Beijing BEIZHONG Steam Turbine Generator Co.Ltd.

T255-460 330MW Turbo-generator

Q96M

Manual for 330MW Turbine Generator

Q96M SYE
Version：1

Reviser： Revision date： Revision notice：

Prepared：汪云山

Checked：郑瑞华

Reviewed：史艳华

Approved：潘海升

Date:2008.4
 Beijing BEIZHONG Steam Turbine Generator Co.Ltd.
File no：Q96M SYE
Content

Preface 6
1. General introduction 6
1.1 Summary 6
1.2 General characteristic of generator 9
1.2.1 Rated parameters 9
1.2.2 Dimensions and weights 9
1.2.3 Reactance and constants 10
1.2.4 Characteristic curves 11
1.2.5 Coolant 16
1.3 Generator maintenance, overhaul and storage 17
1.3.1 General 17
1.3.2 Tightness checking for hydrogen leaks 17
1.3.3 Hydrogen fire 18
1.3.4 General maintenance of generator during operation 18
1.3.5 Maintenance during a shut down 19
1.3.6 Storage of the generator 21
2 Generator stator 24
2.1 General structure 24
2.1.1 The frame 24
2.1.2 The terminal box 24
2.1.3 The coolers 24
2.1.4 The magnetic core 32
2.1.5 Stator winding 36
2.1.6 High voltage terminal leads 42
2.2 Generator fluid supply circuits 47
2.2.1 CO2 supply circuit 47
2.2.2 H2 or gas supply circuit 47
2.2.3 Deionized water supply circuit 47
2.3 Stator preservation 50
2.3.1 Generator at standstill-closed 50
2.3.2 Generator at standstill – open 52
2.4 Disassembly of a coolers 53
2.4.1 The disassembly of cooler 53
2.4.2 Cooler reassembly 59
2.4.3 Cooler maintenance operations 61
2.4.4 Storage and preservation at standstill 62

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2.5 Stator winding maintenance 63
2.5.1 General requirement 63
2.5.2 Specific equipment 63
2.5.3 Testing the stator winding insulation resistance 64
2.5.4 Test the dielectric strength of the stator winding 65
2.5.5 Stator winding maintenance 66
2.6 Adjustment of the stator 66
2.6.1 Disassembly operations 66
2.6.2 Vertical adjustment 69
2.6.3 Transverse adjustment 69
2.6.4 Reassembly 69
3 Generator rotor 70
3.1 The generator rotor structure 70
3.1.1 The rotor shaft 70
3.1.2 Rotor winding 70
3.1.3 Retaining rings & centering rings 74
3.1.4 Axial fan 80
3.1.5 Excitation connections 80
3.1.6 Cooling of slip rings 82
3.2 Rotor removal and installation 85
3.2.1 Operations required for rotor removal 85
3.2.2 The work after rotor inserted 87
3.2.3 Removal of the generator rotor 87
3.2.4 Rotor installation 98
3.3 Maintenance of generator rotor 101
3.3.1 General requirement 101
3.3.2 Storage and conservation of rotor 101
3.4 Disassembly and reassembly of couplings - unit shaft alignment 104
3.4.1 Disassembly of turbine-generator 104
3.4.2 Reassembly of turbine-generator coupling - shaft alignment 105
3.5 Maintenance of rotor winding 105
3.5.1 Preparatory operations 105
3.5.2 Precautions to be taken during tests 106
3.6 Fan 109
3.6.1 Disassembly of main fan blades 109
3.6.2 Reassembly of main fan blades 109

3.6.3 Maintenance of fan blades 109

4. Generator end structures 111

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4.1 End structures 111
4.1.1 Journal bearing 111
4.1.2 Lower half-bearing 111
4.1.3 Upper half bearing 117
4.1.4 End shield bearing 117
4.1.5 Clamping collar 117
4.1.6 Shaft seal 117
4.1.7 Oil deflectors 118
4.1.8 Ventilation guides 124
4.1.9 Axial alignment key 124
4.2 Maintenance operations for bearing and shaft seal rings 124
4.2.1 Assembly of the external support of the rotor 124
4.2.2 Removal of the journal bearings at the turbine and excitation ends 128
4.2.3 Assembly and disassembly of the bearings and accessories 141
4.2.4 Reassembly, assembly and maintenance of the shaft seal rings 156
4.2.5 Reassembly, assembly and maintenance of the oil deflectors 159
4.2.6 Disassembly and reassembly of hydrogen guides (fan nozzle rings) 168
4.2.7 Disassembly and reassembly of axial alignment system tooling 170
4.2.8 Disassembly and reassembly of bearing oil inlet and outlet pipes 171
5. Generator detection and protection 180
5.1 Stator detection and protection 180
5.1.1 Temperature sensors for magnetic core, copper shield 180
5.1.2 Temperature instrumentation of stator bars 181
5.1.3 Temperature instrumentation of cooling water of stator winding 181
5.1.4 Temperature instrumentation of circular phase connections 182
5.1.5 Temperature instrumentation of hydrogen 182
5.1.6 Leading-out of stator temperature instrumentation 187
5.1.7 Frame grounding 187
5.2 Temperature instrumentation of journal bearing 191
5.2.1 The thermocouple with rigid sheath 191
5.2.2 Temperature instrumentation of journal bearing 191
5.2.3 Temperature instrumentation of restraining bearing 191
5.3 Rotor detection and protection 192
5.3.1 Shaft vibration measurement 192
5.3.2 Detection of inter-turn insulation fault in rotor winding 192
5.3.3 Rotor grounding 202
5.3.4 Insulation of bearing excitation end 202
5.3.5 Insulation of restraining bearing 203

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6 Generator installation 211
6.1 General requirements 211
6.2 Generator installation procedures 211
6.3 Foundation plate installation 213
6.4 Stator and terminal box installation 215
6.5 End shield bearing and winding cover-H2 fan nozzle ring installation 216
6.6 Brush and soundproof housing installation 217
6.6.1 Documents preparation 217
6.6.2 Seat box installation 217
6.6.3 Brush gear installation 217
6.6.4 Restraining bearing installation 217
6.6.5 Soundproof housing installation 218
6.7 High voltage terminal installation 218
6.7.1High voltage bushing installation 218
6.7.2 Current transformer and water manifold installation 219
6.7.3 Intermediate connection installation 220
7 Generator operation 221
7.1 Unit start-up 221
7.2 Unit shut-down 221
7.3 Monitoring in operation 222
7.4 Alarm and treatment 223
7.4.1 Stator winding temperature alarm and treatment 223
7.4.2 Hot hydrogen temperature alarm and treatment 225
7.4.3 Cold hydrogen temperature alarm and treatment 225
7.4.4 Stator core end structure and copper shield temperature alarm and treatment 225
7.4.5 Journal bearing temperature alarm and treatment 226
7.4.6 Shaft vibration alarm and treatment 226
7.5 Other protection items 227
Appendix A Visual examination and dye penetrate examination of journal bearing 229
Appendix B Hydrogen cooled turbine generator sealing glue operation instruction 231
Appendix C Storage condition of insulation material for installation 233
Appendix D calculation of perpendicular distance between arc and chord for centering by steel wire 234
Appendix E High terminal connection installation inside terminal box 235
Appendix F Supplement for Inspection and Test Item of the Generator 239

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Preface
This manual is used for reference only. It applies to the 330MW generators (type: T255-460) made by BSTG. For
the contents not specified in this manual, please refer to the IEC standards, the related ALSTOM standards and
factory standards.
This manual is about the main technical data ， structures, installation, operation and maintenance of 330MW
generator (type T255-460) and so on.
This manual can only be used for the generator. The auxiliary system (including excitation system, seal oil systems,
cooling water system and hydrogen system, etc.) will be mentioned in separate specific manuals.
1.General introduction
1.1 Summary
The generator itself is basically composed of three distinct parts:
●the generator stator and end structures
●the generator rotor
●the brush gear
Static excitation system, including excitation transformer, provides DC power to the field (rotor) winding. This
system is described in a separate manual.
It should be noted that:
●the cooling of the machine with hydrogen under a pressure of 3 bars(g) and with the stator windings cooled by
water, on the one hand
●the necessity for a rigorous hydrogen tightness where the shaft comes out of the two ends of the stator, on the
other hand
leads to the addition of several ancillary devices or ‘auxiliaries' of the generator. These are:
●the supply system of the shaft sealing oil, the purpose of which is to prevent any hydrogen leaking from the
generator enclosure via the clearance between the stationary and rotating parts (shaft ends) at the ends of the stator
●the unit supplying deionized water to cool the bars of the stator winding
●the gas supply unit
—hydrogen for normal operation
—CO2 for the intermediate phases of filling or emptying the stator.
All of these auxiliary functions are dealt with in separate specific manuals.
It should be emphasized that the lubricating oil system of the turbine bearings also provides:
●the oil flow necessary to lubricate the generator journal bearings
●the oil flow necessary for hydrogen tightness at the ends of the generator shaft.
The description of the generator can therefore be divided into several essential categories:
●The general of the generator
●the generator stator
●The generator rotor
●the end structures

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●the monitoring and measuring instruments and the generator protection devices.
●The installation of the generator
●The operation of the generator
Drawing 1-1 represents the longitudinal section of the generator.

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Drawing 1-2 represents the electrical and hydraulic diagram of the stator winding.

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1.2 Main characteristic of generator
1.2.1 Rated parameters
Type T255-460
Rated speed 3000r/min
Active power 330MW
Power factor 0.85
Rated voltage 24kV
Voltage variation ±5%
Rated current 9339A
Number of poles 2
Frequency 50Hz
Excitation current 2495A
Insulation class F (Application class B)
Water temperature at inlet of H2 Cooler ≤38 ℃
Type of cooling:
—Cooling of magnetic core H2
—Cooling of stator winding deionized water
—Cooling of rotor winding H2
—Cooling of H.V. voltage terminals deionized water
Normal duty conditions:
—Stator water temperature rise 18K
—Rotor winding temperature rise 48K
—H2 pressure 0.3MPa(g)
—Deionized water temperature 46 ℃
—Power 330MW
Abnormal duty conditions:
—With one cooler out of operation 258.8MVA(220MW)
—Steady state negative phase-sequence current I2/IN 12%
2
—Transient negative phase-sequence current (I2/IN.) t 10s

1.2.2 Dimensions and weights

(1) Dimensions
—External dimensions
Length of frame 7600 mm
Overall length including (soundproof) 11990 mm
Overall width 3800 mm
External frame height 4025 mm
—Magnetic core
External diameter 2550 mm
Bore diameter 1300 mm
Lamination stacking length 4600 mm
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Effective length 3838 mm
—Rotor
Overall length 10630 mm
Bearing span 7700 mm
Shaft body diameter 1100 mm
Shaft body length 4750 mm
Retaining ring diameter 1178 mm
Fan diameter 1220 mm
(2) Weight
—Installed generator 254 t
—Complete stator 175 t
Frame 45.2 t
Magnetic core 108.3 t
Clamping plate 7.6 t
Winding copper 8.6 t
Insulation and wedging 3.4 t
—Complete rotor 48.3t
Slot closing wedges 0.67 t
Retaining rings 3.5 t
Winding copper 5.7 t
Insulation and wedging 0.4 t
—Fan 0.3 t
—Terminal box framework 2.8 t
—Complete bearing assemblies 13.9 t
—Coolers (total mass) 4.6 t
(3) Transportation Dimensions and weights
—Stator
Total weight 179t
Total length 7660mm
Total width 3800mm
Total height 4085mm
—Rotor
Total weight 46.6t
Total length 10630mm
Maximum diameter 1100mm
1.2.3 Reactance and time constants:
(1) Reactance
Synchronous direct-axis Xd (unsaturated) 175.5%
Synchronous direct-axis Xds (saturated): 162.8%
Transient direct-axis X’d (unsaturated) 30.6%
Transient direct-axis X’ds(saturated) 27%
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Sub-transient direct-axis X”d (unsaturated) 21.8%
Sub-transient direct-axis X”d s (saturated) 18.5%
Synchronous quadrature-axis Xq (unsaturated) 162.8%
Sub-transient quadrature-axis X”q (unsaturated) 23.5%
Sub-transient quadrature-axis X”q s (saturated) 20%
Negative phase-sequence reactance X2(unsaturated) 22.7%
Negative phase-sequence reactance X2s(saturated) 19.2%
Zero phase-sequence reactance Xos (unsaturated) 9.4%
Armature leakage reactance Xs 17.3%
（2）Resistance at 75°C
Stator (per phase) 3.52mΩ
Rotor 0.197Ω
（3）Direct axis time constants
Transient open-circuit time constant 4.7s
Sub-transient open-circuit time constant 0.039s
Short-circuit armature time constant 0.023s
Transient short-circuit time constant 0.82s
Sub-transient short-circuit time constant 0.028s
（4）Ground capacitance
Stator, per phase 0.18μF
Rotor 0.36μf
1.2.4 Characteristic curves
(1) No-load characteristic curve(drawing 1-3)
(2) Short circuit characteristic curve (drawing 1-3)
(3) Zero PF at rated current (drawing 1-3)
(4) V curves (drawing 1-4)
(5) Capability curves (water inlet temperature 38℃) （drawing 1-5）
(6) Capability curves (water inlet temperature 20℃) (drawing 1-6)
(7) Power-cooling water temperature curves (drawing 1-7)

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Drawing 1-3 Saturation Curves

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Drawing 1-4 V Curves

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Capability Curves (Water Inlet Temperature 20℃)

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Drawing 1-6

Drawing 1-7 Power- Cooling Water Temperature Curves

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1.2.5 Coolant
(1) Hydrogen
Flow rate 36 m3/s
Losses to be evacuated maxi 2430 kW
Rated pressure 0.3 MPa(g)
Number of coolers 4 groups (2 pieces)
(2) Deionized water
Total flow rate (winding) 60 m3/h
Terminals connections 9 m3/h
Losses to be evacuated 1135 kW
Number of coolers 2
(3) Raw water
Rated temperature 38 °C
Overall flow rate: hydrogen coolers 325 m3/h
Water coolers 120 m3/h
(4) Journal bearing and oil seal
Journal bearings Elliptical
Diameter 450 mm (turbine end)
420 mm (excitation end)
Useful width 260 mm (turbine end)
280mm (excitation end)
Specific pressure 2.09 MPa
Oil flow rate 475 L/min (turbine end)
430 L/min (excitation end)
Losses 150kW (turbine end)
140 kW (excitation end)
Shaft seals:
—Type single circuit shaft sealing
—Number 2
—Diametric clearance on H2 side 0.16 mm
—Diametric clearance on air side 0.08 mm
—Oil flowrate 40 L/min (turbine end)
30 L/min (excitation end)
Restraining Bearing
—Type cylindrical
—Diameter 160mm
—Number 1
—Oil flowrate 24 L/min
(5) Slip ring and brush
—Slip ring diameter 410mm
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slip ring width 168mm
slip ring material 50Mn
—Brush NCC634
dimensions 32×32
quantity 80

1.3 Generator maintenance, overhaul and storage

1.3.1 General
Maintenance work on a turbogenerator may only be carried out if certain requirements regarding
safety and working procedures are met.
They are:
—tightness and checking for hydrogen leaks
—maintenance of the unit in operation
—maintenance of the unit at standstill
—general instructions regarding storage
When the generator is at standstill for a short or long period of time, various precautions should
be taken. These instructions on preservation are given in chapter 2 (generator rotor) and in
chapter 3 (generator stator).
1.3.2 Tightness checking for hydrogen leaks
The tightness of a generator is systematically tested after maintenance work involving the
opening of the hydrogen enclosure. This check is performed with the generator full of air.
If there is an increase in hydrogen consumption while the generator is in operation it is
imperative to check for hydrogen leaks.
A difference shall be made between these two cases.
(1) Checking the tightness of the generator
With the generator closed and the seal oil circuit in service, fill the generator with air to the
nominal operating pressure.
With the temperature stabilized, the generator is said to be tight if the pressure falls by less than
0.004MPa in 24 hours.
If this is not the case, check for leaks using soapy water. Check the joints which have been
disassembled and reassembled and the shaft seals.
Check also that the seal oil circuit and the cooling circuits (coolers, pipe connections, valves etc)
are operating correctly. The generator may only be refilled with hydrogen if it is satisfactorily
tight.
(2) Checking for hydrogen leaks
Micro-leaks from different parts of the generator and its auxiliaries, and in particular
consumption of hydrogen by the seal oil circuit, mean that frequent topping up with hydrogen is
necessary in order to maintain the pressure in the generator enclosure as near as possible to its

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normal value.
As soon as hydrogen make up become more frequent, in other words, when the hydrogen
consumption increases, attempts should be made to establish the cause immediately.
In order to do this, it is necessary:
 to carefully monitor the conductivity of the stator cooling water
 to monitor the temperature of the various cooling circuits (stator water, raw water, hydrogen,
air etc)
 to check the overpressure valves
 to try and locate the hydrogen leak
The leak may be located using a hydrogen detector or an analyzer placed against the bearing vent
holes, the vents of the various circuits, and the outer seals (coolers, terminals, bearing, etc).
The leak may be located by isolating each hydrogen cooler separately and monitoring the
increase in hydrogen consumption.
Monitoring the gas flow in the buffer tank of the stator winding cooling water circuit may yield
information also.
WARNING:
 if an increase in the conductivity of the stator winding cooling water accompanies the
increased hydrogen consumption, the unit should be shut down and the constructor notified
 do not make up the hydrogen if the consumption is abnormal
 if the fall in pressure is more than 0.04 MPa in 24 hours , fill the generator with air and try
and locate the leak as explained in section (1)
 once a leak has been detected, it is vital to identify the leaking hydrogen circuit and where
hydrogen might possibly accumulate (condenser, coolers, tank, pump, high points, etc). If
there is any doubt, proceed with a systematic search using an analyzer. Drain the zones
where hydrogen has been detected.
As soon as the leak has been identified, ensure that its repair will not require replacing the
hydrogen in the machine with air, and then commence work.
The generator shall only be started up again when the hydrogen tightness is correct.
1.3.3 Hydrogen fire
Hydrogen escaping through a leak may lead to the gas jet catching fire. The fire department can
only treat fires exterior to the generator itself. However the hydrogen frame may be extinguished
by removal of all hydrogen from the generator.
In the event of a hydrogen fire, rapidly evacuate all hydrogen from the generator and its
auxiliaries, full with carbon dioxide and alert the fire department
1.3.4 General maintenance of generator during operation
The suggested frequency of each operation represents a minimum level of precaution.
The user may increase the frequency of these operations at his own discretion.
The following table shows the maintenance operations to be carried out on the generator during
operation, together with their frequency.
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The operations are described in the chapter s indicated.
Operations Frequency
Testing bearing insulation – opposite turbine end Weekly

Checking wear of rotor ground brushes Weekly

1.3.5 Maintenance during a shut down

The maintenance of a generator basically depends on the number of hours of operation and its
service life. There are several categories for overhauling a generator: mo (minor or mo
overhaul), MO (major or MO overhaul) and TYO (ten years or TYO overhaul).
(1) Minor or mo overhaul
The object of this overhaul is to be able to imagine as precisely as possible the state of a
generator. At the same time, doing the minimum number of dismantling operations in order to
allow the generator to be serviced until the next overhaul, and to be able to estimate the contents
of the next intervention. It is rare that repair work or modifications are planned at the time of mo.
Operations planned at the time of the standard minor overhaul of a generator, are defined in the
table attached in the appendix.

(2) Major or MO overhaul

The object of this overhaul is to be able to check the exact state of a generator in order to be able
to authorize its service until the next major overhaul.
A major overhaul involves taking out the rotor. Specific maintenance operations or modifications
resulting from previous observations and experience must be included in the standard program.
Operations planned at the time of the standard major overhaul of a generator and its excitation
system, are defined in the table attached in the appendix.

(3) A ten year or TYO overhaul

A ten year overhaul of a generator is above all an MO completed by systematically replacing the
parts which are highly stressed during or at the time of dismantling and previous re-assembly
operations.
A TYO can equally be used to carry out improvements resulting from experience.
Operations planned at the time of the standard ten yearly overhaul of a generator and its
excitation system, are defined in the table attached in the appendix.
NOTE：
The generator is only one component in the electrical energy production series. Therefore its
maintenance cannot be done independently from other links.
Therefore it must be checked that the generator overhaul programme is sufficient to allow its
operation without reaching the critical overhaul limit.

Appendix The overhaul item of the generator (only for reference)

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Item Operation description mo MO TYO chapter

A Before shut down of the unit

Checking of the operating data × × ×
Checking of the short circuited rotor turns × × × 5.3.2
B Before disassembly
Insulation measurement of the bearing at
opposite turbine end and third bearing × × × 5.3.4
(restraining bearing)
C Disassembly operations
Soundproof shield for brush gear × × ×
Brush gear × × ×
Fan cover for brush gear × ×
Third bearing (restraining bearing) × ×
Little shaft at opposite turbine end ×
Support box for brush gear ×
Outer oil deflectors × × × 4.2.5
Bearing cover × × × 4.2.5
Clamping collar × × × 4.1.3
Journal bearing (either elliptical or tilting pad) × × × 4.2.2
Seal ring × × × 4.2.4
Upper 1/2 bearing end shield × × 4.2.3
Lower 1/2 bearing end shield × × 4.2.3
Winding cover fan nozzle ring partially × × 4.2.6
Inner oil deflectors partially × × 4.2.5
Fan blades × × 3.6.1
Rotor disassembly × × 3.2.3
H2 coolers(if necessary for access) partially × × 2.4.1
Draining of stator water circuit × ×
Phase connections × ×
Opening of neutral point × ×
D Stator checking tests
1 magnetic core
Visual inspection × ×
Ring flux tests ×
2 winding
Visual inspection × ×
Air tightness test × ×
Insulation resistance of the stator winding × × ×
Polarization index × × ×
Insulation resistance-circuit in water × × × 2.5.1
Radial wedging × × 2.5.1
3 frame-cooler compartments-terminal box
Visual inspection × × ×
Blowing of bottom point pipework × × ×
Visual inspection of foundation tie rods ×

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Item Operation description mo MO TYO chapter
US tests of foundation tie rods ×
4 coolers 2.4.3
Clearance of tube bundle and water boxes × × ×
Clearance of tube bundle at gas end × ×
Tightness tests at water side × ×
Blowing-purging and draining of pipework × × ×
E Rotor checking tests
Inter-turn short circuit detectors × ×
Visual inspection × ×
Blade liquid penetrate test ×
Visual inspection of blades × ×
Rotor tightness × ×
Geometrical checking of the shaft seal
× × 3.3.1
supporting surface
Visual inspection of the shaft seal and
× × ×
journal bearing supporting surfaces
Rotor insulation resistance × × ×
Visual inspection of the rotor winding × ×
Visual inspection of the turbine coupling × ×
Visual inspection of small shaft and the
× ×
coupling at excitation end.
F Brush gear and slip rings
Visual inspection of slip rings × × ×
Dimension check of slip rings × ×
Visual inspection of brushes, brush gear,
× × ×
brush holders, springs
Visual inspection of slip ring connection × × ×
Insulation resistance of brush gear × × ×

1.3.6 Storage of the generator

(1)General storage conditions

During storage, equipment is kept in good condition by protective covers and initial conditioning
and also by continual checks on the storage conditions. These checks are very important.
The equipment should be stored in closed buildings with heating facilities and concrete flooring
coated with anti-dust paint. It should be protected against dripping water and direct sunlight which
are likely to damage the protective agents. The flooring should be strong enough to withstand the
loads imposed on it.
The buildings should be organized so as to facilitate delivery and removal of equipment.
The equipment should be kept off the floor by crating or supports, with a plastic sheet between the
equipment and the support-It should be protected against insects and small rodents and should be
arranged so as to facilitate access for inspection, and if necessary, replace the packing.

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A log book should be started as soon as the equipment arrives at the site of storage, to ensure that all
equipment is monitored during storage. The following information should be entered in the record
book:
 2 daily temperature and humidity readings inside the storage building.
 Storage conditions.
 Inspections made, together with a general report on the state of the equipment and the storage
conditions, and the dates of such operations.
 A detailed report (with date) of any anomalies observed during inspection.
 A detailed report (with date) of readings taken in order to remedy any storage defects.
Parts protected by paint should be examined on arrival at the site of storage and every moth during
storage. Any paintwork damaged by knocks or slinging should be touched up and restored to its
initial condition. When replacing a drying agent or volatile inhibitor, use the same quantities as those
originally contained in the crate. The replacement products should be placed in the same position as
the original products.

(2) Storage of miscellaneous parts

Miscellaneous parts are all components of the generator other than the rotor and the stator (e.g.
bearings, journal bearings, spare stator bars, bolts, fans, etc.).These parts may be dispatched in crates
or, in some cases, besides the mechanical protection which is necessary, special protection (mould
mildew-proof, moisture-proof, salt fog-proof) should be made.
 Parts dispatched in crates
The packing should be sealed and the crates should contain drying agents and / or volatile
inhibitors.
Every time the crates being opened for inspection (customs, quantity, quality, state of protection),
the protective agents should be replaced and the packing restored to its initial state as soon as
possible.
The crates should be checked carefully as soon as they arrive at the site of storage, and dubious
packing should be renewed and the protective agents should be replaced.
An inspection should be carried out every week in order to check the state of the packing. Any
defects should be corrected immediately by replacing the faulty packing and protective agents.
Every three months, the protective agents should be replaced and the packing should be restored
to its original condition. This operation may be brought forward or delayed (+ or - 15 days) in
order to take advantage of a period when the ambient humidity is falling.
All these actions, inspections and operation should be entered in the record book, giving the date
and the nature of the work carried out.

（3）Storage of space bars for stator winding

Space stator bars should be packed inside a sealed cover and placed in a crate, positioned away
from the danger of knocks. The cover should contain drying agents.
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When the crates arrive on site, or during inspection, the condition of the packing should be
checked carefully. If it has to be reconditioned, replace the drying agents and restore it to its
initial state.
Every six months, the drying agents should be replaced and the packing reconditioned. This
operation may be brought forward or delayed (+ or - 15 days) in order to take advantage of a
period when the ambient humidity is failing.
An inspection should be carried out every week in order to check the general state of the
packing. If any defect is observed, carry out the appropriate conditioning.

（4）Storage of rotor and stator

See chapter 3.3.2 for rotor storage and chapter 2.3 for stator storage.

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2．Generator stator
2.1 General structure (See drawing 2-1)

2.1.1 The frame

The frame is a single block; this allows the stator to be assembled entirely at the factory, including
the stacking and clamping of the magnetic core and the definitive installation of the stator bars, their
wedges and connections.
In this way, the finished stator can be delivered to the plant.
As the frame must withstand the internal pressure of the hydrogen, the whole assembly, together
with its welded joints, is designed to give complete tightness, and is carefully tested after
manufacture.
The frame forms the outer casing of the turbo-generator.
It reassembles a tank, the ends of which have centrally located openings crossed by the shaft ends.
The frame is made up of a series of plates electrically welded together. The steel plates used are of
good welding quality.
It constitutes a practically cylindrical shell, and is provided with frame feet (support brackets) along
each side.
It is reinforced internally by rings placed perpendicular to the shaft axis.
These rings give the frame the necessary rigidity, and also support the bars holding the magnetic
core.
The frame also envelops the cooling circuit, and the axial subdivisions are designed to ensure
optimum distribution of gas to all parts of the generator.
Each end of the frame is fitted with a thick machined flange whose function is to support the shaft
bearing assembly.
It also has compartments containing the coolers and is dimensioned to withstand, without damage,
all the various stresses to which it is subjected (transport, tensional stress, etc.).

2.1.2 The terminal box

The terminal box is fastened to the underside of the frame, on the excitation end.
It is made up of welded plates, some non-magnetic.
The bottom plate has six openings in which the six generator outlet terminals are fitted.
The terminal box is hydrogen-cooled.
The terminal boxes are fastened on site by means of bolts.
The frame-terminal box tightness is maintained by a thin bead of weld applied during site erection.
This weld is sufficient for hydrogen tightness during operation and it allows fairly easy removal in
the event of subsequent interventions which would require the removal of the terminal box.

