Home

ALTERNATOR Service & Operating Manual

Contents

1. 1 Electrical insulation CAUTION WHEN INSULATED BEARING IS USED THE ACCESSORIES IN CONTACT WITH THE SHELL MUST BE ELECTRICALLY INSULATED TEMPERATURE SENSOR 18 SERVICE AND OPERATING MANUAL ALTERNATORS b Insulation check Single bearing machine Maintain the rotor at the drive end side to insulate it from the earth disconnect the coupling if not done Measure the insulating resistance between the shaft and the ground The insulation should be better than 0 1 MO measured under 500 V DC 1 Bearing shell 2 Insulating film 3 Bearing housing 4 Rotor 5 Insulating wedging Double bearing machine Maintain the rotor at the drive end side to insulate it from the earth disconnects the coupling Dismount the drive end bearing if not done Measure the insulating resistance between the shaft and the ground The insulation should be better than 0 1 MO measured under 500 V DC Installed shell accessories e g RTD must fit 0 1 MO measured under 500 V DC 2 4 2 Storage of Sleeve bearings machine a General points CAUTION FOR MINERAL OIL WE RECOMMEND THE USE OF TECTYL PRODUCTS FROM VALVOLINE GmbH SUCH AS TYPE 511 M FOR SYNTHETIC OIL WE RECOMMEND THE USE OF JELT 003400 SPRAY FROM ITW SPRAYTEC NOTE It is possible to start the machine up without removing the recommended protection agent b Short term storage When a sleeve bearing machine has to be s
2. 2 S I AT 4 Drive end Non drive end End shield O Ring End cover Non drive end shield Ball bearing 6226 C3 End cover End cover fixing screw Ball bearing 6226 C3 Bearing pre load washer oo NIJA End cover fixing screw SX ove 14 SERVICE AND OPERATING MANUAL ALTERNATORS 2 3 9 Anti friction bearing installation drawing following Machine type A52 2 Two bearings Bearing assembly Power plant Drive end Non Drive end 1 End cover 5 End shield 2 End cover fixing screw 6 End cover fixing screw 3 bearing 6232 MC3 7 End cover 4 End shield 8 Roller bearing NU 1028 MC3 Bearing assembly Marine Drive end Non Drive end 1 9 End shield 2 same as a power plant 10 End cover 3 11 End cover fixing screw 4 12 Bearing pre load spring 13 Ball bearing 6226 C3 14 O Ring SERVICE AND OPERATING MANUAL ALTERNATORS 2 3 9 Anti friction bearing installation drawing following Machines A53 and A54 av Aa e ZR P Drive end side 2 bearing machine Non drive end side 1 End shield 1 End shield 2 M12 stud 2 M12 stud 3 End cover 3 End cover 4 Shaft 4 Shaft 5 Ball bearing 6232 MC3 5 Ball bearing 6328 MC3 6 Spring LEROY SOMER SERVICE AND O
3. During the start up period check the temperature of the bearings The temperature should stay below 95 C and then drop down to the temperature normally recommended refer to the technical characteristics for Sleeve bearings in Section 1 orque Nm In case of oil oozing retighten the bearing fixing screws and the plugs to the recommended torque c Water cooled bearing type EFW start up data To identify your bearing characteristics refer to section 1 Proceed as for the self lubricated bearings and check the water flow of the cooler refer to the data contained in section 1 Water has to be filtered as per chapter 2 7 5 Sx eve d Oil circulation bearing with non accurate oil flow 4096 40 To identify your bearing characteristics refer to section 1 This chapter typically applies for standard bearings as for bearing types E Z K E Z Q The oil circulating bearings without Leroy Somer lubricating system are delivered with a breather an oil inlet flow regulating system The oil flow regulating system consists of an adjustable pressure reducing valve A a diaphragm NOTE The breather can be removed if it is proved that the bearing casing is in depressure regarding the atmosphere Fit a plug tin place of the breather The oil flow adjustment does not request high accuracy Do not feed the bearing with an oil flow higher than this one indicated in section 1 Ensure that the complete oil s
4. If no torque value is specified into the concerned chapter the following values can be used SERVICE AND OPERATING MANUAL ALTERNATORS Steel and copper alloy Plugs greasy thread Q nominal Torque Q nominal Torque inches inches mN G1 14 160 G1 230 G2 320 G2 v 500 6 2 3 Cleanliness The whole machine must be kept clean CAUTION ALL THE CLEANING PERIODS INDICATED IN THIS MANUAL MAY BE CHANGED INCREASED OR DECREASED ACCORDING TO SITE CONDITIONS The air inlet and air outlet surfaces must be maintained clean Louvers can be cleaned as per the filters refer to chapter 2 8 CAUTION DIRT ENTERING THE MACHINE MAY POLLUTE AND THUS REDUCE THE ELECTRICAL INSULATION The rotating diodes must be keep clean The rotating diodes cover has to be clean Refer to chapter 7 4 6 3 ELECTRICAL MAINTENANCE 6 3 1 MEASURING INSTRUMENTS a Instruments used AC voltmeter 0 600 Volts DC voltmeter 0 150 Volts 10E 3 to 10 ohms Megohmmeter 1 to 100 MOhms 500 Volts AC Ammeter 0 4500 DC Ammeter 0 150 Frequency meter 0 80 Hz Ohmmeter Low resistance can be measured by means of an appropriate ohmmeter or by using a Kelvin or Wheatstone bridge NOTE The identification of the equipment polarity may differ from one ammeter to another Sx eve b Identification of ohmmeter polarity In many testing procedures the ohmmeter polarity is important diode test
5. 1250 90 generator on concrete base Maximum levels for Turbines Turbines Max advised 4 5 hydraulic gaz steam overall mm s rms 2 2 ROTOR 2 2 1 Revolving field coil The revolving field coil comprises a stack of steel laminations stamped and cut to reproduce the indentation of the projecting poles The steel lamination stack up is terminated at each end with high conductivity electrical plates To enable parallel operation between machines and in order to ensure stability high electrical conductivity bars are inserted in holes crossing the poles from one side to the other These bars are welded with the stack end laminations in order to obtain a complete cage winding or LEBLANC dampening cage The winding B is placed around the pole A and is impregnated with epoxy resin class F machine insulation or with varnish class H machine insulation The winding is made of insulated flattened copper with high electrical conductivity The aluminium plates E are pressed against the winding acting as a heat dissipator and ensure excellent clamping of these coils Support bars C on each pole protect the end windings against the centrifugal force The revolving field coil is heated and shrunk onto the shaft 2 2 2 Excitation armature The excitation armature is constructed by stacking magnetic steel laminations These steel laminations are held in place
6. 6 PREVENTIVE MAINTENANCE 6 1 MAINTENANCE SCHEDULE The purpose of the general maintenance schedule below is to help establish the maintenance schedule particular to the installation The suggestions and recommendations are to be followed as closely as possible in order to maintain the machine efficiency and in order not to reduce the service life of the machine The maintenance operations are detailed in the chapters relative to the subjects concerned Example bearing see chapter 2 LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE Frequency of maintenance Days Hours Comments STATOR Winding temperature 1 Refer to 2 1 3 Bolts tightening 8000 1 Refer to 6 2 2 Cleaning air inlet and outlet 1000 Refer to 6 2 3 Insulation 8000 1 Refer to 6 3 2 Polarisation index 8000 1 Refer to 6 3 2 ROTOR Insulation 8000 1 Refer to 6 3 2 Cleaning diodes 8000 1 Refer to 7 4 Diodes tightening 8000 1 Refer to 2 2 4 Polarisation index 8000 1 Refer to 6 3 2 TERMINAL BOX Cleaning 8000 1 Regulator assembly 8000 1 Applicable if mounted in the terminal box Bolts tightening 8000 1 Refer to 6 2 2 SLEEVE BEARINGS Following technical specification in Section 1 Oil leak 1 Refer to 2 4 9 Oil temperature 1 Refer to 2 4 10 Oil level 1 Refer to 2 4 5 Oil drain 8000 16000 Following environment cleanness Refer to 2 4 5 Bolts tightening 8000 1 Refer to 2 4 ANTI FRICTION BEARINGS Re greasing Bearing
7. 2400 V 500 V DC 1000 V DC The measured value at 25 C must be over b lu 1 where Un the nominal voltage is in Kilovolts e g a generator of 6 6 KV must have an insulation resistance greater than 22 8 If the minimum insulation level is not reached dry the windings refer to chapter 7 5 Applied test voltage DC Field insulation measurement Disconnect the two ends of the field at the rotating diodes bridge The measurement should be taken between one end of the field winding and the earth The applied test voltage must be of 500 V DC The measured value must be over 20 MO If the minimum insulation level is not reached dry the windings refer to chapter 7 5 d Exciter insulation measurement CAUTION ALL ACCESSORIES MUST BE DISCONNECTED AVR EMC FILTER REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY THE ACCESSORIES TO DISCONNECT To measure the exciter field insulation disconnect the two ends of the exciter field at the terminals located on the top of the exciter To measure the exciter armature insulation disconnect the two ends of the exciter armature at the rotating diodes bridge The measurement should be taken between one end of the field winding and the earth The applied test voltage must be of 500 V DC The measured value must be over 20 MQ If the minimum insulation level is reached dry the windings refer to chapter 7 5 Polarization index The p
8. Oil inlet connection hole Connection hole for the oil sump temperature measurement Out Inlet cooling water ExWxx Oil cooler Type ExWxx Oil drain plug Metal tabs optional for EFZLx Oil outlet connection hole Oil outlet pipe Marking 67
9. PADS WILL CAUSE DAMAGE OF THE BEARING Both top and bottom halves of the shells are prepared for assembly 32 SERVICE AND OPERATING MANUAL ALTERNATORS 2 4 9 Oil leakage trouble shooting A bearing loss more than 4 drops of oil per day can be considered as a leakage Below this quantity this phenomenon is named oozing and is inherent to sleeve bearing technology An oil oozing need a periodic cleaning done by the end user without necessary corrective action Oil leakage can occur in the Sleeve bearings if certain measures are not taken a Self lubricating bearing Is the oil level correct see chapter 2 4 5 a Is the Sleeve bearing in decompression see chapter 2 4 5 d If the depression level is abnormal add a protective screen Is the leakage occurring around the parting line Clean the parting lines carefully with a solvent Apply a sealing compound refer to chapter 2 4 5 upon reassembly see chapter 2 4 6 b Cil circulation bearing All information and instructions concerning the self lubricating bearings apply Is the bearing oil flow correct for data refer to section 1 To adjust the oil flow refer to chapter 2 4 4 Is the Sleeve bearing under pressure To measure refer to chapter 2 4 5 This pressure most certainly comes from the oil return circuit Check the oil return circuit refer to chapter 2 4 3 The back pressure can often be eliminated by inserting a siphon effect on the o
10. absence of item B rings or in case of absence of groove on the shaft The length L shown on the diagram is stamped on the shaft end The side C represents the machined side of the bearing Remove the centring upper half shell upper B part Fit the electric machine to the drive system centering 45 SERVICE AND OPERATING MANUAL ALTERNATORS Remove the centering lower half shell lower B part Carry out the alignment by moving the machine assembly by means of lifting screws mounted on the brackets see alignment procedure below Use shims in order to obtain proper alignment The centering of the rotor in relation to the stator should be checked by measuring the concentricity of the shaft in relation to the bearing After having tightened the fastening screws completely the rotor stator alignment must be better than 0 05 mm axis to axis that is 0 1 mm reading Shafts alignment limits regarding the drive Check the axial positioning of the rotor in relation to the stator For this verification use an upturned half shell B part use of the symmetry of the L L part as shim The outside of the shim B part must be facing the groove machined on the shaft to within 1 mm Mount the cover plates by replacing the transportation half shells delivered separate with the machine to avoid foreign matter entering in the machine Make sure the closing plates are correctly centered in relation to t
11. and if there is likelihood of freezing the exchanger must be drained For an open machine it is recommended that the air inlet and outlet be closed Before starting the machine up again it will be necessary to carry out a start up inspection 4 2 INSTALLATION OF THE MACHINE 4 2 1 Fitting the coupling double bearing machine only The coupling must be balanced separately before assembly on the machine shaft Refer to the balancing instructions in chapter 2 2 5 The shrinking of the half coupling onto the electrical machine shaft end must be choose by the gen set manufacturer in such way as it should be removable for maintenance e g bearing change 43 SERVICE AND OPERATING MANUAL ALTERNATORS 4 2 2 Fitting the stator Four plates on the frame enable the unit to be fitted to a skid The fixing bolts must support the forces created by the static and dynamic loads The machine may be positioned by means of 4 dowel pins The dowel pins make later realignment easier The use of pins is optional The machine may be aligned through the use of 4 jacking screws These jacking screws allow the machine to be positioned according to the various axes 4 3 ELECTRIC MACHINE ALIGNMENT 4 3 1 Alignment general points a General points The alignment consist to obtain the driving shaft and the driven shaft coaxial when operating at the nominal conditions machine rotating at its operating temperature The mac
12. and shutdown alarm Nominal air inlet stator 5 K shutdown 80 Stator air outlet temperature Alarm points and shutdown alarm Nominal air inlet stator 35K shutdown Nominal air inlet stator 40K NOTE For an open drip proof machine the nominal air temperature entering the stator corresponds to the ambiant temperature Inhibit the stator air sensor safety alarm for few seconds during the machine start up NOTE For a water cooled machine CACW the nominal air entering the stator may be approximated as following Tair entering stator Twater entering cooler 15 K SERVICE AND OPERATING MANUAL ALTERNATORS d Stator vibration sensor This chapter concerns the setting of seismic probes For setting of proximity probes refer to the rotor The vibration level of the machines is directly linked to the duty and to the site characteristics We propose the following adjustment Vibration Alarm Site Highest Vibration level 50 Vibration Trip Vibration Alarm 50 do not pass over the values of the following chart The machines are engineered to be able to withstand the vibration level specified by the standard 1508528 9 and BS5000 3 Maximum levels for reciprocating Internal combustion engines Nominal speed Generator vibration level nominal conditions rpm Overall Any harmonics mm s rms s 1000 Hz 721 0 5 mm pp 1299 ud 1239 lt 9 mm s rm lt 720 8 200 Hz
