BHEL GUIDE: HYDRO GENERATORS

SL.NO. DESCRIPTION PAGE

NO.
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 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

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 embedment 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 FOUNDATIONS: STATOR/LOWER BRACKET

1.1. 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.

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. AUXILIARIES

1. Unit control board.

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, punching 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 manufacturer’s instructions
either in service bay or in the place of installation.

1.1. PREPARATION

• Transport wound sectors of stator to power house service bay and place them on
raised platform or supports.
• Check core and winding for mechanical damage if any and take corrective action.
• Clean and debur stator joining flanges, megger the stator winding to ascertain,
winding healthiness.
• 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.
1.2. 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.
• Support stator sector on screw jacks to avoid its tilting, also arrange for a temporary
holding arrangement.
• 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.
• Use leatheroid or CAF packing between the core at the joints as specified in the
drawing.
• Install dowels and fasteners of joint flanges and complete tightening of fastners.
• Install dowel of stator frame and foundation plate.
• 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.
• Finally assemble two halves together, install dowels, fasteners and complete
tightening checking of joints.
• Check elevation of stator on the upper machined flange and correct if need be.
• Check and correct horizontality of stator frame by adjusting taper wedges or adding
or removing the packers installed underneath it.
• Check magnetic axis of stator core with respect to turbine flange top is as per design
requirement.
• Position piano wire 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).
• Check stator core diameter (ID) as per requirements of FQA. (Refer Sketch No.1).
• Position, foundation plates of stator with respect to stator frame. Install dowels and
fasteners.
• 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.
• Complete checking insulation resistance testing, dry out HV testing of winding as per
technical instructions/standards.
• Paint stator end winding with redgel coat (refer instruction for painting issued by
manufacturer).
• Complete painting of stator core and winding as per guide lines of drawing.
• Remove temporary platforms, installed for the purpose of winding.

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. ROTOR

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

• Shaft
• Rotor spider
• Rotor rim
• Poles and their inter connections
• Current carrying leads
• Brake track
• Rotor fan
• 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.

• Rotor spider is bolted type.

• Shaft is dispatched 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

• 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.
• Prepare spider, shaft collar mating surfaces, conical studs for assembly.
• Lift spider fairly levelled, with the aid of crane, lower it on the shaft collar.
• Complete tightening of collar studs.
• Depending on construction, sometimes 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.
• Shaft with the bush fitted on it is lowered and made to rest on thrust bearing.
• Assembly work of rim, poles etc. with spider is done on erection bay, except the hot
wedging of rim keys. (Refer tech. requirement).
• Spider assembly is lowered over shaft, placed in the stator bore to complete assembly of
spider with rotor bush.
• Rim keys are fitted, heating of rim, upto a temperature of 900C is carried out to complete
hot wedging.

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.

• 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 shaft, place spider
on support block with screw jacks, at the assembly place.
• 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.
• Check and regulate position of spider, to make wedge bars vertical.
• Check slot surfaces in the wedge bar of spider, for rim keys are true.
• Check the distance between the slots in the wedge bar along the top and bottom end are
as per drawing.
• Check the keys for trueness and insert in the slots of wedge bars, while 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.
• In case brake segments are bolted to rim, align brake segments along the periphery of
wedge bars as shown in the drawing.
• Check that, all segments are at the same elevation.

2.3.2 PREPARATION OF RIM SEGMENTS AND ASSEMBLY

• Remove preservatives and clean laminations.

• Eliminate burrs, dents, by using a electric sander.
• 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.
• 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.

2.3.3 ASSEMBLY OF RIM

• Arrange brake segments on outer periphery of wedge bar leveled and supported on screw
jacks.
• 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.
• Position reamed bars on technological studs to continue with further laying of rim
segments by staggering each layer of punching as indicated in drawing.
• Complete laying of balance two layers of chamfered and three to four layers of plane
segments.
• 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 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.
• 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.

