generator rotor insertion drg 4.5-9913-0002 0410e2p_kran

8/10/2019 Generator Rotor Insertion Drg 4.5-9913-0002 0410e2P_Kran

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View Z

Z

End wall

segment TE

Bearing pedestal TEBearing cover

Bearing pedestal TEBase

Intermediate frame TE

EE

TE

This description explains how to remove the rotor from a 2-pole generator. Depending on the actualdesign, certain details might be different from those included in this description. Because of this, it isnecessary to contact the manufacturer in order to obtain further information. The exploded view shows anexample of a generator with laterally arranged cooling units and outbound lines on top.

Stator

Rotor

Cover

Sheet: 01/14

Cover

Base frameIntermediate frame TELabyrinth ring TE

Shaft bushing TE

Bearing

pedestal TEBase

Bearing pedestal TEBearing cover

Shaft bushing EE

Labyinth ringEE

Intermediate frame EE

Bearing pedestalEE

Base

Bearing pedestalEE

Bearing cover

Air guide baffle ring TE

Exciter set

Air guide baffle ring EE

CoolerExploded view

End wall segment EE

Rotor

End wall segment TE

CoverEnd wall segment TE End wall segment EE

TE EE

Bearing

pedestal TEBase

Shaft bushing TE

Bearingpedestal EE

Base

Exciter - Set

Bearingpedestal EE

Bearing coverBearing

pedestal TEBearing cover

Longitudinalsection

Intermediate frame EEIntermediate frame TE

Stator

Shaft bushing EE

Rotor

Turbogenerator Revision

Energy Sector Rotor removal and installation4.5-9913-0002/1 0410


2/14



Sheet: 02/14

Step 1: Safety precautions

Only skilled personnel is authorized to perform any disassembly or assembly work on the generator. The accident prevention regulations applicable on the construction site must be complied with.

The valid safety regulations must be observed when working on platforms.

Lifting equipment and hitching gear must be of a size and strength adequate for the required loads. Round slings must be used as hitching gears.

Suitable measures must be used to secure the rotor against unintended movements during every step, as well as after the rotor is in its resting position after having been removed.

Removed parts must be safely stored outside marked walkways. They must be stored in such a way that it is impossible for the parts to unintentionally change position or topple over.

Do not store any tools or component parts in the area of base frame and generator windings.

Suitable aids or materials (e.g., foil) must be used to protect uncovered openings from soiling and to prevent foreign particles from entering them.

Openings must be adequately marked and blocked in line with operator protection requirements.

Equipment required:

In the Siemens scope of delivery following items are included:1 x slide plate2 x sliding shoe1 x slide pedestal2 x set-down troughSlide grease

The generator operator has to provide:- gantry crane and hitching gears (sling equipment for jacking the rotor)- chain or rope hoists- securing devices- foil- wire reels- water level- height-levelling supports

Not all of the tools and equipment included in this description are part of the standard scope ofsupply included with the generator. The agreed scope of supply must be checked. If necessary,various parts, tools, and equipment may have to be ordered separately.

Front wall segment TE

TE EE

Bearingpedestal TE

Base

Shaft bushing TE

Bearingpedestal EE

Base

Bearingpedestal EE

Bearing cover

RotorStator

Bearingpedestal TE

Bearing cover

Intermediate frame TE Intermediate frame EEShaft bushing EE

Cover

Exciter set

End wall segment EE


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4/14

Screweyelets

Special tool

The picture shows a section of the

special tool used for removing rotors.The brackets that can be seen in thebackground are mounted on thebottom of the sliding block withhexagonal bolts. The sliding block isplaced in the area of the bearing ornear the bearing in the direction ofthe generator center. The coppershim is inserted in between in orderto protect the bearing.

Sliding block,U-brackets

Sliding block,

Base

Sliding shoe

Copper shim

for bearing



Sheet: 04/14

Step 3: Disengaging the rotor on the turbine end

The rotor must be disengaged on the turbine end.

The drive-side coupling half must be jacked apart from the coupling recess with the help of the original clamping bolts.

It might be necessary to remove the fan blades on both rotor ends as preparation for the following step.

The fan blades must be removed if the fans diameter is greater than the inner diameter of the rotor retaining ring or if the is the danger that the fan blades will interfere with the housing.The corresponding dimensions can be gathered from the Axial and radial rotor play specifications.

The blades must be removed according to the instructions made for design group 1345.