13. bearing elevation due to the oil film The machine goes from point 1 to point 2 X NE X m D7 Anti horaire Counter Clock Wise Horaire Clock Wise 2 2 1 1 Clear diametrical clearance Oil film oil film thickness Attitude angle X 5 sem fim Cos 8 d Anti friction bearing shaft elevation Caused by thermal growth of the anti friction bearing 2 Y 0 01 mm 4 1 cold in rotation or stopped 2 hot in rotation or stopped 44 SERVICE AND OPERATING MANUAL ALTERNATORS 4 3 2 Two bearings machine alignment a machines without axial end play standard The alignment must take the tolerances of the coupling into account A misalignment acceptable by the coupling must not create an excess load on the bearing subsequent to the axial and radial stresses outside the tolerances of said bearing Shafts alignment limits to follow Angular error parallelism error To check the alignment there are different methods the double concentricity method is described in the alignment procedure chapter 4 3 4 b machines with axial end play The alignment must be performed using the same method as for a machine having no axial end play CAUTION THE ROTOR AXIAL LOCATION MUST BE CHECKED TO AVOID ANY MAGNETIC OFFSET CAUTION THE FAN THRUST OF THE ELECTRICAL MACHINE MUST BE HELD THROUGH THE COUPLING A
14. by rivets The excitation coil is keyed and heat shrunk onto the shaft The windings are enamelled copper wires class F insulation or H depending on the customer s request or size of the machine 2 2 3 Fan machines IC 0 A1 The synchronous machine is characterized by a self ventilation system A centrifugal fan is mounted between the revolving field coil and the front bearing Air intake is at the rear of the machine and the exhaust on the drive end side The fan consists of a hub which is keyed and heat shrunk onto the shaft The flange is made of welded steel attached to the hub with hexagonal head cap screws The ventilation effect is obtained through inclined blades The air is exhausted by centrifugation The air inlet and outlet must remains free during operation 2 2 4 Rotating diode bridge a General points The rectifier bridge comprising six diodes is placed at the rear of the machine The rotating bridge is made of glass fibre with a printed circuit to connect the diodes together This bridge is supplied with alternating current by the excitation armature and supplies direct current to the revolving field coil The diodes are protected against over voltage by rotating resistors or by varistors These resistors or varistors are mounted in parallel with the revolving field coil 10 SERVICE AND OPERATING MANUAL ALTERNATORS c Rotating rectifier test Carry out the test using a D C source a
15. cSt 40 VG 32 32 Vitam GF 32 VG 46 46 Degol CL46 VG 68 68 Degol CL 68 VG 32 31 5 Energol CS 32 VG 46 46 Energol CS 46 VG 68 68 Energol CS 68 VG 32 30 1 Mechanism LPS 32 VG 46 43 8 Mechanism LPS 46 VG 68 61 9 Mechanism LPS 68 VG 32 30 TERESSO 32 VG 46 43 TERESSO 46 VG 68 64 TERESSO 68 VG 32 30 D T E Oil Light VG 46 43 D T E Oil Medium VG 68 64 D T E Oil Heavy Medium VG 32 32 Tellus Oil 32 VG 46 46 Tellus Oil 46 VG 68 68 Tellus Oil 68 The only synthetic lubricant allowed are those one issued from the following list viscosit Type cSt 40C Summit SH 46 Summit SH 68 MOBIL 31 SHC 624 65 SHC 626 SHELL 32 Madrella Oil AS 32 Madrella Oil AS 68 f Oil sump capacity liters KLUBER 32 Summit SH 32 44 62 81 Summit SH 100 Madrella Oil AS 46 keen a 23 SERVICE AND OPERATING MANUAL ALTERNATORS g Sealing Compound Mineral oil On split surfaces it is possible to use following compounds never dry Loctite 128068 Hylomar M Marton Domsel Universal Dichtmasse 200 PU Reinz Dichtungs gmbh On split surfaces only do not use on floating labyrinth seals it is possible to use following compounds Terostat 9140 Teroson Blue silicone RTV n Loctite Blue RTV 6B Permatex Hi Temp RTV FAG 26B Permatex NOTE We do not recommend the use of sealing compound onto the floating labyrinth seals However for certain leakage type the use of Curyl T may help to solve
16. if several basic rules are followed c Parallel coupling CAUTION AN IMPROPER COUPLING CAN BE THE ORIGIN OF DAMAGES HIGH MECHANICAL OVERTORQUE AND OVER CURRENT At the coupling the following values must not be overpass Max frequency shift 0 1 Hz Max phase offset 10 electrical angle Max voltage phase neutral between machines at phase offset 0 5 96 of the nominal voltage In case of faulty coupling of mains fugitive disappearing inducing a faulty coupling over what it is acceptable by the generator ACEO cannot be considered as responsible of the damages 5 2 MECHANICAL START UP INSPECTION 5 2 0 General points a Alignment fixing prime mover The installation must comply with the manufacturer s installation rules for drive machine alignment mounting An arrow at the drive end end shield indicates the direction of rotation b Cooling The air inlet and exhaust must be unobstructed The cooling auxiliaries water circulation in the cooler etc must be operating c Lubrication Lubrication must be carried out anti friction bearings refer to chapter 2 3 Sleeve bearings refer to chapter 2 4 5 2 1 Vibrations The vibration measurement must be taken on each bearing in the three directions The measured levels must be lower than the specified values indicated in the chapter 2 1 8 Adjust the sensor as per chapter 2 1 3 53 SERVICE AND OPERATING MANUAL ALTERNATORS
17. mm Re mm 5 7 e Cil for sleeve bearing We do not have any special recommendation regarding any mineral oil manufacturer The used oil must comply with the requested viscosity refer to Section 1 For frequent cold starting lower than 15 witho ut oil sump heater please contact us A new oil viscosity may be advised Use a non foaming mineral oil without additives If an oil containing additives has to be used make sure that the supplier confirms the chemical compatibility of the oil and the lead anti friction properties CAUTION SYNTHETIC OILS MAY BE USED ONLY IF USED LUBRICANT ARE ISSUED FROM THE FOLLOWING LIST Since the synthetic lubricants are not standardized no guarantee can be given regarding their chemical and mechanical behavior Some synthetic lubricant may become acid and destroys bearing parts white metal oil ring sight indicator in a short time If synthetic oil has to be used during the first 2000 hours of use the lubricant should be checked at short intervals 22 LEROY SOMER SERVICE AND OPERATING MANUAL ALTERNATORS 2327 en 11 2011 0 Viscosity data for information x 850 775 700 625 550 500 450 400 365 315 280 240 205 175 140 115 85 60 40 20 10 x CST at 40 CST at 100C ISO VG B SAE J306c Transmissions C SAE J300d motors lt Co N SEMER Few examples of mineral oil viscosity viscosity Type ISO
18. still warm Impurities and residues will thus be removed Unscrew the oil drain plug 27 Release the lubricating oil and collect it NOTE If the lubricating oil contains unusual residues or is visibly changed eliminate the causes If necessary carry out an inspection Tighten the oil drain plug 27 using the following torque values u 8 36 oaei m Remove the screw plugs from the oil filler hole 4 21 SERVICE AND OPERATING MANUAL ALTERNATORS NOTE Make sure that no impurities get into the bearing Use a lubricant with the viscosity indicated on the bearing type plate Fill the lubricant through the oil filler hole 4 up to the middle point of the oil sight glass 23 The oil level limits are as follows minimum oil level bottom of the oil sight glass maximum oil level 2 3 the top of the oil sight glass NOTE Insufficient lubricant leads to temperature rises and thus to damage to the bearing Too much lubricant leads to leakage In the case of bearings lubricated by a loose oil ring too much lubricant could break the oil ring thus leading to damage to the bearing Tighten the screw plug into the oil filler hole 4 using the following torque values aos we ve zz a agem 20 20 eo d Pressure measurement of a Sleeve bearing housing The external environment of the electric machine may cause pressurizing or depressurizing of the Sleeve bearing and lead
19. the encountered issue CAUTION COMPOUND WITH SILICONE BASE CAN POLLUTE THE SYNTHETIC OIL BATH THE USE OF SILICONE BASE COMPOUND CAN BE DONE ONLY AFTER CHECKING COMPATIBILITY WITH OIL MANUFACTURER Sx eve 2 4 6 Dismantling a Tools and equipment The following tools and equipment are necessary Allan key set Wrenching key set Open jaw spanner set Feeler gauges up 0 05mm Caliper gauge Emery paper Sleeve scraper Lifting equipment Permanent sealing compound refer to chapter 2 4 5 Clean cloth Oil with the viscosity indicated see bearing type plate Detergents Liquid screw locking compound e g LOCTITE 242 Liquid sealing compound and Teflon tape DANGER BEFORE TRANSPORTING OR LIFTING CHECK IF THE EYE BOLTS ARE TIGHT INSECURE EYE BOLTS COULD RESULT IN THE BEARING BECOMING LOOSE BEFORE MOVING THE BEARING BY THE EYE BOLTS MAKE SURE THAT THE SPLIT LINE SCREWS ARE TIGHTENED OTHERWISE THE BOTTOM HALF OF THE BEARING COULD BECOME DETACHED MAKE SURE THAT THE EYE BOLTS ARE NOT EX POSED TO BENDING STRESS OTHERWISE THE BOLTS COULD BREAK Follow exactly the instructions for the use of the lifting equipment NOTE Make sure that the work place is clean Contamination and damage to the bearing especially of the running surfaces have a negative influence on the operating quality and could lead to premature damage Shut down the installation and ensure that any unintended operation
20. to oil leakage Example The oil return line of a circulation bearing opening directly into a diesel motor lower sump and allowing the housing back pressure to return to the bearing Example A vacuum generated by a coupling located too close the Sleeve bearing and acting as a fan The relative depression or pressure during operation must remain less than 5 mm of water column The relative pressure is the pressure difference existing between the bearing oil sump and the bearing outside measured close to the seals Pe external pressure close to the seal Pi bearing oil sump pressure Pm machine expansion chamber gain access as indicated by the arrow Pe Pi lt 50Pa A Pm Pi 50Pa Note 50Pa 5mmWC AS Field pressure measure Using a transparent tube as water column manometer Connect a flexible transparent tube to the upper part of the bearing Connect a pressure tap corresponding to the flexible tube used Install the pressure tap in place of the filling plug located on the top of the bearing housing Partially fill the pipe with water NOTE Be careful not to cause water to enter the bearing Measure the pressure or depression in millimeters of water column NOTE Given the low pressures measured to make the reading easier it is advised to incline the water column manometer by 5 7 diagram below A reading amplification of 10 is thus obtained 5mm 10
21. Bearing reassembly 2 3 5 Antifriction bearing protection devices 2 3 9 Antifriction bearing installation drawing 2 4 SLEEVE BEARINGS Plain 2 4 0 Description of horizontal Sleeve bearings a Physical description b Operating description of Self lubricating bearing c Operating description of Oil circulation bearing 2 4 1 Electrical insulation of Sleeve bearings a Illustration diagram of the insulating film b Insulation check 2 4 2 Storage of Sleeve bearings machine a General points b Short term storage c Long term storage 2 4 3 Oil circulation installation 2 4 4 Start up of Sleeve bearings a General check before start up b Self lubricating bearings start up data c Water cooled bearing type EFW start up data d Oil circulation bearing with non accurate oil flow 0 40 e Oil circulation bearing with accurate oil flow 5 10 f Inspection of Sleeve bearings at the end of start up 2 4 5 Maintenance of Sleeve bearings a Verification of oil level Temperature verification Oil draining Pressure measurement of a Sleeve bearing housing e Oil for sleeve bearing f Oil sump capacity g Sealing Compound b C d LEROY SOMER SERVICE AND OPERATING MANUAL ALTERNATORS 2 4 6 Dismantling a Tools and equipment b Lifting equipment c Dismantling of the shaft seal type 10 outboard side d Dismantling of the shaft seal type 20 outboard side Dismantling of the top half of the housing
22. ICE AND OPERATING MANUAL ALTERNATORS b Supply line To avoid excessive difficulties of cleaning and to allow an easy ducting it is necessary to use pipes requested for hydraulic duty After installation of the oil lines rinse the entire oil circuit in order to avoid dirt or impurities entering inside the bearing and its connections Rinse with washing oil It is important to remove the instrumentation for example pressure gauge flow meter during the rinsing operation to avoid any pollution NOTE Never leave the Sleeve bearing on the rinsing circuit as insoluble particles could enter the bearing and damage it The oil circulating bearings are equipped with an oil inlet pressure regulating system item 1 The delivered oil pressure has to be reduced by the bearing system before entering the bearing to get the correct oil flow refer to chapter 2 4 4 for start up A filtering unit must be installed on the supply system Refer to chapter 2 4 10 C gravity oil return CAUTION REMEMBER THAT THE OIL EXHAUSTED FROM THE BEARING GOES BACK TO THE TANK ONLY BY GRAVITY EFFECT CAUTION NOT TO FOLLOW THESE RULES MAY CAUSE HEAVY LEAKS BY BEARING SUMP OVERFLOW CAUTION ADVISES AND REQUEST DONE IN THIS CHAPTER DO NOT ALLOW THE INSTALLATOR TO COMPLETE BY ITS OWN CALCULATIONS NEEDED FOR A CORRECT OPERATION OF ITS SYSTEM Some bearing may have two exhaust In this case the both exhaust lies must be connected Because o
23. ING 7 5 0 General points All electric machines must be stored under dry conditions If a machine is placed in damp surroundings it must be dried before it is put into service Units operating intermittently or placed in areas with high temperature variations are exposed to dampness and must be dried very thoroughly if necessary 7 5 1 Drying method a General points During the drying operation measure the winding insulation and the polarization index each 4 hours To survey the insulation progress record the measured values and plot the obtained progress function of the time When the insulation value becomes constant the machine can be considered as dry When the resistance is constant it may be assumed that the machine is dry This operation may take up to 24 hours depending on the size of the machine and on the degree of dampness This may even take up to 72 hours CAUTION TAKE FIRE PREVENTION MEASURES DURING THE DRYING OF THE MACHINE ALL THE CONNECTIONS MUST BE TIGHTENED b Drying generator stop The procedure Drying generator in rotation should be preferred to the following one if it is possible to run the generator at its nominal speed Several thermometers must be positioned onto the winding and the temperature must not exceed 75 167 t f one of the thermometers exceeds this value immediately reduce the heating effect Dry by using an external source of heat for example heaters or lamps Le
