660MW Generator

7/28/2019 660MW Generator

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-FAQCP

Page 2 of 87

600MW

-FAQCPGenerator Field Assembly Quality Control Points

S.O:

User name &Generator No..

Installation Company:

Supervision Company

T F AService start time

Completion Date:

Note: The FAQCP contains generator manufacturers for TFA to record the installation process

which not only improve installation quality but also a important task for our TFA.In order to

provide you high quality service. We advice Installation representative, Supervision

representative and power plant representative witness the installation process and accomplish

the FAQCP record job. This book interpretation of SHANGHAI GENERATOR WORKS all.


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Catalogue

....................................................................................................................................................... 6

Part 1 Open-case inspection ............................................................................................................................... 6

................................................................................................................ 7

Part 2 key point of generators installation ................................................................................................................. 11

..................................................................................................................................................... 15

Part 3 Generator body .................................................................................................................................................... 15

1. Seating plates and stator emplacement .................................................................. 15

2. (Temperature measuring element check ) ............................................................................ 15

3. (Test the insulation water manifold pipe)......................................................................... 16

4. (Check the three phases' main insulation of generator)........................................ 16

5. (Terminal box installation) ................................................................................................... 17

6. (Rotor check ) .............................................................................................................................. 17

6.1 (Check the elasticity & non-cylindrical degrees of rotor ) ................. 17

6.2 (Rotor airtight test) ................................................................................................. 19

6.3 (Rotor electric test) ................................................................................................ 19

7. (Check the seal bearing and seal bearing seat) ......................................... 207.1 (Check the sealed bearing) ..................................................................................... 20

7.2 (Check the seal bearing) ............................................................................................. 22

7.3 pre-installation(Seal bearing fitting clearance) .......................................... 26

8. (Stator coil water circuit pump pressure test) ................................................................. 27

9. flexible connector within terminal box ...................... 28

(Hand-lapped insulation surface of end winding & potential relocation tests) ...................................................... 28

10. ..................................................................................... 29

Check stator main lead terminalsneutral enclosure& lead bushing adapter............................................... 29

11. (Preinstall & check stator bracket) ........................................................................................ 30

11.1 ................................................................................................... 30

(Check the combination surface gap between Level face divides in and Vertical joint surface) ................... 30

11.2 (Bracket oil leakage test).............................................................................................. 32

11.3 (Check the insulation of bearing seat) ..................................................................... 33

12. (Check of contact surface between bearing and bearing seat ) ....................................... 33

12.1 600MW (For 600MW tilling pad bearing) ....................................................... 33

12.2 660MW (For 660MW elliptical bearing) ......................................... 33

13. ........................................................................................................................ 34

(Water pump pressure test of cooler and installation of encloser) ......................................................................... 34

14. CG (The gap between Stator and rotor the size of CG) ................................. 3515. (Check rotor interturn fault monitoring) ......................................................... 36

16. ............................................................................................................ 38


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(Check swaying& run out of shaft and coupling face of rotor on EE & TE) ...................................................... 38

17. (Install blower shroud and stationary blades) ............................................. 39

18. (Install the air tight mount and check the insulate ) ............................................ 40

18.1 600MW (double rings for 600MW generator) ........................................................ 4018.2 660MW (single ring for 660MW generator) .............................................................. 43

19.(Check injection of sealant) .............................................................................................. 45

20. (Measure the gap between bearing and rotor shaft ) ............................................... 45

20.1 600MW ............................................................. 45

Gap between Upper half tilling pad bearing and shaft (For the bearing of 660MW ultra-critical generator) 45

20.2 660MW .................................................................................................... 45

Elliptical BearingFor the bearing of 660MW ultra-critical generator.................................................... 45

21. 600MW .......................................................................................................... 46

Floating oil ring inspection (for 600MW generator) ............................................................................................. 46

22. 660MW .................................................................................. 47

Gap between deflector oil ring and shaft(for 660MW ultra-critical generator) ..................................................... 47

23. ................................................................................................................................ 48

(Check related gap between top half bearing and top dowel) ................................................................................ 48

23.1 600MW (600MW supercritical) .......................................................................................... 48

23.2 660MW (660MW ultra-critical generator) .................................................................. 48

24. (check of double insulation leads) .................................................................................. 49

24.1 600MW ................................................................................................ 49

Check of double insulation leads (for 660 MW)............................................................................................ 49

24.2 660MW ............................................................................. 50Wire of Turbine side Potential measurements(for 660MW ultra supercritical) ............................................ 50

25. (The related gap between end shield and rotor shaft) ................................................. 50

25.1 600MW (600MW supercritical).................................................................................................. 51

25.2 660MW (660MW ultra-critical) .......................................................................................... 51

26. (Check & Assembly of cooler) ........................................................................................... 52