2.1.3 The coolers

The warm hydrogen is cooled by gas-to-water heat exchangers or coolers which are represented
schematically in drawing 2－2
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The coolers are generally composed of several elements fitted in the cooling compartments.
Each cooler unit is basically made up of:
 a frame
 a nest of tubes and the end tube sheets
 a water supply system and filling monitor.
To facilitate cleaning of the cooling tubes without having to remove the coolers, the water box can
be opened with the machine running. Because of this, there must be perfect tightness between the
coolers and the compartments which can also permit differential expansion between them. These
elements are also in contact with 3 media: air, water and hydrogen.

（1）Cooler chassis
The chassis (7) is constituted of metal profiles assembled in the form of a box. It serves to hold the
end tube sheets as well as two sheet metal pieces parallel to the gas flow and which act as guide
runners.
Inside the chassis are a series of intermediate tube sheets which support the cooling tubes.
The chassis permits the transportation and handling of the cooler without additional tools, and serves
to attach it inside the generator frame.
The chassis is protected by anti-rust paint.
（2）Tube nest and end tube sheets
The active part of the cooler unit consists of a nest of firmed tubes (6) running perpendicular to the
gas flow. The tubes can be finned by:
—either winding a wire around the tubes, aligned radially to the axis,
—or by a series of thin metal parallel sheets, traversed by all the tubes.
In both cases, the fins are made of materials offering good thermal conductivity (e.g. copper).

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The end of each tube, free of fins, is expanded into a thick plate, the end tube sheet (4). The end tube
sheets provide for the even distribution of water into the tubes as well as attaching them to the
chassis.
One of the end tube sheets is firmly fastened to the chassis; the other sheet is only guided axially in
order to allow for differential expansion between the tubes and the chassis.
The tube nest is held within the chassis by intermediate support plates.

（3）Water supply
On each end tube sheet, water boxes or water manifolds (1) and (2) are fixed.
The water box on the inlet/outlet end (1) is fitted with an inlet pipe (8) and an outlet pipe (9). The
inside of the box is divided into compartments by dividing walls.
The water box on the opposite end is simply an enclosure of the end tube sheet.
This system provides a multi-pass flow within the tube nest which optimizes the efficiency of the
heat exchanger, reduces internal temperature differences, and groups the cooling pipe-work together.
As the coolers are placed horizontally on the generator, threaded plugs situated in the high and low
points of each water box indicate when they are full, enable gas bleeding, and allow draining of the
units.
The inside surfaces of the water boxes are protected by a coat of bituminous paint and the outside
receives a coat of anti-rust paint.

（4）Tightness of coolers
The coolers are in contact with three media: air, water and hydrogen. Because of this, there must be
perfect tightness between the coolers and the three media.
1) Tightness between the hydrogen circuit and ambient air
Drawing 2－3 represents the tightness system between the frame and the coolers.
The facing edges of the tube sheet (2) are machined smooth.
Between each sheet and the metal frame (3) is placed a rubber gasket (4) which is compressed
inside its housing by parts (5) and (6).
The frame (3) is bolted to the cooler extension (1) and tightness is provided by a gasket (7).
This system maintains perfect tightness between the cooler and the cooler extension while
allowing movement between the different parts.
2) Tightness between the hydrogen circuit and the water circuit
Here the tightness comes from the perfect quality of each cooling tube. This quality is checked
throughout the manufacturing process.
Tightness also comes from correctly expanding each tube in the tube sheets.
Absence of water-to-hydrogen and hydrogen-to-water leaks is checked by hydraulic tests
made on the finished cooler.
3) Tightness between the water circuit and the ambient air
This tightness is obtained by placing a flat gasket between the tube sheet and the water box
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and then by adequate clamping between these two parts.
Before installation, hydrostatic pressure test and sealing test must be made.
Test pressure should be 0.8MPa gauge and applied for 15 minutes.
The sealing test shall be carried out according to JB/T6227 “checking method and evaluation
of the sealing ability of hydrogen-cooled machines”.
（5）position of the coolers in the generator（see drawing 2-4）
The coolers are mounted horizontally in the generator, the water being supplied from a unit
positioned diagonally to each end of the generator.
They are placed in the upper part of the frame, and are positioned symmetrically with respect to the
stator axis.
They are position (symmetrically) within the hydrogen circuit.
The coolers are connected in parallel on the water circuit.

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2.1.4 The magnetic core
The magnetic core structure sees drawing 2-5
(1)Magnetic core segment

The magnetic core is made up of a stack of special grain-oriented magnetic steel segments, or
laminations.
These laminations are characterized by their method of manufacture - cold rolling - their low loss
and high permeability, and their special cold-rolled coating.
Each segment is further insulated with a thin coat of oil varnish containing colloidal silica.
This type of magnetic lamination presents several advantages:
 As the maximum magnetic permeability is in the direction of the flux flow, the radial height of
the yoke can be reduced: This allows the construction of a single-block stator.
 Considerable reduction of the magnetomotive force required in the yoke.
 Lower overall core loss than with ordinary laminations.
 high stacking factor, due to the high permeability of this cold-rolled steel
 Protective coating, applied at the outset to both faces, which resists temperatures above 300°C
and reinforces the main electrical insulation provided by enamelling the punching.
The core stack is made up of many punching packets (1) each several centimeters thick, with
staggered joints between adjacent laminations within each packet.
Separating the packets are radial vent ducts (2), through which the hydrogen flows to cool the
magnetic core.
The first packets at each end of the core are provided with a specially reinforced insulation.
The spacer ribs on the vent ducts are non-magnetic.
In addition to the radial field flux, the core ends are also subject to a front fringing flux, whose axial
component increases with a low excitation current, particularly when operating with reactive load
absorption.
The additional losses caused by this fringing flux have necessitated specific design features at the
core ends in order to prevent unacceptable temperature rises:
 The outermost laminations (2) are stepped (i.e. with progressive reduction in radial core height)
in order provide a better trap for the fringing flux, and to facilitate entry of hydrogen into the air
gap.
 These laminations are glued together in their packets
 The teeth of the end laminations are slit down to the level of the bottom of the slot in order to
minimize sling currents in the teeth.
The outer edge of each lamination is provided with dovetail slots which serve to fasten the core to
the key-bars (4) evenly spaced around the inner frame bore.

(2) The flexible support system (see drawing 2-6)

In operation, the magnetic core of a two-pole generator is subjected to an elliptical deformation

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which rotates at the same speed as the rotor and produces a 4-node vibration mode.
In order to minimize the transmission of radial vibrations to the frame, end structures, and
foundations, the core is stacked on key-bars which are fastened to the frame via a special flexible
mounting.
Each key bar (1) is welded on the support ring (6), which is itself welded onto the spring bars (2)
which are the both welded onto the frame ring (3). This arrangement provides the vibration
decoupling between the magnetic core and the frame.
The flexible support system is designed to allow not only for radial displacement caused by
magnetic attraction and expansion, but also for tangential displacement arising from normal or
accidental torques. These displacements are, of course, relative to the fixed frame, which is anchored
to the foundations via the frame feet. The damping between the core and the frame is sufficient to
ensure that only a small percentage of core vibrations are transmitted across the support system: this
guarantees a low level of vibrations in the frame.
The inner face of the key-bars has a dove-tail section (5) onto which the core laminations (4) are
fixed.
(3)Core clamping plates-flux shields (see figure 2-5)
1) Core Clamping Plates
Two single-piece plates (6), one at each end of the stator, provide firm axial clamping of the
magnetic core assembly.
The clamping force exerted by these plates is transmitted to the core via clamping fingers (7),
welded onto the end laminations opposite each tooth; this arrangement ensures adequate distribution
of pressure from the plate of the core. This clamping force corresponds to an elastic deformation of
the two clamping plates, achieved by tightening the nuts (5) on the threaded ends of the key bars (4)
which tie the two plates together.
2) Flux shields
In view of the considerable alternating magnetic fields in the immediate vicinity of the clamping
plates, special precautions are taken to minimize stray load loss in these areas.
Both ends of the core are protected by an annular cooper damper screen, or flux shield (8), which is
shaped to fit the core clamping plate. These damper screens shield the core end assemblies from the
front leakage flux flowing between rotor and stator
(4)Cooling of magnetic core and core end
1) Magnetic core
Calories lost in the magnetic core (1) are removed by cold hydrogen flowing through the radial vent
ducts (2) under the action of the fans. These vent ducts are formed by splitting up the core, along its
whole length, into packets separated from each other by radial spacer ribs. Core cooling is thus of the
"radial" type.
2) Core end structures
Cold hydrogen flowing between the clamping fingers (7), and in the space between the flux shield
(8) and the clamping plate (6), removes the calories lost in these end structures.
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2.1.5 Stator winding

(1) The stator winding (see drawing 2-7)

The stator conductor bars are made up of a bundle of elementary copper strands which are either
solid (4) or hollow (3).
These insulated strands are transposed according to the Robel method along the entire length of the
magnetic core. In this way the additional loss caused by leakage flux is minimized.
Each bar consists of a single or double Robel. In this case the insulation between each Robel is
obtained by means of a separator (5).
The electrical conductor is a composite assembly of elementary copper strands. It is insulated from
the core by an insulating wrapping.
This insulation is obtained by wrapping the bar with a mica tape.
To avoid the formation of corona or sparking, the slot portion of the bars is covered with a low
resistance conductive paint, and the end windings are coated with resistive paint.
At the end of each bar (see drawing 2-8) all the strands are electrically connected by means of the
"water box" (3), on which the flanges (19) and the loops (4) are assembled, which provide the
electrical connection between two bars. This connection is made after the bars are re-wedged in their
slots.

(2) Radial and tangential wedging in the core (see drawing 2-9)
The high current levels in the conductor bars require wedging which is particularly resistant to
mechanical stresses and vibration. Bars are equipped with radial and tangential wedging in the stator
core slots.

1) Radial wedging
The slot bottom bar (1) pushes radially against the core (3) via the slot bottom pad (4). This pad is
made of thermo-setting resin which moulds itself to the bottom of the bar and thereby ensures
uniform contact pressure between the bar and the core. The slot bottom bars (1) and air gap bars (2)
are separated by an insulating wedge (5) and leveling strips (7). The bars are held radially by the
combined effort exerted by the slot closing wedges (6) and the tapered wedges (9) pushing against
the air gap bar (2) via ripple spring (8).

2) Tangential wedging
Each slot bottom bar (1) and air gap bar (2) is blocked tangentially by inserting a set of tapered
wedges (10) between the magnetic core (3) and the screwing in order to immobilize the bars in the
stator slots.

(3)The end winding bracing (See drawing 2-8)

The end windings of the stator bars must be anchored by means of a special support system built on
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to the active part of the machine.
Insulating support brackets (8) are attached to the magnetic core clamping plate (20). On these
brackets are mounted support rings (11) and (14), against which rest the slot bottom bars (1), via
intermediate hot- polymerized packing blocks (13).
The bracing between the air gap bars (2) and the slot bottom bars (1) is obtained by inserting hot-
polymerized spacing blocks (10) and (12). Radial clamping is achieved by means of the "crocodiles''
(15) whose tie-rods are anchored in the support brackets (8).
In drawing 2-10, the tangential wedging of the slot bottom bars (1) and air gap bars (2) is obtained
by means of wedge blocks (3) which push out the tapered wedges (4) when a nut and bolt system (6)
is tightened. The tapered wedges (4) push against the bars through intermediate hot polymerized
strips (5). The wedge/stator bar assembly thus forms a rigid cone capable of withstanding normal
and accidental electromagnetic forces

(4)Cooling of stator winding (see drawing 2-8)

We have seen that the stator winding bars and circular phase connections have inner channels. In
these channels flows deionized water which evacuates the losses of the hollow strands as well as
their neighboring solid strands.
This water is supplied by the water manifold (6) and goes to each bar via a flexible insulated tube (5)
connected to the water box (3). The water box feeds water into each hollow strand of the stator bars.
Warm water is removed in the same way.
Each bar has its own water supply line, so there is the same number of parallel water circuits as there
are bars in the stator winding.
The risk of a water leak in the generator is eliminated by the pressure difference between the
hydrogen and the water. Any flaw in the deionized water circuit the addition of hydrogen to the
water. This leads to a slight increase in hydrogen consumption without jeopardizing the operation of
the generator, provided that the winding temperatures remain within the prescribed limits.

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2.1.6 High voltage terminal leads

(1)High voltage terminal connection leads (see drawing 2-11)

The ends of each phase are linked to the connections (1), designed to lower the winding outlets in
the frame (5) close to the high voltage terminal axis (6).
The coppers serving the different fittings as well as the circular phase connections are carefully
insulated along their whole length.
The connections (1) are linked to the terminals (6) by hollow copper intermediate conductors (3).
The link with the rings (1) is obtained by the flanges (8) fixed by screws to the end of the circular
phase connections.
At the terminal end (6) this link is obtained by the flanges (7) fixed by screws onto the terminal
heads.
A device composed of blocking wedges (2) rigidified by non-magnetic nuts assures the support and
positioning of the hollow conductors' (3) end.
The cooling of the terminal connections (1) and the linking connections at the terminals (3) is
guaranteed as for the stator bars by an internal circulation of water from the inlet water header (9)
and the flexible connection (10) and towards the circular phase connections and the stator bars.

(2) H.V. bushing (see drawing 2-12)

The generator is equipped with six power outlet terminals.
These High Voltage terminals are hydrogen tight, condenser-bushings which connect the stator
winding to the outside grid system (for the phase terminals) and to the neutral point (for the neutral
terminals).
They are located in the lower part of the generator frame, in the terminal box.
The terminal is essentially composed of a hollow cylindrical conductor (1) of high-conductivity
electrolytic copper.
The upper part of the terminal is clamped inside a collar which connects it to the corresponding
phase connection via a hollow lead made of the same quality copper.
The lower part of the terminal is flanged and screwed to the connection piece (outlet flange) to
which the bus bar connections or neutral bar are fixed.
The ends of the terminals are silver-plated to improve the electrical connection.
An insulating sheath (2) is wrapped around the copper conductor.
Inside this sheath are wound layers of metallic or semi-conductive materials acting as a condenser
and which are grounded through the collar (6). The outside potential of the terminal is thereby fixed.
The hydrogen tightness at each end of this insulating sheath is provided by a rubber O-ring (4) held
down by a non-magnetic steel profiled ring (3) which is tightened down by a non-magnetic nut (5).
The collar (6) is hot shrunk directly onto the condenser body. This mounting collar of austenitic cast
steel fixes the terminal in the bottom of the terminal box; the longer end (9) is on the air side and the
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shorter (8) on the hydrogen side.
Another rubber O-ring provides hydrogen tightness between the collar and the terminal box.
The insulating sheath is covered along its entire length, except under the collar, by an insulating
cover (7).
This resin coating applied to both sides of the mounting collar and completely covering the
insulating sheath, including the ends, provides perfect gas tightness.

(3) The layout of H.V. bushing (see drawing 2-13)

The above-mentioned drawing gives a schematic representation of the position of the terminal box,
and marks the generator outlet terminals.
Viewing the generator (1) from above - with the terminal box (13) at the right hand or excitation
end-we see the row of three phases terminals (7) (8) and (9), and the three neutral terminals (10) (11)
and (12).
The terminals are identified as follows:
 phases terminals : W1 (7), V1 (8) and U1 (9)
 neutral terminals : W2 (10), V2 (11) and U2 (12)
Drawing 2-13 identification of the terminals
Note: There are installation marks on the terminal box. The side marked with CT is close to the
generator centre; the side marked with COT is far away from the generator centre.
After the stator terminal leads connected with the H.V. bushings by hollow copper intermediated
conductors. A hydrostatic pressure test and sealing test for the whole stator water circuits should be
made again. Install the insulating box (11) on the electrical connection and pour glue into insulating
box. (See appendix E)

(4)Circular phase connection (see drawing 2-14)

The circular phase connections (1) are parts of the copper ring of ring-shaped section made up of a
grounding insulation (2) and an inner water circulation duct (4)
According to the end-winding diagram, one or two ends of each circular phase connection part have
a connection to the stator end-winding. The circular phase connections (1) are held by the insulating
supports (3) and radially clamped by the clamping flanges (5) and the screws (6).
The screws (6) rest on the insulating supports by means of the nuts (7) and possess a braking system
(8).The screws (6) are equipped with an insulating tube (9)

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2.2 Generator fluid supply circuits

The calorific losses of the rotor and the stator core are evacuated by hydrogen.
Because of the risk of spontaneous explosion of a hydrogen-air mixture, it is essential, when filling

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the generator enclosure, to use an intermediate gas so as to prevent the formation of such a mixture.
The gas used for this intermediate filling phase is carbon dioxide, which is neutral with respect to
both air and hydrogen.
Calorific losses of the stator winding are evacuated by deionized water circulating in the bars.
The following distinct circuits are thus necessary:
 CO2 supply circuit
 H2 or gas supply circuit
 Deionized water supply circuit

2.2.1 CO2 supply circuit

Carbon dioxide is heavier than both air and hydrogen. It is fed in through a distribution/venting duct
located at the bottom of the generator, and fills the enclosure from the bottom upwards.
As it enters the generator, the CO2 displaces the air or H2 upwards; these gases then escape via the
venting/distribution ducts located at the top of the machine into the open air.
The C02 supply unit, and the pressure and purity monitoring systems for the CO 2 - air and CO2 - H2
mixtures during filling and emptying operations are described in the AUXILIARIES Manual.

2.2.2 H2 or gas supply circuit

The top of the generator is connected with the open air via special venting/distribution ducts.
When the gas or H2 supply units are connected up to these ducts, the generator may be filled with
either of these two gases from the top downwards. As the C0 2 is heavier than both gases, it is forced
out via the venting/distribution ducts at the bottom of the machine.
The air and H2 supply units, and the pressure and purity monitoring systems for the C0 2-air and C02-
H2 mixtures, are described in the AUXILIARIES Manual.

2.2.3 Deionized water supply circuit（see drawing 2-15）

The deionized water used for cooling the stator winding is supplied by an auxiliary module
described in a separate manual.
The deionized water (1) enters the inlet manifold (2) and then flows through the flexible hoses (3)
which supply the stator winding bars (4). It then flows through each of the bars -connected in
parallel between the manifolds-before returning to the outlet manifold (6) via the outlet hoses.
The outlet manifold (6) is connected to the auxiliary unit by means of the union (7).
The H.V. bushing is cooled by means of the other deionized water circuit, which U-shape water inlet
manifold is located in the lower part of the terminal box. After cooling H.V. bushing and hollow
copper intermediate conductors, the water shall flow into the water outlet manifold. The water
inlet/outlet manifold and the water inlet/outlet manifold for terminal leads (on the lower part of the
terminal box) are insulated from the earth. They shall be reliable earth while the generator is in
operation.
This type of water circulation is called "individual bar circuit".
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2.3 Stator preservation

2.3.1 Generator at standstill-closed

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(1)Seal oil circuit available
 The stator winding cooling water circuit is in operation
 The shaft seal oil circuit must be in operation
 The filling of the machine with air is left to the discretion of the utility.
① Generator remains in H2 at rated pressure
 The water-to-water exchanger must not be in operation: Either closes the secondary circuit, or
by-pass the primary circuit (i.e. the water circulating in the stator winding).
 The stator winding cooling water is in circulation. The pressure must be at least 0.02 MPa below
that of the gas in the machine in order to prevent possible micro-leaks from making the winding
insulation damp.
This pressure is read on the pressure gauge mounted on the generator inlet line
② generator remains in H2 at reduced pressure
 The H2 pressure must remain ≥ 0.05MPa gauge to prevent air from entering the machine.
 The H2 pressure shall be adjusted according to the pressure setting range of the water circulating
in the stator winding to respect the difference previously defined, i.e. 0.02MPa minimum. (See
NOTE 1).
 The requirements for stator cooling system should be done in accordance with item ①
③ Generator in air above atmospheric pressure (see NOTE 2)
 The air pressure shall be adjusted according to the pressure setting range of the water circulating
in the stator winding ,i.e. item
 The requirements for stator cooling system should be done in accordance with item
NOTE 1: The generator does usually not start-up in air condition. For special condition, detailed
instruction should be given.
NOTE 2：At any case, the duration that the generator is filled with CO 2 is not higher than 24 hours.
In general, it should be limited in 6 hours.
(2) The generator is filled with air at atmospheric pressure
 The generator is filled with air at atmospheric pressure （ see NOTE 2 ）
 The stator water circuit exchanger is locked and isolated
 The pumps of the stator winding cooling water circuit are mandatory stopped
 The shaft seal oil circuit is stopped
① the stator winding cooling water circuit is in operation
a. Duration of standstill < 3 weeks
 The exchanger is locked. The pumps of the first/ second circuit are stopped to prevent possible
micro-leaks from making the winding insulation damp
After having checked the generator bottom points when re-starting, the normal water con-
ductivity level must be restored (≤1.0μs/cm); to achieve this, circulate the cooling water through
the system for approx. 24 hours after bringing the H2 to its rated pressure.
b. Duration of standstill: between 3 weeks and 4 months
 The stator water circuit exchanger is locked and isolated
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 The winding is drained by gravity. Blow through by means of the gas used for the
conditioning defined below
 The circuit is either filled with dry and oil-free filtered air for stator windings with natural
aeration or air scavenging, or with inert gas (helium, nitrogen) for hydrogen conditioned stator
windings; in the later case, an alight overpressure is required with respect to the atmospheric
pressure in order to compensate for possible micro-leaks.
c. Duration of standstill: more than 4 months
 The stator water circuit exchanger is locked and isolated
 The winding is drained by gravity. To remove water pockets, carry out several blows through
operations with dry and oil-free filtered air for stator windings with natural aeration or air
scavenging, or with inert gas (helium, nitrogen) for hydrogen conditioned stator windings. After
having isolated the generator from the water circuit, vacuum-dry the winding and break vacuum
using dry and oil-free air (dry air can be replaced by nitrogen)
② The stator winding cooling water system
a. Duration of standstill < 3 weeks
 The stator water circuit exchanger is locked and isolated. The pumps of the first/second
circuit are stopped to prevent possible micro-leaks from making the winding insulation
damp.
 The circuit in operation can be disconnected from the other systems: In this case, before re-
starting, the conductivity level of the water left in the circuit must be complied from related
standards.
 The circuit in operation can’t be disconnected with the other systems: In this case, drain the
water in circuit thoroughly, and then fill the circuit with water.
b. Duration of standstill: between 3 weeks and 4 months
 The stator water circuit exchanger is locked and isolated. The pumps of the circuit are
stopped to prevent possible micro-leaks from making the winding insulation damp.
 The winding is drained by gravity. Disconnected generator from other systems by blind
flange, then fill the generator with Nitrogen.
c. Duration of standstill: more than 4 months
 The stator water circuit exchanger is locked and isolated
 The winding is drained by gravity. To remove water pockets, carry out several blows through
operations with dry and oil-free filtered air for stator windings with natural aeration or air
scavenging, or with inert gas (helium, nitrogen) for hydrogen conditioned stator windings.
 After having isolated the generator from the water circuit, vacuum-dry the winding and break
vacuum using dry and oil-free air (dry air can be replaced by nitrogen)
2.3.2 Generator at standstill - open
 The shaft seal oil circuit is shut down
 The generator is in air at atmospheric pressure
(1) The stator winding cooling water circuit is in operation
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① Duration of standstill < 3 weeks
 The stator water circuit exchanger is locked and isolate. The pumps of the circuit are stopped
to prevent possible micro-leaks from making the winding insulation damp.
Drain the generator bottom points to check before re-starting that there were no leaks during
the standstill period
After having checked the generator bottom points when re-starting, the normal water
conductivity level must be restored; to achieve this, circulate the cooling water through the
system for approx. 24 hours after bringing the H2 to its rated pressure.
② Duration of standstill: Between 3 weeks and 4 months
 The stator water circuit exchanger is locked and isolated
 The winding is drained by gravity. And filled with Nitrogen. Avoid using more Nitrogen,
disconnecting the other parts of circuit from generator by blind flange. The pressure is not need to be
higher than the atmospheric pressure.
③ Duration of standstill: More than 4 months
 The stator water circuit exchanger is locked and isolated
 The winding is drained by gravity. To remove water pockets, carry out several blows through
operations with dry and oil-free filtered air for stator windings with natural aeration or air
scavenging, or with inert gas (helium, nitrogen) for hydrogen conditioned stator windings.
After having isolated the generator from the water circuit, vacuum-dry the winding and break
vacuum using dry and oil-free air (dry air can be replaced by nitrogen)
(2) The stator winding cooling water circuit is not in operation
① Duration of standstill < 3 weeks
 The stator water circuit exchanger is locked and isolated. The pumps of the circuit are stopped to
prevent possible micro-leaks from making the winding insulation damp.
 Leave water in generator; disconnect the mechanism from other generator.
 After having checked the generator bottom points when re-starting, the normal water
conductivity level must be restored; to achieve this, circulate the cooling water through the
system for approx. 24 hours after bringing the H2 to its rated pressure.
② Duration of standstill: Between 3 weeks and 4 months
 The stator water circuit exchanger is locked and isolated.
 The winding is drained by gravity. Fill generator with Nitrogen and its pressure is not need to be
higher than the atmospheric pressure.
③ Duration of standstill: More than 4 months
 The stator water circuit exchanger is locked and isolated
 The winding is drained by gravity. To remove water pockets, carry out several blows through
operations with dry and oil-free filtered air for stator windings with natural aeration or air
scavenging, or with inert gas (helium, nitrogen) for hydrogen conditioned stator windings.
After having isolated the generator from the water circuit, vacuum-dry the winding and break
vacuum using dry and oil-free air (dry air can be replaced by nitrogen)
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2.4 Disassembly of coolers
2.4.1 The disassembly of a cooler involves:
(1) Preliminary disassembly
See drawing 2-16
—cutting off the cooling water supply
—removing the drain plug (4C)
—draining the internal water supply to the element
—disconnecting the water inlet and outlet pipework

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Parts list for drawing 2-16 assembly of coolers

4A frame 4B coolers
4C draining plug 4D horizontal holes for lifting lugs
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4E vertical holes for lifting lugs 404 metal frames
405 seal ring 406 seal pad
407 clamping flange 408 clamping strip
409 clamping strip 412 screws
413 lock washer 414 screws
415 lock washer 416 screws
417 straight stop piece 418 plates
419 screw 420 nuts
421 lock plate vertically 422 screws
423 nut 424 lock plates vertically
425 lock washer 426 lock washer
427 screw 428 spring washer
430 seal ring 431 supports
432 washers

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Parts list for drawing 2-17 assembly of coolers
3A frame 3B coolers
3C cooler rib 3D man holes
3E U-shape pothook 3F metal string
3G screwed metal string 3H equipment for fastening string
3J traveling crane 3L trunnion
301 handling support 302 screws
305 support 306 pin
307 pin 311 wood supports upon request
320 lifting beam 321 screws
322 nut 328 support

(2)Disassembly of the water boxes

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See the drawings2-16 and 2-17。
For each water box:
—Identify the existing reference marking
—Remove the screws (430)
—Remove the support (431)
—Open the locks (428)
—Remove the nuts (427)
—Remove the locks (428)
—Separate the water box
—Remove the tightness seals (432)
—Plug the supply pipes
—Clean the contact surfaces of the water boxes and the tube sheets.

(3) Removal of a cooler

See drawings 2-16 and 2-17
—Removing the drain plug (4C)
—Disconnect the water inlet and outlet pipework
—Identify the existing reference mark
—Open the locks (415) and (426)
—Remove the screws (414)
—Remove the clamping strips (408), (409) and the clamping brackets (407)
—Remove the screws (412) locks (413), and (425)
—Remove the clamping brackets (404) equipped with a seal (406)
—Remove the seals (405)
—Fit at (4E) a lifting ring (3L) at the excitation end cooler end.
—Assemble sling (3F) in this ring (3L)
—Using the inspection holes (3D), remove the maintenance screws (416) locks (417) and plates
(418) of the cooler on the housing guides of the frame
—Sling as indicated in phase IV in drawing 2-17.Remove the screws (422) and stop pieces (421)
which are used to fasten the coolers.