24. LEROY SOMER ALTERNATOR Service amp Operating Manual SERVICE AND OPERATING MANUAL ALTERNATORS TABLE OF CONTENTS 1 GENERAL INFORMATION 1 1 INTRODUCTION 1 1 0 General points 1 1 1 Safety notes 1 1 2 Conditions of use a Generalities b Vibratory analysis 1 2 GENERAL DESCRIPTION 1 2 1 Generator 1 2 2 Excitation system 2 DESCRIPTION OF SUB ASSEMBLIES 2 1 STATOR 2 1 1 Electric machine armature a Mechanical description 2 1 2 Excitation field winding 2 1 3 Stator protection a Heating resistor b Stator winding temperature sensor C Stator air sensor d Stator vibration sensor 2 2 ROTOR 2 2 1 Revolving field coil 2 2 2 Excitation armature 2 2 3 Fan machines IC 0 A1 2 2 4 Rotating diode bridge General points b Tightening torque for the rotating diode fastening screws Rotating rectifier test 2 2 5 Balancing 2 2 6 Rotor vibration sensor 2 3 ANTI FRICTION BEARINGS rolling bearing 2 3 0 Description of antifriction bearings 2 3 1 Start up of antifriction bearings 2 3 2 Storage of machine with anti friction bearings 2 3 3 Maintenance of antifriction bearings a General points b Lubricant c Cleaning bearings 2 3 4 Servicing the antifriction bearings a General points b Removing the bearings c
25. N IN CASE THE SYSTEM INSTALLED WITH VIBRATION DAMPERS THE DAMPERS MUST BE PERIODICALLY CHECKED AND CHANGED EACH FIVE YEARS In case of failure of the cooling unit the synchronous machine Remains able to operate safely during a certain time few minutes The machine can be started without the cooling system In such event the bearing temperature will slowly increase permitting the bearing temperature sensors to detect overheating trigger the alarm and protect the bearing by stopping the machine 36 SERVICE AND OPERATING MANUAL ALTERNATORS 2 6 3 Oil cooling unit Water Oil exchanger This system does not apply to high thrust capability bearings bearings noticeable by the fifth digit of their code Example cannot be used for a bearing EFZLA The cooling unit is a compact system totally fitted on the machine close to the bearing The oil is pumped from the bearing sump passes through an Water to Oil cooler and is then routed back to the bearing shell The water flow is ensured by the electrical machine The oil circulates under low pressure The oil flow is fixed at the factory without any possible adjustment The pump must run permanently as long as the synchronous machine will rotate The Water flow must be ensured as far as the pump is operating No specific maintenance is required except vibration dampers CAUTION IN CASE THE SYSTEM INSTALLED WITH VIBRATION DAMPERS THE DAM
26. NGER DURING DISMANTLING OF THE FLOATING LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING 38 THIS IS UNDER TENSION AND COULD SPRING BACK AND LEAD TO INJURY Open the hook spring 49 and remove the bottom half of the seal 52 from the shaft d Dismantling of the shaft seal type 20 outboard side Untight all seals fixing screw 49 and remove them Simultaneously remove in axial direction both top and bottom 48 52 halves of the rigid labyrinth seal Remove the split line screws 50 Separate the top half of the rigid labyrinth seal 59 from the bottom half 63 e Dismantling of the top half of the housing Remove the flange screws 8 Remove the split line screws 12 Lift the top part of the housing 1 until the top part of the housing can be moved in axial line over the bearing shell without touching it f Removal of the top half of the shell Unscrew the split line screws 19 and lift the top half of the shell 11 CAUTION DO NOT DAMAGE THE THRUST AND RADIAL RUNNING SURFACES Dismantling of the loose oil ring Open both split lines of the loose oil ring 44 by untightening and removing the screws 47 Separate both halves of the loose oil ring 44 carefully without using any tools or other devices Illustration 1 Opening of the loose oil ring To check the geometry of the loose oil ring put it together as follows Press the positioning pin 45 into the holes 46 Ad
27. ON USE A LIQUID SCREW LOCKING COMPOUND E G LOCTITE 242 FOR ALL HOUSING SPLIT LINE AND FLANGE SCREWS a Fitting in the bottom half of the shell Apply some lubricant on the spherical seating 14 in the bottom half of the housing 21 and on the running surfaces of the shaft Use the same type of lubricant as indicated for bearing operation see type plate Place the bottom half of the shell 13 on the running surface of the shaft Turn the bottom half of the shell 13 into the bottom half of the housing 21 with the split line surfaces of both halves in true alignment In case the bottom half of the shell does not turn in easily check the position of the shaft and the alignment of the bearing housing CAUTION ONLY FOR BEARINGS EF K THESE OPERATIONS SHOULD BE CARRIED OUT MOST CAREFULLY THE THRUST PARTS OF THE BOTTOM SHELL SHOULD NOT BE DAMAGED Lower down the shaft till it sits on the bottom half of the shell 13 b Assembly of the shaft seal machine side The machine side shaft seal is standard wise a floating labyrinth seal The integrated seal groove is in the top and bottom halves of the housing DANGER DURING ASSEMBLY HOLD THE HOOK SPRING ENDS SECURELY TO AVOID THEM SUDDENLY RELEASING AND CAUSING POSSIBLE INJURY Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing Put the hook spring 49 around the shaft and hook both ends into each other Put
28. OT NECESSARILY SHOW THE KVA LOAD OF THE MACHINE 7 2 TROUBLESHOOTING 7 2 0 General points When a defective part is replaced with a spare part make sure that it is in good condition 7 2 1 Regulator trouble shooting procedure Refer to the enclosed regulator manual 7 3 ELECTRICAL TESTS 7 3 1 Stator winding test See chapter 6 3 7 3 2 Rotor winding test See chapter 6 3 7 3 3 Excitation armature winding test See chapter 6 3 7 3 4 Excitation field winding test See chapter 6 3 7 3 5 Rotating diode bridge test See chapter 2 2 7 3 6 Electric panel test Use electrical diagrams for assistance Sx eve 7 4 CLEANING THE WINDINGS 7 4 0 General points The cleaning of the winding is an heavy service operation which has to be engaged only if necessary The cleaning of the windings become necessary as soon as the insulation resistance and or the polarization index are not satisfactory refer to chapter 6 3 2 7 4 1 Coil cleaning product a General A long term efficient cleaning can only be done in a work floor if equipped with specialized devices A site cleaning because less efficient can be considered only for a transient period CAUTION SOLVENTS WHICH ARE HIGHLY CHLORINATED AND SUBJECT TO HYDROLYSIS IN DAMP ATMOSPHERES ARE PROHIBITED THEY QUICKLY BECOME ACIDIFIED PRODUCING CORROSIVE AND CONDUCTIVE HYDROCHLORIC ACID CAUTION DO NOT USE TRICHLORETHYLENE PERCHLORETHYLENE OR TRICHLORETHANE Avoid mix
29. PERATING MANUAL ALTERNATORS 2 3 9 Anti friction bearing installation drawing following Machine type A56 Power plant 6 poles and more Z 1 4N A 7 s g gt 8 6248 Pa NU 232 8 prd 6 pd i i 1 i X INI LAM st co lt T gt lt Q LO T T Lo e OG c oo ce N t LO N Q LO e E e ed T LO LO Q Q S Q il 1 Bearing carrier 3 Snap ring 5 Rotating deflector 7 Inside bearing cover 2 Outside bearing cover 4 Fixed deflector 6 Nut 8 Anti friction bearing Machine type A56 Power plant 4 poles only T E 2 Ns Fi NU 232 BS N 6 as g i 1 T Lo y S S IS 9 9 8 amp 1 Bearing carrier 3 Snap ring 5 Rotating deflector 7 Inside bearing cover 2 Outside bearing cover 4 Fixed deflector 6 Nut 8 Anti friction bearing Sx ovs SERVICE AND OPERATING MANUAL ALTERNATORS 2 4 SLEEVE BEARINGS Note For vertical machines refer to the attached specific bearing notice Refer to the at
30. PERS MUST BE PERIODICALLY CHECKED AND CHANGED EACH FIVE YEARS In case of failure of the cooling unit the synchronous machine Remains able to operate safely during a certain time few minutes The machine can be started without the cooling system In such event the bearing temperature will slowly increase permitting the bearing temperature sensors to detect overheating trigger the alarm and protect the bearing by stopping the machine Water has to be filtered as per chapter 2 7 5 Water Oil 2 7 COOLER 2 7 0 Description of the cooler a General points The purpose of the cooler is to remove machine heat losses mechanical ohmic etc The exchanger is located on the top of the machine Normal operation The internal air goes through the exchanger transferring the heat and then goes back to the machine CAUTION IN CASE THE HOUSING INSTALLED WITH VIBRATION DAMPERS THE DAMPERS MUST BE PERIODICALLY CHECKED AND CHANGED EACH FIVE YEARS CAUTION THE COOLER MUST BE FULLY OPERATIONAL AS SOON AS THE MACHINE IS ROTATING EVEN IF THE MACHINE IS RUN AT NO LOAD b Description of Air Air coolers The internal air flow is moved by a fan fixed on the machine shaft The internal cooling air circulates through the machine and through the air cooler in a closed circuit The External air circulation can be created through natural ventilation machine class IC 6 A1 A1 or through separate ventilat
31. RATING MANUAL ALTERNATORS 503 GENERATOR START UP CHECK LIST votage Jv Feaeny Hz Speed rem Output Power al kVA Power Factor STATIC CHECKS Mechanical checks e Direction of Rotation Clock Wise or Anti clock Wise Mechanical Fixing of the generator Coupling Alignment to the engine Cooling Coolant flow and level Air inlet and exhaust free Bearing lubrication Sleeve Bearings Lubrication flow level oil type or Anti friction Bearings Greasing Temperature sensors correct readings Space Heaters TypeofAVR FO 2F 3F Electrical connections between alternator AVR and main panel e Output power cables connections following phase order Terminal box connections AVR detection voltage Supply power and excitation terminals Network detection 3F only Command signals equalisation and synchronisation for 2F and 3F Excitation polarity and booster Protective devices Bearing oil level fault detectors Temperature sensors etc External accessories e g remote potentiometer ALL CURRENT TRANSFORMERS MUST BE CONNECTED Windings insulation e Insulation test of the Stator Rotor Exciter armature Exciter field Measured values in MOhms All works must be carried out by a qualified and authorized person For more information please ref
32. Rotor vibration sensor This chapter concerns the setting of proximity probes For setting of seismic probes refer to the stator chapter The vibration level of the machines is directly linked to the duty and to the site characteristics We propose the following adjustment Vibration Alarm 50 of the Bearing shell gap Vibration Trip 7596 of the Bearing shell gap 11 SERVICE AND OPERATING MANUAL ALTERNATORS 2 3 ANTI FRICTION BEARINGS 2 3 0 Description of antifriction bearings The bearings are installed at each end of the machine They can be replaced The bearings are protected from external dust by labyrinth seals The bearings must be lubricated regularly The old grease is forced out at the lower part of the bearings by the force of the new grease being injected 2 3 1 Start up of antifriction bearings The bearings are pre lubricated in the factory but before they are put into service it is necessary to complete this lubrication CAUTION UPON START UP GREASE THE MACHINE WHILE IT IS RUNNING SO AS TO FILL ALL THE FREE SPACES IN THE GREASING DEVICE Record the temperature of the bearings during the initial operating hours Poor lubrication can cause abnormal heating If the bearing hisses lubricate it immediately Some bearings may make a clattering noise if they do not operate at normal temperature This may occur if the weather is very cold or when the machine is operating under abnorm
33. ULATOR AND EXTERNAL When the automatic voltage regulator is located in the AUXILIARIES terminal box it is fitted on a separate plate insulated from a vibration by means of dampening pads The operation of The regulator instruction manual may be considered as an the regulator is explained in chapter 3 independent manual included in the machine instruction manual CAUTION THE DAMPENING PADS MUST BE CHECKED PERIODICALLY AND REPLACED EVERY FIVE YEARS 2 18 3 Electrical contact tightening Applicable for brass thread que Due ure Dre e Torque 2 5 20 35 57 87 Nm 2 19 PROTECTION DEVICES 2 19 1 Stator protection devices See Stator protection in chapter 2 1 3 2 19 2 Bearing protection devices See Bearing protection in chapter 2 3 5 or chapter 2 4 9 2 19 3 Cooler protection devices See Cooler safety in chapter 2 7 5 2 20 NAMEPLATES 2 20 1 Main nameplate The main nameplate is fitted to the stator It gives the manufacturer s electrical characteristics the type of machine and its serial number The serial number is necessary for any contact with the factory For machines with anti friction bearings the quantity of grease the type and frequency of lubrication are stipulated 2 20 2 Lubrication nameplate The machines with Sleeve bearings have a lubrication plate attached to the bearing giving Oil change frequency Oil capacity of bearing Oil viscosity The machines with anti fric
34. ags according Category 4C of SEI standard Optional maritime packing In case of extended storage period with a special design with double sealing can be used This packing enable access to the shaft in order to perform the periodic shaft rotation recommended for antifriction bearings refer to chapter 2 3 2 This packing provides access to the dessicant for periodic change every 18 months Breaking the hermetic protective film discharges Leroy Somer of its long duration storage guarantee 4 1 4 Unpacking and installation DANGER THE FOUR LIFTING HOOKS MUST BE USED TO LIFT THE MACHINE WITH SLINGS ONE HOOK AT EACH CORNER OF THE MACHINE Rotors of machines with Sleeve bearings and single bearing machines are blocked during transportation so as to avoid any movement Withdraw the retaining bars The retaining bar is screwed to the end of the shaft and to the front support CAUTION ALL THE LOCKING DEVICES PAINTED RED OR WITH RED STICKER MUST BE REMOVED The end of the shaft is protected from corrosion Clean it before coupling 4 1 5 Storage measures of a site machine Before stopping the machine for a long period several months it is essential to take several precautionary measures Refer to chapter 2 3 2 anti friction machine or chapter 2 4 2 sleeve bearing machine The heating resistor must be switched on at all times For water coolers the water flow must be shut off If the water is not treated
35. al temperature conditions start up phase for example The bearings will become quieter after having reached their normal operating temperature 2 3 2 Storage of machine with anti friction bearings This chapter must be taken in consideration if a machine is stopped more than 6 months Grease the bearings machine stopped inject two time the grease volume used for a standard maintenance Every 6 months turn the the machine shaft line of few turns Then inject a standard grease volume Sx eve 2 3 3 Maintenance of antifriction bearings a General points Antifriction bearings or ball bearings do not require special maintenance They must be lubricated regularly with the same type of grease as used in the factory For information concerning the lubrication quantity and interval refer to Section 1 Characteristics and Performance CAUTION LUBRICATION MUST BE CARRIED OUT AT LEAST EVERY 6 MONTHS CAUTION IT MUST BE DANGEROUS TO MIX GREASES WHICH HAVE DIFFERENT SOAP BASE IT IS NECESSARY TO GET THE GREASE SUPPLIER APPROVAL OR TO CLEAN THE BEARING BEFORE TO PROCEED NOTE After a regreasing the bearing temperature may increase of 10 to 200 This temporary temperature increase may stay few tens of hours NOTE For re greasing period lower than 2000 hours we recommend to install a continuous greasing system to limit the maintenance operators visit These type of system must be disable during machine stop The grease