ESTE EE

Intermediate frame EEIntermediate frame TE

Stator Rotor

Bearingpedestal EE

Base

Bearingpedestal TE

Base

Bearingpedestal TE

Bearing cover

Bearingpedestal EE

Bearing cover


5/14

Caution!

The slide plate must be inserted carefully. Damage tothe rotor and stator must be prevented without fail.

The picture shows the slide plates required finalposition. The rotor has already been removed in thepicture.

Slide plate



Sheet: 05/14

Step 4: Insert the slide plate

Clean the slide plate, apply a thin film of slide grease to the top side, and wrap it in sheeting.

The slide plate, covered in foil, must be slid in through the generator gap between the rotor and stator, above the EE bearing. It must be placed centrally underneath the rotor by guiding it on both sides.

After this, the foil between the rotor and the slide plate must be removed.

TE EE

Slide plate, final position

Slide plate,Inserting position

Bearingpedestal TE

Base

Bearingpedestal EE

Base


RotorStator

Intermediate frame TE

Bearingpedestal TE

Bearing cover

Bearingpedestal TE

Bearing cover


6/14

1. Lifting

3. Lowering

Bearingpedestal TE

Base

2. Removal

Intermediate frame

TE in installationposition

Rotor

Supports adjustable

in height

Intermediate frame

TE in parkingpositionBase frame

Hitching gear



Sheet: 06/14

Step 5: Removing the intermediate frame on the turbine end (TE)

The first step is to release the TE bearings intermediate frame from the base frame. To do this, remove the bearing pedestal bolts and alignment pins from the base frame.

DANGER:

Danger of injury from heavy loads falling.The rotor must NOT be suspended from the suspension eyelets on the bearing cover.

After this, the hitching gears are attached to the rotor shaft near the bearing. The bearing is lifted a few millimeters with the intermediate frame + shaft still attached to it.

The goal behind this is to place thin rolls (welding wires) underneath the intermediate frame. These rolls are used as aids for transportation. Alternatively, a lubricated slide pad may be used.

Once these aids have been positioned, the bearing is lowered together with the intermediate frame. The intermediate frame must now be released from the bottom part of the TE bearing block.Remove the screws and dowel pins.

After this, the rotor must be lifted with the crane until the intermediate frame can move freely and can be pulled out from the side. The intermediate frame must be safely stored.

During the next step, the sliding shoe is inserted between the centrally aligned slide plate and the rotor, flush with the edge of the retaining ring.

Once the sliding shoe has been positioned, the rotor can be lowered until it is bearing on the sliding shoe.

Finally, the TE bearing is supported with the help of height-adjustable elements.

TE EE

Lifting

Slide plate, final position

Bearingpedestal TE

Base

RotorStator

Intermediate frame TE Sliding shoe

Gantry crane


7/14

View B

Disassembly

Hitching gearBearingpedestal TE

Bearing cover

Rotor

Caution!

If a hydraulic jack is used

instead of a crane, the jackmust be placed underneaththe coupling or between thebearing block and thecoupling. Insert suitablematerial for shaft protectionbetween shaft and jack (e.g.,copper or aluminum sheets).

Supports adjustable in height

Bearing

pedestal TEBase



Sheet: 07/14

Step 6: Removing the TE bearing cover and the top bearing shell

The TE bearing covers threaded connection must be completely disassembled.

The hitching gears are attached to the bearing covers eyelets. The bearing cover must be carefully lifted off.

The bearing cover is placed in its resting position with the crane. It must be safely put down on a suitable soft support pad (wood, rubber, or similar). The slinging ropes are removed.

The bearing shells screw couplings must be unscrewed. After this, the measuring cable for the bearing insulation monitoring system is removed and the top bearing shell is removed.

The bearing shell must be packed up and stored safely.

TS ES


B

Lifting

Stator RotorGantrycrane

Bearingpedestal EE

Base

Bearingpedestal TE

Bearing cover

Bearingpedestal EEBearing cover

Slide plate, finalpositionSupports adjustable in height Sliding shoe

Bearingpedestal EEBase


8/14

Hitching gear

Rotor withcoupling on the

turbine end

Bearingpedestal TE

Bearing cover

Bearingpedestal TE

Base

Support adjustable

in height

Bearing support



Sheet: 08/14

Step 7: Removing the lower bearing block section and the lower bearing shell on the turbine end (TE)

The shaft must be lifted by 0.1 to 0.3 mm on the turbine side. For this purpose, the hitching gears must be attached in the immediate vicinity of the bearing block. If the space available allows, the attachment

should be made on the side facing the fan hub. The high-pressure hose and the oil line for the jacking oil (if any) that are located underneath the bearing shell must be removed. The grounding cable must be removed.

