If the temperature indicated by any thermometer in thrust
and guide bearings increases sharply even if the absolute temp. is not very high, the
machine should be stopped and the reason for the same is ascertained. The bearing run
can be continued for about 12 hours.
Observe the oil level in thrust bearing oil bath. After starting, the oil level rises due to
centrifugal forces, heating and aeration. Check that the oil does not leak through the
bearing housing and oil retaining sleeves.
9.5 SETTING OF OVERSPEED DEVICE

CHECK THE SETTING OF OVERSPEED DEVICE BY SPEEDING-UP THE UNIT
TO SPECIFIED OVERSPEED SETTING. IT SHOULD BE LITTLE HIGHER THAN
MAXIMUM LOAD THROW-OFF SPEED. KEEP A WATCH ON ABNORMAL
9.2
KNOCKING AND NOISE DURING SPEEDING UP. UNIT SHALL NOT BE
MAINTAINED AT OVER SPEED FOR A LONG TIME. INPECT GENERATOR
COMPONENTS AFTER OVERSPEED TEST, INCLUDING TIGHTENING OF ALL
HARDWARES, POLE/RIM KEYS ETC.
9.6 VOLTAGE BUILD-UP

Before building-up the voltage, generator shall be run for dry out of windings by short
circuiting the three-phase terminals and by circulating the current through windings. For
supplying excitation to the generator field windings, the static excitation equipment can
be used under manual control, by giving 11 kV station supply to the HV terminals of
excitation transformer.
The voltage shall be built-up only after satisfactory condition of winding insulation
achieved by dry out. In order to build-up the voltage in stator winding, switch on the
excitation system and increase field current. Generator terminal voltage shall be
increased in steps of 2 kV and the unit shall be allowed to run for about 5 minutes every
time before increasing the voltage. Check the brushes for any sparking. Over voltage
protection check can also be done at this stage.
During the process of voltage build-up, monitor the vibration of shaft and bearing
brackets and if necessary, rebalance the machine before proceeding to the next higher
voltage. In this way, balance the machine under excited condition upto rated voltage.
9.7 SYNCHRONISATION AND LOADING

Stop the unit and connect the generator terminals to transformer terminals through bus
bars. Restart the unit and build-up voltage as explained above. Synchronize and load the
unit. Load shall be increased in steps of 10 MW and sufficient time shall be allowed at
every stage to watch the performance. Check for abnormal noise, vibration etc. and keep
a watch on winding, core and bearing temperatures. Collector brushes shall also be
checked for smooth function.
Measure the vibration of the bracket and the shaft at top bracket and bottom bracket with
and without excitation and no load. If necessary, rebalance the machine before
proceeding to the next higher load. In this way, balance the machine under excited
condition upto rated load.
Conduct partial, full load and max. load throw off tests and check for satisfactory voltage
and speed rise.
9.8 PUTTING INTO OPERATION

Before putting the generator on commercial load, following final checks should be
made:
9.3
(a) All balance weights are permanently welded/locked as per drawing, after removal of
temporary locking provided during balancing of a unit.
(b) Check carefully the tightness of fixing details of poles and keys, fan, rotor, air baffles,
stator, brackets, cover plates etc.
(c) Check carefully the stator winding for absence of any bulging of insulation or flow of
varnish.
(d) Check the interpolar joints of the rotor field winding. If necessary, tighten the holding
down nuts etc.
(e) Check the sealing of oil baths and vapour seal clearances.
(f) Check water and oil pipe lines for any leakage.
(g) Check working of braking system.
(h) Check the connections of current carrying leads and cables.
(i) Measure the insulation resistance of all the windings of the generator and compare them
with the measurements carried out earlier.
(j) Check the welding of rotor spider, top and bottom brackets, stator and other details.
(k) Blow the collector with dry compressed air as during starting period the most sensitive
wear of the brushes is observed.
(l) Check the oil levels in the bearing housings.
9.9 STOPPING
Following sequence shall be followed for stopping the unit when running on load.
(a) Reduce the output of generator till it is almost zero.
(b) Trip line circuit breaker.
(c) Reduce the field current till the terminal voltage is almost zero.
(d) Trip field circuit breaker.
(e) Allow the machine to decelerate to braking speed and apply brakes.
(f) Shut off cooling water supply to air/oil coolers, after machine comes to stand still. .
(g) Shut off H.S. Lubrication system and interpad cooling system.
(h) Release and reset brakes.
9.10 HANDING OVER