• Complete assembly of rim, including final pressing and tightening of technological stud
nuts as per drawing requirements.
• Remove technological stud one by one and carry out broaching of holes if necessary and
install permanent studs.
• 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.
• After final pressing and tightening, lock the upper and lower nuts by tack welding with rim
at one edge as indicated in drawing.
• Lock nuts in brake segments by tack welding the nut with projected portion of stud.
• Check studs in the brake segments do not project beyond the surface of the brake
segments.
• 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.
• NOTE: Wedging is done uniformly by controlling concentricity of rim, by ensuring uniform
gap, between the rim and wedge bar.
• 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
a) Using strip heaters.
b) Passing DC through pole coils if assembly has been completed.
• When the temperature of the rim attains a value indicated drawing, drive the keys by
required amount as marked.
• 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.
• 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.

NOTES:

a) 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.
b) Paint the rotor red with red oxide primer.
 c) 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.
d) Rim building pins should not be too slack, otherwise built rim may become egg shaped.

2.4 MOUNTING OF POLES ON ROTOR RIM/DISC

2.4.1 PREPARATION OF POLES FOR MOUNTING

• Check poles do not carry mechanical damage.

• Check that pole core laminations at face are in one plane. File the protruding laminations,
if any. Check surface by knife edge.
• 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).
• Blow the poles with dry and clean compressed air (Refer sketch 3).
• Check insulation resistance of pole coils to ascertain healthiness of insulation.
• 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.
• 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.
• Carry out inter turn insulation test/HV testing of poles as specified by the manufacturer.
• Prepare layout of poles and select poles such that poles having equal weight are installed
diametrically opposite.
• Check contact surfaces of pole keys and form pair of keys.
• 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.
• 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.
• 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.
• 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.
• Straighten and clean pole end connections, join and complete pole to pole connections by
soldering and carry out clamping as per drawing.
• Assemble flexible connections of damper winding.
• 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.
• 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.
• Clean the rotor with dry and clean compressed air and paint the rotor with enamel as
indicated in the drawing.

3. LOWER BRACKET

3.1 PREPARATION AND ASSEMBLY

• Remove preservatives from all machine surfaces.

• Check machined surface for mechanical damages and eliminate defects, if any, clean inner
surface of oil bath.
• Check and prepare and assemble foundation plates, with bracket arms as applicable.

3.2 OIL COOLERS

• 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.

3.3 BRAKE JACK

• Complete overhauling of brake jacks, replace defective seals where necessary.

• Fabricate a device for hydraulic testing of brake jacks and test the jacks as called in
drawing.
• 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.
• Assemble jacks on lower bracket arms at their respective locations with packers as
indicated in drawing.
• Complete laying of pressure, return oil pipes to the possible extent and pipe clamping
arrangements.
• In case of umbrella machine complete assembly of thrust bearing (Ref preparation and
assembly of thrust bearing).
• 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 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.
• Lift the lower bracket fairly leveled, lower in stator bore to rest foundation plates on
wedges/packers.
• 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.
• Flange elevation is taken for setting elevation of bracket and other assemblies of
generator.
• 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.
• Complete tightening of foundation stud nuts and check that the elevation and centering
of lower bracket are within 0.5mm.
• Adjust vertical height of jacks with reference to turbine flange by adding or removing the
appropriate shims placed underneath jacks. (Refer relevant drgs).
• Complete laying, welding, cleaning of balance brake jack piping.
• 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 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.
• Fix crane hook/hooks to lifting device.
• Lift the rotor by 300-400mm, check and ensure braking of lifting hoist.
• Lift the rotor such that flange bottom surface is accessible for cleaning and checking.
• Prepare the flange surface and check it with knife edge to ensure trueness of surface,
prepare rubber O-seal.
• Check and ensure that the generator shaft flange passes through the lower bracket bore.
• Advice turbine section to keep the turbine flange prepared.
• 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.

• 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.
• Lift the rotor slightly to correct centering of rotor flange with respect to generator flange.
After centering within +1.00mm, release the crane.
• Insert the coupling stud/bolt and complete the assembly and tightening of studs to
required stress.
• Install tubular shaft; slipring etc.

4. UPPER BRACKET

4.1 Upper bracket assembly comprises of a central part housing thrust and guide bearings
(suspended type) or guide bearing alone (semi umbrella type) or in case of no bearings
depending on design this will support the generator flooring, slipring stator any parts
and generator dome.

