Generator OS43024

Copyright 2008 ABB. All rights reserved.
4) Rubber hoses for leakage water to be disconnected. 4-legs lift
Lifting-device shall only be used when lifting the cooler housing. Cooler housing Max 90
o
3) 5)
2)
1)
Alternative 1
D=30, Ellipsed
Lifting hooks position towards lifting device
Working procedure of assembly and disassembly of cooler top: 1. Loosen and remove the bolts holding the flat protection plate on top of the machine and lift it off. 2. Observe the rubber hoses attached to the stator end plates. Loosen them, but do not drop them into the machine. 3. Place the cooler housing with coolers on top of the machine with a gap 10-20cm between the cooler housing and machine. 4. Connect the rubber hoses, for leakage water, to the connections on the cooler drainers and tighten the hose clamps. 5. Lower the cooler housing on to the machine and tighten the bolts holding it to the side panels. Be careful NOT to drop any bolts or nuts into the machine. Re-assembly the cooler top in the reverse order as describe.
Type des. Prep. Appr. Resp. dept
Prod. class:
Part no.
Annelie Kruse Flood Mats A AP/MMO
2008-03-12 2008-05-09 Approved ABB AB, Machines
Doc. kind Title
Instruction Mounting of cooling top

Lang. Rev. ind.
No. of p.
3
Page
Doc. no.
3BSM001483-A
; SAVEDATE: 2008-03-13 14:16
en
FILE: 3BSM001483-A en.doc; TEMPLATE: TECHN_DOC_STAND_P.dot -; SKELETON:
Lifting-device shall only be used when lifting the cooler housing.
Max 90
4-legs lift Cooler housing D=30, Ellipsed
Alternative 2
Lifting hooks position towards lifting device
Union of steel Adapter
Working procedure of assembly and disassembly of cooler top: 1. Loosen and remove the bolts holding the flat protection plate on top of the machine and lift it off. 2. Lower the cooler housing on to the machine and tighten the bolts holding it to the side panels. Be careful NOT to drop any bolts or nuts into the machine. 3. Connect the leak water detector by insert the adapter with the sensor into the union. Re-assembly the cooler top in the reverse order as describe.
Doc. no.
Lang.
Rev. ind.
Page
ABB AB, Machines
3BSM001483-A
en
REVISION Rev. ind. Page (P) Chapt. (C) Description Date Dept./Init.
Doc. no.
Lang.
Rev. ind.
Page
ABB AB, Machines
3BSM001483-A
en
Service & repair
6\QFKURQRXV PDFKLQH
Dismantling and assembly of PMG-stator
Document No.: 3BSM 005438
Contents
6DIHW\
1.1 General safety instructions ............................................ 3
'LVPDQWOLQJ DQG DVVHPEO\ RI 30* VWDWRU

2.1 2.2 2.3 Dismantling of PMG stator............................................ 4 Assembly of PMG stator ..............................................11 Recommended tightening torque for bolts on the machine........................................................................ 17
6\QFKURQRXV PDFKLQH
127,&( The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any kind arising from the use of this document, nor shall ABB be liable for incidential or consequential damages arising from the use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABBs written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.

3BSM 005438, Rev. B EN -
3BSM 005438
ii
6\QFKURQRXV PDFKLQH 6DIHW\
6DIHW\
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The procedures described in this manual are only to be performed by trained personnel authorized by the user. The manufacturer is not responsible for malfunctions that comprise safety as a result of alteration, use of non ABB replacement parts, neglect or misuse. Replacement parts may vary from those shown in this manual. Should you have questions on those parts please contact ABB Automation Technologies AB. The actual appearance of the machine may vary from the illustration in this manual. Should pre-owned ABB equipment be purchased and reconditioned, the equipment should not be used until testing and analysis demonstrate that the equipment meet the original or upgraded specifications. The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards. The recommended precautions and procedures of the manufacturers should be followed.
3BSM 005438, Rev. B EN -
3BSM 005438
6\QFKURQRXV PDFKLQH 'LVPDQWOLQJ DQG DVVHPEO\ RI 30* VWDWRU
'LVPDQWOLQJ DQG DVVHPEO\ RI 30* VWDWRU
'LVPDQWOLQJ RI 30* VWDWRU
:$51,1* 5LVN RI SHUVRQDO LQMXU\

%HIRUH GLVPDQWOLQJ WKH IROORZLQJ PXVW EH GRQH 1. The machine must be completly stopped, dead, disconnected and grounded before dismantling the PMG stator.
Remove the bolts on the rear end cover and take away the cover. See Figure 2-1 on page 4.
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3BSM 005438, Rev. B EN -
3BSM 005438
Remove the cable from the earth fault brush holder and disconnect the cable from the cable clamps of the sheet metal housing for PMG stator. See Figure 2-2 on page 5.
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Remove the brushes and the brush holder in accordance with Figure 2-3 on page 5.
3BSM 005438, Rev. B EN -
)LJXUH

3BSM 005438
Loosen the bolts and remove both halves of the PMG protective cover plates. See Figure 2-4 on page 6.
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Remove the cover drum after removing the bolts. Be careful not to damage the slip ring for rotor earth fault protection. See Figure 2-5 on page 6.
3BSM 005438, Rev. B EN -
)LJXUH

3BSM 005438
Remove the PMG stator cables from the terminal block. See Figure 2-6 on page 7.
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Place a sheet of stiff paper or plastic in the air gap around the rotor as shown in Figure 2-7 on page 7.
3BSM 005438, Rev. B EN -
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3BSM 005438
Attach a lifting chain to the PMG stator housing and remove the bolts. See Figure 2-8 on page 8.
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&$87,21 5LVN RI 3HUVRQDO LQMXU\

%H FDUHIXO QRW WR JHW \RXU KDQGV EHWZHHQ WKH KRXVLQJ IODQJH DQG WKH H[FLWHU VWDWRU KRXVLQJ Insert the tip of a large screw driver between the housing flange and the exciter stator housing and break loose the PMG stator housing which is held in place firmly by sealing compound.
3BSM 005438, Rev. B EN -
3BSM 005438
Lift away the PMG housing carefully with the crane. See Figure 2-9 on page 9.
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3BSM 005438, Rev. B EN -
3BSM 005438
:$51,1* 0DJQHWLF IRUFH

7KHUH DUH YHU\ VWURQJ PDJQHWLF IRUFHV EHWZHHQ WKH 30* URWRU DQG VWDWRU 1. 2. 3. Be extremely careful when moving the PMG stator housing to aviod damage to components due to magnetic forces. Remove you wrist watch, credit cards and other digital equipment before working around those magnetic forces. Personnel with pace maker should not be working in the vicinity of the PMG.
Now you are ready for changing diodes or thyristor according to section Dismantling and assembly of diodes and thyristor. See Figure 2-10 on page 10
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3BSM 005438, Rev. B EN -
3BSM 005438
10
$VVHPEO\ RI 30* VWDWRU
:$51,1* 0DJQHWLF IRUFH

7KH 30*URWRU KDV YHU\ VWURQJ SHUPDQHQW PDJQHWV 7KH PDJQHWV DWWUDFW PHWDO FKLSV DQG PHWDO IUDJPHQWV DURXQG DQG QHDU WKH URWRU 1. 2. 3. 4. Inspect all 20 magnets with your fingers to ensure that they are completely free from foreign material. Be extremely careful when moving the PMG stator housing to aviod damage to components due to magnetic forces. Remove you wrist watch, credit cards and other digital equipment before working around those magnetic forces. Personnel with pace maker should not be working in the vicinity of the PMG.
Before assembling the stator, make a simple protection sleeve of stiff paper or plastic and tape the ends together. See Figure 2-11 on page 11.
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3BSM 005438, Rev. B EN -
3BSM 005438
11
Check that the wires from the PMG stator are correctly strapped to the bracket as shown in Figure 2-12 on page 12.
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3BSM 005438, Rev. B EN -
3BSM 005438
12

%H FDUHIXO QRW WR JHW \RXU KDQGV EHWZHHQ WKH KRXVLQJ IODQJH DQG WKH H[FLWHU VWDWRU KRXVLQJ Lift the PMG-stator with a crane and move carefully over the paper sleeve. See Figure 2-13 on page 13.
)LJXUH Be sure that the guide pins fit into the holes in the exciter stator housing.

While the stator is suspended, put all the bolts in place including flat washers and start tightening them very lightly. The air gap between rotor and stator is approx. 1.75 mm.
3BSM 005438, Rev. B EN -
3BSM 005438
13
After tightening the bolts, place feeler gauges between stator and rotor with the desired thickness at 9 oclock, 3 oclock and 12 oclock position to check that the air gap is still correct. See Figure 2-14 on page 14.
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Remove the feeler gauges. Check the air gap with a feeler gauge in a final check around the periphery. The air gap (tolerance) must not exceed 0.2 mm. ,I WKH WROHUDQFH EHWZHHQ DQG RFORFN RU EHWZHHQ DQG RFORFN H[FHHGV PP WKH EROWV PXVW EH ORRVHQHG DQG FDUHIXOO\ UHWLJKWHQHG 7KH SHULSKHU\ PXVW EH UHFKHFNHG ZLWK IHHOHU JDXJHV XQWLO WKH UHTXLUHG WROHUDQFH LV REWDLQHG $IWHU WKH WROHUDQFH LV UHDFKHG UHGULOO WKH JXLGH SLQ KROHV DQG LQVHUW WKH UROO SLQV Connect the wires from the PMG stator to the terminal as shown in Section 2.1 Figure 2-6 on page 7.
3BSM 005438, Rev. B EN -
3BSM 005438
14
Take one half of the protective cover plate and slide it behind the brush holder mounting bracket. Insert a bolt loosely. Take the other half and place it on top. Attach two bolts to assemble the two halves. Insert all the other bolts on the periphery. Tighten these carefully with a pinch bar while checking visually that the white plastic ring does not touch the rotating shaft extension (sleeve). See Figure 2-15 on page 15.
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Adjust the two brush arms so that the angle between the inserted brush and the centre line of the rotor is 90 degree. See Figure 2-16 on page 15 and Figure 2-17 on page 16.
3BSM 005438, Rev. B EN -
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3BSM 005438
15
90o
)LJXUH Insert the brushes and connect the leads to the brass plate below. Connect the cable from box GL. Replace the rear end cover and tighten all bolts.
3BSM 005438, Rev. B EN -
3BSM 005438
16
5HFRPPHQGHG WLJKWHQLQJ WRUTXH IRU EROWV RQ WKH PDFKLQH

Recommended tightening torque for bolts, property class 8.8, slightly coated with oil. 127( 'R QRW XVH 0RO\EGHQXP GLVXOSKLGH 0RO\FRWH
%ROW VL]H 7RUTXH (Nm) (lbft)
0 22.5 16.6
0 45 33
0 79 58
0 190 140
0 420 300
0 735 550
0 1500 1100
3BSM 005438, Rev. B EN -
3BSM 005438
17
3BSM 005438
2003-01-15
Service & repair
6\QFKURQRXV PDFKLQH
Dismantling and assembly of exciter stator
Document No.:3BSM 005439
Contents
6DIHW\ 1.1 General safety instructions .........................3 5HPRYDO DQG DVVHPEO\ RI WKH H[FLWHU VWDWRU 2.1 Removal of the exciter stator......................4 2.2 Assembly of exciter stator ........................10 2.3 Recommended tightening torque for bolts11
6\QFKURQRXV PDFKLQH
127,&( The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any kind arising from the use of this document, nor shall ABB be liable for incidential or consequential damages arising from the use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABBs written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
3BSM 005439, Rev. B EN -
3BSM 005439
-ii
6DIHW\

3BSM 005439, Rev. B EN -
3BSM 005439
6\QFKURQRXV PDFKLQH 5HPRYDO DQG DVVHPEO\ RI WKH H[FLWHU VWDWRU
5HPRYDO DQG DVVHPEO\ RI WKH H[FLWHU VWDWRU
5HPRYDO RI WKH H[FLWHU VWDWRU

%HIRUH UHPRYDO WKH IROORZLQJ PXVW EH GRQH 1. The machine must be completely stopped, dead, disconnected and grounded before removing the exciter stator.
Remove all external cables from the junction boxes on the exciter stator housing. Remove the upper clamping bar of the cooling duct and those on the sides. See Figure 2-1 on page 4.
)LJXUH

3BSM 005439, Rev. B EN -
3BSM 005439
Remove the screws of the inner cover plates between the stator housing plates and the exciter stator with a pneumatic power tool. See Figure 2-2 on page 5.
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Remove the guide pins (one on each side) from the mounting flanges as shown in Figure 2-3 on page 5 and Figure 2-4 on page 6.
3BSM 005439, Rev. B EN -
)LJXUH

3BSM 005439
)LJXUH

Remove the four M16 hex. head socket cap screws, (two on each side) with the socket wrench using a pipe extension. See Figure 2-5 on page 6.
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3BSM 005439, Rev. B EN -

3BSM 005439
:$51,1* +HDY\ OLIW

7KH H[FLWHU VWDWRU LV D KHDY\ XQLW 1. Use lifting equipment that is appropriate for the load, see TBA for weight.
Place a pipe or steel rod through the lifting eyes, attach a lifting strap between the welded lifting eyes and the iron rod or pipe as shown, and carefully try to lift the unit. See Figure 2-6 on page 7.
3BSM 005439, Rev. B EN -
)LJXUH

3BSM 005439
Check the centre of gravity and adjust the straps, test carefully until the unit can be lifted straight up without tipping to the rear or to the front. See Figure 2-7 on page 8.
)LJXUH

Having lifted the unit, slide the unit axially away from the generator and put it on two wooden blocks. See Figure 2-8 on page 8 and Figure 2-9 on page 9.
3BSM 005439, Rev. B EN -
)LJXUH

3BSM 005439
)LJXUH

Each set of brass shims must be held together, marked and stored so that they are returned to the same side when reassembling the stator housing.
3BSM 005439, Rev. B EN -
3BSM 005439
$VVHPEO\ RI H[FLWHU VWDWRU

Place a pipe or steel rod through the lifting eyes, attach a lifting strap between the welded lifting eyes and the iron rod or pipe as shown and carefully lift the unit. See Figure 2-6 on page 7 in Section 2.1. Check the centre of gravity and adjust the straps, test carefully until the unit can be lifted straight up without tipping to the rear or to the front. Having lifted the unit, slide the unit axially and very carefully over the rotor. See Figure 2-7 on page 8 in Section 2.1. Place the same shims under the stator housing feet. Replace the guide pins and the bolts. Check the air gap. Assemble the inner cover plates between the generator housing and the exciter stator housing. See Figure 2-2 on page 5 in Section 2.1. Assemble the clamping bars for the cooling duct. See Figure 2-1 on page 4 in Section 2.1. Assemble all external cables.
3BSM 005439, Rev. B EN -
3BSM 005439
10
5HFRPPHQGHG WLJKWHQLQJ WRUTXH IRU EROWV

Recommended tightening torque for bolts property class 8.8, slightly coated with oil. 127( 'R QRW XVH 0RO\EGHQXP GLVXOSKLGH 0RO\FRWH
0 22.5 16.6
0 45 33
0 79 58
0 190 140
0 420 300
0 735 550
0 1500 1100
3BSM 005439, Rev. B EN -
3BSM 005439
11
3BSM 005439
2003-01-15
Service & Repair
6\QFKURQRXV PDFKLQH
Dismantling and assembly of bearings
Contents
6DIHW\ 1.1 General safety instructions .........................3 'LVPDQWOLQJ DQG DVVHPEO\ RI EHDULQJV 2.1 Dismantling of bearings..............................4 2.2 Change of bearing liner ............................15 2.3 Assembly of bearings ...............................21 2.4 Recommended tightening torque for bolts .....................................................30
6\QFKURQRXV PDFKLQH
127,&( The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABBs written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
3BSM 005446, Rev. B EN -
3BSM 005446
ii
6DIHW\

3BSM 005446, Rev. B EN -
3BSM 005446
6\QFKURQRXV PDFKLQH 'LVPDQWOLQJ DQG DVVHPEO\ RI EHDULQJV
'LVPDQWOLQJ DQG DVVHPEO\ RI EHDULQJV
'LVPDQWOLQJ RI EHDULQJV

%HIRUH GLVPDQWOLQJ WKH IROORZLQJ PXVW EH GRQH 1. The machine must be completely stopped, dead, disconnected and grounded before dismantling the bearing.
Before starting the dismantling of the bearing, rotate the rotor so that the poles are at 90 degrees to the vertical. Loosen all cables from the cable brackets. Remove the tubes from the air-lock seal, see Figure 2-1 on page 4. Loosen the cable from the vibration detector and remove the vibration probes. If lower half of the bearing shell will be removed from the bearing housing, the temperature probes has to be dismantled from the bearing housing. See Figure 2-2 on page 5 7KH WHPSHUDWXUH SUREH LV D SDUW RI ERWK WKH EHDULQJ VKHOO DQG WKH EHDULQJ KRXVLQJ DQG KDV WR EH UHPRYHG LI WKH EHDULQJ VKHOO ZLOO EH PRYHG IURP LWV SRVLWLRQ.
Tubes from air-lock seal
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3BSM 005446, Rev. B EN -

3BSM 005446
Temperature probe
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Bearing housing
Bearing shell
Disconnect the tubes between the run-out tanks and the upper halves of the bearing. Disconnect the level-indicators on the run-out tanks. Remove the cooler top and the sheet metal end covers around the bearing and the part including the run-out tank if such exist. Remove even the cooling duct for the exciter at the ND-end if both bearings are to be inspected or repaired. Remove the bolts of the upper half of the air-lock seal which attach the air-lock seal to the bearing housing before attempting to dismantling of the bearing. Refer to Figure 2-3 on page 5.
)LJXUH

(The air-lock seal prevents the rotor from sucking in oil along the shaft. The seal provides an air-lock at atmospheric pressure).
3BSM 005446, Rev. B EN -
3BSM 005446
To be sure not to destroy the air-lock seal, remove the upper half by removing two bolts. See Figure 2-4 on page 6.
)LJXUH

Loosen and remove the eight M24 hex. head socket bolts in the upper half of the bearing housing. See Figure 2-5 on page 6.
)LJXUH
3BSM 005446, Rev. B EN -

3BSM 005446
Insert a lifting eye and carefully lift the upper half away from the lower half. See Figure 2-6 on page 7.
)LJXUH

3BSM 005446, Rev. B EN -
3BSM 005446
Remove the bolts from the upper half of the bearing shell. See Figure 2-7 on page 8.
)LJXUH

To separate the bearing shell, use the bolt in Figure 2-8 on page 8 and Figure 2-9 on page 9.
)LJXUH

3BSM 005446, Rev. B EN -
3BSM 005446
This bolt is for used to separate the two halves of the bearing shell.
)LJXUH Insert a lifting eye and lift away the upper bearing shell. See Figure 2-10 on page 9.
)LJXUH

3BSM 005446, Rev. B EN -
3BSM 005446
Remove the springs on each bearing seal and remove the bearing seal. See Figure 2-11 on page 10.
)LJXUH

Loosen the jacking-oil connections to the bearing shell by removing the two bolts on the connections. See Figure 2-12 on page 10.
)LJXUH
3BSM 005446, Rev. B EN -

3BSM 005446
10
Loosen the earth connection, see Figure 2-13 on page 11.
)LJXUH

3BSM 005446, Rev. B EN -
3BSM 005446
11
Place a magnetic foot with a dial indicator so that the indicator can measure a vertical movement (lift) of the rotor as shown in Figure 2-14 on page 12. Place a hydraulic jack (30 ton lifting capacity) underneath the rotor shaft as shown and lift the rotor 0.3-0.4 mm.
:$51,1* &RPSRQHQW GDPDJH

'R QRW OLIW RU ORZHU WKH URWRU VKDIW PRUH WKDQ WKH DERYH VWDWHG WROHUDQFH RWKHUZLVH \RX FDQ GDPDJH WKH EHDULQJ DW WKH RWKHU VLGH RI WKH PDFKLQH
)LJXUH

3BSM 005446, Rev. B EN -
3BSM 005446
12
Place two distance elements in the air gap between the rotor poles and the stator. Attach 2 lifting eyes into the lower half of the bearing shell as shown in Figure 2-15 on page 13 and draw the assembly toward you so that it slides around the journal, with use of a hand-ratchet.
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Insert a lifting eye as shown in Figure 2-16 on page 13 and remove the lower bearing shell, see Figure 2-17 on page 14. Be careful.
)LJXUH
3BSM 005446, Rev. B EN -

3BSM 005446
13
)LJXUH

Store both halves of the bearing shells in a very clean place. It is strictly forbidden to store metal chips and other metallic components together with the bearings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
3BSM 005446, Rev. B EN -
3BSM 005446
14
&KDQJH RI EHDULQJ OLQHU

Make sure that your working area is cleaned completely and free from foreign material. Place the bearing shell half on the work bench and remove one of the cross-recessed countersunk head screws (including the washer) with a Phillips screw driver. See Figure 2-18 on page 15.
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Place a piece of wood against the bearing liner on the opposite side where the screw is still in place. Knock carefully against the edge of the liner until it can be removed at the side where the screw has been removed. See Figure 2-19 on page 15.
3BSM 005446, Rev. B EN -
)LJXUH

3BSM 005446
15
The liner material is very soft. Be very careful, when installing the new liner, not to scratch or to damage the new liner. Tap down the new liner with very little force by using a plastic hammer as shown in Figure 2-20 on page 16 until the liner projects approx. 5 mm above the horizontal joint of the bearing shell.
)LJXUH Place a drop of Loctite in the tapped hole. See Figure 2-21 on page 16.