After successful running of the machine as per contractual requirement, same will be
handed over to customer for operation as per grid demand.
9.4
ANNEXURE – I
HIGH VOLTAGE TEST ON WINDINGS
1.1 SCHEDULE OF HV TESTS ON STATOR WINDING AT SITE
S.No. Stage of testing Test voltage (rms value)

1 Bottom bars : After placing the bottom bars in 27 kV
position in stator slots, test bottom bars at
2 Top bars : After placing top bars in stator 25 kV

slots, test top bars and bottom bars together at
3 Official HV test : test separately with other 23 kV

two phases earthed after completing winding,
brazing and stringing etc.
1.2 SCHEDULE OF HV TEST ON FIELD WINDING AT SITE
S.No. Stage of testing Test voltage (rms value)

1 After mounting the wound pole on rotor and 5.50 kV
driving the pole keys hard but before
interconnection, test between each field coil
and pole body
2 Official HV test between collector and earth 4.75 kV

after making all connections between field
coils and upto collector
NOTES:
(1) H.V. tests specified are AC, rms voltage at 50 Hz for a duration of 60 seconds.
(2) IR value shall be recorded before and after each HV test.
(3) In case of failure during HV test, testing at any stage, the subsequent tests shall be
at the specified voltage, for 60 seconds duration irrespective of the duration of
application of voltage during failure.
(4) Impedance test of wound poles to at 60 to 100 V AC before conducting HV test:
(i) Before mounting the wound poles on rotor
(ii) After mounting the poles on rotor, but before connections
(5) Two terminals of each phase to be checked for electrical isolation by continuity test.
A - 1.1
ANNEXURE - II
INSULATION RESISTANCE TESTING AND DRYOUT
2.0 GENERAL
The insulation resistance of a winding is a function of the type and assembly of
insulating material. In general it varies directly with the thickness of insulation and
inversely with the conductor surface area. The value of insulation resistance also varies
inversely with the amount of moisture in the insulation and the amount of solvent left in
the bonding varnish of the winding connections. Insulation tests are carried out normally
using a megger. Where polarization index values are required, the megger must be
capable of supplying a steady voltage for 10 minutes. The results obtained using D.C.
test methods are affected by the general conditions of the surface of the windings as well
as by the leakage through the main insulation. Interpretation of the results may be
difficult if contamination is present; for this reason before carrying out the test, the
surface of the winding should be examined to make sure that they are clean and dry, and
not contaminated by moisture, oil, salt, carbon dust or other foreign matter.
2.1 INSULATION RESISTANCE TESTING

2.1.1 SAFETY PRECAUTIONS FOR TESTING
Before attempting any insulation resistance test, it is essential to earth the frame of the
machine and parts of the winding not being tested. Dry insulation resistance is capable
of holding an electrical charge for several hours after the removal of the applied
voltage. For reasons of both safety and accuracy, it is essential that the winding, or
section under test is adequately earthed both before and after the application of the test
potential. For large machines a period of 30 minutes should be allowed.
2.1.2 METHOD OF TEST

Initial test may be carried out without disconnecting the supply cables, but if
unsatisfactory result is obtained, then the windings should be isolated from all
externals cables and connections before repeating the measurement of insulation
resistance. Insulation resistance should be measured between each individual phase
and earth with the remaining phase earthed. The insulation resistance (R ph) of one
phase to earth on a 3-phase winding is approximately twice that of the complete
winding; therefore, the measured value must be divided by two to obtain a value for
comparison with the value recommended. In practice each test is carried out by
conductor or terminal of the winding under test and the other lead to the frame. The
instrument is then switched on and the test voltage maintained for one minute at which
stage the insulation resistance reading (R1) is noted. The test is continued and an
additional reading (R10) after 10 minutes is noted for calculation of the PI-value.
2.1.3 POLARISATION INDEX