27 Before twice grouting (Alignment of Turbine and Generator. In

cold state.) .................................................................................................................................................... 52

28.(installation & inspection of ladder shims) ................................................................... 53

29. .......................................................................................................... 54

(Centering & Butt joint of Turbine and Generator) ............................................................................................... 54

30.(Generator foundation bolt installation & inspection) .......................................... 55

31 Before twice grouting .................................... 56

(Alignment of slip ring axis(exciter) and generator rotor) ..................................................................................... 56

31.1 (Slip Ring Axis) ........................................................................................................................ 56

31.2 (exciter) ..................................................................................................................................... 56

32 .......................................................................... 57

(Slip ring axis (Exciter) and generator rotor connect coupling (after twice alignment)) ....................................... 57

33. (Swing test of slip ring axis (exciter)) ............................................................. 58

34. ........................................................................................................................ 59(Bearing installation of Slip ring axis (Exciter)).................................................................................................... 59

34.1 (slip ring axis) ............................................................................................................................ 59


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34.2 (exciter) ..................................................................................................................................... 60

35. Installation of brush holders.................................................................................................... 60

36. (water circuit pump pressure test of exciter)......................................................... 61

37. (Installation of exciter grounding detection device) ................................................. 6238. (Electrical test of exciter) .................................................................................................. 62

39. (Stator winding DC test) ................................................................................................. 63

40. (Stator winding AC test) ......................................................................................................... 64

41.Take carefully inspection before Generator wind test .............................. 64

42. (Wind pressure test) ................................................................................................................ 67

................................................................................................................................................. 67

Part 4 Oil Water & Hydrogen system ................................................................................................................ 67

1. (hydrogen system)............................................................................................................................ 67

2. (oil system) .................................................................................................................................... 68

3. (water system) ................................................................................................................................ 68

4. (Site commissioning of the equipments manufacturers confirmation) ......... 70

5. specification of prevent seal oil into frame ..................................... 71

6. --........................................................................................................................... 73

Water system assembly installationinstallation of water pipes .......................................................................... 73

7. ................................................................................................................. 80

Attachments ofspecification of prevent seal oil into frame ........................................................................... 80


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600MW

Part 1 Open-case inspection

1. Check the packaging without damage, if the damaged boxes be found, it must be reported to the

company.

2. Check parts look no obvious bump against injury appearance, deformation, rust, according to the

actual situation reflected (recommended photos form).

3. Reflects the number of parts according to the number in the packing list.

4After open the important assembly parts case, must keep the parts inside storehouse. Requirements

of storage according to packaging.

(Signature by four parties: )

(Power plant Representative)

(Installation Company)

(Supervision Company)

TFA

(date)


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Part 2 key point of generators installation

f

Installation of Stator fame & seating plant

check thermometric elements

Test the insulation water manifold flange

Test the main insulation of the generator

Install terminal box

check rotor Water pressure test of stator coil

Install Hand-lapped insulation of end

winding connectors & flexible connector

check the size of Gland seal ring and gland

seat bracket

Preinstall & check stator bracket

check contact surface between bearing and

bearing seat


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Water pressure test of

stators cooler

Electric test of rotor

Install stators cooler Adjust detector of rotor winding

shorted turns

Generator Rotor Thread

check swaying& run out of shaft and

coupling face

Adjust generators magnetize center

Check gap between blower shroud and stationary

blades

Installation of bearing gland seal & oil seal

check the gap between bearing shaft and bearing

check the related gap between bearing and float oil

ring


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600MW

Check related gap between upper half bearing

and top dowel

Installation of double insulation leads

Second Centering of Turbine and

Generator

Twice grouting of generator

foundation

Centering & Butt joint of Turbine and

Generator

Centering of exciter and Generator

Twice grouting of slip ring axis

exciter foundation

Exciter (slip ring axis) and generators

rotor connect coupling

Swaying test


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600MW

Part 3 Generator body

1. Seating plates and stator emplacement

Requirements: Check whether the seating plates have wrong holes or not. Avoid wrong holes

when emplace the stator frame foot on seating plates. Exact data requires

according to installation guide & drawings.

(On-site inspection)

Attached photos

(Without exception within the visible parts of the stator

and the foreign body)

(Photo:inside the stator,end)

Signature by four parties




TFA

(date)

2. (Temperature measuring element check )

250V 1

Requirements: After the stator placed check all the DC resistance and AC resistance of all the

temperature sensor on the terminal row .Use the millimeter and 250V mugger,

Insulation resistance 1M.


Attached the test report)




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600MW



TFA

date

3. (Test the insulation water manifold pipe)500V 10

2500V 69#70#

71# 30K

Requirements: Use 500V megger , check the insulation of water manifold pipe, resistance 10

M( not post-cooling water).