4.2 PRE-ERECTION

• Remove preservatives, clean the surfaces and prepare the central part and arms for
assembly in line with general guidelines.
• 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.
• Carry out locking of fasteners as indicated in drawing.
• Carry out trial assembly of chequered plating to complete the welding of strips, drilling
and threading of chequered plate fixing arrangement.
• Check and prove threads of radial jacks and carry out assembly with upper bracket arms.
(If provided).

4.3 ERECTION

• Prepare mating surfaces of upper bracket arms and stator frame.

• Install upper bracket, adjust its elevation level and carry out its centering with respect to
shaft and assembly with stator frame.
• Centering tolerance 0.1 to 0.2mm radial.
• Levelling tolerance 0.02mm/mt.
• Carry out installation and tightening of bracket arms holding down bolts.
• Carry out reaming and dowelling of bracket arms with stator frame only after the
completion of alignment and centering of the machine.

5. THRUST BEARING

5.1 Thrust bearings are of two types in common use:

• Thrust bearing pivoted type.
• Thrust bearing spring mattress type.

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) Oil coolers.
h) Instrumentation.

• PREPARATION OF ASSEMBLY
- Remove preservative from all components of thrust bearing. Check for mechanical
damage and eliminate if any.
- 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.
- 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.
- Check, TSD, RTD fittings in pad segments to ensure correctness of threads and depth
of pockets.
- Check and prove bedding of thrust bearing pad segments, Babbitt surface with mirror
surface of runner disc. Complete leading-edge preparation, as called in drawing (Refer
instruction for bedding of pads).
- 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.
NOTE: Check eccentricity of IB ports and correct if necessary.
- Check that insulation on runner disc is intact and it’s gluing with disc is free of
hollowness.

• ASSEMBLY AND LOADING OF THRUST BEARING (PIVOTED TYPE)

- 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.
- 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.
- 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.
- 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).
- Assemble thrust bolts, supports and thrust bearing pad segments.
NOTE: All thrust bolts, supports and thrust bearing pad segments.
- 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.
- 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.
- Carry out heating of thrust collar, in a temperature controlled heating chamber to
attain required expansion.
 - 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.
- 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.
- When the temperature of collar is about 400C, check the fitting of locking ring and
install it.
- Lift the runner disc, by crane and assemble with thrust collar along with insulating
dowels and fasteners, release crane after completing assembly.
- Install thrust bearing pads and load thrust bearing as given below:

Lift the rotor jack by 2-3mm, by operating the jacking pump, so that, mechanical lock
of jacks is released. On ascertaining de-locking of jacks, release the pressure of jacking
system to lower the rotor so that TB disc with collar sits on thrust pads.

- Clean oil bath interior thoroughly and assemble it on upper bracket with its sealing
element.
- Complete laying, welding, clamping of HS lubrication pipes as per drawing.
- 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:

a) Spring plate.
b) Spring assembly.
c) Thrust bearing pad segments.
d) Runner disc.
e) Thrust collar and locking.
f) Oil bath and HS lubrication system.
g) Oil coolers.

• Preparation and assembly

- Remove preservatives from all components of thrust bearing. Check for mechanical
damage and rectify if found.
- Measure height of each spring assembly and segregate spring assemblies according to
height in the step of 0.1mm.
- Make sets of spring assemblies for all thrust pad segments such that average height
of spring assemblies for each pad is similar.
- 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.
- Assemble pad stops.
- Arrange spring assemblies on the spring plate for each pad segment such that shorter
spring assemblies are at inner periphery.
- 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.
- 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).
- Assemble anchor plates as per drawing. Ensure the clearance between pin and pad
stop, anchor plates is as per drawing.
- 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

PREPARATION
- Remove preservatives and thoroughly clean thrust collar.
- Clean and check the shaft surface at the place of thrust collar assembly.
- Check suitability of thrust collar ring by mounting it in the groove of shaft.
- Check shaft surface, inner bore of thrust collar for trueness and for mechanical damage
if any. Correct the damages by suitable means.
- Check pressure oil feeding passages of thrust collar are clear and the spiral groove on
inner surface of collar does not carry sharp edges.

