INSTALLING INSTRUCTION

FOR BRUSHLESS EXCITATION AIR-COOLED TURBO-GENERATOR OF WX21Z SERIES

0JS.461.396C

SHANDONG JINAN POWER E UIP!ENT FACTOR" THE PEOPLE#S REPUBLIC OF CHINA

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0JS.461.396C T20 2$/

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General All WX21Z series of turbo-generators are three-phase, two-pole, synchronous generators with power ranges from 100 W to 200 W. !heir rate" spee" an" fre#uency are $000r%min, &0'( or $)00r%min, )0'( an" their rate" *oltages are 11.&+, 1$.-+, 1&..&+, 20.0+, &0'( or

1$./+, 1..0+, 1-.0+,21.0+,)0'(. 0esi"es the brushless e1citation system, each generator of this series also has a cycling close"air-cooling system in which all the parts are coole" by e1ternal cooling air e1cept the rotor win"ings 2which are coole" by inner cooling air3. !hey may be "ri*en by turbine of the con"ensation type, the bac4 pressure type or the steam e1traction type etc., an" are wi"ely use" in thermal power plants, central heating power plants, steam 5 gas combine" cycle power stations, coal mining power plants an" surplus 5 waste heat power plants etc.. !he simple construction, few au1iliary e#uipments, con*enient installation an" maintenance, safe an" reliable operation, low cost an" #uic4 repayment of in*estment of this series of generator ma4e them easy an" con*enient to install, operate an" maintain in power plants. 6or "etaile" installation "imensions of each generator, please refer to the installation "iagrams supplie" by our factory. !he structure intro"uction of each part is liste" below. !he performance parameters of each generator conform to the items liste" in G0%! .0)7-2002 89e#uirements 6or !urbine !ype :ynchronous achine ; an" the correspon"ing re#uirements liste" in the <=> stan"ar". !he supply scope of each generator is liste" in the 8supply list; offere" by our factory. 2. <nstallation site an" wor4ing con"itions !he normal installation site an" wor4ing con"itions of this series of generators are liste" as follows? - Altitu"e not e1cee"s 1000 meters. - !emperature of incoming cooling air not o*er @70. - <nstalle" in a wor4shop where the temperature of the en*ironment is no less than @&. - !he inlet water temperature of air-cooler shoul" be no more than @$$. $. :tructure intro"uction $.1 A*erall layout !he series of generators are air-coole", self-*entilate" 2-pole machines with cylin"rical rotors. !hey each ha*e a close" cooling circuit employing air-to-water heat e1changers locate" un"er it, in the

foun"ation. !he o*erall layout of this series of generators is shown in 6ig.$-1.

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$.2 >ooling system !here are two i"entical cooling air circuits, symmetrical about the mi"plane of the generator .!he cooling air blown into the generator by the fans on both en"s of the rotor are "i*i"e" into se*eral parts? Ane part < enters the en" (one of the rotor win"ings to cool the en"s of the rotor win"ings before coming into the air gap. Another part << enters the air gap "irectly, combining with the air from the en" of the rotor win"ings, to cool the surface of the rotor bo"y. Ane part comes into the mi""le part of the housing along the a1ial air channel after cooling the en"s of the stator win"ings, from there, it comes into the air gap to cool the mi""le part of the rotor. !hen, combining with the cooling air 2< an" <<3, they flow to the air coolers together after cooling the stator win"ings an" the stator core along the ra"ial air channels in the stator core. After being coole" by air coolers, they return to the fans again, forming a complete circulation. !he stator win"ings are coole" in"irectly. !he heat in them are transferre" to the wall of slots, passe" on from the win"ing insulation to the stator core which is coole" by cooling air flowing in the ra"ial air channels in it. !he housing, acting as the air channel of the stator, ma4e it possible for the cooling air to enter each pac4et of the stator core from the outer circumference so that an a1ial e*en "istribution of temperature may be ensure". !he cooling air enters the rotor from the space between the retaining ring plate an" the shaft, an" flows into the air chamber at the en" of the rotor win"ings, then enters the hollow con"uctors from the slots of the air inlet. <n the con"uctor, the cooling air splits up into the portions A an" 0. Bortion A flows in the hollow con"uctors in the slots before it reaches the center of the rotor, where it comes out into the air gap through ra"ial holes in the hollow con"uctors an" the slot we"ges. Bortion 0 flows in the hollow con"uctors of the en"-win"ing before it reaches the polar a1is, where it lea*es the hollow con"uctors an" enter the air gap through short slots in the en" of the rotor bo"y. $.$ :tator 2inclu"ing en" co*ers3 $.$.1 !he housing, forme" by wel"ing many thin steel plates, is split hori(ontally into top an" bottom hal*es that ha*e many walls in them. After being fi1e" with the win"ings an" ,B< treate", the laminate" stator core is put into the bottom half of the housing. !hen the top half is mounte" on an" bolte" with the bottom half. $.$.2 !he housing, bearing the weight of stator an" magnetic tor#ues, ser*es to passing them onto the foun"ation an" gui"ing the flow of the cooling air together with en" co*ers. !he outer co*er shiel" the air circuit of the generator from the surroun"ings, while the inner co*er separates the air