—Horizontally pull the cooler element inside its housing on 2600 mm, with the help of a traveling
crane.
—Wedge the cooling element as indicated in phase II in drawing 2-17, using a support (328) and a
wedging block (311) if requested.
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—Remove the shackle (3E) and the sling (3F)
—Fit the cross beams (320) onto the supports (305) using screws (321) and (322)
—Fit the two handling assemblies onto the ribs (3C) of the cooler (3B)
—Position the gudgon (306)
—Fit the shackle (3E) and the sling (3F)
—Remove the support (328) and the wedge (311)
—Horizontally pull the cooling element by 4000 mm
—Reposition the wedging (328), (311)
—Fit the second handling element
—Fit the shackle (3E) and the sling (3F)
—Sling as indicated in phase II in drawing 2-17
—Remove the support (328) and the wedging (311)
—Horizontally pull the cooling element and place it in the horizontal position on an opposite wedge
—Plug the water inlet and outlet pipework.

2.4.2 Cooler reassembly（see drawing 2-16 and 2-17）

NOTE: After transported to installation site, work should be carried out on coolers according to
appendix F “Hydrogen cooling turbine generator——gas-tight components installation regulation in
site”.

(1)Operations required for cooler reassembly

—identify existing markings
—ensure cleanliness
—install the water boxes fitted with new gaskets (432)
—insert locks (428) (do not fold back), and nuts (427)
—after filling cooler with water, re-tighten nuts (427)
—fold back lock plates (428)

(2) Preliminary operations)

—Lubricate the sliding faces of the angle iron guiding the cooler compartments into the frame (3A)
—On turbine end, install the handling support (301) on the frame end shield by means of the screws
(302)
—Fix a turnbuckle (3H) in the lifting lug of the handling support (301) and pass the cable (3G)
through the frame cooler compartment towards the extremity of the excitation end.
—Put the cable (3G) aside
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—Remove the draining plugs (4C)
—Fix the cross beam (320) on the supports (305) by means of the screws (321) and (322)
—Install the two handling devices on the ribs (3C) of the cooler (3B)
—Install the pins (306) (307)
Install shackle (3E) and sling (3F)
PHASE I
—Fix a lifting lug (3L) at the cooler end (4D) on turbine end
PHASE II
—Sling a given in PHASE II, using the traveling crane (3J)
—Lift the cooler horizontally and place it at the end of its compartment
—Fix the cable (3G) of the turnbuckle (3H) in the lifting lug (3L) fitted on the cooler on turbine end
PHASE I.
—Introduce the cooler, drawing it horizontally into its compartment.
—Stop this operation when the handling device comes close to the frame
—Wedge the cooler as given in PHASE II by means of a support (328) and a wood support (311)
fabricated upon request.
—Remove the first handling device
—Remove the corresponding shackle (3E) and sling (3F)
PHASE III
—By means of the second handling device, using the traveling crane （3J）and equipment (3H) to
draw the cooler horizontally. Stop this operation as soon as the handling device comes close to the
frame.
—Reinstall the supports (328) (311)
—Remove the second handling device
—Remove the corresponding shackle (3E) and sling (3F)
PHASE IV
—On excitation end, fix a lifting lug (3L) on cooler end (4E)
—Place the sling (3F) in the lug (3L)
—Sling as given
—Remove the supports (328) (311)
—Keep on securing the cooler end on excitation end; simultaneously draw it horizontally into its
compartment using the turnbuckle (3H) (3J)
—The cooler reaches its final location
—Centre it longitudinally
—Passing through the inspection openings (3D) lock the cooler to the frame compartment guides by
means of the screws (416), the rectangular stop pieces (417) and the plates (418). These plates are
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welded onto the cooler afterwards
—Remove the sling (3F)
—Remove the screws (302) the handling support (301) the turnbuckle (3H), the cable (3G)
—Install the stator filters
—Install and centre the flanges (404) fitted with the washers (405)
— Fix the flanges (404) on the frame end shield by means of the screws (412) and stop pieces (413)
(425) and lock
—Install the washers (406)
—Install the stuffing supports (407)
—Install the stuffing links (408) (409) and fix them on the flange (404) by means of the screws
(414) and stop pieces (415) (426)
—Lock and round the stop pieces (415)
—Reinstall the draining plugs (4C)
—Through the inspection openings 3D, place the stator filters against the coolers with the screws
(419) (422). Lock the counter-nuts (420) (423). Round the stop pieces (421) (424).
After finishing the filtration in generator, remove the filter. Fix the coolers onto the lower orbit by
screws (416) and stop pieces (418) and fasten the coolers onto the top orbit by screws and stop
pieces.

2.4.3 Cooler maintenance operations are:

(1)Cleaning of bundle
The inside of the tube bundle is cleaned by passing through each tube a bundle or nylon brush fixed
to the end of a handling rod.
IMPORTANT:
—Do not use metal brushes which could scratch the internal surface of the tubes. Chemical cleaning
products are also prohibited.
—This operation can be performed on a cooler mounted in a H2-filled generator frame.
If cleaning is performed on a cooler removed from the generator, rinse through the bundle with clean
water and allow draining completely.
During this operation, clean the water boxes and repaint them if necessary.
(2)Plugging of a defective tube
After identifying the faulty cooler and disassembling the water boxes, locate the defective tubes.
There are two possibilities:
—the cooler is in a H2-filled generator.
—the cooler is in an air-filled generator, or removed from the generator.
Plug each end of the tubes temporarily: those which cannot withstand slight air overpressure or
depression are considered defective.
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Put the defective tubes out of service by plugging both ends with conical brass plugs.
IMPORTANT:
—Only 5 to 7 % of the tubes of a bundle can be plugged without disturbing the operation of the
cooler, and therefore of the generator.
The only purpose of this plugging is to put the unit back into normal operation.
The causes of the tube rupture are established during a more thorough maintenance operation so that
a permanent repair can be made.
(3)General inspection
Each time a water box is disassembled, make sure that the tube sheets and finned tubes are neither
eroded nor corroded.
The tube fins must not show traces of oxidation, which might be due to micro-leaks.
The complete cooler can be subjected to a water pressure test before re-starting.
The best pressure shall be the rated operating pressure + 0.2 MPa. Fill the cooler with water which
does not react chemically with the materials used for tube sheets and tubes. Hold the pressure for
half an hour: no pressure drop or seepage should be observed with constant temperatures.

2.4.4 Storage and preservation at standstill

(1)Storage
Before storing a cooler:
—if possible, rinse through the cooler with water which does not react chemically with the tubes and
tube sheets.
—ensure complete draining of the cooler
—if possible, dry the cooler with oil-free, dry, hot air
—plug the water inlets and outlets with blind flanges
—cover the cooler
—protect it against shocks.

(2)Preservation at standstill
When the generator is at standstill, certain precautions must be taken to prevent damage to the
coolers. The possibilities are as follows:
—the generator is at standstill for less than 15 days (a tolerance of 10 % is permitted) and the
'cooling
water" system is available.
Keep this system in operation and check that the water temperatures will not cause by-pass of the
water flow to the cooler.
During this period, make sure that each cooler is completely full
—the generator is at standstill for more than 15 days (with a tolerance of 10 %), the "cooling water'

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system in or out of service.
Each cooler must be drained completely
—the "cooling water" system is out of service for at least 2 days (without tolerance). Each cooler
must be drained completely
—the "cooling water" system is out of service for less than 2 days.
If possible, make sure that each cooler is completely full before stopping the system.
During this period, do not perform any check or manoeuvre which could modify the water level in
the coolers. It is recommended that the cooler isolating valves should be closed.
The purpose of these precautions is to ensure that all possible steps are taken to prevent the
formation of the triple phase metal - water - gas" which causes serious corrosive phenomena.

2.5 Stator winding maintenance

2.5.1 General requirement
The maintenance of the stator does not require any disassembly or re-assembly operations.
Nevertheless:
—the stator winding must be tested electrically insulation resistance measurements, dielectric tests
—the stator winding must be inspected visually and cleaned.
Specific equipment and precautions are required for electrical tests.
The general state of the stator winding and its wedging must be checked by the manufacturer's
specialists.
They are likewise required in the case of damage to the stator winding or its cooling water system.

2.5.2 Specific equipment

（ 1 ） Insulation resistance measurements must be performed using a 2500 V d.c meg-ohmmeter
with stabilized voltage.
（2）The following equipment is needed for the dielectric tests :
—380 V ax. 500 A supply source, with connection box close to the generator
—high voltage transformer with adjustable supply and compensating coil on secondary winding:
Secondary voltage : 0 to 70 kV
Primary voltage : 380 V - 50 Hz (or 60 Hz)
Max. apparent power : 900 kVA
Max. mains power : 190 kVA
—potential transformer, class 0.2
—digital voltage meter for checking high voltage, or any similar instrument of equivalent quality.
（3）Precautions to be taken during tests
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Electrical testing of the stator winding requires:
—a protective enclosure to prevent personnel from coming into contact with the generator winding
during the whole test period
—danger-live conductor's notices
—rotating lights switched on during the tests.
IMPORTANT:

Never apply d.c or a.c voltage to a water-filled stator winding with the pumps stopped.

2.5.3 Testing the stator winding insulation resistance

A test is performed every 12 to 18 months on the whole winding- A further test is performed every 4
years on each winding phase,
(1) Insulation resistance test on complete winding (3 phases in parallel)
① Preliminary conditions
—The machine is filled with hydrogen at rated pressure.
—The stator water system is in operation and the water conductivity is normal, i.e. approximately
0.5 micro Siemens/cm, measured at the machine inlet.
—The braid connecting the neutral bar to the ground is removed.
—The circuit breaker is open.
② Test
—Connect the edge of the 3 phases.
—Using the megohmmeter, apply a d.c voltage Ue to the generator terminals between the winding
and the ground. Ue usually equals 2500 V where appropriate.
—After applying the voltage for 1 minute, note the insulation resistance of the tested phase.
For a generator temperature of 20° C and an normal water conductivity, the phase-ground insulation
resistance is equal to or greater than 52MΩ。
If the value obtained is smaller than 80 % of the above value, or if an insulation resistance difference
exceeding 20 % between phases is revealed, inform the manufacturer.
(2)Phase-by-phase testing of stator winding insulation resistance
① Preliminary conditions
—The machine is filled with hydrogen at rated pressure.
—The stator water system is in operation and the water conductivity is normal, i.e.
0.5microsiemens/cm, measured at the machine inlet.
—The neutral bar is removed.
The bus bar connections are disassembled.
—The 2 phases not tested are connected to the ground.
②. Test
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—Using the meg-ohmmeter, apply a d.c voltage Ue to the generator terminals between the phase
tested and the ground. Ue usually equals 1000 V, or 2500 V where appropriate.
—After applying the voltage for 1 minute, note the insulation resistance of the tested phase
—Ground the tested phase
—Disconnect the phase to be tested from the ground
—Test this second phase, then the third one as described above
For a generator temperature of 20°C, the phase- ground insulation resistance is equal to or greater
than 155MΩ if the value obtained is smaller than 80 % of the above value, or if an insulation
resistance difference exceeding 20 % between phases is revealed, inform the manufacturer.

2.5.4 Test the dielectric strength of the stator winding

(1)Preliminary conditions
—The generator is closed and filled with hydrogen at rated pressure
—The stator water system is in operation and the water conductivity is normal
—The insulation resistance has just been tested and the results are satisfactory
—The neutral bar has been removed
—The connections to the busbar have been removed
—The non-tested phases are grounded
—The stator R.T.D. are connected in a single point to the ground (they are not short-circuited)
—The rotor winding is grounded by a conductor other than rotor grounding brushes
—The current transformer secondary is short-circuited.
(2)Tests
An ac. voltage Ua is applied to the generator terminals between one phase and the ground.
Ua is applied progressively (approx. 1 kV/sec) up to its maximum value 1.5 Un (Un is the rated
stator voltage). The hold time of the voltage plateau is 1 minute.
Perform the test again on either of the other two phases.
If the maximum voltage cannot be obtained, the manufacturer must be requested to search for the
fault.
The stator winding insulation resistance must be tested again after the dielectric strength test and the
same results as previously must be obtained.
After the first installation of generator, 2.8Un DC, withstand voltage test should be made for 1
minute. Only it is accepted, the AC withstand voltage test can be made, the test value is 0.8×
(2Un+1000) V, for 1 minute. From then on, only 2.5Un DC. voltage withstand test should be made,
and the AC voltage withstand test need not to be made.
2.5.5 Stator winding visual inspection
Maintenance of the stator winding consists of a visual inspection, to ensure that there is no
accidental pollution.
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If traces of oil are found, clean the winding using the solvent specified by the manufacturer.
Spray two or three times, allow draining and drying with slightly pressurized, oil-free air.
White dust caused by insulation wear may be found. If so, inform the manufacturer.
During overhauls, clean the accessible portions of the terminals with a dry, lint-free cloth, and
perform a general inspection

2.6 Adjustment of the stator

Before closing the turbine-generator coupling it is necessary to check the relative positions of the
coupling plates.
This check may necessitate a modification of the stator adjustment in order to ensure that the
coupling plates are in the correct relative position.
2.6.1 Disassembly operations
See drawing 2-18and 2-19
—Disassemble the axial alignment key, turbine end and excitation end, as described in chapter 4.2.7.
—Relax foundation tie-rods (401) by loosening nuts (403).
—Position handling trunnions (3D) and fasten by means of screws (301) and (302).
—Tighten the screws (301) with a torque of 1200 N.m. and tighten the screws (302) with a torque of
350N.m.
—Place wedging (3F) in vertical axis of trunnions (3D).
—Position shims (3G) and jacks (3E).
—If a lateral adjustment is necessary, fit the screws (3B).

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2.6.2 Vertical adjustment

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Correction of the stator angular position can be determined by measuring the parallelism of the
turbine-generator coupling faces in the vertical plane, (See chapter 3.4).
Once this value is known:
—Prepare the adjusting shims.
—Slightly lift one side of the stator by means of jacks (3E).
—Take out the existing adjusting shims and clean them.
—Modify the wedging thickness as described previously.
IMPORTANT: Use the minimum amount of shims possible in order to prevent buckling.
—Insert the wedging between feet (4E) and sole plates (4F).
—Lower the stator on its supports.
—Follow the same procedure for the other side of the stator.
NOTE: Lifting each side of the stator separately prevents unwanted transverse movements.
2.6.3 Transverse adjustment
Correction of the stator transverse position can be determined by measuring the parallelism of the
turbine-generator coupling faces in the horizontal plane (See chapter 3.4).
Once this value is known:
—Lift the stator by means of jacks (3E).
—Shift the stator transversely by means of screws (3B).
—Re-place the stator on its sole plates.
2.6.4 Reassembly
With the stator on its support:
—By means of nuts (404), re-tighten tie-rod (401) (402) and (403) of frame feet (4E) located at both
ends of the generator frame.
—Check the coupling as indicated in chapter 3.4.
—Remove jacks (3B).
—Remove jacks (3E) and shims (3G).
—Remove wedging (3F).
—Remove screws (301) and (302) and disassemble trunnions (3D).
—Using nuts (403) tense tie-rods (401) until an elongation required is obtained.
—Re-assemble the axial alignment key, turbine and excitation ends, as described in chapter 4.2.7
NOTE: The flexible support system is designed between the stator core and frame. To prevent
vibration between stator core and frame, the key bars at upper and lower part of the stator core are
fastened by bolts before transportation. After the stator are positioned on site, these bolts must be
taken away to restore the flexibility function.

3. Generator rotor

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3.1 The generator rotor structure
The generator rotor structure sees drawing 3-1.

3.1.1 The rotor shaft

Rotor shaft include two parts: generator shaft and small shaft.
The generator shaft is made of a single forging whose ingot is made in an electric furnace and then
vacuum forging.
The steel used is a high fracture resistant alloy.
The actual characteristics of the steel are measured from specimen test pieces taken from the
forging- In addition, ultrasonic tests are carried out on the rough forging to verify its homogeneity
and the absence of inclusions.
The longitudinal slots which house the field coils are milled into the shaft body and are arranged so
as to generate a magneto-motive force wave approaching a sine wave.
The central, non-wound part of both poles has shallower slots which contain the damper winding.
The rotor winding, which is unevenly arranged around the body, thus produces a dissymmetry of
inertia with respect to both of the main planes of the rotor. Slots, milled perpendicular to the axis of
rotation, restore this equilibrium.

3.1.2 Rotor winding

(1)Straight part of the winding
① the structure of straight part of the winding see drawing 3-2
The rotor winding comprises a number of turns (5) stacked inside the rotor slots, and which
constitute the field coils which make up the poles of the rotor.
Each turn (5) is made up of elementary strands (6) of cold worked silver-bearing copper.
The insulation between turns is obtained by means of insulating layers glued on the external faces of
the wires in each turn. Along the whole core length, the copper turns are provided with either single
(11) or double (12) slits. The turns are arranged such as radial ducts are formed with respect to the
turns.
Within each slot, the coil is insulated from the shaft ground (1) by means of lateral (7) and slot-
bottom (8) insulating strips. At the top of the coil, a non-conductive wedge (4) insulates the field
winding from the damper winding (3).
This damper winding (3) forms a complete squirrel-cage whose function is to channel currents
induced on the rotor periphery during operation.
The damper winding is made of copper with a low silver content. The ends of the damper coils are
silvered in order to provide better electrical contact between coils of different slots.
The damper winding, like the non-conductive wedge (4), and the slot closing wedge (2), has radial
openings (13) which thus complete the continuous radial channels between the slot bottom and the
air gap.
The pole body is also provided with damper coils in order to optimize rotor protection.
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The damper winding is not insulated from the rotor ground (1), nor from the slot closing wedges (2):
this facilitates the flow of induced currents through these parts.
An axial channel, or subslot (10) is machined along the whole length of the shaft body under the
field winding slots. This hollow sub slot is used for cooling the rotor winding
The rotor winding coils are held tangentially in the shaft body by the rotor teeth (1).
A slot-bottom wedge (9) holds the bottom of the winding and prevents the insulating strip (8) from
being sheared between the slot bottom and sub slot (10). The wedge is of insulating material and has
holes providing an opening into the radial gas ducts from the sub slot channel.
The entire slot assembly is held against centrifugal force by the slot closing wedge (2). In the wedge
are openings (13) providing gas discharge from the radial cooling ducts into the air gap.
② Cooling of the slot portion of the winding (See drawing 3-3)
The slot portion of the winding is cooled by circulating hydrogen. An axial-radial system circulates
the gas through the rotor and windings in two identical circuits, each cooling half of the rotor.
The axial fans circulate the hydrogen within the generator. Part of the gas supply (1) flows between
the shaft (2) and the end-winding (3). It then enters the sub slot (4) underneath the wound slot (5)
with sufficient speed to reach the middle of the rotor. This is the axial part of the rotor cooling
circuit.
From the sub slot, the hydrogen gradually escapes, via the radial gas ducts (6) in the coils, toward
the air gap (7). This is the radial part of the rotor cooling circuit.
The hydrogen flowing through the radial ducts (6) is heated by contact with the copper and
evacuates these calories towards the hydrogen coolers.
(2) End-winding
① the structure of the end-winding see drawings 3-4 and 3-5.
The end-windings (2) are that part of the rotor winding which extend beyond the shaft body (1).
At the shaft end, each coil comprises two straight axial sections (3) connected to each other by
curved connection pieces (4), which ensure the continuity of the turns. Radial steps (5) between the
various coil turns are also carried out on the end windings.
Each of the conductors has either longitudinal or transverse slots in one of its surfaces. When these
conductors are superimposed to form the end-winding coils, each turn thus has longitudinal or
transverse cooling ducts.
The electrical connections between coils (6) and between poles are located in the end-winding.
The turns are insulated from each other by insulating strips glued to the outside surfaces of each
conductor, as in the slot portion.
Insulation between the different coils in the end-winding results from the distance separating them,
which is sufficient for the voltage used.
To prevent grounding, an insulating cylinder (10) is placed around the end-winding inside the
retaining ring (9). The straight part (3) of the end-windings is insulated from the shaft by the
extension of the slot wall insulation beyond the shaft body.

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The end-windings are held tangentially by insulating wedges (11) arranged between the straight
parts of the coils.
Together the coils and wedges form a continuous structure.
The end-windings are held axially by insulating wedges (12) pressed between the coil connection
pieces (4). There are also insulating axial wedges against the end-winding on the shaft body side
(13) and on the centering ring side (14). The centering ring is held by the retaining ring (9) which is
shrunk onto the shaft body (1).
The axial wedging system completely immobilizes the end-windings.
The end-windings, the radial wedges, and the tangential wedges are held radially against centrifugal
forces by the retaining ring (6).
② Cooling of endwindings
See drawings3-6 and 3-7
The circulation of hydrogen in the rotor (1) is an axial- radial one. Cold gas flows in at each end of
the rotor underneath the retaining rings (2) in a tube (3) with partitions so as to separate gas inlets
and outlets.
The supplying of the longitudinal ducts (4) of the end windings is performed one turn after the other
through lateral inlets (5) which are themselves supplied via a part of the openings (6) inside the
cooling tube (3).
On the one hand, hot gas is dissipated through lateral ducts (7) which through the intermediary of the
gas outlet openings (8) inside the cooling tube (2)- communicate with the compartment (9). From
there, gas is dissipated through the slots (9) machined at the end of the rotor body; and on the other
hand it is directly dissipated in the first slits (4) of the rotor winding.
The tightness between the gas inlet and outlet openings is obtained by means of the wedging (10)
between turns.
The main fans generate the necessary overpressure for hydrogen circulation.
The cooling of end windings is thus performed by a cold gas circulation in a multitude of elementary
circuits in parallel.
3.1.3 Retaining rings & centering rings
See drawing 3-8
(1) Retaining rings
The retaining rings (2) are non-magnetic steel cylinders which hold the end-windings against the
effect of centrifugal force.
The characteristics of the steel are tested using specimen pieces taken from the forging during
manufacture, and also on the finished rings.
The endwinding and its wedging press against the retaining ring via an insulating cylinder (5).
The retaining rings are hot shrunk onto the shaft body tightly enough to avoid separation at runaway
speed.

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They are held axially by bayonet-fitting locking rings (4) via which axial thermal expansion stresses

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originating in the winding are transmitted to the rotor.

(2) Centering ring

The centering ring (3) is shrink-fitted inside the retaining ring (2) at the end opposite the shaft body.
The shrink fit is of sufficient strength to withstand the centrifugal forces created at runaway speed.
The centering ring minimizes the deformation the retaining ring would undergo if it was mounted
only on the shaft body.
The centering ring also acts as a stop-piece for the end windings (6).
The centering has a machined bevel on its inner diameter which facilitates the flow of cooling gas
under the end windings.

3.1.4 Axial fan

See drawing 3-9
On each end of the rotor is an axial fan with individual blades (1) mounted on a fan support ring (2).
The fans create the necessary pressure to ensure hydrogen circulation through the rotor and stator
circuits.
The outer diameter of the coupling plate on the turbine end does not allow mounting of a separate
support ring. The support ring is therefore an integral part of the shaft forging.
On the excitation end, this is not the case, and the support ring (2) is hot shrunk onto the shaft (3)
with a sufficient shrink fit to avoid loosening at runaway speed.
Each fan support ring has a circular shoulder (4) onto which the blades axe fitted. This shoulder is
provided with tapped holes (5) evenly spaced around its circumference for receiving the fastening
screws (6).
The fan blades （1） are of high resistance aluminium alloy. Their mechanical characteristics are
checked during manufacture.
The post of each blade is profiled to match the shoulder (4) on the support ring which holds the
blades against centrifugal force.
Mounting screws (6) fasten the blades to the support ring.
As the turbine end and excitation end fans work in opposite directions, two sets of opposite pitch
blades are necessary.

3.1.5 Excitation connections

See drawing 3-10.
The DC current supplied by external static excitation system to the rotor winding is sent through slip
ring (7), radial connecting rod(2), (20), the central shaft connections or "D bars" (1), the radial
connecting rods (2), and the outer axial connections (3) which feed directly into the winding.
Rotor winding is inside the frame (H2 side) and slip rings are outside frame (air side). So every part
of excitation connection must be H2-tight as well as conduct current.

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（1）Central shaft connection
The central shaft connection (1) is made of two D-shaped solid copper bars, separated by layer
insulation, and housed in the central shaft bore.
The shaft bore provides a means of linking the excitation unit and the generator without interfering
with the journal bearing, the shaft seals, or the axial fan.
The central shaft connection is insulated from the shaft by an insulating sheath (6).
The seal rings (10) is used for H2 seal at
(2)Radial connecting rods
Radial connecting rods are connected to two end of central shaft connection. The radial connecting
rods are copper rods screwed into the central shaft connections (1). The ones inside the frame are
connected with outer axial connections (3); the ones outside the frame are connected with two slip
rings (7). Radial connecting rods constitute the radial connection of excitation circuit.
The seal rings (10) are used to insure seal at radial connecting rods.
(3) Slip ring
Slip ring is made of high strength and wearable chromium alloy steel. Brushes contact slip ring by
sliding on it to conduct the current from static part to rotating part. Between slip ring and shaft there
is insulation sleeve.
3.1.6 Cooling of slip ring
When generator is running, electric loss and friction loss will occur on slip rings. These losses will
increase the temperature of slip rings.
Slip rings are cooled by air, to see drawing 3-11. Cold air enters the soundproof housing through
shutter (8) on the housing, then through the brush gear to cool the slip rings and brushes into the seat
box (7) driven by slip ring fan (3) through the ventilation opening on the seat box (7).
Slip ring fan (3) and fan cover (4) drive and lead the air in the ventilation system of slip ring.

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3.2 Rotor removal and installation
3.2.1 Operations required for rotor removal
—Disconnecting of soundproof of brush gear
—Disconnecting of brush gear
—Disconnecting of fan cover of brush gear
—Disconnecting of small shaft at excitation end
—Disconnecting of seat box of brush gear
—Disconnecting of bolts of turbine end coupling
—Disassembly of rotor ground brush
—Disassembly of the field winding detection probe （ NOTE ： the rotor winding detection probe
must be disassembled before assembling and disassembling the rotor）
—Disassembly of power angle probes (or speed probes at turbine end) and their support.
—Disconnecting of jacking and lube oil supply
—Disassembly of an inspection hatch
—Disassembly of outer oil deflectors
—Disassembly of bearing closings
—Disassembly of vibration detectors
—Disassembly of temperature detectors
—Disassembly of clamping collar
—Disassembly of upper half-journal bearing
—Disassembly of upper 1 /2 bearing
—Disassembly of inner oil deflectors
—Positioning of external support
—Disassembly of shaft seal rings
—Disassembly of lower 1/2 journal bearing
—Disassembly of pipework
—Disassembly of lower 1/2 bearing
Disassembly of fan nozzle ring
—Disassembly of blades
The above-mentioned work should be done at turbine end and excitation end simultaneously. It also
can be done respectively. As a result, the rotor should be put on the external support.

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3.2.2 The work after rotor inserted

The works after the rotor has been on its position can be carried out as the contrary process that the
rotor is removal in chapter

After reassembly, the generator is in stage of start condition. Some inspection must be done .They
are: the stator sealing test, insulation check between bearing excitation end and earth, temperature
sensor element check, vibration probe check and the earth of three water manifold.

3.2.3 Removal of the generator rotor

See attached drawings 3-12～3-17

NOTE: The rotor should be handled carefully to avoid knocking it against the various components of
the stator.

Make sure that the insulation of the stator bars is not damaged during the operation.

The end windings and their wedging should never be used as a support or a walkway.

Protect the lower part with cardboard.

Instructions for wedging and slinging the rotor must be followed carefully.

The rotor must never be handled by or supported on the retaining rings. As soon as possible, it
should be protected against dust.

PRELIMINARY NOTE (see position 3-13 VII): it is imperative to position the rotor in a way that
the flange (331) is properly orientated in relation to the rack (324).

For this reason, place the flange (331) at the end (3H) of the shaft. The axis (332) will be horizontal.
POSITION I:

The rotor is supported by the external supports (3B) at the turbine end and (3C) at the excitation end.
POSITION II:

With the help of support jacks (3B) and (3C) raise the rotor to the maximum being sure that the
retaining ring (3E) does not come into contact with the magnetic core (3D) or the winding (3N).

Position the shim (316), the metal sheet (315) and the rotor shoe (302) on the magnetic core (3D).

ATTENTION: the rotor shoe (302) must not come into contact with the retaining ring (3E).

Lower the rotor onto the rotor shoe (302)

Remove the external support (3C)

POSITION III:

Turbine end

—Fix the handling extension (312) onto the support (3R) with the help of screws (313).
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—Fix the upper half-collar (308) to the handling support (3R) with the help of the axis (3W) or a
shackle (3U).