ASSEMBLY
- Lift collar fairly leveled.
- Coat the conical surface of shaft and collar by clean heavy medium turbine oil/molysulf
grease.
- Mount thrust collar on shaft, coinciding relative match marks of shaft and collar.
- 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.
- 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.
- Release the pressure of both, hydraulic pressing device and oil injectors and remove
pressing device.
- Insert thrust collar locking ring in the shaft groove above thrust collar and assemble
retaining ring or key as the case may be.
- 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.
- Assemble thrust bearing runner disc with insulated dowels and bolts.
- Release lower bracket jacks to rest the collar on thrust pads.

5.2 HS LUBRICATION PUMP

• Install the pumping unit and control gear as per drawing.

• Complete grouting of pump foundation and control gear.
 • Complete cable laying, termination and connection of power source.
• Assemble micro filter on high-pressure line as per drawing, check low pressure filter
on pump suction is installed.
• Fill oil in thrust bearing oil bath about 50mm above the suction pipe of pump.
• Start the pump for a short interval to ensure correct direction of rotation.
• After ascertaining correct direction of pump rotation start and run pump continuously.
• Test oil pipe line as per drawing.
• Cover oil cooler windows temporarily to avoid entry of foreign matters in the oil.
• Carry out hydraulic testing of oil coolers as called in drawing to ensure healthiness of
cooling tubes.
• Prepare machines for checking alignment.

NOTES:

a) Plug in type oil coolers are installed only when the final boxing of boaring is done.
b) External cooling system coolers are installed on availability of foundation from
customer.
c) 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.

5.3 LEVELLING OF THRUST BEARING: PREPARATION FOR CHECKING ALIGNMENT

• 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).
• 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.
• Any lifting or lowering is carried out by adding or withdrawal of packers under the
bracket arm, supporting thrust bearing.
• 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.

5.4 LEVELLING OF THRUST BEARING/ROTOR

• Assemble support ring segments of guide bearing maintaining a clear gap between
bearing journal and ring segments.
• 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.
• Fix a level on rotor spider top for levelling the bearing by the rotation of the rotor.
• 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.
 • 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 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.
• 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.
• Transfer the above points on generator guide bearings and flange. Number them in
same order as that of runner disc.
• 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.
• 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.
• 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 indicators to
zero.
• 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.
• 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.
• 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 X-AXIS Y-AXIS

Angle of rotation 0 90 180 270 360 0 90 180 270 360
Gen. Guide bearing
nearest to thrust
bearing (a).
Gen. Shaft flange (b).
(b - a) = c.

• 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.
• The stainless-steel shims are graded with steps in a wedge form covering not less than
2/3 radial depth of thrust collar.
 • Maximum height of wedge is calculated as
𝐷𝑟 ∗ 𝑤𝐹
ℎ=
2 ∗ 𝐿𝐹
- Where ‘h’ is the maximum height of wedge in mm.
- ‘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 ∗ 𝛥
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.

• Allowable deviation during centering of generator shaft with respect to turbine shaft
for the process of coupling, turbine and generator.

Type of Deviation Nomenclature Allowable deviation in

mm.
Shift of generator shaft axis with respect to A 0.10mm
turbine shaft.
Non parallelity of the mating surfaces of the B
flanges at the shaft diameters (mm).

Up to 600 0.020
Up to 1000 0.025
Up to 1500 0.030

• 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).

5.6 ASSEMBLY AND ALIGNMENT OF SLIP RING

• Clean the slip ring by blowing clean, dry compressed air.

• 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.
• 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.
• While carrying combined alignment of turbine and generator shaft, record dial gauge
readings in the format given below:
 Level X-Axis Y-Axis
Angle of rotor 0 90 180 270 360 0 90 180 270 360
rotation in
Slip ring (a).

Generator guide
bearing (b).

(a-b) = c.

• 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 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.
• Allowable tolerance of run out = 0.10mm.

5.8 CENTERING OF STATOR, UPPER AND LOWER BRACKETS

• 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.
• Maximum variation in air gap may be + 5%. However, in unavoidable circumstances
variance up to 10% at few locations could be allowed.
• 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.
• Check stator and rotor form and plot the formation as indicated in fig. 1, 2, 3 for rotor,
stator and super imposition of rotor on stator. Procedure for checking is described here
under.