36. all the bearing on the shaft it is necessary to heat the bearing The heat source may be an oven or a space heater the use of oil baths is strongly discouraged The use of an induction bearing heater is recommended CAUTION NEVER HEAT A BEARING TO MORE THAN 125C 257 F Push the bearing up to the shaft shoulder and check after cooling that the inner ring is still in contact with the shoulder Lubricate using the recommended grease 2 3 5 Antifriction bearing protection devices As an option the bearing may be protected from over heating by RTD or PTC sensors customer s choice For special use in warm surroundings where the temperature of the bearings exceeds the authorised limit for a bearing known to be in good condition contact us Bearing Alarm points and shutdown alarm 90 194 shutdown 95T 203 To improve the machine protection the alarm set point may be reduced following site effective information Alarm temperature Highest recorded temp 15 do not pass over the values of the previous chart E g At site the common bearing temperature is 60 C Set the alarm temperature to 75 instead of 90 C as indicated in the previous chart 13 SERVICE AND OPERATING MANUAL ALTERNATORS 2 3 9 Anti friction bearing installation drawing Machine type A50
37. anliness 6 3 ELECTRICAL MAINTENANCE 6 3 1 Measuring instruments a Instruments used b Identification of ohmmeter polarity 6 3 2 Insulation check of the winding a General b Armature insulation measure C Field insulation measurement d Exciter insulation measurement e Polarisation index SERVICE AND OPERATING MANUAL ALTERNATORS 7 SERVICING 7 1 GENERAL SERVICING 7 2 TROUBLE SHOOTING 7 2 0 General points 7 2 1 Regulator trouble shooting procedure 7 3 ELECTRICAL TESTS 7 3 1 Stator winding test 7 3 2 Rotor winding test 7 3 3 Excitation armature winding test 7 3 4 Excitation field winding test 7 3 5 Rotating diode bridge test 7 3 6 Electric panel test 7 4 CLEANING THE WINDINGS 7 4 0 General points 7 4 1 Coil cleaning product a general b Cleaning products 7 4 2 Cleaning the stator rotor excitation and diodes 8 using specific chemical product b Rinsing using soft water 7 5 DRYING THE WINDING 7 5 0 General points 7 5 1 Drying method a General points b Drying generator stop Drying generator in rotation 7 6 RE VARNISHING 10 FOLDOUT Sx eve SERVICE AND OPERATING MANUAL ALTERNATORS 1 GENERAL INFORMATION 1 1 INTRODUCTION 1 1 0 General points This manual provides installation operating and maintenance instructions for synchronous machines It also describes the basic construction of these machines This manual is general it applies to an entire group of synchronous generat
38. at the vibration level is in accordance with the generator as per chapter 5 2 1 and duty request b Rotating checks at no load excited In AVR manual mode Voltage adjustment check the excitation current value refer to AVR manual and to the generator test report In AVR automatic mode Voltage adjustments Voltage range check the excitation current value refer to AVR manual and to the generator test report At the nominal speed excited measure the vibrations Check that the vibration level is in accordance with the generator as per chapter 5 2 1 and duty request Generator and site safeties Proceed to the site safeties adjustment over voltage relay over current relay differential protection negative sequence relay The setting points are not under our responsibility Check the synchronizer setting following chapter 5 1 3 For any operation at a speed exceeding the nominal range generally the main frequency 3 the generator excitation must be shut off refer to the electrical diagram d Rotating checks at full load Operating In parallel with the mains Adjust the Power Factor Load the generator step by step Check the excitation current at 25 of the rated load Check the excitation current at 100 of the rated load At the nominal speed full load measure the vibrations Check that the vibration level is in accordance with the generator as per chapter 5 2 1 and duty request 49 SERVICE AND OPE
39. ation see type plate Check if the engraved numbers 15 on the bottom and top halves of the shell correspond Place the top half of the shell 11 on the shaft both engraved numbers 15 should be on the same side CAUTION AN INCORRECTLY PLACED SHELL COULD JAM THE SHAFT THUS LEADING TO THE DAMAGE OF BOTH SHAFT AND BEARING CAUTION FOR BEARINGS TYPE EF K ONLY PLACE THE TOP HALF OF THE SHELL CAREFULLY ON THE SHAFT THE THRUST PARTS OF THE TOP HALF OF THE SHELL SHOULD NOT BE DAMAGED Tighten up the split line screws 19 by using the following torque values eefa Bearing size GOOL Check the split line of the bearing shell by using a feeler gauge The split line gap should be less than 0 05 mm If the split line is greater than this dismantle both top and bottom 11 13 halves of the shell Torque Nm Check the mobility of the loose oil ring 44 Marine bearing only A guide bush in the top half of the shell secures the function of the loose oil ring Check the mobility of the loose oil ring 44 in the guide bush SEMER e Closing of the bearing Check the true alignment of the shell 11 13 and bottom half 21 of the housing The positioning pin 3 in the top half of the housing fits in the corresponding positioning pin hole 2 The bearing shell is thus placed into its right position Check if the engraved numbers 20 on the top and bottom halves of the housing correspond Clea
40. ave an opening for an exhaust for the damp air Drying generator in rotation Disconnect the machine from the mains Short circuit the machine stator at the machine terminals Disconnect the Voltage regulator and short circuit the booster Install an amp meter on the short circuited winding Run the machine at its nominal speed to air cool the machine Energized the machine exciter field using an separate ex citation source Use a DC source batteries Adjust the excitation current to get the nominal current at the stator machine armature Warm up during 4 hours stop and leave it to cool down winding temperature lt 50 61 SERVICE AND OPERATING MANUAL ALTERNATORS Check the winding insulation and the polarization index If necessary conduce an other drying period C A Stator B Rotor C Exciter 7 6 RE VARNISHING CAUTION RE VARNISHING MUST ONLY BE CONSIDERED IF ABSOLUTLY NECESSARY A RE VARNISHING OPERATION DONE ON A WINDING STILL DIRTY OR NOT PERFECTLY DRY MAY CONDUCE TO A DEFINITIVE LOSS OF INSULATION AS eve 2327 en 11 2011 62 SERVICE AND OPERATING MANUAL ALTERNATORS 10 TYPICAL CUT VIEWS 10 1 MACHINE CUT VIEWS 10 1 1 Machine type A52 1 Rotor 10 Polar wheel 2 Bearing drive end 11 Balancing disc 3 Fan hub 12 Exciter field 4 Drive end shield 13 Exciter armature 5 Fan 14 Non drive end shield 6 Fan screen 15 Bearing non drive end 7 Sta
41. best practice rules and to secure any operation over the defined tender respect of capability curve overspeed For low voltage machines power supply cables must be connected directly to the machine terminals without adding washers etc For high voltage machines power supply cables should be connected to separate terminals or to current transformer terminals NOTE THE GLAND PLATE IS MADE OF NON MAGNETIC MATERIAL CAUTION DO NOT ADD WASHERS TO THE POWER SUPPLY CABLE TERMINALS OTHER THAN THOSE USED BY THE MANUFACTURER OF THE ELECTRIC MACHINE Check that the lugs are tightened CAUTION ALL CURRENT TRANSFORMERS MUST BE CONNECTED OR SHUNTED CAUTION THE VOLTAGE TRANSFORMER MUST NEVER BE SHUNTED CAUTION THE INSTALLED POWER CABLES MUST BE FIXED AND SUPPORTED IN SUCH A WAY AS TO BE ABLE TO WITHSTAND THE VIBRATION LEVEL REACHED BY THE GENERATOR IN OPERATION refer to Vibration chapter The power cables must not stress push pull bend the generator terminals 47 SERVICE AND OPERATING MANUAL ALTERNATORS b On request NEMA 4 1 Phase E 4 An arrow located the front bearing indicates the a Standard units IEC 34 8 direction of rotation Except by special request of the customer the phase In the terminal box a specific marking plate indicates the sequence is carried out using the IEC 34 8 standard An specific generator phase sequence arrow located on the front bearing indicat
42. both halves of the seal 52 53 in their place on the shaft Put the hook spring 49 into the spring groove 50 Turn the floating labyrinth seal on the shaft 27 SERVICE AND OPERATING MANUAL ALTERNATORS CAUTION THE FLOATING LABYRINTH SEAL SHOULD TURN EASILY ON THE SHAFT A JAMMED SEAL COULD LEAD TO OVERHEATING DURING OPERATION AND EVEN TO SHAFT WEAR If the floating labyrinth seal jams dismantle it from the shaft Remove the worn parts of the seal carefully by using emery paper or a Sleeve scraper Dismantle the floating labyrinth seal NOTE We do not recommend the use of sealing compound onto the floating labyrinth seals However for certain leakage type the use of Curyl T may help to solve the encountered issue Apply sealing compound on the guide surfaces of the integrated seal groove in the bottom half of the housing Illustration 2 Coating of sealing compound on the integrated seal groove Apply a uniform layer of sealing compound on the seal surfaces and on the split line surfaces of both halves of the seal 52 53 E 8 X g 6 na Er gj und m EC cof E Hj Y 7 8 SS Illustration 3 Coating of sealing compound on the floating labyrinth seal Place the bottom half of the seal 52 with the labyrinths onto the shaft The oil return holes at the bearing side must be opened Turn the seal in the opposite direction to the anti rota
43. cator a thermometer and a temperature sensor b Operating description of Self lubricating bearing Upon stopping the shaft rests on the lower bearing there is metal to metal contact During the start up phase the shaft rubs against the anti friction metal of the bearing Oil lubrication is used After having reached its transition speed the shaft creates its oil film At this point there is no further contact between the shaft and bearing CAUTION PROLONGED OPERATION AT EXTREMELY SLOW ROTATION SPEEDS SEVERAL rpm WITHOUT LUBRICATION COULD SERIOUSLY DAMAGE THE SERVICE LIFE OF THE BEARING AS C Operating description of Oil circulation bearing Proceed as for the self lubricated bearings For special duty of high speed machine or high loaded bearing it might be necessary to have an oil circulation System external device which ensure the cooling and the circulation of the oil The oil warmed by the bearing losses is externally cooled and is returned directly to the shell To obtain efficient cooling the oil flow must be correct refer to section 1 2 4 1 Electrical insulation of Sleeve bearings a Illustration diagram of the insulating film Following the used technology shaft circulating current may occurs When necessary ACEO insulates the Non Drive End bearing to avoid shaft circulating current An insulating film is applied to the bearing housing spherical seat A Sp
44. cceptable In any cases national environmental and sanitary regulation must be fulfilled DANGER THE PROHIBITED SOLVENTS ARE CHLORINATED SOLVENT TRICHLORETHYLENE TRICHLOROETHANE WHICH BECOMES ACID FUEL OIL EVAPORATES TOO SLOWLY GASOLINE CONTAINING LEAD BENZINE TOXIC Blow compressed air onto the bearings to evaporate the excess solvent Fill the bearing with the new grease Re assemble the cage and the parts which have been dismantled filling them with grease Use a grease pump to complete the bearing lubrication while machine running 2 3 4 Servicing the antifriction bearings a General points CAUTION CLEANLINESS IS IMPERATIVE b Removing the bearings The inner bearing race is mounted shrunk onto the shaft The outer bearing race is free or slightly tightened on the hub depending on the type of bearing To remove the bearing from the shaft it is necessary to use a dedicated hub puller to avoid damaging the surface of the shaft NOTE Heat the bearing during the pulling operation makes the operation easier and prevent the shaft from scratch Sy Bearing re assembly A bearing can be refitted if it is known to be in perfect condition As far as possible we recommend to use a new bearing Before refitting a bearing carefully clean the surface of the bearing and the other parts of the bearing Measure the shaft diameter to check it is within the recommended tolerances To inst
45. contained in these systems must not be stored over a period of 1 year b Lubricant Recommended lubricant SKF LGWA2 SHELL GADUS S3 V220C lithium complex base SHELL RETINAX LX2 lithium complex base CASTROL LMX NLGI2 TOTAL Multis complex EP2 Recommendation for a grease choice Mineral oil or PAO SHC Base soap grade NLGI 2 Lithium complex base Base oil viscosity at 40 C 100 to 200 mm2 s Dye penetration test DIN 51817 296 minimum Use of grease which do not fit to the recomended figure substitution grease Mineral oil or PAO SHC Base soap grade NLGI 2 or NLGI 3 Lithium base Base oil viscosity at 40 C 100 to 200 mm2 s Dye penetration test DIN 51817 296 minimum CAUTION THE USE OF A SUBSTITUTION GREASE CONDUCE TO REDUCE THE RE GREASING PERIOD OF 30 12 SERVICE AND OPERATING MANUAL ALTERNATORS NOTE Lithium and complex lithium soap can be mixed Lithium complex and calcium lithium soap can be mixed In case of change of grease brand it is recommended to proceed to a massive greasing to waste the previous grease Cleaning bearings This note is applicable when the type of grease is changed Dismantle the machine in order to get to the bearing Remove the old grease with a palette knife Clean the lubricator and the grease removal tube For greater cleaning efficiency use a brush with solvent NOTE The most widely used solvent is gasoline white spirit is a
46. ducts not delivered by ACEO and then installed in the terminal box must meet the electrical insulating distances This applies to power cables and lugs and to added transformers etc IPhase Phasein Phase in the air mm Phase Earth in the air mm Phase Phase Creeping mm Phase Earth Creeping mm IPhase Phasein in the air mm Phase Earth in the air mm Phase Phase Creeping mm Phase Earth Creeping mm 4 4 3 Added products in the terminal box This may apply to site added customer CTs VTs etc ACEO must be informed if some appliances have to be installed in the generator terminal box The products not delivered by ACEO and then installed in the terminal box must meet the electrical insulating distances Refer to chapter 4 4 2 The installed appliances must be able to withstand vibration Sx ovs 5 START UP 5 0 START UP SEQUENCE The generator start up commissioning must follow the following sequences 5 0 1 Static checks Machine fixing as per chapter 5 2 Alignment as per chapter 5 2 Cooling as per chapter 5 2 Bearing lubrication as per chapter 5 2 Electrical connections as per chapter 5 1 0 and chapter 5 1 2 Winding insulation as per chapter 6 3 2 5 0 2 Rotating checks a Rotating checks not excited Run the generator without excitation by steps to verify the bearings temperature as per chapter 5 2 At the nominal speed not excited measure the vibrations Check th
