Hydro Generators

7/17/2015
HYDRO GENERATORS
HYDRO GENERATORS
SL.NO.
DESCRIPTION
01
GENERATOR ASSEMBLY AND ERECTION
02
GENERATOR SUB-ASSEMBLIES & AUXILIARIES.
03
STATOR
04
ROTOR
05
LOWER BRACKET
06
UPPER BRACKET
07
THRUST BEARING
08
LEVELLING OF THRUST BEARING.
09
CENTERING OF STATOR, UPPER AND LOWER BRACKETS.
10
MAGNETIC CENTERING OF STATOR AND ROTOR.
11
AIR AND OIL COOLERS
12
ASSEMBLY OF PMG STATOR.
13
ASSEMBLY OF BRUSH ROCKER WITH SLIP RING.
14
EXCITATION SYSTEM.
15
BOXING OF BEARINGS.
16
UNIT CONTROL BOARDS.
17
EXTERNAL OIL LP LUBRICATION SYSTEM.
18
BRAKE JACK SYSTEM.
19
FIRE EXTINGUISHING SYSTEM.
20
PREPARATION OF HYDRO GENERATOR FOR STARTING AND
PAGE NO.
COMMISSIONING.
21
DRYING OF THE GENERATOR.
22
TESTING OF THE GENERATOR.
23
PUTTING INTO OPERATION.
24
INSTRUCTIONS FOR CHECKING AND PROVING, BEDDING OF

GUIDE AND THRUST BEARING PADS.
25
INSTRUCTION ON CLEANING OF OIL PIPE LINES.
GENERATOR ASSEMBLY AND ERECTION:
http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced12.htm#THRUSTBEARING
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Ensure readiness of following customer inputs for starting assembly and erection of
generator.
Power house roofing completed, sides, windows and entry covered.
Service bay is concreted and embedments if any are installed.
Generator barrel and floor concreting and curing completed.
Generator stator and lower bracket foundation are checked, chipping completed and
pockets are clear.
Generator barrel and its floor painted from inside.
3 phase 4 wire construction power supply, tapping points available in power house.
Ventilation and water supply arrangements.
EOT crane commissioned and load tested.
Proper precautionary measures to avoid flooding of P/H either from U/S or from D/S.
(U/S Upstream, D/S Downstream).
1.
1.1
FOUNDATIONS: STATOR/LOWER BRACKET.

Check depth of foundation pocket with a sample stud.
1.2
Check foundation pocket and other openings in generator barrel are as per
drawing.
1.3
Check elevation of foundation and chip off the loose concrete of foundation surface
to expose hard surface.
1.4
Check surface flatness of foundations with a machined plate and correct by

chipping and grinding, to obtain 80% of contact, evenly spread over the entire area to
ensure sound seating for foundation plates, packers and taper wedges etc.
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2. FOUNDATION PLATES AND STUDS.

2.1
Check and prove matching of foundation plates, bolts with stator frame.
2.2
Check and prove threads of foundation studs and nuts.
2.3
Assemble foundation plates with stator frame to check and ensure 80% of
contact between the foundation plates/stator frame. Match mark the foundation
plates and stator frame.
2.4
Remove protective paint from foundation plates and stud surfaces in the areas, to
be embedded in concrete.
2.5
Remove paint from packer plates and complete deburring. In case, taper wedges
are supplied, check the machined surfaces for flatness and contact.
2.6
Install foundation plates, studs and position them to approximate elevation and
to unit axis within 1mm.
GENERATOR:
Generator of a hydro station consists of the following sub-assemblies and auxiliary
equipment.
A.
SUBASSEMBLIES.
1.
Stator.
2.
Rotor with fans.
3.
Lower bracket with brakes and jacks.
4.
Upper bracket.
5.
Thrust bearing.
6.
Guide bearings.
7.
Air, oil coolers and pipe lines.
8.
SSG speed sensing gear.
9.
Excitation system.
B.
1.
AUXILIARIES.
Unit control board.
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2.
Hydrostatic lubrication system.
3.
External/LP oil cooling system.
4.
Brake jack system/power pack.
5.
Dust collector.
6.
Stator heater. (Anti condensation heater).
7.
Air, oil and water pipe lines.
8.
Fire extinguishing system / CO2 system.
1.
STATOR.
Stator of a generator depending on its overall size is dispatched to site either partially
wound or completely wound, fully assembled or in segments. Partially wound
segments are assembled and the balance winding at the joints of segments is carried
out at site OR
Stator frames, punchings and winding materials are dispatched as loose components
for assembly of stator core in the form of a ring. In which case, assembly of stator
frame, core building, core shake testing, laying of winding, bus bars etc. including
stage testing, final testing is carried at site.
Assembly of stator may be done as per manufacturers instructions either in service

bay or in the place of installation.
1.1
PREPERATION.
1.1.1
Transport wound sectors of stator to power house service bay and place
them on raised platform or supports.
1.1.2
Check core and winding for mechanical damage if any and take corrective
action.
1.1.3
Clean and debur stator joining flanges, megger the stator winding to
ascertain, winding healthiness.
1.1.4
1.1.5
1.1.6
Prove and assemble stator turning device. (If any).

Cut extra length of binding ring and bus bar connections if any noticed during
inspection.
Check all threaded holes for any damage and retap them if necessary.
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1.2
1.2.1
1.2.2
ASSEMBLY AND INSTALLATION.

Turn the stator sectors after assembling device to make it vertical (if
transported in horizontal condition) and remove stator turning device. Transfer
and position the sector on stator foundation plates already kept aligned in situ
or on stools in service bay as the case may be.
Install dowel between foundation plate and stator frame.
1.2.3
Support stator sector on screw jacks to avoid its tilting, also arrange for a
temporary holding arrangement.
1.2.4
Prepare adjoining sector of stator, lower and assemble with the sector
already placed in generator barrel to form one half or 2/3rd of stator.
1.2.5
Use leatheroid or CAF packing between the core at the joints as specified in
the drawing.
1.2.6
Install dowels and fasteners of joint flanges and complete tightening of

fastners.
1.2.7
Install dowel of stator frame and foundation plate.
1.2.8
Carry out assembly of remaining two sectors as described above to form

another half of stator by maintaining a gap of 10mm between the two halves. In
case complete stator is supplied in four quadrants.
1.2.9
Finally assemble two halves together, install dowels, fasteners and complete
tightening checking of joints.
1.2.10 Check elevation of stator on the upper machined flange and correct if need be.
1.2.11 Check and correct horizontality of stator frame by adjusting taper wedges or
adding or removing the packers installed underneath it.
1.2.12 Check magnetic axis of stator core with respect to turbine flange top is as per
design requirement.
1.2.13 Position pianowire with plumb bob at the center of stator bore within 0.1mm,
checking by inside micrometer. Shift stator with respect to center of turbine
shaft bore within a tolerance of 0.1mm. (remove dowels of foundation plates
while stator centering).
1.2.14 Check stator core diameter (ID) as per requirements of FQA. (Refer Sketch
No.1).
1.2.15
Position, foundation plates of stator with respect to stator frame. Install

dowels and fasteners.
1.2.16 Install temporary working platform at the joints of stator. Carry out winding of
stator and installation of busbar etc. as per technical instructions of
manufacturer and relevant drawings and instructions.
1.2.17 Complete checking insulation resistance testing, dry out HV testing of winding
as per technical instructions/standards.
1.2.18 Paint stator end winding with redgel coat (refer instruction for painting issued
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by manufacturer).
1.2.19 Complete painting of stator core and winding as per guide lines of drawing.
1.2.20 Remove temporary platforms, installed for the purpose of winding.
1.2.21 Note: In the event of assembly of stator sectors done in service bay. Stator
sectors are assembled over stools and winding is carried out. Completely
assembled stator is then transferred and positioned in generator barrel with
respect to turbine center and elevation to technical requirements.
2.0
ROTOR.
The rotor of a hydro generator consists of following sub-assemblies.

a)
Shaft.
b)
Rotor spider
c)
Rotor rim
d)
Poles and their inter connections
e)
Current carrying leads
f)
Brake track
g)
Rotor fan
h)
Slipring.
2.1
ASSEMBLY AND ERECTION OF ROTOR.
2.1.1
ROTOR SPIDER.
Depending on type of thrust bearing arrangement of generator and size of
spider is dispatched to site in one of the forms detailed here under.
2.1.2
UMBRELLA TYPE GENERATOR.

With load bearing bracket and bearing arrangement below rotor.
2.1.2.1
Rotor spider is bolted type.
2.1.2.2
Shaft is despatched with rotor bush mounted on it and spider portion

separately. In such construction, assembly of rotor rim, poles etc. is done in
erection bay and the spider is bolted to rotor bush at the place of installation
in stator bore.
2.2
UMBRELLA TYPE MACHINE.
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2.2.1
Prepare and install shaft, vertically upright on base plate of rotor erection
pedestal and then fasten it by means of nuts and bolts. Check that shaft is
vertical.
2.2.2
Prepare spider, shaft collar mating surfaces, conical studs for assembly.
2.2.3
Lift spider fairly levelled, with the aid of crane, lower it on the shaft collar.
2.2.4
Complete tightening of collar studs.
2.2.5
Depending on construction, some times fixing of spider to rotor bush is done

at the place of installation, after lowering spider in the stator bore, in which
case following procedure is adopted for assembly.
2.2.6
Shaft with the bush fitted on it is lowered and made to rest on thrust bearing.
2.2.7
Assembly work of rim, poles etc. with spider is done on erection bay, except
the hot wedging of rim keys. (Refer tech. requirement).
2.2.8
Spider assembly is lowered over shaft, placed in the stator bore to complete
assembly of spider with rotor bush.
2.2.9
Rim keys are fitted, heating of rim, upto a temperature of 900C is carried out
to complete hot wedging.
2.2.10
NOTE: Heating is done gradually by controlling temperature rise 5-6

degree/hour. Fast heating is not recommended.
2.3
ASSEMBLY OF RIM.
Rim can be of two types, depending upon the design construction preferred.
2.3.1
Rim can be built of segmental type laminations.
2.3.2
Rim can be built of solid forged disc mounted on shaft.
2.3.1 LAMINATION TYPE RIM.