chamber in front of the fan 2absorption3 from the

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one behin" the fan2compression3 . $.$.$ !he stator core, laminate" by fairly large number of low loss col" rolling silicon steel sheets with insulating paint on both si"es of them, is "i*i"e" into many pac4ages by *entilation channels so that the temperature of the stator core may "istribute e*enly. 6igure $-2 Air circuit of the cooling system

!he self-supporting core is laminate" outsi"e housing. <t is fi1e" an" presse" tight by position bars on the bac4 of the core an" en" rings which ha*e goo" mechanic performance an" small elasticity. !he e1istence of the en" rings, ma"e of har"ene" an" tempere" cast aluminum alloy, forms such an e1cellent shiel" between the en" of the core an" the lea4age magnetic fiel" at the en" that the loss at the en" may be re"uce". 6or the assembly of the housing an" the core with win"ings, please see figure $-$. After the stator core has been furnishe" with win"ings an" insulate", it is hung onto the housing by wel"ing with some steel pipes through se*eral ear-bearing rings. As the tangential *ibration of the wel"e" part of the core is near (ero an" the ra"ial *ibration is transmitte" onto the foun"ation after being wea4ene" by the housing plates, the loa" bearing ability of the foun"ation is ob*iously strengthene". 0esi"es, this style of construction can also bear the "ifferent e1pansion of the core an" the housing "ue to heat. !he separation of the stator an" the housing pre*ent the *ibration of the core from transferring so that the noise maybe re"uce" to a minimum *alue. $.$.7 !he stator win"ing is a $-phase, "ouble layer win"ing. =*ery coil consists of two bars each of which is compose" of two rows o f C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$ 1.+ B+,%2(0%% E3-)&'&).$

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T.&'( 22 T20 6&2 A)+-C..(0/ T,+4.-G0$0+'&.+ .1 WX21Z S0+)0% rectangular copper stran"s wrappe" with two layers of glass sil4 tapes. <n or"er to re"uce the a""itional losses, thin rectangular copper stran"s an" $)0C9obel con*ersion in the linear part are a"opte" to re"uce the ring current in the coil to the minimum. !he main insulation consists of many layers of 6 class poor-resin mica tapes woun" continuously aroun" the whole length of the bar. 6or corona protection, corona-proof construction is a"opte" for the win"ings. After the win"ings ha*e been set in place, they are ,B< treate" together with the core. :tator un"ergone such treatment has such e1cellent "ielectric performance an" integral performance that the abrasion of insulation "ue to the relati*e mo*ement of moul"e" bars against the slot wall "uring operation which is common for tra"itional generators "oesnDt e1ist any more. !he reliability an" "urability of the generators are then highly enhance". !his impro*ement ma4e it possible for the generators to be operate" in such power plant as thermal power plant an" pea4-shift power stations etc. where the loa"s are in constant changes.

6igure $-$ !he core assemble" in two-half housing

1.!op half housing 2. :upporting rings $. >ore 7. 'ori(ontal split line &.6oot of housing ). 0ottom half housing .. 'ori(ontal amplitu"e of core *ibration -. ,ertical amplitu"e of core *ibration

$.$.& !he en"s of stator win"ings are short an" in*olute"ly forme" before being fi1e" onto the brac4ets tightly with elastic Eibber ropes. After being ,B< treate", the en"s of the win"ings form a soli" bloc4 that ensures a higher anti-su""en-short-circuit performance for the generator. $.$.) !he en" of all the win"ings are supporte" by trape(oi"al brac4ets of insulating material which are bolte" on the en" rings an" are tightly tie"to them 2the brac4ets3 by elastic fiberglass ropes. $.$.. !he en"s of the top an" bottom bars are Foine" together with slee*es