)LJXUH
3BSM 005446, Rev. B EN -

Place the washer in the tapped hole and tighten the cross-recessed countersunk screw with a Phillips screw driver (Figure 2-22 on page 17). Tap down the liner very carefully by using a
3BSM 005446
16
plastic hammer as shown in Figure 2-20 on page 16 until the liner is even with the horizontal joint.
)LJXUH

After both halves have been fitted with new bearing liners, place both halves with the plane machined surfaces down onto the work bench. Insert the four M 24 hex. socket head cap bolts and tighten carefully each bolt a little at a time with a torque wrench until both halves are assembled with a torque of 735 Nm. Hold down the bearing shell assembly while tightening the bolts. See Figure 2-23 on page 17.
3BSM 005446, Rev. B EN -
)LJXUH

3BSM 005446
17
Measure the inner bearing liner diameter at both ends of the liner in the bearing shell and at least two diametrically opposite places with an inside micrometer as shown in Figure 2-24 on page 18 and Figure 2-25 on page 18.
)LJXUH

)LJXUH Write down the values measured and compare them with the shaft diameter values from the final test protocols. A radial play between bearing liner diameter and rotor shaft diameter of a minimum of 0.34 mm and a maximum of 0.45 mm is acceptable. Separate the bearing shell halves for assembly into the bearing housing.
3BSM 005446, Rev. B EN -
3BSM 005446
18
%($5,1* ,168/$7,21 The bearing insulation consists of a self-adhesive teflon strip which is attached to the spherical contact surface of the bearing shell.
&$87,21 8VH RI $FHWRQH

$FHWRQH LV D IODPPDEOH DQG KHDOWKHQGDQJHULQJ OLTXLG )ROORZ WKH UHFRPPHQGHG SUHFDXWLRQV DQG SURFHGXUHV RI WKH PDQXIDFWXUHU Before assembly in the bearing housing, check with your hands and your eyes that no cracks are visible and no metal particles or chips are embedded in the Teflon strip. If the Teflon bearing insulation is damaged, it must be replaced with a new self-adhesiveTeflon strip. After removal of the damaged Teflon strip, the cast iron spherical contact area must be cleaned with ACETONE or equal in order to remove all parts of the old adhesive. Heat the bearing shell to 100oC, it takes approx 12 hours in an oven and the bearing shell should be hot throughout. The new Teflon strip must be applied very carefully. Use a wooden spatula to remove all air bubbles from underneath the Teflon strip. See Figure 2-26 on page 19 and Figure 2-27 on page 20.
)LJXUH

When cutting the insulation strip into shape of the spherical surface, an excess edge must be left all around, this surface including the holes in the bottom shell. The excess edge is at least 5 mm. It is an advantage to bend the excess edge around the corners in order to protect edges when handling the bearing shell.
3BSM 005446, Rev. B EN -
3BSM 005446
19
)LJXUH

%($5,1* 6($/6 Grooves to accomodate bearing seals are provided on each side of the bearing housing. The seals are of a glass-fibre construction, containing a labyrinth seal facing the rotor shaft and a rubber seal on the outer diameter facing the bearing housing. The seal must be assembled so that the axial oil drain hole is located at the 6 oclock postion and the radial guide pin (roll pin) fits into the upper half of the bearing housing at the 12 oclock position (The roll pin prevents rotation of the bearing seal). See Figure 2-28 on page 20.
3BSM 005446, Rev. B EN -
)LJXUH

3BSM 005446
20
$VVHPEO\ RI EHDULQJV

The teflon lining of the bearing shell is very soft and can be damaged quite easily. Inspect both the upper and lower bearing shell very carefully for damage, metal chips, impurities and even air bubbles in the lining. The inspection is to be made by eye and by using your hand, feeling after damage. 127( ,I ERWK EHDULQJV KDYH EHHQ UHPRYHG PDNH VXUH WKDW WKH PDWFKLQJ EHDULQJ VKHOOV DQG EHDULQJ KRXVLQJV ZKLFK DUH VWDPSHG ZLWK LGHQWLW\ QXPEHUV DUH UHDVVHPEOHG 7KH FRPSRQHQWV KDYH EHHQ PDFKLQHG WRJHWKHU DQG PXVW EH PDWFKHG IRU UHDVVHPEO\
&KHFN WKDW WKH EHDULQJ KRXVLQJV DUH DEVROXWHO\ FOHDQ DQG IUHH IURP IRUHLJQ PDWWHU
Basically, reassembly is executed in the reverse order as described in Section 2.1. The hydraulic jack is still underneath the rotor shaft as described in Section 2.1 Figure 2-14 on page 12. Apply a thin coat of oil to components which are to be assembled.
3BSM 005446, Rev. B EN -
3BSM 005446
21
Insert five lifting eyes in the lower bearing shell and lift the shell over and onto the rotor shaft. Lower the bearing half on the shaft, remove the upper lifting eye, hold onto 2 of the lifting eyes as shown in Figure 2-29 on page 22 and allow the shell to glide around the journal until the lower shell is inserted. See Figure 2-30 on page 22 and Figure 2-31 on page 23.
)LJXUH

)LJXUH
3BSM 005446, Rev. B EN -

3BSM 005446
22
)LJXUH

Connect the jacking oil connections and the earth connection to the bearing shell. See Figure 2-32 on page 23.
)LJXUH

3BSM 005446, Rev. B EN -
Lower the rotor shaft carefully into the bearing liner. Check the distance between the bearing journal and the bearing liner with a feeler gauge on front and rear end of liner and on both sides. The tolerances must be as equal as possible and the minimum distance between bearing liner and journal must be 0.1 mm. Otherwise the rotor must be jacked up again. Using a plastic hammer knock slightly at the horizontal joint of the bearing
3BSM 005446
23
shell to adjust the spherical position of the bearing. Repeat until an acceptable tolerance is obtained. See Figure 2-33 on page 24.
)LJXUH

Assemble the air-lock seal and the bearing seals. Check the clearance (about 0.5 mm) between the air-lock seal and the shaft. See Figure 2-34 on page 24.
)LJXUH
3BSM 005446, Rev. B EN -

3BSM 005446
24
Lift the upper bearing shell into position as shown in Figure 2-35 on page 25.
)LJXUH

Insert the four M24 hex. head cap bolts and tighten the bolts with a torque wrench to 735 Nm. See Figure 2-36 on page 25. Be sure that the bolts for separating the shell are in the original position as before the dismantling.
)LJXUH
3BSM 005446, Rev. B EN -

3BSM 005446
25
Clean the upper part of the bearing housing and apply a thin coat of oil to the spherical bearing seat. See Figure 2-37 on page 26.
)LJXUH

3BSM 005446, Rev. B EN -
3BSM 005446
26
&$87,21 8VH RI VHDOLQJ FRPSRXQG

)ROORZ WKH UHFRPPHQGHG SUHFDXWLRQV DQG SURFHGXUHV RI WKH PDQXIDFWXUHU Clean the horizontal joint of the lower and upper bearing housing carefully and apply a thin coat of Permatex Form a Gasket no. 2 sealing compound . See Figure 2-38 on page 27, Figure 2-39 on page 28 and Figure 2-40 on page 28.
)LJXUH

3BSM 005446, Rev. B EN -
3BSM 005446
27
)LJXUH

)LJXUH
3BSM 005446, Rev. B EN -

Lift the upper bearing half into place. Tighten the eight M24 hex. head socket cap bolts with a torque wrench to 735 Nm. See Figure 2-5 on page 6 in Section 2.1.
3BSM 005446
28
Check the bearing insulation by megging as shown in Figure 2-41 on page 29 and Figure 2-42 on page 29.
Loosen the hub for the earth device and pull out the earth connector and connect for megging )LJXUH
)LJXUH
3BSM 005446, Rev. B EN -

3BSM 005446
29
5HFRPPHQGHG WLJKWHQLQJ WRUTXH IRU EROWV

Recommended tightening torque for bolts property class 8.8, slightly coated with oil. 127( 'R QRW XVH 0RO\EGHQXP GLVXOSKLGH 0RO\FRWH
0 22.5 16.6
0 45 33
0 79 58
0 190 140
0 420 300
0 735 550
0 1500 1100
3BSM 005446, Rev. B EN -
3BSM 005446
30
3BSM 005446
2001-09-13
Service - a protable business for customers

Valid for AMB 710, AMC, AMI 710-900, AMS, AMT, GAE, GBA, MAA, MAE, MBA, MBE
Merely during the last 40 years ABB in Vsters has manufactured more than 3,000 synchronous motors/generators and induction motors in the power output range 2 55 MW/65 MVA. These motors and generators are operating in different industrial processes in vital places around the world. It is consequently not strange, but rather natural, that there is a qualied group of experts for after-sales market services whose task is to assure the highest possible reliability of this installed base of motors and generators.
3BSM005556 RevH_0802
Service Notes
A protable process requires that all the component parts function satisfactorily. ABB is naturally well aware of this and of the responsibility it takes as supplier of motors and generators. This responsibility is not limited to the supply of reliable motors/generators commissioned in an appropriate way. ABB therefore offers services aimed at giving the motor/generator as trouble-free operation as possible over its entire life cycle. These services are also intended to extend the life of the motors/generators. The range of services comprises spare parts, workshop services, site services, service packages and technical support. They are implemented in co-operation with service companies both within and outside the ABB Group, which gives a global coverage. It is no exaggeration to say that ABB feels a sense of responsibility for the motors and generators it has supplied a long time after the warranty period has expired. The entire organization takes responsibility for the delivered motors/generators. But this responsibility is rooted above all in the service market group. The main task of this group is to develop services products and to make certain that they are implemented in the best interests of our customers. This involves
everything from the addition of new spares to the stock of spare parts, top-class system analyses to availability analyses to establish whether actions are needed to assure the reliability or life of a motor/generator. Despite extremely reliable products and all reasonable preventive maintenance, it is inevitable that production disturbances occur on some occasion. Fast emergency actions are then the only thing that can minimize production losses. And the closer the assistance is available, the faster can actions be taken. The nearest assistance is always to be found in the customers own maintenance organization. Our role is therefore to offer support to the customers organization or for this to be done by a local service company under supervision from us. Support is available in the form of troubleshooting documentation, distance support, supervision and training courses The service market group is made up of people whose knowledge complements that of each other. Together, they cover a very broad range of competencies. All the members of the group share one thing in common, namely their solid experience of rotating electrical machines in general.
Product Lifecycle Services

Installation & Commissioning Training Support & Remote Services Spare Parts & Repairs Maintenance & Field Services
Migration & Retrots

Optimization
3BSM005556 RevH_0802
Preventive maintenance preserves the plants production capacity The goal of preventive maintenance is to change the maintenance work from being mainly emergency interventions, where each problem is addressed as it arises, to planned actions with focus on reliability and minimizing of production disturbances. The basis of preventive maintenance is the implementation of a maintenance programme with recommended intervals. When supplemented by maintenance based on condition monitoring, analyses and checking of the performance carried out by experienced personnel, any deterioration can be discovered in time and corrective actions taken. Improved plants through value-raising measures The machines supplied by us are always matched with the drive application for which they are intended. They are also state-of-the-art machines at the time of their delivery. However, developments never stand still. We are constantly gaining new experience. Todays products consequently have a better performance and better operating characteristics per than the motors/generators supplied earlier. The upgrading/modernization of motors and generators supplied earlier and in service in many cases can therefore be a very protable way to increase value. This value lies in higher production, less maintenance, higher raliability and longer life. Central support With an installed base throughout the world, it is impossible to maintain in-depth specialist competence close to each individual customer. The solution is therefore to provide strongly centralized support services. Support that enables local ABB staff in sales and service companies to act as if the centrally located specialists were on the spot.
Krister Johansson Manager Working since 1989 at ABB as prod. engineering, supply management and the last four years as responsible for sales & marketing of motors. Phone +46 (0)21 329509, Email: krister.o.johansson@se.abb.com Bjrn Lindberg Technical support Has been with ABB since 1994 and rotatng machinery since 2002, the latest year with development. Phone +46 (0)21 329667, Email: support.machines@se.abb.com
Yngve Anundsson specialist Sales and Technical support Working since 1975 at ABB. Worked as head of the test room and project manager. Since 1998 with After Sales. Phone +46 (0)21 329521, Email: yngve.anundsson@se.abb.com Jonas Burstrm Sales and Technical support Working since 1988 at ABB. The last years with synchronous motors and generators as projectmanager and area sales manager Phone +46 (0)21 329527, Email: jonas.bustrom@se.abb.com Erik Englund Sales and Technical support Working since 2005 at ABB and with rotating electrical machines since 2006. Phone: +46 (0)21 325802 Email: erik.englund@se.abb.com Stefan Wilson Sales and technical support Working since 1970 with rotating electrical machines in production, supply management, and after sales service.
Phone: +46 (0)73 044 05 03 E-mail: support.machines@se.abb.com sa rnstedt Orderhandling Working in ABB since 1987 and within Machines form 2007.
Phone + 46 (0)21 329558, Email: aftersales.machines@se.abb.com
Roger Andersson Orderhandling Working since 1988 at ABB. The last years with electrical machines.
Phone +46 (0)21 348912, Email: aftersales.machines@se.abb.com
Phone + 46 (0)21 329425, Email: aftersales.machines@se.abb.com
ABB AB Machines Elmotorgatan 2, Building 394 Tel: +46 21 32 90 00 Fax: +46 21 32 90 10
www.abb.com/motors&generators e-mail: Spare parts: aftersales.machines@se.abb.com Technical support: support.machines@se.abb.com
Specications subject to change without notice.
Service Notes
Tobias sterholm Technical support Working since 2002 at ABB with rotating electrical machines as development engineer and with technical support. Phone +46 (0)21 329446, Email: support.machines@se.abb.com Mikael Levin Sales and Technical support, orderhandling Working since 1989 at ABB with electrical machines as mechanical designer and project manager. Phone +46 (0)21 329579, Email: mikael.levin@se.abb.com ke Lfberg Commissioning Working since 1990 at ABB with commissioning of control systems and electrical machines.
Phone:+46(0)21329499 Email:stefan.wilson@se.abb.com
Jonas Carlsson Orderhandling Working in ABB since 2001 within Machines from 2005.
Phone + 46 (0)70-3997937, Email: support.machines@se.abb.com Mikael Karlsson Commissioning Working with commissioning of control systems and electrical machines.
Phone + +46 (0)21 329456, Email: jonas.carlsson@se.abb.com Kjell Gaufn Orderhandling Working since 1964 with rotating electrical machines, with sales and production.
Phone: +46 703 30 86 80 E-mail: support.machines@se.abb.com Marko Pikkarainen Commissioning Working with commissioning of control systems and electrical machines.
Phone +46 (0)21 329561, Email: aftersales.machines@se.abb.com Leila Yli-Kerko Orderhandling Working since 1975 with rotating electrical machines as machine operator, quality control inspector and mechanical designer.
Type of motors and generators manufactured by the Machines factory in Vsters. These machines are of the following types: Synchronous machines; AMS, AMT, GAE, GBA Induction machines; AMB 710, AMC, MAA, MAE, MBA, MBE, AMI 710-900
Recommended spares and spares support

Valid for AMB 710, AMC, AMI, AMS, GBA
Availability is a matter of top priority, which requires special efforts. However, sooner or later, what shouldnt happen does happen. A stoppage due to the failure of some part. It is now that the right spare should be available. If this is not so, you must then have the right supplier, who is able to dispatch the right component, quickly and reliably. Recommended spares, sets of spares and spares support are concepts synonymous with a high reliability
Scope of spares adapted to desired reliability and calculated risks
3BSM005991 RevB_0510
Service Notes
Summary Recommendations for suitable spares can be made on the basis of the knowledge of the supplied product/plant, experience of the application and the operating conditions. We have prepared for our motors and generators with accessories a list of recommended spares classied for different stages in the lifetime of the motor/generator. The recommended sets of spares have been coupled to our recommended maintenance programmes. Furthermore, we have matched them with different safety levels.
Benefits The recommended spares are based on operating experience gained from thousands of machines. The total investment in spares need not occur at the same time as the investment in a new machine. It is often sufcient to cover the rst 3 to 4 years in conjunction with a new investment. The long-term scope of spares is suitably determined after a few years of operating experience. With the classied recommended spares, each customer has the opportunity to choose the scope of spares matched with the reliability demanded by the application and the calculated risks that are reasonable to take.
Product Lifecycle Services

Installation & Commissioning Training Support & Remote Services Spare Parts & Repairs Maintenance & Field Services Migration & Retrofits Optimization
Structure of recommended sets of spares

Spares for normally 3 years of operation or max. 20,000 equivalent hours of operation. The spares are selected on the basis of general experience. The aim is to cover the need for spares according to level 1 and 2 in the recommended maintenance programme. Spares for normally 3 12 years of operation or max. 80,000 equivalent hours of operation Spares should be selected on the basis of the rst years of operation. The aim is to cover the need for spares for preventive maintenance according to level 3 and 4 in the maintenance programme. Maintenance consumables and Maintenance replacement Spares/components to be replaces at the maintain intervals. The scope covers both planned and unplanned maintenance
3BSM005991 RevB_0510
Spares for extra reliability
ABB Automation Technologies AB Machines Elmotorgatan 2, Building 394 Tel: +46 21 32 90 00 Fax: +46 21 32 90 10 www.abb.com/motors&drives e-mail: aftersales-machines@se.abb.com
Specifications subject to change without notice.
Service Notes
Normal spares needs
Operation consumables and Operation back-up
Consumables that are to be replaced at certain intervals and spares that are critical to operation. Spares for further increasing the availability.
Operation backup, extension
Capital spares
Spares which in afew cases maybe be justied when extra reliability is needed. The scope can vary within wide limits from rotor coils to a complete spare machine.
Review of spare parts ABB Machines after-sales group les all the documents for each supplied machine. Based on the motors or generators serial number, detailed information can be retrieved for use later on to review the spares. In these reviews recommendations are given not only for the replacement of parts but also changing over to more modern solutions. Spares support With a well-planned stock of spares a stock where the spares are based on spares recommendations where the spares are easy to nd the basis for a high availability has been set for the machines supplied by us. But despite this, it is inevitable that spares must be procured. Spares utilized have to be replaced. It is not always possible to predict the need for spares and to stock them.
In these cases it is necessary to have a supplier having good spares logistics who is able to dispatch quickly the missing component. We have a well-planned spares support arranged in co-operation with ABB Logistic Center. By means of well-developed logistics, individually adapted routines for spares of different types and co-operation with global courier services, we are able to provide suitable spares support. For certain spares, e.g., printed circuit boards, repairs and return to the stock are a cost-effective solution. We have the routines for this. With access to the drawings, also for older machines, we are able to manufacture spares or propose new, modern solutions.
We reserve all rights in this document and in the information contained therein. Reproduction,use or disclosure to third parties without express authority is strictly forbidden. ABB Automation Technology Products; 2003
1.
Purpose The purpose of this instruction is to define the grouting methods that we recommend as a supplier of electric machines. There are other methods for grouting but the following methods have been found to work well in most cases.
2.
General safety instructions The work described in this manual is only to be performed by trained and authorized personnel. The manufacturer is not responsible for incorrect use, which affect the safety due to change, use of components from other supplier than ABB, neglect or misuse. The actual design can differ from the illustrations in this instruction. Contact ABB at slightest uncertainty that can affect the safety. Use of solvents when cleaning and use of lubricants and other chemicals can affect the health and/or the safety of the personnel. The recommended safety measures and procedures from the supplier shall be followed. The user must see to that the machine is properly secured in all points when lifting and other work that may cause injuries.
3.
References This document refers to a number of order specific documents. 1. Outline drawing The measurements of the electric machine are indicated on the outline drawing valid for the order. 2. Foundation detail drawing See valid figure drawing for mounting of foundation details (stated on outline drawing) for measurements of foundation details.
Type des. Prep. Appr. Resp. dept
Part no.
MKU / Stefan Palmgren / Palmgren Stefan J MKU
2003-05-27 Approved
Doc. kind Title
Installation Instruction Grouting of machine foundation plates

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No. of p.
7
Page
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3BSM007280
en
4.
Preparations before mounting and coarse alignment Before mounting of the machine is begun, check that the foundation corresponds with the valid foundation detail drawing. The rotor is not in the magnetic neutral position at delivery due to transport locking. The theoretical measurement for the axial neutral position of the machine is indicated on the valid outline drawing (measurement L5 on the foundation detail drawing). See test protocol in the machine manual for the exact as built measurement and use this measurement for final fine alignment. The foundation details are normally supplied with the contact surfaces untreated. If the surfaces are treated with paint or other rust prevention, these surfaces must be sand blasted clean before grouting is done.
5. 5.1
Mounting and alignment Separate grouting of sole plates The sole plates should be aligned in accordance with the specified outline drawing and foundation detail drawing. 1. Check on the underside that the threaded holes in the sole plates for the electric machine mounting screws are covered with foam rubber strips and that the holes for taper pins are covered with tape. The threaded holes are covered with foam rubber strips so the list, when mounting the machine, can be compressed and create space for the top of screws under the sole plates. Every thread in the sole plate will then be used. The holes for taper pins are covered to avoid that these are filled with grouting mix. 2. Mount the anchor bolts in the holes in the sole plate (see figure 1). The nuts of the anchor bolts shall be screwed on so the plastic tubes are tight mounted between the square washers and the sole plates, and the top of the anchor bolts are in level with, or just above the upper edges of the nuts (See figure 3). Cut the plastic tubes if necessary.
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Figure 1
3. Lift the sole plates in place. The plates are supported by adjustment screws that run through the sole plate and rest on steel washers. The adjustment screws are later used to adjust the plates vertically. (See figure 2.)
Machine CL Machine center height according to outline drawing + 2 mm for shims Adjustment screw
Steel washer
Figure 2 4. Adjust the position of the plates horizontally and vertically (See figure 2) 5. The plates should be appropriately locked horizontally before grouting is begun. 6. Check the location of the sole plates acc. to drawing: Foundation details. 7. After grouting process the adjustment screws should be cut flush with the sole plate 5.2 Grouting of machine with pre-mounted sole plates When grouting a machine with sole plates, the plates shall be mounted on the machine according to valid foundation detail drawing. Taper pins are to be mounted after final fine adjustment. Mounting of sole plates to machine: 1. Min. 2 mm shims should be placed between the machine and sole plates before the machine is put on the sole plates (See figure 3.) 2. Assemble the pipes (item 9 on drawing: Foundation details) on the mounting screws of the machine. This is done to centre the hole of the machine foot to the sole plate, which will allow horizontal adjustment after grouting. When the sole plates are centred, the mounting bolts are tightened so that the plate is fixed against the machine feet (See figure 3). 3. The anchor bolts are mounted in the holes according to valid foundation detail drawing before the machine is lifted into place. The nuts of the anchor bolts shall be screwed on so the plastic tubes are tight mounted between the square washers and the sole plates, and the top of the anchor bolts are in level with, or just above the upper edges of the nuts (See figure 3). Cut the plastic tubes if necessary.
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Figure 3 4. Mount the M16 adjustment screws from beneath the sole plate (see figure 3.1). Tighten the screws so they run free from the bottom of the recess in the foundation. If necessary cut the bolt flush with the topside of the sole plate. The adjustment screws are used to create extra support for the plate after grouting. They have no adjustment function.
Figure 3.1
WARNING Heavy lift

The machine is a very heavy unit. Use lifting equipment that is appropriate for the load, see valid outline drawing for weight.
5. Trestle the machine according to valid foundation detail drawing during grouting. Adjustment of height is done with appropriate shims. To raise the machine lifting jacks with low design (max 80 mm). The lifting jacks are placed between foundation and sole plate.
*)
Support blocks + Shims
*) A
Lifting jacks
*)U s e d w h e n 4 lifting jacks/side are needed
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Figure 4. 6. Grouting
WARNING Risk of personal injury

Grout is health- and environment-impairing, see manufactures product information.
Grouting is done in the recesses of the foundation. The grouting shall be done with a for the application appropriate fluent shrink-free grouting mix. To achieve a good result, the use of Masterflow 928 or other equivalent product is recommended. Follow the suppliers instructions and work descriptions accurately. During the grouting the anchor bolts hangs down in the recess holes of the foundation, see valid foundation detail drawing. If Masterflow 928 is used, it is recommended to perform the grouting in two stages. For other grouting mixes the supplier recommendations shall be followed. Firstly, the holes for the anchor bolts are grouted. These are filled with grouting mix to about 2 cm from the upper edge. (See figure 1) When this has cured, any water that has protruded is removed and the final grouting under the sole plates is done. The whole space under and around the sole plates is to be filled with grouting mix. It is of outmost importance that no air pockets are formed under the sole plates, as this can lead to operation disturbances such as e.g. vibration problems. The mixing of the grouting mix shall be done exactly according to the manufacturers instructions. 7. Fine alignment Before the machine is fine aligned, the grouting mix must cure. Contact the supplier of the grout for information about curing times. After the grouting has cured the anchor bolts shall be tightened to the torque value indicated on the foundation detail drawing. This procedure shall be done before the fine alignment is begun. Fine alignment is done according to the electric machine operations and maintenance manual. The machine can be adjusted horizontally when the bolts have been loosened. The height of the machine is adjusted with shims. Some machines are equipped with vertical adjustment screws that can be used to lift the machine. In other cases lifting jack with low design are used. When desired alignment result is achieved the screws are tightened to the torque value indicated on the foundation detail drawing. Taper pins are mounted after final fine alignment.
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8.
Other
WARNING Component damage

To avoid damages the following instructions must be carried out. Check that air ducts and spaces in connection to the machine are free from loose concrete remnants and other pollution that can be drawn into the machine when started. Air ducts with concrete walls shall be painted for concrete to bond the concrete dust.
9.
Responsibility The purchaser is responsible that the foundation is dimensioned and designed correctly. Consideration shall be taken to, amongst others local conditions, occurring forces, passage for pipes and cables and also that service and maintenance can be performed.
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REVISION Rev. ind. Page (P) Chapt. (C) A B C D General Fig: 1 & 3 General P 2-5 Description Warning signs and text added Anchoring bolts were counter sunk Sole plates where foundation plates, point 4 add in 5.2 Chapter 4; 5.1.1; 5.1.2; 5.2; 5.2.3; 5.2.4; 7 Date Dept./Init. MK/SP MKU/WM MK/SP MKU / HAAK
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Service & Repair
Synchronous machine
Instruction for removal of rotor on site
(GBA/AMS 1000, 1120, 1250, 1250A)
Contents
1 - Safety 1.1 General safety instructions ......................... 3 2 - Instruction for removal of rotor on site. 2.1 Overhaul of machines according to Level 4 inspection in the manual............................. 4 2.2 Planned work.............................................. 5 2.3 Removal of main rotor ............................... 6 2.4 Assembly of main rotor............................ 13 2.5 Recommended tightening torque for bolts16
Synchronous machine Removal removal
NOTICE The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any kind arising from the use of this document, nor shall ABB be liable for incidential or consequential damages arising from the use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABBs written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
3BSM 009020, Rev. B EN 060628
3BSM 009020
ii
Synchronous machine Safety
1 Safety
1.1 General safety instructions
3BSM 009020, Rev. B EN 060628
3BSM 009020
Synchronous machine Rotor removal
2 Instruction for removal of rotor on site.