2.3.1.1
Depending on type of construction of rotor spider with shaft or without

shaft, place spider on support block with screw jacks, at the assembly place.
2.3.1.2
Support blocks are located near about each vertical wedge bar and the
height is selected such that the lowest surface of the rim, remains above the
floor of 500-600mm.
2.3.1.3
Check and regulate position of spider, to make wedge bars vertical.
2.3.1.4
Check slot surfaces in the wedge bar of spider, for rim keys are true.
2.3.1.5
Check the distance between the slots in the wedge bar along the top and
bottom end are as per drawing.
2.3.1.6
Check the keys for trueness and insert in the slots of wedge bars, while
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putting keys check that the thinner and lower key lies on the inner side and
thicker lies at the outer periphery and reset on the support block as shown
on the drawing.
2.3.1.7
In case brake segments are bolted to rim, align brake segments along
the periphery of wedge bars as shown in the drawing.
2.3.1.8
Check that, all segments are at the same elevation.
2.3.1.9
PREPARATION OF RIM SEGMENTS AND ASSEMBLY.
2.3.1.10
Remove preservatives and clean laminations.
2.3.1.11
Eliminate burrs, dents, by using a electric sander.
2.3.1.12
Weigh the segments to arrange and stack them as per weight groups of
10% difference in weight. While stacking check that all segments are
arranged in the same direction.
2.3.1.13
Check number of segments required in each layer and carry out

chamfering edges of segments for three layers, at the place of their
matching with wedge bars, as indicated in drawing if applicable.
2.3.1.14
ASSEMBLY OF RIM.
2.3.1.15
Arrange brake segments on outer periphery of wedge bar leveled and

supported on screw jacks.
2.3.1.16
Arrange first layer of chamfered segments on outer periphery of wedge

bar such that they rest with wedge bar supported by brake segments &
screw jacks.
2.3.1.17
Position reamed bars on technological studs to continue with further

laying of rim segments by staggering each layer of punching as indicated in
drawing.
2.3.1.18
Complete laying of balance two layers of chamfered and three to four

layers of plane segments.
2.3.1.19
Always check that there is no gap between wedge bar and rim or there is
uniform gap at all wedge bars, after pressing from outside towards center of
segment with hammer with copper flat placed over the surfaces. It is
necessary to take care of the following points during entire rim building
process.
a)
Rim segment surfaces are cleaned thoroughly and deburred before

laying the subsequent layer of segments.
b)
Rim assembly is done by staggering each layer of punching as

indicated in drawing.
c)
Rim segments with ventilating duct supports, are laid at proper height
of rim as indicated in drawing.
d)
Segment of same weight groups are laid in each layer.
e)
In order to obtain dimensions of height of each packet, check the
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number of segments, in the packet, after pressing.

f)
During pressing, ovality of rim is avoided. This can be checked by

absence of gap between wedge bar and the rim of uniform gap at all
wedge bars. In case of ovality, this is corrected before consolidation of
rim, by applying pressure on the rim towards its center. Check height
of pressed packet of rim along its periphery for uniformity.
2.3.1.20 Carry out stage pressing of the rim as indicated in the drawing and lock the
packets by welding MS flats or rounds, on the inner and outer surface of rim
along its height to avoid bulging of the pressed portion of rim.
NOTE: Tightening of nuts during pressing is done uniformly, after hammering the
assembled rim segments.
2.3.1.21
Complete assembly of rim, including final pressing and tightening of

technological stud nuts as per drawing requirements.
2.3.1.22
Remove technological stud one by one and carry out broaching of holes if
necessary and install permanent studs.
2.3.1.23
Carry out final pressing with permanent studs, nuts in rotation two or
three times, with intervals of 18-24 hours. Check that the nuts are finally
tightened to the stress as indicated in drawing.
2.3.1.24
After final pressing and tightening, lock the upper and lower nuts by tack
welding with rim at one edge as indicated in drawing.
2.3.1.25
Lock nuts in brake segments by tack welding the nut with projected
portion of stud.
2.3.1.26
Check studs in the brake segments do not project beyond the surface of
the brake segments.
2.3.1.27
Perform wedging of rotor rim in cold condition by hammering the longer

key with a 6 to 8 kg hammer, till it stops going. Mark keys, for the amount
by which they are to be driven during hot wedging process.
2.3.1.28
NOTE: Wedging is done uniformly by controlling concentricity of rim, by

ensuring uniform gap, between the rim and wedge bar.
2.3.1.29
Cover rim by asbestos cloth or other refractory material and leave spider
arms exposed to create temp. (In case tech. requirement calls for)
difference between spider and rim, for hot wedging of the rim. The rim may
be heated by the following methods.
i) Using strip heaters.
ii) Passing DC through pole coils if assembly has been completed.
2.3.1.30
When the temperature of the rim attains a value indicated drawing, drive
the keys by required amount as marked.
2.3.1.31
The lower end of the driven key is cut flush with the help of device
supplied and grind the surface, wherever required to bring surface to
drawing requirements.
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2.3.1.32
Mark location of pole stoppers in pole slots of rim and install them as
indicated in drawing. Check the relative difference in elevation of stoppers is
with in drawing requirements. Alternately install stoppers before lowering
the pole in T slot of rim.
NOTE:
1)
Stopper location is decided such that when the pole is installed the centre of
pole core coincides with the magnetic axis/stoppers are inserted in place
before the assembly of pole.
Paint the rotor red with red oxide primer.
2)
The clearance between the rim ID and spider key bar face should be equal at
each key bar during rim building to ensure uniform gap.
3)
Rim building pins should not be too slack, otherwise built rim may become
egg shaped.
2.4
2.4.1
MOUNTING OF POLES ON ROTOR RIM/DISC.

PREPARATION OF POLES FOR MOUNTING.
2.4.1.1 Check poles do not carry mechanical damage.

2.4.1.2 Check that pole core laminations at face are in one plane. File the protruding
laminations, if any. Check surface by knife edge.
2.4.1.3 Press the pole coil along with washers to check that a gap of 0.5 to 1mm exists
between core face and pressed coil along with washers.
(Refer sketch 3). To maintain the designed gap steel washers may be added or
removed or grinding of insulating washers is carried out. (If insulating washer
needs grinding minimum thickness of washer as per drg. Should be ensured).
2.4.1.4 Blow the poles with dry and clean compressed air (Refer sketch 3).
2.4.1.5 Check insulation resistance of pole coils to ascertain healthiness of insulation.
2.4.1.6 Pole coils having insulation resistance less than 10 M/W, when measured by
500V megger at a temperature of 100C to 300C is considered to be poor. To
improve the IR, pole coils may be dried at a temperature of 80-850 C. Drying
process shall be slow and continued for 50-70 hours/till improvement. If the IR
does not improve, then the cause should be investigated.
2.4.1.7 If drying of poles after mounting on rim becomes necessary, the drying is done
by passing DC not exceeding 50% of the rated value, through the windings, of
the pole coil.
2.4.1.8 Carry out inter turn insulation test/HV testing of poles as specified by the
manufacturer.
2.4.1.9 Prepare layout of poles and select poles such that poles having equal weight
are installed diametrically opposite.
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2.4.1.10 Check contact surfaces of pole keys and form pair of keys.
2.4.1.11
Check free movement of pole springs in the pocket of rim/disc and install
springs. To prevent their falling off, during mounting of poles, cover, the
springs with a metallic sheet strips 1-1.5mm thick and 100-150mm wide (Refer
sketch 4) these strips are removed after positioning of poles in the slot.
2.4.1.12 With the help of device, carry out turning and mounting of poles. If the device
is not provided by manufacturer the device as per sketch no. may be
fabricated and used. Lower the poles in the rotor rim slots until pole rests on
the support/stopper.
2.4.1.13
Insert short wedge, with the thick and diverted, downward. Drive the long
wedge between the short one and the rotor rim (before installation, friction
surfaces of wedges are coated with antiseizing grease). If the wedges are not
found compact during wedging, put the metallic shim of required thickness
below the wedge along slot length.
2.4.1.14 Complete wedging by a sledge hammer or pneumatic hammer. After wedging

the wedges protruding below the rotor rim/disc are cut flush with rim
surface/disc and the long end on top side of rim is cut as per drawing. Lock
wedges by tack welding as indicated on drawing.
NOTE: The pole body must be in tight contact with rim face, steel shim must
not get sand witched between pole body and rim.
2.4.1.15
Straighten and clean pole end connections, join and complete pole to pole
connections by soldering and carry out clamping as per drawing.
2.4.1.16 Assemble flexible connections of damper winding.