C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$ 1.+ B+,%2(0%% E3-)&'&).$ JPEF A)+-C..(0/ T,+4.-G0$0+'&.+ T.&'( 22 T20 ?&2 .1 WX21Z S0+)0% an" sil*er sol"er. At the non-"ri*e en", the terminals an" the connecting rings between phases are fi1e" on the same brac4ets as the en" of all the win"ings 2<n general there are ) terminals. !he connection "imensions, the position as well as the phase-se#uence of the terminals are all shown in the installation "iagram we offere"3. $.7 9otor !he main parts of the rotor are? the rotor bo"y, the rotor win"ings an" its insulation, the "amping win"ings, the retaining rings an" the fans etc.. !he following is the "etaile" "escription of each part? $.7.1 !he rotor bo"y is machine" from a forge" piece of a high #uality alloy steel. !here is a flange forge" integrally with the shaft on the turbine si"e. <n or"er to guarantee enough mechanical strength for the narrowest part of tooth root, step slots are a"opte" which may enhance the utili(ation ratio of the slots by accommo"ating as more e1citation turns as possible. An GE=, an a1ial center-hole which e1ten"s to the un"er part of the rotor win"ings was "rille" in the shaft to accommo"ate the two semicircular copper lea"s 2insulate" from each other3 for the e1citation current. $.7.2 !he rotor win"ing consists of many concentric coils that are compose" of har"-"rawn rectangular hollow con"uctors ma"e of copper alloye" with 0.1H sil*er. As this 4in" of con"uctors ha*e better creep performance an" higher offset limit than general copper con"uctors, harmful "eformation of rotor win"ings may be a*oi"e" "uring operation. Air inlets an" outlets are opene" in hollow con"uctors for the flowing of cooling air to cool the rotor win"ings "irectly. !he air outlets of the rotor win"ings are in a 8,; "istribution in slots that result in an e*en airflow e*erywhere of the win"ings. A goo" cooling effect is thus achie*e" an" o*er-heate" points a*oi"e". All the insulating materials use" are of class 6 type. !he slot liners an" insulators between coils are all ma"e of Gome1 papers. :pecial construction an" processing treatment are a"opte" for the rotor win"ings an" insulation so that they may change together with temperature "uring operation. !he mi""le parts of the rotor win"ings are positione" in the slots so that they may stretch an" contract integrally in the slots ta4ing the center of the rotor as their primiti*e point. !he relati*e mo*ement between coils is thus a*oi"e". $.7.$ Eamping win"ings

!he function of the "amping win"ings is to pro*i"e a low resistance path for negati*e se#uence currents so that this part of energy wonDt

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pro"uce any "estructi*e effects elsewhere. !he "amping win"ings consist of slot we"ges, "amping rings, "amping teeth an" "amping segments. !he slot we"ges, which are all e#ual in length to the rotor bo"y, are ma"e of copper-nic4el alloy ha*ing a high-con"ucti*ity an" e1cellent mechanical performance. In"er retaining rings, there are "amping rings, "amping teeth an" "amping segments which ser*e to connecting the slot we"ges to form a complete "amper-cage. <n or"er to re"uce the contact resistance, all the contact surfaces are ano"i(e" a layer of sil*er. !his "amping win"ings are sufficient to bear the negati*e magnetic fiel" which is represente" by <2 in G0%!.0)7-2002.!he permissible continuous negati*e se#uence current <2 is -H <G an" the permissible transient negati*e se#uence ability 2<2 % <G32Jt is -s. $.7.7 9etaining rings !he retaining rings, ma"e of austenitic stainless steel 1- n1->r that has a high anti-stress an" anti-corrosion performance, are assemble" to hol" the en" win"ings firmly in their primiti*e place an" protect them from "eformation "ue to centrifugal forces. !he retaining rings are shrun4 onto the bo"y of the rotor in a hanging state 2shown in figure $-73, an" then they are rotate" for a "istance of half tooth to be loc4e" by means of a bayonet coupling which is forme" by a tooth on both the rotor an" the retaining ring. Eue to the o*erhung "esign of the retaining ring, no forces cause" by the thermal e1pansion of rotor win"ings can be transmitte" to the shaft. !his may a*oi" any "amages to the contact surface "ue to the alternati*e stress "uring operation.

6igure $-7 9otor retaining ring with bayonet loc4

1 Brotru"ing tooth of the retaining ring 2 :lot we"ge $ Brotru"ing tooth of the rotor bo"y 2at the en"3

$.7.& A1ial fans A screw fan is fi1e" on each en" of the shaft to "ri*e the air in C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$ 1.+ B+,%2(0%% E3-)&'&).$