47. e Dismantle the oil cooler Remove the encrustation by using for instance a wire brush Install the oil cooler 26 into the bearing 26 SERVICE AND OPERATING MANUAL ALTERNATORS b Wear checking Carry out a visual check of the wear condition of all bearing parts The following graph provides information on the parts that must be replaced in case of wear The right evaluation of the wear condition especially of the running surfaces of the bearing shell implies a lot of experience If in doubt replace the worn part with new ones Maintenance proceedings Shell Scoring Bearing temperature before inspection not increased shells increased new shells White metal New shell lining damaged Shaft Baffles broken or New shaft seal seal damaged Loose Geometrical form New loose oil ring oil ring roundness flatness visibly changed c Insulation checking only for insulated bearing Check the insulating layer of the spherical seating 14 of the top half 1 and bottom half 21 of the housing In case of damage contact Leroy Somer d partement ACEO factory Sx ovs 2 4 8 Assembly of the Bearing CAUTION REMOVE ALL IMPURITIES OR OTHER OBJECTS SUCH AS SCREWS NUTS ETC FROM INSIDE THE BEARING IF LEFT INSIDE THEY COULD LEAD TO DAMAGE OF THE BEARING COVER UP THE OPENED BEARING DURING BREAKS CAUTION CARRY OUT ALL ASSEMBLY OPERATIONS WITHOUT MAKING USE OF FORCE CAUTI
48. eal the flange surfaces the split line surfaces of the top 48 and bottom 51 half of the carrier the flange surfaces of the housing 30 SERVICE AND OPERATING MANUAL ALTERNATORS Apply a uniform layer of sealing compound on the lateral surfaces of the groove at the top 48 and bottom 51 half of the seal carrier the flange surfaces of the top 48 and bottom 51 half of the seal carrier the split line surfaces of the bottom half of the seal carrier Illustration 8 Application of sealing compound on the seal carrier Place the top half of the seal carrier 48 on the top half of the seal 53 Press the bottom half 51 of the seal carrier against it Push the shaft seal completely into the housing i f N M i Illustration 9 Assembly of the seal carrier Align the split lines of the seal carrier and the housing Tighten up the screws 55 by using the torque values bees ue 16 2 oo bem Sx ovs 9 Assembly of the type 20 Outboard Side Seals Check if the engraved numbers on the bottom half 63 and top half 59 of the rigid labyrinth seal correspond Clean the flange surfaces of the top half and bottom half 63 of the rigid labyrinth seal the split line surfaces of the top half and bottom half 63 of the rigid labyrinth seal the flange surfaces of the housing Apply a uniform layer of sealing compound on the following parts the flange surfaces
49. ed onto journal surface thrust faces and seals surfaces Fill the bearing oil cavities with oil CAUTION THE BEARINGS ARE DELIVERED WITHOUT OIL Clean the external parts of the bearing Dust and dirt impede the radiation of the heat Check if the temperature monitoring equipment works 19 SERVICE AND OPERATING MANUAL ALTERNATORS b Self lubricating bearings start up data To identify your bearing characteristics refer to section 1 Fill the bearing with the recommended oil The oil must be new absolutely free of any traces of dust or water The oil level limits are as follows minimum oil level bottom of the oil sight glass maximum oil level 2 3 the top of the oil sight glass NOTE It is recommended to filter the oil before filling the bearing CAUTION NOT ENOUGH LUBRICANT LEADS TO TEMPERATURE RISES AND THUS TO DAMAGE TO THE BEARING TOO MUCH LUBRICANT LEADS TO LEAKAGES Retighten the split line and flange screws 12 by using the following torque values Torque Nm 170 330 570 1150 lightly oiled Check the firm position of the top sight glass 5 Check the firm position of the oil sight glass 23 If a temperature sensor or thermometer is used check they are correctly fixed Retighten all screw plugs in the connection holes 4 22 24 27 by using the necessary torque values Plugs threads G 1 Plugs threads G2 1 2 Check the operation of the temperature monitoring equipment
50. el Check the oil level at regular intervals The oil level limits are as follows minimum oil level bottom of the oil sight glass maximum oil level 2 3 the top of the oil sight glass admissible oil level 70706 FOTO S n n fasce Optimum top oil level Optimum bottom oil level Minimum admissible oil level b Temperature verification Check the bearing temperature and record it A bearing temperature which suddenly varies without any obvious reason change of ambient temperature etc indicates abnormal operation It is then necessary to inspect the bearing Oil draining NOTE Risk of pollution Please observe the instructions for the use of the lubricating oil The manufacturer can provide information on waste oil disposal It is recommended to drain the oil at intervals of 8000 hours of operation in dirty environment eg gen set application 16000 hours of operation in clean environment eg hydro power plant A yearly inspection of the oil sump is recommended Have a special attention to water contamination It is possible to decide the oil change only after making an analysis and not at fixed period In such practice the oil analysis report must fulfill pollution recommendation of chapter 2 4 10 e Shut down the installation and secured it against unintended operation Take all necessary measures to collect all of the lubricating oil Release the lubricating oil while it is
51. er to the service manual Tested by Date amp Signature Sx eve 50 SERVICE AND OPERATING MANUAL ALTERNATORS ROTATING CHECKS WITH EXCITATION AT NO LOAD CONDITIONS e Verification of the bearings temperature 1 e In manual mode Voltage adjustment Excitation current check e Inautomatic mode Voltage Setting referring to nominal voltage Excitation current check e Parallel coupling Adjustment to parallel operation A FAULTY SYNCHRONISING CAN BE THE ORIGIN OF DAMAGES HIGH MECHANICAL OVER TORQUE e Maximum acceptable values for synchronisation to the mains Maximum frequency shift 0 1 Hz Maximum Phase offset 10 Maximum voltage P N difference 5 of Un Control Adjustment of the site safeties e Over voltage Over current by short circuit on stator in separate excitation mode Negative sequence relay Over speed Differential protection in static conditions Other protective device CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY WITH EXCITATION LOADED Voltage stability Adjustment of the Power Factor Verification of the excitation current versus load from 25 to full load at rated PF Maximum load value 1 Vibrations measurements in mm s RMS other unit 1 At nominal speed measure the vibrat
52. es and the end plates 1 Single internal tube 2 External tube with internal grooving and with External fins 3 Internal plate 4 External plate 5 Outside wall of the pressure tank 6 Flow of water or liquid leaks A Air B Leakage C Water AS d Description of Air Water single tube exchanger The internal air flow is moved by a fan fixed on the machine shaft The internal cooling air circulates through the machine and through the air cooler in a closed circuit The internal air circulation can be created through natural ventilation machine class IC 8 A1 W7 or through separate ventilation machine class IC 8 A6 W7 An exchanger comprises a fin tube block containing a steel frame a fin tube block crimped mechanically onto the tubes The tube bundle is roll expanded in the end plates The water distribution in the tubes is provided by two water boxes One water box is equipped with collars for fitting the inlet and outlet water lines Neoprene seals provide watertightness between the water boxes and the end plates 1 Tube with fins 2 End plate 3 Water bar A Air B Water 38 SERVICE AND OPERATING MANUAL ALTERNATORS 2 7 1 Water Cooler operating condition a Water Cooler installation Assembly example 1 Outlet flange 2 Inlet flange 3 Water cooler 4 Connecting flange 5 Tap 6 Flexible junction 7 Pipe 8 Draining and de aeration 9 Water leakage detector Wa
53. es the direction of rotation In the terminal box a specific marking plate indicates the Nu OM a da NUR specific generator phase sequence d 4 2 connection NEMA Clockwise rotation viewed Counter clockwise Clockwise rotation viewed Counter clockwise rotation from the shaft drive end rotation viewed from the from the shaft drive end viewed from the shaft following IEC shaft drive end following drive end IEC The phases are marked The phases are marked The cables are marked The cables are marked U1 V1 W1 U1 V1 W1 U1 V1 W1 U1 V1 W1 Viewed from the front of Viewed from the front of The terminals are marked The terminals are marked the terminal box the the terminal box the terminals are terminals are T3 T2 T1 T2 T1 UT VT WT Ui Vi Wi Viewed from the front of Viewed from the front of The installer connects The installer connects the terminal box the the terminal box the gt U1 L3 gt U1 cables are cables are 2 M o Ec A U1 V1 W1 Ut V1 W1 gt Wl Li gt W1 The installer connects The installer connects L1 gt U1 T3 L3 gt U1 L2 gt V1 T2 L2 gt V1 T2 L3 gt W1 1 L1 gt W1 T1 T6 T5 T4 T6 T5 4 Ui Vi Wi U1 Wi L1 W1 uig Vt wi T3 T2 Ti T2 Ti L2 L3 L3 12 11 L3 L3 L2 11 L1 L2 Sx eve 48 SERVICE AND OPERATING MANUAL ALTERNATORS 4 4 2 Insulating distances Pro
54. etc and must be known As a second instrument you must use a voltmeter in the direct current position in order to check the polarity of the ohmmeter connections Proceed as explained below Evers 7 6 3 2 Insulation check of the winding a General The insulation resistance enables the status of the machine insulating to be verified The following measurements can be taken at any time without any damage to machine insulating material The insulation check must be done Before the start up After a long standstill As soon as an abnormal operation occurs If the measurement indicates a poor result we advise contacting our Service department To perform the measurement the generator must be stopped If the insulation resistance is less than that required it is necessary to clean and to dry the machine refer to chapter 7 5 DANGER BEFORE ANY WORK THE RULES CONCERNING THE SAFETY OF MATERIALS AND PERSONS MUST BE APPLIED TOTAL LOCKING OF THE GENERATOR FUNCTIONS GROUNDING OF THE PHASES b Armature insulation measure Disconnect the three phases at the generator terminals CAUTION ALL ACCESSORIES MUST BE DISCONNECTED AVR EMC FILTER REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY THE ACCESSORIES TO DISCONNECT 58 SERVICE AND OPERATING MANUAL ALTERNATORS The measurement has to be taken between one phase and the earth Machine nominal voltage Un lt 2400 V Un
55. f Removal of the top half of the shell 9 Dismantling of the loose oil ring h Dismantling the machine side shaft seal i Removal of the bottom half of the shell j Dismantling of the machine seal 2 4 7 Cleaning and checking a Cleaning b Wear checking Insulation checking only for insulated bearing 2 4 8 Assembly of the Bearing a Fitting in the bottom half of the shell Assembly of the shaft seal machine side Installation of the loose oil ring Fitting in the top half of the shell Closing of the bearing Assembly of the type 10 Outboard Side Seals 9 Assembly of the type 20 Outboard Side Seals h Assembly of the RD thrust pads bearing type E A 2 4 9 Oil leakage trouble shooting a Self lubricating bearing b Oil circulation bearing 2 4 10 Sleeve bearing protection devices a Sight level glass b Oil thermometer Thermostat or sensor Pre lub pump Oil filtering and pollution b C d e f C d e I 2 6 OIL CIRCULATION LUBRICATING UNIT 2 6 0 General points 2 6 1 Oil circulation by gravity return General points b Supply line C gravity oil return 2 6 2 Oil cooling unit Air Oil exchanger 2 6 3 Oil cooling unit Water Oil exchanger Sx eve 2 7 COOLER 2 7 0 Description of the cooler General points b Description of AIR AIR coolers Description of AIR NATER DOUBLE TUBE EXCHANGER d Description of AIR WATER SINGLE TUBE EXCHANGER 2 7 1 Water Cooler operating condition a Water Cooler instal
56. f the requested engineering rules the return ducts frequently have big size Their manufacturing is frequently done by welding It will be necessary to clean the welds and to rinse the oil lines before use gt 200 mm mini 300mm Min Average slope 150 mm m Install a breather as close as possible of the bearing output The breather should be to a minimum of 200 mm above the highest point of the bearing The breather line should be linked to the top side of the main oil line It is imperative to quickly go down after the bearing output Install an elbow minimum 609 immediately after th e bearing exhaust item 3 Pipe with a Minimum slope of 15 so a difference of 25 cm for 100cm long minimum 300 mm high The difference of level between return oil sump and bearing exhaust must be strictly higher than H 200 mm The average slope of the return line must be strictly higher than 15 cm per meter of ground line The average slope is based on the difference of level between bearing exhaust and return sump oil level The oil return line must no be exposed to counter current air flow air which should went from the oil return sump and go toward the bearing Eg a return line which should exhaust above the oil level inside an engine oil sump should receive a crankcase back pressure which should have a real negative effect NOTE The requested oil flow is indicated in section 1 Oil return line
57. g valve A a diaphragm NOTE The breather can be removed if it is proved that the bearing casing is in depressure regarding the atmosphere Ensure that the complete oil supply and return lines have been rinsed as instructed in the chapter 2 4 3 Ensure that the installation instructions have been followed refer to chapter 2 4 3 such as filtering unit return line properly inclined etc Proceed as for the self lubricated bearings and then start the oil supply system pump etc The oil flow must be strictly adjusted within the requested value using a flow meter Run the generator Machine running and oil at the operating temperature the oil sight glass level should be within 1 3 and 2 3 of the glass If the level reach the top of the oil sight glass investigate for the oil return line design f Inspection of Sleeve bearings at the end of start up Supervise the bearing during the trial run 5 10 operating hours Pay special attention to oil level bearing temperature sliding noises of the shaft seals tightness of the sump plugs tightness of the bearing accessories occurrence of vibrations CAUTION IF THE BEARING TEMPERATURE EXCEEDS THE CALCULATED VALUE OF 15 k STOP THE MACHINE IMMEDIATELY INSPECT THE BEARING AND DETERMINE THE CAUSES In case of oil oozing retighten the bearing fixing screws and plugs to the recommended torque Syd 2 4 5 Maintenance of Sleeve bearings a Verification of oil lev
58. he shaft Sx eve 4 3 4 Alignment procedure a Checking Double concentricity alignment method This method is not sensitive to axial movements the alignment methods using axial measure may often be perturbed by small axial movement of the rotor It is possible to check the alignment with the coupling installed Equipment required Two rigid brackets The rigidity of the two brackets is very important Two micrometers Implementation During the measures both shafts must turn simultaneously in the same direction For example the coupling installed with its screws untightened By turning both shafts simultaneously the measurement is not affected by the error resulting from run out of the two shaft ends The C1 and C2 micrometers are located at an angular difference of 180 More the distance L is long better should be the sensitivity to detect the angular error The reading should be performed 4 times for the C1 and C2 micrometers at 12h 3h 6h 9h It is recommended to record the results and draw the axes for better evaluation as explained below Interpretation of measurements by means of an example Values given in millimeters The reading is considered positive when the micrometer stylus is pushed inwards 46 SERVICE AND OPERATING MANUAL ALTERNATORS MEASUREMENTS 1 34 C1 C2 0 90 0 164 0 102 1 00 Measurements referring to the vertical plane Cons