2.4.1.17
Assemble the current carrying leads as per drawing and complete the
clamping, locking of fasteners. Carry out testing of current carrying leads as
specified by manufacturer.
2.4.1.18
Assemble lower and upper fans with rim/disc and check that locking of all
fasteners has been completed in accordance with drawing. Clean the rotor;
carry out dry out test for high voltage as per drawing.
2.4.1.19
Clean the rotor with dry and clean compressed air and paint the rotor with
enamel as indicated in the drawing.
3.0
LOWER BRACKET.
3.1
PREPARATION AND ASSEMBLY.
3.1.1
Remove preservatives from all machine surfaces.
3.1.2
Check machined surface for mechanical damages and eliminate defects, if

any, clean inner surface of oil bath.
3.1.3
Check and prepare and assemble foundation plates, with bracket arms as
applicable.
3.2
OIL COOLERS.
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3.2.1
3.2.2
3.3
Dismantle all oil coolers mounted on lower bracket and check

healthiness/soundness of water tubes, by carrying hydraulic testing, as
indicated in the respective drawing.
Replace the damaged sealing elements.
BRAKE JACK.
3.3.1
Complete overhauling of brake jacks, replace defective seals where

necessary.
3.3.2
Fabricate a device for hydraulic testing of brake jacks and test the jacks as
called in drawing.
3.3.3
Check that the jacks return to their close position when pressure is released.
Sticking of pistons is not desired, in case of any such defects, its cause should
be found and rectified.
3.3.4
Assemble jacks on lower bracket arms at their respective locations with

packers as indicated in drawing.
3.3.5
Complete laying of pressure, return oil pipes to the possible extent and pipe
clamping arrangements.
3.3.6
In case of umbrella machine complete assembly of thrust bearing (Ref

preparation and assembly of thrust bearing).
3.3.7
After obtaining clearance from turbine section, install lower bracket pit air
seal and complete grouting of anchors, foundation bolts of pit air seal.
3.4
3.4.1
3.4.2
INSTALLATION.
Clean taper wedges/packers and check that the friction surfaces are free
from defects/damages.
Position the wedges/packer to approximate elevation and location.
3.4.3
Lift the lower bracket fairly leveled, lower in stator bore to rest foundation
plates on wedges/packers.
3.4.4
Install foundation studs and adjust the elevation of bracket to drawing

requirements by adjusting height of taper wedge / packers placed underneath
reference of turbine shaft is taken.
3.4.5
Flange elevation is taken for setting elevation of bracket and other

assemblies of generator.
3.4.6
Carry out centering of lower bracket with respect to turbine shaft. This is
done by fixing a piano wire with weight suspended at the center of guide
bearing cylinder and shifting lower bracket to the center of turbine shaft bore.
3.4.7
Complete tightening of foundation stud nuts and check that the elevation
and centering of lower bracket are within 0.5mm.
3.4.8
Adjust vertical height of jacks with reference to turbine flange by adding or
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removing the appropriate shims placed underneath jacks. (Refer relevant

drgs).
3.4.9
Complete laying, welding, cleaning of balance brake jack piping.
3.4.10
Install, clamp the pipes and connect jacking pump. Adjust pressure relief
valve of jacking system after ensuring required list of rotor along with turbine
runner and shaft.
3.5
LOWERING AND ASSEMBLY OF ASSEMBLED ROTOR - LOWER BRACKET BRAKE

JACKS:
3.5.1
3.5.1.1
PREPARATION.
Ensure that all jacks or lower bracket are raised by 15mm above brake track
elevation mechanically and locked. Check that all jacks are in horizontal plane.
Assemble, rotor lifting device/lifting beam on the shaft.
3.5.1.2
Fix crane hook/hooks to lifting device.
3.5.1.3
Lift the rotor by 300-400mm, check and ensure braking of lifting hoist.
3.5.1.4
Lift the rotor such that flange bottom surface is accessible for cleaning and
checking.
3.5.1.5
Prepare the flange surface and check it with knife edge to ensure trueness of
surface, prepare rubber O seal.
3.5.1.6
Check and ensure that the generator shaft flange passes through the lower
bracket bore.
3.5.1.7
Advice turbine section to keep the turbine flange prepared.
3.5.1.8
Prepare 15-20 wooden battens thickness = air gap-3mm, and 70 mm wide for
use between rotor pole and stator during lowering process of rotor, to avoid
rubbing of rotor poles on stator.
3.6
Lift and transfer the rotor to machine center and lower, when the rotor is
200-300mm above stator. Carry out centering of rotor w.r.t stator bore.
Continue lowering of rotor by use of micro speed hoist till rotor enters stator
bore. Insert wooden battens between pole and stator and ensure that these
battens remain free during entire process of rotor lowering. In the event of any
of the batten getting jammed, shifting of rotor may be done so that the battens
remain free.
NOTE: Care is taken and it is ensured that the generator flange does not rest or
hit the lower bracket at the time of its entry in the bore.
3.6.1
Continue lowering of rotor and checking of free movement of wooden batten,

till rotor rest over the jacks. Install rubber O seal on the generator flange
spigot when it is 200-300 mm away from the generator shaft.
3.6.2
Lift the rotor slightly to correct centering of rotor flange with respect to
generator flange. After centering within +1.00mm, release the crane.
3.6.3
Insert the coupling stud/bolt and complete the assembly and tightening of
studs to required stress.
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3.6.4
Install tubular shaft; slipring etc.
4.0
4.1
4.2
UPPER BRACKET.
Upper bracket assembly comprises of a central part housing thrust and

guide bearings (suspended type) or guide bearing alone (semiumbrella type)
or in case of no bearings depending on design this will support the generator
flooring, slipring stator any parts and generator dome.
PRE-ERECTION.
4.2.1
Remove preservatives, clean the surfaces and prepare the central part and
arms for assembly in line with general guidelines.
4.2.2
Check the flatness of surfaces of arms and central parts. Carry out assembly
of arms by using dowels. Check tightness of fasteners and ensure soundness of
arm assembly by checking with 0.03mm filler gauges. Joint is considered to be
sound if there is no gap and the filler does not pass.
4.2.3
Carry out locking of fasteners as indicated in drawing.
4.2.4
Carry out trial assembly of chequered plating to complete the welding of

strips, drilling and threading of chequered plate fixing arrangement.
4.2.5
Check and prove threads of radial jacks and carry out assembly with upper
bracket arms. (If provided).
4.3
ERECTION.
4.3.1
Prepare mating surfaces of upper bracket arms and stator frame.
4.3.2
Install upper bracket, adjust its elevation level and carry out its centering
with respect to shaft and assembly with stator frame.
4.3.3
Centering tolerance 0.1 to 0.2mm radial.
4.3.4
Levelling tolerance 0.02mm/mt.
4.3.5
Carry out installation and tightening of bracket arms holding down bolts.
4.3.6
Carry out reaming and dowelling of bracket arms with stator frame only after
the completion of alignment and centering of the machine.
5.0
5.1
THRUST BEARING.
Thrust bearings are of two types in common use.
5.1.1
Thrust bearing pivoted type.
5.1.2
Thrust bearing spring mattress type.
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5.1.1
THRUST BEARING PIVOTED TYPE.

Following are the main components in this type of construction.
a)
Thrust bearing frame.
b)
Thrust bolts, thrust block, pad support etc.
c)
Thrust bearing and segments.
d)
Runner disc.
e)
Thrust collar and locking ring.
f)
Oil bath and HS lubrication system.
g)
h)
Oil coolers.
Instrumentation.
5.1.1.1 PREPARATION OF ASSEMBLY.

5.1.1.2
Remove preservative from all components of thrust bearing. Check for

mechanical damage and eliminate if any.
5.1.1.3
Assemble thrust bolts in the respective bushes, check all bolts, travel to the
maximum depth of respective bushes. Position all bolts as per drawing to
measure looseness of bolts in bush, when pressed sideways with a special
device, maximum deflection of bolts measured with dial gauge should not be
more than 0.10mm. Bolts having deflection beyond this value should be referred
to plant.
5.1.1.4
Carry out bedding of thrust block with their seating surface of thrust bearing
pad segments by scraping or by lapping the surfaces using grinding paste.
5.1.1.5
Check, TSD, RTD fittings in pad segments to ensure correctness of threads and
depth of pockets.
5.1.1.6
Check and prove bedding of thrust bearing pad segments, babbit surface with
mirror surface of runner disc. Complete leading edge preparation, as called in
drawing (Refer instruction for bedding of pads).
5.1.1.7
Thrust bearing runner disc is to be handled very carefully and it should be

ensured that no damage takes place to any portion of disc during handling.
Ensure that mirror surface is always protected by suitable means to avoid any
kind of mechanical/chemical damage.
5.1.1.8
5.1.1.9
5.1.1.10
NOTE: Check eccentricity of IB ports and correct if necessary.

Check that insulation on runner disc is in tact and its gluing with disc is free of
hollowness.
ASSEMBLY AND LOADING OF THRUST BEARING (PIVOTED TYPE).
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5.1.1.11
Clean oil bath inner sleeve (oil bath partition) and assemble with sealing
element on upper bracket. Carry out kerosene test to ensure leak proofness of
joint.
5.1.1.12
Check thrust bearing frame and upper bracket mating surfaces for flatness. If
necessary carry put bedding of mating surfaces to achieve minimum 80% of
contact area evenly spread over the entire area.
5.1.1.13
Install holding down stud/bolts of thrust bearing frame and assemble frame
with upper bracket, coinciding their match marks and dowel holes. Check and
ensure that the thrust bearing frame sits properly on the bracket.
5.1.1.14
Complete locking of dowels by welding a blank plate or as called in drawing.