Once the shaft is lifted, the lower bearing shell can be swiveled out.

After this, two eye bolts must be placed on the bottom of the TE bearing block. These must be placed diagonally opposite to each other.

Lower the rotor until the rotor rests on the slide shoe.

The hitching gears must be attached to the eyelets. After this, the height-adjustable support must be removed.

The lower bearing block section can now be lowered, removed sideways and safely stored.

TE EE

Lifting

Slide plate, finalpositionSliding shoe

Bearingpedestal TE

Base

RotorStatorGantry crane

Support adjustable in height


9/14

Slide pedestal Rotor Detail Z

Removal direction

Adapter plate



Sheet: 09/14

Step 8: Assembling the sliding block on the turbine end (TE) and the adapter plate on the exciter end (EE)

The sliding block must be assembled on the TE bearing point. In order to ensure that the bearing is protected, the assembly process must be carried out only while using the copper shims included in the scope of supply.

It is necessary to assemble the sliding block perpendicularly to the rotor axis. Use a water level to check the horizontal alignment.

The EE bearing must be held securely by the transportation securing device. Attach a rope sling to the bearing to pull out the rotor.

A rope hoist or a chain hoist must be used as the pull mechanism. This hoist must be attached to an appropriate and sufficiently stable anchor point.

As an alternative to this procedure, the rotor can be moved out from the coupling end (TE) with the help of hydraulic jacks or equivalent tools.

Before starting to pull out the rotor, it is necessary to remove the bolts with which the EE intermediate frame is bolted onto the base frame.

The crane is attached to the rotors exciter side with the use of suitable hitching gears (round slings). If the space available allows, the attachment should be made on the fan side, next to the bearing point.

It is necessary to position the crane perfectly perpendicular to (and above) the center of the rotor. The rotor must be carefully lifted until the EE bearing is no longer bearing a load.

TE EE

Slide plate, finalpositionSliding shoe

Stator Rotor

Z

Gantry crane

Slide

pedestalAdapter plate for

attaching the rope hoist

Bearingpedestal EE

Base

Bearingpedestal EE

Bearing cover

Intermediate frameEE


10/14

10 axial securing (divided)20 axial securing (divided)30 anti-rotation locks (shim between the shaft and the upper bearing shell in bothbearings)

Bearing transportationsecuring , Assembly

Drawing

Rotor

Bottom bearing shell

Top bearing shell

Separating joint



Sheet: 10/14

Step 9: Travel out the rotor (start)

The rotor is pulled out from the stator by exerting an axial pull while continuously guiding the crane.

The force required to pull out the rotor is equal to the frictional force that must be overcome. The latter can be approximated with FR= x FN. The normal force is calculated as follows: F N= F G= m x g.where m is the shaft mass that can be gathered from the dimension drawing text and g equals gravitational acceleration. For comparison purposes, bear in mind that the coefficient of static friction for steel

steel is = 0.15. If this value is used for the calculation, the result obtained is approximately the maximum force that the attachment point of the chain or wire rope used to pull out the rotor must hold.

A suitable anchor points must be selected according to this information. Since the slide plate is lubricated, the coefficient of friction will decrease significantly as soon as the rotor is moving.

In order to be able to transmit the axial tensile force onto the rotor, the EE bearing is fixed using thetransportation securing device.

As part of another step that has already been carried out, the rotor was lifted until the EE bearing was no longer bearing a load.

On the turbine end, the rotor is still bearing against the sliding shoe.

TE EE

Slide plate, Finalposition

Pulling direction

Sliding shoeSlide pedestal

Stator Rotor Gantrycrane

Adapter plate forattaching the rope

hoist

Bearingpedestal EE

Base

Bearingpedestal EE

Bearing cover



11/14



Sheet: 11/14

Step 10: Travel out the rotor (continued)

Continue to pull out the rotor until the sliding block comes into contact with the slide plate. When continuing the process, the sliding shoe will reach the leading edge of the slide plate on the exciter end, at which point it

can be removed.

No attachment points other than the points specified for attaching the axial pull mechanism must be used. In particular, no forces must be exerted on the slip rings while removing the rotor.

This also applies to the fan blades if they have been left on the rotor due to there being enough space available.