59. hine must be aligned according to the ACEO standard and adhere to the manufacturer s alignment standard for the drive machine When heating the machine has its shaft line which grow up Between stop and rotation the shaft axis location inside its bearing is different The total axis height elevation is composed of the thermal elevation and of the bearing elevation CAUTION THE ALIGNMENT MUST BE DONE TAKING IN CONSIDERATION THE SHAFT MOVEMENT CORRECTION The correct locating of the parts must be obtained by inserting shims under the machine pads The double bearing machines are mounted with bearings ball or roller or Sleeve bearings The axial clearance of the bearings if the machine has Sleeve bearings must be distributed as well as possible taking into account the axial thermal expansion The Anti friction bearing machines with a positioning bearing standard machine do not have axial play The machines are delivered with the rotor mechanically centered axially and radially in relation to the stator CAUTION THE ALIGNMENT STANDARDS OF MANUFACTURERS OF DRIVE MACHINES ARE FREQUENTLY MORE PRECISE THAN THOSE OF THE A C E O b Axis height Thermal elevation AH mm cf Him AT x H m Height of the machine axis AT frame temperature elevation 30 C Coefficient of steel elongation 0 012 1 AS C Sleeve bearing shaft elevation The calculated displacement is given in section 1 Exact Sleeve
60. idering the vertical plane C1 The vertical action towards the top of shaft A on the micrometer is dominant In the plane C1 the axis A is higher than axis B 0 9 0 1 2 0 05 mm In the vertical plane C2 the vertical action towards the top of shaft B on the micrometer is greater In the plane C2 the axis B is higher than axis A 0 134 0 102 2 20 16 mm The respective position of the axes is as follows C1 Regarding the vertical plane the angular alignment error is 0 16 0 05 100 400 0 0525 mm 100mm not acceptable Measurements referring to the horizontal axis In the plane C1 the axis B is further to the right than A 0 104 0 86 2 2 0 09 mm In the plane C2 the axis B is further to the left than A 0 70 1 64 2 0 47 mm The representation of the shafts is as follows C1 Regarding the horizontal plane the angular error is 0 47 0 09 100 400 0 14 mm 100mm not acceptable In the both planes the parallelism error is 5 9 0 103mm OF 416 47 0 496mm not acceptable 4 4 ELECTRICAL CONNECTIONS 4 4 0 General points The installation must comply with the electrical diagrams Refer to the attached the electrical diagrams Check that all the protection devices are correctly connected and in good working order The assembler has the responsibility to mechanically and electrically protect the generator within the
61. il return line then make sure that the circuit modification does not disturb the oil return flow 2 4 10 Sleeve bearing protection devices a Sight level glass A sight level gauge is placed on each bearing housing on the left or the right The level control method is described in chapter 2 4 5 a b Cil thermometer optional The thermometer gives the oil sump temperature The recorded oil sump temperature must stay below 85 C in normal condition Thermostat or sensor optional The recorded oil sump temperature must stay below 85 C in normal condition The shell temperature must stay below 90 in normal condition Shell metal Alarm points and shutdown alarm 95 203 F shutdown 100 212F Oil sump Alarm points and shutdown alarm 85 185 F shutdown 906 194 To improve the bearing protection the temperature set points can reduced following the effective site condition Alarm temperature Highest recorded temp 5K Trip temperature Alarm temperature 5 Highest recorded temp Temperature measured at the site in the worst temperature Eg A bearing reach 80 in the worst site condition Adjust the alarm set point to 85 C instead of 95C a s previously recommended Adjust the trip set point to 90 C instead of 100C a s previously recommended d Pre lub pump optional A pump takes up the oil from the bearing oil sump and pours it over the bearing shell This pum
62. ing 10y This paragraph applies to standard bearings with low axial thrust self lub or oil circulation as types E Z K E Z Q Maximum acceptable pollution following ISO 4406 18 16 13 following NAS 1638 class 9 Filtering level to ensure oil circulation bearing following ISO 16889 Pasio 100 filtering 25 AS 2 6 OIL CIRCULATION LUBRICATING UNIT 2 6 0 General points Oil circulating bearing are noticeable by the third digit of their code Letters Z X U indicate the use of an oil circulating bearing Example of oil circulating bearing EFZLK ERXLA For engineering reason need of cooling need of lubrication an external oil supply can be requested Following the machine engineering the lubricating oil can come from different sources e Oil from the drive engine System with gravity return e Oil lubricating unit System with gravity return e Unit heater 2 6 1 Oil circulation by gravity return a General This chapter applies for bearings which need an oil circulation system The operating condition sequences of operation maintenance are given by a specific notice attached to the present one 1 Oil inlet 2 Oil sight level indicator 3 Exhaust elbow 4 Immediate slope 5 Following ducts 6 Return oil sump 7 Breather Correct oil flow is obtained by regulating the pressure at the bearing inlet item 1 34 SERV
63. ion machine class IC 6 A1 A6 1 Air to Air cooler 2 Ambient air 3 Internal air The air cooler comprises a main housing containing the tubes and an end housing which act as an air guide 37 SERVICE AND OPERATING MANUAL ALTERNATORS Description Air Water double tube exchanger The internal air flow is moved by a fan fixed on the machine shaft The internal cooling air circulates through the machine and through the air cooler in a closed circuit The internal air circulation can be created through natural ventilation machine class IC 8 A1 W7 or through separate ventilation machine class IC 8 A6 W7 Eg machine class IC 8 A1 W7 1 Air to Water cooler The double tube technique keeps the cooling circuit from being affected by possible water leakage The double tube provides a high safety level In case of leakage the water goes from the inside of the internal tube to the coaxial space between the two tubes The water is drained axially to a leakage chamber where it may activate a sensor An exchanger comprises a fin tube block containing a steel frame a fin tube block crimped mechanically to the tubes The tube bundle is roll expanded in the end plates parts 3 and 4 The water distribution in the tubes is provided by two removable water boxes part 5 A water box is equipped with collars for fitting the inlet and outlet lines Neoprene seals ensure watertightness between the water box
64. ions or Drive End H V A Non Drive End H V A All works must be carried out by a qualified and authorized person For more information please refer to the service manual Tested by Date amp Signature 51 SERVICE AND OPERATING MANUAL ALTERNATORS 5 1 ELECTRICAL START UP INSPECTION 5 1 0 General points Electrical connections auxiliaries safeties and power connections must comply with the diagrams provided Refer to chapter 4 DANGER CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY 5 1 1 Winding Insulation The insulation and the polarization index must be measured on start up and then each year To measure the insulation refer to the chapter 6 3 2 5 1 2 Electrical connections The phases must be connected directly to the machine links with no spacers or washers etc Make sure that the lugs are sufficiently tightened CAUTION ALL CURRENT TRANSFORMERS MUST BE CONNECTED 5 1 3 Parallel operation a Definition of parallel operation Between machines Parallel operation is possible if the power ratio between the smallest machine and the largest machine is less than or equal to 10 With the mains The mains is defined as a source of power greater than or equal to ten times the output of the machine with which it will be coupled b Possibility of parallel operation Parallel operation if planned at the outset does not cause any problems
65. is prevented Interrupt the cooling water supply EFW bearing only Remove all thermo sensors from the connection holes Take all necessary measures to collect the lubricating oil Unscrew the oil drain plug 27 and collect the lubricating oil refer to chapter 2 4 5 c b Lifting equipment The following steps are to be observed before using the lifting equipment To transport the complete bearing unit Check if the split line screws are tight 12 Check if the eye bolts are tight 6 Connect the lifting equipment to the eye bolts 6 24 SERVICE AND OPERATING MANUAL ALTERNATORS To transport the top half of the housing Check if the eye bolts are tight 6 Connect the lifting equipment to the eye bolts 6 To transport the bottom half of the housing Screw 2 eye bolts 6 with suitable threads tight into the tap holes 17 marked with a cross z Connect the lifting equipment to the eye bolts 6 To transport the Bearing shells Screw 2 eye bolts or w hooks with suitable threads ree into the tap holes 9 Connect the lifting equipment to the screw hooks c Dismantling of the shaft seal type 10 outboard side Loosen all screws 55 and turn them off Remove simultaneously in axial direction both top half 48 and bottom half 51 of the seal carrier from the housing Shift the top half of the seal 53 a little about 20 mm Tilt it over carefully until the hook spring 49 unbends DA
66. just both halves of the loose oil ring till the split lines match each other Tighten the screws 47 25 SERVICE AND OPERATING MANUAL ALTERNATORS h Dismantling the machine side shaft seal Shift the top half of the seal 53 a little about 20 mm Tilt it over carefully until the hook spring 49 unbends DANGER DURING DISMANTLING OF THE FLOATING LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING 38 THIS IS UNDER TENSION AND COULD SPRING BACK AND LEAD TO INJURY Open the hook spring 49 and turn the bottom half of the seal 52 in the opposite direction to the anti rotation pin out of the integrated seal groove of the bottom half of the housing i Removal of the bottom half of the shell CAUTION MAKE SURE THAT ALL BEARINGS MOUNTED ON A SHAFT LINE ARE OPENED LOOSEN THE SPLIT LINE SCREWS OF THE HOUSINGS CAUTION THE LIFTING EQUIPMENT SHOULD NOT COME IN TOUCH WITH THE SEAL AND RUNNING SURFACES OF THE SHAFT Lift the shaft up to the point where shaft and bottom half of the shell 13 do not touch each other any more Protect the shaft against unintended movement Turn the bottom half of the shell 13 out of the bottom half of the housing 21 and remove it from the shaft j Dismantling of the machine seal Usually it is not necessary to dismantle the machine seal 10 if maintenance works are carried out If due to certain reasons the split machine seal must be dismantled please observe that this operati
67. lation b Standard operation with water Emergency operation without water 2 7 2 Start up of the water cooler General points 2 7 3 Maintenance of the water cooler General points b Cleaning C Leak detection for a double tube exchanger 2 7 4 Servicing the water cooler Cooler removal b Cooler re assembly 2 7 5 Cooler protection devices Leak detection float system b Water temperature sensor Water filtering 2 8 AIR FILTERS 2 8 0 General 2 8 1 Cleaning a Air filter cleaning period b Air filter cleaning procedure 2 18 TERMINAL BOX 2 18 0 Description 2 18 1 Electric panel a Compounding panel if compound regulator b Booster plate if shunt regulator 2 18 2 Automatic voltage regulator 2 18 3 Electrical contact tightening 2 19 PROTECTION DEVICES 2 19 1 Stator protection devices 2 19 2 Bearing protection devices 2 19 3 Cooler protection devices 2 20 NAMEPLATES 2 20 1 Main nameplate 2 20 2 Lubrication nameplate 2 20 3 Rotation direction nameplate SERVICE AND OPERATING MANUAL ALTERNATORS 3 VOLTAGE REGULATOR AND EXTERNAL AUXILIARIES 4 INSTALLATION 4 1 TRANSPORT AND STORAGE 4 1 1 Transport 4 1 2 Storage warehouse 4 1 3 Maritime packing 4 1 4 Unpacking and installation 4 1 5 Storage measures of a site machine 4 2 INSTALLATION OF THE MACHINE 4 2 1 Fitting the coupling double bearing machine only 4 2 2 Fitting the stator 4 3 ELECTRIC MACHINE ALIGNMENT 4 3 1 Various align
68. llways possible because of 8 19 2 27 798 a lack of access When the air gap can be reached the 10 37 7 30 1083 measure can be fastidious because of paint and resin 12 64 9 33 1467 coating on the checked surfaces 14 103 36 1890 To make the measure more reliable and easy the air gap 16 160 check will be done onto the exciter Air gap 1 mm max offset 0 1 mm 1 mm s Air gap max offset 10 of air gap b Double bearing machine Verification of the air gap is not necessary The rotor is mechanically centered by its construction Even after dismantling and reassembling the machine the rotor will return to its position without verification of the air gap The exciter air gap of generators type A60 and A62 are site adjustable c Single bearing machine When the machine is delivered the rotor is mechanically centered in the stator see chapter on alignment After dismantling the machine it will be necessary to center the rotor in the stator by using the two half shells delivered with the machine as explained in the chapter 4 3 3 If you do not have 1 2 shells use a dial indicator to check the concentricity between the shaft machined surface and the front bearing machined surface 6 2 2 Bolts tightening Check the tightening of the sleeve bearing fixing bolts refer to chapter 2 4 Check the tightening of the rotating diodes refer to chapter 2 2 4 Check the tightening of the terminal box accessories refer to chapter 2 18
69. ment characteristics General points b Axis height Thermal elevation C Sleeve bearing shaft elevation d Antifriction bearing shaft elevation 4 3 2 Two bearings machine alignment a machines without axial end play standard b machines with axial end play 4 3 3 Single bearing machine alignment General points b Single bearing machine 4 3 4 Alignment procedure a Checking Double concentricity alignment method 4 4 ELECTRICAL CONNECTIONS 4 4 0 General points 4 4 1 Phase sequence standard machine IEC 34 8 b if wanted NEMA 4 4 2 Insulating distances 4 4 3 Added products in the terminal box 5 START UP 5 0 START UP SEQUENCE 5 0 1 Static checks 5 0 2 Rotating checks a Rotating checks not excited b Rotating checks at no load excited C Generator and site safeties d Rotating checks at full load 5 0 3 Generator Start Up check list 5 1 ELECTRICAL START UP INSPECTION 5 1 0 General points 5 1 1 Windings Insulation 5 1 2 Electrical connections 5 1 3 Parallel operation a Definition of parallel operation b Possibility of parallel operation c Parallel coupling 5 2 MECHANICAL START UP INSPECTION 5 2 0 General points a Alignment fixing prime mover b Cooling Lubrication 5 2 1 Vibrations 6 PREVENTIVE MAINTENANCE 6 1 MAINTENANCE SCHEDULE 6 2 MECHANICAL MAINTENANCE 6 2 1 Air gap check General points b Double bearing machine Single bearing machine 6 2 2 Bolts tightening 6 2 3 Cle