—Sling as indicated and remove the upper half-collar (308) on the rotor journal (3A).

—Fix the shim (305) onto the upper half-collar (308) using screws (314) and do not block.

—Gently pivot the half-collar (308), shim (305) assembly around the rotor.

—Tighten the screws (314).

—Fix the lifting beam (3S) onto the pad (304) with the help of screws (310).

—Fix the pad (304) onto the handling support (3R) with the help of the axis (3W).

—Sling as indicated and remove the pad (304) from the shim (305).

—Fix the upper half-collar (308) onto the pad (304) with the help of screws (306) and do not block.

—Position a wedge (3T) in order to facilitate the rotation of the pad.

—Position the hoist (3P).

—Sling the pad (304) with the hoist (3P) and tool (3S).

—With the help of the hoist (3P), gently pivot the assembly around the rotor so that it can be
lowered.

—Remove the screws, (314) the shim (305), and wedge (3T).

—Remove the hoist (3P).

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Parts list to drawing 3-12～3-17

3A Generator rotor 3B External support turbine end
3C External support excitation end 3D Magnetic core
3E Retaining rings 3F End shield bearing excitation end
3G Turbine end 3H Excitation end
3K Centre of gravity of the rotor 3M End shield bearing turbine end

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3N Stator winding 3P Hoist
3R Handling support 3U Straight shackle
N Distance between K and shaft end on excitation end
L Position of the shim ref: 341 S Position of the shim ref: 340
3T Wedge 3S Lifting beam
3W Gudgeon pin Φ16 302 Rotor shoe
304 Rotor support 305 Shim
306 Screws M24×100 307 Tallow
308 Upper half collar 309 Rotor extension
310 Screws M14×40 311-1 Screws M30×130
311-2 Screws M20×150 311-3 Nut M20
312 Handling extension 313 Screws M20×50
314 Screws M16×25 315 Protective shim
316 Shim 317 Screws M24×50
318 Washer 24 320 Protective shim
321 Shim 322 Rotor shoe (similar with 302)
323 Jack support 324 Rack
326 Screws M42×4.5 327 Jack
329 Extensions 330 Screws M20×50
331 Flange 332 Should rod
333 Pin 340 Hollowed out hard wooden wedge
370 Sling

—Using handling support (3R) and equipment (312) sling half the collar with axis (3W) or shackle
(3U).
—Raise the assembly and support it against the cooler ring.
—Remove axis (3W) or shackle (3U). Release the handling support (3R).
—Block the screws (306) with a 540.m.N. tightening torque
POSITION IV:

—Excitation end (3H).

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—Assemble the extension (309) on the shaft (3A) using screws (311).
—Clean the protective shim (320).
—Place the shiny cardboard (321) which will possibly be stuck to the external surface of the sheet
(320).
—Lightly coat the internal surface of the sheet (320) with tallow (307).
—Sling the rotor as indicated.
—Raise the rotor and remove the rotor shoe (302), the sheet (315) and the shim (316).
—Introduce the protective shim (320) into the stator bore taking care not to damage the shiny
cardboard, in its final position, the sheet must even out the end of the -magnetic core (3D) at the
excitation end(3H).
—Side (3G), attach the sheet (320) to the end shield bearing (3H) using a small diameter cable, in
the aim
of avoiding the sheet being dragged along with the rotor as it's being removed.
—Introduce the rotor shoe (322) at the (3H) side and position it at the (3G) side.
ATTENTION: It could be necessary to slightly raise the rotor (3A) using the external support (3B) in
order to position the pad (322).
—The pad (322) must not touch the retaining ring (3E).
—Position the rotor shoes (302) at the (3H) side.
ATTENTION: the pad (302) must not touch the retaining ring (3E).

—Remove the rotor from the pads (302) and (322).

—Remove the slinging.
—Remove the external support (3B) as indicated in chapter 3.78.13.
POSITION V:
At the excitation end (3H)
—Position the jacking support (323).
—Approximately align the rack axis (324) and the rotor axis (3A) using adjusting shims as
requested.
—Fix the jacking support (323) using screws (326),
—Fix the jack (327) equipped with a rack (324) on the support (323) using screws (317), (318) and
do not assemble the extensions (329) using screws (330).
—At the support side (323) fixes the flange (331) to the end of the extensions (329) using screws
(330).
—Fix the other end of the extensions (329) to the extension (309) using screws (330).
—Align the rack axis with that of the rotor and block the screws (317) (318).
—Connect the end of the rack (324) and the flange (331) to the axis (332) and the pin (333).
POSITION VI:

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—Sling the rotor as indicated
—Slightly raise the rotor (3A) in order to eliminate the pressure on the pad (302).
—Position the dust protectors on the rotor.
—With the help of the jack (327), remove the rotor, coordinating the movements of the traveling
crane and the rotor.
ATTENTION: during the removal of the rotor:
—Make sure that the protective shim (320) remains immobile.
—Monitor the movement of the pad (322) to ensure a continuous movement.
—The support (304) must not touch the sheet (320) as long as it is outside the magnetic core (3D).
—Monitor the movement of the pad (302) and remove it as soon as the retaining ring (3E) is
removed from the end winding cones (3N).
—After a rotor movement corresponding to the travel of the rack, disassemble one of the extensions
(329) and carry out the removal of the rotor.
POSITION VII:
—When all the extensions have been disassembled and the rack (324) is at the end of its travel at the
support side (323), position the wedging (340) under the rotor (3A). Adjust the height of the
wedging as requested.
ATTENTION: the wedging (340) must not touch the retaining ring (3E).
—Remove the rotor from the wedging (340).
—Remove the pin (333) and axis (332).
—Remove the screws (317) (318), the jack (327) and the rack (324).
—Remove screws (326) and support (323) and adjusting shims.
—Remove the screws (330) and the flange (331).
POSITION VIII:
—Sling the rotor (3A) as indicated, placing the shims (341) between the rotor and the sling (370).
The sling is wrapped around the rotor to avoid it moving on the rotor during its handling.
—Slightly lift the rotor (3A) and remove the wedging (340).
—Remove the rotor making sure that the support (304) and the turbine end coupling do not hit the
various components of the stator.
POSITION IX:
—Remove the rotor from the wedging (340).
ATTENTION: the wedging (340) must not touch the retaining rings (3E).
—Protect the rotor as indicated in chapter 3.77.16.
—Remove the protective shim (320).

3.2.4 Rotor installation

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See the annexed drawings 3-12～3-17 (Note: Rotor winding detection probe is not assembled then)
—Clean the protective shim (320)
—Place the shiny cardboard (321) which may be glued on the external face the shim (320)
—Slightly coat the internal face of the shim (320) with tallow (307)
—Introduce the protective shim (320) in the stator core, making sure not to damage the shiny
cardboard. In the final position, the shim and the magnetic arc end are flush on excitation end (3H).
—By means of small diameter cables secure the shim (320) to the end shield bearing (3F) to prevent
it from being introduced together with the rotor.
Position IX
Give the rotor such an angular position that the flange (331) is correctly oriented versus the rack
(324) (see position in V). Therefore offer the flange (331) up to the shaft end (3H). The axis (332) is
then horizontal
Turbine end (3G)
—Assemble the support (304) onto the rotor (3A).
—Place the collar (308)
—Assemble the support (304) and the collar (30S) using the screws (306)
—Lock the screws (306) by 540 N.m
EXCITATION END (3H)
—Install the extension (309) on the shaft (3A) with the screws (311-1, 311-2, and 311-3)
—Sling the rotor as indicated, inserting the shim (341) between the rotor and the sling (370). The
sling will be given one locking turn around the rotor so as to avoid any displacement of the sung
during rotor handling.
—Check if the rotor body is horizontal by means of a level. Adjust the sling if necessary.
POSITION VIII

—Introduce the rotor into the stator bore, making sure that the support (304) or the coupling on
turbine end does not shock the various stator components. The rotor will enter the stator as deep as
allowed by the sling.
—Install the supporting wedge (340) under the rotor (3A) and adjust the height by wedging as
required.
WARNING: The support wedge (340) shall not rest on the retaining ring (3E).
—Lower the rotor down on the protective shim (320); making sure that the support (304) is resting
on the magnetic core (3D) and on the support wedge (340).
—Remove the sling.
POSITION VII
—Place the jack support (323)
—Align the rack axis (324) with the rotor axis (3A) approximatively with the adjusting shims as
required.
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—Fix the jack support (323) by means of the screws (326)
—Fix the jack (327) fitted with the rack (324) on the support (323) using the screws (317) (318). Do
not lock.
—At the shaft end, fix the flange (331) with the screws (330).
—Align the rack and the rotor axes and lock the screws (317) (318).
—Connect the rack end (324) to the flange (331) using the shoulder rod (332) and the pin (333).
—Sling the rotor as indicated
—Sling the rotor as indicated
—Slightly lift the rotor (3A) and remove the support wedge (340)
—Remove the dust protections coating the rotor
WARNING: Make sure that all protection coatings have been removed before installation of the
rotor.
POSITION VI
—By means of the jack (327) introduce the rotor (3A), harmonizing rotor and crane displacements.
—As soon as the retaining ring (3E) is placed deep enough in the magnetic arc (3D), install the rotor
shoe (322) between the body and the protective shim (320).
—Once the rotor shoe (322) is completely introduced over the magnetic arc, lower the rotor (3A)
down to transfer its support onto the shoe (322) and therefore to withdraw the support (304).
WARING; During the rotor displacement, make sure that the shoe (322) is correctly drawn along.
Make sure that the protective shim (320) is not carried in.
—after a displacement of the rack length, insert an extension (329) between the extension (309) and
the flange (331) using the screws (330).
—Keep entering the shoe (302) until the retaining ring is drawn into the end-winding (3N).
—Go ahead until all the extensions (329) are installed.
NOTE: The natural sag of the rack increases with its length. Wedging may be necessary, in order to
ensure that the extension pieces do not buckle as a result of the compressive stress to which they are
subjected.
—The rotor will be pulled until the turbine coupling plate socket is at a distance of 5 to 10 mm from
the turbine plate.
POSITION V
—Lower the rotor down on the shoe (302)
—Remove the sling
—Withdraw the pin (333) and the shoulder rod (332)
—Withdraw the screws (330) and remove the extensions (329)
—Withdraw the screws (326) and remove the jack support (323) and the adjusting shims as required
with the jack (327) and the rack (324).
—Remove screws and bolts (317) (318), jack (327) and rack (324)
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—Remove screws (326), jack support (323) and adjusting shims as needed
POSITION IV
—Install the external support as indicated in chapter 3.78.12 and remove the support of the shoe
(322).
—Sling the rotor as indicated.
—Remove the support of the shoe (302)
—Remove the shoes (302) and (322), the protective shim (320) making sure not to damage the shiny
cardboard.
—Position the shim (316) and the protective shim (315).
See situation II and III
—Position the shoe (302)
WARING: The shoe (302) must not rest against the retaining ring (3E).
—Place the rotor on the shoe (302)
—Remove the sling
EXCITATION END
—Withdraw the screws (311) and remove the extension (309)
TURBINE END POSITION Ⅲ
—Loosen the screws (306) so as to separate the lower shoe (5 mm).
—Slip the shim (305) between the lower half shoe and the rotor 3A.
—Fix the shim on the upper-half collar (308) by means of screws (314).
—Fix the tooling (3S) by means of screws (310) on the lower half shoe.
—By means of the handling support (3R) on to which the tooling is fixed (312), and using screws
(313) sling the half collar with the gudgeon pin (3W) or a shackle (3U).
—Slightly lift the assembly and pull it on to the rotor journal (3A).
—Position a wedge (3T) so as to allow rotation of shoe.
—Position hoist (3P)
—Sling the shoe (304) by means of hoist (3P) and tooling (3S).
—Using the hoist, gently rotate the assembly around the rotor (3A).
—After a rotation of the shoe of 180° sling the lower half shoe (304) by means of handling support,
tooling (3S) and gudgeon pin (3W).
—Remove the screws (306)
—Remove the lower half shoe (304)
—Carry out 180° rotation of upper half collar (308)
—Sling the upper half collar and remove it after having removed the screws (314) and after having
removed the sling (305) manually.

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POSITION Ⅱ
—By means of jacks of supports (3B) and (3C) lift the rotor as high as possible, making sure that the
retaining ring (3E) does not touch the magnetic core (3D) or the windings (3N).
—Remove the rotor shoe (302), the protective shim (315) and the shim (316) and the rotor is now on
POSITION I

3.3 Maintenance of generator rotor

3.3.1 General requirement
In addition to the precautions to be taken for storing and preserving the rotor in good condition,
given in chapter 3.3.2 maintenance mainly consists of a visual inspection of:
—the retaining rings, to check their general condition and to ensure that there is no rust on the
surfaces in contact with the shaft body. A more thorough inspection may be carried out by taking a
micrographic replica on the external surface of the retaining rings. Consult BSTG if necessary.
—the slot closing wedges, to check that the ventilation channels are not partially blocked. Inform
BSTG if necessary.
—the journals and shaft seal contact surfaces, to check for scratches, pitting and signs of over-
heating. Defects less than 0.1 mm deep should be smoothed with a stone. In the case of larger
defects, consult BSTG. Pitting indicates that the bearing (excitation end) is incorrectly insulated or
that the shaft is incorrectly grounded at the turbine end. Signs of over-heating indicate abnormal
operation of the bearing or the corresponding shaft seal.
Lastly, electrical readings may be taken to check that the rotor winding is in good condition. These
are described in chapter 3.5.
Visual inspection of the rotor should be performed immediately after its removal. After inspection,
stick adhesive tape along each slot to block the ventilation holes.
If necessary, blank the extractor fans of each retaining ring with adhesive tape.
Close ventilation inlets under the retaining rings with suitably-shaped cardboard, held in place by
adhesive tape.
Clean journals, shaft seal contact surfaces and coupling surfaces with solvent and coat with tallow
grease or Vaseline.

3.3.2 Storage and conservation of rotor

The non-magnetic steel used to manufacture retaining rings is particularly sensitive to the
phenomenon of stress corrosion, especially in humid conditions.
A certain number of recommendations should therefore be respected in order to give the retaining
rings adequate protection during assembly and during long or short periods of shutdown and
overhaul of the units.
Whether or not a rotor is transported in a container, it is always protected by a gastight cover with
drying agents and volatile inhibitors inside.
The retaining rings are thus protected from damp.
(1)Storage on site
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①. Arrival of rotor
Insulation should be checked as soon as the rotor arrives on site, as described in chapter 3.77.31.
The packing includes two measuring terminals for this, either at one end of the gastight cover or at
one end of the container as appropriate.
This insulation reading should be compared with the reading taken before transportation.
If the level of insulation is appreciably lower, the tightness of the cover should be checked, drying
agents and volatile inhibitors replaced and any necessary repairs carried out.
Each time the packed rotor is handled; the tightness of the cover should be checked and, if necessary,
repaired.
②. Storage of rotor
During storage, rotor should be given mechanical protection (for example, frame and tarpaulin) to
protect it against knocks and parts accidentally falling on it.
Make sure air circulates between tarpaulin and packing.
This precaution obviously does not apply if the rotor is in a container.
Insulation should be measured every week.
Insulation readings should be recorded in the log book or report.
If any, the hygrometric sensors on the cover should also be checked.
The rotor should be unpacked as late as possible. When it has been unpacked, the temporary pro -
tective products should be removed using suitable solvents.
③.Storage of rotor for long periods
If the rotor is to be stored for more than 3 months, it should be packed in a heat-welded cover with
drying agents and volatile inhibitors inside.
The rotor, insulation, state of products and tightness of cover should be checked as above.
(2)Rotor assembly
As soon as the rotor has been unpacked, the retaining rings should be protected by heating covers
which keep them at a temperature above the ambient temperature.
The heating covers should be placed on the retaining rings and supplied with electricity whenever
this does not interfere with handling.
After handling, the heating covers should be placed on the rings again and supplied with electricity,
particularly once the rotor has been mounted in the open stator.
NOTE: the heating covers supplied by the user.
(3)Stator assembly - rotor in position
The heating covers should not be removed until immediately before the stator is closed.
The following recommendations must be followed in each case:
—First case : Generator still open or temporarily sealed (for example, by tarpaulin)
Use a blower with hot air to protect the generator enclosure from fluctuations in external tem-
perature
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For a temporarily sealed machine, use a circulating air dehumidifier
This device should be connected to an access door or manhole so that dry air circulates axially
through the machine in a closed circuit
—Second case: Generator closed with air at atmospheric pressure
Use a dryer if one is included in the installation
If there is no dryer or it is unavailable, use a dehumidifier
—Third case: Machine closed in air pressure higher than atmospheric pressure
Use a dryer if there is one
If there is no dryer or it is unavailable, the pressure should only be maintained above atmospheric
pressure for as long as is necessary to check tightness for example. Then return to atmospheric
pressure and use desiccant which cannot be used at pressures greater than atmospheric pressure
—Fourth case, machine closed and in hydrogen
—The machine may be at reduced or rated pressure and the dryer should be in operation

(4) Periods of shutdown - machine closed

Follow recommendations given in paragraph 3 Stator assembly - rotor in position
(5)Periods of shutdown - machine open
When the machine is open, the following recommendations should be respected as appropriate
—Where the operation only requires a manhole or access door to be opened or a cooler to be
removed
If operation takes less than half a day, it is not necessary to take any special precautions
If operation takes longer than half a day, use a blower with hot air to protect the machine against
fluctuations in external temperature
If operation takes more than a week, use temporary blanking plates and a dehumidifier
—Where the operation necessitates more extensive disassembly
If the retaining rings are accessible at both ends, the heating covers should be mounted on them and
supplied with electricity
—If one of the retaining rings is inaccessible, prated the whole rotor against fluctuations in external
temperature by blowing hot air over it
Cover openings whenever possible.
As soon as operation is over, refer to recommendations given paragraph 3, Stator assembly - rotor in
position, for the period before disassembly
(6)Transportation of rotor for inspection or repair
Before transportation, pack the rotor in a heat-welded cover with drying agents and volatile
inhibitors. Protect the cover with a tarpaulin or, if possible, use the container provided for
transportation.

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3.4 Disassembly and reassembly of couplings - unit shaft alignment
This chapter describes the uncoupling and coupling of the turbine and generator, and gives the
instructions necessary for the turbine-generator shaft alignment
The procedure for disassembling and reassembling the coupling bolts and the necessary tooling are
specified in the Turbine Manual.

3.4.1 Disassembly of turbine-generator

—Remove coupling bolts
—Start up shaft line jacking system
—Using the screws located on the turbine coupling plate, separate the generator rotor, and then
move back by 8 to 10 mm to disengage completely.
—Test eccentricity and parallelism of coupling sleeves.
(1)Testing of coupling plate eccentricity
—Fix a dial gauge on one of the two plates and position the needle on the other
—Set the dial gauge to zero
—Rotate the turbine and generator shafts simultaneously, using for example the crane
—Stop jacking system and wait until shaft line has stabilized
—Read the dial gauge
—Re-start the jacking system and continue quarter-turn rotations and measurements until the shaft
line has made a complete turn
—Check the zero on the dial gauge
—Check the readings obtained against the values obtained on first assembly.
(2)Testing of coupling plate parallelism
—Start up the jacking system
—Find reference points A, B, C and D determined on first assembly and rotate the shaft line so as to
bring them into their reference positions
—Stop jacking system and wait until shaft line has stabilized
—Using shims or a micrometer, measure the distance between the coupling faces at points A, B, C
and D
—Re-start the jacking system
—Rotate turbine and generator shafts simultaneously by a quarter turn
—Stop jacking system and wait until shaft line has stabilized before measuring again
—Continue in this way until the shaft line has made a complete turn
—Calculate the average of the values obtained from the four measurements performed at each
reference point
—Check against the values obtained on first assembly
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NOTE: These tests can be performed simultaneously

3.4.2 Reassembly of turbine-generator coupling - shaft alignment

Before re-coupling the generator to the turbine, ensure correct turbine and generator shaft alignment
by testing the eccentricity and parallelism of the coupling plates as indicated in chapter 3.4.1. The
results must be in accordance with the attached drawing 3-18.
In order eliminate the difference of flexibility in all direction, the rotor should be turn in low speed
for 4 to 6 hours.
If necessary, modify the position of the generator stator as indicated in chapter 2.6 in order to obtain
a correct adjustment.
After that:
—position the coupling bolts
—assemble the coupling plates by means of these bolts
—close the coupling according to the procedure given in the Turbine Manual
.

3.5 Maintenance of rotor winding

Under normal conditions, there are no special precautions for maintenance of the rotor winding,
apart from electrical readings designed to check its general condition.
These readings consist in:
 Measuring insulation resistance
 Measuring impedance
 Measuring resistance
3.5.1 Preparatory operations
(1) Tooling necessary
—megohmmeter,
—variable a.c voltage source capable of supplying a 10 A current less than 100 V,
—ammeter,
—voltmeter,
—micro-ohmmeter or dual Thomson bridge.
(2)Precautions to be taken during tests
The following precautions must be taken during the tests: Only authorized operators can perform the
tests.
Before test:
—Mark out the test zone clearly by means of a safety tape 2 m horizontally from the rotor to be
tested.
—Ensure that warning lights have been installed and are in good working order.
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—Check that the test unit and the rotor body to be tested are grounded.
—Make sure that the test unit operates correctly.
During test:
—The people attending the test MUST remain outside the area delimited by the safety tape.
—If, during test, somebody enters the area delimited by the safety tape, for whatever reason, the
operator
must cut off the supply immediately.

3.5.2 Procedure to be used

UR is the dielectric factory- acceptance voltage and is defined as follows:
UR = 4850.
(1) Testing insulation resistance
This measurement should be taken systematically at the beginning of each overhaul, after packing or
during storage.
Insulation resistance is measured at d.c voltage UE defined as follows:
—For a rotor which has not been mounted in a stator: UE = 2500 V
—For a rotor mounted in a stator : UE = 500 V.
—Using the megohmeter, apply voltage UE between ground and rotor winding (slip ring). Read the
value of the insulation resistance when UE has been applied for 1 minute.
Stop the megohmmeter and discharge the rotor winding by grounding.
This value must be greater than 100 megohm at 20°C or than 50 megohm at 30°C.
If the resistance of the generator rotor is below the above value, measure polarization index Ip
defined below:
Ip = Insulation resistance after 10 minutes/Insulation resistance after 1 minute
If Ip is greater than 2, the insulation is considered satisfactory.
If Ip is less than or equal to 2, the insulation is insufficient and the area under the retaining rings
must be dried.
Two cases may arise:
a. The rotor is inside the stator.

— rotate the unit at rated speed none excited for several hours and take another measurement.
b. The rotor is out of the stator.
—drive low pressurized warm air, dry and oil-free air under the retaining rings, raising air
temperature gradually to 100°C. The temperature of the coppers must not exceed 80°C. Then
measure the insulation resistance.
If the insulation resistance remains below 1 megohm after drying, consult the manufacturer.
(2)Impedance measurement

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The electrical connection between the rotor winding and the excitation busbar must be open.
The impedance of the rotor winding should be measured by applying an alternating current
(maximum 10 A).
Impedance may be deduced by taking a voltage reading and a current reading at the winding
terminals.
If the value is less than 0.9 times the initial value, the manufacturer should be informed.
(3)Measuring resistance
The electrical connection between the rotor winding and the excitation busbar must be open.
The resistance of the rotor winding may be measured at slip rings using a micro-ohmmeter or a
Thomson double bridge.
As the temperature of the rotor is uniform and known, compare with the resistance given in chapter
1.2.3.
A significant difference between the reading taken and the initial value indicates a fault in the
winding. Inform the manufacturer.

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3.6 Fan
3.6.1 Disassembly of main fan blades
This operation requires a torque wrench capable of applying the tightening torque.
In addition to the usual precautions taken, the exact position of each blade at both turbine and
excitation ends must be marked carefully before disassembly so that each blade can be replaced in
exactly the same position, thus preventing possible unbalances developing during rotation.
Disassembly operations should be carried out as follows (see drawing 3-19):
—Mark position of each blade (401) for remounting
—Undo nut locks (402) which block the two screws fixing each blade
—Remove the two screws (403), the nut locks (402) and the corresponding blade (401)
—Arrange and store the blades after disassembly
NOTE:

—In order to reach the bottom blades, turn the rotor using the crane or a jack. This operation is
facilitated by switching on the jacking oil system, if available, or topping up the journal bearings
with oil.
—The same operations are performed at both the turbine and excitation ends

3.6.2 Reassembly of main fan blades

On assembly, the screws or bolts must be coated with supranite or tallowed Teflon fluid.
Then proceed as follows:
—When remounting blades, check that each blade (401) is placed in exactly the same position as
before disassembly
—Place a double nut lock (402) and the screws (403) on the blade
—Check theoretical clearance between each blade foot
—Fix each blade (401) with screws (403) using torque wrench 400 N.m.
—This operation is identical for the blades on the turbine and opposite turbine side.

3.6.3 Maintenance of fan blades

Check the blades visually to find any shock or friction marks. Search for the cause and send the
blades concerned to the manufacturer for decision.
Perform a visual inspection of the blade surface in contact with the rotor, in order to check that the
bearing capacity is correct.
Examine the fastening screws to find whether there are permanent deformations (reduction in area,
shearing of threads, seizing, etc.). Replace each defective screw and inform the manufacturer.

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4. Generator end structures

4.1 End structures

See drawings 4-1(turbine end) and 4-2 (excitation end)
The generator rotor (1) turns in journal bearings (2) assembled in the bearings (3). These bearings
are built into the end structures of the frame (4) by means of the end shield bearing (9).
There are also the hydrogen tight shaft seals (5), the oil tight covers (6) as well as the ventilation
guides (7).
The generator axial guiding (8) is situated on the bearing support.
At the excitation end, an electrical insulation of these elements must be provided.
4.1.1 Journal bearing
See drawing 4-3
The rotor shaft revolves inside elliptical journal bearings. These are composed of two steel half rings
(1) and (2) held together by screws (3) and centering pieces (4).
The outer contact surface of the journal bearing is spherically machined (5) to form a swivel seating
when mounted inside the support ring: this makes it easier to align the bearing bore with the shaft
journal.
Each half bearing is provided with tapped handling holes (6).
In the lower half journal bearing (2) are located: the lube oil supply line (8) leading to the oil inlet
grooves (9), and the high-pressure oil supply line (10) leading to the jacking pocket (11) which
serves to raise the shaft.
The inner surface (13) of the journal bearing is lined with white metal to improve the friction
coefficient with the journal.
A recess (7) is machined into each journal bearings where the oil film is formed.
4.1.2 Lower half-bearing
See drawing 4-4
The lower half-bearing is a fabricated structure made up of a half spherical seat (1) assembled with
the shaft seal support (2).
The half spherical seat (1) also carries the oil pipework (3).
The connection with the end shield bearing (4) is made by screws (5) securing a joint contact face
which carries a hydrogen tight device.
At the excitation end, the double insulation means that an intermediate ring (6) is needed between
the lower half-bearing (1) and end shield bearing (4), and that electric insulation is also necessary.
( see chapter 5.3.4 )

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4.1.3. Upper half-bearing
See drawing4-5
The upper-half-bearing is a steel fabricated structure obtained by welding a horizontal axis half-ring
(1) onto a shaft seal support (2).
The connection with the end shield bearing (4) is made by screws (5) securing a joint contact face
which carries a hydrogen tight joint device.
At the excitation end, the double insulation means that an intermediate ring (6) is needed between
the lower- half-bearing (1) and the end shield bearing (4), and that electric insulation is also
necessary (see chapter 5.3.4).
4.1.4 End shield bearing
See drawing 4-6 (turbine end shield bearing) and 4-7 (excitation end shield bearing)
The end shield bearing is a steel fabricated structure obtained by welding a horizontal axis cylinder
(2) onto a thick steel sheet disc or end shield (1). The assembly is made rigid by ribs (3).
It ensures the bearing support and the generator frame closing.
It is fixed by screws onto the frame (4) securing the joint contact face earning a hydrogen tight
device.
4.1.5 Clamping collar
See drawing 4-8.
The lower half bearing (1) carries a machined half ring serving as a lower support to the journal
bearing (3). This is covered by the clamping collar (4). The journal bearing contact with the
clamping collar and the lower half bearing (1) is on the spherical contact surface.
At each end of the collar (4), a flange of great thickness ensures its connection to the lower half
bearing (1) by screws.
After assembly, this collar exerts on the journal bearing (3) a clamping force sufficient to ensure
immobilization during unit operation.
4.1.6 Shaft seal
See drawing4-9
The hydrogen tightness of the machine is ensured principally by the shaft seals. They are made up of
a support or end shield (4) and the rings (7).
The hydrogen tightness is obtained by forced circulation of oil at the hydrogen end (1) and the air
end (2), thus separating the air and hydrogen casing.
The oil supply and treatment plant is described in the "Auxiliary" manual.
（1）End shield support of the shaft seal
The end shield support of the shaft seal is part of the bearing. At its base, it is made rigid by a thick,
horizontal steel sheet which makes up the contact surface with the half bearing, the assembly being
carried out by screws.
At its outer edge, the end shield support has a machined groove serving as housing for the tightness
rings and the oil supply.