Complete cleaning and assembly of oil pipes coming between pad segments.
(Incase of external oil cooling only).
5.1.1.15
Assemble thrust bolts, supports and thrust bearing pad segments.
5.1.1.16
NOTE: All thrust bolts, supports and thrust bearing pad segments.
5.1.1.17
5.1.1.18
Place runner disc, with its mirror surface resting on babbit surface of pads and
complete leveling of disc, by regulating height of thrust bolts.
Prepare and assemble thrust collar key if any.
5.1.1.19
Check that locking ring of thrust collar and the groove for locking ring in the
shaft, suit each other with regard to their dimensions. Install and check
suitability of ring.
5.1.1.20
Carry out heating of thrust collar, in a temperature controlled heating

chamber to attain required expansion.
5.1.1.21
NOTE: Levelling of thrust collar is carried before hand and the collar is heated
along with lifting devices, to minimize the time of handling during process of
mounting.
5.1.1.22
After ascertaining expansion of bore with technological device lift the collar
with crane and mount it on shaft very carefully. Ensure that the color is in place
as called in drawing.
5.1.1.23
When the temperature of collar is about 400C, check the fitting of locking ring
and install it.
5.1.1.24
Lift the runner disc, by crane and assemble with thrust collar along with
insulating dowels and fasteners, release crane after completing assembly.
5.1.1.25 Install thrust bearing pads and load thrust bearing as given below.
5.1.1.25.1
Lift the rotor jack by 2-3mm, by operating the jacking pump, so that,
mechanical lock of jacks are released. On ascertaining delocking of jacks,
release the pressure of jacking system to lower the rotor so that TB disc with
collar sits on thrust pads.
5.1.1.26 Clean oil bath interior thoroughly and assemble it on upper bracket with its
sealing element.
5.1.1.27 Complete laying, welding, clamping of HS lubrication pipes as per drawing.
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5.1.1.28 While connecting HS lubrication oil pipelines with thrust bearing pads ensure
that the passages in the pads for oil are clear and non-return valves of the
system are in working condition.
5.1.2
THRUST BEARING (SPRING MATTRESS TYPE).

Following are the main components in this type of construction:
i.
ii.
iii.
iv.
v.
vi.
vii.
5.1.2.1
Spring plate.
Spring assembly.
Thrust bearing pad segments.
Runner disc.
Thrust collar and locking.
Oil bath and HS lubrication system.
Oil coolers.
Preparation and assembly.
5.1.2.1.1
Remove preservatives from all components of thrust bearing. Check for

mechanical damage and rectify if found.
5.1.2.1.2
Measure height of each spring assembly and segregate spring assemblies

according to height in the step of 0.1mm.
5.1.2.1.3
Make sets of spring assemblies for all thrust pad segments such that average
height of spring assemblies for each pad is similar.
5.1.2.1.4
Thoroughly clean spring plate assembly which will be either welded or bolted
with the bracket. Carry reaming and dowelling of spring plate with bracket in
case of both types.
5.1.2.1.5
Assemble pad stops.
5.1.2.1.6
Arrange spring assemblies on the spring plate for each pad segment such
that shorter spring assemblies are at inner periphery.
5.1.2.1.7
Clean pad segments. Clean their lubrication holes and dry compressed air.
Measure thickness of pad segments at few places to confirm that it is within
permissible limits as indicated on respective drawing. Ensure adequate chamfer
is provided on the leading edge and oil groove of the pad segments.
5.1.2.1.8
Place the pad segments assembled with pins as per drawing on the spring
assemblies which are already in position (in case of large and heavy pad
segments whose manual handling is difficult. A device is supplied for
insertion/withdrawal of pad segments shall be used).
5.1.2.1.9
Assemble anchor plates as per drawing. Ensure the clearance between pin
and pad stop, anchor plates is as per drawing.
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5.1.2.1.10
5.1.2.2
Connect hydrostatic lubrication pipelines and accessories. Ensure that

throttle and non-return valve to be connected are clear before their
assembly.
ASSEMBLY OF THRUST COLLAR ON SHAFT BY HYDRAULIC PRESS.
5.1.2.2.1
PREPARATION:
5.1.2.2.1.1
Remove preservatives and thoroughly clean thrust collar.
5.1.2.2.1.2
Clean and check the shaft surface at the place of thrust collar assembly.
5.1.2.2.1.3
Check suitability of thrust collar ring by mounting it in the groove of shaft.
5.1.2.2.1.4
Check shaft surface, inner bore of thrust collar for trueness and for
mechanical damage if any. Correct the damages by suitable means.
5.1.2.2.1.5
Check pressure oil feeding passages of thrust collar are clear and the spiral
groove on inner surface of collar does not carry sharp edges.
5.1.2.2.1.6
5.1.2.2.1.6.1
ASSEMBLY:
Lift collar fairly leveled.
5.1.2.2.1.6.2
Coat the conical surface of shaft and collar by clean heavy medium turbine
oil/molysulf grease.
5.1.2.2.1.6.3
Mount thrust collar on shaft, coinciding relative match marks of shaft and
collar.
5.1.2.2.1.6.4
Mount hydraulic pressing device and connect two pumps of oil injectors to
thrust collar as per given scheme. Fill clean turbine oil in the pump reservoirs.
5.1.2.2.1.6.5
Operate injectors pumps and simultaneously increase the hydraulic pressure

of the pressing device, so that collar starts sliding down along shaft. Continue
the process of pressing and oil injecting till thrust collar moves down and
permits assembly of thrust collar locking ring.
5.1.2.2.1.6.6
Release the pressure of both, hydraulic pressing device and oil injectors and
remove pressing device.
5.1.2.2.1.6.7
Insert thrust collar locking ring in the shaft groove above thrust collar and
assemble retaining ring or key as the case may be.
5.1.2.2.1.6.8
Raise the hydraulic pressure in oil injectors, until collar slips back and rests
tightly against locking ring. Release pressure in the injectors remove pump
connection and assemble, lock, the plugs in the thrust collar.
NOTE: Record the pressure of the injectors at which the collar slides back and
rest against locking ring. This will form a guide for future during post
commissioning repairs.
5.1.2.2.1.6.9
Assemble thrust bearing runner disc with insulated dowels and bolts.
5.1.2.2.1.6.10
Release lower bracket jacks to rest the collar on thrust pads.
5.2
HS LUBRICATION PUMP.
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5.2.1
Install the pumping unit and control gear as per drawing.
5.2.2
Complete grouting of pump foundation and control gear.
5.2.3
Complete cable laying, termination and connection of power source.
5.2.4
Assemble micro filter on high-pressure line as per drawing, check low

pressure filter on pump suction is installed.
5.2.5
Fill oil in thrust bearing oil bath about 50mm above the suction pipe of pump.
5.2.6
Start the pump for a short interval to ensure correct direction of rotation.
5.2.7
After ascertaining correct direction of pump rotation start and run pump
continuously.
5.2.8
Test oil pipe line as per drawing.
5.2.9
Cover oil cooler windows temporarily to avoid entry of foreign matters in the
oil.
5.2.10
Carry out hydraulic testing of oil coolers as called in drawing to ensure

healthiness of cooling tubes.
5.2.11
Prepare machines for checking alignment.

NOTE:
5.3
i)
Plug in type oil coolers are installed only when the final boxing of boaring
is done.
ii)
External cooling system coolers are installed on availability of foundation

from customer.
iii)
Above description is for upper bracket machine. In case of lower bracked

machine, assembly of thrust collar gets eliminated. Thrust collar being
integral part of shaft. Assembly of thrust bearing may be carried out at
appropriate stage of erection with lower bracket.
LEVELLING OF THRUST BEARING PREPARATION FOR CHECKING ALIGNMENT.
5.3.1
After transferring load of rotor on thrust bearing, complete load sharing of

thrust bearing pads, such that total load of rotor is evenly shared by all pads
(By regulating the height of thrust bolts in case of pivoted type thrust bearing
only).
5.3.2
Measure difference in magnetic center of stator, rotor and adjust it such that
rotor axis, coincides with that of stator, while machine on thrust bearing (Refer
instructions on Magnetic Centering of stator/Rotor).
NOTE: Deflection in the bracket due to hydraulic thrust may be taken in to
account while deciding the thrust bearing elevation.
5.3.3
Any lifting or lowering is carried out by adding or withdrawal of packers under

the bracket arm, supporting thrust bearing.
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5.3.4
5.3.5
5.4
Check and correct leveling of bracket, if required.

After setting of thrust bearing elevation, take measurement, between
coupling flanges and at runner with top cover face, to ensure that the turbine
runner attains correct elevation as per drawing, on coupling of turbine generator
shafts.
LEVELLING OF THRUST BEARING/ROTOR.
5.4.1
Assemble support ring segments of guide bearing maintaining a clear gap

between bearing journal and ring segments.
5.4.2
Assemble 4 nos. of guide bearing pads equally spaced and clamp generator
shaft with the help of wedges placed between pad and bearing housing. While
clamping ensure that shaft verticality is not disturbed.
5.4.3
Fix a level on rotor spider top for levelling the bearing by the rotation of the
rotor.
5.4.4
Start HS lub pump/Rotor turning device and rotate the rotor. Check level
variation, pump is switched off and level is checked when the rotor stationary
and freely suspended.
5.4.5
Complete level variation checking and correct it by adjusting the shims

placed underneath bracket supporting arms in case of spring mattress type, (in
case of pivoted type by regulating height of thrust bearing bolts) and remove
level from spider.
5.5
5.5.1
ALIGNMENT OF GENERATOR ROTOR SHAFT.