70. n Oil filler hole Top sight glass Eye bolt Screw Screw Tap hole in the top and bottom halves of the shell up size 14 Machine seal Top half of the shell Split line screw bearing housing Bottom half of the shell Spherical seating Sx eve Engraved number bearing shell Recess Tap hole Screw Split line screw bearing shell Engraved numbers bearing housing Bottom half of the housing Connection hole for temperature measurement of the journal part Oil sight glass Connection hole for the oil sump temperature measurement Out Inlet cooling water Type ExW xx Oil cooler Type ExWxx Oil drain plug 1 5 12 D 15 17 18 66 SERVICE AND OPERATING MANUAL ALTERNATORS 10 2 2 Oil circulation bearing 10 12 13 14 15 half of the housing Positioning pin hole Positioning pin Connection hole for the thrust part oil supply optional Top sight glass Eye bolt Screw Screw Tap hole in the top and bottom halves of the shell up size 14 Machine seal Top half of the shell Split line screw bearing housing Bottom half of the shell Spherical seating Engraved number bearing shell Recess Tap hole Screw Split line screw bearing shell Engraved numbers bearing housing Bottom half of the housing Connection hole for temperature measurement of the journal part
71. n the split line surfaces of the top and bottom halves 1 21 of the housing Apply sealing compound over the whole surface of the split line of the bottom half 21 of the housing Place the top half of the housing carefully into the machine shield without touching the seals or the bearing shell 29 SERVICE AND OPERATING MANUAL ALTERNATORS Lower the top half of the housing 1 vertically on the bottom half of the housing 21 Lower the top half of the housing 1 until the split line of the housing is not visible any more Gently hit the bottom half of the housing 21 with a nylon hammer thus ensuring the alignment of the spherical seating Insert the split line screws 12 Tighten them hand tight Insert the flange screws 8 Tighten them using the following torque values orque Nm 170 330 570 1150 Tighten the split line screws 12 of the housing crosswise using the same torque values f Assembly of the type 10 Outboard Side Seals DANGER DURING ASSEMBLY HOLD THE HOOK SPRING ENDS 49 SECURELY TO AVOID THEM SUDDENLY RELEASING AND CAUSING POSSIBLE INJURY Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing Place the hook spring 49 around the shaft and hook both ends into each other Locate both halves of the seal 52 53 in their place on the shaft Locate the hook spring 49 in the spring groove 50 Turn the floating labyrin
72. needle fitted on the drive end side bearing must face a groove machined on the shaft If the needle is missing the distance A distance from the groove up to the first bearing part is stamped on the shaft enabling checking Example for a sleeve bearing machine Sx ovs 4 3 3 Single bearing machine alignment a General points The alignment consist also to get the rotor of the synchronous machine coaxial to its stator A et B give the shaft line alignment D et E give the alignment of the stator regarding the rotor Because of the engineering of the synchronous machine the only requested adjustment is C For generators type A60 and A62 E can be adjusted refer to 6 2 1 b Single bearing machine It is imperative to position the rotor axially in relation to the stator in order to achieve correct magnetic centering of the rotor in the stator Single bearing machines are delivered by the ACEO factory with the rotor centered mechanically axially and radially in relation to the stator Two half shells B parts mounted on the front flange act as a front es for the transportation and installation The outside of the centring half shells face a groove machined on the shaft A The half shells have L L construction symmetry The length A shown on the diagram is stamped on the shaft end allowing alignment in case of
73. nerating a three phase current coupled with the three phase rectifier bridge comprised of six diodes supplies the excitation current to the generator revolving field The excitation armature and the rectifier bridge are mounted on the synchronous generator rotor shaft and are interconnected electrically with the revolving field of the machine The excitation field winding stator is supplied by the control in direct current 1 Excitation field winding 2 Excitation armature 3 Rotating diode bridge 4 Revolving field 5 Machine stator Sx eve SERVICE AND OPERATING MANUAL ALTERNATORS 2 DESCRIPTION OF SUB ASSEMBLIES 2 1 STATOR 2 1 1 Electric machine armature a Mechanical description The machine stator comprises low loss steel laminations assembled under pressure The steel laminations are blocked axially by a welded ring The stator coils are inserted and blocked in the slots then impregnated with varnish and polymerised to ensure maximum resistance to mould excellent dielectric rigidity and perfect mechanical linking 2 1 2 Excitation field winding The excitation field winding comprises a solid element and a winding The excitation is flanged on the rear end shield of the machine The winding is made of enamelled copper wires 2 1 3 Stator protection a Heating resistor The heating element avoids internal condensation during the shutdown periods It is connected to the main terminal box s
74. nual Any operating condition other than those specified by the original tender must receive a Leroy Somer agreement Any modification of the machine structure must receive a Leroy Somer agreement b Vibratory analysis It is the responsibility of the gen set manufacturer to ensure that the different assembled system will be vibratory compatible ISO 8528 9 and BS5000 3 It is the responsibility of the gen set manufacturer to ensure that the shaft line torsional analysis has been done and accepted by the different parties ISO 3046 CAUTION EXCEEDING THE VIBRATORY LEVEL ALLOWED BY THE STANDARD ISO 8528 9 amp BS5000 3 MAY CREATE HEAVY DAMAGES BEARING DAMAGE STRUCURE CRACKS EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF THE SHAFT LINE ex ABS LLOYD MAY CREATE HEAVY DAMAGES CRANKSHAFT FAILURE GENERATOR SHAFT FAILURE Refer to chapter 2 1 3 for further information about the accepted vibration level of the standard ISO 8528 9 and BS5000 3 SERVICE AND OPERATING MANUAL ALTERNATORS 1 2 GENERAL DESCRIPTION 1 2 1 Generator The synchronous generator is an alternating current machine without rings or brushes The machine is cooled by the flow of air through the machine For a better comprehension use the drawings of chapter 10 1 2 2 Excitation system The excitation system is mounted on the side opposite the coupling The excitation system comprises two assemblies The excitation armature ge
75. o hold the cooler when it comes out of its housing Remove the cooler using slings that can be attached to the connecting flanges b Cooler re assembly Carry out the operations of the Cooler Removal chapter in the reverse order Be careful to push the cooler completely into its housing before tightening the fastening screws of the cooler to the casing 2 7 5 Cooler protection devices a Leak detection float system A magnet float activates a switch located in the float guiding rod 1 Guide rod 2 Magnetic float A No potential contacts x Blue y Brown z Black b Water temperature sensor optional A temperature sensor may be installed into the water inlet flow of the cooler Proposal of adjustment of the water inlet sensor Alarm temperature Water site temp max 5 Trip temperature Alarm temperature 5 c Water filtering Water filtering is not ensured by Leroy Somer Water filtering must be better than 300 u 40 SERVICE AND OPERATING MANUAL ALTERNATORS 2 8 AIR FILTERS 2 8 0 General Only use approved filters Any filter not correctly engineered may conduce to air flow restriction and then to abnormal generator cooling or to dust entering the generator 2 8 1 Cleaning a Air filter cleaning period The cleaning period depends of the site conditions and can change The cleaning of the filter is requested if the record of the stator winding temperature using
76. of the top 59 and bottom half 63 of the rigid labyrinth seal the split lines of the bottom half 63 of the rigid labyrinth seal Illustration 10 Application of sealing compound on the rigid labyrinth seal 31 SERVICE AND OPERATING MANUAL ALTERNATORS Place the top half 59 of the rigid labyrinth seal on the shaft and press slightly the bottom half 63 of the rigid labyrinth seal from below against it Lightly push the rigid labyrinth seal completely into the housing Tighten the split line screws 61 Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the housing CAUTION PRESS THE RIGID LABYRINTH SEAL FROM BELOW AGAINST THE SHAFT Adjust the rigid labyrinth seal in such a way that the clearance f between the shaft and the rigid labyrinth seal at both split lines has the same figure O 3 59 e mo v Intl Illustration 11 Alignment of the rigid labyrinth seal Tighten the screws 60 by using the following torque values beni 2 h Assembly of the RD thrust pads bearing type E A Clean both top and bottom halves of the shroud ring and all RD thrust pads Check if the parts show any visible damage Carry out the assembly of both thrust parts of the top 6 and bottom 27 half of the shell according to the following instructions An RD thrust pad on both sides of the top half of the shell ha
77. olarization index enables the status of the machine insulating to be verified and gives an indication of the pollution of the winding A poor polarization index may be corrected by a cleaning and drying of the winding The following measurements can be taken at any time without any damage to the machine insulating material CAUTION ALL ACCESSORIES MUST BE DISCONNECTED AVR EMC FILTER REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY THE ACCESSORIES TO DISCONNECT NOTE It must be done using a stable DC source Use a specific polarization index appliance under 500 or 1000 DC volts refer to insulation of the winding chapter for the correct applied voltage Open the winding star point Disconnect AVR cables from the stator terminals Apply the requested voltage After 1 minute record the Insulating resistance After 10 minutes record the Insulating resistance The polarization index must be higher than 2 Proceed for each phase 59 SERVICE AND OPERATING MANUAL ALTERNATORS 7 SERVICING 7 1 GENERAL SERVICING DANGER BEFORE WORKING ON THE GENERATOR MAKE SURE THAT THE START UP CANNOT BE ACTIVATED BY ANY MANUAL OR AUTOMATIC SIGNAL DANGER BEFORE WORKING ON THE MACHINE MAKE SURE THAT YOU HAVE UNDERSTOOD THE OPERATING PRINCIPLES OF THE SYSTEM IF NECESSARY REFER TO THE APPROPRIATE CHAPTERS IN THIS MANUAL CAUTION GIVEN THE POWER FACTOR APPLIED TO THE MACHINE A VOLTMETER OR KILOWATT METER DOES N
78. on can be carried out only from the inner part of the machine Loosen the split line screws of the machine seal and remove the flange screws 7 Non split machine seals can be dismantled only after dismantling the machine shield or the shaft completely In the case the machine seal is equipped with a hamp packing some visible changes can be noticed such as tallow excess black color of the seal due to temperature development Even in such cases it is not necessary to renew the hamp packing Color changes will appear with a new hamp packing too until the seal clearance adjusts during operation Sx eve 2 4 7 Cleaning and checking a Cleaning CAUTION USE ONLY NON AGGRESSIVE DETERGENTS SUCH AS FOR INSTANCE VALVOLINE 150 ALKALINE CLEANING COMPOUNDS PH VALUE 6 TO 9 SHORT REACTION TIME DANGER PLEASE OBSERVE THE INSTRUCTIONS FOR THE USE OF THE DETERGENTS CAUTION NEVER USE CLEANING WOOL OR CLOTH RESIDUES OF SUCH MATERIALS LEFT IN THE BEARING COULD LEAD TO EXCESSIVE TEMPERATURES Clean the following parts thoroughly top half of the housing 1 bottom half of the housing 21 top half of the shell 11 bottom half of the shell 13 sealing surfaces of the top half 48 and bottom half 51 of the seal carrier or of the rigid labyrinth seal loose oil ring 44 Water cooler cleaning bearing type EFW only Check the condition of the oil cooler 26 In case the oil cooler 26 is encrusted with oil sludg
79. ors Additionally in order to make information finding easier Section 1 Characteristics and Performance has been included describing the machine completely type of construction type of bearing protection index and so forth this will enable you to determine exactly the chapters which apply to your machine This synchronous machine has been designed for a maximum length of service To achieve this it is necessary to pay special attention to the chapter concerning the periodic maintenance schedule for the machines 1 1 1 Safety notes The warnings DANGER CAUTION NOTE are used to draw the user s attention to different points DANGER THIS WARNING IS USED WHEN AN OPERATION PROCEDURE OR USE MAY CAUSE PERSONAL INJURY OR LOSS OF LIFE CAUTION THIS WARNING IS USED WHEN AN OPERATION PROCEDURE OR USE MAY CAUSE DAMAGE TO OR DESTRUCTION OF EQUIPMENT NOTE This warning is used when an operation procedure or delicate installation requires clarification 1 1 2 Conditions of use a Generalities A machine must only be installed operated by qualified and trained persons Any technical engineer operating maintaining this machine must be allowed to practice in regard with local working laws eg to be certified to operate on high voltage devices A machine can only be operated for the duty foreseen by its original tender The main data of this machine are summarized in Section 1 of this ma
80. p ensures bearing lubrication increasing the greasing effect during operation at very low speed and start up period Check the electrical connection of the pump motor to be sure of the rotation direction the rotation direction is indicated on the pump The pump has to be run few seconds before the synchronous machine starting pre lub effect and stopped as soon as the main shaft line pass over200 rpm For application having a long stop period time over 5 minutes eg Steam Turbine hydro turbine the pump has to be run as soon as the speed pass below 200 rpm The pump has to be run continuously during barring period eg engine maintenance 33 SERVICE AND OPERATING MANUAL ALTERNATORS e Oil filtering and pollution Following indication are related to the maximum acceptable oil pollution level and to the oil filtering level filter efficiency which has to be installed to obtain a clean oil Refer to Section 1 to get data about the used bearing The viscosity change must remains within 1096 of a fresh oil lubricant Acidity change must remains TAN 0 5 mg KOH g of a fresh oil lubricant Humidity ratio must remains below 0 05 96 This paragraph applies to bearings designed for high axial thrust tilting pads technology as used in bearings type motes A Maximum acceptable pollution following ISO 4406 17 15 12 following NAS 1638 classe 7 Filtering level to ensure following ISO 16889 oce 100 filter