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(2) Shaft seal rings
Inside the support ring (4) are mounted two shaft seal rings (7). These rings are made of several
segments placed end-to-end to form rings. The rings are held together by two positioning springs (6).
Shaft seal oil is fed into the oil supply groove from where it flows between both rings and the
generator shaft (3) and then out on the hydrogen side (1) and the air side (2). The oil flow prevents
air from reaching the hydrogen and vice versa as long as the oil pressure is greater than the hydrogen
pressure.
Oil on the hydrogen side (1) is collected in the lower half-bearing from where it is drawn off towards
the oil unit.
Oil on the air side (2) is collected in the lower half- bearing from where it, along with the bearing
oil, is carried to the lube oil system.

4.1.7 Oil deflectors

See the drawing 4-10
The inner and outer oil deflectors prevent the leakage of oil or oil vapors.
These light alloy pieces are in several parts with bolted and pinned contact surfaces. The outer edge
of the covers is machined to allow their fastening on to the supporting structure.
The central bore of these covers has transversal grooves in which deflectors (5) adjusted to the
shaft's (6) diameter is housed.
On the lower part, axial holes (7) allow the oil recovered by the deflectors to be evacuated towards
the bearing enclosure (8) or the shaft seal enclosure (4).
At the excitation end, the outer oil deflector is insulated from the generator mass by positioning an
electric insulant at the area where it is fastened (see chapter 5.3.4).

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4.1.8 Ventilation guides
See drawing 4-11
At each end of the generator are fixed partitions (1) which close off the stator end winding (2) from
the end shield (3). The space between the partition and the end shield acts duct (4) directing cool
hydrogen towards the axial fan (5).
This partition also serves as a ventilation guide around the outside of the axial fan.
The parts described above are of lightweight alloy. To facilitate assembly, they are in several pieces
that are pinned and screwed together to form a rigid whole which is fastened to the radial web (6) on
the stator frame end.
4.1.9 Axial alignment key
See drawing 4-12
The axial alignment key maintains the axial alignment of the generator after the stator axis and shaft
line have been properly positioned. It ensures axial alignment while the generator is operating.
An alignment key is located on both the turbine end and excitation end.
On the lower half bearing (1) are welded two rails forming a U-shaped female mating member (2).
Across from this part is a corresponding T-shaped male mating member (4) mounted on the
foundation block, which fits loosely between the two rails. The male member is positioned by means
of a key (5) and fastened by screws to the foundation block; after the stator and shaft line alignment
has been adjusted, two adjusting wedges are fitted into the spaces between the male and female
members. These wedges are held in by fastening screws (8).

4.2 Maintenance operations for bearing and shaft seal rings

4.2.1 Assembly of the external support of the rotor
During the different stages of disassembly and reassembly of the end structures, the rotor should be
held at the turbine end and excitation end by a support located outside the bearing.
The positioning of this external support entails the following: see drawing 4-13.
(1)Assembly of the external support
A: turbine end
—Position the beam (303) on the support (301).
—Assemble the support (301) with the end bearing (3B) using screws (310).
—Fix the shims (304) on the beam (303) using screws (311).
—Position the screws (307).
—Raise the beam (303) using screws (307) so as to position the jacks (308) and wedges as required
(309).
B: excitation end
—Position the beam (305) on the support (302).

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3A rotor 3B end shield bearing turbine end

3C end shield bearing excitation end 3D hole M12 for handling of support
3E hole M12 for handling of beam 301 support turbine end
302 support excitation end 303 beam turbine end304 shim turbine end
305 beam excitation end 306 shim excitation end
307 screw 308 jack
309 wedging as required 310 screwM16×100 311 screw M10×25

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—Assemble the support (302) with the end shield bearing (3C) using screws (310).
—Fix the shims (306) on the beam (305) using screws (311).
—Position screws (307).
—Raise the beam (305) using screws (307) position jacks (308) and wedges as required (309).
NOTE: The rotor should always be raised and lowered using jacks (308); the screws (307) only
serve as a mechanical stop.
—When the rotor (3A) is to be lowered, it should be slightly raised using jacks (308). Reset the
screws (307) and lower the rotor.
—When the rotor is to be raised, raise it with the jacks (308), and then fit the screws (307) on the
support
(301) or (302).
(2) Disassembly of the rotor external support
In the event where the rotor is in its stator, be sure that the rotor is in contact with its journal bearing.
The jacks (308) are not raised. The external support can therefore be disassembled.
A. Turbine end
—Remove the jacks (308) and the wedging (309)
—Lower the beam (303) and removing the screws (307)
—Remove the screws (307) and (311)
—Remove the shims (304)
—Remove the screws (310), the support (301), and the beam (303).
B.Excitation end
—Remove the jacks (308) and the wedging (309)
—Lower the beam (305) removing the screws (307)
—Remove the screws (307) and (311)
—Remove the shims (306)
—Remove the screws (310), the support (302), and the beam (305).
4.2.2 Removal of the journal bearings at the turbine and excitation ends.
(1)Removal of the journal bearing
See drawing 4-14～4-18
①. Removal of the clamping collar
—Identify the clamping collar (401) reference.
—Remove the screws (402).
PHASE I:
—Fasten the support (303) to the support (302) using the screws (316).
—Sling the handling support (302).
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—Fasten the support (302) onto the collar (3K) using screws (317)
—Vertically raise the collar (3K) in order to loosen the stop pieces (404).
—Remove the clamping collar (3K.) and place it on a wooden wedging.
—Remove the plates (405) remaining on the lower 1/2 bearing.
—Remove the screws (317) and the support（303）.
② Removal of the upper 1/2 journal bearing
See drawing 4-18
—Identify the lower and upper 1/2 bearing references
—Open the locks (402)
—Remove the screws (401)
PHASE II :
—Fit the lifting beam (317) onto the upper 1/2 journal bearing (3L) using screws (313).
—Fasten the support (315) to the support (302) using screws (316).
—Sling the handling support (302)
—Fasten the support (302) onto the lifting beam (312) using the cotter pin (314)
—Fit the washer (304) and immobilize the axle (314) using the pin (305)
—Vertically raise the 1/2 journal bearing (3L) in order to remove the centering bushes (403)
—Remove the 1/2 journal bearing and place it on a wooden wedging.
—Remove the pin (305) then the axle (314) and remove the support (302).
—Remove the screws (313) and the lifting beam (312)
③ Removal of the lower 1/2 journal bearing
—Remove the centering bushes (403)
—Remove the jacking oil circuit copper pipe in front of the journal bearing,
—Vertically raise the rotor. The maximum elevation will be 0.2 mm.

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Parts list for drawing 4-14, 4-15, 4-16 removal of the journal bearing
3A lower 1/2 bearing 3B upper 1/2 bearing
3C end shield bearing 3D shaft
3E generator frame 3F lower /12 journal bearing
3G sling 3H lifting ring
3J shackle 3K clamping collar
3L upper 1/2 journal bearing 302 handling support
303 support 304 washer
305 pin 312 lifting beam
313 screw 314 shoulder pin
315 support 316 screw
317 screw 322 guide plate
323 screw 324 handling flange
325 screw 326 requested wedging
327 requested wedging
328 handling flange

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PHASE III:
—Fit the guiding plates (322) onto the side of the lower 1/2 bearing (3F) and fix them using the
screws (323).
—As indicated, fit the handling flange (324) or (328) on the 1/2 journal bearing (3F) using the
screws (325).
—Fit the lifting ring (3H) onto the end of the handling flange (324) or (328).
—Pass the sling (3G) under the rotor and fix it to the ring (3H) using the shackle (3J)
—Grease the journal (3D).
PHASE IV:
—Gently pivot the 1/2 journal bearing on the journal making sure to place a wedging (327) on the
contact surface.
—When the 1/2 journal bearing is in contact with the wedging (327), continue to rise in such a way
that the wedging (326) can be introduced.
—Place the 1/2 journal bearing on the wedging (326)
—Remove the sling (3G).
—From this moment, the lower 1/2 journal bearing is in a position similar to that of the upper 1/2
journal bearing.
—The removal of the lower 1/2 journal bearing is carried out in the same way as the upper 1/2
journal bearing.
(2) Installing the journal bearings on turbine end and excitation end
see drawing 4-14～-18
① Installation of the lower 1/2 journal bearing
—The rotor is secured by the outer support and fitted by 0.2 mm versus its normal position
—Check the cleanness of the lower 1/2 journal bearing (3F)
—Clean then lubricate the spherical seat of the 1/2 bearing ring (3A)
PHASE IV:
—Mount the guiding plates (322) on the outer side of the 1/2 journal bearing (3F) and lock them by
means of the screws (323).
—Mount the handling flange (324) or (328) on the 1/2 journal bearing (3F) as indicated and fix it by
means of the screw (325).
—Fit the lifting ring (3H) at the end of the handling flange (324) or (328).
—Mount the lifting beam (312) on the 1/2 journal bearing (3F) by means of the screws (313).
—Mount the support (315) on the support (302) by means of the screws (316)
—Sling the handling support (302).
—Hook the handling support (302) on the lifting beam (312) by means of the shoulder axis (314).
—Fit the o-ring (304) and lock the shoulder axis (314) with the pin (305).

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—Install the wedges (326) and (327) and place the 1/2 journal bearing (3F) resting on these wedges.
WARNING: from now make sure that the oil flow openings of the journal bearing and the lower 1/2
bearing are facing each other when the journal bearing will be installed.
—Remove the pin (305), then the shoulder axis (314) and loose the handling support (302).
—Sling as indicated by hooking the sling (3G) to the lifting ring (3H) by means of the shackle (3J).
—Once this performed lift the 1/2 journal bearing and remove the wedging (326).
PHASE III:
—Lower the 1/2 journal bearing on the journal ，slightly turn it up to its normal position, the
wedging (327) having been removed.
WARNING: during the 1/2 journal bearing rotation, make sure that the sling moves freely.
—Remove the sling (3G).
—Remove the screws (313) and the lifting beam (312).
—Remove the screw (325) and the handling flange (324).
—Remove the screws (323) and the guiding plates (322).
—Adjust the parallelism journal bearing/journal according to drawing 4-19 and 4-20 by lateral
action on the lower 1/2 journal bearing.
—Place the rotor into its 1/2 journal bearing.
—Check the horizontal clearance between journal and journal bearing according to drawing 4-19
and 4-20
—Install the centering rings (403).
—Check that the oil supply openings of the lower 1/2 journal bearing and of the lower bearing is
facing each other.
—Install the jacking oil circuit flexible hoses.
② Installation of the upper 1/2 journal bearing
—Check the cleanness of the upper 1/2 journal bearing (3L).
—Mount the lifting beam (312) by means of the screws (313).
—Identify the existing marks.
PHASE II:

—Mount the support (315) on the support (302) by means of the screws (316)
—Sling the handling support (302).
—Hook the handling support (302) on the lifting beam (312) with the shoulder axis (314).
—Fit the o-ring (304) and lock the shoulder axis (314) with the pin (305).
—Lower the upper 1/2 journal bearing (3L) on the lower one (3F).
—Remove the pin (305) then the shoulder axis (314) and remove the handling support (302).
—Remove the screws (313) and the lifting beam (312).

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—Check the clearances between journal bearing and journal according to drawing 4-19 and 4-20.
—The clearances checked on machine internal and external ends must not vary by more than 0.05
mm.
—Unless the parallelism between journal bearing and journal must be readjusted.
—Install and lock the screws (401) fitted with the o-rings (402) with a torque of 620 N.m.
③ Installation of the clamping collar
—Check the cleanness of the contact surfaces of the clamping collar and the upper 1/2 journal
bearing.
—Identify the existing marks.
—Install the upper 1/2 oil deflectors.
PHASE I:
—Mount the support (303) on the support (302) by means of the screws (316)
—Sling the handling support (302).
—Hook the handling support (302) on the clamping collar (3K) with the screws (317).
—Install the screws and the o-ring (402) and (403) on the clamping collar (3K), see drawing 4-17.
—Install the clamping collar (3K.) on the upper 1/2 journal bearing, after having located the
centering locking screw (404) into its housing.
—Remove the screws (317) and remove the handling support (302).
—Tightening the screws (402) with a torque of 1130 N.m.
（3）Maintenance operations for elliptical journal bearings
After arriving at the power plant, the recheck of the journal see appendix A.

A visual inspection of the white metal (babbit) should not reveal any scratches, blisters, pining or
signs of heating.
Scratches on the white metal are caused by impurities in the lubricating oil, which should be filtered
(see Turbine Manual).
If the scratches are more than 0.5 mm deep, and particularly if they lead to or cross the jacking
pocket or the lateral grooves, the journal bearing must be reconditioned.
Smaller scratches may be removed by surface scraping.
Blisters on the white metal are indications of localized non-adherence.
The journal bearing should be reconditioned if:
—There is a blister on the lower half journal bearing
—The surface area of the largest blister on an upper half journal bearing is greater than 5 % of the
total surface area of the upper half journal bearing
—The total surface area of the blisters on the upper half journal bearing is greater than 5 % of the
surface area of the upper half journal bearing
Although pitted white metal does not damage the journal bearing, it shows that the bearing assembly
is incorrectly insulated or that the shaft is not properly grounded.
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Pitting occurs on the corresponding journal.
Remove pitting by surface scraping.
If the white metal shows signs of heating, this may be due to the malfunctioning of the lubricating or
jacking system.
Check the jacking oil circuit (see below).
The journal bearing should be reconditioned if there are geometric faults in the bearing support
surface. In other cases, signs of heating can be removed by surface scraping.
Ultra-sonic testing may be used to check that the white metal adheres to the shell properly. The
attached table gives the acceptance criteria used by BSTG.
The spherical contact surfaces of the journal bearings and spherical seats should not show any signs
of seize or local contact. Remove any faults by scraping.
If the journal bearing has been changed, check contact between journal bearing and spherical seat.
The total contact surfaces area should be greater than 80% in the range of 90%.
The jacking oil circuit should be disassembled. It should be re-assembled before the journal bearing
is remounted in the generator. Check if the spring is in good condition.
The cylindrical contact surfaces of the spherical seats and clamping collars must not show any signs
of seizing or local contact. Any faults should be removed by scraping.

Acceptance criteria for ultrasonic examinations

Type of journal bearing Maximum single area of non- Maximum sum of areas of non-
adherence adherence

Upper half-journal bearing 0.2% of babbitted surface 1% of babbitted surface

Lower half journal bearing 0% 0%

Zone A 2% of surface of zone A 1% of surface of zone A

Remainder of babbitted surface 2% of remainder of surface -
Total babbitted surface - 1% of total babbitted surface
Zone A zone of journal bearing between the vertical axis and the axis which forms an angle of 45 %
in the direction of rotation of the journal and which passes through the centre of the journal bearing.

4.2.3 Assembly and disassembly of the bearing and accessories

(1) Disassembly of the upper 1/2 bearings
See drawings 4-21～4-29.
—Disassemble the fixing screws and auxiliary of the upper 1/2 bearings
—At the joint contact surface disassemble the adjusted bolts (407) or (432), the washers (406) or
(431) and the nuts (404) or (429). (See drawing 4-23 and 4-24)

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—Disassemble the screws (403) or (430), the washers (406) or (431)
—Assemble the handling support (420), the tooling (317) on the bearing with the screws (315) (316)
(see drawing 4-22) —slightly lift the bearing to separate the shaft seal rings
—Move the bearing by means of the parting screws (433) or (408). Shift the 1/2 bearing by
slackening the hoist (3P) as soon as sufficient space is provided so as to avoid the rotor shoulder.
—Lower the bearings (4A) down on a wooden wedge
—Clean all the contact surfaces of the upper 1/2 bearings and protect them if necessary.
(2) Disassembly of the lower 1/2 bearings
See drawings 4-21～4-29.
—Coat the rotor supporting portions with plenty of tallow
—Assemble the dummy 1/2 journal bearing (306) or (307) between the rotor and the bearing.
—Assemble the dummy 1/2 journal bearing (322) or (323) by means of the collar (302), the spacers
(304), washers (305) and the screws (3E)
—Disassemble the fixing screws and auxiliary of the lower 1/2 bearings
—Separate the bearing by means of the screws
—Remove the parting screws
—Introduce a thin sling into the hole (3F) and fix the 1/2 bearing by a lifting lug and a shackle
screwed at the 1/2 bearing section, slightly stretch
—Fix a ring (3L) on the end shield bearing (3B), fix a hoist to this ring and to the lower 1/2 bearing,
slightly stretch
—By means of the crane and the hoist turn the bearing by 180°
—Secure the 1/2 bearing in this position by screwing both pins (334) into the end shield bearing,
passing them through the fastening holes
—Remove the sling and the hoist
—Sling the 1/2 bearing using the handling support (320) and the tooling (314), while following the
instructions on the support, slightly stretch
—Disassemble both pins (334)
—Disassemble the dummy 1/2 journal bearings
—Take the screws (3E) out and remove the collar (302), the dummy 1/2 journal bearings (322) or
(323) and (306) (307)
—Shift the 1/2 bearing by slackening the hoist (3P) as soon as sufficient space is provided so as to
avoid the rotor shoulder
—Lower the bearings (4A) down on a wooden wedge
—Clean all the contact surfaces of the lower 1/2 bearings (4A) (4B) (4C) and protect them if
necessary.
(3)Reassembly of bearing
See drawings 4-21～4-29.

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① Fit the lower half bearings
Fit the gaskets to the end shield on turbine end and to the intermediate ring on excitation end.
—Install the shaft seal rings. For this assembly refer to document chapter 4.2.4
—Install the half dummy journal bearing (322) or (323) in the bottom of end shield bearing fitted
with its collar (302).
—Carefully grease the rotor supporting surface.
Phase Ⅰ:
—Sling the lower half bearing by means of the handling support (320) and the tooling (314) and
(321) in accordance with the indications on the support.
—Shift the lower half bearing while slackening the hoist (3P). See drawing 4-21 and 4-22.
Phase Ⅱ:
—After having inserted the half bearing in the end shield, level the assembly back with the hoist
(3P).
—Slightly lift the assembly using the crane so that the copper insert (318) or (319) can be placed
between the oil seal supporting surface and the journal and install the half dummy journal bearing
(306) or (307) between the rotor and the half bearing.
—Lower the crane down until the half bearing is resting on the journal bearing.
—Secure the assembly in this position by means of the two pins (334) screwed through the end
shield bearing (3B) fixation holes.
—Remove all the handling tooling.
—Assemble the dummy journal bearing (322) or (323) by means of the collar (302) positioned in the
end shield with the screws (3E), washers (305) and shuns (304).
Phase Ⅲ:
—Fit a small sling in the hole (3F) and hang up the half bearing by means of a lifting ring and a
shackle screwed at the half bearing section; slightly tighten.
—Fix a ring (3L) on the end shield bearing (3B). Attach a hoist to this ring and to the lower half
bears. Slightly tighten.
—Remove both pins (334).
—To aid the rotation of the half bearing, slightly tighten the hoist and simultaneously slacken the
crane.
—Continue in this way until the assembly has rotated 180". The lower half bearing is in low
position.
② Transfer and fastening of the 1/2 bearing
—Lubricate the rotor on the movement surface.
—Install threaded rods (331) and two pin (334) through the bearing fixing holes, so that they are
diametrically opposed and screwed into the end shield.

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Parts list for drawing 4-21, 4-22

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3A frame 3B end shied bearing
3E collar fixing screws 3F vibration sensor holes
3I upper half bearing 3J lower half bearing (excitation end)
3L ring 3N shackle
3P hoist 302 handling collar
304 spacers 305 washer
306 dummy journal bearing φ450（excitation end）
307 upper dummy journal bearingφ420(turbine end)
310 screw 311 spring washer
312 screws 313 spring washer
314 handling tooling lower half bearing 315 screw
316 washer 317 handling tooling upper half bearing
318 copper sheet 319 copper sheet
320 handling support 321 dummy journal bearingφ450（excitation end）
322 upper dummy journal bearingφ420(turbine end) 330 tallow
331 threaded rod 332 nut
333 washer 334 pin
335 guide

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Parts list for drawing 4-24

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4A end shied bearing 4B frame
4C intermediate seal ring 4D contact surface of intermediate seal ring
421 screw 422 position pin
423 washer 424 nut
425 locking nut 426 screw
427 washer 435 collar
436 screw 437 spring washer
438 rubber sealing strip 439 collar
440 screw 441 washer
442 gun 443 plug
444 hole for shackle 446 bended tube
447 non return valve 448 rubber pad
449 rubber pad 450 bended tube
451 screw 452 locking washer
322 round washer

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—Fit 4 washers (333) and 4 nuts (332) on to the threaded rods.

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—Gradually tighten each nut so that the whole bearing can be transferred on to the rotor.
—Proceed in this way until the lower 1/2 bearing is in its final position.
—Install several bearing fixing screws with their fittings.
—Remove threaded rods, washers and nuts.
—Remove the lower and upper handling journal bearings and half collar.
—Remove the protective copper shim.
—Fit all the 1/2 bearing fixing screws and block them at 350 N.m.
③ Fit upper half bearings
—Position the shaft seal rings
To perform this assembly it is necessary to refer to document chapter 4.2.4
④ Assembly of the upper half bearings
See drawings 4-21～4-29.
PHASE I :
—Sling the upper half bearing by means of the handling support (320) and the tooling (317).
—Shift the upper half bearing while slackening the hoist (3P).
—Coat the contact surfaces with tight seal.
PHASE II:
—After having re-inserted the half bearing into the end shield, level the assembly back with the
hoist.
—Position the upper half bearing on the lower half bearing
—Fit the adjusted bolts (407) or (432), the washers (406) or (431) and the nuts (404) or (429) on the
joint contact surface.
—Remove the handling tooling.
—Fit the screws (403) or (430) and the washers (406) or (431)
—Clamp the screws of the joint contact surface (403) or (430)
—Fit all fixing screws of the upper 1/2 bearing and block the screws to 350 N.m.

4.2.4 Reassembly 、assembly and maintenance of the shaft seal rings.

(1)Disassembly of shaft seal rings
See drawing 4-30
—The upper and lower 1/2 bearings (4B) and (4D) are disassembled.
—Place the upper and lower 1/2 bearings in the horizontal position
—Apply a vertical force on each segment (401) in order to remove its shoulder from the seal body
—Remove the segment (401) or (402) thus freed
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—After having removed the upper segments (401) or (402), remove the springs (403) and (404) and
the pins (405).
(2)Reassembly of shaft seal rings
See drawings 4-30.
NOTE: Before assembly, we recommend that the rings are tested on an adjusting gauge.
—The lower and upper half bearings (4C), (4B) and (4E), (4D) are not assembled.
—Make sure that the segments (401), (402) and the springs (403), (404) are clean.
—Install the spring (403) at the turbine end and the spring (404) at the excitation end in the housing
of the shaft seal
—Assemble the pins (405) on each housing of the shaft seal.
—Stretch and hook each spring to the pins.
—Install the 4 lower and upper shaft seal segments (401), (402) while following the instructions
indicated on the pieces.
CAUTION:
The lower segments do no have slots
The upper segments are slotted.
—Check the correct position of the segment + spring set.
(3)Maintenance of shaft seals
See drawing 4-31
Ensure that there are no scratches on the contact surfaces of the shaft seal rings and supports. If there
are, remove by scraping.
Test the effective contact of each segment (3B) on adjustment gauge (3A). If necessary, correct the
geometry of the rings by scraping.
Assemble the segments of a ring on gauge (3A) and check that there is no clearance either where the
segments join or between any of the segments and the gauge.
Make any minor alterations as necessary where the segments join or on the contact surface of the
gauge.
Check the length of the lower and upper springs with respect to the drawing:
If there is an excess of over 5 mm with respect to the theoretical dimension, replace the springs.
(4) Storage conditions of shaft seal rings.
BSTG recommends that sets of sealing rings be stored available for overhauls or repairs.
These rings are delivered in a special packaging which it is advisable to leave intact. It shall not be
opened until the rings are required.
The spare rings shall be kept at a temperature as close as possible to 20℃.

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4.2.5 Reassembly 、assembly and maintenance of the oil deflectors
(1) Disassembly of oil deflectors and bearing closings
① Disassembly of outer oil deflectors
See drawing 4-32
AT THE CONTACT SURFACE:
—remove the adjusted bolts (450)
—remove the screws (446) and (444)
—Remove the screws (441) from the upper half oil deflector (4D)
—Separate the upper 1/2 oil deflector (4D)
—Remove the upper 1/2 oil deflector (4D) and put it on a wooden wedging
—Un-tighten the screws (441) of the lower 1/2 oil deflector (4E)
—While holding the lower 1/2 oil deflector, separate it in such a way that the positioning pins (443)
can be removed
—Remove the screws (441)
—Remove the lower 1/2 oil deflector (4E) and place it on a wooden wedging
—If need be, protect every contact surface
② Disassembly of bearing closings
See drawings 4-33 and 4-34.
At the contact surface:
—remove the adjusted bolts (466)
—remove the screws (464)
—Attach two lifting rings (303) fitted with their washers (304) to the holes of the upper 1/2 closing
(3A)
—Sling the upper 1/2 closing by means of shackles as indicated and slightly tension
—Unscrew all the screws (461) from the upper 1/2 closing (4K)
—Separate the upper 1/2 closing (4K) so that the positioning pins may be removed (463)
—Remove the upper 1/2 closing and place it on a wooden wedging
—Fit two lifting rings (303), themselves fitted with washers (304), into the lower 1/2 bearing holes
(3B)
—Sling the lower 1/2 closing (3B) by means of shackles (302) as indicated and slightly tension
—Unscrew all the screws (461) of the lower 1/2 closing
—Separate the lower 1/2 closing (4L)
—Remove the lower 1/2 closing and put it on a wooden wedging

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—Clean all contact surfaces of the end shield bearing (4M) and of the 1/2 bearing closings (4K) and
(4L)
—If need be, protect all contact surfaces
③ Disassembly of the inner oil deflectors
See drawings 4-35
—Remove the screws (423) from the upper 1/2 oil deflector
—Remove the upper 1/2 bearing (4A) following chapter 4.2.3
AT THE CONTACT SURFACE:
—remove the screws (425)
—remove the adjusted bolts (428)
—Remove the upper 1/2 oil deflector and place it on a wooden wedging
—Un-tighten the screws (423) of the lower 1/2 oil deflector
—Separate the lower 1/2 oil deflector and hold it
—Remove the screws (423) and rotate the 1/2 oil deflector into top position
—Remove the lower 1/2 oil deflector and place it on a wooden wedging
—Remove the seal (431)
—Clean ail contact surfaces of the bearing (4A) and (4B) and of the oil deflectors
—If need be, protect all the contact surfaces
(2) Reassembly of the oil deflectors and bearing closings
① Reassembly of the inner oil deflectors
See drawing 4-35、4-36
—Check that the contact surfaces are clean
—Glue the gasket (431) on the lower half oil deflector with glue (432)
—Coat the contact faces with sealing pulp
—Position the lower half oil deflector (4D) on the rotor (4C) and rotate it to the bottom position
—Fit the screws (423) and the washers (424) without blocking them
—Glue the gasket (431) on the upper half oil deflector (433) with glue (432)
—Apply sealing glue on the gasket (431)
—Assemble the upper half bearing in accordance with chapter 4.2.3.
—Fit the fixing screws (434/435) of the upper half oil deflector on to the upper half bearing
—Block all the screws (434) at a torque of 70 N.m
② Reassembly of the bearing closings
See drawing 4-33、4-34

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TURBINE END
—Check that the contact surfaces of the upper half closing (4K), the lower half closing (4L) and the
end bearing are clean
—Coat all the mounting with sealing pulp
—Install the lower half closing (4L) temporarily on a wooden block under the rotor
—Place two lifting rings (303) fitted with washers (304) into the holes of the lower half closing (3B)
—Sling the lower half closing (3B) with the shackles (302) as indicated and put it into position
WARNING: Make sure that the sling never touches the rotor
—Fit the screws (461) and the washers (462) but do not block them
—Remove the sling, the lifting rings (305) and washers (304)
—Place two lifting rings (303) fitted with washers (304) into the holes of the upper half closing (3A)
—Sling the upper half closing (3A) with the shackles (305) as indicated and put it into position
ON THE JOINT CONTACT FACE:
—Fit the screws (464), the washers (462) and the nuts (465) but do not block them
—Fit the adjusted bolts (466), the washers (462) and the nuts (465) and block them at a torque of
104N.m
—Remove the sling, the lifting rings (303) and washers (304)
—Tighten the screws (464) at a torque of 186 N.m
—Fit the screws (461) and the washers (462) but do not block them
—Fit the metal pins which are provided with the tooling
—Tighten all the screws (461) at a torque of 70 N.m
—Dismantle the metal pins and replace them with insulating pins (463)
EXCITATION END
The installation of bearing closings excitation end is carried out in the same way as turbine end. But
there exist insulation parts such as (474), (475), (476) along with the bolt tightening between bearing
closings and end shield bearing. Be careful during installation. Check the insulation condition
between bearing closings and end shield bearing after installation. If there exist short circuit, try to
eliminate it.