2.1 Overhaul of machines according to Level 4 inspection in the manual
Preparations
WARNING - Heavy lift

Make sure that all equipment is in good condition and appropriate for the load before starting the procedure.
Site PPE requirements. Hi Viz Jacket Safety Helmet Safety Glasses Safety Boots
3BSM 009020, Rev. B EN 060628
3BSM 009020
2.2 Planned work
WARNING - High voltage This work involves the main circuits of the generator normally connected to the high voltage supply net. Before you start to work: 1. Make sure the generator is disconnected from the high voltage net and that the circuit breaker is locked in the open position so it not accidentally (or otherwise) can be closed during the measurements. Note also that capacitors can contain dangerous voltages, so be sure to ground all details before you touch them.
2.
Remove the cooler top, covers, bearings, main rotor and perform level 4 inspection. Dismantling, assembling and inspections including measurements in accordance with the order specific manual for the machine.
3BSM 009020, Rev. B EN 060628
3BSM 009020
2.3 Removal of main rotor
WARNING - Risk of personal injury When the rotor is moved out of the stator and is supported for fitting a new extension piece, make sure to place an external support under the exciter end. The centre of gravity is otherwise outside the support and the rotor will tip, possibly endangering personnel.
Sliding support plate Draw plate Sliding plate
Figure 2-1 NOTE: It is strongly recommended that rotor removal and reassembly should be performed by professional service or commissioning engineers authorised by ABB. 1. Ensure that a valid work permit is applicable and all members of the working party are familiar with the work method statement, the specific maintenance procedures and test required. Ensure before working on any electrical equipment, general electrical safety precautions are to be taken and local regulation are to be respected, according to instructions of the customer personal in charge of security, in order to prevent personnel accidents. See users manual, Chapter 7.
3BSM 009020, Rev. B EN 060628
2.
3BSM 009020
3.
Ensure before start of work that the machine is disconnected from the high voltage net and that the circuit breaker is locked in the open position so it not accidentally (or otherwise) can be closed during work and measurements. Ensure that the machine is grounded. See user manual, Chapter 5. Before use inspect the installed lifting equipment and ensure that all lifting equipments have current test certificates. Disconnect the machine shaft from all the driven objects. The rotor pole position should be 3, 6, 9 and 12 oclock. Remove the end plates on the cover and cooler top by the crane. Remove the PMG stator and in accordance with the users manual. Remove the exciter stator by the truck and in accordance with the users manual. Remove the oil pipes, temperature probes etc from the bearing in accordance with the manual.
4. 5. 6. 7. 8. 9.
10. Assembly the draw plate to the shaft end on ND-end. 11. Apply the towing equipment on D-end and ND-end, use tackle blocks/chain hoists (optional equipment) and slings (optional equipment). See Figure 2-2 on page 7. D-end - shall be mounted somewhere on the gearbox/steam turbine, on a hook in the wall or something else and around the shaft end, and shall be used as counterstay to prevent to much movement during the removal of the rotor. ND-end - shall be mounted on a hook in the wall or somewhere else and to the draw plate mounted on the shaft, and shall be used to draw the rotor out of the stator.
Towing equipment Max 5kN
Max 5kN
Towing equipment
3BSM 009020, Rev. B EN 060628
Figure 2-2
3BSM 009020
12. Before the slings are mounted around the shaft the sliding support plate must be mounted. Place the sliding support plate into the air gap between the rotor and stator in pole position 12 and then slide the plate around to pole position 6. Extreme care should be taken when inserting and sliding the tool not to damage the stator core and winding. See Figure 2-3 on page 8. Sliding support plate
Figure 2-3
3BSM 009020, Rev. B EN 060628
3BSM 009020
13. Erect the mobile/overhead crane on the ND-end side for removing of the rotor. See Figure 2-4 on page 9.
Figure 2-4 14. Loosen the end shield on the ND-end. 15. Dismantle the upper half of D-end bearing in accordance with the users manual.
3BSM 009020, Rev. B EN 060628
3BSM 009020
16. Lift the rotor on D-end about 0.5 mm by a 20-30 tons lifting jack. 17. Remove the lower half of the D-end bearing shell in accordance with the users manual. 18. Place the sliding plate into the sliding support plate at the D-end, see Figure 2-5 on page 10.
Sliding plate
Figure 2-5 19. Lower the rotor so that it rests on the sliding plate. 20. Gently pull the rotor towards to the ND-end and at the same time loosen on the D-end until upper part of the sliding tool reach the ND-end of the stator core, about 50 mm left of the end of the stator core. Support underneath the ND-end shield. See Figure 2-6 on page 10.
5kN
50
3BSM 009020, Rev. B EN 060628
Sliding plate
Figure 2-6
3BSM 009020
10
21. Move the slings to be around the rotor body and lift with the mobile/overhead crane and move carefully towards the ND-end. Be sure that the rotor is in balance before moving so the rotor not will destroy the stator coil ends. Move until the rotor is free to be removed.
Figure 2-7 22. Support underneath the shaft on the D-end and underneath the pole on ND-end by hard wood and remove the support underneath the ND-end shield. See Figure 2-8 on page 11.
Figure 2-8 23. Remove the ND-end shield and bearing.
3BSM 009020, Rev. B EN 060628
3BSM 009020
11
24. Lift the rotor and lay it down on the cradle. See Figure 2-9 on page 12.
Figure 2-9 25. Perform the inspection Level 4 in accordance with the users manual. Store the rotor on solid supports and high enough so that the exciter not will be destroyed. Protect the rotor with a tapaulin. Store both halves of the bearing shells in a very clean place. It is strictly forbidden to store metal chips and other metallic compontents together with the bearings. Make sure that the bearing halves are stored together and that they cannot be mixed with other components when both bearings (D-end and ND-end) are store together. The bearing halves are marked with identity numbers to avoid incorrect assembly which could cause serious problems.
3BSM 009020, Rev. B EN 060628
3BSM 009020
12
2.4 Assembly of main rotor

1. 2. 3. 4. If the sliding tool have been removed, mount it back according to step 2-3. Place the sliding support plate into the stator winding. Extreme care should be taken when inserting the tool not to damage the stator core and winding. Place the sliding plate into the sliding support plate on the ND-side. Lift the rotor and support underneath the shaft on the D-end and underneath the pole on ND-en by hard wood and assembly the ND-end shield and bearing. See Figure 2-8 on page 11
Figure 2-10 5. Lift the rotor in position as in Figure 2-11 on page 13 and put a support underneath the ND-end shield. The rotor pole possition should be 3,6,9 and 12 oclock. The rotor shall now rest approx. 250 mm on the sliding plate. Be sure that the rotor is in balance when moving the rotor into the stator so the rotor will not destroy the stator winding.
Sliding plate
3BSM 009020, Rev. B EN 060628
Figure 2-11
3BSM 009020
13
6. 7.
Move the slings from the rotor body to between the exciter and the bearing, see Figure 2-12 on page 14. Apply the towing equipment on D-end and ND-end, use tackle blocks/chain hoists (optional equipment) and slings (optional equipment). See Figure 2-12 on page 14. D-end - shall be mounted somewhere on the gearbox/steam turbine, on a hook in the wall or something else and around the shaft end, and shall be used to draw the rotor into the stator. ND-end - shall be mounted on a hook in the wall or somewhere else and to the draw plate mounted on the shaft, and shall be used as counterstay to prevent to much movement during assembling of the rotor. Towing equipment
Towing equipment 5kN
Figure 2-12 8. 9. Gently pull the rotor towards to the D-end and at same time loose on ND-end until the rotor is back in same position as before dismantling. Place a 20-30tons lifting jack underneath the shaft on D-end. See Figure 2-13 on page 14.
Sliding plate
3BSM 009020, Rev. B EN 060628
Figure 2-13
3BSM 009020
14
10. Lift the rotor, on D-end, about 0.5mm with the lifting jack. 11. Reassembly the end shield on the D-end. 12. Assembly the lower half of the D-end bearing and end shield in accordance with the users manual. 13. Remove the towing equipments. 14. Remove the sliding plate from the sliding support plate. 15. Lower the rotor down into the D-end bearing wiht the lifting jack. 16. Remove the lifting jack from the D-end. 17. Remove the lifting slings. 18. Remove the sliding support plate by sliding the plate from position 6 to position 12 and remove the plate carefully from the air gap. Be careful not destroy the stator winding and stator coil ends. 19. Reassembly the upperhalf of the D-end bearing accordance with the users manual. 20. Reassembly the oil pipes, temperature probes, etc to the bearing in accordings with the manual. 21. Reassembly the exciter stator and in accordance with the users manual. 22. (If PMG) Reassembly the PMG stator in accordance with the users manual. 23. Reassembly the end plates on the cover. 24. Reassembly the cooler top. 25. Connect the machine shaft to the driven/driving object. 26. Clean and clear site working area of all tools and equipment.
3BSM 009020, Rev. B EN 060628
3BSM 009020
15
2.5 Recommended tightening torque for bolts

Recommended tightening torque for bolts property class 8.8, slightly coated with oil. NOTE: Do not use Molybdenum di-sulphide, Molycote.
Bolt size Torque (Nm) (lbft)
M8 22.5 16.6
M 10 45 33
M 12 79 58
M 16 190 140
M 20 420 300
M 24 735 550
M 30 1500 1100
3BSM 009020, Rev. B EN 060628
3BSM 009020
16
3BSM 009020
2006-06-28
Service & Repair
Synchronous machine
Replacement of diodes and thyristors
Document No.: 3BSM901869
Contents
1 - Safety
1.1 General safety instructions ............................................ 3
Chapter 2 - Replacement of diodes and thyristors

2.1 2.2 2.3 Change of diode ............................................................. 4 Change of control pulse unit.........................................11 Recommended tightening torque for bolts on the machine........................................................................ 12
Synchronous machine
NOTICE The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any kind arising from the use of this document, nor shall ABB be liable for incidential or consequential damages arising from the use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABBs written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
3BSM901869, Rev. - EN -
3BSM901869
ii
Synchronous machine Safety
Safety
1.1 General safety instructions
3BSM901869, Rev. - EN -
3BSM901869
Synchronous machine Replacement of diodes and thyristors
Chapter 2 Replacement of diodes and thyristors
WARNING - Diode fault

If a faulty diode or thyristor the recommendation is to replace all diodes, thyristors and control pulse unit.
Warning - Magnetic force

There are very strong magnetic forces between the PMG rotor and stator. 1. 2. 3. Be extremely careful when removing the PMG stator frame. There are very strong magnetism to avoid, and prevent damage to components due to magnetic forces. Remove your own wrist watch, credit cards and digital equipment before working around those strong magnetic forces. Personnel with pace maker should not be working in the vecinity of the PMG.
2.1 Change of diode

In order to loosen the assembly bracket, remove the two plastic plugs (one on each screw). Open the spring lock as shown in Figure on page 5 and Figure on page 5 at the assembly bracket by using a screw driver and a mirror.
3BSM901869, Rev. - EN -
Figure 2-1
(1250-11)
3BSM901869
Figure 2-2
(1250-12)
Loosen the hex. head socket cap bolts while pushing out the spring lock and lower the bracket so much that the diode can be removed. See Figure 2-3 on page 5.
3BSM901869, Rev. - EN -
Figure 2-3
(1250-13)
Observe and write down the direction of the black arrow on the front of the diode. The replacement diode must point in the same direction during the assembly proceedure.
3BSM901869
The guide pin (roll pins) on each side of the diode are loose items. Make sure to place them in a safe place to avoid loss. See Figure 2-4 on page 6
Figure 2-4
(1250-14)
Clean the contact surface between the diode and the assembly bracket and the contact surface between the diode and the heat sink with piece of cloth damped in ACETONE. See Figure 2-5 on page 6.
3BSM901869, Rev. - EN -
Figure 2-5
(1250-15)
3BSM901869
Clean the contact surfaces of the new diode by using steel wool and a cloth damped with ACETONE. See Figure 2-6 on page 7 and Figure 2-7 on page 7.
Figure 2-6
(1250-16)
3BSM901869, Rev. - EN -
Figure 2-7
(1250-17)
3BSM901869
Apply a thin coat of Silicon grease (ABB part number 1269 0011-105) to both sides (contact areas) of the diode. See Figure 2-8 on page 8.
Figure 2-8 Place the diode back between the heat sink and the mounting bracket.
(1250-18)
NOTE: Rotate the diode so that the arrow marking of the diode is visible at the front. Check that the black arrow on the diode points in the same direction as the one that was removed earlier. See Figure 2-9 on page 8.
3BSM901869, Rev. - EN -
Figure 2-9
(1250-19)
3BSM901869
Be careful that both guide pins (roll pins) are in place before tightening the bolts. See Figure 2-10 on page 9.
Figure 2-10
(1250-20)
Tighten the screws carefully one at a time so that the mounting bracket applies an even pressure to the diode. A spring is attached at the rear side of the mounting bracket which snaps in place when the right torque is reached. (Note that in the dismantling mode, the screw driver was used to remove this spring to permit loosening of the screws). Use a dentists mirror (a mirror with a handle) behind the spring to check that the spring has snapped in place. Check with the mirror that there
3BSM901869, Rev. - EN -
3BSM901869
is no visible gap between the spring and the mounting bracket body. The spring must be in place before the assembly is completed. See Figure 2-11 on page 10.
Figure 2-11 Replace the plastic plugs.
(1250-21)
3BSM901869, Rev. - EN -
3BSM901869
10
2.2 Change of control pulse unit

Disconnect the thyristor cables from the control pulse unit. Loosen the two bolts which hold the control pulse unit to the holder, see Figure 2-12 on page 11.
Loosen the two bolts
Figure 2-12 Observe the connection of the control pulse unit, the new control pulse unit should have same connection. For reassembly, mount the components in the reverse order.
3BSM901869, Rev. - EN -
3BSM901869
11
2.3 Recommended tightening torque for bolts on the machine

Recommended tightening torque for bolts, property class 8.8, slightly coated with oil. OBS: Do not use Molybdenum di-sulphide, Molycote. Bolt size Torque (Nm) (lbft) M8 22.5 16.6 M 10 45 33 M 12 79 58
M 16 190 140
M 20 420 300
M 24 735 550
M 30 1500 1100
3BSM901869, Rev. - EN -
3BSM901869
12
3BSM901869
2009-03-18
Installation and maintenance
Synchronous generator, type AMS 1250LD Project: TABACAL Project no.: L 000979
NOTICE The information in this document is subject to change without notice and should not be construed as a commitment by ABB AB, Machines. ABB AB, Machines assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any kind arising from the use of this document, nor shall ABB be liable for incidential or consequential damages arising from the use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB AB, Machiness written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
Skeleton No. 3BSM005467, EN, Rev. E
Synchronous generator, type AMS Table of Contents
Chapter 1 - Introduction
1.1 1.2 1.3 1.4 1.5 1.6 General information.................................................................................................... 7 Safety .......................................................................................................................... 7 Site conditions............................................................................................................. 7 Prerequisites................................................................................................................ 8 Contraindications ........................................................................................................ 8 Manual system and related documents ....................................................................... 9
Chapter 2 - Transport, Storage and Preparation for erection

2.1 Transport and unpacking .......................................................................................... 10 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.3.1 2.3.2 2.3.3 Protective measures prior to transport ..................................................... 10 Check upon arrival................................................................................... 10 Transport anchor points ........................................................................... 11 Transport anchor points ........................................................................... 12 Lifting of crated equipment ..................................................................... 13 Unpacking................................................................................................ 13 Lifting of equipment ................................................................................ 14 Short term storage of crated generator..................................................... 16 Long term storage of crated generator..................................................... 16 Short term storage of uncrated generator................................................. 17 Long term storage of uncrated generator................................................. 18 Check of foundation................................................................................. 18 Vertical and horizontal positioning.......................................................... 19 Removal of the transport locking device ................................................. 21
Storage (this generator is prepared for long term storage) ....................................... 16
Preparation for erection ............................................................................................ 18
Chapter 3 - Alignment
3.1 3.2 3.3 3.4 3.5 Preparations for generator installation...................................................................... 22 Rough levelling of generator after erection .............................................................. 23 3.2.1 Rough alignment...................................................................................... 23 Grouting .................................................................................................................... 24 Correction for thermal expansion ............................................................................. 25 Final alignment and inspection ................................................................................. 25
Chapter 4 - Mechanical and electrical installation

4.1
Skeleton No. 3BSM005469, Rev. - EN -
Mechanical installation ............................................................................................. 26 4.1.1 4.1.2 4.1.3 Cooling arrangement................................................................................ 26 Connection of oil pipes ........................................................................... 26 Mounting of main terminal box ............................................................... 27
XYK 210 090- FLD
4.2
Electrical installation ................................................................................................ 28 4.2.1 4.2.2 4.2.3 Connection of control equipment ............................................................ 28 Connection of high voltage cables........................................................... 28 Earth connection ...................................................................................... 28
Chapter 5 - Commissioning
5.1 5.2 5.3 5.4 5.5 5.6 Check of mechanical installation.............................................................................. 29 Check of electrical installation ................................................................................. 30 Electrical checks ....................................................................................................... 31 Before the first start attempt ..................................................................................... 36 The first start attempts .............................................................................................. 36 5.5.1 5.6.1 Start interlocking...................................................................................... 36 Normal vibration levels ........................................................................... 37 5.6.1.1 5.6.1.2 5.6.1.3 5.6.2 5.7 5.7.1 5.7.2 5.7.3 Bearing housings ...............................................................37 Structural vibrations ..........................................................37 Shaft vibrations .................................................................38 Checks during running of the generator ................................................................... 36
Temperature levels................................................................................... 38 Page 1....................................................................................................... 39 Page 2....................................................................................................... 40 Page 3....................................................................................................... 41
Check list .................................................................................................................. 38
Chapter 6 - Operation
6.1 6.2 6.3 6.4 Start up procedure..................................................................................................... 42 Continuous supervision............................................................................................. 42 Shut down procedures............................................................................................... 43 Alarm during operation............................................................................................. 43
Chapter 7 - Maintenance
7.1 7.2 7.3 Preventive maintenance ............................................................................................ 46 Before all maintenance work .................................................................................... 46 Recommended maintenance program....................................................................... 47 7.3.1 7.3.2 7.3.3 7.3.4
Generator ................................................................................................. 48 Stator........................................................................................................ 49 Stator terminal.......................................................................................... 50 Rotor ........................................................................................................ 51 Bearings ................................................................................................... 53 PMG (Permanent magnetic generator) .................................................... 55 Exciter and Rectifier ............................................................................... 57
7.3.5 7.3.6 7.3.7
XYK 210 090- FLD
ii
7.3.8 7.3.9 7.4 7.5
Rotor earth brush ..................................................................................... 58 Cooling system ........................................................................................ 59
Main rotor coil turn insulation (voltage drop test).................................................... 60 Fault finding.............................................................................................................. 60 7.5.1 7.5.2 7.5.3 7.5.4 Diode fault ............................................................................................... 61 Altering the firing voltage........................................................................ 63 Lubrication............................................................................................... 64 High temperature in bearing .................................................................... 66 7.5.4.1 7.5.4.2 7.5.4.3 7.5.5 7.5.5.1 Trouble shooting 1 ............................................................66 Trouble shooting 2 ............................................................67 Trouble shooting 3 ............................................................68 Trouble shooting ...............................................................69
High winding and/or air temperature....................................................... 69
Chapter 8 - Disposal and Recycling

8.1 8.2 8.3 General...................................................................................................................... 70 Dismantling the machine .......................................................................................... 70 Separation of different types of material .................................................................. 70 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 8.3.8 8.4 8.5 8.6 Normal carbon steel ................................................................................. 70 Electrical silicon steel non oriented ......................................................... 71 Special high quality steel ......................................................................... 71 Mixed metallic material ........................................................................... 71 Stainless steel........................................................................................... 71 Cast iron................................................................................................... 71 Aluminium ............................................................................................... 71 Copper...................................................................................................... 72
Waste as land fill....................................................................................................... 73 Hazardous waste ....................................................................................................... 73 Final comments......................................................................................................... 73
XYK 210 090- FLD
iii
Synchronous generator, type AMS Chapter 1 Introduction
Chapter 1 Introduction
1.1 General information

This installation and maintenance manual for the generator is a part of the main documentation for this project. (refer to Section 1.6 ). This document is a manual for the generator with serial number 8267 088 and manufacturers order number L 000979. Actions described in this manual are only to be performed by trained personnel with previous experience in similar tasks, and authorized by the user.
1.2 Safety
The machine is manufactured and intended for use only as described by this manual. Modification, alteration, or lack of maintenance as described in the manual, may adversely affect the safety and efficacy of this machine. The manufacturer is not responsible for malfunctions that comprise machinesafety as a result of alteration, use of non ABB replacements parts, neglect or misuse. Replacements parts may vary from those shown in this manual. Should you have questions on those parts please contact ABB AB, Machines. The actual apperarance of the machine may vary from the illustration in this manual. Should pre-owned ABB equipment be purchased and reconditioned, the equipment should not be used until testing and analysis demonstrate that the equipment meets the original or upgraded specifications. The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards. The recommended precautions and procedures of the manufacturer should be followed.
1.3 Site conditions