The measured insulation resistance of a winding normally increases with the time of
application of the D.C. test voltage. The increase is usually rapid for the first one to
A - 2.1
two minutes and thereafter the slope of the curve steadies of with time; for the next 10
to 30 minutes, the increase is a function of the absorption characteristics of the
insulation and hence of its general condition. On majority of the winding, the value
reached in 10 minutes will be greater than 90% of the final steady state reading. The
polarisation index of a winding is defined as the ratio of the insulation resistance after
10 minutes (R10) to the insulation resistance after 1 minute (R1) i.e.
Polarisation Index (P.I.) = R10/R1
On a clean dry winding, the polarisation index value should not be less than 2.0. If a
value below this is obtained, then a dry out should be carried out .
2.2 DRY OUT

2.2.1 Methods of dry out
(a) Space Heaters
Electric space heaters may be used for drying windings where the moisture is on or
close to the surface of the outer layer of insulation. However, if the moisture has
penetrated the winding insulation, then the method is unlikely to be successful on its
own. If used in conjunction with direct heating, it can prove useful in keeping the
overall temperature upto the specified dry out value.
(b) Short Circuit Running

The stator terminals should be short circuited by connecting the three main terminals
together. Connections must be made with cable or copper strip of adequate section to
carry the full load current of the machine. Approximately equal current should flow in
each phase during the dry out. The stator frame must be solidly earthed. The machine
should be run up using the prime mover. As a first part of the dry out schedule, the
machine should be run without excitation as the windage losses will generate
sufficient heat to raise the temperature of the winding to an acceptable rate. Initially
excitation should be applied to cause approximately 15% of the full load current to
flow. As the temperature goes up, the excitation should be varied to follow the heating
rate specified in Para 2.4. In general the circulating current must not be allowed to
exceed the full rated value, otherwise overheating of the stator may occur.
(c) Direct current heating

Where the controllable low voltage direct current supply is available from a motor
generator set or rectifier equipment, then this may be used for dry out of the A.C. stator
windings (with or without the rotor in position) and DC field Circuit.
2.2.2 A.C. Stator

All the phases should be connected in series using copper strip or cable of adequate
section to carry the full load current. Initially the value of current should be set at
approximately 15% of the full load rating and adjusted as the temperature rises to
follow the heating schedule. The direct current supply and any external cables must be
disconnected before any insulation resistance reading are taken. Usually, about 50-60%
of rated current may be sufficient to maintain dry out temperature. The end windings
A - 2.2
must be properly covered by suitable non hygroscopic covers to contain the heat
within, and the direct heating can be supplemented by use of space heaters located
below the winding for quick results. Asbestos sheets are not recommended for
covering the end windings as these are hygroscopic and may hinder satisfactory dry
out.
2.2.3 DC Field circuits

For drying out the DC field windings all the coils should be connected in series and
current passed through the circuit so as to follow the rate of temperature rise specified
below. In general the value of current used should not exceed the maximum value
specified for the machine field circuit. As field circuits are inductive, it is essential
when breaking the circuit (to take insulation readings) that the current is brought down
to a low value by either having a resistance in series with the supply or by reducing the
voltage to as near zero as practicable.
2.2.4 Dry out temperature

In general when using direct heating of the winding by passing current the
temperature should be raised to approximate 80 0 C as measured by thermometers
attached to the end windings are 900C when measured by embedded temperature
detectors (ETD’S). The rate of temperature rise for a winding which has been allowed
to get damp due to moisture pick up from highly humid atmosphere should be limited
to 5 to 60 C per hour, where a winding has been soaked with water than the rate of
temperature rise should be limited to 2 to 3 0 C per hour, otherwise damage to the
insulation is likely to occur. Once the maximum temperature is reached it should be
maintained through out the dry out period. To ensure that the moisture is effectively
removed there must be free circulation of air around the windings. The generators
covers must be opened occasionally to allow continuous interchange of air as
otherwise the air may become saturated and there by slow down the rate at witch
moisture comes out from the windings. A convenient method of following the
progress of dry out is to take insulation resistance reading (R 1 & R10) at regular
intervals of say 6 hour and to plot them, along with the calculated value of
polarization index and winding temperature. For damp windings readings should be
taken every 1 to 2 hours. On grossly contaminated windings the dry out will be slower
and the intervals may be increased to 4 to 8 hours. During the initial period of the dry
out the insulation values tend to decrease appreciable as the temperature rises but over
a period of time they will rise again. Once the maximum temperature has been
reached, it should be maintained as constant as practicable so that the measured
changes in insulation resistance reflect accurately the progress of the dry out. The dry
out process should be continued beyond the time at which the insulation resistance has
started to increase and heat should be maintained until the insulation resistance is
above the minimum acceptable value. Polarization index is not substantially affected
by temperature and hence a value of minimum to should be achieved. Since the
winding will cool off slightly during the time that the insulation resistance and
polarization index tests are carried out, two points should be observed.
A - 2.3
(a) When individual phases are being checked, the order in which readings are taken
should be kept the same during each test period.
AND
(b) If the cooling is significant (e.g. on small machines) then the polarisation index
value will be slightly optimistic unless the insulation resistance values are related
to the same temperature.
2.2.5 Completion of dry out