PREPARATION.
Check that the stator sole plates, stator holding down bolts and thrust bearing
bracket holding down bolts are all tightened.
5.5.2
Mark four or eight points (as applicable) at x, y, -x, -y, 90/450 apart on
the rim of thrust bearing, number these points in continuity opposite to direction
of rotation.
5.5.3
Transfer the above points on generator guide bearings and flange. Number
them in same order as that of runner disc.
5.5.4
These points may be number punched so that they become permanent

marks for use as reference in checking alignment during post commissioning
process in case need arises.
5.5.5
Install two sets ida of dial indicators having 0.01mm least count, 900 apart
at X and Y axis on generator guide bearing journal and on generator shaft
flange.
5.5.6
Check and ensure clamping of shaft at generator bearing with guide pads,
while clamping ensure that the shaft verticality is not disturbed. Set all dial
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indicators to zero.
5.5.7
Start HS lubrication pump, and ensure that the oil is flowing of all TB pads,
rotate the rotor in the direction of rotation by manual means, by providing two
or four groups of persons at the bottom end of rotor. Uniform pressure is applied
by the groups for rotation.
5.5.8
Rotate the rotor by 900/450 (as required) record dial gauge readings in
the format.
NOTE: Dial gauge readings are noted with HS lub pump stopped and the rotor is
stationary freely suspended.
5.5.9
Take three sets of readings and observe consistency. All sets of reading
will be nearly consistent with 1 Dvn if the shaft is rotating freely without
obstruction at any place. To verify magnitude and direction of misalignment,
plot coordinates of C on a graph paper and draw a circle of minimum radius,
which passes through any three points and encompasses other two. The
diameter of this circle (linear joining center of circle) represents the magnitude
and a linear joining center of circle and O represents direction of
misalignment. In a corrected process this diameter should not exceed 0.10mm.
LOCATION
Angle of rotation
90
X-AXIS
180
270
360
90
Y-AXIS
180
270
360
Gen.
Guide
bearing nearest to
thrust bearing (a).
Gen. Shaft flange
(b).
(b - a) = c.
5.5.10
In case the magnitude of misalignment is beyond permissible limits, the

same is corrected and brought within permissible limits either by scraping the
insulation placed between thrust collar and runner disc or by introducing
stainless steel shims of appropriate height and size in a wedge form.
5.5.11
The stainless steel shims are graded with steps in a wedge form covering
not less than 2/3 radial depth of thrust collar.
5.5.12
Maximum height of wedge is calculated as

Dr x wF
h=
---------------------2 x LF
Where h is the maximum height of wedge in mm.

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Dr is the diameter of runner disc/thrust collar in mm.

LF is the distance between points of measurement of run out mm i.e. the
perpendicular distance between dial indicators placed at guide bearing and
flange.
wf is the maximum run out of flange in mm.
Depth of placement of shim is calculated as
Dr x
a
-------------------h
Where a = Depth of placement of packing in mm.

= Thickness of packing in mm.
NOTE: In case provision of HS lubrication is not foreseen in the design. An

arrangement for rotation of rotor with powerhouse crane is supplied. Thrust
bearing pads are lubricated with molybdenum compound, while checking the
alignment to ensure smooth rotation.
5.5.13
Allowable deviation during centering of generator shaft with respect to

turbine shaft for the process of coupling, turbine and generator.
Type of Deviation
Nomenclature
Shift of generator shaft axis with

respect to turbine shaft.
Non parallelity of the mating
surfaces of the flanges at the
shaft diameters (mm).
Allowable
deviation in
mm.
0.10mm
Up to 600
Up to 1000
0.020
Up to 1500
0.025
0.030.
5.5.14
After centering the generator shaft with respect to turbine to above

requirements, further process of coupling turbine generator shaft correction of
turbine shaft misalignment is carried out (Coupling of generator turbine flanges
described in turbine section).
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5.6
HYDRO GENERATORS
ASSEMBLY AND ALIGNMENT OF SLIP RING.
5.6.1
Clean the slip ring by blowing clean, dry compressed air.
5.6.2
Check insulation resistance of slip ring and assemble at its place of

assembly on shaft, after heating for expansion or as may be called in drawing.
5.6.3
Install two sets of dial gauges, 900 apart, one set each at X and Y on one
of the collector rings and the other at guide bearing and set them to zero.
5.6.4
While carrying combined alignment of turbine and generator shaft,

record dial gauge readings in the format given below:
Level
Angle
of
rotor
rotation in
Slip ring (a).
90
X-Axis
180
270
360
90
Y-Axis
180
270
360
Generator
guide
bearing (b).
(a-b) = c.
5.6.5
Plot the coordinates of point C on a graph paper and draw the throw circle
diameter and carry out the corrective measures to bring the run out of slip ring
with in permissible limit.
5.7
5.7.1
ASSEMBLE AND ALIGNMENT OF PMG ROTOR:

Assemble PMG rotor over generator shaft, check and correct the
alignment, during the process of combined axis alignment checking, along with
slip rings.
5.7.2
Allowable tolerance of run out 0.10mm.
5.8
CENTERING OF STATOR, UPPER AND LOWER BRACKETS:
5.8.1
On having centered the rotor with respect to turbine runner labrynth,

check centering of stator, with respect to rotor and shift the stator to achieve
the best possible results of stator, rotor air gaps.
5.8.2
Maximum variation in air gap may be + 5%. However, in unavoidable

circumstances variance upto 10% at few locations could be allowed.
5.8.3
Check the centering of upper and lower brackets with respect to generator
shaft and correct by shifting the bracket in the desired direction to achieve
centering within permissible limits of 0.1mm.
5.8.4
Check stator and rotor form and plot the formation as indicated in fig. 1, 2,
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3 for rotor, stator and super imposition of rotor on stator. Procedure for checking
is described here under.
5.9
STATOR FORM.
5.9.1
Take one pole as datum (in this illustration pole no.1).
5.9.2
Locate the center of this pole opposite to 20 (i.e. equal to no. of poles)
equi-distant peripheral positions of stator and measure the air gap at both top
and bottom of this datum pole.
5.9.3
Rake average of top and bottom air gap.
5.9.4
Draw a reference circle of the same dia as in case of rotor form, and plot
the stator form as shown in fig.2 with respect to the reference circle. Place the
rotor form so as to given the largest difference in air gap between stator and
rotor. From this concentricity figure we can find out the amount and direction in
which stator should be shifted to improve the air gap concentricity.
EXAMPLE
Stator form.
Pole no.1 has been taken

as datum.
Loc. Pt. On
Stator.
Air gap
Top
Air gap
Bottom.
01
02
03
04
05
06
07
08
09
10
22.16
22.50
22.55
22.30
22.40
22.20
22.66
22.75
23.00
22.85
22.20
22.80
23.40
22.25
23.45
22.70
22.30
22.60
22.80
22.85
5.10
5.10.1
5.10.2
Average
Air gap
in mm.
22.18
22.65
22.97
22.77
22.92
22.45
22.45
22.67
22.90
22.85
Loc. Pt. On
Stator.
Air gap
Top.
Air gap
Bottom.
11
12
13
14
15
16
17
18
19
20
23.15
22.50
22.60
22.00
22.55
22.70
23.15
23.20
23.00
22.55
23.00
23.10
22.60
22.65
22.80
22.80
22.95
22.85
22.25
22.40
Average
Air gap
in mm.
23.07
22.80
22.60
22.33
22.68
22.75
23.05
23.02
22.62
22.48
ROTOR FORM.
Mark a datum position on the stator core (say upstream mark) and locate
center of each pole opposite to the datum mark and measure the air gap at the
top and bottom of each pole.
Take average of top and bottom air gap of each pole.
5.10.3
Draw a reference circle as shown in fig.1 which represents some assumed

air gap (In this case the circle represents as assumed air gap of 21mm).
5.10.4
Plot the rotor form as shown in Fig.1 with respect to above reference
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circle.
EXAMPLE
ROTOR FORM.
Pole
No.
01
02
03
04
05
06
07
08
09
10
DATUM -
Air gap
Top
22.28
22.38
22.63
22.78
22.93
23.08
22.18
22.73
22.78
22.88
5.11
Air gap
Bottom
22.08
22.28
22.33
22.33
22.58
22.53
22.28
22.68
22.68
22.58
Average
Air gap.
22.18
22.33
22.48
22.56
22.76
22.80
22.75
22.71
22.73
22.73
UP STREAM MARK.
Pole No.
11
12
13
14
15
16
17
18
19
20
Air gap
Top
22.78
22.83
22.68
22.69
23.18
23.38
23.28
22.78
22.48
22.28
Air gap
Bottom
22.63
22.53
22.28
22.53
22.93
23.13
23.55
23.23
22.63
22.28
Average
Air gap.
22.70
22.68
22.48
22.61
22.05
23.25
23.41
23.00
22.55
22.28
MAGNETIC CENTERING OF STATOR AND ROTOR OF VERTICAL

BYDROGENERATORS.
For magnetic centering the center line of the rotor and the stator shall be at the
same elevation during operation. To achieve proper magnetic centering
following precautions shall be taken during erection at sites.
5.11.1
ROTOR POLE MOUNTING.