This generator is to be used on a site with conditions according to ABB AB, Machiness Technical Specification (included in binder Users Manual), clause D Site conditions and nowhere else.
XYK 210 090- FLD
1-7
1.4 Prerequisites
The operator must: be proficient in the application of the machine and electricity. be thoroughly trained in the skills and have the knowledge required to operate this machine. be thoroughly familiar with the contents of this manual and other operators manuals that deals with the machine and accessory devices that may be used with this machine. be fully qualified and trained in the operation of this machine and able to distinguish normal from aberrant device behaviour. never reset an alarm or trip until the reason for the alarm/trip has been located and necessary remedy has been made to make a safe restart of the machine.
1.5 Contraindications
The machine is not designed, sold or intended for any use except as indicated above. Furthermore, it is not intended to be used outside of the machine specifications or limitations. The machine must be in good working order.
XYK 210 090- FLD
1-8
1.6 Manual system and related documents

Project: TABACAL Project number: L 000979 Serial number 8267 088
Users Manual for the generator
ABB AB, Machines Scope of Supply General ABB AB, Machines AMS Synchronous generator Technical Specification Drawings for the generator Circuit Diagrams Machine part list
Test Reports
Installation & Maintenance manual Accessories & Instructions Main terminal box
XYK 210 090- FLD
1-9
Synchronous generator, type AMS Chapter 2 Transport, Storage and Preparation for erection
Chapter 2 Transport, Storage and Preparation for erection
2.1 Transport and unpacking 2.1.1 Protective measures prior to transport

Irrespective of the method of transport or the distance, all generators are provided with an axial movement locking device on the drive end bearing, to protect the bearings against damage during transport. Machined metal surfaces, such as the shaft extension, are provided with an anti-corrosive coating before delivery. The bearings are flooded with oil during the tests prior to delivery. This gives sufficient protection against corrosion for even the longest transport distances. The cooler should drain (blow) off water. For shipping overseas a generator of this size is packed in a strong wooden crate and should be located under deck. The wooden crate is provided with metal plates for protection and indications showing where the lifting wires are to be applied.
2.1.2 Check upon arrival

When the transport company delivers a generator to the customer, the responsibility for the handling passes to the customer or other party. Any transport damage must be reported within less than one 1 week after arrival if the transport insurance is to be claimed. It is therefore important that evidence of careless handling are to be checked and reported immediately to the transport company and the supplier. A generator which is not to be installed immediately upon arrival must not be left without neither supervision nor without protective precautions. If the storage period is to be 9 months or more special precautions must be taken.
Skeleton No. 3BSM005471, EN, Rev. G
XYK 210 090- FLD
2-10
2.1.3 Transport anchor points
CAUTION - Risk of component damage

Components on the generator housing can get damage during transport. 1. Make sure the anchoring is tight so no movement is allowed in either direction.
Anchoring point
It is important to be careful within this area.
Figure 2-1 Anchor points during transport on lorry. Beware of area that is dotted in accordance with Figure 2-1 on page 11.
XYK 210 090- FLD
2-11
2.1.4 Transport anchor points
CAUTION - Risk of component damage

Components on the generator housing can get damaged during transport. 1. Make sure the anchoring is tight so no movement is allowed in either direction.
Anchor point
Figure 2-2 Anchor points during transport on lorry or by vessel, located on both sides of the crate.
XYK 210 090- FLD
2-12
2.1.5 Lifting of crated equipment

The crate with equipment is very heavy. 1. 2. Use lifting equipment that is appropriate for the load. Lifting must be performed with great care and using steel cables long enough to assure the angle requirements shown in Figure 2-3 on page 13. Centre of Gravity is shown on each crate.
0.86xB
60o
Figure 2-3
2.1.6 Unpacking
Place the generator so that it is out of the way of any other goods handling and on a flat, vibration-free surface. Remove top and sides of the wooden crate. When the crating has been removed a check should be made to see that the generator is not damaged and that all accessories are included. Tick off the accessories on the packing list which is enclosed. Report immediately to the supplier if there is any damage, suspected damage or if accessories are missing.
XYK 210 090- FLD
2-13
2.1.7 Lifting of equipment

The generator and the cooling top are very heavy units. 1. Use lifting equipment that is appropriate for the load, see Technical Specification for weight.
When lifting the machine, with the cooler top delivered separate, ensure to have accurate angle on lifting slings, as shown in Figure 2-4. (Otherwise there will be risk of damaging the upper sheet metal housing).
60o
60o
Figure 2-4 When lifting the cooling top see Figure 2-5 and also the instruction Mounting of cooler top included in the binder Users Manual
XYK 210 090- FLD
2-14
Lifting hooks (not included) position towards lifting device
D=30, Ellipsed
Lifting device
4 Lifting points,approx. lifting angle 45o
Figure 2-5

The terminal box is very heavy. 1.
.
Use lifting equipment that is appropriate for the load, see outline drawing included in the binder Users Manual.
Figure 2-6 on page 15 shows an example how the main terminal box should be lifted. As an option a smaller box could be included in the scope of supply, instead of as shown in Figure 2-6 on page 15. Then it will just be supplied with two lifting loops on top. Not included
Figure 2-6
XYK 210 090- FLD
2-15
2.2 Storage (this generator is prepared for long term storage) 2.2.1 Short term storage of crated generator
Storage < 9 month Measures to be taken by customer or other part. The machine should be left in the crate. The crate should preferably be stored indoors and shall be placed on a vibration-free, flat and well-drained surface. If the crate is to be stored outdoors, the crate must be covered with a tarpaulin on the top extending at least 1 meter out from the crate to avoid direct rain on the crate. The crate should be kept dry, protected from rain and moisture.
Before commissioning the following items should be carried out: Visual external inspection of bearings and entering shaft Check insulation resistance in accordance with Section 5.3
2.2.2 Long term storage of crated generator

Storage > 9 month Long-term storage must be notified before delivery, so that the machine can be prepared and packed for the actual condition. If an unscheduled long-term storage is needed, please contact ABB. The machine should preferably be stored indoors and shall be placed on a vibration-free, flat and well-drained surface. Measures to be taken by customer or other part. If the machine is to be stored outdoors, it must be covered with a tarpaulin on the top extending at least 1 meter out from the crate to avoid direct rain on the machine. 1. 2. 3. 4. 5.
Remove top and sides of the wooden crate. (Indoors) Open the plastic protection to allow for a good ventilation. If cooler top is delivered separate, the cooler top must be mounted immediately on the machine or if not applicable dont remove the temporary transport covers. (Indoors) The machine should be protected from rain and moisture. If the machine is stored in a harsh environment measures should be taken to protect it against dust and dirt. To avoid condensation in the machine, the heating elements in main machine and exciter must be connected according to the circuit diagram, included in the binder Users Manual. Check regularly the anti-corrosion coating on NOT painted areas like shaft, flanges etc. and touch up if necessary. Measures should be taken to ensure that the heaters work properly at all time.
6. 7.
XYK 210 090- FLD
2-16
8. 9.
Corrosion preventive oil should be filled in the bearings, according to section 3.1 on page 22, once every 12 month. Rotation of the rotor is not required. The axial transport-locking device must always be mounted during transportation of the machine.
Before commissioning the following items should be carried out: Visual external inspection of bearings and entering shaft. Visual inspection of exciter. Visual inspection of rotor and stator windings. The corrosion preventive oil in the bearings must be drained before rotation. Check insulation resistance in accordance with Section 5.3 .
2.2.3 Short term storage of uncrated generator

Storage < 9 month The machine should preferably be stored indoors and shall be placed on a vibration-free, flat and well-drained surface. Measures to be taken by customer or other part. If the machine is to be stored outdoors, it must be covered with a tarpaulin on the top extending at least 1 meter out from the crate to avoid direct rain on the machine and be placed on at least 100 mm high rigid supports, as to make sure that no water can enter the machine from below. 1. 2. 3. 4. Open the plastic protection to allow for a good ventilation. If cooler top is delivered separate, the cooler top must be mounted immediately on the machine or if not applicable dont remove the temporary transport covers. (Indoors) The machine should be protected from rain and moisture. If the machine is stored in a harsh environment measures should be taken to protect it against dust and dirt. To avoid condensation in the machine, the heating elements in main machine and exciter must be connected according to the circuit diagram, included in the binder Users Manual. Check regularly the anti-corrosion coating on NOT painted areas like shaft, flanges etc. and touch up if necessary. Measures should be taken to ensure that the heaters work properly at all time. The axial transport-locking device must always be mounted during transportation of the machine
5. 6. 7.
Before commissioning the following items should be carried out:

Visual external inspection of bearings and entering shaft. Check insulation resistance in accordance with Section 5.3 .
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2-17
2.2.4 Long term storage of uncrated generator

Storage > 9 month Long-term storage must be notified before delivery, so that the machine can be prepared and packed for the actual condition. If an unscheduled long-term storage is needed, please contact ABB. The machine should preferably be stored indoors and shall be placed on a vibration-free, flat and well-drained surface. Measures to be taken accordance with Section 2.2.3 Short term storage of machine, < 9 month and in accordance to below: Corrosion preventive oil should be filled in the bearings, according to section 3.1 on page 22, once every 12 month. Rotation of the rotor is not required.
Before commissioning the following items should be carried out: Visual external inspection of bearings and entering shaft. Visual inspection of exciter. Visual inspection of rotor and stator windings. The corrosion preventive oil in the bearings must be drained before rotation. Check insulation resistance in accordance with Section 5.3 .
2.3 Preparation for erection

The structural design of the foundation is not included in ABBs undertaking, the customer or a third party is therefore responsible for this. Furthermore, the grouting operation is normally also outside ABBs undertaking and responsibility. The installation should be planned as early as possible.
2.3.1 Check of foundation

Before lifting the generator onto the foundation a check should be made to ensure that the foundation fulfils the following requirements: The foundation must be carefully cleaned. It must be flat. (If any inclination has been agreed upon the permissible inclination must be stated on the installation drawing.) Check that the position of the anchoring holes and the height of the foundation are in agreement with corresponding measurements in the inspection and test record, Magnetic neutral position, included in binder Users Manual. Attach a steel wire to the foundation to indicate the centre line of the generator. Mark also the axial position of the generator.
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2.3.2 Vertical and horizontal positioning
CAUTION - Risk of personal injury

Use a piece of carboard to insert the shims under the generator to avoid jamming your fingers if the jacks should fail. The vertical positioning of the generator is made with hydraulic jacks (optional equipment) placed as tight as possible to the two footplates in the middle and tight to the two outer footplates as shown in Figure 2-7 on page 19 and Figure 2-8 on page 20. As alternative if vertical adjustment screws are included the vertical positioning of the generator is made with them. ABB AB, Machiness delivery includes shims with 1 mm thickness, placed as shown in Figure 2-9 on page 20. Shims needed with other thicknesses are to be provided by the customer. Bracket plates, with adjusting screws for horizontal positioning of the generator are placed on the sole plates, as shown in Figure 2-7 on page 19.
Hydraulic jack Guiding pin only on D-end Vertical adjustment screws, if included
CL
Guiding pin only on D-end Bracket w. adj. screw
Figure 2-7
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Hose
Pump
Hydraulic jack, recommended NIKE CLF 220-13
Figure 2-8
Footplate, machine
Footplate in foundation Figur 2-9.
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Shims
Shaft height acc. to outline drwg.
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2.3.3 Removal of the transport locking device

The transport locking device is clamped to the shaft and bolted to the drive end side of the generator. The transport locking device consists of a divided clamp ring which locks the rotor against axial movements and rotation. See Figure 2-10 on page 21. Remove the screws which are screwed into the bearing housing. Remove the screws which hold the two halves of the locking device together. Lift off the transport locking device carefully. (Save the locking device for future needs).
Figure 2-10
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Synchronous generator, type AMS Chapter 3 Alignment
Chapter 3 Alignment
Introduction Good planning and preparation result in fast, simple and correct installation. Safe running conditions with maximum of accessibility are assured.
3.1 Preparations for generator installation

Auxiliary tools for the erection should be made and assembled at site if required: Suitable material for set-up and shimming as well as other auxiliary tools for erection are normally not included in ABB's delivery. (Auxiliary tools for erection, like hydraulic jack and bracket plates with adjusting screws, can be purchased from ABB as generator accessory.) Attachments for gauges, extension brackets and other alignment tools are to be made. Before the rotor is turned, oil must be poured into the bearings, by using an extender piping connected to the oil inlet pipe on the bearing . The funnel has to be placed above the bearing as the Figure 3-1 on page 22 shows. The outlet pipe should be open.
Connect to the oil inlet pipe
Figure 3-1. A simple lever is needed for turning the rotor. While turning the rotor, oil must be continuously poured into the funnels at both end of the generator.
Skeleton No. 3BSM005472, EN, Rev. F
If the generator is to be erected outdoors, sun and rain protection must be provided to eliminate measuring errors.
NOTE: When the surroundings are neither heated nor dry, heating equipment must be provided.
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3.2 Rough levelling of generator after erection

Check that the generator is radially and axially level. Make adjustments by placing shims under the four feet. The generator must be sitting on all feet on each side.
3.2.1 Rough alignment

Axially
Warning - Heavy lift

The generator is a very heavy unit. 1. Use lifting equipment that is appropriate for the load, see Technical Specification for weight. 2. If the unit has a cooling top, never lift the unit in the lifting ears of the cooling top.
Lift the generator onto the foundation plates as close to the actual position as possible. NOTE: The rotor is NOT in the magnetic neutral position when the generator is delivered. The rotor is in the magnetic neutral position when the dimension B and C is fulfilled, see Figure 3-2 on page 23. Read the correct distance in the Inspection and Test record Magnetic neutral position, included in the binder Users Manual.
A A to D-end to N-end
Figure 3-2. NOTE: It is important that the rotor is IN the magnetic neutral position when the generator is in operation.
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3.3 Grouting
When the generator has been properly aligned, its base elements are attached to the foundation by grouting. Use only non-shrinking concrete for grouting to ensure proper adhesion between the base frame and grouting. Make sure that the grouting fills properly the whole space around and under the base element. Do not use a vibrator in order to avoid any disturbance in the alignment. After the grouting has set (cured), adjust vertically to the final elevation by putting shims between the base frame and the base element. Check also the other alignments of the generator and adjust, if necessary. Non-shrink grout is recommended for the best results. For shaping and grouting, the manufacturers instructions to be followed.
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3.4 Correction for thermal expansion

Temperatures have a considerable influence and should be considered during the alignment. The temperature of the generator is lower during erection than it will be under operating conditions. For this reason the shaft centre is going to lie higher during operating conditions. Depending on the type of coupling, the distance between the generator and driven equipment, etc. compensating alignment may be necessary. The vertical movement of the shaft of due to thermal expansion the electrical generator is in acc. to drawing shaft displacement, included in the binder Users Manual.
3.5 Final alignment and inspection

After the generator has been roughly positioned, as described before, the final alignment can start. Lubricate the bearings at regular intervals during the final alignment in accordance with section 3.1 on page 22. The normal fault tolerance for alignment which ABB accepts is below 0.1 mm at operating temperature.
Radial misalignment Gap (angular displacement) Axial displacement Figure 3-3.
r b a
The tolerances given by the coupling manufacturers must not be used in deciding how accurate the alignment should be because these tolerances indicate what the coupling can accept. Excessive tolerances will give rise to vibrations, bearing damage etc. and therefore should tolerances as narrow as recommended above be aimed at. Finally check the axial distance between the two coupling halves.
An alignment record should be drawn for future checks.
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Synchronous generator, type AMS Chapter 4 Mechanical and electrical installation
Chapter 4 Mechanical and electrical installation
4.1 Mechanical installation 4.1.1 Cooling arrangement

Air to water If the cooler housing is delivered separately the following action needs to be taken: 1. Remove the transport roof on the generator.

The cooler housing is a heavy unit. 1. 2. 3. Use lifting equipment that is appropriate for the load, see Outline drawing for weight. Lift the cooler housing over the generator. Connect the hoses for the water leakage detector to the cooler drain, according to drawing 3BSM 001483-A . Lower the cooler housing until its almost resting on the generator (if possible), this will make it easier to adjust the housing to the generator. After all the bolts have been put in place lower the housing completely and tighten the bolts. Connect the cooler pipes. The cooling water pipes shall be laid so that they do not obstruct service and maintenance. The water pipes should be designed so that only a short part needs to be dismantled to allow cooler removal. The piping should be designed so that no stress is applied to the cooler flanges. Before the pipes are connected to the cooler they should be properly cleaned.
4.
4.1.2 Connection of oil pipes

The bearings are made for flood lubrication, the inlet pipe can be provided with an orifice to avoid overfilling. The return pipes should have an incline of 40-50 mm/m in order to guarantee trouble-free oil circulation. The oil pipes should be designed so that they do not obstruct service and maintenance. The pipes should be designed so that no stress is applied to the flanges on the generator.
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WARNING - Oil leakage

Flushing with the bearings connected might cause oil leakage. 1. Bypass the generator before flushing the oil system.
For required oil flow and pressure see outline drawing. The oil pipes should be carefully flushed before they are connected to the generator.
4.1.3 Mounting of main terminal box
CAUTION - Component damage

Great care should be taken when handling the main terminal box as it contains delicate equipment. To be able to transport the machine the main terminal box for the high voltage connection is delivered separately and must be fitted at site. The terminal should be supported so that no stress is applied to the generator. 1. 2. 3. 4. Remove the protection cover fitted over the generator bushings. Level the main terminal box so that no stresses will be induced to the generator bushings when they are connected to the busbars in the main terminal box. The joint between the main terminal box and the generator should be tightened according to instruction 3BSM 001263R0001, included in the binder Users manual. Before the high voltage cables are connected to the main terminal box the insulation resistance (megged) should be checked. Check both the generator insulation resistance (stator winding resistance) and the insulation resistance of the main terminal box according to instruction in Section 5.3 . The joint between the main terminal box and the generator should be insulated according to instruction 3BSM 004941, included in the binder Users manual. The insulation material has to be stored cold. For that reason it must be bought locally, ABB AB, Machines can not supply the insulation.
5.
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4.2 Electrical installation 4.2.1 Connection of control equipment

For terminal box location and content see outline drawing (included in binder Users manual). Connections should be made according to circuit diagram. NOTE: Space heaters in exciter and stator should be connected as soon as possible after unpacking. If the permanent supply is not available a temporary supply should be connected.
4.2.2 Connection of high voltage cables

The high-voltage cables are connected according to the terminal markings. Striping, splicing and insulation of the high voltage cables should be performed according to the instructions from the cable manufacturer. The high voltage cables are connected according to the terminal markings. The stator insulation resistance should be checked before final connection of the cables. Neutral point connection inside the cubicle.
4.2.3 Earth connection

The earth lead may be connected either inside or outside the terminal box and to both sides of the generator. For connection points on the generator see outline drawing (included in binder Users manual).
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Synchronous generator, type AMS Chapter 5 Commissioning
Chapter 5 Commissioning
On the commissioning personnel lies a great responsibility for a safe and trouble free operation of the generator during its lifetime. Commissioning should only be made by qualified personal. The following are tests and checks on the generator that are recommended by the manufacturer. If other tests are to be performed, the manufaturer should be consulted.
5.1 Check of mechanical installation

Check alignment of the generator prior to commissioning. Go through the alignment report and ensure that if the generator is accurately aligned according to ABB AB, Machiness alignment specifications. See Chapter 3 Alignment. Alignment protocol should always be included in the commissioning report.
Check that the generator is properly anchored to the foundation. Check for cracks in the foundation and the general condition of the foundation.
Bearing insulation Megging of bearings should be performed before the generator is coupled to the turbine . See section 5.3 on page 31.
Other checks Open the generator at both ends and check that no loose parts are present inside the generator. Check that no parts have come loose during transportation and that the air-gap is free. If possible, turn the rotor and make sure that the rotor turns freely and that no abnormal sound can be heard. See section 3.1 on page 22. Check the airgap between the exciter stator and rotor, see the test record Air gap measurement (included in binder Users manual).
WARNING - Magnetic force

There are very strong magnetic forces between the PMG rotor and stator.
1. 2.
Remove your own wrist watch, credit cards and other digital equipment before working around those strong magnetic forces. Personnel with pace maker should not be working in the vicinity of the PMG. Check the air gap between the PMG stator and rotor, see the test record Air gap measurement (included in binder Users manual).
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NOTE: The lubrication system must be commissioned and running before the rotor is turned. Check the assembly of the main terminal box and cooling system. Check pressure and flow for oil and cooling system according to outline drawing (included in binder Users manual).
5.2 Check of electrical installation

When the stator has been megged (See section 5.3 on page 31) the cables can be permanently connected to the busbars in the main terminal box. Check connection of high-voltage cables observing the following. Make sure the busbars and insulators do not have any cracks or other damage. Check the the bolt connections between stator busbars and terminal box, and make sure it has been tightened with a torque wrench and that a spring washer has been used. Check all busbars, insulators and connections in terminal box. Make sure the incoming high-voltage cables are suitably routed and the bracing suitably carried out. Make sure the incoming cables are stress-relieved in a proper way. Check phase sequence of incoming cables.
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5.3 Electrical checks

Bearing insulation resistance check
WARNING - High voltage

This work involves the main circuits of the generator normally connected to the high voltage supply net. Before you start to work: 1. Make sure the generator is disconnected from the high voltage net and that the circuit breaker is locked in the open position so it not accidentally (or otherwise) can be closed during the measurements. Note also that capacitors can contain dangerous voltages, so be sure to ground all details before you touch them.
2.
All connections of control equipment are to be checked and function tested. A bearing insulation check should be carried out before the generator is connected to the turbine . Remove the earth device located on the bearing on the drive end side. Megger the shaft to ground using no more than 500 Volt DC. See Figure 5-1 on page 31 and Figure 5-2 on page 32.
Loosen the hub for the earth device and pull out the earth connector and connect for megging Figure 5-1
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Figure 5-2 Insulation resistance is acceptable if the megger value is more than 1 Mohm.
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General for rotor and stator The winding shall be dry during the test and therefore the standstill heating elements should have been active for at least some days before the megging is performed. The winding temperature should also be recorded. According to normal standards the winding insulation resistance is to be stated at a winding temperature of 40 o C. The value measured is therefore converted to a corresponding 40 o C-value, with the help of the following diagram. Conversion factor, k 100 50
10 5
1 0.5 (0.25)-
0.1 0.05
o -10 0 10 20 30 40 50 60 70 80 90 100 ( C) Winding temperature 14 32 50 68 86 104 122 140 158 176 194 212 (oF) when meggering
R = Megger-value at a specific temperature R40 = Equivalent insulation resistance at 40oC Example: R40 = k x R R = 30 M measured at 20oC k = 0.25 R40 = 0.25x30=7.5 M Recommended minimum insulation resistance at 40oC must exceed the following value
R(40)> U+1 Mohm Where R(40)= Equivalent insulation resistance at 40 oC. U = Rated generator voltage in kV (stator or rotor). The insulation resistance of a new generator, having a clean and dry winding, is considerably higher as will be found in the test report of the generator. If the measured value is considered too low the winding must be cleaned and/or dried.
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Main stator winding insulation resistance check
WARNING - High voltage