③ Assembly of outer oil deflectors

See drawing 4-32、4-36
TURBINE END
—Check that the contact surfaces are clean
—Coat the contact surfaces with sealing pulp
—Install the lower half oil deflector (4E)
—Fit the screws (441) and the washers (442) but do not block them
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—Fit the metal pins which are provided with the tooling
—Install the upper half oil deflector (4D)
ON THE JOINT CONTACT FACE:
—Install the supporting plates for the earth brushes (see chapter 5.3.3), fasten them by means of the
screws (447) fitted with washers (449) and nuts (44S) without blocking them, and bolts (450) fitted
with washers (446) and nuts (445).
—Fit the screws (444), the washers (446) and the nuts (445) but do not block them
—Tighten the screws (444) at a torque of 186 N.m
—Tighten the screws (447) at a torque 43 N.m
—Check the position of the oil deflector in relation to the shaft, in accordance with drawing 4-36
—Tighten all the screws (441) at 70 N.m
—Dismantle the metal pins and replace them with the insulating pins (443).
EXCITATION END
The installation of outer oil deflectors’ excitation end is carried out in the same way as turbine end.
Be careful that there exists a sealing pad (455) fitted on the contact surfaces between the outer oil
deflectors and bearing closings.

⑶Maintenance of the bearing oil deflectors

Maintenance of the bearing oil deflectors mainly consists of visual checks to ensure that the
deflector rings have not been knocked or damaged.
If they have, they must be replaced.
Make sure that no foreign bodies are blocking the oil outlets of the lower half oil deflectors.

4.2.6 Disassembly and reassembly of hydrogen guides (fan nozzle rings)

The hydrogen guides assembly includes: ventilation guides and fan nozzle rings. Rotor removal
necessitates the disassembly and reassembly of the fan nozzle rings turbine end and excitation end.
The winding cover, however, can be left in position. (See drawing 4-37)
(1) Disassembly of the fan nozzle rings
—Identify marks of the sectors concerning the fan nozzle ring
—Open locks (405) and (408)
—Remove screws (403), bolts (406) and remove locks (405), (408)
ON THE UPPER HALF FAN NOZZLE RING:
—Remove screws (413)
—Open locks (410)
—Remove screws (412) and locks (410)

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—Remove pins (409) using nuts (411)

—Remove 1/2 upper fan nozzle ring

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Carry out same operations for lower 1/2 fan nozzle ring.
(2)Reassembly of the fan nozzle rings
The reassembly of a fan nozzle ring requires the following to be carried out:
—Make sure contact surfaces are clean.
—Position the lower 1/2 fan nozzle ring and hold it by means of some screws (413) fitted with their
washers (414).
—Fit the pins (409).
Carry out same operations for the upper 1/2 fan nozzle ring.
—Fit the screws (403) fitted with their nuts (404) and locks (405). Do not block.
—Fit the bolts (406) fitted with their nuts (407) and locks (408). Do not block.
—Tighten fixing screws (413) to 40 N.m, (403) to 300 N.m, and (406) to 500 N.m.
—Check clearance j=1.5mm (theoretic value) between blades (4A) and fan nozzle ring (4B).
—If clearance j is not correct, remove pins (409). Untighten screws (413) and re-center fan nozzle
ring.
—Fit locks (410) onto pins (409).
—Fit nuts (411), washers (415) onto pins (409). Do not block.
—Fit and block screws (412).
—Fold back locks (410), (405) and (408).
—Fit retaining screws (413) fitted with their washers (414).
—Tighten remaining screws (413) to 40 N.m.

4.2.7 Disassembly and reassembly of axial alignment system tooling

(1)Disassembly of alignment key
Excitation end. See drawing 4-38
—Remove locking screw (407) of adjusting wedges (406)
—Mark adjusting wedges (406)
—Separate adjusting wedges (406) using parting screws
—Remove adjusting wedges
In practice, often one of the adjusting wedges (406) is loose and the other is more or less blocked.
If this happens, first remove the loose wedge.
If necessary, act on the lateral adjusting screw as shown in chapter 2.6.3.
The second adjusting wedge (406) can then be removed without difficulty.
This operation is the same for turbine end.
(2) Assembly of axial alignment system
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Excitation end (See drawing 4-38)
—ensure that contact surfaces are clean
—sling alignment device (401) and position it in relation to alignment plate (4A) and key (404)
—slot alignment device (401) into key (404)
—insert and block each screw (402) fitted with its washer (403)
—remove lifting ring and sling
—position adjusting wedges (406)
—block them with screws (407) and washers (408)
NOTE:
If generator alignment is altered, the wedges (406) should be adjusted according to the new position
of the stator.
TURBINE END
See drawing 4-39
—sling alignment device (401) and position it in relation to alignment plate (4A)
—fit screws (422) and washers (423). Do not block
—fit pins (424), washers (426) and nuts
—block screws (422)
—remove lifting rings and sling
—position adjusting wedges (427)
—block them with screws (428) and washers (429)
NOTE:
If generator alignment is altered, the wedges (427) should be adjusted according to the new position
of the stator
4.2.8 Disassembly and reassembly of bearing oil inlet and outlet pipes
(1)Disassembly of bearing oil inlet and outlet pipe
① Turbine end
See drawing 4-40
—Remove screws (412) and (415) from pipe (411)
—Disconnect pipework (411)
—Remove pipework (411) and place it on a wooden block
—Carry out same operation for pipe works (401) and (420)
—Remove screws (418) from compensator (417)

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—Separate compensator (417)

—Remove compensator and place it on a wooden block

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—Carry out same operation for compensators (408) and (426)
—Clean contact surfaces on lower 1/2 bearing (4A) and on end shield (4B)
—If need be, protect all the contact surfaces.
② Excitation end
See drawing 4-41.
—Remove screws (457) and (464) from pipework (456).
—Disconnect pipework (456)
—Remove pipework (456) and place it on a wooden block
—Carry out same operations for pipeworks (440) and (485)
—Remove screws (468) from compensator (467)
—Separate compensator (467)
—Remove compensator and place it on a wooden block
—Carry out same operations for compensator (453) and (484)
—Clean the contact surfaces on the lower 1/2 bearing (4A) and on the end shield (4B)
—If need be, protect all the contact surfaces
(2)Assembly of bearing oil inlet and outlet pipework
①Assembly at the turbine end
For this assembly, see drawing4-40
—Firstly it's necessary to give the contact surfaces of the 1 /2 bearing (4A) and the end shield
bearing (4B) a good clean.
—Position the seal (419) and the compensator (417).
—Position the screws (418) with their washers (413) and do not block.
—Do the same with the compensator (426) to be assembled with the seal (428) the screws (427) and
the washers (422) and with the compensator (408) to be assembled with the seal (410), the screws
(409) and the washers (403).
—Position the seal (414) on the compensator (417) and position the pipework.
—Place the washers (413) the screws (415) the nuts (416) and do not block.
—Position the second seal (414) on the 1/2 bearing (4A).
—Position the washers (413) and the screws (412) and do not block.
—Check that the seals (414) and (419) are correctly positioned as well as the correct alignment of
the compensator flanges and the pipework.
—After checking and any readjustment necessary, block the screws (412) and (418) to 58 N.m. and
the screws (415) at 155 N.m.

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Parts list for drawing 4-40 pipes –turbine end

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4A lower 1/2 bearing 4B end shield bearing

4C rotor shaft 4D journal bearing
401 oil inlet pipes for shaft seal 402 screw
403 spring washer 404 rubber sealing pad
405 screw 406 nut
407 rubber sealing pad 408 compensator
409 screw 410 rubber sealing pad
411 oil outlet pipes for shaft seal 412 screw
413 spring washer 414 rubber sealing pad
415 screw 416 nut
417 compensator 418 screw
419 rubber sealing pad 420 oil inlet pipes for bearing supply
421 screw 422 spring washer
423 rubber sealing pad 424 screw
425 nut 426 compensator
427 screw 428 rubber sealing pad
429 rubber sealing pad

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Parts list for drawing 4-41 pipes –excitation end

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4A lower 1/2 bearing 4B end shield bearing

4C rotor shaft 4D journal bearing
4E retaining ring 440 oil inlet pipes for shaft seal
441 screw 442 laminated tube
443 insulating washer 444 rubber sealing pad
445 spring screw 446 plat washer
447 insulating plate 448 screw
449 laminated tube 450 nut
451 rubber sealing pad 452 insulating plate
453 compensator 454 screw
455 rubber sealing pad 456 oil outlet pipes for shaft seal
457 screw 458 insulating tube
459 insulating washer 460 rubber sealing plate
461 insulating plate 462 spring washer
463 plate washer 464 screw
465 insulating tube 466 nut
467 compensator 468 screw
469 rubber sealing plate 470 screw
471 insulating tube 472 insulating washer
473 spring washer 474 plat washer
475 rubber sealing plate 476 insulating plate
477 screw 478 nut
479 insulating tube 480 rubber sealing plate
481 insulating plate 482 screw
483 rubber sealing plate 484 compensator
485 oil inlet pipes for bearing supply

—Do the same with the pipework (420) and (401) to be fitted with the relevant assembly
components (compensators, seal pads screws, nuts, washers etc.)
② Assembly at the excitation end
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For this assembly, see drawing 4-41
—Firstly, the contact surfaces of the lower 1/2 bearing (4A) and on the end shield bearing (4B)
must be cleaned.
—Position the real (469) and the compensator (467).
—Position the screws (468) with their washers (462) and do not block.
—Do the same with the compensator (484) to be assembled with the seal (483), the screws washers
(473) as well as for the compensator (453) to be assembled with the seal (455) the screws (454)
and the washers (445).
—Take two seals (461) and an insulating ring (460). Place the insulating ring between the two seals
and position everything on the compensator flanges (467) receiving the pipework (456).
—position the pipeworks (456), the laminated tubes (465), the washers (463), the washers (462),
the screws (464) and the nuts (466).Do not block the assembly.
—Take the other seals (461) and insulating rings (460) and position then between the lower 1/2
bearing (4A) flange and the pipework (456).Position the laminated tubes (458), the laminated
washers (459), the washers (463), the washers (462) and the screws (457). Do not block the
assembly.
(463) the washers (462) and the screws (457). Do not block this assembly.
—Check that the seals and the insulating ring seals are correctly positioned and than flakes and the
pipework are correctly aligned. After checking and necessary readjustment block the screws
(457) and (468) to 58 N.m. and this screws (464) to 155 N.m.
—Do the same for the pipework (485) and (440), compensator (484) and (453), fitted with their
respective assembly components and their seals with insulating ring
NOTE:
The screws fitted in the lower 1/2 bearing or in the end shield will be tightened to 58 N.m.
The screws fitted with a nut will be tightened to 155 N.m

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5. Generator detection and protection
5.1 Stator detection and protection
5.1.1 Temperature sensors for magnetic core, copper shield
(1)Thermocouples of magnetic core and copper shield
Thermocouples work as a temperature detecting component for magnetic core and copper shield.
The thermocouple is a device wherein the ends of two varies of different metals are soldered
together to form what is called a hot junction. When the hot junction is exposed to a heat source, a
potential difference is generated whose magnitude is proportional to the temperature of the source.
With the exception of the hot junction itself, the wires are insulated along their whole length from
each other and from the generator ground. The hot junction is insulated from the generator ground.
The index of thermocouples is K.
The following table gives the correspondence between the temperature and the potential difference
generated in different thermocouple.

For Nichrome-nickel silicon thermocouple (index: K):

T (℃) 0 10 20 30 40 50 60
E.M.F.(mV) 0 0.397 0.798 1.203 1.611 2.022 2.436

T (℃) 70 80 90 100 110 120 130 140

E.M.F.(mV) 2.850 3.266 3.681 4.095 4.508 4.919 5.327 5.733

T (℃) 150 160 170 180 190 200 210 220

E.M.F.(mV) 6.137 6.539 6.939 7.338 7.737 8.137 8.537 8.938

The material and color for the thermocouples:

Indexing number Material and color of anode Material and color of anode
K KPX(nichrome) red KNX(nickel silicon) black

The drawing 5-1 shows how the thermocouple is connected to the measuring device.

The thermocouple is thus protected by both the resistance (6) and the neon spark-gap (7).
As induction may produce a.c potential in the thermocouples, in order to ensure accurate temperature
measurement, the alternating (50Hz) parasitic component of the signal is filtered out by a filter
located within the measuring apparatus.
Each of the thermocouples in the generator can be put out of operation, in which case they are
connected on standby as shown in drawing 5-2.
⑵ Thermocouples of magnetic core
The highest temperature of magnetic core occurs at core end. The temperature detecting points of
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magnetic core are located at the predicted positions of highest temperature at either turbine end or
excitation end. Thermocouple is stuck onto the core end lamination. The core ends are fitted with 12
thermocouples, 2 for each phase at both turbine end and excitation end.

For magnetic core, the serial number of thermocouple at turbine end are 40 ～45, the serial number
of thermocouple at excitation end are 50～55, lead terminals are connected to electrical connectors
respectively, see drawing 5-6“lead-out of temperature detecting components”, and attached
documents”330MW generator temperature sensors layout instruction” .

The temperature indicated by these thermocouples must be below 100 °C, and must on no account
exceed 130°C。
(3) Thermocouples of copper shield
Copper shield works in order to avoid the stator endwinding overheat which is caused by magnetic
leakage from generator end structure. But at the same time copper shield may have overheat effect
because of eddy current by magnetic leakage. The strongest effect point which is caused by magnetic
leakage from generator end structure is located at internal circle of copper shield; the position of the
strongest effect is also the position of the highest temperature. The copper shields are fitted with 6 on
the turbine end and the excitation end, 3 for each end; equal-space distributed alone the
circumference.

The serial numbers of temperature detecting points of copper shield at turbine end are 37 ～39, the
serial numbers of temperature detecting points of copper shield at excitation end are 138 ～140, its
lead terminal is connected to electrical connectors respectively, see drawing 5-6“lead-out of
temperature detecting components” and attached documents“330MW generator temperature sensors
layout instruction”.

The temperature indicated by these thermocouples must be below 115 °C, and must on no account
exceed 150°C。

5.1.2 Temperature instrumentation between stator bars

Temperature detecting components are located at inside of inter-bar spacer which is between the top
bar and bottom bar inside stator slots.

There are 36 double-thermocouples for detecting temperature of stator winding, 1 for each slot. The
serial numbers are 1 ～ 36. The lead terminals of these 36 temperature detecting components are
connected to electrical connectors respectively; see drawing 5-6“lead-out of temperature detecting
components” and attached documents “330MW generator temperature sensors layout instruction”.

The temperature indicated by these thermocouples must be below 90 °C, and must on no account
exceed 120°C。

5.1.3 Temperature instrumentation of cooling water of stator winding

Stator winding is cooled by deionized water. After the heat of stator winding is taken away by
deionized water, temperature of deionized water will increase, the amount of increasing heat is
proportional to the heat situation of stator winding, therefore, by measuring temperature of deionized
water at outlet, the heat situation of stator winding can be estimated.
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The platinum resistance detectors for measuring temperature are of endface type. The detectors are
installed in the small joints (for detecting temperature) which are welded on the water joints on water
manifold for the insulated connection hose.
In the small joint, the detector is pressed against the inside bottom of the small joint by a spring
tightly. The endface of detector contact bottom of small joint very well, so the temperature difference
between them is very small, that is ,the temperature of detector is consider as that of outlet water
flowing through the water joint.
At excitation end (water outlet end), there is an insulated connection hose connected between water
manifold and every top or bottom stator bar. There is a water-outlet temperature detecting point for
each top or bottom stator bar. The serial numbers of water-outlet temperature detecting point at
bottom bar are 60～95, the serial numbers of water-outlet temperature detecting point at top bar are
96～131. The lead terminals are connected to electrical connectors respectively,
See drawing 5-6“lead-out of temperature detecting components” and attached documents“330MW
generator temperature sensors layout instruction”.

The temperature indicated by these platinum resistances must not exceed 85°C。In normal operation,
the temperature is no more than 65°C.
5.1.4 Temperature instrumentation of circular phase connections

The H.V connections, including the circular phase connections, like the stator bars, are water-cooled.
These connections are made of copper tube. As for the water circuit itself, the phase connections is
in series with H.V. intermediate connections and terminals, the cold water passing first through the
terminal from bottom to top, then into H.V. intermediate connections, then into the phase connection
and returning into the outlet manifold.(Please refer to the drawing 1-2).

There is total 6 water outlet of phase connections at excitation end. The phase connection and
terminal circuits are fitted with a total of 6 the platinum resistance detectors, i.e. 1 on each hydraulic
fitting leading into the water outlet manifold. The warm water temperature is therefore monitored at
the point where the Teflon hose meets the water outlet manifold.

The serial number of 6 temperature detecting points for outlet water of terminal leads are 132 ～137,
their lead terminals are connected to electrical connectors respectively, see drawing 5-6“lead-out of
temperature detecting components” and attached documents“330MW generator temperature sensors
layout instruction”.

The temperature indicated by these thermocouples is below 65°C during normal operation, and must
on no account exceed 85°C.
5.1.5 Temperature instrumentation of hydrogen

(1) Platinum resistance for measuring temperature of hydrogen

The platinum resistance for measuring temperature of hydrogen is exposed to hydrogen, so rigid
external jacket is necessary to protect the resistance. Drawing 5-5 shows the structure and
installation situation of platinum resistance.

This wiring method of platinum resistance is same as the wiring method of imbedded platinum
resistance. See drawing 5-3 and 5-4.
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(2) Temperature detection for hydrogen
Hydrogen is the coolant for rotor winding, stator core & stator end structures. The hydrogen is
circled in the generator under the action of the fans. During the circulation, hot hydrogen is cooled in
the coolers. The hydrogen cooler is located at the junction between hot hydrogen and cold hydrogen
inside the generator.

Inside generator, monitoring of cold hydrogen must run simultaneously with monitoring of hot
hydrogen. The temperature of hot hydrogen can show the heat situation of the parts which are cooled
by cold hydrogen, the temperature of cold hydrogen can show working situation of hydrogen
coolers. Generator has 2 cooling chamber, each chamber has 1 (2 groups) hydrogen cooler (see
2.1.3). 2 platinum resistances for measuring temperature of hot hydrogen and 2 platinum resistances
for measuring temperature of cold hydrogen are located at hydrogen inlet and outlet of 2 cooling
chambers respectively. The serial numbers of 8 temperature detecting components of platinum
resistance for measuring hydrogen temperature are 46 ～ 49 and 56 ～ 59, their lead terminals are
connected to the electrical connectors respectively, see drawing 5-6“lead-out of temperature
detecting components” and attached documents“330MW generator temperature sensors layout
instruction”.

Under condition of normal operation, the temperature of cold hydrogen indicated by these platinum
resistances should be blow 48°C, and that of cold hydrogen should not exceed 69 °C.
5.1.6 Leading-out of stator temperature instrumentation

Stator temperature instrumentations are lead out to outside of generator via the electrical connectors.
The electrical connector is an electric connecting component between inside and outside of
temperature detecting component machine. Because inside of generator is filled with high-pressure
hydrogen, the electrical connectors must have of hydrogen seal function in order to prevent
hydrogen leakage; there is a hydrogen seal structure at the position of installation.

Generator has 10 electrical connectors; each electrical connector has 68 contact points. To find the
corresponding components to each electrical connector contact, see attached documents“330MW
generator temperature sensors layout instruction”.

ATTENTION: there are ground contact points on electrical connectors, these contact points are
connected with external shield of components inside generator, in fact these ground contact points do
not contact with ground directly, and additional circuit is needed between the ground contact points
and ground.

Special bracket support which is provided by manufacturer must be used during installation, see
diagram 5-7.

5.1.7 Frame grounding

The magnetic fields present within the generator can give rise to variable potentials in the metallic
parts of the stator. Different levels of electric potential are induced by different levels of magnetic
field on accessories, therefore electric potential difference exists between different accessories, and
this potential difference may endanger the security of the personnel, and may produce electric spark
and electro-erosion.

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For safety of human and machine, the generator stator must be grounded credibly.
This is achieved by providing an electrical connection between the frame and the manifolds at
turbine end and excitation end including the U shape manifold beneath the terminal box during the
generator is in operation.

There are 2 rectangular ground bosses welded to the bottom of the frame. These 2 pillars are
grounded during generator installation; this structure makes the electric connection between frame
and ground and completes the process of stator ground.

The outer surface of these bosses is machined, so as to obtain a clean contact surface for electrical
connection. This is to guarantee stator ground works well.

5.2 Temperature instrumentation of journal bearing

5.2.1 The thermocouple with rigid sheath

Rigid protective sheath thermocouple works as temperature instrumentation for measuring

temperature of journal bearing, drawing 5-8 shows structure and installation of rigid protective
sheath.

The hot junction (2) of thermocouple is located at head of rigid protective sheath (1). The head of
protective sheath and detected parts (journal bearing babbait alloy for this generator) are getting in
touch or close to each other. The hot junction (2) is isolated from protective sheath (1) via insulation
cover (3). With the exception of the hot junction itself, the wires are insulated along their whole
length each other and from the generator ground. Fit the sensors on the support (5) (i.e. the outer
frame of the journal bearing for this generator) by nut-spring equipment (4), and leading-out wires
will be fitted on appropriate position of the generator frame (i.e. end shield bearing for this
generator) via wire connection socket (6).

Drawing 5-9 shows wiring installation of thermocouple.

5.2.2 Temperature instrumentation of journal bearing

Drawing 5-10 shows the structure of temperature detection of journal bearing at either turbine end or
excitation end. Thermocouple (401) is fixed on external surface of journal bearing (4C). The lead
wire is fixed up to the position below end cover by wire clips (402) and bolts (403). Lead wire is
connected to socket (408); the socket is fixed on flange (404) by bolts (411), washers (412) and seal
pads (405). Lead wire socket is also connected to measuring device.

Under condition of normal operation, the temperature indicated by these thermocouples must be
blow 105 °C, and must on no account exceed 120°C.

The operation situation of journal bearing can be estimated by measuring temperature of outlet oil of
bearing. The detailed method is in relevant turbine generator instruction.

Under condition of normal operation, the allowable temperature of outlet oil of bearing must be
65°C, and must on no account exceed 70°C.
5.2.3 Temperature instrumentation of restraining bearing

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Thermal couple is used to measuring temperature of restraining bearing. The thermal couple is in a
rigid sheath, and it has its own connector. The couple is inserted from one side of the bearing
pedestal to the position under the Babbitt of bearing, to see drawing 5-11. The couple is fastened on
the pedestal with its own bolt, nut and seal gasket. The terminals on the connector are for user to
connect the couple to the measuring instrument.
The oil temperature is also need to be measured at outlet of restraining bearing with a thermal
resistance. The oil outlet flange is at the pedestal side. The type of the resistance is WZP-231, Pt100.
The resistance is also in a protection sheath and with connector. The resistance is inserted from the
flange into pipe in which the oil flows back. The oil outlet can be measured directly. Same as the
couple, the Pt 100 resistance is provided with its own fastening device (bolt and nut) and seal gasket
with which it is mounted on the oil outlet flange. The resistance shall be connected to measuring
instrument from the terminals of connector.
In normal operation condition, the temperature of bearing shall not exceed 80℃, and the oil
temperature at outlet shall not be higher than 65℃.
5.3 Rotor detection and protection
5.3.1 Shaft vibration measurement
The shaft vibrations measurement will completed through two sensors which are vertical from each
other .see drawing 5-12.
Vibration sensors (3) is located on external surface of journal bearing (2).Through a hole in the
journal, it’s probe reaches to the position close to surface of the shaft (1). The signals obtained from
the sensors is transmitted to the device (9) via wires (4), and then connected to the control device of
measurement. Lead wires (4) are fixed by clamps (5), screws (6) and washers (7).

Shaft vibration sensors, lead wires and device are matched and will be supplied by turbine generator
contractor, detailed instruction is in separate specific manuals for turbine.

When generator is in condition of normal operation, magnitude of shaft vibration (peak-peak) should
be less than 0.08mm
5.3.2 Detection of interturn short circuit in rotor winding

(1) Special detector monitored detection of inter-turn short circuit in rotor winding (see drawing 5-
13)
The detector (1) can be introduced into the hydrogen-filled generator to the position close to the
shaft (2) surface by an air lock (3) which gives access to a hole provided in the frame. The probe is
installed inside an air lock (4), which is insulated from hydrogen. There are special windings on the
top end of the probe. The rotor fields can induce potentials in these windings. We can observe these
potentials through an oscillograph and judge the shape of the signal, then we can find out that
whether there is short-circuit fault in the inter-turn insulation in rotor winding.
(2) Disassembly and assembly of the probe (see drawing 5-14)
Remove the screw (405) and open the cover (403). Take care not to tension the connection wiring
between the connectors (402) and detector (401) when removing the cover403).

When do this, you can refer to related drawing.

Further steps of disassembly are included in attached drawings.
The assembly process is inverted the disassembly process. While installing the detector, rotate the
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detector so that the reference mark (E) on the base can be parallel with the longitudinal axis of
generator.
During dismounting and mounting the detector, be careful not to damage the detector coil and leads.
(3) Test for localizing and detecting inter-turn short circuits in the rotor winding
When generator is in operation, some abnormal phenomena (such as shaft vibration rise suddenly)
may produce due to the detection in the inter-turn insulation fault in rotor winding. In this case,
we can find out whether there is detection in the inter-turn insulation fault in rotor winding
through the detector.
① generator configuration
It is preferable to take this measurement when the rotor is running at rated speed; the effects of
centrifugal force are then taken into account.

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The test can be performed on a generator which is not connected to the grid. It is easy to achieve this
configuration, but on the other hand it is difficult to detect a minor fault, such as a single short-
circuit between two turns.
The test can also be performed on a generator on load. In this case, considerable modulations of the
signal occur due to the generator load angle.
It is recommended that this test be performed on a short-circuit generator. In this way the accuracy of
the measurement is improved and the distortions of the voltage signal observed during a test in open
circuit are eliminated.