Use 2500V special water megger, test the insulation of water manifold flange to

the ground.Requirements:No.069(Primary water pipe at T.E. ),No.070(Primary

water pipe at E.E.)No.071Water pipe at main lead box,after three points

parallel connection, the insulation 30K(post-cooling water).


) Attached the test report





TFA

date

4. (Check the three phases' main insulation of generator)

After the stator emplacement, open the transportation cover, and then check the three phases'

main insulation of generator.

ABC 2500V 1000 M1min

R60s/ R15s1.3; R600s/ R60s2

Requirements: Stator winding ABC use 2500V meggerrequire1000 M, Absorptions

R60s/ R15s1.3; Polarization index R600s/ R60s2.


(M)

Insulation resistances

Absorptions

Polarization indexR15s R60s R600s R60s/ R15s R600s/ R60s


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600MW

Attached the test report





TFA

date

5. (Terminal box installation) 0.05mm

6

Requirements: The bolts which connect stator and terminal box should installed tighten as

required, check joint surface clearance requirements 0.05mm. Inject sealant

after checked. Torque all bolts be tightened by drawing.Pay more attention to the

six main leads during terminal box installation






TFA

date

6. (Rotor check )6.1 (Check the elasticity & non-cylindrical degrees of rotor )

A BC

A phase to B phase C phase&

ground

B AC B phase to A phase C phase&

ground

C AC

C phase to A phase C phase&

ground


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(T.E.) (Unit)mm

No.

Measure

position

Measure items

Design

value

Tolerance

On-site

measure

value

1 D1

(Rotor journal diameter)

500

-0.063

2 D2 500

3 D3 500

4 D4 500

5 D5 500

6 D6 500

7

(elasticity degree of rotor)0.03

8

(Non-cylindrical degrees of rotor) 0.03

E.E. (Unit)mm

No.

Measure

position

Measure items

Design

value

Tolerance

On-site

measure

value

1 D1 500

2 D2 500


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600MW

3 D3

(Rotor journal diameter)

500

-0.0634 D4 500

5 D5 500

6 D6 500

7

(elasticity degree of rotor)

0.03

8

(Non-cylindrical degrees of rotor)

0.03






TFA

date

6.2(Rotor airtight test) 1.4MPa 2 0.02MPa/h 10

-5ml/s

Requirements1.4 MPa air test for 2 hours. ExpectationsLeakage 0.02MPa/h or halogenseveral leak detection 10-5ml/s no alarm for qualified.







TFA

date

6.3(Rotor electric test)a. 20 500V 10

2510M

b. GBT1029c.


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600MW

Requirementsa.Rotor insulation resistance: Rotor winding in the cold state (room temperature

is 20 ). Use the 500V megger to test. 10 minutes of insulation

resistance10M when the temperature is 25

b. Rotor DC resistance: use a bridge to measure the resistance. Resistance

tolerance according to "Factory test reports, test method according to

GBT1029 requirements with GB

c. The rotor with AC impedance: Test purpose to detect generator rotor winding

turn-to-turn without static and dynamic short-circuit fault.

Data Reference to "Factory test report".







TFA

date

7. (Check the seal bearing and seal bearing seat)

Note: The following items should be checked after the cases opened.

7.1 (Check the sealed bearing)aa.Check the level points face dislocation of the sealed bearings

0.025mm Requirementsthe junction plane dislocation and surface gap(The junction plane axial and

tangential dislocation 0.025mm)


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600MW

UW

The level points face dislocation of the sealed bearings and slots of bearings U&W

(Unit)mm

b(Gland seat's slot width)(Unit)mm

(Manufactory

Record)(Install Record)

EE

TE

EE

TE




(Supervision Company)TFA

U

LEFT

RIGHT

TE

EE

W

LEFT

RIGHT

TE

EE


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600MW

date

7.2(Check theseal bearing)aa. Seal bearing thickness (seal bearing on Hydrogen side, seal bearing on air side after assembly)

0.05mm

RequirementsAfter unpackingseal bearing, do the following checks before apart Thickness

change requirement 0.05mm.

(Unit)mm

Manufactory

Record

PositionA B C D E A1 B1 C1 D1 E1

thickness

TE

EE

(InstallationRecord)

thickness

TE

EE

b ()


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600MW

Seal bearing inside diameter (seal bearing on Hydrogen side, Gland seal bearing on air side after

assembly)

0.02mm

Requirements: Check diameter of seal bearing immediately after unpacking and before bolts on

half surface are not dismantled yet. max change 0.02mm.

(Unit)mm

PositionA-A1 B-B1 C-C1 D-D1 E-E1

(MR)

T.E.

E.E.

(IR)

T.E.