The dry out should be terminated, and the source of heat removed, after the minimum
levels of insulation resistance and nearly constant (but not less than two) polarisation
index have been reached and maintained for at least another 24 hours based on 6
hourly readings.
NOTE : If PI value tends to increase with successive readings the dry out should
be continued till nearly constant value is reached.
2.3 RECOMMENDED MINIMUM INSULATION RESISTANCE

2.3.1 Stator winding
(i) Insulation resistance of stator winding varies considerable for different insulation
systems, atmospheric condition and service life, but for practical purposes a
recommended minimum one minute value for each phase of the winding may be
obtained from the following equation:
IR min = 2.Ft (2kV + 1) Mega ohms

where kV = line voltage in Kilovolts.
‘Ft’ is a factor dependent on winding condition and winding temperature at which the
test is carried out. Values of Ft are given below:
Values of ‘Ft’
Machine after
Winding New machine Machine after service for
Service, clean
Temperature Dry, unaged Several years with normal
0 and
C and clean Industrial Contamination
uncontaminated
10 32 16 8
20 16 8 4
30 8 4 2
40 4 2 1
50 2 1 0.5
60 1 0.5 0.25
70 0.5 0.25 0.125
80 0.25 0.125 0.0625
A - 2.4
(ii) Polarisation Index
The PI value shall be recorded in addition to IR. It is not uncommon on a clean, dry
winding to achieve a PI value of 2.0 & more after proper dry out. However, this may
not be achievable in some cases due to adverse atmospheric conditions such as
presence of moisture, dirt or dust etc. The minimum PI value acceptable for
satisfactory operation in such cases shall be taken as 1.5.
NOTE : It is recommended that a dry out shall be carried out irrespective of

IR/PI value before H.V. test or building up voltage during
commissioning.
2.3.2 ROTOR WINDING

(i) Insulation Resistance
The values normally achieved for a new and clean individual pole assembly is 200
M.Ohm at room temperature. The minimum acceptable limit for satisfactory
operation is 50 M.Ohm below which dry out is recommended. It is expected that on a
newly assembled machine with clean, dry and uncontaminated winding, the IR value
shall not be less than 2 M.Ohm, measured between collector and earth. However,
for satisfactory operation under any condition, minimum IR value of total rotor
winding measured between collector and earth shall be not less than 1M.Ohm.
However, in such cases, it is recommended that the generator be run for several hours
on light load to improve the IR value such that mal-operation of earth fault relay
caused by low IR is avoided.
(ii) Polarisation – Index

PI value is not required or recommended for rotor winding circuits.
2.5 COLLECTOR ASSEMBLY AND BRUSHGEAR

Normal expected value for a new machine is 5 M-Ohm, but minimum acceptable
value for satisfactory operation is 2 M-Ohm.
General Note:
The IR values recommended are for guidance. As stated in IEEE-43, it is impractical
to specify a definite minimum value of IR or PI of a rotating machine below which
the machine cannot be operated. It is recognized that it is sometimes possible to
operate a machine with value lower than the recommended minimum value, but it is
not considered a good practice in the majority of the cases.
A - 2.5
ANNEXURE – III
STATOR FORM AND ROTOR FORM
3.1 GENERAL
The purpose of checking stator and rotor forms is to minimize the inequalities in the
air gap all-round the circumference. This will ensure minimum possible unbalanced
magnetic pull with the built up stator and rotor, which will have a beneficial effect on
vibration performance of generator.
The stator and rotor must be built as circularly as possible, ensuring that the
difference in radius of diametrically opposite poles is within 0.2 mm. This can be
achieved by building the rim concentric to the spider (i.e. ensuring uniform gap on all
key bars) and properly grinding the pole seating surface and T-Slot groove in rim
while assembling the rotor poles.
NOTE: BEFORE TAKING STATOR AND ROTOR FORMS MEASUREMENTS, IT IS