This work involves the main circuits of the generator normally connected to the high voltage supply net. Before you start to work: 1. Make sure the generator is disconnected from the high voltage net and that the circuit breaker is locked in the open position so it not accidentally (or otherwise) can be closed during the measurements. Note also that capacitors can contain dangerous voltages, so be sure to ground all details before you touch them. When testing the insulation resistance of the stator winding disconnect the surge capacitors, lighting arresters and the fuses to the PTs, if such equipment is installed. If a neutral resistor is installed be sure that it is disconnected. Be sure that the secondary connections of the CTs and spare cores ARE NOT OPEN.
2. 3. 4. 5.
Megging should be performed in the terminal box and from the synchronizing circuit breaker (when the high voltage cables has been connected). If the insulation resistance is low when measuring from the synchronizing circuit breaker, disconnect high voltage cables and perform the megging direct on the terminals in the terminal box. A 5000 Volt DC megger should be used. Reading should be made after 1 minute. Main stator Polarization Index check The Polarization Index Test (dielectric absorption test) is an extension of the conventional oneminute resistance test, where the testing time is extended to 10 minutes. To make the test a motor-driven or an electronic megger is necessary to give a sufficiently steady voltage during the testing. The insulation resistance shall be read every minute. The ration of the resistance value after 10 minutes to the resistance value after 1 minute is called the Polarization Index. R10 R1 R1 = Insulation resistance after 1 - minute R10 = Insulation resistance after 10- minute
The Polarization Index should exceed 2. Field circuit insulation resistance (main- and exciter rotor)
Meggering should be performed at the exciter rotor connection to the main rotor. A 500 V DC megger should be used. Reading should be made after 1 minute.
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NOTE: If 1000V DC megger is used the rectifier has to be short circuit before measuring. PMG- and Exciter stator winding insulation resistance A 500 V DC megger should be used. Reading should be made after 1 minute. (When the cables to the terminal box have been disconnected). Drying high-voltage windings The drying process generally takes several days and the insulation resistance, in principle, follows the curve shown below: R (M)
1 Figure 5-3
Time (Days)
During the drying process it is important that the temperature does not increase too rapidly and that the final temperature is not too high. The temperature increase may not exceed 5 oC per hour and the final temperature may not exceed 100 oC. The temperature must be watched carefully throughout the drying process and the insulation resistance measured at intervals. When a steady value for the insulation resistance has been achieved, the winding is dry. Cleaning high-voltage windings The following cleaning precautions are recommended. When the outer casing and winding cover have been dismantled, first remove as much as possible of the extraneous matter with a paintbrush, stiff brush and a vacuum cleaner. Note that dirt may be blown into cooling ducts and pockets and lodge there if compressed air is used. If the winding is covered with oil or oil mixed with dust, it should be cleaned using a suitable solvent: HAKU 1025/920 (ABB AB, Machines part number: 1245 0011-175), varnolene or white spirit may be used. Take great care, see manufacturers recommended precautions.
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5.4 Before the first start attempt

Check that the Motor Excitation Control Panel (MCP) is equipped for starting this type of motor. The motor must be started and synchronized with reluctance torque. The field current must be applied after synchronization. Correct procedure is to measure the stator current during the start to set correct time for field apply see startprocedure curve according to the technical specification included in binder Users manual. Stator voltage, stator current and field current to exciter stator need to be recorded versus time during the commissioning.
5.5 The first start attempts

During the first starts of a synchronous motor the following parameters should be observed, noted and included in the commissioning report. Starting time Starting current Voltage drop Time after start when field current is applied Vibration levels.
5.5.1 Start interlocking

If the lubricating or cooling systems are provided with pressure or flow monitors, should these also be included in the start interlocking systems. A counter for the number of start up and a duty time meter should be included in the equipment.
5.6 Checks during running of the generator

During the first hours/days of running it is important to keep a close surveillance of the generator in case of any changes in vibration or temperature levels or abnormal sounds should occur. Check the connection of oil and cooling water pipes and check for leaks when running the generator.
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5.6.1 Normal vibration levels

The vibration levels given in the table below is intended for protecting the generator from damage during operation and indicating normal and acceptable levels. Please note that transient conditions, such as starting or synchronization, are excluded from these recommendations. Important for vibration monitoring is to detect deviations from normal levels during operation, and the following guidlines are recommended: Set the alarm level at 2 times the normal level during operation Set the trip level at 4 times the normal level during operation
The alarm and trip levels should in no case be above what is given in the tables below. Example: The normal vibration level during operation at site is 1.5 mm/s. The alarm level should then be set at 3 mm/s, and the trip level at 6 mm/s.
5.6.1.1 Bearing housings

Vertical/horizontal mm/s rms Testroom (typical) Alarm Trip 1.8 4.5 8.0 in/sec rms 0.07 0.18 0.31 micron p-p 32.4 81.0 144.1 mills p-p 1.3 3.2 5.7 mm/s rms 2.3 7.0 15.0 Axial in/sec rms 0.9 0.28 0.59 micron p-p 41.4 126.0 270.1 mills p-p 1.63 5.0 10.6
Table 5-1: Acceptable vibration levels for bearing housings. The values are valid for all speeds. (Measured frequency range 10-1000 Hz)
5.6.1.2 Structural vibrations

The following values are valid for structural vibrations in the supporting structure of the generator, covers etc are excluded. Vertical/horizontal mm/s rms Testroom (typical)
Axial mills p-p 3.2 5.0 10.6 mm/s rms 4.5 11.0 20.0 in/sec rms 0.18 0.43 0.79 micron p-p 81.0 198.1 360.1 mills p-p 3.2 7.8 14.2
in/sec rms 0.18 0.28 0.59
micron p-p 81.0 126.0 270.1
4.5 7.0 15.0
Alarm Trip
Table 5-2: Acceptable vibration levels for supporting structures. The values are valid for all speeds. (Measured frequency range 10-1000 Hz)
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5.6.1.3 Shaft vibrations

The following values are valid for shaft vibrations measured with eddy-current probes. Vertical/horizontal mm/s rms Testroom (typical) Alarm Trip in/sec rms micron p-p 50.8 76.2 101.6 mills p-p 2.0 3.0 4.0
Table 5-3: Acceptable vibration levels for shaft vibrations. The values are valid for all speeds.
5.6.2 Temperature levels

The temperatures of the bearings and stator winding and air should be checked when the generator is running for the first time. The bearings reach a stable temperature after about 45 to 60 minutes when running at full speed if the temperature of the oil to the bearings is about 40 oC. The stator winding temperature depends on the load of the generator. If full load cannot be obtained during or soon after commissioning, the present load and temperature should be noted and included in the commissioning report. Recommended settings for alarm and trip levels, see the test record Setting List included in the binder Users manual.
5.7 Check list

The following checklist and protocols should be completed during commissioning and returned to ABB AB, Machines toghether with the commissioning report after completed commissioning. Checks to be made during operation, please see Chapter 6 Operation.
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5.7.1 Page 1
Customer: Site name: Serial number: Order number: Date: Name and company of responsible commissioning engineer:
o First run up, date ..................................... o Direction of rotation: clockwise (Seen from D-end) o Direction of rotation: counterclockwise (Seen from D-end) o No abnormal noise
Comments ............................................................................................................................................................... ................................................................................................................................................................
o Second run up (to full speed), date ................................

Starting time ............................. s Retardation time .................. min Comments ............................................................................................................................................................... ...............................................................................................................................................................
Generator data
Output: Frequency: Excitation: V kVA Hz A Power factor: Speed: Oil quality: Voltage: r/min Current: V A
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5.7.2 Page 2
Time Bearing temp. ( C)

o
Inlet Oil
Vibr. (mm/s, m)
Winding temp. (oC)
Cooling air/water m3/h

o
Comments Vibrations, noise, etc.
Dside
Nside
(oC)
(l/s)
Dside
Nside
max
min
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5.7.3 Page 3
Time (A)
Stator (cos) (V)
Exciter Field (A)
Load (MW)
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Synchronous generator, type AMS Chapter 6 Operation
Chapter 6 Operation
6.1 Start up procedure

Before start up of the generator a check has to be made that: Beware that all protection covers and other equipment is correctly installed and that no person is close to voltage carrying equipment or rotating parts. Authorization has been given to start and that there is no risk of personal or property damage. Required oil supply is fulfilled in accordance to drawing Outline synchronous generator, included in the binder Users Manual. Required cooling media is fulfilled in accordance to drawing Outline synchronous generator. No shut down means are in operation. Personnel and equipment associated to the generator are ready for start up of generator.
6.2 Continuous supervision

The operating personnel should inspect the generator at regular intervals. This means that they should listen, feel and smell the generator and its associated equipment in order to obtain a feeling for normal operating condition. The object of the supervision inspection is to thoroughly familiarize personnel with the equipment. This is imperative if abnormal occurrences are to be detected and remedied in time. It is therefore recommended that a supervision inspection sheet(attached) will be filled in. Data from a supervision inspection should be kept for future reference and can be of great help at maintenance work, trouble shooting and repairs. The programme for suitable supervision inspections can be found below. The border between supervision and maintenance is rather diffuse. Normal supervision of operation includes logging of operating data such as load, temperatures etc., and the comments made are used as a basis for maintenance and service. During the first period of operation (- 200 hours) supervision should be intensive. Temperature of bearing and winding, load, current, cooling, lubrication and vibration shall be checked frequently and logged. During the following duty period (200 - 1000 hours) a check-up once a day is sufficient. A record of supervision inspection should be used and filed with the customer. Thereafter the time between inspections may be further extended if operation is continuous and stable.
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6.3 Shut down procedures

During shutdown of the generator, lubrication oil and cooling media supply has to be ensured. When the generator not is in operation, cooling water has to be switched off and the anticondensation heaters to be switched on. Those actions are to be made to avoid condensation within the generator.
6.4 Alarm during operation

If alarm during operation e.g.: Cooling Water Lubrication Temperature Vibration etc.
The generator has to be unloaded and deenergized (triped). After coasting down the generator make necessary investigation to find out the reason for the alarm before next start.
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RECOMMENDED SUPERVISION INSPECTION SHEET (2 pages)
Customer: Site name: Serial number: Order number:
Name and company of responsible commissioning engineer:
Date:
Time Bearing temp. (oC)
Inlet Oil
Vibr. (mm/s, m)
Winding temp. (oC)
Cooling air/water m3/h

o
Dside
Nside
(oC)
(l/s)
Dside
Nside
max
min
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Customer: Site name: Serial number: Order number:
Name and company of responsible commissioning engineer:
Date:
Time (A)
Stator (cos) (V)
Exciter Field (A)
Load (MW)
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Synchronous generator, type AMS Chapter 7 Maintenance
Chapter 7 Maintenance
7.1 Preventive maintenance

A generator often forms an important part of a larger installation and if it is supervised and maintained properly it will be much more reliable in operation. The border between supervision and maintenance is rather diffuse. Normal supervision of operation includes logging of operating data such as load, temperatures etc., and the comments made are used as a basis for maintenance and service. After commissioning or maintenance supervision should be intensive. Temperature of bearing and winding, load, current, cooling, lubrication and vibration shall be checked frequently. Local condition has to be considered when decision of maintenance interval and level.
7.2 Before all maintenance work

Safety precaution
WARNING - Risk of personal injury

Before any maintenance or test is performed the following must be done: 1. 2. The generator must be completely stopped, dead, disconnected and grounded before any inspection covers are opened on the generator. Before working on any electrical equipment, general electrical safety precautions are to be taken and local regulation are to be respected, according to instructions of the customers personnel in charge of security, in order to prevent personnel accidents. Employees who perform maintenance on electrical equipment and installations shall be qualified persons as required and shall be trained in and familiar with the specific maintenance procedures and tests required.
3.
Preparation and preplanning of maintenance Preparation and preplanning is recommended before all maintenance, special level 3 and 4. Requirements of:
Lifting capacity. Tools including rotor removal at level 4. Manpower and needed competence. Spare parts and other overhaul kit (replacement and consumables).
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7.3 Recommended maintenance program

Maintenance program Interval Level 1 (L1)
max. 10 000h (equivalent hours) of operation or yearly
Level 2 (L2)
max. 20 000h (equivalent hours) of operation or max. 3 years
Level 3 (L3)
max 40 000h (equivalent hours) of operation or max. 6 years
Level 4 (L4)
max 80 000h (equivalent hours) of operation or max. 12 years
Preparation for Open inspection covers. inspection
Open inspection covers.
Disassembly covers. Disassembly PMG stator. Open bearings. Open water coolers. Megger, stator Megger, rotor Fibre-optic or video borescope. Oscilloscope/Test equipment.
Open bearings. Removal rotor and exciter. Open water coolers. Megger, stator. Megger, rotor. Rotor removal equipment. Torque wrench. Oscilloscope/Test equipment. Acc. to L3 and suggestion from inspection L1, L2 and L3. Rotor kit.
Instrument/ Tools
Megger, stator. Megger, rotor.
Parts/ Spare parts
Bearing liners, Brushes, Air-lock filter (bearing), Control pulse unit, Thyristors, Diodes. Other order specific parts. Approx. 1 day.
Acc. to L1 and suggestion Acc. to L2 and suggestion from inspection L1. from inspection L1 and Silicon tape. L2. Water cooler. Rectifier kit. Bearing kit. Gaskets. Approx. 2 days. Approx. 5 days.
Expected downtime
Approx. 10 days.
Option: Diagnostic insulation test of the stator winding. Equivalent hours = Total operation hours + No of starts x 20 Example of maintenance schedule:
Interval
Hours x 1000
10 L1
20 L2
30 L1
40 L3
50 L1
60 L2
70 L1
80 L4
Program
Timing of the inspection and overhauls are largely determined by the number of operating hours, the mode of operation and the number of starts of the generator. Local condition has to be considered.
The maintenance intervals shall be co-ordinated for the generator, in a suitable way.
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7.3.1 Generator
Location 1. Generator L1 X L2 X L3 X L4 X Activity 1. Look through all logged or recorded data available; load, temperature, vibrations etc. Fill in the report. If values deviate from time of commissioning or earlier inspection please contact supplier. 2. Inspect exterior of generator for rust, leaks or other defects. 3. Check tightness of all fastenings. 4. Replace air filter, if necessary. 5. Ensure ventilation ducts are clean and free of obstruction if connected to external air. 1. Inspect grouting and anchored bolts. Check for excessive clearances and correct as required. Inspect for cracks in the foundation. 1. Replacing, cleaning and modification acc to recommendation in earlier inspections and suppliers service bulletin.
Approved
X X X X 2. Foundation
X X X X
X X X X X
X X X X X
3. Service/Repair
General cross-section AMS machine (actual design acc. to outline included in binder Users Manual.)
Inspection covers on both ND- and D-end sides.
Figure 7-1.
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7.3.2 Stator
Location 1. Stator winding L1 X X L2 X X L3 X X X L4 X X X Activity 1. Inspect winding connections. 2. Inspect winding and bracing rope. 3. Inspection for cleanliness, discoloration, condition of insulation, looseness, movement and wear. Clean if necessary. 4. Measure and record insulation resistance. Refer to Section 5.3 . 5. Measure Polarization Index. Refer to instruction Commissioning section Electrical checks, included in the binder Users Manual. 1. Inspect for discoloration. 1. Check sealing. 1. Verify function of all RTDs. 1. Function check.
Approved
X X
X X
X X
2. Pressure finger 3. Air cover 4. RTDs 5. Heaters
X X X
X X X
X X X X
X X X X
Air cover Sealing Air cover
Stator coils
Bracing rope Pressure finger
Figure 7-2.
XYK 210 090- FLD
7-49
7.3.3 Stator terminal

Location Terminal box L1 X X L2 X X L3 X X X X L4 X X X X Activity 1. Check all line- and neutral connections. 2. Check general condition. 3. Check tightening torque at all connections and insulation behind the terminals. 4. Test e.g. Current transformers (CT), etc. if applicable.
Approved
Example of a terminal box for a generator (actual design acc. to outline for terminal box). See drawing XYK 210780-FLD in users manual.
XYK 210 090- FLD
7-50
7.3.4 Rotor
Location 1. Rotor X 2. Rotor coils X X L1 L2 L3 X X X X X 3. Rotor coil support X X X X L4 X X X X X X X Activity 1. Check all brazed connections for cracks. 2. Measure field circuit insulation resistance, 500V DC megger. Refer to Section 5.3 . 1. Check turn insulation, discoloration etc. 2. Check inter connections. 3. Check turn insulation (voltage drop test). Refer to Section 7.4 . 1. Inspect coil supports, screws, washers and insulation. 2. Check upper coil support insulation plate, Max. movement, 10mm radially out of original position.
Approved
Brazed connection Inter connection

Lower coil support Rotor coils
Connection rotor and exciter rotor Upper coil support Figure 7-3.
Insulation plate
XYK 210 090- FLD
7-51
Location 4. Pole shoes 5. Pole bolts
L1 X
L2 X
L3 X
L4 X X
Activity 1. Check pole shoes for discoloration. 1. Inspect by knocking on bolt head. If pole bolts are loose or corroded, ABB has to be contacted. 1. Inspect fan blades and weldings. 1. Inspect balancing weights and fastening details. 1. Check air gap after assembling of machine.
BY BY ABB Cust.
6. Fan 7. Balancing 8. Air gap
X X
X X X
Fan
Balancing weights Pole shoes Figure 7-4. Pole bolts
XYK 210 090- FLD
7-52
7.3.5 Bearings
Location 1. Bearing inspection 2. Bearing housing and support 3. Shaft seals X X X X X X X X L1 L2 L3 X X X X X X L4 X X X X X X Activity 1. Open bearings. 1. Inspect for leaks. 2. Inspect all bolted joints. 3. Inspect guide support. 1. Check for leaks. If leaks check wear and damages. 2. Clean drain holes in the shaft seals. 3. Check the clearance between the shaft seals and shaft with a feeler gauge after assembling. 4. Shaft surface 5. Bearing liners 6. Bearing insulation 7. Oil piping 8. Measuring instrument 9. Lube oil X X X X X X X X X X X X X X X X 1. Verify that sealing surface are free from corrosion and wearing. 1. Visual inspection of contact surfaces. 1. Measure insulation resistance. Refer to Section 5.3 . 1. Inspect for leaks. 1. Verify function of all measuring instrument. 1. Analyse oil for contamination and replace oil and clean the system if necessary. Refer to Section 7.5.3 . 2. Check for water in each bearing and remove if necessary. 10. Air filter X X X X 1. If necessary replace filter for air intake to the air-lock seals, located on bearing pedestals.
Approved
XYK 210 090- FLD
7-53
Air-lock seals
Shaft seal Bearing liners Bearing shell
Bearing housing
Bearing insulation
Figure 7-5.
XYK 210 090- FLD
7-54
7.3.6 PMG (Permanent magnetic generator)
WARNING - Magnetic force

There is a very strong magnetic forces between the PMG rotor and stator. 1. 2. 3.
.
Be extremely careful when removing the PMG stator housing to avoid damage to components due to magnetic forces. Remove your wrist watch, credit cards and other digital equipment before working around those magnetic forces. Personnel with pace maker should not be working in the vicinity of the PMG. L3 X L4 X X X X Activity 1. Visual inspection. 2. Measure insulation resistance, 500V DC megger. Refer to Section 5.3 . 1. Visual inspection. 1. Check air gap.
Approved
Location 1. PMG Stator
L1
L2
X 2. PMG Rotor 3. Air gap
X X X
XYK 210 090- FLD
7-55
PMG stator
PMG rotor
Permanent magnets
Figure 7-6.
XYK 210 090- FLD
7-56
7.3.7 Exciter and Rectifier

Location 1. Exciter Rotor L1 X L2 X X 2. Diodes, thyristors and RC-circuit (Rectifier) 3. Control pulse unit (Rectifier) 4. Rotor terminals 5. Exciter stator X X X 6. Air gap 7. Heaters L3 X X X X X X X X X X X X L4 X X X X X X X X X X X X Activity 1. Visual inspection. 2. Measure insulation resistance, 500V DC megger. Refer to Section 5.3 . 1. General cleaning. 2. Check all bolts fastening. 3. Inverse voltage test. Refer to Section 7.5.1 . 1. Check wiring to and from the unit. 2. Check firing level. Refer to Section 7.5.1 . 1. Check all connections to the exciter. 1. Visual inspection. 1. Measure insulation resistance, 500V DC megger. Refer to Section 5.3 . 1. Check air gap. 1. Function check.
Approved
Exciter stator Exciter rotor Rectifier
Connection rotor and exciter rotor

Figure 7-7.
XYK 210 090- FLD
7-57
7.3.8 Rotor earth brush

Location 1. Brush and brush holder L1 X L2 X L3 X L4 X Activity 1. Visual inspection of brush. Replace if shorter than 15 mm.
Approved
Shaft
Figure 7-8.
XYK 210 090- FLD
+ + + + +
Brush holder
Brush
7-58
7.3.9 Cooling system

Location 1. Coolers
Refer to instruction in included in the binder Users manual.
L1 X X*) X*)
L2 X X*) X*)
L3 X X X X
L4 X X X X X X
Activity 1. Visual inspection. 2. Check for cleanliness, corrosion and erosion of air and water sides. 3. Clean air and water sides. 4. Inspect protection anodes (placed in tube sheet) for proper activity and replace if necessary. 5. Pressure test. 6. Function check of casing water leakage detector.
Approved
X*) X
X*) X
X X
*) If bad efficiency clean the heatexchanger by using brush or chemical rinsing. Actual design acc. to outline included in binder Users Manual
Tube
Tube plate
Water box
Gasket Figure 7-9.
XYK 210 090- FLD
7-59
Synchronous generator, type AMS Chapter 7 Maintenance If temperature detectors show normal temperature, usually no additional maintenance to supervision inspection is required for the cooling system. If the coolers have to be cleaned, find instruction included in binder Users Manual. If temperature detectors show an abnormal temperature, or close to alarm level, in winding or cooling air a check of the cooling system has to be made. If the coolers have to be cleaned, find instructions included in binder Users Manual. Water leakage detector To empty the water leakage detector of water, open the ball valve at the bottom of leakage detector, see drawing included in the binder User Manual. Figure 7-10
7.4 Main rotor coil turn insulation (voltage drop test)
WARNING - Electricity 230 V or 400 V 50 Hz / 208 V or 480 V 60 Hz

During the voltage drop test there is a AC-voltage over the field windings. Be careful so no personal injury occur. 1. 2. Connect all measuring cables before start of measurement. Connect a earth current circuit breaker as protection.
The test is carried out by applying an AC-voltage over the entire field winding and measuring the current and the voltage drop across the total winding as well as each single coil, see Figure 7-11. The applied voltage should be 230 V or 400 V 50 Hz / 208 or 480 V 60 Hz depending on the rated frequency of the machine.
+ U
U1 The voltage over a single coil (U) should not differ more than 3% from U/4.
2 U
U4
Figure 7-11
7.5 Fault finding

The generator is protected with alarms and trips for most kinds of abnormal running conditions, both electrical and mechanical. Some of these protections can be reset and the generator restarted directly as the fault is known or easy to locate. XYK 210 090- FLD 7-60
Examples of protections that if they give an alarm or trip, may need further investigations to be located are: Diode fault protection. High temperature in bearing. High temperature in winding or in cooling air. Vibration protection.
7.5.1 Diode fault

In case any of the diodes in the rotating rectifier should fail, the diode fault protection will pick up and trip the generator. To determine and locate a faulty diode, open the cover of the rotating rectifier and megger with an ohm-meter over one of the diodes. If a faulty diode is detected, disconnect all diodes and test them separately to locate the faulty diode. NOTE: If a faulty diode or thyristor the recommendation is to replace all diodes, thyristors and control pulse unit. Refer to the instruction Replacement of diodes and thyristors included in the binder Users Manual. To test the thyristors, firing unit and diodes the following method can be used: Open the cover of the rotating rectifier. Disconnect the rotor winding from the rectifier. Apply alternating voltage to the plus and minus bars of the diode bridge according to figure 7-12. A 600 ohm resistor shall be connected to limit the current flow as shown in figure 7-12.
Note: An equipment specially made for this test is possible to buy from ABB AB, Machines. Test equipment
Rectifier unit
Supply voltage Uac
osc
Exciter side
600 + Figure 7-12