② Measurement and record

The measurement consists in recording the output voltage by detector when close to the rotor in the
airgap.
The sensitivity of the detector can be adjusted by rotating it.
a. Generator in open circuit
The rotor is running at rated speed, at no load and is at rated stator voltage.
 Record the shape of the voltage wave produced by the tangential winding of the detector
 Analyze the recording
 For an abnormal voltage make two or three recordings while reducing the speed of the unit to
1000 r.p.m
NOTE: the excitation system must not be in the “regulation mode”; ensure that the exciting current
corresponds to the nominal voltage for operation in open circuit
 Once a speed of 1000 rpm has been reached, disconnect the generator field.
NOTE: the recording obtained shall be compared with a precious recording, to see if there has been
any significant change in the shape of the signal.
b. generator on load
There are no particular instructions for this test. All operating characteristics must be stabilized
during the test.
c. generator short-circuited
with the short-circuit fitted:
 start up the unit and stabilize it at rated speed
 excite the rotor up to 30% of the normal rotor current
 record the shape of the voltage wave produced by the two detector windings
 analyse the recording see paragraph③.
 for an abnormal voltage make two or three recordings while reducing the speed of the unit to
1000 r.p.m
 once this speed has been reached, disconnect the generator field.
③ Analysis of the recording
The recording of the voltage due to the leakage flux from the rotor slots is shown on drawing 5-
15.
a) Identify the polar (3D) and interpolar (3E).The damper slots correspond to the smallest
peaks (3F). (This does not apply to an open circuit test).
b) Measure the peak-to-peak voltage (×D) and (×G) of each half coil of each pole.
NOTE: the rotor slot (3M) is located between voltage peaks. Each slot therefore has two possible
voltage values; either may be selected initially, but the same one must be used throughout the
analysis.

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c. Plot the different values (as shown) on a graph and mark the polar and inter polar axes. For each
pole, values (XD) and (XG) must be the same.
d. Take the mean of the values measurement per coil for each pole. Compare the poles.
Any dissymmetry in the results indicates an inter-turn insulation defect.
NOTE: Results of an on-load test are analyzed as described above, but the generator load angle has
to be taken into account.
④ Localizing the short-circuit
If possible a fault should be localized by recording a signal identifying the position of the rotor
relative to the detector at the same time as the detector voltage signal. Since the position of the rotor
“blip” relative to the rotor axes is known, the fault can be localized easily.

5.3.3 Rotor grounding

Make the rotor ground reliably. It is one of main method to avoid the journal bearing and the shaft
damaged by current passing through the oil film.
Install an earth brush on turbine end to make the rotor ground.
The earth brush is fixed on the outer deflector at turbine end (see drawing 5-16).

Brush (409) and brush holder (401) are fitted onto a support plate (4A) which is bolted onto the oil
deflector. Link the joint (419) to twin brushes (418) with brush wires. A conductive braid connects
the boss to ground (see drawing 5-17). The cabling is protected by a thermoshrinking sheath and
fixed by wire clip (405).Wire clip (405) is fitted onto the outer oil deflector or welded on the frame.
A spring presses the brush down onto the shaft, the pressure exerted being constant throughout the
period of wear (so avoiding the need for pressure adjustment). See drawing 5-16.

5.3.4 Insulation of the bearing at excitation end

It is also one of main method to avoid the journal bearing and the shaft damaged by current passing
through the oil film.
For insulation of the bearing at the excitation end, it includes the following items:
 Insulation between bearing pedestal and end shield bearing;
 Insulation between oil pipe and bearing pedestal & end shield bearing
 Insulation between outer deflector and end shield bearing;
All these insulation will be realized by installing the insulated tube and insulated pad.
The status of the insulation may be measured by the special terminal.
(1) Insulation between bearing pedestal and end shield bearing .See drawing 5-18.
Journal bearing（2）、seal ring（10）and inner deflector（12）will be insulated from end shield
bearing(6) through the insulated ring（7）.The temperature sensors and the vibration sensors may
lead the journal bearing to ground. So all these sensors should be insulated.
Seal ring (6 ） must be insulated and must avoid the hydrogen leaking from the generator. For
this ,we supply the seal washers（8）and（9）。
(2) Insulation of oil pipe
The insulation between oil pipe and bearing pedestal will be realized through the insulated
parts （ 16 ） .The insulation between oil pipe and end shield bearing will be realized through
insulated parts（17）.
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(3)Insulation of outer deflector
There is a certain gap between oil deflector of the outer deflector and the shaft when assembly (see
drawing 4-36).There are insulated parts (14) between deflector and end shield bearing.
(4) Measurement of the insulation resistance
See drawing 5-19.
We name the special terminal （5）and （6） as terminal 1 and 2.Terminal 1 is connected with
bolt between oil pipe and bearing through lead wire (4), i.e. there are equivalent potential between
terminal 1 and bearing. Terminal 2 is connected with bolt between end shield bearing (4) and
insulated ring, i.e. there are equivalent potential between terminal 1 and end shield bearing.
This measurement requires a 500V meter.
At the situation of unit at standstill, oil circuit at standstill, the insulation resistance should be at
least 4KΩ.
At the situation of unit in operation, oil circuit in operation, the insulation resistance should be at
least 100Ω.
Compare the resistance between terminal 1 and earth, terminal 2 and earth.
When unit is at standstill, measure the resistance between terminal 1 and the shaft, terminal 2 and the
shaft, then compare them.
If the insulation resistance is lower, find out the defect and eliminate it.

5.3.5. Insulation of restraining bearing

There is insulation between the pedestal of restraining bearing and the seat box of brush gear. The
screws are insulated too from pedestal by insulation tube and gasket. There are insulation tubes and
gaskets between inlet and outlet flanges and tubes.

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Parts list for drawing 5-15 recording and analyzing of the voltage due to the leakage flux from
the rotor slots
3A pole A 3B Pole B
3D polar axis 3E interpolar axis
3F damper slot peaks
xD peak-peak voltage corresponding to 1/2 to coil x
(right hand part of coil x, pole A)
xG peak-peak voltage corresponding to 1/2 to coil x
(left hand part of coil x, pole A)
Note:
This diagram represents a rotor with 7 coils per pole and 3 dampers in the centre of the pole.

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Parts list for drawing 5-18 insulation of bearing at excitation end

1 generator shaft 2 journal bearing
3 clamping collar 4 bearing
5 end shield bearing 6 intermediate ring
7 end shield bearing insulation 8 hydrogen tightness seal
9 hydrogen tightness seal 10 shaft seal support ring
11 shaft seal ring 12 inner oil deflector of the bearing
13 outer oil ring of the bearing 14 insulation of outer oil deflector
15 oil pipes 16 insulation of bearing pipework
17 insulation of the end shield pipework

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6 Generator installation
The full description of generator installation is not included in this section; this section just describes
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some cases during the installation of generator.

6.1 General requirements

⑴ Before installing generator, the roof, walls and windows of the main workshop must be
completed and have well functions of water-proof and sand-wind-proof. The room temperature must
be at least 5℃ during the installation of stator.

⑵ Before the installation of generator, installation staff must familiar with the relevant drawings and
technical documents, staffs must count the amount of all parts and accessories and establish
reasonable and feasible technical and safety policy according to relevant standard and installation
regulation of large turbine generator.

⑶ Some components of generator must be subjected to special tests during installation of generator,
some of components need to be tested before installation. The details of special tests are not included
in this instruction.

⑷ All measurements, inspections and tests during installation of generator must have detailed
records, the copy of these records must be provided to workshop.

(5) During the installation of generator, every person who entering the generator must wear gumshoe
Brush and special uniform (no metal attachments). Metal and other dirt are not permitted to take into
generator, keep clear inside the generator at all time.

6.2 Generator installation procedures

⑴Foundation plate assembly
See section 6.3

⑵ Stator and terminal box installation

See section 6.4

⑶End shield bearing and winding cover-H2 fan nozzle ring installation.
See section 6.5.

⑷lower 1/2 bearing installation

See relevant parts and drawings of section 4.2.3:

5EG.012.425S end shield bearing assembly at turbine end

5EG.012.421S end shield bearing assembly at exciter end
5EG.048.026S lower bearing assembly
5EG.048.022S lower bearing assembly at excitation end

⑸ Rotor installation
See relevant parts and drawings of chapter 1-section 3.2:
5EG.487.079S rotor installation
5EG.487.069S rotor installation
5EG.487.047S rotor installation
5EG.487.048S rotor installation
5EG.487.049S rotor installation
The relevant parts and drawings about rotor overhung support are in section 4.2.1:
5EG.487.080S rotor external support assembly
Note: Before rotor being installed, the small shaft should be dismounted from rotor in order to
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install the tools. When small shaft is being assembled, measure the turn-off at the journal of small
shaft, and turn-off should not exceed 0.04 mm. After dismounting installation tools, reassembly the
small shaft.
⑹ Lower half bearing installation
See relevant parts and drawings of section 4.2.2:
5EG.264.142S journal bearing φ450 (turbine end)
5EG.264.143S journal bearing φ420 (excitation end)
5EG.048.023S journal bearing handling
5EG.048.024S journal bearing handling
5EG.048.025S journal bearing collar handling
⑺ Gas guide ring and blade installation
Gas guide ring installation, see the relevant parts and drawings of section 4.2.6:
5EG.013.213S Winding cover-H2 fan nozzle ring general layout
Blade installation, see the relevant parts and drawings of section 3.6.2:
5EG.217.528S Blade mounting
Check whether the gap between gas guide ring and blades is satisfactory to requirement after blade
installation.
⑻inner deflector installation
See the relevant parts and drawings of section 4.2.5:
5EG.012.432S covers assembly (excitation end and turbine end)

⑼upper1/2 bearing installation

See the relevant parts and drawings of section 4.2.3:
5EG.012.425S end shield bearing assembly at turbine end
5EG.012.421S end shield bearing assembly at excitation end

⑽upper 1/2 journal bearing and clamping collar installation

See the relevant parts and drawings of section 4.2.3:
5EG.264.142S journal bearing φ450 (turbine end)
5EG.264.143S journal bearing φ420 (excitation end)
5EG.012.425S end shield bearing assembly at turbine end
5EG.012.421S end shield bearing assembly at excitation end

⑾ Oil pipeline installation

See the relevant parts and drawings of section 4.2.8:
5EG.012.425S end shield bearing assembly at turbine end
5EG.012.421S end shield bearing assembly at excitation end

⑿detectors installation
This procedure needs to install the following detecting components:
①Journal bearing temperature detecting component –See the relevant parts and drawings of section
5.2.2:
F5000063S journal bearing thermocouple testing
②Shaft vibration detecting component - See the relevant parts and drawings of section 5.3.1:
5EG.421.204S bearing vibration instrumentation
③Bearing insulation measurement - See the relevant parts and drawings of section 5.3.4:
5EG.421.448S bearing insulation testing
④Grounding brush assembly - See section 5.3.3.
5EG.125.221S Grounding brush assembly
⒀ Hydrogen cooler installation
See the relevant parts and drawings of section 2.4.2
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5EG.487.030S generator cooler handling
0EG.340.534S turbine generator cooler installation

⒁ Stator filter installation

See drawing: 5EG.433.048S stator filter assembly
Attention: Stator filter is just a tool. Install the hydrogen cooler onto generator after installation of
stator filter, but do not fix and tighten the cooler with frame by bolts. After installing cooler seal
components and cover plate, let generator rotate for 4～6 hours without load, the solid grains inside
the generator will go toward the filter screen and attach on the filter screen before they go through
cooler. Open both end covers of cooler and remove the filter after filtration, and then clean the
attachment stuff. And re-assembly seal components and cover plate of cooler. Staff gets into man-
hole and bolting the cooler with guide track, staff also needs to tighten cooler from top.

⒂Outer deflector cover and bearing baffle installation

See the relevant parts and drawings of section 4.2.5:
5EG.012.432S covers assembly (excitation end and turbine end)

⒃Man-hole, hand-hole cover plate assembly

See drawing: 5EG.034.415S generator site assembly

⒄Brush gear and soundproof housing installation

See section 6.6.

⒅axial alignment plate and turbine coupling installation

Positioning of generator rotor shafting operates with turbine simultaneously, see turbine instruction.
Do position adjusting to stator after positioning of generator rotor, then grind the axial key of both
end based on the requirement of site installation and install axial alignment.
Position adjusting of stator, see relevant parts of section 2.6
Axial alignment plate and turbine coupling installation see the relevant parts and drawings of section
3.4:
5EG.020.453S axial alignment assembly
5EG.020.454S axial alignment assembly (for turbine end)
5EG.086.017S stator lateral adjustment
5EG.263.526S bearing adjusting device

⒆ Hollow copper intermediate connections, H.V. terminal bushings and current transformers
installation
See section 6.7

6.3 Foundation plate installation

─ Documents preparation
0EG.340.223S generator installation layout
5EG.020.688S foundation plate assembly
0EG.314.061S stator leveling and rotor alignment

─ Installation process
⑴ Do high intensity block technical experiment, determine the ingredient and facture. The high
intensity blocks is not allowed to shrinkage or expand after solidification, the resist-intensity of
block is at least 60MPa.

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⑵ According to the requirement of foundation plate assembly diagram, make sure the height mark
(150mm lower than the finished surface in this case) of base surface which at the place of high
intensity block. Carefully roughen the foundation concrete and remove all loose particles.

⑶ According to the requirement of generator installation layout, check whether the steel tubes to be
embedded are in the correct position to foundation bolts, also check whether the perpendicularity is
satisfactory to the requirement of assembly drawing.

⑷ According to the requirement of foundation plate assembly, place sub sole leveling plates to the
positions of item.3,.4,.5,.6, 7, 11 and 12 which are indicated in assembly diagram.

⑸ Remove the subsole leveling plates.

⑹ Replace the subsole leveling plates to the positions, according to diagram, install expansion bolts
No.25, nuts No.26 and washer No.27, but do not tight any components.

⑺ Install adjusting bolts No. 24 on every subsole leveling plate, and adjust the height of plates by
adjusting bolts according to the requirement of stator leveling and rotor alignment (0EG.314.061S).

⑻ Lock the bolts No.26 on every subsole leveling plate, and then check the height of every
foundation plate again.

⑼ Place model box at the place where is required to make high intensity blocks, and then cast high
intensity blocks.

⑽ Remove nuts No.26 and washer No.27, trim away the extra parts of expansion bolts No.25 which
is higher than subsole leveling plate. Meanwhile, the adjusting bolts (No.24) should not protrude
subsole leveling plate; trim the protrusion part if the extra part exists.

⑾Place each sole plate (No.2, No.9). According to drawing “generator installation layout”, check
the following items:
Check transverse and longitudinal position of each foundation plate;
Check the levelness and parallelism of side foundation plates;
Check the contact condition between foundation plate and accessorial sole plates;
Positive gradient of sole plate and centering condition of embedded steel pipe for anchor bolt are
need to be inspected according to the requirement of generator installation diagram. Adjust in time if
any requirement is not achieved.

⑿ According to the requirement of generator installation drawing, check whether the foundation
bolts for foundation plate (No.14) and embedded steel tubes are in the correct position, also check
whether the perpendicularity is satisfactory to the requirement of drawing.

⒀ Check whether the height of plate surface No.32 is correct and clean it up according to the
requirement of foundation plate assembly diagram.

⒁ Place plate of No.32 to specified position according to generator installation drawing, and then
check its height and levelness, place packing piece of No.28, 29 and 30.

⒂ Place plate No.14, inspect its transversal position, longitudinal position, height and levelness. The
error between height and levelness can be adjusted by adjusting packing piece No. 28, 29 and 30.

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⒃ Install 4 anchor bolts for installing plate No.14 (including Bolt No.31, plate No.23 and nuts
No.20). Adjust height of bolts in order to make nuts No.20 at t he upper position and stud (No.31))
end is lower than upper surface of plate No.14.

⒄ Tighten lower nuts (No.20) by a torque of 2500 N*m.

⒅ Apart from the anchor bolts which are for plate No.14 is installed in this process, other anchor
bolts which include anchor bolts for stator and anchor bolts for seat box for brush gear are installed
loosely (not tightened) after positioning of stator and seat box, these anchor bolts are tightened
according to the requirement of foundation plate assembly diagram after the adjustment of generator
position finished.

6.4 Stator and terminal box installation

─ Documents preparation
5EG.311.236S Seal cover for transporting stator
5EG.472.018S Handling trunnion general layout
5EG.671.876S Stator and terminal box positioning
5EG.020.688S Foundation plate assembly
0EG.340.223S generator installation layout
5EG.307.579S terminal box assembly
5EG.034.415S generator site assembly
5EG.086.017S stator lateral adjustment
─ Installation procedures:

⑴ Check the seal condition of joints of stator according to drawing 5EG.311.236S. Inspect if there is
any defects on stator which is caused during transport or storage.

⑵ Lifting the terminal box and lower it down to the generator pit.

⑶ Install 4 stator lifting trunnions according to the requirement of the drawing” handling trunnion
general layout” 5EG.472.018S, the side of lifting trunnion with plain surface should face down,
tighten the bolts between lifting trunnion and frame by a torque of 1200N*m.
The lifting trunnion should be removed before the operation of generator.

⑷ Carry the stator onto the required position of sole plate according to the requirement of generator
installation layout.

⑸ Place 4 jacks below the 4 generator lifting trunnions according to the requirement of stator and
terminal box positioning drawing 5EG.671.876S.

⑹ Lift stator by jacks, and place packing piece No.17 below the feet of stator frame according to
foundation plate assembly drawing, each foot needs 5mm. of packing pieces.

⑺ Set down stator. Install studs No.1, 8 and relative connecting components according to foundation
plate assembly drawing: nuts (No.15), washers (No.16), plates (No. 18) and nuts (No.19). Fasten
nuts gently (incompletely)
Tighten up the nuts completely after the adjustment of barb bolts at position of stator.

⑻ Install 4 lifting pulleys under frame according to the requirement of stator and terminal box
position drawing 5EG.671.876S, each lifting pulley has load capacity of 2t.

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⑼ Lift the terminal box to the installation position by lifting pulley.

⑽ Fix the terminal box onto the frame by using bolts (No.1) and washers (No.2) according to the
requirement of terminal box assembly drawing 5EG.307.579S.

⑾ Tighten the connecting bolts between terminal box and frame by using torque of 1000N*m.

⑿ Weld the contact surface between frame and terminal box in order to prevent hydrogen leakage.
All the process is according to the requirement of generator site installation drawing 5EG.034.415S.
Note：Terminal box installation: see appendix E。

6.5 End shield bearing and winding cover-H2 fan nozzle ring installation

─ Documents preparation
5EG.013.213S Winding cover-H2 fan nozzle ring general layout
5EG.012.425S End shield bearing assembly at turbine end
5EG.012.421S End shield bearing assembly at excitation end
─ Installation process:

⑴ When generator is taken from manufacturing workshop, the internal end covers (includes winding
cover and H2 fan nozzle rings) are installed inside generator stator. After the stator is in position, the
H2 fan nozzle rings should be removed in order to install rotor. The upper H2 fan nozzle rings
should be taken away and stored after disassembly and the lower ones should be placed temporarily
lower place inside generator. The lower ones are reinstalled after installation of rotor.

⑵ Inspect whether the internal end cover inside stator is in final and good condition according to
winding cover-H2 fan nozzle ring general layout 5EG.013.213S.

⑶Install end shield bearing at turbine end according to the requirement of end cover assembly at
turbine end drawing 5EG.012.425S. From this diagram, the end shield bearing at turbine end
consists of end shield bearing; lower half bearing, clamping collar, upper half bearing and so on. In
this working process, only end shield bearing (i.e. No.1 in drawing) and its relative parts are
installed, such as end shield bearing machining at turbine end, connection components and seal
components with frame, including 78 bolts No.44, 2 position pin No.45, 2 nuts No.13, 2 washers
No.14 and 50, injecting glue.

⑷ Install end shield bearing at excitation end according to the requirement of end shield bearing
assembly at excitation end 5EG.012.421S. From this diagram, the end cover at excitation end
consists of end shield bearing; lower half bearing, clamping collar, upper half bearing, and
intermediate ring and so on. In this working process, only end shield bearing (i.e. No.1 in drawing )
and its relative parts are installed, such as end shield bearing machining at excitation end, connection
components and seal components with frame, including 78 bolts (No.14), 2 position pins (No.6) , 2
nuts (No.4) , 2 washers( No.5) 2 washers (No. 7), injecting glue.

⑸ Install intermediate ring NO.18 and its connection components and seal components with end
shield bearing, such as bolts (No.43 ), backing ring No. 39, 38 and 40, 41, laminated tube No.42 and
seal rubber tape. If the intermediate ring is installed on the end shield bearing when the generator is
shipped from manufacturing workshop, it is needed to inspect the condition of assembly and
insulation.
NOTE: Seal between end shield bearing and frame, to see:
Appendix E: High terminal connection installation inside terminal box
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Appendix F Hydrogen cooling turbine generator—gas-tight components installation regulation in
site

6.6 Brush and soundproof housing installation

6.6.1 ─ Documents preparation
F1000003S overall assembly
0EG.314.061S stator leveling and rotor alignment
5EG.020.688S foundation plate assembly
5EG.125.241S brush gear assembly
0EG.340.223S generator installation layout
5EG.264.829S restraining bearing assembly
5EG.307.256S soundproof housing assembly
6.6.2 Seat box installation
⑴ check seat box. Before the seat box (No.4 in brush gear assembly drawing) being shipped, there
are conducting plates (No.5and No.9 in brush gear assembly), connection leads (No.10, 11), clips,
screws and so on installed inside it. Check if they are there, the insulation is none damaged and they
are fixed firm.
⑵ According to brush gear drawing, place the shims (No.12) on the sole plates on which seat box
will be installed.
⑶ Position the seat box. Adjust the seat box in lateral and longitudinal direction.
⑷ According to foundation plate assembly drawing, install the bolts, nuts, washers, and plate.
After finishing generator installation, tighten the bolts by a torque of 350 N*m.
6.6.3 Brush gear installation
According to foundation plate assembly drawing, install the fan cover and brush gear, make
sure that the clearance between lower edge of brush holder and surface of slip ring is 0.5~3.5mm.
The bare part of conducting plates, connection leads and their connection parts shall be wrapped
with insulation tape.

Adjust the position of conducting rings according to the position of slip rings. When installing
brushes, make sure the brushes near generator are 14 mm away from the end of slip ring in axial
direction, and the ones on the other side are 2 mm away from end of slip ring in axial direction( to
see the drawing). So, the brushes will be in the central portion of slip ring when generator is in
operation because of the expansion of the rotor shaft. It is required to grind the brushes before
starting the generator to rated speed so that they can contact slip ring well.
6.6.4 Restraining bearing installation
⑴ Restraining bearing is at the end of the whole generator shafting. The position of its pedestal
shall be adjusted and aligned together with the main journal bearing of turbine and generator in the
mean time the expansion and lift in the bearing of the shafting shall be taken in to account.
⑵ According to restraining bearing assembly drawing, place the lower half pedestal( No.3 ) on the
seat box, adjusting the shims between pedestal and seat box (No.34,35,36,37 ) to locate the central
line of the pedestal. Fix the pedestal on seat box with screws (No.30), insulation washers (No.31),
and insulation tube (No.32).
Note: The restraining bearing is an insulated one; the insulation part of above pieces must not be
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damaged during being installed.
⑶ Install lower half and upper half bearing(No.5), check the clearance.
⑷ Fasten the screws ( No.4) to fix the bearing, then install bearing cover(the upper part of
pedestal) and fix the cover and pedestal together.
⑸ Ream the hole for insulated pin(No.40), then install the pin.
⑹ Install the other parts according to the drawing. Install the oil pipes.
6.6.5 Soundproof housing installation
⑴ Position the soundproof housing according brush gear assembly drawing. Make sure that the
clearance between shaft and wind deflector which is mounted at inner side (near generator) of
soundproof housing evenly.
⑵ According to diagram C in soundproof housing drawing, mark the position of 11-Ф14 holes.
⑶ Take away the soundproof housing, drill 11--Ф14holes, install the expansion bolts(No.15).
⑷ Position the soundproof housing again and fix it on the foundation with expansion bolts.
⑸ According to soundproof housing drawing, mount the doors and their attachments.
⑹ Fix the wind deflector.

6.7 High voltage terminal installation

6.7.1 High voltage bushing installation

NOTE: the high voltage bushing installation see appendix F “Hydrogen cooling turbine
generator—gas-tight components installation regulation in site”

⑴ Preparation
．Tools for installation

⑵ High voltage bushing installation

① Installation of 2 high voltage bushings in the middle of terminal box.

． Install 2 M16 hookers whose diameter is fitted to locking device.
． Fix 2 lifts on terminal box where the high voltage is installed.
． Lift high voltage bushing by crane to the place below terminal box or lift high voltage bushing to
a lower place and then lift it up to the place below terminal box.
．Connect high voltage bushing to the first lifter
．Remove the crane from the high voltage bushing while pull the high voltage bushing tightly with
lifter, then lift the high voltage bushing until it reaches center position.
．Use the second lifter to undertake the weight of high voltage bushing
． The 2 lifters working simultaneously until the high voltage bushing is assembled with 2 studs,
washers and nuts.
Attention: do not forget to put O seal ring before installation of high voltage bushing.
．Tighten the nuts and lift the high voltage bushing to final position (the lifters lift the high voltage
bushing gently during this step)
．Put stud go through locking hole.
．Guarantee the position of washer is correct.
．Install the high voltage bushing at suitable position.
．Use specific bolts to fix the high voltage busing
．Remove the stud which is used before.
．Lock the high voltage bushing tightly.
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② High voltage bushing of side surface installation

．Use the same method as above to fix high voltage busing
．Use lifter to undertake the weight of high voltage bushing
ATTENTION: Do not forget to put O seal ring before installation of high voltage bushing.

．Use lifter to lift up the high voltage bushing until the studs, washers and nuts can be assembly to
the bushing
．The movement of high voltage bushing can be adjusted by hands; the movement adjustment also
can be made by the tools which are fixed on the locking device. The adjustment is stopped until the
high voltage bushing reaches the final position.
．Lift the high voltage bushing up to its position and tighten nuts.
．Guarantee the position of washers is correct.
．Fix high voltage bushing by bolts
．Use corresponding bolts to fix the whole high voltage bushing.
．Lock high voltage bushing tightly.

6.7.2 Current transformer and water manifold installation

⑴ Water manifold installation

．Make sure the water manifold is at the place below terminal box
ATTENTION: Before welding the bottom manifold, the high voltage bushing must be protected
to be damaged by welding spark.
．Prepare the fixing support of manifold and manifold
．Install manifold and adjust its position
．Weld the support
．Non magnetic welding rod, welding seam a=5

⑵ CURRENT TRANSFORMER INSTALLATION

ATTENTION: Current transformer must be installed manually to avoid any kind of stress or
vibration.

① Preparation:
．Clean flange holes, studs and nuts carefully by solution
．Before installation, locking nuts should be installed on the stud which fix current transformer.
．Install stud with torque of 89Nm
．Lay on propylene polymer to thread.
．Put stud go through fixing flange, and use nut to lock it tightly.

②Current transformer installation:

．Set up the nuts onto the studs.
．Install current transformer carefully onto stud.
．Fix components detection device, tighten up locking nuts when the size is satisfied to requirement
of drawing, stop tightening until all components are tightened.
⑶ Half bushing end flange installation

．Inspect the contact surface of bushing end flange and the surface of silver plating on thread which
contact with high voltage bushing.
．Install and adjust the relative position between bushing end flange and high voltage bushing. Link
two half bushing end flanges together by using bolts.
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⑷ The installation of insulated water hose which is between high voltage bushing and manifold.

6.7.3 Intermediate connection installation

Gas tightness test and hydraulic pressure test should be done with the stator water circuit system
before connecting intermediate connection with the stator phase lead.
See Appendix E: High terminal connection installation inside terminal box.

NOTE:
The detailed installation process, to see:
Appendix E: High terminal connection installation inside terminal box
Some tests must be made before operation of generator, do water pressure test and air tight test to the
whole winding water system, after these tests, do water flow rate test, insulation resistance detection,
DC withstand-voltage test, DC leakage test and AC withstand-voltage test. Do ventilation test before
installation of rotor, do AC impedance measurement after installation of rotor. Hydrogen leakage test
is made at the final stage.

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7 Generator operations

This section describes some questions during the operation of generator. The detailed operation rules
will be written by the user itself.

7.1 Starting the unit

Before starting the unit, verify that all faults on each system have been cleared.
Before starting the unit, the auxiliary systems must be put in service in following order:

(1)Sealing oil control system

The lubricating oil system must be first in service.
The sealing oil systems must be in complete operation before running the unit on turning gear and
put the stator in hydrogen pressure.
The process of starting the sealing oil system is described in the specific manual of sealing oil
control system.

(2)Hydrogen control system

Hydrogen control system cannot be in operation until the sealing oil control systems have been in
complete service.
During starting the hydrogen control system, replace the air with carbon dioxide (CO 2), and then
replace the carbon dioxide (CO2) with hydrogen.
The process of starting the hydrogen control system is described in the specific manual of hydrogen
control system.