T.&'( 22 T20 9&2 A)+-C..(0/ T,+4.-G0$0+'&.+ .1 WX21Z S0+)0% cooling air circuit. !he fan bla"es, whose pitch is a"Fustable accor"ing to the airflow "esire", are ma"e of a "ropforge" silicon-aluminum alloy. !hey are fi1e" onto the hub 2which is shrun4 onto the shaft3 with bolts. !his type of fan has such characters as low-pressure hea", large airflow an" high efficiency etc.. $.& 0earings 2see fig. $-&3 $.&.1 At both en"s of the generator, there is a pe"estal bearing that is separate" from the generator an" is compose" of two hal*es "i*i"e" hori(ontally. !here is a small pe"estal bearing on the si"e of e1citer. !he bearing shells are ma"e of steel, coate" insi"e with a white metal alloy ,.$- which wonDt form Bb K:n eutectic when wo4 un"er high temperature. <n or"er to pre*ent the oil from lea4ing into the generator, the bearings are separate" from the generator. !he bearings are pro*i"e" with lube from a common oil supply system with the turbine. !he lube may be fee" in from either the left or the right si"e of the bearing. !o re"uce the friction of the bearing "uring the course of generator starting, each bearing has been pro*i"e" with a high pressure Fac4ing oil unit. 6or the measuring of the shaft *ibration an" the temperature of the bush, correspon"ing places

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6igure $-& Be"estal bearing

1 Lower half bearing pe"estal 2 Ipper half bearing pe"estal $ 0earing ring 7 :haft sealing & 0earing alloy ) 0earing shell

. 'igh pressure Fac4ing oil unit

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6ig. $-) 0earing with insulation

1. 0earing pe"estal 2.<nsulation between bearing pe"estal an" bearing ring $.bearing ring 7 bearing shell &. Moint for high pressure Fac4ing oil ) A"Fusting plate

ha*e been left on bearings for customers. !he shaft sealing of generator, which are of the contactless labyrinth type, pre*ent the lubricant an" oil fume from escaping effecti*ely by separating the interior an" outsi"e of the bearing pe"estal. $.&.2 0earing insulation <n or"er to pre*ent the shaft current from flowing through the bearings, the bearing on the non-"ri*ing en" has been insulate" 2see 6ig.$-)3. !he insulators are inserte" between the bearing ring an" the bearing pe"estal. !he oil shiel"ing ring an" the high pressure Fac4ing oil unit are also insulate".

6ig. $-. >on*entional "iagram of bearing insulation

1.9otor of generator 2.=1citer $.Groun"ing brush 7.0earing on turbine si"e &.0earing on non-"ri*e en" 2insulate"3 ).0earing shell ..A"apter plates -.0earing ring /.<nsulating strips 10.0earing pe"estal 11.0earing pe"estal

$.&.$ An E=, two groun"ing brushes are mounte" to groun" the roto r reliably 2see 6ig $-.3. C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$ 1.+ B+,%2(0%% E3-)&'&).$

T.&'( 22 T20 11&2 A)+-C..(0/ T,+4.-G0$0+'&.+ .1 WX21Z S0+)0% $.) easuring e#uipment !he measuring e#uipments are use" to monitor the temperature an" *ibration of the generator to ensure a safe operation. !he measuring "e*ices matching this series of generators are liste" as follows? $.).1 !emperature measuring of the stator :i1 resistance thermometers Bt100 are embe""e" between the layers of the win"ings e*enly aroun" the circumference to "etect the correspon"ing temperature "uring operation. $.).2 !emperature measuring of the col" air A resistance thermometer Bt100 is installe" in each col" air channel for remote temperature "etection or connection to annunciators. $.).$ !emperature measuring of the hot air A resistance thermometer Bt100 is mounte" in each hot air channel for remote temperature "etection or connection to annunciators. 0esi"es, there is also a thermometer with electrical contacts mounte" in each hot air channel for fiel" temperature "etection or connection to annunciators. $.).7 !emperature "etection of the bearings A "ial type thermometer with electrical contacts is mounte" at the oil outlet of each bearing for alarm signal an" the "etection of oil temperature. $.).& !emperature measuring of the e1citer hot air A "ial type thermometer with electrical contacts an" a resistance thermometer Bt100 are mounte" in hot air channel. $.).) !here is a slip ring with brush on the en"2GE=3 of rotor, in or"er to testing insulation between rotor win"ing an" earth. !a4e wire to testing e#uipment on generator, so the insulation between rotor win"ing an" earth can be teste".

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!he terminals of $.).1 $.).& shoul" all be arrange" in the terminal bo1 of generator on the turbine si"e to facilitate the connection "uring installation. $.).. <n or"er to monitor the lea4age of cooling water, a float switch is installe" un"er the floor of cooler room. <ts wirings shoul" be "esigne" by power plant factory 2or be wire" to the terminal bo1 of generator3. $.. >omplement air filters A close" self-*entilate" cooling air circuit is ne*er completely free of lea4ages. !he air in the high-pressure (ones 2e.g.? those on the pressure si"e of the fan3 may escape to the outsi"e, while those outsi"e the low pressure (ones 2e.g.? those on the suction si"e of the fan3 may be "rawn into the low-pressure (ones. <n or"er to pre*ent the "ust from entering the generator along with the complement air, a complement air filter is fi1e"

on each en" co*er. Euring the course of operation, the filters shoul" be often chec4e" an" cleane" to ensure goo" *entilation.