E.E.

c ()Misalignment and clearance check seal bearing on air side after assembly

0.025mm

Requirements: tolerance 0.025 mm

Note: After unpackingseal bearing, do the following check before apart.


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TFA

date

7.3 pre-installation(Seal bearing fitting clearance)

Requirements: Put Seal bearing on rotor for pre-installation, sealing seat and sealing bearing for

pre-instillation.

a double rings600MW 600MW supercritical Measure Position

mm

Design Value

mmActual Measure

T.E. E.E.

Radial

gaps

13

0.23~0.2814

15

16

Axial gaps

9

0.306~0.38510

11

12

b single ring660MW 660MW ultra-critical


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600MW

Measure Positionmm

Design Value

mmActual Measure

T.E. E.E.

Radial

gaps

13

0.34~0.3614

15

16

Axial gaps

9

0.21~0.2410

11

12





TFA

date

8. (Stator coil water circuit pump pressure test) 0.75MPa 8

63# 68#

RequirementsAfter the install flexible connector and insulation water pipe.Stator coil water pump

pressure test. 0.75Mpa for 8 hours, no leakage. The water in the coil must be

blown to dry immediately when the test finished, and the three-phase main

insulation be retested.No.63 THRU No.68 on the board need our engineer to

install, and then checked by Power plant Representative.

Water requirements of pure water


Attached test reports





TFA

date


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600MW

9. flexible connector within terminal box(Hand-lapped insulation surface of end winding & potential relocation tests)

3

RequirementsAll the bolts involved these installed parts need to tighten according to the

drawing.Make sure to meet the following three conditions before hand-insulation

aStator water pump pressure test is qualified

bStators temperature units inspection is qualified

cStators three phases insulations inspection is qualified

After the hand-insulation the test of potential relocation test should be done by user.

The method of Potential relocation of hand insulation test can be divided into positive connect and

reverse connect:

a 100

KV v

20KV 1000

a. Positive connects: wrap the aluminum foil outside the hand insulation of the end of the stator

winding. The DC high voltage is connected with the tested stator windings. Rated voltage is set for

the step-up generator. And an insulation bar of 100 M is pu t on the aluminum foil. Then the

to-ground voltage of each foil packet is measured by the digital voltmeter.

Requirements:

Rated voltage of the generator (KV) 20KV


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Potential relocation allowed (V) 1000V

b20KV 30

b. reverse connect: In each tin foil with high Voltage20KV, Winding end through uA meter

grounded, read mA meter values, Qualification requirements: lto 30uA.

Voltage

(leakage of the winding ends)

1 2 3 4 5 6







TFAdate

10.Check stator main lead terminalsneutral enclosure&lead bushing adapter

M30 40mm

6.5mm

Requirments:Involved in this part of the installation torque of all bolts must be tightened

according todrawing and

stop gasket

must do the insurance. Screw for pegging

CT should be screwed in lead box about 40mm and tightened by nuts. Neutral

enclosure should be only one grouded.Min of 6.5mm electrical clearance should be

maintained between metal parts of bus and metal studs.


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600MW


(Signature by four parties: )




TFA

(date)

11. (Preinstall & check stator bracket)11.1

(Check the combination surface gap between Level face divides in and Vertical joint

surface)

0.05mm

Requirements: check the contact areas with a thin ruler,which are between the up-down

bearing bracket and stator,the up-bearing bracket and down-bearing bracket.the

thin ruler of 0.05mm should not be allow to be slipped in.


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600MW

Level face divides in

Vertical joint surface

1. T.E. level face divides in (Unit)mmPosition

Item

Tolerance

maxOn-site measure value


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600MW

A1~A26

Measurement of bracket level

face divides in

0.05

2. T.E. vertical joint surface (Unit)mm

Position

Item

Tolerance

max

On-site measure value

1~14

Measurement of bracket vertical

joint surface

0.05

3. E.E. level face divides in (Unit)mm

Position

Item

Tolerance

max


A1~A26 Measurement of bracket level

face divides in

0.05

4. E.E. vertical joint surface (Unit)mm

Position

Item

Tolerance

max


1~14

Measurement of bracket vertical

joint surface

0.05





TFA

date

11.2 (Bracket oil leakage test)

Requirements: set the bracket vertical then check the bearing return oil chamber, sealing oil,

floating oil into the tubing on into the lubricating oil check each weld seams

cover whether there is oil leakage.







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Requirements

a 75%

100 0.02mm

0.1mm 50-60mm 100mm

Check the contact surface between sphere surface of bearing and bearing seat carefully,

make sure that contact areas 75% and the contact points should uniform distribution.

Oil feed hole should sealed 100%.Use feeler gauge to check the gap between bearing

and bearing seat , make sure that the contact surface around oil groove is required which

means feeler gauge can only put in 0,02mm in depth max. Use 0.01mm feeler gauge to

check the gap between bearing and bearing seat, the depth is 50-60mm, max 100mm.

b

Bearing color penetrant test

c 4 8

Scratch bottom half bearing at 4 and 8 oclock positions for transition scrape, according

drawing of Bearing.