NECESSARY TO CENTRALISE THE GENERATOR SHAFT WITH RESPECT
TO INNER DIA.METER OF GUIDE BEARING SUPPORT RING. NEXT, FIT
FOUR DIAMETRICALLY OPPOSITE CENTRALISING BLOCKS WITH JUST
SUFFICIENT CLEARANCE (0.02 TO 0.03 MM) TO ENABLE ROTATION OF
ROTOR. THE ROTOR SHOULD REMAIN IN THIS POSITION THROUGHOUT
THIS PHASE OF WORK.
3.2 STATOR FORM

3.2.1 Mark equivalent peripheral position, equal to no of poles, on the stator bore I.D.
3.2.2 Using any one pole as a datum; bring centerline of this pole tip opposite to the mark
point on stator bore.
3.2.3 Measure the air gap at top and bottom ends of stator bore, approximately 200 mms
from the ends.
3.2.4 Rotate the datum pole successively to remaining marked position on stator bore and
take readings.
3.2.5 Draw a reference circle of known diameter on a graph. Its diameter shall be kept a
little smaller than the air gap readings.
3.2.6 Mark the points as per air gap readings. out side the reference circle and join them to
obtain stator form. This plot represent the profile of stator bore and is indicative of
its circularity. Refer Fig. A 3 1.
3.3 ROTOR FORM
3.3.1 Mark a datum point on stator bore, which can correspond to the erection mark
location on stator frame.
3.3.2 Bring center of each pole successively opposite this datum mark on stator bore.
3.3.3 Measure the air gap at top and bottom ends, approximately 200 mms from the ends
of stator core.
3.3.4 Study the air gap readings taken for rotor form and orient so as to obtain the
position of largest difference in air gap between stator and rotor. Plot air gap
A - 3.1
readings of rotor form to the same scale on a different transparent paper, but inside
the reference circle. This represents the profile of pole tip.
3.3.5 The air gap variation between stator and rotor form represent the inequality in built
up generator. The purpose of this exercise is to reduce this inequality.
3.4 SHIFTING OF STATOR
3.4.1 Examine the stator and rotor form plotted for top and bottom ends of generator.
Superimpose the two forms, and by rotating the rotor form, identify the pole
corresponding to maximum air gap variation.
3.4.2 Take the difference of air gap readings on the stator form corresponding to
maximum air gap and the opposite pole. Half of this difference is the shift of the
stator required.
3.4.3 The shifting of stator will be in a direction opposite to the maximum air gap Ref.
Fig. A 3.1. For this fine shifting of stator; radial screw jacks are to be used and fine
movement of stator along with its lateral shifting, if any shall be monitored by
means of four dial gauges fixed at 900.
After above adjustment, stator form and rotor form are to be checked again. If
required, further adjustment of the stator position has to be done. Since, the core is
long, separate plots are to be drawn for top air gap readings and bottom air gap
readings. It has to be checked that there is not much difference between top and
bottom air gap readings corresponding to each pole. If the difference between top
and bottom air gap readings at any pole is large, the mounting of pole has to be
checked.
3.5 EXAMPLE
An example has been enclosed to illustrate the plotting of stator form, rotor form,
direction and extant of stator shift.
The stator and rotor forms have been plotted based on following air gap readings.
STATOR FORM Pole No. 7 has been taken
as datum
Location point on stator Air gap (Top), mm Air gap (Bottom), mm
1 29.90 29.20
2 29.10 28.60
3 29.4 28.45
4 29.90 28.70
5 29.75 28.50
6 29.60 28.50
7 29.50 28.25
8 28.90 28.60
9 29.80 29.00
10 29.60 29.55
11 29.65 29.65
12 30.35 30.35
13 30.90 30.25
14 30.80 30.15
15 30.00 29.95
16 29.75 29.55
A 3.2
ROTOR FORM Datum-Upstream mark