During assembly of wound poles on the rotor rim it must be ensured that all
pole center lines are at the same elevation and at the center line of rotor rim.
To achieve this following method is recommended.
5.10.4.1
Decide the location of pole on the rim on the basis of its type and weight.
5.10.4.2
Measure the pole body length (Refer fig.2) (Dimension P).
5.10.4.3
Measure the stacked rim height on the corresponding pole seating face (at
the center of this face) (Refer fig.1 Dimension R).
5.10.4.4
The pole stop height shall be equal to dimension (R-P)/2. If required the
height of the supplied pole stops shall be reduced by machining or increased by
weld deposit and subsequent machining so that height variation of all pole
stops are within 0.5mm.
5.10.4.5
Mark the centerline of the pole with white paint on the pole face.
5.10.4.6
Assemble the pole, using modified pole stop.
5.10.4.7
5.10.4.8
Assemble all the poles adopting the methods given above and complete
the rotor assembly.
The above procedure ensures that all the poles lie on the same centerline.
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5.11
ROTOR LOWERING.
Before rotor lowering mark the centerline of the stator core at the inner bore.
Since core height may vary at various diameters the average height may be
determined for marking the centerline on inner stator bore. Just after rotor
lowering, check visually or with the help of marked sticks, the matching of rotor
and stator centerlines. To facilitate the checking the center lines marked on
stator and rotor can be transferred to a convenient location, by marking another
line above or below the centerlines. This is done to have a preliminary idea of
matching of stator and rotor centerline.
5.12
AFTER ROTOR LOWERING.

In case the variation in centerline elevation of the stator and rotor is more than
the desired value then corrective action shall be taken. In case the rotor pole
mounting is done as per procedure given above and setting of thrust bearing
elevation is correct then correction is required ONLY on stator. Appropriate
shims shall be added or removed from the bottom of each stator sole plate to
raise or lower the stator centerline, as desired. After correction the magnetic
centering shall be checked again, as per method given in section C above.
The centerline of stator and rotor shall match during normal operation.
However, during standstill condition the rotor elevation is set a little higher than
running elevation taking into account the thrust bearing bracket deflection and
thrust bearing spring deflection. This fact must be kept in mind, while checking
or adjusting magnetic center of any vertical Hydro generator having verified
corrected centering and magnetic axis.
5.13
Release foundation of lower bracket and stator for grouting.
5.14
Complete drilling, reaming and dowelling of upper and lower brackets, lock
the dowels as called in drawing.
5.15
Having locked turbine generator shafts at TGB and lower generator guide
bearing after centering rotor with respect to best possible clearances of runner
labyrinths. Boxing of bearings and the machine is performed.
5.16
Measure radial distances between bearing skirt and housing of TGB, LGB
and UGB at X & Y axis. Punch the dimensions at convenient visible locations for
use of centering the runner, during post commissioning process without calling
for dewatering of turbine.
6.0
6.1
AIR AND OIL COOLER.
AIR COOLERS.
6.1.1
Carry out hydraulic testing of air coolers as per technical instructions to

prove the healthiness of cooler tubes and joints.
6.1.2
Assemble air coolers on stator frame and complete welding of supports

etc.
6.1.3
Carry out the hydraulic testing of control valves as recommended and
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assemble them with coolers.

6.1.4
Install air release plugs and drain valves on coolers as called in drawing.
6.2
OIL COOLERS.
6.2.1
Repeat 7.1.1.
6.2.2
Assemble coolers on oil baths of guide and thrust bearings.
6.2.3
Check cleaning of oil pipes and assemble them.
6.2.4
Complete laying, tack welding of water, oil and air pipe lines and fix
clamping arrangements.
6.2.5
Dismantle pipes for final welding, cleaning and hydraulic testing as called
in drawing.
6.2.6
Install pipes with supports and clamping arrangement as per drawing.
7.0
7.1
ASSEMBLE OF PERMANENT MAGNET GENERATOR STATOR.

Clean stator by blowing dry compressed air.
7.2
Check stator winding for absence of mechanical damage.
7.3
Check healthiness of winding insulation with 500V megger.
7.4
Carry out testing of stator and rotor as called in technical requirements.
7.5
7.6
Mount PMG stator on its bracket, center it to achieve best possible

centering with respect to rotor poles. Tight the holding down fasteners and
complete drilling, reaming and dowelling of PMG stator frame with bracket as
called in drawing.
Alternately mount speed-sensing gear as per drawing.
8.0
ASSEMBLY OF BRUSH ROCKER WITH SLIP RING.
8.1
Mount brush rocker for the slip ring. Adjust brush rocker height such that,
friction surfaces of slip rings and brushes are at the same elevation.
8.2
Check insulation of brush rocker which should not be less than 1 M W, if IR

is found less, its cause should be investigated and eliminated.
8.3
Check and ensure that 3-4mm clearance is maintained between the

brush holder and slip ring friction face.
8.4
Carry out bedding of brushes with friction surface of slip ring.
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9.0
9.1
9.2
EXCITATION SYSTEM.
Install excitation panels as called in drawing.

Assemble excitation transformer with the frame.
9.3
Check and assemble the loose components, received along with the
equipment.
9.4
Complete cable laying and termination of control cables (customer

scope).
9.5
Complete laying and termination of power/control cables of BHEL scope.
9.6
Check the test excitation system in accordance with test schedule of

manufacturer.
9.7
Arrange and connect separate temporary power source for testing of

equipment during commissioning.
9.8
NOTE: Temporary power source is removed and restored to main source

of power house once the commissioning tests are over.
9.9
After switching the set in to the system adjust the limiters of various
organs.
10.0
10.1
BOXING OF BEARINGS.
UPPER GUIDE BEARING.
10.1.1
Clean bearing housing thoroughly by dry compressed air.
10.1.2
Check bearing skirt surface for trueness.
10.1.3
Check insulation resistance of bearing with 1000V megger, in case of low

IR the cause may be found and eliminated to achieve the desired IR value.
10.1.4
Clean pads, assemble and clamp with shaft by wedges to ascertain the
packing desired to maintain the drawing clearances.
10.1.5
NOTE: While clamping the pads on bearing skirt it may be ensured that the
shaft does not get displaced.
10.1.6
Install required amount of thick stainless steel shims between pad and
support, to maintain a clearance of 0.15 to 0.18mm between the housing and
pad supports. Alternately adjust the clearance between taper wedge and pad
support, by regulating the height of taper wedge.
10.1.7
NOTE: Bedding of taper wedge is ensured with U blocks before assembly.
10.1.8
Install TSD, RTDs and complete clamping, dressing of TSD, RTDs leads and
cover the housing temporarily.
10.1.9
On completion of lower bearing and turbine bearing assembly, remove

temporary covers of housing, check for cleanliness and remove wedges fitted
between pad and housing.
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10.1.10
10.2
Assemble oil vapour seal maintaining the clearance between stationary and
rotating part as per drawing. (Take out the leads of bearing earthing before
assembly of oil vapour seal).
GENERATOR LOWER GUIDE BEARING ASSEMBLY.
10.2.1
Release clamping and remove the four bearing pads, placed for clamping.
10.2.2
Ensure all bearing components are thoroughly cleaned.
10.2.3
Clean bearing housing by blowing compressed air.
10.2.4
10.2.5
Install bearing pad supporting segments, maintaining clearance between

journal face and rings as called in drawing.
Check bearing journal face for trueness.
10.2.6
Install and clamp all pads with bearing journal, to check and ascertain
amount of packing needed for maintaining clearance of 0.15 to 0.18mm between
pad supports and housing.
10.2.7
After fixing stainless steel shims between pad and pad support check and
ensure that the clearance between bearing pad support and housing are within
specified requirements, called in drawing. Alternately, between pad support and
wedges as the case may be.
10.2.8
10.2.9
Install RTD, TSD and other instruments as per drawing.

Assemble vapour seal maintaining clearance between stationary and
rotating parts as indicated in drawing. Assemble all coolers with sealing
elements.
10.2.10
Assemble inner tank of generator LGB with sealing element.
10.2.11
Install VGB bearing earthing brush and connect the leads.
10.2.12
10.3
Fill oil of specified grade in bearing housing to check the leakages if any.
After ensuring soundness of joints complete the oil filling, to the level as called
in drawing.
THRUST BEARING.
10.3.1
Clean bearing housing thoroughly and blow compressed air.
10.3.2
Install TSD, RTD level gauges relay, oil contamination detector etc.
10.3.3
Complete dressing and clamping of TSD, RTD leads.
10.3.4
10.3.5
Check insulation resistance between thrust bearing collar and disc which
should not be less than 1 M W when measured with 500-1000V megger.
Check that all fasteners are locked as called in drawing.
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10.3.6
Remove temporary covers of oil cooler windows and assemble oil coolers
with sealing elements. Alternately the blind flanges in case of external cooling
arrangement.
10.3.7
Clean inner tank of bearing and assemble with upper bracket/lower brackets
as the case may be.
NOTE: In case of forced lubrication of thrust bearing, oil coolers are installed
outside and oil is circulated by pumps through suitable piping system.
10.3.8
10.3.9
Fill oil of specified grade to check leakage if any. After ensuring soundness of
joints, complete the oil filling, to the level called in the drawing.
Boxing of turbine bearing is described in turbine portion.
1.0
UNIT CONTROL BOARD.
1.1
Install unit control boards on the channel frame.
1.2
Check and ensure they are secured to frame firmly and vertical.
1.3
Check that all the relays and other components are in place as per
scheme.
1.4
1.5
1.6
Carry out laying and termination of power and control cables as per cable
schedule.
Connect DC, AC source.
Test the panel in accordance with testing schedule and confirm
functioning of each and every components, relays etc.
2.0
EXTERNAL LP OIL LUBRICATION SYSTEM.
2.1
Carry out hydraulic testing of coolers and control valves.
2.2
Install coolers, pumps, filters, control panels etc. as per project drawing.
2.3
Complete laying and tack welding of pipes.
2.4
Complete installation of fixtures and clamping of pipes.
2.5
Dismantle the pipes for completing welding and cleaning.
2.6
Carry out acid cleaning and hydraulic testing of pipes as called in

drawing.
2.7
Install pipes and clamping arrangements with supports etc.
2.8
Carry out laying and termination of power and control cable.
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2.9
2.10
Check and test the control panel in accordance with instructions.