5.9 STATOR FORM

• Take one pole as datum (in this illustration pole no.1).

• Locate the center of this pole opposite to 20 (i.e. equal to no. of poles) equidistant
peripheral positions of stator and measure the air gap at both top and bottom of this
datum pole.
• Rake average of top and bottom air gap.
• 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 Air gap Air gap Average Loc. Pt. On Air gap Air gap Average
Stator. Top Bottom. Air gap Stator. Top. Bottom. Air gap
in mm. in mm.
01 22.16 22.20 22.18 11 23.15 23.00 23.07
02 22.50 22.80 22.65 12 22.50 23.10 22.80
03 22.55 23.40 22.97 13 22.60 22.60 22.60
04 22.30 22.25 22.77 14 22.00 22.65 22.33
05 22.40 23.45 22.92 15 22.55 22.80 22.68
06 22.20 22.70 22.45 16 22.70 22.80 22.75
07 22.66 22.30 22.45 17 23.15 22.95 23.05
08 22.75 22.60 22.67 18 23.20 22.85 23.02
09 23.00 22.80 22.90 19 23.00 22.25 22.62
10 22.85 22.85 22.85 20 22.55 22.40 22.48

5.10 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.
• 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).
• Plot the rotor form as shown in Fig.1 with respect to above reference circle.

EXAMPLE
ROTOR FORM. DATUM - UP STREAM MARK.

Pole Air gap Air gap Average Pole Air gap Air gap Average
No. Top Bottom Air gap. No. Top Bottom Air gap.
01 22.28 22.08 22.18 11 22.78 22.63 22.70
02 22.38 22.28 22.33 12 22.83 22.53 22.68
03 22.63 22.33 22.48 13 22.68 22.28 22.48
04 22.78 22.33 22.56 14 22.69 22.53 22.61
05 22.93 22.58 22.76 15 23.18 22.93 22.05
06 23.08 22.53 22.80 16 23.38 23.13 23.25
07 22.18 22.28 22.75 17 23.28 23.55 23.41
08 22.73 22.68 22.71 18 22.78 23.23 23.00
09 22.78 22.68 22.73 19 22.48 22.63 22.55
10 22.88 22.58 22.73 20 22.28 22.28 22.28

5.11 MAGNETIC CENTERING OF STATOR AND ROTOR OF VERTICAL

HYDROGENERATORS.

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.
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.
• Decide the location of pole on the rim on the basis of its type and weight.
• Measure the pole body length (Refer fig.2) (Dimension ‘P’).
• Measure the stacked rim height on the corresponding pole seating face (at the center of
this face) (Refer fig.1 Dimension ‘R’).
• 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.
• Mark the centerline of the pole with white paint on the pole face.
• Assemble the pole, using modified pole stop.
• 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.

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.

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.

• Release foundation of lower bracket and stator for grouting.

• Complete drilling, reaming and dowelling of upper and lower brackets, lock the dowels as
called in drawing.
• 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.
• 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. AIR AND OIL COOLER

6.1 AIR COOLERS

• Carry out hydraulic testing of air coolers as per technical instructions to prove the
healthiness of cooler tubes and joints.
• Assemble air coolers on stator frame and complete welding of supports etc.
• Carry out the hydraulic testing of control valves as recommended and assemble them with
coolers.
• Install air release plugs and drain valves on coolers as called in drawing.

6.2 OIL COOLERS

• Repeat step-1 of 6.1

• Assemble coolers on oil baths of guide and thrust bearings.
• Check cleaning of oil pipes and assemble them.
• Complete laying, tack welding of water, oil and air pipe lines and fix clamping
arrangements.
• Dismantle pipes for final welding, cleaning and hydraulic testing as called in drawing.
• Install pipes with supports and clamping arrangement as per drawing.

7. ASSEMBLY OF PERMANENT MAGNET GENERATOR STATOR

• Clean stator by blowing dry compressed air.