TFA

date

13. (Water pump pressure test of cooler and installation of encloser)


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600MW

0.8MPa 2

RequirementsHydrogen water cooler must take water pump pressure test at 0.8Mpa 2 hours

separately. Make sure that no leakage of water or change of Pressure gauge. Pay

more attention to the different from EE and TE cooler encloser during installation:

EE side cooler encloser have two more internal arc pipes than TE side. Involved

in this part of the installation torque of all bolts must be tightened according to

drawing and stop gasket must do the insurance.







TFA

date

14. CG(The gap between Stator and rotor the size of CG)

(Unit):mm

Measure

point Position Drawing demand

MR

IR


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600MW

Signature by four parties(Power plant Representative)



TFA

date15. (Check rotor interturn fault monitoring)

90

Requirements: After the Generator Rotor Thread in, rotor interturn fault monitoring must be

Vertical to Rotor

From T.E. to E.E.

up

0.76mm

gap with the pointthe difference

0.76mm on

average

down

left

right

From E.E. to T.E.

up

0.76mm

gap with the point

the difference

0.76mm on

average

down

left

right

From

Stator TE end side to the TE

rotor coupling surface(CG

size)


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90


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TFA

date

16. (Check swaying& run out of shaft and coupling face of rotor on EE & TE)

0.03mm 0.02mm

Requirements: swaying 0.03Run out of shaft and coupling face 0.02mm

T.E. (Unit)mm

E.E.

(Unit)mm

No.

Measure

position

A B A-B C

1 1-5

2 2-6

3 3-7

4 4-8

5 5-1

6 6-2

7 7-3

8 8-4

swaying Run out of shaft and

coupling face

No.

Measure

position

A B A-B C

1 1-5

2 2-6

3 3-7

4 4-8


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TFA

date

17. (Install blower shroud and stationary blades)

Requirements: Involved in this part of the installation torque of all bolts must be tightened

according to drawing and stop gasket must do the insurance.

T.E. (Unit)mm

No.

Measure

position

Design Value

MR

IR

1 A 2.29~2.44

2 B 2.29~2.44

5 5-1

6 6-2

7 7-3

8 8-4

swaying Run out of shaft and

coupling face


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3 C 1.85~2

4 D 1.85~2

E.E.

No.

Measure

position

Design Value

MR

IR

1 A 2.29~2.44

2 B 2.29~2.44

3 C 1.85~2

4 D 1.85~2





TFA

date

18. (Install the air tight mount and check the insulate )



18.1 600MW(double rings for 600MW generator)18.1.1

(The gap between oil block of bottom half of gland seal bracket and shaft)


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600MW

Measure position

mm

Design value

mm

Installation record

TE(down)

0.102~0.152

TE(left)

0.7~0.807

TE(right)

0.7~0.807

EE(down)

0.102~0.152

EE(left)

0.7~0.807

EE(right)

0.7~0.807

18.1.2 ( Check the insulation between bracket and bottom half of gland seal bracket)

No.

Items

Design

Value

On-site value

1

Insulation Between E.E. Bracket

and Bottom Half of Seal Bracket

1M

2

Insulation Between T.E. Bracket

and Bottom Half of Seal Bracket

1M

3

Insulation Between E.E. Bracket

and Buffer Ring

1M

18.1.3 (The gap around airtight bearing)

(The radial gap between airtight bearing and shaft)

mm

Design Value

mm

IR

T.E. 0.23~0.28

E.E. 0.23~0.28

The axial gap between mount and airtight bearing

mm

Design Value

mm

IR

T.E. 0.306~0.385

E.E. 0.306~0.385

0.1mm


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Note: The difference between seal ring brackets EE&TE. Seal ring bracket could be moved easily

if the installation is ok. Insulating sleeve bolts which to fasten the Seal ring bracket must be

0.1mm lower than the surface of middle ring.

18.1.4(The gap between oil block of top half of gland seal bracket and shaft)

Measure position

mm

Design Value

mm

IR

T.E. Up

1.289~1.462

T.E. Down

0.102~0.152

T.E. Left

0.7~0.807

T.E. Right

0.7~0.807

E.E. Up

1.289~1.462

E.E. Down

0.102~0.152

E.E. Left

0.7~0.807

E.E. Right

0.7~0.807

18.1.5 (Check insulation between stator bracket and gland sealbracket)

No.

Item

Design Value

On-site Measure

Value

1

Insulation Between

E.E.Bracket and Seal Bracket

1M

2

Insulation Between

T.E.Bracket and Seal Bracket

1M

Signature by four parties(Power plant Representative)



TFAdate


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600MW

18.2.2 (Insulation between bracket and inside oil deflection)

No.