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$.- Air coolers !he cooler is a surface heat e1changer use" to cool the hot air coming out from the generator. !he air coolers consists of some single-piece coolers 2which is manufacture" by "ensely slee*ing aluminum finne" in a hori(ontal3 arrangement in the cooler-room 2whose wall shoul" be smooth3 un"er the generator. !he "etaile" installation "imensions an" technical "ata are all shown in the "rawings we supplie". <f the cooling water is erosi*e to copper an" iron 2e.g.? sea water3, special re#uirement shoul" be liste" in the or"er. $./ >oupler !he coupler is of the integral e1pansion bo1 coupling type. As no sli"ing occurs when this type of coupler through which the generator is connecte" with turbine suffers su""en compact tor#ues, the tor#ues may be passe" on i"eally. 0esi"es, the coupler is easy to be mounte" an" "ismantle". !here is no a""itional air loss "ue to the e1istence of protru"ing parts because all the nuts are completely sun4 into the flange holes. Gote? !he type of coupler a"opte" is "epen"ent on what 4in" of turbine the generator matches. When there are two bearings in the bac4 bearing bo1 of turbine, hot slee*e coupler shoul" be a"opte" an" the rotor of generator shoul" correspon"ingly be the single pi*ot-point construction. While when there is only one bearing in the in the bearing bo1 of turbine, integral forge" coupler shoul" be a"opte" an" the rotor of generator shoul" correspon"ingly be the "ouble pi*ot-points construction. $.10 Gui"ing "e*ice !here is a longitu"inal gui"ing "e*ice on each si"e of the mi""le of generator through which the generator can be mo*e" bac4war" an" forwar" "uring installation. 6or leftwar" an" rightwar" mo*ement of generator "uring installation, two trans*ersal gui"ing "e*ices are installe" on each si"e of the en"s of generator. While for leftwar" an" rightwar" mo*ement of the interme"iate plate of bearing, a brac4et is mounte" on each si"e of the bearing on E=. !he gui"ing "e*ices an" the brac4ets are all wel"e" onto the correspon"ing pre-embe""e" parts un"er them. !he a"Fusting bolts are brace" on the interme"iate plate of bearing, while the a"Fusting bolts of the trans*ersal gui"ing "e*ices are brace" on the base plate of the generator housing, the a"Fusting bolts of the longitu"inal gui"ing "e*ices are brace" on the gui"ing seat which is wel"e" on the base plate of the housing. !he position of the bearing on E= an" the housing of the generator may be a"Fuste" by rotating the a"Fusting bolts. 7. <nstallation !he generator shall installe" accor"ing to the installation "rawing 2supplie" with generator3 by our factory, the "esign an" installation "rawing for power plant supplie" by "esign institution, an" the C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$

1.+ B+,%2(0%% E3-)&'&).$ A)+-C..(0/ T,+4.-G0$0+'&.+ T.&'( 22 T20 13&2 .1 WX21Z S0+)0% installation rules "rafte" by power "epartment. !he following is some intro"uction? !he "imensions shown in the "rawing 8Assembly Blan Generator; are the col" state "imensions when the center of stator coinci"es with that of the rotor. <n or"er to guarantee the coinci"ence of the center of stator an" rotor "uring operation, the hot e1pansion of generator an" turbine shoul" be ta4e into account "uring fiel" installation, that is, the stator of generator shoul" be mo*e" a certain "istance towar" GE= "uring installation. !he "istance is half of the sum of the e1pansion of turbine towar" generator an" the e1pansion of the generator rotor 2the e1pansion *alue of rotor is shown in correspon"ing "rawing 8Assembly Blan Generator;, which is about 1%1000 of the length of the rotor bo"y3. !he e1citer stator shoul" be mo*e" a "istance which is the sum of the e1pansion of turbine an" generator an" then installe". 7.1 <nstruction for parts-installation !he complete set is compose" of stator, rotor, pe"estal bearings, e1citer an" air-cooler etc., which are pac4e" an" transporte" to power plant. 0efore installation, you shoul" chec4 the parts accor"ing to 8 the pac4ing list ; an" 8the "rawings supplie" with the generator; carefully to ma4e sure no parts ha*e been omitte". 7.2 <nstallation of the base plates

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6ig. 7-1 6oun"ation <nstallation