• Check stator winding for absence of mechanical damage.
• Check healthiness of winding insulation with 500V megger.
• Carry out testing of stator and rotor as called in technical requirements.
• 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. ASSEMBLY OF BRUSH ROCKER WITH SLIP RING

• 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.
• 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.
• Check and ensure that 3-4mm clearance is maintained between the brush holder and slip
ring friction face.
• Carry out bedding of brushes with friction surface of slip ring.
9. EXCITATION SYSTEM

• Install excitation panels as called in drawing.

• Assemble excitation transformer with the frame.
• Check and assemble the loose components, received along with the equipment.
• Complete cable laying and termination of control cables (customer scope).
• Complete laying and termination of power/control cables of BHEL scope.
• Check the test excitation system in accordance with test schedule of manufacturer.
• Arrange and connect separate temporary power source for testing of equipment during
commissioning.
NOTE: Temporary power source is removed and restored to main source of power house once the
commissioning tests are over.
• After switching the set in to the system, adjust the limiters of various organs.

10. BOXING OF BEARINGS

10.1 UPPER GUIDE BEARING

• Clean bearing housing thoroughly by dry compressed air.

• Check bearing skirt surface for trueness.
• 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.
• Clean pads, assemble and clamp with shaft by wedges to ascertain the packing desired to
maintain the drawing clearances.
NOTE: While clamping the pads on bearing skirt it may be ensured that the shaft does not get
displaced.
• 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.
NOTE: Bedding of taper wedge is ensured with U blocks before assembly.
• Install TSD, RTDs and complete clamping, dressing of TSD, RTDs leads and cover the
housing temporarily.
• 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.
• 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).

10.2 GENERATOR LOWER GUIDE BEARING ASSEMBLY

• Release clamping and remove the four bearing pads, placed for clamping.
• Ensure all bearing components are thoroughly cleaned.
• Clean bearing housing by blowing compressed air.
• Install bearing pad supporting segments, maintaining clearance between journal face and
rings as called in drawing.
• Check bearing journal face for trueness.
• 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.
• 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.
• 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.
• Assemble inner tank of generator LGB with sealing element.
• Install VGB bearing earthing brush and connect the leads.
• 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.
10.3 THRUST BEARING.

• Clean bearing housing thoroughly and blow compressed air.

• Install TSD, RTD level gauges relay, oil contamination detector etc.
• Complete dressing and clamping of TSD, RTD leads.
• 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.
• Remove temporary covers of oil cooler windows and assemble oil coolers with sealing
elements. Alternately the blind flanges in case of external cooling arrangement.
• 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.
• 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.

11. UNIT CONTROL BOARD

• Install unit control boards on the channel frame.

• Check and ensure they are secured to frame firmly and vertical.
• Check that all the relays and other components are in place as per scheme.
• 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 component, relays etc.

12. EXTERNAL LP OIL LUBRICATION SYSTEM

• Carry out hydraulic testing of coolers and control valves.

• Install coolers, pumps, filters, control panels etc. as per project drawing.
• Complete laying and tack welding of pipes.
• Complete installation of fixtures and clamping of pipes.
• Dismantle the pipes for completing welding and cleaning.
• Carry out acid cleaning and hydraulic testing of pipes as called in drawing.
• Install pipes and clamping arrangements with supports etc.
• Carry out laying and termination of power and control cable.
• 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.

NOTES:
a) Oil leakage is not permitted.
b) Check and ensure functioning flow indicator.

13. BRAKE JACK SYSTEM

• Install brake jack panel.

• Carry out laying and welding clamping of air pipes between pressure reducer and brake
panel.
• Carry out laying and termination of control cables.
• Check operation of components installed in the brake panel in line with requirement.
• Clean air pipes and test the pipes for leakages (air leakage is not permitted).
• Adjust pressure reducing valve to deliver the air pressure, recommended for braking
operation.
• 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.

14. FIRE EXTINGUISHING SYSTEM

• Carry out installation of fire extinguishing equipment in accordance with manufacturer’s

instructions.
• Complete laying of control cables and test the equipment.
• Ensure that system id ready duly commissioned before the stator voltage build up.

15. 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.
• Installed chequered plating, railings etc.