Run the pumps, on total system being ready and test the system by
circulating the oil.
NOTE:
a)
Oil leakage is not permitted.
b)
Check and ensure functioning flow indicator.
3.0
BRAKE JACK SYSTEM.
3.1
Install brake jack panel.
3.2
Carry out laying and welding clamping of air pipes between pressure
reducer and brake panel.
3.3
3.4
Carry out laying and termination of control cables.

Check operation of components installed in the brake panel in line with
requirement.
3.5
Clean air pipes and test the pipes for leakages (air leakage is not
permitted).
3.6
Adjust pressure reducing valve to deliver the air pressure, recommended

for braking operation.
3.7
Check operation of brakes and ensure that brakes, return back to their
normal position and do not stick to cylinder.
NOTE:
Refer lower bracket for jacking details.
4.0
4.1
Carry out installation of fire extinguishing equipment in accordance with

manufacturers instructions.
4.2
4.3
FIRE EXTINGUISHING SYSTEM.
Complete laying of control cables and test the equipment.

Ensure that system id ready duly commissioned before the stator
voltage build up.
MISCELLANEOUS.
Install dust collector as per layout drawing and carry out testing and
commissioning.
Install stator anti-condensation heater and carry out cabling inside

barrel.
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Installed chequered plating, railings etc.
PREPARATION OF HYDRO GENERATOR FOR STARTING AND

COMMISSIONING.
1.1
Prepare the hydro generator set for the first starting and its speeding to
rated speed.
1.2
Clean hydro generator from dirt and dust. Blow the generator with clean
and dry compressed air. Clean and rub with cloth and internal surface of the
stator frame and air baffles.
1.3
Examine all inner parts of hydro generator exciter if any and permanent
magnet generator/SSG specially the air ducts and remove all foreign objects
from them. Clean commutator of the exciters with spirit.
1.4
Check installation of dowels and tightening of fixing bolts of stator lower

and upper brackets, brakes, exciters and permanent magnet generator. Check
the locking of all the nuts, particularly in rotating parts of generator and air
baffles.
1.5
Check all the air baffles and make sure that they do not touch the
rotating parts of generator and the gaps are within limits as prescribed in the
drawings.
1.6
Checks that all cover plates are closed tightly.
1.7
Check that all the thermal indicators are installed at the required places
and all instruments are functioning normally.
1.8
To prevent entry of dirt and dust into oil bath during first starting do not
connect the pipe lines for vapour seal to air baffles in the design, such system
of connecting the pipe to air baffles exists.
1.9
Check that water circulation is normal through the air coolers and oil
coolers of thrust and guide bearings.
1.10
Before starting the set the temperature of oil in thrust and guide
bearings should not be less than 150c. Just before starting of the set circulate
water through the coolers if temperature of oil is more than 250C.
1.11
When oil temperature is
1.12
Check that fire extinguishing system in the generator functions

normally.
1.13
Blow the brakes and check their working with compressed air at
required pressure.
1.14
Jack the rotor on brake/jack for lubricating the thrust bearing pads. If HS
lubrication system is not called at the design.
1.15
1.16
Ensure that generator excitation system is switched off.

Start the hydro set and maintain it at low speed and make sure that
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there is no jamming, unwanted noise, run-out of shaft and slip rings. Then raise
its speed to 70 to 75% of the rated speed. In case of any kind of abnormality
the machine should be stopped immediately. If on careful checking no
abnormality is observed, bring the set to rated speed.
Run the machine till temperature in thrust and guide bearing become practically
stable. Check the fitting of the brushes and ensure that there is no interference,
abnormal noise or vibrations etc. Allowable vibration (double amplitude of
oscillations) at different places is as under depending upon the generator
speed.
S.N.
01
02
03
04
Place of
measurement
Bracket with built
in guide bearing.
Commutator
and
slip rings.
Shaft in the zone of
-----------Shaft in the zone of
guide bearing.
Admissible vibrations in mm.

Speed up
to 100 RPM
0.18
Speed up
to 187.5
0.15
375
RPM.
0.10
750 RPM.
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.07
In the limit of guide bearing gap.
Vibrations in the brackets are measured in vertical and horizontal directions

and at all other places in the radial direction.
1.17
If bracket vibrations and shaft vibrations are found beyond permissible

limits during first spinning. Carry out balancing of generator rotor before
proceeding with bearing run.
1.18
During running of the hydro set carefully observe the reading of the
thermometers embedded in the thrust and guide bearing pads and placed in
the oil bath. The temperature should increase gradually without sharp kicks, at
first with increment and then with diminishing increment; within 2-3 hours of
operation it should become constant. Stable temperature of oil and pads
should not exceed 500C and 750C respectively.
If the reading of any thermometer in thrust and guide bearings increases
sharply, even if the absolute temperature is not very high, hydro set must be
stopped immediately and the reason for heating be found out and eliminated.
1.19
Carry out over speed test of machine and confirm operation of overspeed
mechanical device, initiating impulse for closing of machine.
2.
2.1
DRYING OF THE GENERATOR.
Dry out of the generator may be carried as recommended by adopting

the following methods:
a)
By short circuit current.
b)
By ventilation losses.
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c)
By direct current.
2.2
General conditions which act as guideline in all the methods of drying

are given below:
2.2.1
Heating of the generator should not be fast. Rate of rise of temperature

is maintained at 5-80C/hr in the beginning and 30C/hr afterwards so that in
the first 10 hours temperature rise does not exceed 500C. Maximum
temperature should be attained in 20-24 hours after the beginning of the
drying process. Maximum temperature at any place should not be more than
750C when measured with a thermometer and 900C when measured by
resistance method.
2.2.2
During dry out of the generator temperature should be observed

constantly and readings recorded in the protocol of drying. Temperature should
be taken after every hour.
During dry out process measure and record insulation resistance of stator and
rotor. Insulation resistance of the stator is measured by means of 1000V or
2500V megger and that of the rotor by a 500V megger.
2.2.3
During drying insulation resistance generally decreases in the beginning

due to the evaporation of moisture when the windings are heated, then
increases gradually and in the end becomes constant or increases slightly.
Drying is considered to be complete if insulation resistance remains constant
at constant temperature for six hours.
Minimum allowable insulation resistance per phase of the stator winding R 60
at 750C is
U
R60 =
---------------1000 + 0.01S
Where U rated voltage in volt.

S = rated capacity in KVA.
Allowable value of insulation resistance at temperature below 750C is obtained
by multiplying the above figure with a factor Kt tabled below:
C
Kt
75
1
70
1.2
60
1.8
50
2.6
40
3.9
30
5.5
20
8.6
10
12
Value of the absorption coefficient of insulation
R60
---http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced12.htm#THRUSTBEARING
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R15
Should not be less than 1.3 at winding temperatures from 10-300C.

2.2.4
For generator rotor and exciter winding insulation resistance should not
be less than 0.5 M W at working temperature. Rotor windings do not require
separate drying as they are dried during drying of the stator winding.
Minimum duration of drying is 50 hours.
Ventilation accelerates the drying process. Therefore drying of generator
should be done, if possible with the set rotating. After completion of the drying,
the generator must be checked very carefully.
2.3
During drying by short circuit currents all the three phases of stator
winding are shorted and an ammeter is connected in every phase. Shorting
should be done before the generator circuit breaker. Earth the stator frame
reliably and speed up the generator to less than the rated speed. Excitation
current is regulated so that the current in any phase of the stator winding is
not more than 50%, of the rated current. Later it may be increased upto the
rated value.
2.4
For drying by ventilation losses method the generator is run at the rated
speed or even at higher speed (upto 1.1 times the rated speed) without
excitation and without water supply to the air coolers.
2.5
For drying by direct current is done by passing current through the

stator winding, three phases of which are connected in series. Value of the
current is limited to the maximum allowable temperature of heating.
Scheme of current supply must ensure possibility of smooth regulation of
current during its switching on and switching off as there is possibility of break
down of insulation with sharp variation of current. Drying is done with the rotor
unexcited. For hydro generators with high moisture content in the stator
winding insulation it is not recommended to dry it by direct current of even low
voltage as direct current may cause electrolysis. Such generators should be
dried by blowing hot air or by ventilation losses.
After the drying machine should be stopped and allowed to cool off slowly.
During this cooling down process a complete temperature Vs insulation
resistance curve should be plotted and retained as a record of clean and dry
condition of the windings at various temperatures. Future insulation checks
can be related to this curve and indication obtained as to the state of the
windings.
2.6
Carry out HV testing of stator and rotor windings in accordance with

manufacturers instructions.
3.0
3.1
TESTING OF THE GENERATOR.
Start the unit and check the generator operation (without excitation) at
rated speed till the bearings attain a stable temperature. Record the
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temperature rise of the oil bath and bearing pads. Observe the oil level in
thrust bearing oil bath. After starting, the level rises because of centrifugal
forces, heating and oil aeration. Check that the oil does not leak through the oil
baths and pipe lines. Check and, if necessary, adjust the brush rocker of
exciters and generator slip rings.
Check that there is no abnormal knocking and noise and if necessary, stop the
unit to eliminate the trouble.
Before connecting the generator to the mains, test it for partial (25%, 50%)
and total load throw off and the rise of voltage while applying load is to be seen
jointly with the customer.
Measure the vibration of the brackets, exciters and stator and also the shaft
run out with and without excitation and on load, carry out balancing of rotor on
excitation if necessary.
Stop the generator by braking as per the generator specifications in order to
check the braking system. After having completed the trial starts, switch on
the hydro generator to the largest transmission line disconnected at the
receiving end to check for the absence of self Excitation.
3.2
3.2.1
TECHNICAL REPORT ON TESTS:

Test the hydro generator and prepare the following final documents.
3.2.2
Record sheet of measurement of stator and rotor winding insulation

resistance when cold and in warmed up state with respect of frame and
between the windings.
3.2.3
Table of the following measurements run out of shaft, commutators and

slip rings, vibrations of stator brackets and magnetic system. These values
should be measured at no load without and with excitation as well as on load.
3.2.4
Record sheet of generator no load characteristics.
3.2.5
Record sheet of generator short circuit characteristics.
3.2.6
3.2.7
Record sheet of resistance measurements of all the main and pilot

exciter windings in cold state.
Record sheet of exciter no load characteristics.
3.2.8
Record sheet of insulation resistance measurements of armatures, main

and commutating poles of main and pilot exciters in cold and in warmed up
state, as applicable.
3.2.9
Record sheets of the testing of electrical strength of insulation of

generator rotor and stator windings, armatures, main and commutating poles
of main and pilot exciters.
3.2.10
Record sheet of temperature in various parts of the generator during

the run test at rated load.
3.2.11
Record sheet of stable temperatures in the thrust bearing and guide
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bearings.
3.2.12
If during testing, considerable deviations are detected which exceeds

the limits specified in generator specifications, the generator must not be
connected on load without the approval of the manufacturer.
4.0
PUTTING INTO OPERATION.
4.1
Putting into operation of the hydro set is done after positive results of
its complete testing and inspection carried out under load for 72 hours and
after removal of abnormalities observed.
4.2
After complete testing and inspection under load, it is necessary to

carry out the following:
a)
Check carefully the conditions of the fixing details of the rotor, air baffles,
stator, brackets, cover plates, exciters and permanent magnet generator.
b)
Check carefully the stator winding for absence of any bulging of insulation
or flow or varnish or compound due to poor soldering and poor brazing.
c)
Check the interpolar joints of the rotor. If necessary tighten the holders
etc.
d)
Check the sealing of the oil bath.
e)
Check the oil and water pipelines to see if there are any leakages of water
or oil.
f)
Check the brakes and the brake pipelines to see if there is any oil leakage
during rotor lifting with the help of brakes-cum-jack. Check working of the
braking system.
g)
Check the connections of the current carrying leads and cables.
h)
Measure the insulation resistance of all the windings of hydro generator

and compare them with measurements carried out before starting the
commissioning tests.
i)
Check the welding seams of rotor spider, bracket, air baffles and other
details.
j)
k)
l)
Check the brush rockers of the commutators.

Below the slip rings with compressed air as during starting period the
most intensive wear of the brushes is observed.
Check the brush rocker of the slip ring.
m)
Check the oil level in oil bath.
n)
Remove all the troubles and the defects.
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Observe during operation of the hydro generator, inspection of the guide

bearings and thrust bearings should be done in case their temperature is near
the maximum permissible or in case temperature variations are observed
during 72 hours test.
INSTRUCTIONS FOR CHECKING AND PROVING, BEDDING OF GUIDE AND THRUST

BEARING PADS:
This activity is carried out in a covered area of stores or erection bay of power
house, while shaft is in horizontal position.
PREPARING BEARING PADS/SHAFT:

Remove preservatives from bearing pads and bearing journals of shaft.
Check pads for mechanical defects and eliminate if any found.
Check bearing journal of shaft, for surface defects if any and eliminate by
suitable means.
Complete polishing of shaft journal with fine emery tape.
Make arrangements for covering of shaft journal by a thin sheet of plywood or
rubber sheet, to avoid damage to the machined surface. Protection may be
removed only, when, required for, rubbing of pads over journal.
CHECKING BEDDING AND PROVING:

Rub, babbited surface on respective journal surface of turbine or generator
shaft as the case may be.
Continue scraping of shining points of babbited surface, which represent high
points.
After each operation of scraping, rubbing process of pads over journal shall be
carried, till such time, shining points over babbited surface are achieved all
over the area.
Two to three such points/cm2, evenly spread all over the surface is considered
satisfactory.
After checking and proving the bedding, complete, chamfering of pad on the oil
inlet edge as called in drawing.
Complete thrust bearing pad bedding with mirror surface of thrust bearing
runner disc, wherever called for.
Emboss, identification marks, for unit number and bearings, for traceability.
Apply preservatives and pack the pads in a wooden case, having protected
them from mechanical damage.
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Pads are drawn from stores only, when required at site for assembly during
checking of alignment and boxing up.
INSTRUCTION ON CLEANING OF OIL PIPES.
1.1
All the pipes should be mechanically cleaned by using kerosene/diesel with

the help of wire brush or chain, to remove all the remains of weld slags and scaling
etc.
1.2
After mechanical cleaning, inspect the pipes for thorough cleaning and allow
to dry.
1.3
For removal of rust/corrosive particles, pipe will be cleaned by acid pickling

process.
1.4
Pipes shall be filled with 5% dilute HCL/H2SO4 solution by plugging one end
of the pipes.
1.5
1.6
1.7
Pipes shall be kept filled with above solution for 8-24 hours.
After acid pickling pipes are neutralized by caustic soda/sodium
bicarbonate solution for about one hour.
Pipes shall be flushed with water after neutralization.
1.8
Inspect the pipes for cleanliness if needed cleaning process may be

repeated.
1.9
Carry out flushing of pipes with turbine oil after ensuring proper cleaning
and dryness of pipes.
1.10 Having accomplished oil flushing, close both ends of pipes to avoid entry of foreign
matters.
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GENERATOR ASSEMBLY AND ERECTION

GENERATOR SUB-ASSEMBLIES & AUXILIARIES.

LEVELLING OF THRUST BEARING.

CENTERING OF STATOR, UPPER AND LOWER BRACKETS.

MAGNETIC CENTERING OF STATOR AND ROTOR.

AIR AND OIL COOLERS

ASSEMBLY OF PMG STATOR.

ASSEMBLY OF BRUSH ROCKER WITH SLIP RING.

UNIT CONTROL BOARDS.

EXTERNAL OIL LP LUBRICATION SYSTEM.

BRAKE JACK SYSTEM.

FIRE EXTINGUISHING SYSTEM.

PREPARATION OF HYDRO GENERATOR FOR STARTING AND

DRYING OF THE GENERATOR.

TESTING OF THE GENERATOR.

PUTTING INTO OPERATION.

INSTRUCTIONS FOR CHECKING AND PROVING, BEDDING OF

INSTRUCTION ON CLEANING OF OIL PIPE LINES.

GENERATOR ASSEMBLY AND ERECTION:

Power house roofing completed, sides, windows and entry covered.

Service bay is concreted and embedments if any are installed.

Generator barrel and floor concreting and curing completed.

Generator barrel and its floor painted from inside.

Ventilation and water supply arrangements.

EOT crane commissioned and load tested.

FOUNDATIONS: STATOR/LOWER BRACKET.

Check surface flatness of foundations with a machined plate and correct by

2. FOUNDATION PLATES AND STUDS.

Check and prove threads of foundation studs and nuts.

Rotor with fans.

Lower bracket with brakes and jacks.

Air, oil coolers and pipe lines.

SSG speed sensing gear.

Hydrostatic lubrication system.

External/LP oil cooling system.

Brake jack system/power pack.

Stator heater. (Anti condensation heater).

Air, oil and water pipe lines.

Fire extinguishing system / CO2 system.

Assembly of stator may be done as per manufacturers instructions either in service

Prove and assemble stator turning device. (If any).

ASSEMBLY AND INSTALLATION.

Install dowels and fasteners of joint flanges and complete tightening of

Install dowel of stator frame and foundation plate.

Carry out assembly of remaining two sectors as described above to form

Position, foundation plates of stator with respect to stator frame. Install

The rotor of a hydro generator consists of following sub-assemblies.

Poles and their inter connections

Current carrying leads

ASSEMBLY AND ERECTION OF ROTOR.

UMBRELLA TYPE GENERATOR.

Rotor spider is bolted type.

Shaft is despatched with rotor bush mounted on it and spider portion

UMBRELLA TYPE MACHINE.

Complete tightening of collar studs.

Depending on construction, some times fixing of spider to rotor bush is done

NOTE: Heating is done gradually by controlling temperature rise 5-6

Rim can be built of segmental type laminations.

Rim can be built of solid forged disc mounted on shaft.

2.3.1 LAMINATION TYPE RIM.

Depending on type of construction of rotor spider with shaft or without

Check and regulate position of spider, to make wedge bars vertical.

Check that, all segments are at the same elevation.