A 6i1ation of bearing 0 6i1ation of generator 1 0ase plate 2 6oun"ation bolt $ :li"ing plate 7 o:2 Lubricant & 0ase plate of housing ) Ba" . 6oun"ation base plate - :upporting bolt

!he generator is supporte" on the base plates *ia pa"s, sli"ing plates

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0JS.461.396C T20 14&2

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an" supporting bolts 2see fig. 7-13. 0y a"Fusting them, the generator may be correctly positione" in height. !he s#uare pa"s are glue" to the clean cement foun"ation by epo1yn material :i4a"ur.72 an" the sli"ing plates on which the supporting bolts are brace" are place" on the pa"s in the mi""le of which o:2 is smeare" to facilitate the a"Fusting of the sli"ing plates. After the alignment has been complete", the support bolts are secure" in place by point wel"ing. !he foun"ation bolts for the generator go all the way through the foun"ation plates so that the generator may be firmly fi1e" in place by tighten them. 0ut the foun"ation bolts for e1citer "oes not, they will be poure" in blin" holes.

6igure 7-2 6oun"ation "eposition platform

1 :tator base plate of generator 2 :ealing angle steel2supplie" by our factory 3 $ :li"ing plate 7 Ba" & Eeposition platform ) Groun" of the generator room . 6oun"ation

!he gap 2see fig. 7-23 between the bottom of generator an" the foun"ation shoul" be seale" at last 2!he sealing strips will be supplie" by us. 6or "etails, please see the "rawing of foun"ation sealing we offere".3. After installation, a platform 2see fig. 7-23 shoul" be "eposite" aroun" the generator as our recommen"ation. !his platform "oesnDt bear the weight of the generator. 7.$ <nstallation of the stator After the parts liste" in the "rawings of 8the installation of the base plates; an" 8sealing at the inlet an" outlet for the cooling air; supplie" by our factory ha*e been installe", the stator shall be fi1e" in place. !a4ing the inner holes of the win" gui"e rings at the two en"s as the "atum to align the concentricity of the stator with the a1is of turbine that is a1iality . 6or a1ial installation "imensions, please refer to the 8installation "rawing; supplie" by our factory. 7.7 <nstallation of the rotor !he installation of the rotor shall be carrie" out by the special tools supplie" by our factory. !he special tools are "esigne" with the C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$

1.+ B+,%2(0%% E3-)&'&).$ A)+-C..(0/ T,+4.-G0$0+'&.+ T.&'( 22 T20 1<&2 .1 WX21Z S0+)0% assumption that there is only one crane in the power plant. !he usin g metho"s of these special tools are "emonstrate" in fig.7-$, fig.7-7, fig. 7&, an" the following is the correspon"ing e1planations? 7.7.1 !he two outer co*er plates an" the win" gui"e rings 2part 7 in fig.$-13 of the stator shall be "ismounte" before installing the rotor. =*ery parts shoul" be properly mar4e" so that they may be fi1e" bac4 in their original positions "uring installation. 7.7.2 Blace papers in stator, then insert part 1 2B!6= plate3 into stator. But some lubricating grease 6=!! :B=Z7 on part 12B!6= plate3. 7.7.$ !he interme"iate bloc4 & an" sli"ing shoe part $ ha*ing been mounte" on the E= fan hub, the rotor shall be inserte" into the stator slowly by hanging the rotor at the spot where part $ is mounte" with ropes so that the two pins of part & may be inserte" into the pin holes in part $. When the rotor reaches the position shown in fig. 7-$, put it on cauls Go. .2the cauls shoul" be prepare" by the power plant3. 7.7.7 Blace the sli"ing shoe 2part 73 in place, lay "own the rotor so that the sli"ing shoe 2part $ 3 may press on the sli"ing plate part 1 an" then mo*e the hanger rope to the outer si"e of bearing pe"estal 2see fig. 7-73. !a4e off the caul after hanging up the GE= of rotor an" push the rotor towar" the stator by sli"ing part $ along part 1. Bart $ shoul" be fille" with air