Pole No. Air gap (Top), mm Air gap (Bottom), mm
1 30.60 30.70
2 29.65 30.70
3 30.60 30.65
4 30.65 30.25
5 29.95 29.75
6 29.60 29.75
7 29.85 29.45
8 30.15 29.75
9 30.75 30.40
10 30.80 31.00
11 30.60 31.00
12 30.50 30.70
13 30.20 30.60
14 30.90 30.95
15 30.50 31.00
16 30.70 30.70
The minimum air gap has been marked as AB in Fig. A 3.1. As explained above the
direction of stator shift is opposite to the maximum air gap i.e. in the direction B to
A as shown in Fig. A 3.1.
The decision regarding the amount of stator shift shall be taken only after carefully
analyzing the stator the stator form and rotor form reading. As mentioned above in
4.2 above half the difference of appositive air gap stator form reading, at location of
maximum air gap (i.e. Pole 14 & pole 6 in fig. A 8.1) is the amount of stator shift.
Since both the stator and rotor form are not truly circular the effect of stator shift on
air gap at adjacent pole may be different. Considering this factor and to get
optimum air gap reading, the average of half the difference of air gap readings of
adjacent poles are taken to decide the amount of stator shift, as explained in the
table below:
A-3.3
S.NO. AIR GAPS DIFFERENCE HALF THE AVERAGE AMOUNT
DIFFERENCE SHIFT OF STATOR
SHIFT
(1) (2) (3) (4) (5) (6)
Pole 15 Pole 7
Top 2.5 1.35 1.15 0.575
Bott. 2.95 0.30 3.25 1.625
Pole 14 Pole 6 0.9125

Top 3.7 1.20 2.50 1.250 1.525 ≈ 0.9 mm
0.975
Bott. 3.1 0.25 2.85 1.425 1.362 ≈ 1.0 mm
Pole 13 Pole 5
Top 3.1 1.70 1.40 0.700
Bott. 2.85 0.25 2.60 1.300
NOTE:
(1) The readings given in column (1) & (2) are the difference in
Rotor form and stator form e.g. length of line AB for pole no. 14 in Fig. A 3.1 is
3.7 mm.
(2) The value is Col. 4 indicates the amount of stator shift
required as described in Para 3.4.
(3) The column 5 indicates the average of readings in column 4
for Pole nos. 15 & 14 and set of Pole 14 & 13. From the above it can be seen that
the stator has to be shifted by 0.9 mm (i.e. rounding off 0.915) to 1 mm (i.e.
rounding off 0.975) to achieve optimum air gap readings. This is decided after
careful study of complete set of readings. The bottom average air gap readings
1.525 and 1.326 have been ignored because shifting the stator by this amount
would have deteriorated the top air gap readings.
A 3.4
ANNEXURE - IV
APPLICATION OF MOLYBDENUM-DI-SULPHIDE GREASE
Application of MOLYBDENUM-DI-SULPHIDE GREASE to the critical

components/surfaces allows free expansion and facilitates easy removal/assembly
of generator components.
As is well known, during normal operation of generator, some of the generator

components expand and contract either due to thermal cycling or due to centrifugal
forces.
Similarly, during maintenance, some components require dismantling and