Moreover, it is absolutely necessary to ensure that the applied tensile forces act solely in an axial direction. Avoid any oblique or a skew pulling. Do not use the crane to carry out any axial pulling movements.

The rotor and stator components must not come into contact with each other while the rotor is being removed.

TE EE

Cover

Slide plate, finalposition


hoist

Pulling direction

Sliding shoeSlide pedestal

Stator Rotor Gantry crane

Bearingpedestal EE

Base

Bearingpedestal EE

Bearing cover


Other stages in the removal process

The sliding block comesinto contact with the slide

plate

Removal of thesliding shoe


12/14



Sheet: 12/14

Step 11: Placing of the rotor exciter end (EE) on the set-down trough

The rotor continues to be moved out until its attachment position (geometrical center of the rotor) is located outside the stator and the attachment area is freely accessible.

As soon as the position just described has been reached, the rotor body is placed down. A support trough must be used for this purpose. The trough must be placed near the EE retaining ring, centrally underthe rotor body. The height difference in relation to the hall floor must be compensated for with stable pad elements.

The support trough and pad elements must be placed in such a way that the required hitching gear rope spread for the following crane work can be achieved.

Basically, the rotor must be put down in such a way that a safe resting position that completely prevents any subsequent sliding or settling movements from occurring after the crane is removed is maintained.

The aids used for axially pulling the rotor can now be removed.

TE EE

Cover



hoist

Pulling direction

Gantry crane

Slidepedestal

Stator Rotor

Height-levellingsupports

Set-downtrough

Bearingpedestal EE

Base

Bearingpedestal EE

Bearing cover


Equipment of set-down trough

Body set-down trough

Set-downtrough

Bearing area


13/14

Caution!

A rotor, which is not suspended horizontally, will reduce the clearance inthe air gap needed when the rotor is moved out. This makes it possible forthe stator and rotor to come into contact with each other. Due to the largemass of the rotor, this contact will most probably result in heavy damage.Because of this, the rotor must be balanced with great care.

Alternative support Sufficient rope spreading



Sheet: 13/14

Step 12: Suspending the rotor horizontally

The hitching gears for the crane are placed approximately in the geometrical center of the rotor. Basically, the attachment points must be separated by a minimum of 600 mm.

The rotor must be slung in such a way that it is hanging in a horizontal position after being lifted. (Please observe the bearing weight.) A water level must be used in order toensure that a perfectly horizontal position is achieved. The rotors position is monitored by observing, from both bearing points, how the rotor lifts off during the crane lifting operation.Both ends must lift off their supports at the same time.

In order to be able to perform corrections, the rotor must be put down again in the same position. The correction is made by moving the slings by a few centimeters. They are moved

in the direction of the end that came up later than the other. This procedure must be repeated until the rotor is in a perfectly horizontal position.

It is absolutely necessary to ensure that the rotor is moved out as evenly as possible. Any sudden braking or accelerating movements by the crane can cause uncontrollable rotor movements,

which in turn can lead to damage to the stator and/or rotor.

As long as the rotor is still in the proximity of the stator, the rotor ends must be carefully guided by hand. This way, small displacements can be corrected.

TE EE

Cover


Gantrycrane

Slidepedestal

Stator Rotor


Set-downtrough

Rope spreading 600 mm

Bearingpedestal EE

Base

Alternativesupport

Bearingpedestal EE

Bearing cover

Intermediate frame EERubber pad


14/14



Sheet: 14/14

Step 13: Put down the rotor onto the final position

The rotor must be removed completely.

Once removed, the rotor must be safely put down on the support trough or in a shipping crate.

The rotor may not be supported on the cap and the slip rings. This also applies to the fan blades if they were left on the rotor.

These components must not be used for support or securing purposes either.

Once all work is done, a visual inspection of all gaps and openings must be carried out. Moreover, it must be ensured, once again, that all removed parts are safely stored.

These steps must be followed in the opposite order in order to install the rotor.

If it becomes necessary to disassemble the EE bearing, the procedure to be followed is the same as that for disassembling the bearing on the turbine side.

Caution!

If the EE bearing has to bedisassembled, the procedurefollowed is the same as that usedfor the bearing on the turbine end.

TS ES

Cover


Stator Gantrycrane

Rotor

Slidepedestal

Set-downtroughs


Bearingpedestal EE

Base


BearingPedestal EE

Rubber pad

generator rotor insertion drg 4.5-9913-0002 0410e2p_kran

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