JPEF

2before pushing the rotor3 whose pressure is 0.) 1 Ba to ensure an e1cellent sli"e property "uring the course of pushing the rotor into place. When the outer si"e of part $ is pushe" near the core la""er of stator core, part 7 shoul" be fille" with air whose pressure is the same as part $ an" the air pressure in part $ may be switche" off at this moment. Gote that part $ may be hung onto the rotor bo"y with rope temporarily an" may be "rawn out from GE= when the rotor is at the position shown in fig. 7-&. 7.7.& <n or"er to align the rotor, part 2 2lift frame3 is prepare" at the bearing pe"estal to lift the turbine en" of the rotor an" a"Fust its height. After the turbine en" has been mounte" to lower bearing shell an" the bearing pe"estal on GE= has been fi1e" in place, the hanger rope on GE= may be release" an" the special tools $, 7, & for inserting an" with"rawing the rotor may be "ismounte". 7.7.) Eraw out the sli"ing plate 2part 13. 0e careful to protect rotor against lubricating grease. Gote? !he steps of "rawing out the rotor are Fust the opposite to the abo*e- mentione" se#uence. 7.7.. <nstallation of the fan bla"es on both en"s? !he fan bla"es shoul" be mounte" onto the fan rings accor"ing to the

numbers an" mounting angles mar4e" on them. !he fastening of the fan bla"es is shown in fig. 7-).

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0JS.461.396C T20 16&2

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6igure 7-$
1 :li"ing plate 2 Lift frame $ :li"ing shoe 7 :li"ing shoe & <nterme"iate bloc4 ) >rane cable . >aul - anometer

<nstallation of the interme"iate bloc4 0efore installation, smear o:2 on the fan bla"es an" the threa"s of the nuts, fasten the nuts for steel wire with 1%$ of the re#uire" fastening tor#ue before fastening tight the nuts for steel wire with a wrench 2the fastening tor#ue is .)0Gm. !wist the stop screw an" loc4 it by a"hesi*e !:2)2 2 a"e in Nantai !aisheng3 or other similar pro"ucts. Gote that the nuts for steel wire shoul" not be replace" by common nuts.

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0JS.461.396C T20 1?&2

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Assembly of the sli"ing shoe 6igure 7-7

6igure 7-&

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6igure 7-) <nstallation of the fan bla"es

A Label of the fan bla"es E 9otor shaft 1 6an hub 2 6an bla"es $ Gut 7 :top screw & :top screw ) Washer . Anti-mo*ement washer - 'e1 nut

7.7.-

ounting of the air gui"e rings !he air gui"e rings shoul" be mounte" accor"ing to the mar4s ma"e "uring "ismounting. After mounting, the gap between the inner hole of the air gui"e ring an" outer circle of fan bla"es shoul" be a *alue between 1.10mm an" 2.&0mm an" shoul" be the same along the circumference. <f the re#uirement canDt be met, alignment shoul" be ma"e in time. <f the center of rotor has alrea"y been aligne" with that of the turbine, the re#uirement may be met by a"Fusting the stator 2As the air gui"e rings ha*e been aligne" with the inner hole of the stator core, the win" gui"e rings shoul" not be mo*e" in case an un-uniform gap appear between the rotor an" the stator3. !he "ifference of gap between the rotor an" the stator shoul" be within O1H of the specifie" *alue "uring the first installation, while after the maFor repair the "ifference shoul" be within O2H. !he gap between the fan bla"es an" the air gui"e ring shoul" be 1.20 mm$.00mm.

7.7./ <nstallation of the shaft coupling !he rotor an" the flange for lin4ing the turbine is integrate" together. As the "iameter of the flange is less than that of the nati*e routine turbine flange, it is con*enient for it to pierce through the bearing pe"estal on E=. When "rawing out the rotor, it is "ifficult for the turbine flange to pierce through the bearing pe"estal because its "iameter is a bit large. :o it is necessary that a shaft coupling 2which shoul" be pac4e" an" shippe"

C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$ 1.+ B+,%2(0%% E3-)&'&).$ JPEF A)+-C..(0/ T,+4.-G0$0+'&.+ T.&'( 22 T20 19&2 .1 WX21Z S0+)0% separately3 be prepare" between the generator an" the turbine for mi""le connection. !his coupling shoul" be mounte" onto the turbine in a"*ance an" then after the rotor has been inserte", it is lin4e" with the rotor of the generator. When the rotor is to be "rawn out, you only nee" to "ismantle the coupling between the shaft coupling an" generator. 6or "etaile" installation "imensions, please refer to the 8installation "rawing of the shaft coupling; supplie" by our factory. <f there is no bearing on E=, this clause "oesnDt e1ist. 7.& <nstallation of the outer en" co*ers !he outer en" co*ers which ha*e been matche" an" mounte" with the frame an" mar4e" when lea*ing the factory an" been "ismounte" "uring the installation of the rotor, shall be mounte" an" assemble" accor"ing to the primary mar4s an" the 8installation "rawing of the outer en" co*ers; supplie" by our factory. Euring the course of installation, the gap