Item

Design Value

Actual Measure1

Insulation Between

E.E.Bracket and Inside Oil

Deflection

1M

2

Insulation Between

T.E.Bracket and Inside Oil

Deflection

1M

18.2.3(The gap around airtight bearing)Radial gaps

mm

Design Value

mm

IR

T.E. 0.34~0.36

E.E. 0.34~0.36

Axial gaps

mm

Design Value

mm

IR

T.E. 0.21~0.24

E.E. 0.21~0.24

0.1mm

Note: The difference between seal ring brackets EE&TE. Seal ring bracket could be moved easily

if the installation is ok. Insulating sleeve bolts which to fasten the Seal ring bracket must

be 0.1mm lower than the surface of middle ring.

18.2.4 (Check insulation between stator bracket and gland sealbracket)

No.

Item

Design Value

Actual Measure

1

Insulation Between

E.E.Bracket and Seal Bracket

1M

2

Insulation Between

T.E.Bracket and Seal Bracket

1M


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No.

Items

(mm)

Design Value

(mm)

Measure Value

1

Gap between bearing and

shaft(T.E.Left)

1~1.04

2


shaft(T.E.Right)

1~1.04

3


shaft(T.E.Top)

0.6~0.735

4

Gap between bearing andshaft(E.E.Left)

1~1.04

5


shaft(E.E.Right)

1~1.04

6


shaft(E.E.Top)

0.6~0.735





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21. 600MWFloating oil ring inspection (for 600MW generator)

0.25-0.5mm.


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Requirement: Gaps between 0.25-0.5mm.






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22.660MWGap between deflector oil ring and shaft(for 660MW ultra-critical generator)

Measure Item

(mm)

Design Value

(mm)

Measure Value

T.E.

(mm)

Measure Value

E.E.

Gap between Deflector

oil ring and shaft

top

0.3-0.44

bottom

0.10

left

0.2-0.27

right

0.2-0.27


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23. (Check related gap between top half bearing and top dowel)



23.1 600MW(600MW supercritical)

(Related gap)0.127~0.381mm






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23.2 660MW(660MW ultra-critical generator)


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(Related gap)0.3~0.4mm






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24. (check of double insulation leads)24.1 600MW

Check of double insulation leads (for 660 MW)

250V

Requirement: all stop gaskets must do the insurance.Assembly the parts according to drawings,

then check each insulation test point, by using the 250V mega meter.

(No. & corresponding leading single wires)

(Design value)

(Measured value)

1

buffer ring

1M

2

bearing key

1M

3

bearing stop dowel(combined from twoorigins)

1M


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4 insulated

bearing seat(buffer pad left hand side)

1M

5 insulated

bearing seat(buffer pad right hand side)

1 M

6

bearing oil seal

1 M





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date

24.2660MWWire of Turbine side Potential measurements(for 660MW ultra supercritical)

250V

Requirement: All stop gaskets must do the insurance. Assembly the parts according to drawings,

then check each insulation test point, by using the 250V mega meter.

No

Design

Actual Measure

T.E.

Actual Measure

E.E.

1

Insulation between seal bracket

and ground

1 M

2

Insulation between bearing and

bearing bracket

1 M

3

Insulation between bearing and

bearing bracket

1 M





TFA

date25. (The related gap between end shield and rotor shaft)


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25.1 600MW(600MW supercritical)

(Measure position)

mm

(Design value)

mm

(Install record)

(ET top) 1.29-1.46

(ET bottom) 0.10-0.15

(ET left) 0.7-0.8

(ET right) 0.7-0.8

(EE top) 1.29-1.46

(EE bottom) 0.10-0.15

(EE left) 0.7-0.8(EE right) 0.7-0.8

25.2 660MW(660MW ultra-critical)

(Measure position)

mm

(Design value)

mm

(Install record)

(ET top) 0.65-0.73

(ET bottom) 0.10-0.15

(ET left) 0.375-0.44(ET right) 0.375-0.44

(EE top) 0.65-0.73

(EE bottom) 0.10-0.15

(EE left) 0.375-0.44

(EE right) 0.375-0.44






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26. (Check & Assembly of cooler)

Requirements:Appropriate grinding according to the manufacturer records. Involved in this part

of the installation torque of all bolts must be tightened according to drawing and stop

gasket must do the insurance.

1

4 2

3

cooler

1 2 3 4

T.E.left

T.E.right

E.E.left

E.E.right





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27 Before twice grouting(Alignment of Turbine and Generator. In cold state.)

(According to shafting drawings offered by Turbine company)

Note: Only use flat shims for aiming the center before twice grouting. No using ladder

shims.