A. PREPARATION OF HYDRO GENERATOR FOR STARTING AND COMMISSIONING

• Prepare the hydro generator set for the first starting and its speeding to rated speed.
• 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.
• 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.
• 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.
• 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.
• Checks that all cover plates are closed tightly.
• Check that all the thermal indicators are installed at the required places and all
instruments are functioning normally.
• 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.
• Check that water circulation is normal through the air coolers and oil coolers of thrust and
guide bearings.
• 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.
• When oil temperature is
• Check that fire extinguishing system in the generator functions normally.
• Blow the brakes and check their working with compressed air at required pressure.
• Jack the rotor on brake/jack for lubricating the thrust bearing pads. If HS lubrication
system is not called at the design.
• Ensure that generator excitation system is switched off.
• Start the hydro set and maintain it at low speed and make sure that 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. Place of measurement Admissible vibrations in mm.

Speed up to Speed up to 375 750 RPM.
100 RPM 187.5 RPM.
01 Bracket with built in 0.18 0.15 0.10 0.07
guide bearing.
02 Commutator and slip 0.3 0.3 0.3 0.3
rings.
03 Shaft in the zone of ---- 0.3 0.3 0.3 0.3
--------
04 Shaft in the zone of
In the limit of guide bearing gap.
guide bearing.

Vibrations in the brackets are measured in vertical and horizontal directions and at all other
places in the radial direction.

• 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.
• 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 500°C and 750°C 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.
• Carry out over speed test of machine and confirm operation of overspeed mechanical
device, initiating impulse for closing of machine.

B. DRYING OF THE GENERATOR

• Dry out of the generator may be carried as recommended by adopting either of the
following methods:
- By short circuit current.
- By ventilation losses.
- By direct current.

• General conditions which act as guideline in all the methods of drying are given below:
- 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 50 0C. 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.
- 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.
- 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 75 0C
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 75 0C is obtained by

multiplying the above figure with a factor Kt tabled below:

C 75 70 60 50 40 30 20 10
Kt 1 1.2 1.8 2.6 3.9 5.5 8.6 12

- Value of the absorption coefficient of insulation 𝑅60/𝑅15 Should not be less than 1.3
at winding temperatures from 10-300C.
- 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.
• 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
up to the rated value.
• For drying by ventilation losses method, the generator is run at the rated speed or even
at higher speed (up to 1.1 times the rated speed) without excitation and without water
supply to the air coolers.
• 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 breakdown 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.

• Carry out HV testing of stator and rotor windings in accordance with manufacturer’s
instructions.

C. 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 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.

• Technical report on tests:

- Test the hydro generator and prepare the following final documents.
- 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.
- 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.
- Record sheet of generator no load characteristics.
- Record sheet of generator short circuit characteristics.
- Record sheet of resistance measurements of all the main and pilot exciter windings in
cold state.
- Record sheet of exciter no load characteristics.
- 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.
 - 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.
- Record sheet of temperature in various parts of the generator during the run test at
rated load.
- Record sheet of stable temperatures in the thrust bearing and guide bearings.
- 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.

D. PUTTING INTO OPERATION

• 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.
• 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) Check the brush rockers of the commutators.
k) Below the slip rings with compressed air as during starting period the most intensive
wear of the brushes is observed.
l) Check the brush rocker of the slip ring.
m) Check the oil level in oil bath.
n) Remove all the troubles and the defects.
• 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.

E. 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.

I. 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.

II. 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.
- Pads are drawn from stores only, when required at site for assembly during
checking of alignment and boxing up.

F. INSTRUCTION ON CLEANING OF OIL PIPES

• 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.
• After mechanical cleaning, inspect the pipes for thorough cleaning and allow to dry.
• For removal of rust/corrosive particles, pipe will be cleaned by acid pickling process.
• Pipes shall be filled with 5% dilute HCL/H2SO4 solution by plugging one end of the pipes.
• 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.
• Inspect the pipes for cleanliness if needed cleaning process may be repeated.
• Carry out flushing of pipes with turbine oil after ensuring proper cleaning and dryness
of pipes.
• Having accomplished oil flushing, close both ends of pipes to avoid entry of foreign
matters.