Increase the voltage and check with an oscilloscope the triggering voltage level of the firing unit and the thyristors as shown in figure 7-13 chart 2 and 3. Decrease the voltage to a level under the firing units trigger level, see figure 7-13 chart 1 and measure over each diode separately. A shorted diode will show zero (0) volt on the oscilloscope.
XYK 210 090- FLD
7-61
Test result for healthy rectifier
1. < Triggering voltage level ac < UT Triggering voltage UT level 2. = Triggering voltage level ac = UT UT ac Test Voltage ac
3. > Triggering voltage level ac > UT UT
ac Figure 7-13
XYK 210 090- FLD
7-62
7.5.2 Altering the firing voltage

To alter the firing level on the control pulse unit, the cable have to connected to the terminal corresponding to the new firing level. NOTE: Before altering the firing level, write down the original connections for firing level, thyristors, etc.
Thyristor B Thyristor A
150V 225V 300V 450V 600V 750V 900V 1.1kV 1.3kV 1.5kV
K K-G
K K-G
Drawing number Seriel number
Connect to right firing level

Figure 7-14
XYK 210 090- FLD
x x
7-63
7.5.3 Lubrication
The generators are provided with sleeve bearings with an almost unlimited service life provided that the lubrication functions continuously and that the oil is changed at suitable intervals. Temperature To enable the bearing temperature to stabilize at a normal level, the correct amount or flow of oil is required. The normal bearing temperature is 65 - 85 oC. NOTE: The oil may be warm. Characteristic properties of the oil qualities listed are: The oil is a lubricant based on paraffin having high viscosity coefficient (VI>90) and a particularly low fluid temperature. It includes the following additives: oxidation inhibitor anti-foaming mild EP action, anti-wear additive rust inhibitor
Condition of the lubricant Check the oil with respect to colour, smell, turbidity and deposits in a test bottle. The following requirements shall be fulfilled: The oil should be clear or negligibly turbid. The turbidity may not be caused by water. Strong acid or burnt smell is not acceptable. The quantity of metal impurities may not exceed 0.05% by weight. The original viscosity must be maintained within a tolerance of 10-15%. The original acid number should not be exceeded by more than 1 mg KOH per gram oil.
An oil check should be performed a few days after the first test run of the generator and subsequently as required. If the oil is changed just after the commissioning, it can be used again after removing wear particles by filtering or centrifuging. In doubtful cases an oil sample may be sent to the laboratory to determine viscosity, acid number, foaming tendency, etc. A duty period of 3-8 years before an oil change is necessary is not unusual.
XYK 210 090- FLD
7-64
Oil qualities Unless otherwise stated on ABB AB, Machines drawing Outline synchronous generator included in the binder Users Manual, the bearings are designed for any of the following oil qualities: Oil 7 1201-301 (Oil 7061) ISO VG 32 Viscosity 32 cSt at 40C (20 at 50C) Pour point max. -30C. BP: Energol HLP 32 Castrol: Hyspin AWS 32 Esso: Nuto HP 32 Gulf: Harmony 32 AW Klber: Lamora 32 Mobil: D. T. E. 24 Optimol: Ultra 5025 Shell: Tellus Oil 32 Texaco: Rando Oil HD A 32 Oil 7 1201-302 (Oil 7071) ISO VG 46 Viscosity 46 cSt at 40C (28 at 50C) Pour point max. -30C. BP: Energol HLP 46 Castrol: Hyspin AWS 46 Esso: Nuto HP 46 Gulf: Harmony 46 AW Klber: Lamora 46 Mobil: D. T. E. 25 Optimol: Ultra 5035 Shell: Tellus Oil 46 Texaco: Rando Oil HD B 46
Oil 7 1201-303 (Oil 7081) ISO VG 68 Viscosity 68 cSt at 40C (40 at 50C) Pour point max. -27C. BP: Energol HLP 68 Castrol: Hyspin AWS 68 Esso: Nuto HP 68 Gulf: Harmony 68 AW Klber: Lamora 68 Mobil: D. T. E. 26 Optimol: Ultra 5045 Shell: Tellus Oil 68 Texaco: Rando Oil HD C 68
XYK 210 090- FLD
7-65
7.5.4 High temperature in bearing

7.5.4.1 Trouble shooting 1
Customer Machine type Machine serial no : ....................................................................................................................................... : ....................................................................................................................................... : .......................................................................................................................................
Insufficient lubrication
Section 7.5.4.2
Oil temperature too high
Faulty oil cooler
Replace the cooler
High axial forces
Faulty coupling
Faulty assembled bearing
Has bearing been disassembled?
Open and adjust
Damaged liners
Impurities in the oil? Inductive bearing currents? Complete seizure of bearing
Change oil
Repair bearing insulation Repair bearing journal Replace liners Renewed commissioning
Faulty instrument?
XYK 210 090- FLD
7-66

Oil pump not reliable? Low oil flow Oil filter clogged? Reduction valve shut?
generator protection trips? Check maintenance status Latest adjustment?
Fault finding and action Replace filter
Adjust flow
Too low oil temperature Unsuitable oil quality
Faulty oil heater

Check with ABB AB, Machiness recommendation
Fault finding and action Change oil quality
Oil worn out
Check status of oil change
Replace the oil
XYK 210 090- FLD
7-67

Oil worn out Unstable bearing temperature Impurities in the oil
Replace the oil
Replace the oil
Damaged shaft seals
Repair the seals Repair/replace the air-lock seal and check the air filters Correct oil flow Incorrect inclination of the return pipe?
Air-lock seal out of action Oil leaks Too high oil flow
Problem in oil flow return
XYK 210 090- FLD
7-68
7.5.5 High winding and/or air temperature

7.5.5.1 Trouble shooting
Customer Machine type Machine serial no : ....................................................................................................................................... : ....................................................................................................................................... :.......................................................................................................................................
Faulty instrument
Faulty sensor
Low cooling water flow Cooling water temperature to high Dirty or plugged cooler
High winding and/or air temperature
Clean the cooler
Leaking cooler
Replace the cooler
Air inside the cooler
Bleed the cooler
Overload
Process control
Dirty stator
Clean the stator
XYK 210 090- FLD
7-69
Synchronous generator, type AMS Chapter 8 Disposal and Recycling
Chapter 8 Disposal and Recycling

8.1 General
The manufacturing process of the machine is carried out in accordance with the Environmental Management System ISO 14001. This instruction concerns the disposal and recycling of Large AC-machines. The machines are designed in a way that it is easy to separate the different components and types of material from eachother, making it esier to recycle. NOTE: The methods are described in a very general way. All instructions are to be performed by personnel which is trained and skilled for the procedure.
8.2 Dismantling the machine
Warning - Heavy components

Risk of personal injury when dismantling the machine. 1. Only skilled and trained personnel should carry out the dismantling.
Dismantling the machine is done by simply separating all the components of the machine. Since the machine mainly is assembled with screws and nuts, it is rather simple to carry out the dismantling. When the machine has been dismantled into its different components, the different components has to be separated and grouped together dependent upon the different types of material.
8.3 Separation of different types of material 8.3.1 Normal carbon steel

The following components is separated into one group for normal carbon steel: Rotor body Stator ends Bearing supports Foot plates Encapsulation Side plates Roof
Oil tubes from the lubrication system. If the tubes are made of stainless steal, it is necessary to separate them from the rest of the steel components. If not the stainless steel will cause a very low quality of the total steel collected - it is a poison for the steel manufacturer. Teminal box with the copper separated Bolts and nuts etc ... etc. 8-70
XYK 210 090- FLD
8.3.2 Electrical silicon steel non oriented

The following components is separated into one group for electric silicon steel non oriented: Stator lamination Lamination of the exciter stator Lamination of exciter rotor.
These laminations are welded to respective components and can be separated with a gas burner.
8.3.3 Special high quality steel

The following component is separated into one group for special high quality steel: Pole tips of the rotor.
8.3.4 Mixed metallic material

The following components are separated into one group for mixed metallic material: Coolers.
The coolers often contains Cu/Ni tubes or stainless steel tubes. In the cases of stainless steel these may be separated by using a gas burner or similar and collected in the group for stainless steel. The rest of the cooler may be considered as mixed material.
8.3.5 Stainless steel

The following components are separated into one group for stainless steel: Oil tubes from the lubrication system. If the tubes are made of stainless steal, it is necessary to separate them from the rest of the steel components. If not the stainless steel will cause a very low quality of the total steel collected - it is a poison for the steel manufacturer. Tubes from coolers. See Section 8.3.4.
8.3.6 Cast iron

The following components are separated into one group for cast iron: Bearing housing Bearing spheres.
8.3.7 Aluminium
The following components are separated into one group for aluminium:
Coil supports of the rotor Heat sinks for thyristors and diodes in the exciter.
XYK 210 090- FLD
8-71
8.3.8 Copper
Copper is mostly integrated in the actual components and require some effort in order to be separated. There exist some special tools for making the separation but normally wedges, large hammers, gas burners and manpower is used. The following components are separated into one group for copper: Stator coils The copper is integrated in the stator and is glued to the stator by use of an impregnation resin. Thereafter the copper in the stator is surrounded by several mm of micabased insulation. The separation of copper from the insulation is done by the method granulation, which is used by larger recycling companies. The granulation method cuts the copper into pieces and the copper is then separated from the insulation by a mechanical process. This can also be done by manpower using hammer and wedges. The amount of copper in the stator is large. Stator connection The copper is integrated within the stator winding. It may be cut off and separated from its insulation by granulation or by manpower. Rotor coils in the machines rotor This is clean copper mixed together with layers of insulation. It may be separated from the rotor by loosening the pole bolts of the rotor body and by removing the coil supports. This copper is of high quality and value, and the amout is large. The copper from the rotor coils is to be kept separate from all insulated copper. Rotor connections in the machines rotor This is cable copper that may be separated from the rotor by a gas burner combined with manpower.
WARNING - Dangerous gas

This method is only to be performed in an oven with proper filters in order to prevent hazardous emissions to enter the air. It might come off easier if first heating up the rotor until the epoxy resin within the rotor shaft is carbonised. Clean copper in the terminal box This is the best quality of copper and has to be separated from all types of insulated copper. Stator coils in the exciter stator This is enameled copper that is glued together with the stator by impregnation resin. It may be separated from the exciter stator by manpower or by using special equipment.
XYK 210 090- FLD
8-72

This metod is only to be performed in an oven with proper filters in order to prevent hazardous emissions to enter the air. It might come of easier if first heating up the stator until the impregnation resin is carbonized. Rotor coils in the exciter rotor This is enammelded copper that is glued together by impregnation resin. It may be separated from the exciter by manpower or using special equipment.

This metod is only to be performed in an oven with proper filters in order to prevent hazardous emissions to enter the air. It might come of easier if first heating up the rotor until the impregnation resin is carbonised.
8.4 Waste as land fill

All inslulation material is not to be considered as hazardous waste. It may be used as land fill or sent to power plants to be burned. NOTE: Make sure the power plant is adapted for this kind of fuel and have the proper types of filter etc. in order to prevent gases and dust to enter the environment.
8.5 Hazardous waste

The oil from the lubrication system is to be considered as hazardous waste and have to be taken care of according to regulations. The oil is to be sent for destruction or to be burned in specially prepared power plants.
8.6 Final comments

If there is some questions of enviromental matters not considered in this instruction we ask the user to get in contact with the Environmental Coordinator of the Machine Division.
XYK 210 090- FLD
8-73
Skeleton No. 3BSM005468, Rev. G EN
XYK 210 090- FLD

2001-02-22
We reserve all rights in this document and in the information contained therein. Reproduction,use or disclosure to third parties without express authority is strictly forbidden. ABB Automation Technologies AB; 2003
Bolted joints for current-carrying busbars. Instructions pertaining to assembly. 1. Foreword This document contains general instructions regarding the procedure to be adopted when making bolted joints in busbars. For series-manufactured switchgear, apparatus etc., special assembly instructions are normally provided and these apply to the complete installation including the bolted joints in busbars. For joints in other equipment, where special measures must be taken, e.g. control of tightening torque, special locking facilities etc., instructions are either given on the assembly drawing or are supplied separately for the joints in question. If modifications are necessary during the on-site installation work, it is of the utmost importance that the joints are made in accordance with the applicable standard to ensure satisfactory performance. 2. 2.1 Preparation of contact surfaces Cleaning Dirt, oil and grease are to be removed with white spirits or other suitable degreasing agent. Paints, insulating varnishes, resin residues etc., are to be removed with a steel-wire brush or by scraping with a keen-edged tool. Surface-treated busbars (tinned, nickel plated, silver plated) must not be subjected to mechanical cleaning. Great care must be exercised when cleaning EXCONAL busbars to avoid damaging the copper layer. 2.2 Deburring Burrs and mechanical defects are to be removed with the aid of suitable keen-edged tools. When removing burrs from holes in EXCONAL busbars, the edges should not be chamfered more than necessary. Mechanical grinding, especially of EXCONAL busbars, should be avoided. Care must be taken to ensure that the flatness and the texture of the surfaces are not influenced in any way.
External doc. no. Based on Prep. Appr. Doc. kind Title
3BSM001263R0001 en MO / A. Kruse 1997-04-21 / Engelen Christina Approved Description Assembly Instruction, current-carrying busbars
ABB Automation Technologies AB
Project Customer Proj. no. Doc. des. Ref. des.
Resp. dept Doc. no.
MO
Lang. Rev. ind. Page No. of p.
3BSM001263R0001
en
1 5
FILE: Assembly Instruction current-carrying busbars.doc; TEMPLATE: Techn_Doc_Deliv_P.dot B; SKELETON: ; SAVEDATE: 2005-01-20 10:33:00 AM
2.3
Measures to prevent oxidation and corrosion Depending on the type of busbars material and the environment in which the bars are to be installed, the contact surfaces are to be prepared as specified in the following table:
Material
Environment Indoors, dry places, in oil.
Copper, copper-clad aluminium, tinned, silver or nickel plated bars/surfaces No measures necessary.
Aluminium, both pure and alloyed, the aluminium surfaces in joints aluminiumcopper Surfaces of the joint to be roughened with a wire brush or a rough file and cleaned from sward and oxide particles. Immediately (within 5 minutes), the surfaces are to be coated with petrolatum (vaseline) 1171 5011-102 and the joint fitted together. As above. On joints of aluminiumcopper in severe corrosive atmospheres, use either Cu-Al-strip or paint as per 2965 2273.
Outdoors, damp or corrosive atmospheres.
The contact surfaces are to be coated with petrolatum (vaseline) 1171 5011-102.
Table 1 If the customer or other authorities require that a paste, other than that mentioned above, is to be used, the directions for use must be carefully followed. 3. Bolted joints The design of the joint is shown in Figure 1. Note The plane washer need to be mounted nearest the bar, according to Figure 1.
Doc. kind Title
Description Assembly Instruction, current-carrying busbars

Project Customer Proj. no. Doc. no. Lang. Rev. ind. Page No. of p.
3BSM001263R0001
en
2 5
It is essential that the correct types of plane and spring tension washer are used (refer to the applicable standard pertaining to bolted joints), and that the spring tension washers are correctly positioned, i.e., the outer edge of the washer mates against the busbar or the plane washer.
Plane washer Spring tension washer

Figure 1 3.1 Tightening of bolts and nuts Nuts should be tightened to the same extent as those used in bolted joints of steel structures. Endeavours should be made to achieve a tightening torque which, as near as possible, corresponds to that specified for each respective bolt. The tightening torque for bolts of strength class 8.8 is given in Table 2. As a rule, a torque wrench is not necessary unless it is stipulated on the assembly drawings or in special assembly instructions. The type of wrench used should be such as to enable the easy application of the correct torque. The nuts should not be turned in the anti-clockwise direction after they have been tightened. 3.2 Tightening torque and leverage The tightening torque for dry or lightly oiled bolts of strength class 8.8 is given in Table 2. The maximum force which a person can normally exert with one arm lies between 250 and 500N (newtons), corresponding to the force required to lift a weight of between 25 and 50 kg. For M8 and smaller bolts, a maximum force need not normally be applied.
Doc. kind Title

3BSM001263R0001
en
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To provide some idea of the amount of leverage required, i.e. the distance from the centre of the bolt to the middle of the hand used for applying the force, for larger sizes of bolt, the requisite leverage for an applied force of 300N and for achieving the requisite torque, is given in Table 2.
Bolt M 6 8 10 12 16 20 Table 2
Tightening torque Nm 10 18-25 35-50 60-85 150-200 330-430 1 1,8-2,5 3,5-5 6-8,5 15-20 33-43 kgfm lbf x ft 7,4 13-19 26-37 45-63 110-150 240-320
Leverage distance m
0,12-0,17 0,21-0,28 0,5-0,67 1,1-1,4
Doc. kind Title

3BSM001263R0001
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REVISION Rev. A B Description Change of template. Changed org. name to ABB Automation Technologies AB. Date, Resp. 03-01-08 MVO/PP 04-06-22 MVO/MK
Doc. kind Title

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QLKE, QDKE and QDKR Cleanable Air Coolers

Installation, Operation and Maintenance Instruction
Description Safety Precautions and Warnings

General
The cooler is used for the cooling of air by means of circulating water. The cooler is equipped with removable headers that allow cleaning inside the cooler.
Installation
The air cooler has to be secured to its location. The fixing points of the cooler are sufficiently stable to carry the dry weight of the cooler and the weight of the liquid in the cooler.
The cooler is designed to withstand normal loads during transport. Any transport damage detected must be immediately reported to the shipper and to Coiltech. Make a note of the damage on the consignment note as well.
Labelling
The cooler data plate is located on the connection side of the cooler and indicates the following: Manufacturer. Max. working pressure. Test pressure. Order number. Year of manufacture. Dry weight. Internal liquid volume.
Operating Pressure
The cooler can only be used with a max. working pressure as specified on the data plate, designated: MWP (MPa).
Commissioning
The cooler can be installed for either horizontal or vertical airflow. The standard cooler is constructed with cross-flow water circuit. The direction of the airflow through the coil is therefore insignificant. The supply and return pipes leading to the cooler must be flushed before they are connected to the cooler. When pressurizing the pipe system with the cooler connected, the pressure may not exceed the working pressure indicated on the data plate supplied. When testing the pressure and starting the ventilation system, the venting plugs should be loosened in order to let out any air in the pipe system. This should be done several times during the first period of operation. Adjust the correct water flow. If the flow is too low, the cooling capacity of the coil is reduced and there is risk of deposits accumulating inside the tubes. On the other hand, if the flow is too high, the cooling capacity is increased but there is risk of erosion. If the QDKR cooler is fitted with a leakage detector, the size G 1/4 upper air venting nipple must be removed to prevent exposing the detector system to an excessive pressure. The leakage detector should be fitted to the lowest nipple. We recommend tightening the header bolts before commissioning the cooler. For particulars of the tightening torque and the order in which they are to be tightened, see under the heading: Fitting the QLKZ-01 Replacement Gasket.
Connections
Connect the pipework with the cooler flanges in such a manner that neither the dilatation forces nor the deadweight of the pipework will put a strain on the cooler flanges. The flanges have to be protected against impacts, external stress and strain. CAUTION! Loading and impacts may damage the cooler.
Quality System
Coiltech AB has a certified Quality Assurance System to ISO 9001 and a Certified Environmental Management System to ISO 14001.
Handling and Maintenance

Read all the maintenance instructions before you begin handling this product. The cooler should be installed where it is accessible for cleaning, but not where the general public has access to it. Only let trained personel with profound knowledge of the product and the appropriate safety rules carry out any work on the cooler.
Protection against Freezing and Bursting

Spare coolers or coolers that have been dismantled need a protective cover over their finned surface to prevent personal injury or fin damage, as the finned surface has sharp edges. Coolers must be completely drained of water before they are stored to prevent ice or corrosion damage inside the tubes. Both headers should be dismantled to make sure that the cooler has been completely drained of liquid.
Lifting
The dry weight of the cooler is specified on the data plate located between the liquid connections. The air cooler is equipped with lifting lugs located on the connection and return headers.
Transport
After unloading, carry out a visual inspection to make sure that the cooler hasnt been damaged during transport. It is very important to examine the finned surface of the heat exchanger.
Coiltech
2(4)
Specifications are subject to alteration without notice R 1 019 145-0002D
DIRECTIONS FOR USE
Maintenance and Service

Coolers taken out of Operation
If the air cooler is drained without being removed from the system, the drain plug should not be refitted since the shut-off valves may leak and refill the cooler with liquid. If the system is inoperative for more than one month, the cooler should be completely emptied and cleaned to prevent corrosion in the tubes. 2. Mark the position of the headers to enable correct reassembly, and then remove the headers.
Spare Parts
Maintenance
Contamination on the outside and/or inside of the cooler reduces its cooling capacity. The cooler must therefore be cleaned at regular intervals, depending on the constitution of the air and cooling water. During the initial period of operation, the cooler should be inspected frequently.
Cleaning the inside of the Tubes

The cooler can be cleaned internally by temporarily increasing the water flow, by adding a chemical cleaning agent to the liquid (provided that the agent isnt aggressive to the metals in the cooler) or mechanical cleaning. A cooler with copper alloy tubes can be cleaned chemically with Sulphur amino acid or Potassium hydroxide. Mechanical cleaning can be carried out as follows:
Coiltech guarantee does not cover costs for coolers that are damaged due to improper installation or freezing. 3. Use a QLKZ/QDKZ-08 brush to When ordering spare coolers, speciclean the inside of the finned tubes fy the production number and type as you flush them with water. number that appear on the data plate of the original cooler. 4. Clean the sealing surface of the headers with benzene or acetone The principal Parts of a and fit new QLKZ-01 Gaskets Cleanable Air Cooler according to he instructions in 1. Side panel Figure 2. The gasket is made 2. Finned body of selfadhesive EPDM rubber. The 3. Tube plate U-strip on the partition wall is 4. Connection header reusable. 5. Return header 6. Venting plug 5. When refitting the headers, note 7. Drain plug how they are marked and refit them to their proper locations. Use a torque wrench to tighten the bolted joint to a torque of 70 Nm. Tighten according to the pattern in Figure 2.
Cleaning the Air Side

1. The finned surface can ben cleaned with steam, compressed air or water. Be careful to hold the nozzle perpendicular to the fins and not closer than 150 mm to prevent damaging the fins. 2. The finned surface can also be cleaned with hot water and environmentally compatible detergents. If detergents are used, they may not be aggressive to copper and aluminium. The finnedtube body may not contain any traces of detergent after cleaning as remaining detergents will bind new dust. If fins are deformed after cleaning, use a fin comb made of Nylon to straighten them. The QLAZ-20 Fin Comb is available as an accessory.
1. Drain the coil thoroughly and remove it from the ventilation system, if necessary.
Figure 1. The principal parts of the Air Cooler
Coiltech
3(4)
DIRECTIONS FOR USE
Maintenance and Service