(cooler)

Positioning block


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A1~A4B1~B4C1~C4D1~D4,E1~E4

Note:When installing,record the thickness of each shim A1~A4B1~B4C1~C4D1~D4,E1~E4

according to the drawings under.Fill in the the corresponding box.

On-site inspection:





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date

29.(Centering & Butt joint of Turbine and Generator)

According to shafting drawings offered by Turbine company.

10 1

Note: Check the rotors insulation resistance against ground before connect coupling.Expected value 10M1M


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On-site inspection:





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31 Before twice grouting(Alignment of slip ring axis(exciter) and generator rotor)

31.1 (Slip Ring Axis)

Item

mm

Design Value

IR

concentricity0.05

under shed0.06~0.08

parallelism

0.12

Bearing seat's vertical

alignment to rotor

0.127

swaying0.05





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31.2 (exciter)


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Item

mm

Design Value

IR

concentricity

0.05

under shed0.100.125

parallelism0.078

Bearing seat's vertical

alignment to rotor 0.127

swaying0.05





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date

32(Slip ring axis (Exciter) and generator rotor connect coupling (after twice alignment))

On-site inspection

( Attached The Report)





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date


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33. (Swing test of slip ring axis (exciter))1660~1930NM0.05

1795 135 1660 1930

Requirements: Bolt torque 1660~1930NM, swaying 0.05.The purpose of using the different

torques to fix the bolt in order to adjust the sway within requirement tolerance.

PS: In order to adjust swaying tolerance the torque within 135 NM.Which means after the

adjustMIN torque 1660 NMMAX torque 1930 NM.



Measure position

A

A meter

B

B meter

A-B

A-B

C

C meter

1----5

2----6

3----7

4----85----1

6----2

7----3

8----4

1----5

=A-Bmax-(A-B)min/2=

Coupling face out of=A-Bmax-(A-B)min/2=

Circular run out


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date

34. (Bearing installation of Slip ring axis (Exciter))

34.1(slip ring axis)


according to drawing and stop gasket must do the insurance. check whetherfloat oil ring could be moved smoothly after installation.Gaps reqirements

according to table below.

Measure items

mm

Design value

mm

Actual value

Gap between half upper

bearing bracket and shaft

0.20~0.25

Interference fitness between

first half bearing and

bearing seat

0~0.05

0.10mm0.05mmunitmm

Requirements :Gaps between slip ring axis and Oil Deflection:bottom gap requirement

0.01mm,left and right gap requirement0.05mm

No

Measure position

Measure items

Actual value


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requirements: Involved in this part of the installation torque of all bolts must be tightened

stop gasket must do the insurance. The distance between the bottom of

the brush holder and the surface of collecting-ring is no more than

5mm,which is shown on the drawing, other parts of the brush holderexcept carbon brush can not contact with the surface of collecting-ring.

Details according to drawings.

(Measured value)(Signature by four parties)




TFA

(date)

36. (water circuit pump pressure test of exciter) 0.8Mpa 2

RequirementsKeep the pressure at 0.8Mpa in 2 hours and the check value of Pressure gauge is

stable. No leakage of the exciter cooler.

(On-site inspection)Attached the test report


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37. (Installation of exciter grounding detection device) 3mm 1.5~2.3mm

5.125.2390

RequirementsDistance between Steel Spring washer and Solenoid is 3mm,distance between

carbon brushs copper piece and rotor shaft is 1.5~2.3mm(after the carbon

brushs copper was bending by force ).pay a attention to the elasticity of carbon

brushs copper piece At the install stage. Grounding carbon brushs drawing NO.

5.125.2390






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date

38. (Electrical test of exciter)1. 500V 10 2510M

Exciters rotor coil Electrical test, use the megger at 500V for 10Min, and the insulation

resistance 10M at the temperature of 25.

2.

The test should be done before exciter rotor connected with generator.

a) (DC resistance)

Measure the Armature winding of main exciter, exciter winding and stator winding resistance

of Pilot exciter at the cold state.

b) (Insulation resistance)

1000V


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Take overall cleanliness inspection before generator sealing. Owner shall fill the inspection form to

our company.

1

On-site inspection record (0ffered by power plant)

2

Take photos of key parts (etc)

Stator ends & Inside terminal box (include circuit ring)

3

2011T01

To From C/c Date2011-3-14Corp Page1Fax Or Ret No021-.64633745Tel Subject

1

2

3


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021-64633745 021-64620738

---029To From Shanghai generator worksC/c DateCorp Page1Fax Or Ret No021-64633745Tel SubjectStrengthen the control of generator cleanliness

Power Plant

Thank you for using our generator equipment,

We would be delighted to serve you.Recently one of our customers didnt take strict control of cleanliness duringinstallation, which leads to great damage to the generator. During accidentinspection we found metal remains inside terminal box. In view of this situation, weremind all customers which are under installing and running take great attention tothis issuer

1. Installation process, half year and one year Maintenance must be strictlyaccording to rules, and supervision to strengthen self-control.2. make sure there are no metal remains or other debris in the stator and terminal3. Cleanliness inspection should take under strict regualtations.All parties should

take part in the inspection and signature for recognition .