reassembly for which certain items like keys, dowels, bolts etc. are required to be
opened and refitted properly.
In the main body of this MANUAL, the location for greasing have been indicated in
respective sections. The following, however, summarises the locations where
MOLYBDENUM-DI-SULPHIDE GREASE has to be applied:
(i) a thin coat on top seating surface of stator sole plates before lowering the
stator. The grease should also be applied on the contact faces of holding down
bolts and dowels.
(ii) on OD of key bar to facilitate assembly of rim punching.
(iii) on rim keys before their assembly and seating surface of key-bar.
(iv) on rim locking key under surfaces coming in contact with top rim end plates.
Refer Fig. 5.3.
(v) on the radial keys for shaft and spider coupling. Refer Fig. 5.4, Section - 5.
(vi) on all dowels (e.g. top bracket and stator frame) before putting them in place.
(vii) on taper mating faces of pole keys.
A - 4.1
ANNEXURE – V
CHECKING ROUNDNESS OF ROTOR
5.1 It is necessary to check the roundness of the rotor in order to minimise the
variation in air gap. For this, radius of pole face shall be measured and it should be
ensured that the difference in the radii between any two diametrically opposite
poles is in the range of 0.2 to 0.3 mm.
5.2 The checking of rotor diameter shall be done on both rim A/F and pole O.D.
where the difference in radii is beyond permissible limits, the relevant poles shall
be taken out and rim-seating surface shall be ground to remove the high
spots/protruding punching and the poles re-assembled.
5.3 The measurement of pole face radius can also be carried out with the help of
stick micrometer. Readings are taken between the centralized piano wire and a
straight edge which is firmly pressed against the pole face at its tip center.
5.4 Minimizing the radii difference to reduce the air gap variation will reduce the
UNBALANCED MAGNETIC PULL in operation and will result in low vibration
of the rotor shaft system and bearing brackets.
5.5 While re-assembling the poles on the rotor after correcting the roundness, it is
necessary to ensure that the centre lines of all poles are matching for proper
checking of the magnetic center of the unit at a later stage. For this purpose, refer
to the detailed procedure on magnetic Centering.
5.6 After grinding operations are over, utmost care must be taken to clean all
surfaces free of iron filings, dirt and dust. Otherwise this may lead to a possible
earth fault at a later date.
NOTE :
It is necessary to check the pole face radius at top and bottom of each pole.
The verticality of each individual pole shall be within 0.3 mm, when measured after
assembly on rim. Any large variation could be due to
(i) Rim face not being vertical,
(ii) seating surface of pole on rim not being flat, and
(iii) protrusion of rim punchings or pole punchings.
The verticality can be corrected by grinding of the rim surface and/or seating surface of
pole body which will be in contact which rim.
A - 5.1
ANNEXURE VI
REPLACEMENT OF STATOR BAR AND FIELD COIL
6.1 PROCEDURE FOR CHANGING A FAULTY/ DAMAGED STATOR BAR
6.1.1 Fault location
In many of the cases, the fault can be located by visual inspection after opening the air
guides. Otherwise, the fault can be located by using 2.5 kV megger by sectionalising
the faulty branch.
6.1.2 Removal of insulation and debrazing the joints

No local repair is recommended in case of a fault in the straight portion of a bar. If the
fault /damage ios well away from the core and beyond the first bend, it can be repaired
after ascertaining that the damage is confined to few top layers of insulation. In all
other circumferences the faulty bar should be replaced with a new bar.
 A sharp tool shall be used to cut open the insulation of the joints. Care should be
taken during this operation not to transfer the mechanical strain to the healthy bars.
The end winding bracing with spacers should not be opened before removing the
insulation and debrazing the joints. After removing the insulation, the joints shall
be debrazed by using oxy-acetylene. The surrounding area shall be protected with
wet asbestos putty.
 After debrazing all the required joints, the corresponding slots wedges shall be
removed and the end winding wedging with spacer/mouth slot packers shall be
removed. Side fillers of conducting laminates shall be carefully removed and the
top bars shall be taken out. The slot which houses the faulty bars shall be
thoroughly inspected and any carbon deposits due to fault current shall b e cleaned
with a cloth wet with carbon tetra chloride.
 The faulty bar after removal shall be replaced by a spare bar (the item number
punched on the bar should be checked with the bound stator assembly drawing).
The procedure given in clause shall b e followed for reassembly.
 The bars shall be rebrazed and reinsulated as per drawing 1 263 04 23501.
 A supplementary HV test is advisable after major repairs/replacement of bars.
Consult designer, BHEL, Bhopal.
6.2 REMOVAL OF FIELD COIL