"imensions of the shaft sealing shoul" be guarantee", that is, 0.1&mm 0.$0mm on the left an" right si"e, 0.1&mm 0.$0mm on the top an" 0.1&mm at the bottom. 7.) <nstallation of the bearings? !his installation shoul" be carrie" out simultaneously with that of the rotor. 6or the structure of the bearings, refer to the structure intro"uction part 2clause $.& an" fig.$-&, fig.$-)P fig.$-.3. !he bearings are fi1e" onto the foun"ation through the interme"iate plate with which the bearing pe"estals ha*e been assemble" before lea*ing the factory. Blace the foun"ation base plate on the pa" in which there is a hole, an" then a"Fust the support-screw-bloc4s an" the support bolt screwe" in the mi""le plate to meet the re#uirement for height "imension. After that, the support bolts shoul" be point-wel"e" an" the support-screwbloc4s shoul" be wel"e" with corner steel for fi1ation. !he bearings are finally fi1e" by fastening the foun"ation bolts piercing through the interme"iate plates, the base plate, pa"s an" the foun"ation beam. !he oil gap between the bearing shell an" the bearing Fournal has been machine" accor"ing to the re#uirements of 1.& 1./ of bearing Fournal an" the contact surface has been machine" to a certain angle2!he angle is shown in the 8"rawing of the slee*e bearing;, e.g.? forQ$1& bearing the angle is 10&CO&C3. <f the re#uirement canDt be fulfille", the contact surface may be properly groun" accor"ing to the Grinding specification for

bearing shell until a satisfactory contact is attaine".

C./0 0JS.461.396C I$%&'(()$* I$%&+,-&).$ 1.+ B+,%2(0%% E3-)&'&).$ JPEF A)+-C..(0/ T,+4.-G0$0+'&.+ T.&'( 22 T20 20&2 .1 WX21Z S0+)0% !he bearing shell on GE= is insulate" from the bearing pe"estal an" the high pressure oil pipe.26or "etaile" information, please loo4 at the correspon"ing intro"uction of the structural features an" fig. $-&, fig. $-)3. !he insulating resistance between bearing shell an" bearing pe"estal shall be measure" after installation. !he resistance *alue shoul" be no less than !he oil shiel"ing plates on both en"s of the bearing are also insulate" from the bearing pe"estal with the same re#uirement for the insulating resistance as the abo*e-mentione". !he re#uirement for the gap of the bearing are liste" in the following table 2refer to 6ig. 7-.3?

!ype of the bearing

$1& $&& 700 72& 7&0 &00

Eiameter of the bearingQE

$1& $&& 700 72& 7&0 &00 0-0.0$2 0-0.0$) 0-0.0$) 0-0.070 0-0.070 0-0.070

'ori(on ra"ial gap :

0.270.$2 0.2.0.$& 0.$10.$/ 0.$10.72 0.$70.7& 0.&00.)2

!op ra"ial gap :

0.7-0.)$ 0.&$0..1 0.)20..0.)$0.-& 0.)-0./0 1.001.27

!he re#uirement for the gap "imension A 2shown in 6ig. 7--3of the shaft sealing is? 0.1&mm 0.20mm on the left an" right si"e, 0.$0mm 0.70mm on the top an" 0mm0.10mm at the bottom. 7.. <nstallation of the air-coolers 7...1 !he air coolers ser*e to cool hot air which from generator an" e1citer by bring the heat away through cooling water. !he concrete installation "imensions of the air coolers are shown in the 8"istribution "rawing of the air coolers; an" 8installation "rawing of the float switch; supplie" by our factory. !he inner surface of the cooler room shoul" be painte" with painting. Gote that the room accommo"ating the air coolers shoul" be cleane" after the installation of them. 7...2 Arrangement of the air circuit for e1citer see figure 7-/.<t is a reference for "esigner of plant. 7.- <nstallation of e1citer shoul" be carrie" out accor"ing to 8<nstalling <nstruction for =1citer W0!/&;20M:.7)1.$/->3 an" 8=1citer Assembly;2)M:.001.027>3.

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0JS.461.396C T20 21%&

6igure 7-. Gap of bearing 6ig.7-- Gap of the shaft sealing for the bearing

7./ Ather instructions on installation !he installation of other parts 2e.g.? the connection of temperature measuring lea"s etc.3 shoul" be carrie" out accor"ing to the 8connection "rawing for temperature measuring lea"s;, the 8general installation "rawing; an" the $.), $.- sections of the 8structure intro"uction; in this "irection. !he general routine installations may be carrie" out accor"ing to the 8"rawings an" technical "ata supplie" with the generator; we offere". We "o not re-"escribe them here.

& :uggestion on the "esign of lower oil tan4 of bearing <n or"er to sustain a negati*e pressure in the bearing, please "esign an air e1hausting "e*ice for the lower oil tan4 of the oil system in power plant.

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0JS.461.396C T20 22+/

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