Please reply when received

Thanks & Regards!Power plant: signature: date:

Ret No 021-64633745 or 021-64620738 Receiver Hai Bing Zhang or Feng Wei Thanks


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42. (Wind pressure test)

RequirementsThe test should operate after the Stator winding AC/DC test. Make sure that all

the pipes which connected the generator are finished.Gland oil system is run.

0.31MPa 24h,

1.7m/24h

Requirements: Use the dry and clean Compressed air. Use pressure gauge which pressure level

is 0.31MPa. Test time 24h. If the air leakage not greater than 1.7m / 24h then the

test is qualified.


Attached the test report)





TFA

date

Part 4 Oil Water & Hydrogen system

1. (hydrogen system)1) 7 3

2 1

2)

Note 1Hydrogen leakage system includes 7 detector devices. Three of seven located at shell

of three main lead enclosed bus. Two of seven located at shell of center point

enclosed bus, Remains on each side of EE and TE Lubricating oil pipes.

2Pay attention to the hydrogen system pipes; check if the hydrogen pipes lowest points


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have drain pipes or leakage detector device. Make sure that all the pipes connected

with leakage detector devices are installation with decline, and the horizontal pipe

must be downward-sloping. Recorded all the details


( 7 attached photos take photoes for seven detector points)

(Signature by four parties)




TFA

(date)

2. (oil system)1

2

3 27-49

4

5

Note1Install oil system pipes correctly. Make sure that the pipes connected hydrogen

side turn oil tank is downward-sloping Check to make sure2Oil flushing is

according to regulation. The quality of Seal Oil must be do the rigorous testing

before it run into the bearings3pay more attention to the temperature of seal oil the

temperature arrange from 27to 494Before seal oil system put into use, open

the bracket of hydrogen oil tank for inspection. Check the Hydrogen return oil tank

cleanliness and the float valves is work smoothly. 5Install the defoaming tank

alarm system and put into operation as soon as possible,.






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attach water & oil quality test reports.





TFA

date

4.(Site commissioning of the equipments manufacturers confirmation)

The device name

Equipments are

adjust completed or

not

factory

representatives

power plant

date

Hydrogenoilwater system

Radiofrequency apparatus

Hydrogen gas dryers

Thermal insulation device

Leaking hydrogen monitor

Humidity Monitor

Hydrogen purity meter

Hydrogen cycling fan

Excitation systems

Exciting transformer

Leakage protector


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Seal oil temperature (keep oil temperature) , Advice power plant

owner to adjust temperature of generator operation oil as low as possible which

according to the condition of vibration of generator.

2.

Check liquid leakage detection device have oil leakage phenomenon. If find there

much oil leakage phenomenon, must ask power plant owner stop operation and find

result.

(on-site inspection)______________________________





TFA

6. --Water system assembly installationinstallation of water pipes

a. X Z

0.302.375 3.902.0166

38x3 1.5

X Z 5

4

a. Inspections whether the stator cooling water pipes which connect stator main lead terminals

(position X) and bottom of TE side of water manifold pipe (position Z) are installed according to

the drawing of turbine generator flange interface 0.302.375 and stator cooling water system


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3.902.0166.(the diameter ofoutlet cooling water pipers connects terminal box must be 38x3, the

diameter of the elbow 1.5 diameter of straight pipe. The lengths of the pipes which connect

position X to position Z must be 5m and the use of elbow must be 4 pics)

b.

Operating parameters of stator cooling water

55 m3/h

Rated flow of Stator winding cooling water55 m3/h

44 m3/h80%

Low alarm of Stator winding cooling water44 m3/h80% of rated flow

38.5 m3/h70%

Low-low alarm of Low alarm of Stator winding cooling water(protection of without

water ) 38.5 m3/h70%of rated flow

DCS (attached photos of DCS )

c

Exhaust the air inside the Stator winding before run the generator

To prevent parallel rings gas blocking, take measures to exhaust the air inside the Stator

winding system during stator winding system flooding water. The Details according to the manual

book of stator cooling water system operation reference to second section of chapter one.

Strict accordance with the requirements of manual book only in that way can prevent the gas

blocking. All the measures you take to prevent the gas blocking which according to the

manual book not only used for run a new generator but also for either generator which have

let the cooling water in to the stator winding should take the measures to exhaust the air


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7. Attachments ofspecification of prevent seal oil into frame


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660MW Generator

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