(3)Stator cooling water control system

This system can be only in service after the generator has been filled with compressive-hydrogen,
besides that all parts of cooling water system must experience all kinds of special tests.
ATTENTION: close the water outlet valve before starting the water pump, and then open the
valve gently in order to avoid damage from impact of high-pressure water to stator winding and
pipelines.
The process of starting the stator cooling water system is described in specific manual of stator
cooling water system.

(4)Hydrogen cooling system

The cooling water system of all coolers must be in service.

(5)The cooling system of the excitation equipment

The cooling system of excitation transformer, power rectifier and excitation adjuster must be in
service.
The detailed items are described in the specific manual of excitation system.

(6)Excitation and regulation system

Refer to the specific manual of excitation system.

7.2 The unit shut-down

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After tripping the unit, the main breaker being opening (generator disconnected from the net
work), and the auxiliary systems can be stopped in the following order:

1 Excitation and regulation system

The excitation breaker is automatically open when the turbine generator unit is tripped.
ATTENTION: In any case the excitation system cannot be in service, if the generator speed is
being decreasing or at standstill.

2 Hydrogen control system

FIRST CASE: the duration of the stop is short, and there is not any intervention to do in the
generator, the stator is maintained in hydrogen at the normal pressure.

SECOND CASE: the duration of the stop is short, but the stator has to be visited, the hydrogen
is drained, replaced by CO2 and then by air.

THIRD CASE: for the conservation in the other cases of stop, see the manual section 2.3 and
section 3.3

Generally, if the duration of the stop is long, the generator stator should be filled with hydrogen,
pressure higher than atmospheric pressure or be filled with dry air, pressure higher than the
atmospheric pressure (the minimum pressure is 0.1MPa). This is the best conservation.

3 Sealing oil control system

Sealing oil control system can only be stopped when the stator is filled with air at atmosphere
pressure, and the unit is at standstill.
At this time, the sealing oil system must be in operation, it is very important to avoid humidity
entering the stator.

4 Stator cooling water control system

If the stator is still on H2 pressure and the duration of the stop is short, the system has to be kept in
normal operation. This is the best conservation. If the duration of the stop is long, the unit should
be shut down. The system must be put out of service.

ATTENTION: Never stop this system when the field breaker is closed.

5 Hydrogen cooling system

6 Excitation equipment cooling system

7.3 Monitoring in operation

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⑴ Excitation and regulation system

The setting values of the excitation system are not permitted to change during operation of the
unit. The operation point is the only factor which is permitted to change according to the
dispatcher’s requirement during the operation of unit, i.e. change the setting values of the
generator voltage. The detailed description is included in specific manual of excitation system.

2 Stator temperature monitoring

During normal operation of unit, the normal temperature is as following:

Stator core 100℃

Copper shield 115℃
Between stator winding 90℃
Outlet water of stator winding 65℃
Outlet water of stator lead 65℃
Cold hydrogen 48℃
Hot hydrogen 70℃

⑶ Journal bearing temperature monitoring

Bearing Babbitt layer temperature ≤110 ℃
Outlet oil temperature of lubricating oil ≤65 ℃

⑷ Shaft vibration (peak-peak) ≤0.08 mm

⑸ Sealing oil system

Oil /H2 differential pressure（oil pressure is higher than hydrogen pressure） 0.05 MPa
The detailed descriptions see the specific manual of sealing oil control system.

⑹ Hydrogen control system

hydrogen pressure 0.3 MPa（g）
Hydrogen purity ≥96 %
The detailed descriptions see the specific manual of hydrogen control system.

7 Stator cooling water control system

Water conductivity at stator inlet 0.5～1.5 μS/cm

The detailed descriptions see the specific manual of stator cooling water control system .

7.4 Alarm and treatment

7.4.1 Stator winding temperature alarm and treatment
Alarm is activated by setting the stator winding temperature at one of the following cases:

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(1) The temperature of any stator winding is higher than 90℃

(2) The temperature of any stator winding water-outlet is higher than 80℃

(3) The standard deviation of each bar is higher than 5 ℃ in case of the standard deviation of top
bar and bottom bar is calculated separately.

The calculation method of the standard deviation of outlet water is as following:

Standard deviation from the average of the top bars:

T1= [∑ (Ti1-TM1)2÷36]1/2
Ti1（i=1～36）——temperature from the top bars ℃；
TM1——average temperature of top bars ℃；

Standard deviation from the average of the bottom bars:

T2= [∑ (Ti2-TM2)2÷36]1/2
Ti2（i=1～36）——temperature from the bottom bars ℃；
TM2——average temperature of bottom bars ℃；

⑷If the standard deviation 2T1（top bars）≤ 5 ℃

2T2（bottom bars）≤ 5 ℃
Then the outlet water temperature of each bar:
Ti1（upper bars） > TM1+5 ℃
Ti2（bottom bars） > TM1+5 ℃
If the standard deviation 2T1（top bar）> 5 ℃
2T2（bottom bars）> 5 ℃
Then the outlet water temperature of each bar:
Ti1（top bar） > TM1+2T1 ℃
Ti2（bottom bar） > TM1+2T2 ℃
If the stator winding temperature is too high, the possible cause maybe:
① the generator is over-load；
② the deionized water temperature is too high；
③ the de-ionized water flow rate is not high enough；
④ some certain hollow copper strands are blocked。

Treatment after alarm: firstly, analyze the cause that makes high temperature of stator winding.
Take specific measures to eliminate the defects, such as reduce the generator load or eliminate the
fault in the pipeline of deionized water. If the temperature is too high as a result of the certain
hollow copper strands are blocked, monitor the temperature to avoid reaching the upper limit level
of temperature, and solve the problem when the unit is shut down.
If the measure after alarm is void, the temperature of stator winding increases continuatively, trip
should be made immediately when the temperature of any component of stator winding
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interlamination reaches 120 ℃ or the temperature of outlet water of stator winding interlamination
reaches 85 ℃.

7.4.2 Hot hydrogen temperature alarm and treatment

The alarm should be activated immediately if the temperature of hot hydrogen is higher than 70 ℃

The possible cause that makes the temperature of hot hydrogen high may be:

1 generator over-load；
2 cold hydrogen temperature is too high；
3 hydrogen flowrate is not high enough as a result of gas circuit fault；
4 over leakage of hydrogen；
5 over low-pressure of hydrogen

Treatment after alarm: find out the exact cause, and then take specific measures to eliminate the
defects. If the hot hydrogen temperature maintains high, reduce the generator load to maintain the
hot hydrogen temperature below 60 ℃ and solve the problem when the unit is shut down.

7.4.3 Cold hydrogen temperature alarm and treatment

The alarm should be activated if the hydrogen temperature is higher than 55 ℃ .If the temperature
increases continuatively, the unit should be shut down and check the cooler.

If the hot hydrogen temperature is proper, abnormal condition of coolers operation is the main
cause to make the cold hydrogen temperature too high.

The causes that make the cooler operating in abnormal condition:

(1) Cooling water pipe is blocked
(2) The temperature of second cooling water is too high
(3) Flow rate of second cooling water is not high enough

Treatment after alarm: find out the exact cause, and then take specific measures to eliminate the
defects.

7.4.4 Stator core end structure and copper shield temperature alarm and treatment

Alarm should be activated immediately if either temperature of stator core end is higher than 120
℃ or copper shield temperature is higher than 150 ℃.

If both the following cases take place:

If both the following cases take place:

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 the stator core temperature rises while the copper shield temperature rises ,
 the temperature in the middle of stator core rises while the temperature at the end of stator core
rises

It is usually caused by generator over-load or drop of cooling efficiency of the cooler. The causes
and treatment for cooling efficiency drop of the cooler see section 7.4.2 and 7.4.3.

If only the end structure temperature rises while the copper shield temperature rises, it is usually
caused by the generator end flux leakage. Check and find out whether the generator operates within
the range of the drawing 1-5 and 1-6. Reduce the reactive power of leading phase operation to make
the temperature of stator core end and flux shield maintain within proper range.

The trip should be made immediately if the stator core end temperature reaches
130 ℃.

7.4.5 Journal bearing temperature alarm and treatment

Alarm should be activated if temperature of journal bearing is higher than 110 ℃
Alarm should be activated if temperature of outlet oil of journal bearing is higher than 70 ℃.
If the temperature of bearing Babbitt alloy layer rises, the lubricating oil temperature or the oil flow
rate maybe abnormal. Take specific measures to eliminate defects. If the temperature of bearing
Babbitt alloy layer doesn’t drop, monitor the unit operation strictly. The trip should be made
immediately if the temperature reaches 120 ℃.

7.4.6 Shaft vibration alarm and treatment

Alarm should be activated when magnitude of shaft vibration reaches 0.12mm.

High temperature of journal bearing may cause increase in magnitude of shaft vibration. If the
magnitude of shaft vibration is high while the temperature of bearing bush is at standard value,
reduce the generator load until the load reaches zero. Mechanism imbalance is the reason to make
high magnitude of shaft vibration on generator under zero-load. If the magnitude of shaft vibration
increases suddenly while the generator operates, the reason maybe from interturn fault in rotor
winding. Check the problem by detector, see section 5.3.2.

If the magnitude of shaft vibration still increases, trip should be made immediately when the
magnitude of vibration reaches 0.24mm.

The online monitor and protection see the following:

No item unit Normal value Alarm value Trip value

1 Temperature sensors between stator ℃ ≤ 90 ＞ 100 ＞ 120
winding
2 Stator outlet water temperature ℃ ≤ 65 ＞ 80 ＞ 85
sensors
3 Hot hydrogen temperature sensors ℃ ≤70 ＞ 75
4 Cold hydrogen temperature sensors ℃ ≤ 48 ＞ 58
5 Stator core temperature sensors ℃ ≤ 100 ＞ 120 ＞ 130
6 copper shield temperature sensors ℃ ≤ 115 ＞ 150
7 Journal bearing sensors ℃ ≤ 105 ＞ 110 ＞ 120

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8 Outlet oil temperature of sensors in ℃ ≤ 65 ＞ 70 ＞ 80
journal bearings
9 Restraining bearing Temp. ℃ ≤ 90 ＞ 100 ＞ 120
sensor
10 Outlet oil temperature of sensor in ℃ ≤ 65 ＞ 70 ＞ 80
restraining bearing
11 Shaft vibration detector mm ≤ 0.08 ＞ 0.12 ＞ 0.24

7.5 Other protection items

The other protection items should be made by the user.

The protection items described in section 7.4 are essential and compulsory for generator.
Besides above projects, the following protection items must be made for generator.
1 differential protection；
2 rotor ground protection；
3 stator over-voltage protection；
4 stator over-current protection；
5 voltage balanced protection；
6 current balanced protection；
7 phase sequence protection；
8 under-voltage protection；
9 stator ground protection；
10 inverse power protection。

The rated values of above protection items shall be made by user according to the generator
technical data given in section 1. We recommend some protection values as following:

No Item Setting value Delay Operating Note

1 Difference protection 10% In ⑵+⑶+⑷+⑹ In = 9339 A
100% ground
2 Stator ground protection ⑵+⑶+⑷+⑹
protection
3 Over-load protection 1.1 In 20 s ⑸
4 Max. stator current 1.25 In 6s ⑴
protection
Stator current 8% In 5s ⑸
5
unbalanced protection 12% In 8s ⑴
6 Over-voltage protection 1.1 Un 5s ⑸ Un = 24 kV
7 Max. stator voltage 1.2 Un 3s ⑵+⑷
protection
1.07 Un /fn 5s ⑸ fn = 50 Hz
8 Max. flux protection
1.15 Un /fn 3s ⑵+⑷
9 Mini. voltage protection (0.7 Un) （3s） ⑴ Reference value
1.2 Xd Xd = 1.628
10 Field-loss protection 3s ⑵+⑷
0.5 X’d X’d = 0.306
11 Inverse power （1% Pn） （3s） ⑵+⑷ Reference value ， see
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No Item Setting value Delay Operating Note
protection turbine manual
Max. frequency Reference value ， see
12 (47.5 Hz) （3s） ⑴
protection turbine manual
Max. frequency Reference value ， see
13 (51 Hz) （3s） ⑴
protection turbine manual
14 Out-of-step protection Slide 5 poles ＜5min ⑴

Operation Symbol description：

⑴ Disconnected from the grid
⑵ Generator shut-down
⑶ Turbine shut-down
⑷ Excitation shut-down
⑸ Alarm
⑹ Stator winding cooling water system shut-down

The protection requirements of the auxiliary systems are described in the specific manual.

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Appendix A: Visual examination and dye penetrate examination of journal bearing

1 Glossary of dye penetrate examination indications

1.1 Circular indication

Ratio of indications length and indications width is less than 3

1.2 Linear indication

Ratio of indications length and indications width is more than 3

1.3 Single indication

Apart from isolated indications, if the distance between edges of two neighboring indications is
equal or less than 2mm, the outboard envelope curve of these two indications forms a single
indication.

1.4 Group indication

If the number of indications is more than 3 per square centimeter, these neighboring indications form
group indications.

2 Technical requirement

2.1 Visual examination

 No cracks on surface
 No fault is permitted at lower bearing carrying zone
 Faults on other zones:

a. The unit quantity of indication whose diameter is less than 0.5mm and depth is less than
0.5mm, should be less than 3 per cm 2. This position whose unit quantity of fault is equal to 3
per cm2 should be less than one every 200 cm2.

b. The number of faults whose diameter is less than 1mm, depth is less than 1/3 of bearing
Babbitt alloy layer depth at the place of the fault and depth is less than 1mm is not more than
1 for every 200 cm2. If two faults occur at the same surface, the distance between centers of
faults should be more than 10mm.

2.2 Dye liquid penetrate examination to surface of journal bearing

No indications is permitted on lower carrying zone of journal bearing

Regulation of dye liquid penetrate examination to other zone:

a. No linear indications, crack indications and dense indications are permitted.

b. The situation for the indication whose diameter is less than 0.5 mm and depth is less than
0.5mm, and the unit quantity of indications is equal to 3 per cm 2, may occur at most once for
every 200 cm2.

c. The number of the indications whose distance in between is more than 10mm, diameter is

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between 0.5mm and 1mm, depth is less than 1/3 of tungsten layer depth of the place of the
fault and depth is less than 1mm, is at most 1 within every 200 cm2.

NOTE: Lower load zone of journal bearing is the area whose range is 90 degrees as the center is
perpendicular center line of lower bearing as centering line.

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Appendix B Hydrogen cooled turbine generator sealing glue usage

1 Sealing glue operation condition

1.1 Long-time operation immersed in hydrogen, the sealing glue has good gas-tightness.

1.2 Long-time operation temperature -40～+100oC.

2 Sealing glue technical condition

2.1 Possible operating medium: water, oil, hydrogen and air

2.2 Operating temperature: -40~+100oC

2.3 Age: more then 10 years

3 Sealing glue service instruction

3.1 The glue SWG-1 is used in seal groove, plain surface beside seal groove is coated with glue
SWG-2.SWG-2 is used on flange surface, joint surface and other plain surface.

3.2 Carefully inspecting before installation, make sure seal groove and seal plane are tidy. No burrs,
oil dirt and rust are allowed to exist. No dust, oil dirt, scales and so on exist at installation site.

3.3 Installation process

3.3.1 Plane seal: before assembly, lay on SWG-2 sealing glue uniformly to seal plane.

ATTENTION:
A. Inspect and clean the bush dust or other dirt on the glue layer
B. place the seal plane in horizontal level
C. Wait for a moment after gluing, and then assembly when glue stops flowing.

3.3.2 Groove sealing

A. Lay on SWG-2 sealing glue at the beginning on the seal surface beside groove
B. Do the procedures of 3.3.1 for assembly
C. Injecting SWG-1 sealing glue into first hole, and using screw to block up the first hole
when the glue neighbor holes is discharging, then injecting sealing glue into second
hole, do the same procedure until the last hole is blocked up.

4 Maintenance

During the generator operation, injecting glue if any gas leakage from end shields bearing happens.

5 Overhauls

5.1 General inspection about situation of integrity, make sure no dirt exists after open of seal groove
and plane seal
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5.2 Remove the film of sealing glue and clean seal surface

5.3 Cover sealing glue and seal surface with thin film

5.4 Do assembly by following procedures of section 3

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Appendix C Storage condition of insulation material for installation

Storage of standard insulating tape and insulating material for generator site installation is included
in this section.

1. General requirements: insulating material should be stored in dry and clean warehouse. The
insulating material should be kept away from fire, heating device and sun light.
2. Storage condition: in original pack and start from the date of manufacturing

Below 5℃ storage for 6 mouths

Below 20 ℃ storage for 3 mouths
20℃ -30 ℃ storage for 90 days

Generally, it is better to store the material at 5 ℃

ATTENTION: if the temperature of storage for mica products is blow 10 ℃, the products should be
placed under specific temperature range (10-35 ℃) for at least 24 hours before use.

3. Solventless epoxy glue 53841YQ

Storage period of single group is 2 year if the product is in original pack and at room temperature of
20 ℃.

Using up the mixing glue within 1 hour after mixing 2 single group

4. Epoxy glue

Storage period under room temperature is 6 mouths if the product is stored in dry and ventilated
warehouse

5. Glue injected in insulation box

Storage period of single unit is 1 year if the product is in original pack and at room temperature of 20
℃.

Using up the mixing glue within 1 hour after mixing 2 single group

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Appendix D Calculation of perpendicular distance between arc and chord for centering by
steel wire

Using steel wire for centering, the numerical value of perpendicular distance between arc and chord
of steel wire should be corrected during measuring. The formula is as following:

Fx——perpendicular distance between arc and chord, mm

fm——maxi. perpendicular distance between arc and chord, mm

mp——mass of steel wire unit length, g/m

mW——suspension mass, kg

x——distance from steel wire fixing point to point of perpendicular distance between arc and chord
to be measured, m
2L——distance between two fixing points of steel wires, m

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Appendix E High terminal connection installation inside terminal box

A、Terminal box assembly

1、 Terminal box should be carried to the pit below the stator before the stator in working
position.
2、 Prepare all parts according to drawing 5EG.307.579S (terminal box assembly).
3、 Clean-up: the joint surface between terminal box and frame, the joint surface between
terminal box and high-voltage bushing, inside of terminal box.
4、 Position the stator.
5、 Install 4 lifting pulleys with unit load capacity of 2T below frame according to drawing
5EG.671.876S (Stator and terminal box positioning)
6、 Lift the terminal box to the position of terminal port installation by the lifting pulleys.
7、 Tighten terminal box and stator by bolts No. 1 and washer No. 2 according to drawing
5EG.307.509S (terminal box assembly). Tightening torque to the bolts is 1000N.m
8、 Clean and polish the seal welded junction between frame and terminal box according to
generator site installation 5EG.034.415S.
9、 Carry out sealed welding to the junction between frame and terminal box according to
generator site installation 5EG.034.415S.

B、High-voltage bushing installation

1、 Prepare parts according to drawing 5EG.512.428S (high-voltage bushing assembly).
2、 Install 2 lifting chain pulleys with unit load capacity of 1T on hookers of terminal box sides.
The position of chain pulley is corresponding to the installation position of high-voltage
bushing.
3、 Clean the connecting flange and seal groove of high-voltage bushing.
4、 Use lifting chain pulley to lift terminal bushing, the lifting steel wire is not permitted to
contact directly with the insulation surface in order to avoid damage insulation of surface.
5、 Install sealing ring No.4 on bushing (double check that bushing seal groove is clean ) ,when
the head of leading-out bushing approaches terminal flange hole, insert terminal bushing into
flange hole after installation of sealing ring, tighten stainless steel bolt with terminal box
after terminal bushing is in working position, the blots should have equal torques.

C、Water manifold assembly ( in terminal box )

1、 Prepare all parts and material according to drawing 5EG.175.1672S and 5EG.175.1673S.

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2、 Weld the rib according to the position and size in drawing 5EG.175.1673S.
3、 Weld rib ( No.7 in drawing 5EG.175.1673S) with the fixed ribbed slab ( No.5 in drawing
5EG.175.1673S ) on water manifold according to the position and size in drawing
5EG.175.1672S, pay attention to position of water-inlet of manifold. This procedure can be
completed before terminal box installation according to actual situation.
4、 Assembly other parts according to requirement of drawing 5EG.175.1673S, carry out
chemical acid cleaning and liquid leak check to pipe component according to actual situation
of installation in site, the detailed requirement is from technical drawings. Clean insulation
parts before installation in order to guarantee its insulation capability.
5、 Install the water manifold and terminal box according to drawing
5EG.175.1673S、5EG.175.1672S, clean insulation parts before installation in order to
guarantee insulation capability. Then inspect and measure the insulation and the flange (No.4
in drawing 5EG.175.1673S) should be connected with ground during measuring.
6、 Install pipe component No. 5 according to drawing 5EG.175.1672S, sealing is required to the
connection between pipe component No.5 and high-voltage bushing. underlay the PTFE
plate No.11, tighten pipe component No.5 according to the drawing requirement, enwrap
insulation tape No.3 and coat solvent-free glue No.4 according to position in section A－A
and section B－B.
7、 Install insulating tube No.1 according to drawing 5EG.175.1672S, clean carefully the foreign
mater at each joint before installation.
8、 Connect the water manifold with ground according to drawing 5EG.516.058S; carry out test
to inspect the ground condition.

D、Intermediate connection and fixing installation (generator longitudinal layout)

1、 Prepare materials and parts according to drawing 5EG.512.442S (high-voltage terminal
connection) and drawing 5EG.106.205S (terminal connection fixing at upper of terminal
box).
2、 Install clamping plate of No.14, No. 15 and No.33 according to drawing 5EG.512.442S
(high-voltage terminal connection). Pre-install bolts No.11 and No.36, disassembly the plate
No.14 after marking out the holes on it. Machining the 12－Φ18 holes and 7－Φ18 holes
whose depth are 10mm, according to drawing (8EG.760.1628S).
3、 Fix the plate No.14 on the installation position temporarily.

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4、 Confirm the position relationship between 6 intermediate connections （8EG.512.227S～
8EG.512.232S） and stator connecting lead according to the marks and the drawing
5EG.512.442S (high-voltage terminal connection).
5、 Clean all electric joint surface, free-of water ethanol or propketone may be used for cleaning,
do not use hard staff to clean in order to avoid the damage on silver plating conducting
surface.
6、 Pre-assembly connecting bushing No.9 and No.16 and intermediate connections No.1—6
according to drawing 5EG.512.442S (high-voltage terminal connection), confirm the position
relationship.
7、 Inspect the sealing ring No. 17 and No.20, then install sealing ring No.17 and No.20
according to the position in drawing 5EG.512.442S; inspect and install sealing ring No.10
according to drawing 5EG.512.428S (high-voltage bushing assembly).
8、 Install connecting bushing No. 9 and 16 and intermediate connections No. 1—6, and use
corresponding components to fasten with equal torque. No foreign mater is permitted to enter
into transient connections, connection bushing and high-voltage bushing during installation;
careful inspection must be carried out before installation.
9、 Carry out hydraulic pressure and gas-tighten test and check leakage condition to each joint,
continue the next procedure if the leak check is satisfactory.
10、 Enwrap ployimide film No.25 on connection bushing, the connection bushing should be
connected well with upper and lower transient connections and high-voltage bushing.
11、 Clean terminal insulation box No.23, No.26 with free-of-water alcohol or propketone, coat
solvent-free glue onto internal surface of insulation box and airing.
12、 Pre-install terminal insulation box No. 23,26, adjust vertical position of insulation box in
order to guarantee the length of transient connections, stator terminal lead, and high-voltage
bushing are equal inside insulation box. Mark out the position on the intermediate
connections and stator terminal leads where the upper and lower end of the insulation box is
corresponding to.
13、 If the length of any insulation part inside insulation box is shorter than 30mm, Semi-wrap the
mica strip No.38 for 4-6 layers to ensure the length over 30mm.The mica strip should
cooperate well with original insulation.
14、 Install terminal insulation box No.23, 26 and tighten it up, adjust the box to make a uniform
gap with connection bushing, use epoxy mica clay or solvent-free-glue flexible felt to fill the
big gap, solidification under room temperature in order to prevent injecting glue leakage.

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File no：Q96M SYE
15、 Mix the injecting glue of insulation box of No.24 by specific ratio, carry out solidification
test to injecting glue.
16、 Inject glue by special injecting tool, observe the condition of glue drop and fill new glue until
the glue surface which has been hardened is at same level with top of insulation box.
17、 After glue solidified completely (about 16—24 hours), infrared light may be used to make
glue to solidify quicker and the temperature is not allowed to be too high. Clean external
surface of insulation box.
18、 Insulation test: 24kV DC voltage is exerted to stator winding; the test is satisfactory if the
potential on surface of insulation box is less than 2kV.
19、 Install plate No.14 and clamping plate No.15, No.33 according to drawing 5EG.512.442S
(high-voltage terminal connection). Insert immersed solvent-free-glue flexible felt No.29 into
junction between insulation contact part and each plate.
20、 Install insulation tube No.7 and No.8, insulation tube No. 37 and clamping plate No.31, 30
according to drawing 5EG.512.442S (high-voltage terminal connection). Insert immersed
solvent-free-glue flexible felt No.32 into junction between insulation contact part and each
plate.
21、 According to drawing 5EG.106.205S (terminal connection fixing at upper of terminal box),
connect and fix fixing joint No.2 with angle support No.1, then connect and fix clamping
plate No.5 with No.2 by using shaft collar No.4, insert immersed epoxy-glue flexible felt into
the gap between clamping plate No.5 and insulation box contact part, insert immersed epoxy-
glue flexible felt between shaft collar and clamping plate No.5. The tightening torque to nut
No.13 and 10 is 80Nm.Fix the laminated board No.9 by epoxy glue according to section A-
A.
22、 Clean inside of terminal box.
23、 According to drawing 5EG.311.183S (inspection hatch assembly), install seal ring No.11
after clean seal groove, install man-hole cover plate.

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Appendix F Supplement for Inspection and Test Item of the Generator
1 Stator
1.1 After the generator stator has reached the power plant, do visual inspection, and measure the
insulation resistance between winding and ground, phase and phase.
1.2 Before installing the intermediate connections and the high voltage terminals do hydraulic test,
water flow test and air tightness of water circuit inside the stator according to JB/T6228. The water
pressure is same as the acceptance test water pressure. Air tightness test also can be done according
to ALSTOM standard IBF R28268. After finishing assembly, do hydraulic test, water flow test and
air tightness on stator with intermediate connections and the high voltage terminals together. After
this, mount the insulation covers and inject insulation glue into it. Before inserting the rotor, do
insulation resistance test, DC voltage withstand e test and AC voltage withstand test on stator
winding. When tests being do, temperature sensors shall be grounded to prevent from being
damaged.
1.3 After some fault impact (such as short-circuit close to the generator, generator grounding fault,
faulty synchronizing and so on.) occur on the generator, thorough examine should be done on stator
and rotor. Abnormally high currents and torques may be occurred as result of a short-circuit close to
the generator in service, or of clearance and reclosure of a more distant fault, or of faulty
synchronizing. It is prudent to examine the generator thoroughly, with particular attention to the
stator windings. Any loosening of supports or packings should be made good before returning the
generator to service, to avoid the possibility of consequential damage being caused by vibration. It
may also be desirable to check for possible deformation of the coupling bolts, couplings and shafts.
2 Rotor
2.1 After the generator rotor has reached the power plant, visual inspection should be done
immediately and insulation resistance of the rotor winding must be measured immediately. If the
block condition of the ventilation hole on rotor is damaged, do ventilation test of the gas ventilation
cooling system of rotor, and compare the result with the records made by manufacturer.
2.2 Before inserting the rotor, do gas tightness test (according to IBF R28262) for the central shaft
connection and connection bar copper, ventilation test of the gas ventilation on rotor according to
standard B5680-2004 supplied by manufacturer, insulation resistance test and AC voltage withstand
test.
2.3 After rotor being inserted into stator, AC impedance test should be measured to judge if there
exists interturn short circuit. If doubt, it also can be judge by short-circuit test with the detector
assembled on the generator. And the priority should be given to the later.
3. After finishing the whole generator installation, start the hydrogen, oil and water system, and then
do hydrogen leakage test on the whole generator.
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