Fitting the QLKZ-01 Replacement Gasket
1. Rubber gasket, 10 x 2 mm always to be replaced when dismantling the headers. 2. Rubber U-strip
Fit the rubber gasket so that it borders on the screw holes. Stretch the gasket outward in the corners. Cut the U-strip obliquely so that it follows the bending radius of the header. It should extend inward under the gasket. When you refit the headers, tighten the bolts in the order indicated by s1 s8. Tightening torque: 70 Nm Before start-up, the bolts are re-torqued to 70 Nm.
Coiltech AB: SE-614 81 Sderkping Phone +46 121-19100 Fax +46 121-10101 www.coiltech.com Coiltech, Afrikalaan 303, BE-9000 Gent, Belgium Phone +32 9 218 71 30 Fax +32 9 218 71 39 Coiltech, Schnbrunner Allee 11 AT-1120 VIENNA, Austria Phone +43 1 81 20 206 Fax: +43 1 81 20 250
Figure 2. Fitting the gasket and U-strip
WuXi ECO Coils&Coolers Co.,Ltd. No.19 Xin Nan Zhong Road, Mei Cun Wuxi national High Tech Industrial Development PRC Post code: 214112 Phone +86 (0)510 88558031 Fax +86 (0)510 88558038 www.ecogroup.com info@ecogroup.com
Head Office: 33050 POCENIA (UD) | Via Giulio Locatelli, 22 Phone +39 0432.772.001 Fax +39 0432.779.594 www.ecogroup.com info@ecogroup.com
Coiltech
4(4)
10
11
Date Change Order
12
Description
13
14
Name
This document is confidential and proprietary to AQ Enclosure AB and shall not without the expressed written permission of CTI be copied, imparted to a third party or used for any other unauthorized purpose.
T10
Q89
T7-9
B
Connection box +MTB.GC1

C
AQ Enclosure System AB Box 109 - 567 22 Vaggeryd - Sweden tel +46.393.44400 - fax +46.393.44410
R1
E E
K1-3
F F
K4 GP
H
C1-3 T4-6
E1-3
Created by
GENERAL TOL. ISO UNLESS OTHERWISE 2768 m STATED
Date (yyyy-mm-dd)
Checked By
Date (yyyy-mm-dd)
AQ Articlenumber
KeJo
Material
090123
Project Scale
2762
Units MM
OVER 0.5 6 30 120 400 1000
UP TO 6 30 120 400 1000 2000 0.1MM 0.2MM 0.3MM 0.5MM 0.8MM 1.2MM
3mm
Finish Product Name
1:20 TABACAL
Drw No Rev
A1
Sheet
XYK 210780-FLD
01
1/2
5 70
6 1630
8 1630 1470
10
Date
11
Change Order Description
12
13
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Name
A
This document is confidential and proprietary to AQ Enclosure AB and shall not without the expressed written permission of CTI be copied, imparted to a third party or used for any other unauthorized purpose.
150 280 200
1630
A 70 60
M12
B 1060 800 1080
+MTB.GC1
280 D
AQ Enclosure System AB Box 109 - 567 22 Vaggeryd - Sweden tel +46.393.44400 - fax +46.393.44410
200
500 678 3400
M20 (6x) 22 (6x)
1004
Gland plate
2525 F 1905 F
1000
1200 H
Pressure relief covers 6x 300x600
700 H
300
300
Cu 2x10x80
Created by
GENERAL TOL. ISO UNLESS OTHERWISE OVER UP TO 6 30 120 400 1000 2000 0.1MM 0.2MM 0.3MM 0.5MM 0.8MM 1.2MM 2768 m STATED
Date (yyyy-mm-dd)
Checked By
Date (yyyy-mm-dd)
AQ Articlenumber
KeJo
Material
090123
Project Scale
2762
Units MM
3mm
Finish Product Name
1:20 TABACAL
Drw No Rev
SECTION A-A 1 2 3 4 5 6 7 8 9
0.5 6 30 120 400 1000
A2
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XYK 210780-FLD
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We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. ABB
Suppl. documents, kind Reservdelar Itm 1 2 3 4 5 6 7 8 9 10 Qty 2 2 4 2 4 4 2 8 1 8
Identity XYK 200 500-FLD Type
No. 902 Data Name Lagerbussning Bearing bushing Lagerbussning, J-O Bearing bushing, J-O Lagerisolering, liten Bearing insulation,small Lagerisolation, stor Bearing insulation,large Luftfilter Air filter Axelttning Shaft sealing Montering ttning Mounting of sealing Slang Hose Slang fr jacking-oil Hose for jacking-oil Borste Brush Open document Note
Article No. 2211 0348-2 2211 0348-6 2219 300-2 2219 300-4 2591 038-1 3BSM 007334-A 3BSM 005928-D 2219 303-4 2515 291-L 3BSM 011092-1
ISS Tabacal Siemens ltd Brazil Type des. AMS 1250LD Intended for Trade name
Based on Prepared Approved Resp dept Pcl
808346
Reg No
08-12-17 P-E Lindh 09-05-26 Anders Lindin Take over dept AP/MAA
ABB AB, Machines
Orderbunden stycklista Reservdelar Spare parts Revision A L000979-A XYK 200 500-FLD
Lang Page Cont
sv 1 -
Suppl. documents, kind Reservdelar Itm 1 2 3 Qty 6 2 1
Identity XYK 200 501-FLD Type
No. 902 Data Name Diod Diode Tyristor Thyristor Styrpulsdon Control pulse unit Open document Note
Article No. 3BSM 000248-1 3BSM 000249-1 3BSM 000313-A
ISS Tabacal Siemens ltd Brazil Type des. AMS 1250LD Intended for Trade name
Based on Prepared Approved Resp dept Pcl
808346
Reg No
09-05-25 P-E Lindh 09-05-26 Anders Lindin Take over dept AP/MAA
Orderbunden stycklista Reservdelar Spare parts,commissioning

Revision Lang
ABB AB, Machines
L000979-A XYK 200 501-FLD
Page Cont
sv 1 -
INSPECTION PLAN
CUSTOMER PROJECT TYPE OUR REFERENCE SERIAL NO. : : : : : Siemens Ltd Brazil Tabacal AMS 1250LD L000979-A1 8268 088
CONTENTS: Internal tests Official tests : Item 1 - 29 : Item 60 - 90
Item 60 - 90 for customer approval:
APPROVED
Customer name: Approved by, sign: Date:
AE058721-1
Prep. Appr. Resp. dept.
AP/MAE P.S / Andersson Leif Y AP/MA
2008-05-05 Inspection Plan 2008-05-08 Tabacal
No. of sh.
10
Lang. Rev. ind. Sheet
L000979-A1
Document number
ABB AB, Machines
XYK210044-FLD
en
TEMPLATE: NORMAL.DOT; PRINTDATE: 2008-05-08 3:06:00 PM; SAVEDATE: 2008-05-08 10:33:00 AM; OSKAR VERSION: 3.48 (2008-03-17)
Key to the codes:

Code 1 Indicates place for testing S = At the supplier to ABB L = In our workshop T = In our testroom E = At the erection site Code 2 Indicates who will be present at and supervise the test D = Representative of the engineering department Q = Appointed internal inspector X = Representative of customer - Only visiting of test W = Representative of customer - Witnessed test. If customer or representative of customer is not in time for test at the factory, the test is executed without his presence H = Representative of customer - Mandatory hold point. The test shall be executed with presence of customer or representative of customer - = Not significate character Code 3 Indicates that testresults or certificate should be reported in writing and to whom it should be sent C = Customer via engineering department D = Engineering department Q = Filed at test location or responsible department - = Not significate character Code 4 Indicates the extent of testing 1 = Only first machine on the order A = All machines on the order
Kodnyckel:
Kod 1 Indikerar plats fr prov S = Hos underleverantr till ABB L = I egen verkstad T = I eget provrum E = P uppstllningsplats Kod 2 Indikerar vem som skall nrvara vid och vervaka provet D = Representant frn orderavdelningen Q = Utsedd intern kontrollant X = Representant frn kund - Endast besk vid prov W = Representant frn kund - Bevittnat prov. Om kund eller kundens representant inte infinner sig i tid till provet, kommer provet att utfras utan dennes nrvaro H = Representant frn kund - Obligatorisk hllpunkt. Provet skall utfras med kund eller kundens representant nrvarande - = Icke signifikant tecken Kod 3 Indikerar att provresultatet eller certifikat skall rapporteras skriftligen och till vem protokollen skall skickas C = Kund via orderavdelning D = Orderavdelning Q = Arkiveras p provplats eller hos ansvarig avdelning - = Icke signifikant tecken Kod 4 Indikerar provets omfattning 1 = Endast frsta maskinen i ordern A = Alla maskinerna i ordern
Document number
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Rev. ind.
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ITEM DESCRIPTION Internal tests: 1 Dimensions stacked stator Dimensioner pltlagd stator
DOCUMENT FORM RECORD Acc. drawing 2000 733-009 XYK 215 100-FLD Acc. drawing 2000 733E-537 XYK 215 142-FLD 4104 016E-27 2000 733E-608 XYK 215 710-FLD 3BSM 000830 2000 733E-539 XYK 215 144-FLD 3BSM 000830 2000 733E-580 XYK 215 442-FLD 3BSM 000831 2000 733E-580 XYK 215 442-FLD 4104 016E-34 2000 733E-580 XYK 215 442-FLD
CODE REMARKS 1 2 3 4 L Q Q A
Visual inspection of uninsulated stator coil Okulrbesiktning av oisolerad flkt statorhrva Testing of strand-insulation of stator coil Provning av partisolering p statorhrvor Impulse voltage test on stator coils Sttspnningsprov p statorhrvor Impulse voltage test on stator coils in stator Sttspnningsprov p statorhrvor i stator Dielectric tests of the stator winding before and after VPI Spnningsprov p statorlindning fre och efter VPI Visual inspection of wound stator Okulrbesiktning av lindad stator Dimensions and run-outs of rotorbody complete Dimensioner och kast p rotorstomme komplett Shaft end with flange Uppmtning av hlbild p axeltapp med flns
L Q Q A
L Q Q A
L Q Q A
L Q Q A
L Q Q A
L Q Q A
Acc. drawing 2000 733E-378 XYK 215 106-FLD Acc. drawing 2000 733-542 XYK 215 111-FLD Acc. drawing 2000 733E-609 XYK 215 711-FLD
L Q Q A
L Q Q A
10 Dimensional check of machined pole tips Dimensionskontroll av bearbetad polplatta
L Q Q A
Document number
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Rev. ind.
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ABB AB, Machines
XYK210044-FLD
en
11 Dimension check of rotor coils Dimensionskontroll av rotorspolar 12 High frequency test of rotor coils Hgfrekvensprov p rotorspolar 13 Tightening torque and angular tightening of pole bolts tdragningsmoment och vinkelstyrd dragning av polbultar 14 Tightening torque for support to rotor coils tdragningsmoment fr spolstd 15 High frequency test on wound rotor Hgfrekvensprov p lindad rotor 16 High voltage test on wound rotor Hgspnningsprov p lindad rotor 17 Impulse voltage test on wound rotor Sttspnningsprov p lindad rotor 18 Visual inspection of wound rotor Okulrbesiktning av lindad rotor
Acc. drawing 2000 733E-531 XYK 215 125-FLD 3BSM 005428 2000 733E-531 XYK 215 125-FLD Acc. drawing 2000 733E-639 XYK 215 463-FLD Acc. drawing 2000 733E-639 XYK 215 463-FLD 3BSM 005427 2000 733E-639 XYK 215 463-FLD 3BSM 005427 2000 733E-639 XYK 215 463-FLD 3BSM 005427 2000 733E-639 XYK 215 463-FLD Acc. drawing 2000 733E-639 XYK 215 463-FLD Acc. drawing 2000 733E-546 XYK 215 435-FLD 3BSM 005426 2000 733E-546 XYK 215 435-FLD Acc. drawing 2000 733E-264 XYK 215 708-FLD Acc. drawing 2000 733-156 XYK 215 152-FLD
L Q Q A
L Q Q A
L Q Q A
L Q Q A
L Q Q A
L Q Q A
L Q Q A
L Q Q A
19 Run-out of rotor complete, run-out of shaft end Kast p rotor komplett, kast p axeltapp 20 Measurement of rotor impedance without stator Uppmtning av rotorimpedans utan stator 21 Dimension check of bearing house Dimensionskontroll av lagerhus 22 Measurements of bearing liners mounted in bearing shell Mtning av lagerfoder monterad i lagersklen
L Q Q A
L Q Q A
L Q Q A
L Q Q A
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Sheet
ABB AB, Machines
XYK210044-FLD
en
23 Inspection of wound exciter rotor Kontroll av lindad matarrotor 24 Balancing of complete exciter rotor Balansering av komplett matarrotor 25 Winding control of wound exciter stator Lindningskontroll av lindad matarstator 26 Feet location Fotplattors placering 27 Control of contact surface on machine foot Kontroll av fotplattornas kontaktyta 28 Visual inspection of complete machine Okulr besiktning av komplett maskin 29 Weighing of machine, cooler top and terminal box Vgning av maskin, kylartopp och uttagslda
4104 016E-41 2000 733E-629 XYK 215 469-FLD 4104 016E-42 2000 733E-714 XYK 215 701-FLD
L Q Q A
L Q Q A
4104 016E-37 2000 733E-626 XYK 215 466-FLD
L Q Q A
Acc. drawing 2000 733-545 XYK 215 160-FLD 4107 011E-17 2000 733E-540 XYK 215 131-FLD
L Q Q A
L Q Q A
4104 016E-18 2000 733E-574 XYK 215 425-FLD
T Q Q A
3BSM 901 442 2000 733E-573 XYK 215 420-FLD
L Q Q A
Document number
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Rev. ind.
Sheet
ABB AB, Machines
XYK210044-FLD
en
ITEM DESCRIPTION Official tests: 60 Material check of blank for rotorbody Materialkontroll av mne till rotorkropp 61 Material check of blank to pole tips Materialkontroll av mne till polplattor 62 Pressure test of water cooler Tryckprov av vattenkylare 63 Certificate for Pilot Exciter (PMG) Certifikat fr hjlpmatare (PMG)
DOCUMENT FORM RECORD Acc. drawing Certificate
CODE REMARKS 1 2 3 4 S - C A
Acc. drawing Certificate
S - C A
Acc. drawing Certificate Acc. drawing Certificate
S - C A
S - C A
64 Balancing of rotor complete Balansering rotor komplett 65 Radial bearing clearance Radiell frigng i lager 66 Air gap measurement Luftgapsmtning
4107 011E-5 2000 733E-546 XYK 215 435-FLD 4107 011E-7 2000 733E-551 XYK 215 305-FLD 4107 011E-8 2000 733E-529 XYK 215 150-FLD
L Q C A
L Q C A
L Q C A
67 Dissipationfactor ( tan delta) measurement on complete machine Frlustfaktormtning ( tan delta) p komplett maskin 68 Resistance measurement Resistansmtning
4104 016E-43 2000 733E-596 XYK 215 400-FLD 4104 016E-5 2000 733E-552 XYK 215 310-FLD
T Q C A
T Q C A
69 Heat run at P.F. = 0 Vrmeprov vid cos = 0
4104 016E-16 2000 733E-558 XYK 215 340-FLD
T WC 1
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210044-FLD
en
70 No-load losses at P.F. = 1 Tomgngsfrluster vid cos = 1 71 No-load characteristic and losses Tomgngskurva och -frluster 72 Short-circuit characteristic and losses Kortslutningskurva och -frluster 73 Load point at P.F. = 0 Belastningspunkt vid cos = 0
4104 016E-6 2000 733E-557 XYK 215 335-FLD 4104 016E-6 2000 733E-557 XYK 215 335-FLD 4104 016E-7 2000 733E-557 XYK 215 335-FLD 4104 016E-15 2000 733E-557 XYK 215 335-FLD 4104 016E-14 2000 733E-554 XYK 215 320-FLD 4104 016E-10 2000 733E-555 XYK 215 325-FLD 4104 016E-11 2000 733E-569 XYK 215 395-FLD 4104 016E-12 2000 733E-556 XYK 215 330-FLD 4107 011E-11 2000 733E-560 XYK 215 350-FLD 4107 011E-15 2000 733E-560 XYK 215 354-FLD
T WC A
T WC A
T WC A
T WC A
74 Shaft voltage measurement Mtning av axelspnning
T WC A
75 Phase sequence and terminal marking Fasfljd och uttagsmrkning 76 Voltage and current balance Spnnings- och strmbalans
T WC A
T WC A
77 Overspeed test Rusningsprov
T WC A
78 Vibration measurements Vibrationsmtningar 79 Vibration measurement during retardation or acceleration Vibrationsmtning under utlpning eller upprullning 80 Functional test of jacking oil system Funktionstest av jacking oil system
T WC A
T WC A
T WC A 2000 733E-649 XYK 215 431-FLD
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210044-FLD
en
81
Calibration of orifice in lubricating oil system Kalibrering av strypbrickor till smrjolje systemet
T Q C A 2000 733E-575 XYK 215 430-FLD
82 PMG, Output voltage and frequency PMG, utspnning och frekvens 83 Control of leak water detector Kontroll av lckvattenvakt
Acc.drawing 2000 733E-576 XYK 215 438-FLD 3BSM 003641-1 2000 733E-588 XYK 215 450-FLD 4107 011E-9 2000 733E-553 XYK 215 315-FLD
T WC A
T WC A
84 Magnetic neutral pos., axial play in bearing and distance shaft-end to footplate Magnetiskt neutrallge, axiellt lagerspel och avstnd axeltapp fotplatta
T WC A
85 Measurement of insulation resistance before and after dielectric test Mtning av isolationsresistans fre och efter hgspnningsprov 86 Dielectric test Hgspnningsprov
4104 016E-3 2000 733E-561 XYK 215 355-FLD
T WC A
4104 016E-13 2000 733E-561 XYK 215 355-FLD
T WC A
87 Test of terminal box Provning av uttagslda
4104 016E-25 2000 733E-570 XYK 215 405-FLD
T WC A
Document number
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Rev. ind.
Sheet
ABB AB, Machines
XYK210044-FLD
en
88 Determination of rated excitation current Bestmning av mrkmagnetisering 89 Determination of efficiency at rated P.F. and 100, 75, 50 and 25% load Bestmning av verkningsgraden vid mrk cos och 100, 75, 50 och 25% last
4104 016E-20 2000 733E-611 XYK 215 490-FLD IEC 60034-2 cl. 11 2000 733E-612 XYK 215 480-FLD
T D C A
T D C A
90 Settings list for machine protection Instllningslista fr maskinskydd
T D C A 2000 733E-651 XYK 215 801-FLD
Document number
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Rev. ind.
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XYK210044-FLD
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REVISION Rev. Page (P) ind. Chapt.(C)
Description
Date Dept./Init.
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210044-FLD
en
10
TECHNICAL SPECIFICATION FOR BRUSHLESS SYNCHRONOUS GENERATOR CLIENT PROJECT TYPE OUR REFERENCE DRIVEN BY DATE : : : : : : Siemens Ltd Brazil Tabacal AMS 1250LD L000979-A1 Steam Turbine 2008-05-05
___________________________________________________
SECTION A. RATED DATA B. STANDARDS C. OTHER PERFORMANCE DATA D. SITE CONDITIONS F. INSTALLATION DATA G. INCLUDED ACCESSORIES H. WORKSHOP TESTS PAGE 2 2 2 3 4 5 8
ENCLOSURE INSPECTION PLAN GENERATOR CURVES : - EFFICIENCY CURVES - SATURATION CURVES - A - V-CURVES - CAPABILITY DIAGRAM - GENERATOR OVERLOAD CURVES - NEGATIVE SEQUENCE CURRENT CAPABILITY CURVES - DECREMENT CURVES SHORT CIRCUIT EQUATIONS
NUMBER XYK 210 044-FLD XYK 210 094-FLD PAGE 1 2 3 4 5 6 7 XYK 210 089-FLD
AE058721
AP/MAE P.S / Carlquist Kristina AP/MA
2008-05-05 Technical Specification 30/01/2009 Tabacal
No. of sh.
9
L000979-A1
Document number
ABB AB, Machines
XYK210045-FLD
en
TEMPLATE: NORMAL.DOT; PRINTDATE: 1/30/2009 12:35:00 PM; SAVEDATE: 1/30/2009 12:38:00 PM; OSKAR VERSION: 3.48 (2008-03-17)
A. RATED DATA Output Power factor ( overexcited ) Voltage Frequency Speed Current Exciter type Excitation B. STANDARDS Applicable standards Insulation class stator and exciter Insulation class main rotor Temperature rise, stator within class Temperature rise, rotor within class C. OTHER PERFORMANCE DATA Efficiency at P.F. 0.85 and 100 / 75 / 50 / 25 % load Reactances: - Xd - Xd' unsat/sat - Xd" unsat/sat - X0 - X2 Time constants: - Td' - Td" - Td0' - Ta Excitation main machine: - voltage no load - voltage full load - current no load - current full load % : 98.43 (15%) % " % " % % % s s s s : : : : : : : : : 98.35 98.01 96.68 : : : : : IEC 60034-1 F H B B kVA : : V (5%) : Hz (5%) : r/min : A : : V/A : 45100 0.85 13200 50 1500 1973 GLA 600D 103 / 11
192 30.5 / 26.2 19.6 / 16.7 8.1 19.6 1.12 0.028 9.57 0.18
V V A A
: : : :
69 178 208 540
Document number
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Rev. ind.
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ABB AB, Machines
XYK210045-FLD
en
Sudden short circuit current (peak) Short circuit ratio Max. field forcing for 10 seconds (percentage of rated excitation) Sustained short circuit, stator current for 10 seconds at symetrical conditions Max. permissible overspeed Output with one cooler element out of service Max. continuous negative sequence current Fault condition capability (I2/IN)2t
kA : 33 % : 57
% : 160 % : 235 r/min : 1800 % : 100 % : 8 s : 20
Allowed current harmonic content, with base 45100 kVA Harmonic 5 th 7 th 11 th 13 th 17 th 19 th 23 th 25 th Current content 2.0 1.7 1.2 1.1 1.0 1.0 0.9 0.6 % % % % % % % %
If the current harmonic content is higher than above values, the temperature of the machine may rise above the specified limits.
D. SITE CONDITIONS Ambient temperature range Altitude Location Water temperature range Hazardous area classification Seismic zone C : 0 - +50 m : < 1000 : Indoors C : 10 - +30 : Non hazardous area : Acc. to UBC, Zone 4
Document number
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ABB AB, Machines
XYK210045-FLD
en
F. INSTALLATION DATA Protection form/cooling form Cooler location/No of coolers Water cooling: - Required cooling water flow - Cooling water temperature max. - Temperature rise cooling water - Pressure drop cooling water - Fouling factor - Cooling water type Heat losses: - Cooling water - Lubrication oil Arrangement form Sleeve bearings: - Max. axial play towards D-end - Max. axial play towards N-end - Max. permissible axial thrust - Min. barring speed - Required oil flow to bearings (Total) - Oil temperature range to bearings - Required oil pressure at 40 C At higher pressure an orifice should be used. - Type of oil - Degree of purity for oil Weights: - Total (complete machine, excluding terminal box) - Stator - Rotor - Terminal box Rotor inertia (J=m*rm2) Direction of rotation (at drive end, facing shaft end) mm mm kN rpm l/min C kPa m3/h C K kPa m2C/W : IP 54 IC8 A1W7 : Top / 2+2 : : : : : : 73.0 30 7.4 30 0.0000900 Customer water analysis required
kW : 611 ( at rated load ) kW : 31.4 : IM 1005 : : : : : : : 12.0 12.0 0 45 49.0 40 - 50 200
: ISO VG 46 : 17/15/12 acc. to ISO 4406:1999 kg kg kg kg : : : : 60500 27900 21950 1820
kgm2 : 3638 : CLOCKWISE
First lateral critical speed (based on stiff foundation) r/min : 1800 Noise level (at 1m acc.to ISO 3744) Static force on each machine foot Dynamic force on each machine foot Auxiliary equipment power supply: - Anticondensation heaters in the main machine - Anticondensation heater in the exciter - Anticondensation heater in main terminal box
Document number
dB(A) : 85 dB(A) kN : 74 kN : 390
V, ph, W : V, ph, W : V, ph, W :
380, 3, 2400 380, 3, 400 380, 3, 400