Replacement of field coil is a specialized operation and should be carried out only by
a skilled and experienced person. To replace a field coil, it is necessary to remove the
pole from the rotor. Place the pole assembly upside down (T-heads on top) on a firm
ground level. Remove the steel packing washers and the insulation flange carefully.
Thin long nose pliers may be found useful for easily gripping the pole body insulation
packers initially. Next raise the field coil to a sufficient height to enable manila rope
A 6.1
slings to be passed under both ends of the coil. This can be done by driving wooden
wedges between the pole tips and insulation flange at intervals alongwith side of the
coil. The coil can now be lifted out by passing manila rope (not steel) slings over the
ends of the coil, care being taken to prevent damage to the copper turns from the
slings by interposing a thick sheet of press board. Thoroughly clean all deposits of
dust from the pole body and insulation packers by a clean cloth moistened with white
spirit or Lectraclean and dry by blowing compressed air. Retain the springs under the
field coils or reuse during reassembly.
Assemble the spare coil on the pole body after cutting of the unwanted leads,
flush to copper turns. The spare coil can be then be used in any position. Ensure that
the clearance is uniform on all four sides. The existing pole body insulation can be
used, if undamaged, otherwise new pole body insulation is to be used. First assemble
the corner angle and then epoxy glass laminate sheets. If any clearance is found
between pole body and field coil, this is to be filled epoxy glass fibre sheets. No
slackness is permitted between field coil and pole body. Assemble the steel washers
and the insulation flange of the coil. Check that the height that the height of the coil
assembly is as per drawing. Never lift the coil by slinging around projecting field
turns, as this may result in de- lamination of turns.
Check the IR value of the field coil and also measure its AC impedance.
Conduct HV test as per Annexure-I between the coil and the pole body. Next
assemble the pole on to the rotor. Measure the AC impedance of the coil again if
satisfactory, conduct HV test as per Annexure-I between the coil and pole body.
Finally, connect the pole leads to the adjacent pole and solder the joints using solder.
If a field coil is replaced at any p time, care should be taken to ensure that
the pole is polled hard down on the rotor rim. When the pole keys are driven in. This
can be checked by seeing that there is no gap between the pole body and the rim
seating surface. However, the spring allowance between the steel packers and rim
surface must be available around.
A 6.2

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TABLE OF CONTENTS

8 LEVELS AND ALIGNMENT

1.1 ERECTION PRE-REQUISITES

2.2 ERECTION IN SERVICE-BAY

2.3 ERECTION IN GENERATOR FOUNDTION PIT

APPLY A THIN COAT OF MOLIBDENUM - DI – SULPHIDE GREASE ON

TITLE OF DRAWING DRAWING NO.

3.1 FOUNDATION : STATOR/BOTTOM BRACKET

3.2 SOLE PLATES AND FOUNDATION BOLTS

Description Drawing No.

(c) Stator lifting

4.2 STATOR FRAME

4.3 STATOR CORE

5.2 SPIDER AND RIM ASEMBLY

5.3 MOUNTING OF POLES

5.4 FAN ASSEMBLY

5.5 LOWERING OF MAIN SHAFT AND ROTOR

5.5.1 Lowering of bottom bracket and main shaft

5.5.2 Lowering of rotor assembly

5.6 MAGNETIC CENTERING OF STATOR AND ROTOR

5.6.3 Method of correction

7.2 ERECTION OF TOP BRACKET AND OTHER ASSEMBLIES

7.3 GUIDE BEARING AND INSULATION

8.2 STARTING CHECK

8.3 INITIAL SETTING OF BRACKET

8.5 LEVELLING OF THRUST BEARING

IF ABOVE POINTS ARE NOT SATISFACTORY, THE ALIGNMENT READINGS

Location of X-axis Y-axis

8.8 COMBINED ROTATIONAL CHECK ON GENERATOR & TURBINE SHAFTS

Location of X-axis Y-axis

8.9 ALIGNMENT OF COLLECTOR

Location of X-axis Y-axis

8.10 STATOR AND ROTOR FORM

9.2 PRE-START CHECKS

9.3 BUMP START

Pl Place of measurement Allowable vibrations (max.), mm

9.4.1 After first start

9.4.2 Bearing run

9.5 SETTING OF OVERSPEED DEVICE

9.6 VOLTAGE BUILD-UP

9.7 SYNCHRONISATION AND LOADING

9.8 PUTTING INTO OPERATION

9.10 HANDING OVER

S.No. Stage of testing Test voltage (rms value)

2 Top bars : After placing top bars in stator 25 kV

3 Official HV test : test separately with other 23 kV

1.2 SCHEDULE OF HV TEST ON FIELD WINDING AT SITE

S.No. Stage of testing Test voltage (rms value)

2 Official HV test between collector and earth 4.75 kV

2.1 INSULATION RESISTANCE TESTING

2.1.2 METHOD OF TEST

2.1.3 POLARISATION INDEX

2.2 DRY OUT

(b) Short Circuit Running

(c) Direct current heating

2.2.2 A.C. Stator

2.2.3 DC Field circuits

2.2.4 Dry out temperature

2.2.5 Completion of dry out

2.3 RECOMMENDED MINIMUM INSULATION RESISTANCE

IR min = 2.Ft (2kV + 1) Mega ohms

NOTE : It is recommended that a dry out shall be carried out irrespective of

2.3.2 ROTOR WINDING