ABB AB, Machines
XYK210045-FLD
en
G. INCLUDED ACCESSORIES Cooling arrangement IC8 A1W7 Self circulated inner air circuit cooled by built-on water-air heat exchanger. Protection form IP54. The cooler has following material: Tube material Tube end plates Water box Plate fins Customer connection flange Flange location Design pressure Test pressure : : : : : : Cu 90%/Ni 10% Muntz metal Rilsan coated steel Aluminium ANSI B16.5 Cl.150 Left hand
: 0.6 MPa : 0.9 MPa
4 cooler elements. Two in series on each air side. Exciter Main brushless exciter type GLA for DC excitation complete with diode bridge, thyristors, RC-circuits and control box. Pilot Exciter (PMG) single phase type. MCB - PMG over current protection: 20 A. Mounting arrangement IM 1005 Horizontal machine with two bearings, one shaft extension. DE shaft end forged flange. Foundation details Machine provided with 8 feet. Long sole plate kit for grouting with non-shrinking grout including: Foundation plates (2 pcs), anchoring bolts, holding down bolts, mounting shims, dowel pins and horizontal machine jacking bolts. No alignment or grouting included in ABB scope of supply. Jacking bolts vertical adjustment.
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210045-FLD
en
Bearings Sleeve bearings suitable for flood oil lubrication provided by others, connection at left side on each bearing. The lube oil drain pressure must be less than or equal to the machine ambient pressure. An oil drain pressure of 200-1000 Pa lower than the bearing ambient is recommended. Customer connection flange acc. to DIN. Inlet pipe in stainless steel. Outlet pipe in stainless steel. Lockable pressure reducing valve in stainless steel. Provision for jacking oil only. Emergency oil requirement
Main terminal Heaters in HV terminal box. Large stator terminal box, right side. Stator terminal box protection IP54 with all 12 ends brought out and neutral point terminated inside the box. Connection from underneath. Grounding clamps inside and outside. The main terminal box is delivered as a loose item, assembly on site is not included in ABB's scope of supply. The main terminal box needs to be supported from beneath. Supports are not included in ABB's scope of supply. For terminal box weight see section F.
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210045-FLD
en
Line side 3 - Surge capacitors 3 - Lightning arrestors 3 - Voltage transformers 1 - Earthing device 3 phase, ball-bolt. Neutral side 3 - Current transformers with 2 cores 1 - Current transformer with single core 1 - Neutral grounding resistor, 10 A for 10 sec. 1 - Low voltage contactor 1 Grounding switch with auxiliary contacts Anticondensation heaters Standard 1 phase elements for 3 phase supply. In both main machine, exciter and terminal box. Termination in separate boxes (normally opposite main supply side). The anticondensation heaters should always be connected during stand still. Measurement and control Resistance temperature detectors All PT100 double elements (excl. stator) DIN. 6 in the stator winding 2 in each bearing 2 in cold air 1 in hot air Flow control glass in oil outlet, carbon steel, 1 per bearing. DIN-flanges. Cooling water leakage detector, brass, capacitive sensor with switching amplifier, 230 Vac. Shaft grounding brush on D-end. Painted carbon steel junction boxes provided with standard cable glands.
A
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210045-FLD
en
Surface treatment Standard industrial coating acc. to ISO 12944 C2. Primer coating - modified epoxy1 Top coating - modified epoxy1 1 The binder is an acid cured epoxidized oil. Standard colour : 60 m. : 60 m. : Blue NCS 4822-B05G
H. WORKSHOP TESTS ABB AB Machines standard procedure is to perform a type test for a single machine order. If two or more identical machines are ordered, then a type test is performed on the first machine and routine tests on the remaining machines. Proposed workshop tests according to enclosed INSPECTION PLAN are part of our manufacturing program and are part of the quoted price of the machine. Witnessing of testing Participation in a test specially arranged, time to be agreed between ABB AB Machines and customer, 2 weeks advance notice, date will be confirmed 1 week prior to scheduled test date. The performance calculations are carried out and presented to customer during his visit.
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210045-FLD
en
REVISION Rev. Page (P) Description ind. Chapt.(C) A P4 Sound level updated to 85 dB(A) P7 1 grounding switch added
Date Dept./Init. MAS/KC 2009-01-30
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210045-FLD
en
Pcl Type des. Itm 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 Qty 4 1 2 3 1 1 4 2 2 2 2 2 6 1 2 4
808346 AMS 1250 LD Location D-AND ND-BEARING BETWEEN STATOR FLANGES (INSIDE ENCLOSURE) OUTSIDE STATOR FLANGES (INSIDE ENCLOSURE) INSIDE MACHINE (BETWEEN STATOR FLANGES) INSIDE EXCITER INSIDE TERMINAL BOX D- AND N-BEARING INSIDE MACHINE, OUTSIDE D- AND N-BEARING D- AND N-BEARING D- AND N-BEARING IN EXCITER IN EXCITER IN EXCITER IN EXCITER D-BEARING D- AND N-BEARING Article no 5695 418-29 5695 420-7 5695 420-7 6677 0037-E 3AAM 700199-5 6677 0037-D 3BSM 006087-D 2216 0066-G 2211 0348-2 2211 0348-6 4894 580-A 3BSM 000249-1 3BSM 000248-1 3BSM 000313-A 2211 487-9 2219 300-4 Specification Name RESISTANCE THERMO DETECTOR PT 100 OHM RESISTANCE THERMO DETECTOR PT 100 OHM RESISTANCE THERMO DETECTOR PT 100 OHM STAND STILL HEATER STAND STILL HEATER STAND STILL HEATER SHAFT SEAL COMPLETE AIR COVER BEARING SHELL BEARING SHELL JACKING OIL RC-CIRCUIT THYRISTOR DIODE CONTROL PULSE UNIT THRUST WASHER BEARING INSULATION UPPER HALF LOWER HALF Remark D-AND NDBEARING TEMP. TEMP. HOT AIR TEMP. COLD AIR CONNECTION VOLTAGE ACC. XYK 214100-FMD CONNECTION VOLTAGE ACC. XYK 214100-FMD CONNECTION VOLTAGE ACC. XYK 214100-FMD IN AND OUTBOARD D- AND N-BEARING
ISS 08-12-18 P-E Lindh Approved 09-01-23 Anders Lindin Tabacal Siemens Ltd Brazil
Prepared
Maskindetaljlista List of apparatus Maskindetaljlista
Resp dept
AP/MAA
Rev Ind
Lang Sheet Cont
ABB AB, Machines
L000979-A XYK 210 083-FLD
sv 1 2
Itm 18 19 20 21 22 23
Qty 2 1 1 4 20 1
Location D- AND N-BEARING AT SHAFT ON D-BEARING D-BEARING D- AND N-BEARING INSIDE BOX GA OUTSIDE MACHINE
Article no 2219 300-5 3BSM 011092-1 4395 917-2 2591 038-1 5248 152-1 3BSM 005679-1
Specification
Name BEARING INSULATION EARTH BRUSH BRUSH HOLDER AIR FILTER VARISTOR LEAK WATER DETECTOR
Remark
ISS 08-12-18 P-E Lindh Approved 09-01-23 Anders Lindin Tabacal Siemens Ltd Brazil
Prepared
Maskindetaljlista List of apparatus Maskindetaljlista
Resp dept
AP/MAA
Rev Ind
Lang Sheet Cont
ABB AB, Machines
L000979-A XYK 210 083-FLD
sv 2 -
Formulas for torsional analysis calculations
Airgap torque equation - 3-phase short circuit Torque(t) = 6.72 * e(-t/0.136) * sin(wt) + 1.47 * e(-t/0.122) p.u. Max. torque = 7.90 p.u. after 4.89 ms
Airgap torque equation - 2-phase short circuit Torque(t) = 5.29 * e(-t/0.226) * sin(wt) - 2.65 * e(-t/0.708) * sin(2wt) + 1.47 * e(-t/0.370) p.u. Max. torque = 8.17 p.u. after 6.66 ms
Rated torque: 1.0 p.u. = 247.86 kNm
t = time in seconds w = 2 * pi * 50 at 50 Hz line frequency
AE058721
AP/MAE P.S / Sandin Per AP/MA
2008-05-05 Short circuit equations 2008-05-08 Tabacal
No. of sh.
2
L000979-A1
Document number
ABB AB, Machines
XYK210089-FLD
en
TEMPLATE: NORMAL.DOT; PRINTDATE: 2008-05-08 10:41:00 AM; SAVEDATE: 2008-05-08 10:25:00 AM; OSKAR VERSION: 3.48 (2008-03-17)
Description
Date Dept./Init.
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210089-FLD
en
ABB AB
Machines
Author Date of issue
Classifying code or document type
Scope of Supply
Lang. Print date Internal reference
Leif Andersson 29595

Customer ref.
2008-04-10
en
2009-09-09
Document number
L000979 TABACAL
Rev Page
XYK210093-FLD
1/1
Item Qty
001 1
Description of goods
Generator AMS 1250, LD,TEWAC, IP54 45.1 MVA, 13.2kV, 50Hz, 1500r/m, IM1005
Serial No:
8268088
Design No:
XYK210000-FLD
Comments
C2 Epoxy Standard Industrial Blue
002 003 004 005
1 1 1 1
Rotorwithdrawal sliding plate type Large Terminal Box Spare Parts for 2 years operation Spare Parts for commissioning
XYK210973-FLD XYK210098-FLD XYK200500-FLD XYK200501-FLD
ABB AB
Postal address ABB AB Machines SE-721 70 Vsters/Sweden Telephone +46 (0)21 32 90 00 Telefax +46 (0)21 32 95 10 Reg. no.: 556029-7029 VAT no: SE556029702901 Bank: SEB SE-106 40 Stockholm Sweden SWIFT address: ESSESESS IBAN: SE04 5000 0000 0555 4824 3780
EFFICIENCY CURVES
AMS 1250LD 45100 kVA
1.000
50 Hz
0.85 PF
13200 V
1973 A
1500 rpm
0.995
0.990 2. 0.985 1.
EFFICIENCY [p.u.] (IEC)
0.980
0.975
0.970
0.965
0.960
0.955
0.950 0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
APPARENT POWER [p.u.]

1. PF = 0.85 2. PF = 1.00 U = 1.00 U = 1.00 OUTPUT 1 p.u. = 45100 kVA
AE058721
AP/MAE P.S / Sandin Per AP/MA
2008-05-05 Generator Curves 2008-05-08 Tabacal
No. of sh.
8
L000979-A1
Document number
ABB AB, Machines
XYK210094-FLD
en
SATURATION CURVES - A
AMS 1250LD 45100 kVA 50 Hz 0.85 PF 13200 V 1973 A 1500 rpm
1.6
ARMATURE-VOLTAGE [p.u.] AND CURRENT [p.u.]
1.4
1.2 1. 1.0 2.
0.8
0.6
0.4
0.2
0.0 0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2
FIELD CURRENT [p.u.]

1. OPEN -CIRCUIT SATURATION 2. SHORT-CIRCUIT SATURATION ARMATURE VOLTAGE ARMATURE CURRENT FIELD CURRENT 1 p.u. = 1 p.u. = 1 p.u. = 13200 V 1973 A 191 A
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210094-FLD
en
V-CURVES
1.4
1.2
0.5
0.7
0.9
1.0
0.9 0.85 0.7 0.0 0.5
APPARENT POWER [p.u.]
0.8
+ + + + + + + + + + + + + + +
2.
1.0
3.
+
1. 0.6 0.0 0.4 0.2 UNDEREXCITED 0.0 0.0 0.4 0.8
OVEREXCITED 1.2 1.6 2.0 2.4 2.8 3.2
FIELD CURRENT [p.u.]

1. ACTIVE OUTPUT [p.u.] = 0.00 2. ACTIVE OUTPUT [p.u.] = 0.43 3. ACTIVE OUTPUT [p.u.] = 0.85 GENERATOR OUTPUT FIELD CURRENT 1 p.u. = 45100 kVA 1 p.u. = 191 A
+++ PRACTICAL STABILITY LIMIT - - - POWER FACTOR ACTIVE OUTPUT
P NOTE: --- = 1 IS EQUAL TO p.u. = 0.85 P N P = Nominal active output

N
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210094-FLD
en
CAPABILITY DIAGRAM AT COOLING WATER TEMPERATURE OF 30.0C

1.0 OVEREXCITED 0.8 2. 0.50 0.70 0.6 0.85 0.90 0.4 1.
50 Hz
0.85 PF
13200 V
1973 A
1500 rpm
REACTIVE POWER [p.u.]
0.2
-0.0
0.1
0.3
ACTIVE POWER [p.u.]

0.5 0.7 0.9
1.1
1.3
-0.2
5.
U = 1.00
-0.4
3. 0.90
-0.6
4.
-0.8
0.70
-1.0 UNDEREXCITED
0.50
BASE APPARENT POWER 1 p.u. = 1. STATOR HEATING LIMIT 2. ROTOR HEATING LIMIT 3. PRACTICAL STABILITY LIMIT
45100 kVA 4. ZERO FIELD-CURRENT LIMIT 5. CORE END HEATING LIMIT
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210094-FLD
en
GENERATOR OVERLOAD CURVE

4.0
3.6
3.2
STATOR CURRENT (I) [p.u.]
2.8
2.4
2.0
1.6
1.2
0.8
0.4
0.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0
TIME [S]
IEC 60034-3 Clause 4.15 (I 2- 1) x t = 37.5 s
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210094-FLD
en
NEGATIVE SEQUENCE CURRENT CAPABILITY CURVE

1000.
50 Hz
0.85 PF
13200 V
1973 A
1500 rpm
100.
TIME [SEC.]
10.0
1.0
0.1
0.05 0.06
2
0.1 I N = 1973
1.0 A
10.0
100.0
NEGATIVE SEQUENCE CURRENT (I2) [p.u.]

(I 2/ IN ) x t = 20.0s
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210094-FLD
en
DECREMENT CURVE 3-PH. SHORT CIRCUIT

10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0
50 Hz
0.85 PF
13200 V
1973 A
1500 rpm
2.0
CURRENT (RMS) [PU]
1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3
0.2
0.1 0.0 1 pu = 1973. A 0.5 1.0 1.5
TIME [S]
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210094-FLD
en
Description
Date Dept./Init.
Document number
Lang.
Rev. ind.
Sheet
ABB AB, Machines
XYK210094-FLD
en
Project name: Tabacal Customer:

B
Siemens Ltd Brazil L000979

B
Project no:
1 2 34 5 6 7 8 9 10 11 12
C
List of contents Line connection, Surge arresters Voltage transformers Machine Current transformers Neutral side Heaters Temperature detectors in stator Temperature detectors in bearings Temperature detectors in air Other detectors Revision Notes
Based on
Prepared
20080829 20081205
B Gothilander PE Lindh
Resp. (division/department) Released
Title Circuit diagram
External doc. id. Ref. designation Document id. Rev. Lang. Page Cont.
Customer Project no.
Siemens Ltd Brazil

Project name
Approved
List of contents
Document kind
F
C en 1 2
Work order id.
L000979
D041_A3
Tabacal
L000979A1
MAE
Circuit diagram 4 5 6
XYK 214 100FLD 7
1
L1
L2 L3 Clockwise rotation facing shaft end

+MTB
B
Earthing balls
W1
V1
U1
E1 Surge arresters 17.5kV 10kA Cl.2 E2 E3
C
C1 C2 Capacitors 0.25F 15kV C3
/3.A2
/3.A2
Based on
/3.A2
W1
V1
U1
Prepared
20080619 20081205
Title Line connection, Surge arresters
External doc. id. Ref. designation
Siemens Ltd Brazil

Project name
Approved
F
Rev. Lang. Page Cont.
Work order id.
Document kind
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
1
+MTB
2
/2.E2 /2.E2 /2.E2
3
+MTB.GC1
V1
W1
U1
T4 A N
a n da dn
13200 110 110 3 3 3 50VA Cl 0.5 50VA Cl 0.5 Group 3
B
X12 5 14 12 F1 11 6 7 5 3 1 6 4 2
I>/
T5 A N
a n da dn
T6 A
a n da dn
1 2 3 4 X13 5
1UL1 1UL2 1UL3
C
C
1UNE
14 F2 12
11
6 7
5 3 1
6 4 2
I>/
1 2 3 4 X14 5
2UL1 2UL2 2UL3 2UNE
14 F3 12
11
6 7
5 3
6 4 2
I>/
1 2 3 4
3UL1 3UL2 3UL3 3UNE
E
UL3 UL2
W1
V1
U1
/4.B5
Prepared
/4.B5
/5.A2
/5.A2
Based on
/5.A2
/4.B5
UL1
20080619 20081205
Title Voltage transformers
Siemens Ltd Brazil

Project name
Approved
F
Work order id.
Document kind
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
4
+MTB.GC1
A
/3.E5 UL3 /3.E5 UL2 /3.E5 UL1
B
14 F4 12 11
X15 5 6 7 5 3 1 6 4 2
I>/
1 2 3 4 X16 5
4UL1 4UL2 4UL3 4UNE
C
14 F5 12
11
6 7
5 3 1
6 4 2
I>/
1 2 3 4 X17 5
5UL1 5UL2 5UL3 5UNE
D
14 F6 12 11
6 7
5 3 1
6 4 2
I>/
1 2 3 4
6UL1 6UL2 6UL3 6UNE
Based on
Prepared
20080619 20081205
Title Voltage transformers
Siemens Ltd Brazil

Project name
Approved
F
Work order id.
Document kind
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
1
/3.E2 /3.E2
2
/3.E2
V1
B
+GEN.GF
W1
U1
B
F8 21 13 A1 A2 1 3 22 14 2 4
I>/
3 4 5 6 1 2 Voltage regulator
+GEN
PMG
C
C
F1 G1 45100 kVA x 0,85 13200 V 50 Hz 1973 A
GS
VOLTAGE REGULATOR F2
EXCITER
/6.A2
/6.A2
Based on
/6.A2
W2
V2
U2
Prepared
20080619 20081205
Title Machine
External doc. id. Ref. designation Document kind Document id. Rev. Lang. Page Cont.
Siemens Ltd Brazil

Project name
Approved
F
C en 5 6
Work order id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
1
+MTB
2
/5.E2 /5.E2 /5.E2
4
+MTB.GC1
A
P2
A
X2 11 12 13
V2 2s2 T8 2s1
2500/5A 25VA 10P20
T7
2s2 T9 2s1
W2 2s2 2s1
U2
14 15 16 17 18 21 22 23
2500/5A 25VA Cl 0.5 FS7
T7
1s2 T8 1s1
1s2 T9 1s1
1s2 1s1
24 25 26 27 28 X21 1 2 3 4 5
+Q89.01
P1
C
14
10
13
16
V2
12
15
18
W2
U2
17
11
D
X21 11 12 13
Grounding switch Manual operation
14 Q89 15 16 P2 T10 P1 1s1 X2 41 42 43 Generator protection
100/1A 2.5VA 10P10
1s2
Earthing resistor 762
R1 10A 10sek
Based on
Prepared
20080619 20081205
Title Current transformers
Siemens Ltd Brazil

Project name
Approved
Neutral side
Document kind
F
Work order id.
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
1
+GEN
6
+MTB
Heaters in stator
Heater in Exciter
Heater in terminal box
HE1 1
HE2 1 800 W
HE3 1 800 W
HE4 1 450 W
HE5 1 450 W
800 W
C
C
+GE +MTB.GC1
4HE2
4HE1
2HE2
3HE2
5HE2
2HE1
5HE1
3HE1
1HE2
D
1HE1
5HE2
5HE1
D
Connected at site
3 x 380 V
Based on
Prepared
20080619 20081205
Title Heaters
Siemens Ltd Brazil

Project name
Approved
F
C en 7 8
Work order id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
1
+GEN
Stator winding U
Stator winding V
Stator winding W
Stator winding U
Stator winding V
Stator winding W
R4 White White Red
R2 White White Red
R3 White White Red
R5 White White Red
R6 White White Red
R7 White White Red
C
C
+GA
4R2
4R2
2R2
2R2
3R2
3R2
5R2
5R2
6R2
6R2
4R1
1R2
1R2
2R1
3R1
5R1
6R1
1R1
Based on
Prepared
20080619 20081205
Title Temperature detectors in stator
Siemens Ltd Brazil

Project name
Approved
F
Work order id.
Document kind
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
1
+GEN
Bearing RTD's DEnd R8 R9 NDEnd R10 DEnd
Bearing RTD's NDEnd R11
C
C
+GA
10R4
10R4
10R2
10R2
10R3
10R1
7R4
7R4
8R4
8R4
9R4
9R4
7R2
7R2
7R3
8R2
8R2
8R3
9R2
9R2
9R3
7R1
8R1
9R1
Based on
Prepared
20080619 20081205
Title Temperature detectors in bearings
Siemens Ltd Brazil

Project name
Approved
F
Work order id.
Document kind
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
10
1
+GEN
Hot Air R12 R13
Cold Air NDEnd R14
Cold Air DEnd
C
C
+GA
12R4
12R4
13R4
13R4
12R2
12R2
12R3
13R2
13R2
13R3
11R4
11R4
11R2
11R2
11R3
12R1
13R1
11R1
Based on
Prepared
20080619 20081205
Title Temperature detectors in air
Siemens Ltd Brazil

Project name
Approved
F
Work order id.
Document kind
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
10
11
1
+GEN
Leak water detector
S1 Com
NO
NC
C
C
+GA
1S2
1S3
1S1
Based on
Prepared
20080619 20081205
Title Other detectors
Siemens Ltd Brazil

Project name
Approved
F
Work order id.
Document kind
Document id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7
en
11
12
REVISION
Rev.ind.
A B C
Page
2,3,6 810 5 6 6 6
Description
Changed device designations, value on earthing resistor, transformer ratios. Changed terminal designations Changed auxiliary contact of MCB F8 from SPDT to 1NO/1NC Added auxiliary contacts to Q89 Changed CT ratio from 10/1A to 100/1A Changed earthing resistor from 760 to 762
Date/Init.
080829/RP 081104/RP 081205/BG
C
Based on
Prepared
20080619 20081205
Title Revision Notes
Siemens Ltd Brazil

Project name
Approved
F
C en 12
Work order id.
L000979
D041_A3
Tabacal
L000979A1
MAE
XYK 214 100FLD 7

Generator OS43024

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4) Rubber hoses for leakage water to be disconnected. 4-legs lift

Lifting hooks position towards lifting device

Type des. Prep. Appr. Resp. dept

Annelie Kruse Flood Mats A AP/MMO

2008-03-12 2008-05-09 Approved ABB AB, Machines

Doc. kind Title

Instruction Mounting of cooling top

FILE: 3BSM001483-A en.doc; TEMPLATE: TECHN_DOC_STAND_P.dot -; SKELETON:

Lifting-device shall only be used when lifting the cooler housing.

4-legs lift Cooler housing D=30, Ellipsed

Lifting hooks position towards lifting device

Union of steel Adapter

ABB AB, Machines

ABB AB, Machines

Service & repair

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