81. s a bore for the insertion of a thermo sensor thrust part temperature measurement To mount the RD thrust pad into the correct position proceed as follows Find the position of the location hole 38 on the top half of the shroud ring 39 Insert the RD thrust pad 42 with the anti rotation pin 43 into the corresponding thrust pad location hole 37 Insert all other RD thrust pads 42 into the corresponding thrust pad holes 37 of the top and bottom half of the shell 6 27 SX Illustration 1 Assembly of the RD thrust pads Place the top half of the shroud ring 39 into the top half of the shell 6 by inserting the anti rotation pin 43 into the location hole 38 Match the split line of the top half of the shell 6 with the split line of the top half of the shroud ring 39 in true alignment Ye EN 38 o gt dO e Bh o Illustration 2 Assembly of the shroud ring Tighten the screws 40 by using the following torque values ers Place the bottom half of the shroud ring 41 into the bottom half of the shell 27 Match the corresponding split lines in true alignment Tighten the screws 40 with the same torque value as valid for the top half of the shell 6 Check the mobility of all RD thrust pads 42 If the RD thrust pads jam realign the top 39 and bottom half 41 of the shroud ring CAUTION INSUFFICIENT MOBILITY OF THE RD THRUST
82. s indicated below A diode in good condition should allow the current to flow only in the anode to cathode direction Disconnect the diodes before the test 3 48 volts 1 Field O 2 2 Rotating resistors 3 Exciter armature The inner and outer rings are connected to the revolving field coil 1 Anode 2 Cathode Diode type Negative diode housing diode wire When reassembling ensure that the diodes are be tightened to the correct torque 1 Outer ring 2 2 5 Balancing 2 Inner ring The entire rotor has been balanced according to 1508221 The diode fastening screws must be tightened to the standard in order to obtain a residual imbalance less than correct torque Gen set Class G2 5 Turbine Class G1 b Tightening torque for the rotating diode fastening The balancing is carried out at two levels The first is that Screws of the fan It is recommended when the fan is refitted CAUTION after servicing to respect the initial indexing THE ROTATING DIODE FASTENING SCREWS MUST The second is that of the shaft end The shaft end is cold BE TIGHTENED USING A TORQUE WRENCH stamped to indicate the type of balancing CALIBRATED TO THE RECOMMENDED TORQUE H balancing with Half key carried out as standard Tightening torque F balancing with Full key 1 5 m daN N balancing without key None 3 m daN _ The coupling must be balanced to fit the generator rotor 1 5 m daN balancing 2 2 6
83. size Flange Thread inter Oil flow max mm l min ISO VG 32 ISO VG 68 ISO VG46 ISO VG100 DIN DN32 G1 1 33 7 5 5 5 DIN DN40 G1 1 2 40 11 9 DIN DN50 G2 50 17 16 DIN DN65 G2 1 2 66 30 25 DIN DN80 G3 80 45 40 Sx ovs 35 LEROY SOMER SERVICE AND OPERATING MANUAL ALTERNATORS 2327 en 11 2011 Connection in Y shape It is acceptable to join the return lines of two bearings In this case it is necessary to maintain a constant oil speed Pipe section after 2 sum of the both pipes section f 9 LT Sx eve 2 6 2 Oil cooling unit Air Oil exchanger This system does not apply to high thrust capability bearings bearings noticeable by the fifth digit of their code Example cannot be used for a bearing EFZLA The cooling unit is a compact system totally fitted on the machine close to the bearing The oil is pumped from the bearing sump passes through an Air to Oil cooler and is then routed back to the bearing shell A fan ensure the cooling of the unit using the ambient air The oil circulates under low pressure The oil flow is fixed at the factory without any possible adjustment The pump and the fan must run permanently as long as the synchronous machine will rotate No specific maintenance is required except vibration dampers CAUTIO
84. step tightening at Y of the nominal torque gna step tightening at 1 2 of the nominal torque gu step tightening at 3 4 of the nominal torque final step tightening at 4 4 of the nominal torque The tightening must be done diagonally using a torque wrench b we we ws s 70 2 diagonally tightening principle Make sure that the safety devices are operating Connect the supply and return lines Fill with water whilst carefully draining the circuit CAUTION machine with motorized fan only WE RECOMMEND THAT THE FREE OPERATION OF THE FAN BE CHECKED NO FRICTION NO BLOCKING CAUTION BEFORE START UP CHECK THE CLEANLINESS OF THE COOLER FINS Start up the installation if the other sub assemblies allow this Load the machine KVA adjust the water flow rate to obtain the rated flow rate refer to Section 1 Check the water tightness of the lines and of the exchanger 39 SERVICE AND OPERATING MANUAL ALTERNATORS Check that the temperatures comply with the recommended temperatures 2 7 3 Maintenance of the water cooler a General points A regular cooler clogging will have the result to a regular winding temperature increasing The cooler cleaning period is mainly function of the water purity In case of used of non recirculated water with risk eg river water with algae passing trough the cooler we recommend a tubes visit after one year of operation The follo
85. tached cut view in chapter 10 for an easier understanding 2 4 0 Description of horizontal Sleeve bearings a Physical description Rotation of the machine rotor is guided by Sleeve bearings The bearing housing is constructed in two ribbed parts providing considerable heat extraction potential The sleeve bearing comprises two half shells with an external spherical shape This allows self alignment The guiding surfaces of the sleeve bearing are covered with tin based anti friction metal The spherical seat of the housing of the electrically insulated bearings is covered with an insulating coating The positioning pin of the sleeve bearing in the housing is also insulated with an insulating bush The lubrication ring mounted free on the shaft is made of brass In order to simplify dismantling the ring is cut in two parts assembled using screws A guide for the lubrication ring synthetic materials is attached to the upper bearing half shell for marine applications only The floating labyrinth seals are cut in two parts held together by an expandable ring These seals are inserted in a support A seal positioning pin rests in the support to block it during rotation The upper part of the housing is closed by means of a glass plug allowing observation of the rotation of the lubrication ring A threaded metal plug allows the bearing to be filled with oil The lower housing may be equipped with an oil level sight indi
86. temperature Following technical specification in Section 1 Refer to 2 3 3 See lub plate grease at least every 6 months Refer to 2 3 5 1 Or once a year Sx eve 54 SERVICE AND OPERATING MANUAL ALTERNATORS LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE following Days Hours Comments COOLER Following technical specification in Section 1 Leakage level 1 Refer to 2 7 5 Water temperature 1 Refer to 2 7 5 Cleaning Refer to 2 7 3 following site condition VIBRATION DAMPERS 8000 Voir 2 6 2 2 6 3 2 7 0 2 18 2 FILTERS Following technical specification in Section 1 Cleaning 1000 Refer to 2 8 amp following Section 1 FAN MOTOR Following technical specification in Section 1 Bearing Re greasing Refer to motor lub plate following Section 1 PROTECTION DEVICES 8000 1 Refer to 2 19 et Section 1 sensors 1 Or once a year 55 SERVICE AND OPERATING MANUAL ALTERNATORS Bolt Steel Steel 6 2 MECHANICAL MAINTENANCE greasy thread To obtain additional information on the maintenance of nominal Torque nominal Torque sub assemblies refer to the chapters dealing with the sub mm mN mm mN assemblies concerned I 3 1 0 18 222 4 2 3 20 313 6 2 1 Air gap check 5 46 22 430 a General points 6 7 9 24 540 The direct air gap check is not a
87. ter pipes must be connected stress free Water pipes must be able to expand without restraint CAUTION FOR MACHINE SUPPORTING A VIBRATION LEVEL HIGHER THAN 5 MM S RMS WE RECOMMEND THE USE OF HYDRAULIC FLEXIBLE JUNCTION A pressure limit or must be installed on the system to protect the complete assembly against abnormal over pressure b Standard operation with water CAUTION WATER SUPPLY MUST BE EFFECTIVE AS SOON AS THE GENERATOR IS ROTATING UP TO THE COMPLETE SHAFT LINE STOP CAUTION WATER SUPPLY MUST BE STOPPED AS SOON AS THE GENERATOR IS STOPPED TO AVOID IMPORTANT CONDENSATION INTO THE GENERATOR Sys c Emergency operation without water As an option the machines can be engineered to be able to operate in an Emergency mode without water flow Only machines engineered for this operation case can operate without water flow CAUTION THIS OPERATING CONDITION CORRESPOND TO A POWER DERATED OPERATING MODE In such case the machine operate in open drip proof mode cooling ensured by ambient air with a protection level IP23 The air inlet and outlet flaps located at the non drive end and drive end side of the machine must be open concerned openings are marked by specific labels before running the shaft line 2 7 2 Start up of the water cooler a General points If the cooler has been stocked for more than 6 months recheck the correct tightening of the water boxes The tightening must be done in 4 steps a
88. th seal on the shaft CAUTION THE FLOATING LABYRINTH SEAL SHOULD TURN EASILY ON THE SHAFT A JAMMED SEAL COULD LEAD TO OVERHEATING DURING OPERATION AND EVEN TO SHAFT WEAR If the floating labyrinth seal jams dismantle it from the shaft Remove the worn parts of the seal carefully by using emery paper or a Sleeve scraper Dismantle the floating labyrinth seal NOTE We do not recommend the use of sealing compound onto the floating labyrinth seals However for certain leakage type the use of Curyl T may help to solve the encountered issue Apply a uniform layer of sealing compound on the seal surfaces and on the split line surfaces of both halves of the seal 52 53 AS Illustration 6 Application of sealing compound on the floating labyrinth seal Press the bottom half of the seal 52 against the shaft Place the top half of the seal 53 on the shaft and align both halves of the seal to each other Place the hook spring 49 into the spring groove 50 and stretch until both ends can be hooked E Illustration 7 Assembly of the floating labyrinth seal Align the split line of the floating labyrinth seal and the split line of the seal carrier Check that both engraved numbers 56 and 58 on top and bottom halves of the seal carrier 48 51 correspond Clean the following the seal surfaces of the top 48 and bottom 51 half of the seal parts carrier the groove of the floating labyrinth s
89. the stator winding sensors indicates an abnormal increase in temperature b Air filter cleaning procedure The filter element flat or cylindrical is immersed in a tank of cold or warm water temperature less than 50 C Use water with detergent added Shake the filter gently to ensure that the water flows through the filter in both directions When the filter is clean rinse it with clear water Drain the filter properly there must be no more formation of droplets Refit the filter on the machine CAUTION DO NOT USE WATER WITH A TEMPERATURE HIGHER THAN 50C DO NOT USE SOLVENTS NOTE Do not clean the filter using compressed air This procedure would reduce filter efficiency 2 18 TERMINAL BOX 2 18 0 Description Use the attached Terminal box drawing The main terminal box of the machine is located on the top of the machine The neutral and phase wires are connected to the terminals one terminal per phase and one terminal per neutral line See Terminal Box diagram The openings provide access to the terminals The gland plates are made of non magnetic materials in order to avoid circulating currents The connection of accessories is achieved by terminal strips Use a 5 mm maximum screwdriver to work on the blocking screws See the Machine Protection Devices diagram If products have to be added in the terminal box CT s VT s Shunt ex refer to chapter 4 4 3 2 18 1 Electric panel a Compo
90. tion pin into the groove of the housing until the split lines of the bottom half of the housing and the bottom half of the seal match each other AS Remove the rest of the sealing compound Push the spring hook into the integrated seal groove between the bottom half of the housing and the seal until both ends jut out from the split line Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of the seal Stretch the hook spring until both ends can be hooked Installation of the loose oil ring Open both split lines of the loose oil ring 44 by untightening and removing the screws 47 Separate both halves of the loose oil ring 44 carefully without using any tools or other devices Illustration 4 Opening of the loose oil ring Place both halves of the loose oil ring into the shell groove 13 encircling the shaft Press the positioning pin 45 of each split line into the corresponding hole 46 28 SERVICE AND OPERATING MANUAL ALTERNATORS Adjust both halves of the loose oil ring until the split lines match each other Illustration 5 Installation of the loose oil ring Tighten the screws 47 by using the following torque values emos s 2 ome va 27 27 er d Fitting in the top half of the shell Apply some lubricant on the running surfaces of the shaft Use the same type of lubricant as indicated for bearing oper
91. tion bearings have a lubrication plate fixed on the stator giving Type of bearing Grease change frequency Quantity of grease 2 20 3 Rotation direction nameplate An arrow on the drive end bearing indicates the rotation direction Sx eve 42 SERVICE AND OPERATING MANUAL ALTERNATORS 4 INSTALLATION 4 1 TRANSPORT AND STORAGE 4 1 1 Transport During the transport the intermittent shocks level applied to the machines must remains below 30 m s Machines equipped with roller bearing must have their rotor locked during the transport to avoid false brineling problem Machine temperature must remains within the range 20C to 70 Stay down to 40 during few hours is adm itted The machine must be protected against bad weather conditions and condensation Machines must not be handled at temperature below 20 C 4 1 2 Storage warehouse The machine must be stored in clean and dry premises which are not subject to abrupt changes in temperature or to high humidity 7596 maximum The heating resistor must be switched on at all times Storage at an ambient temperature of 5 to 45 C is recommended The machine must not be subject to vibrations higher than 1mm s rms 4 1 3 Maritime packing The synchronous machine is carefully packed in a wooden crate then hermetically sealed Standard maritime packing For long term storage as seaworthy packing with fully watertight sealed film and dessicant silicagel b
92. topped for more than one month and less than one year Do not drain the bearing Pour the recommended protecting agent through the oil filling hole of the bearing around 50 cc Turn the shaft several times in order to spread the product evenly throughout the bearing Sx ovs c Long term storage When sleeve bearing machine has to be stopped for more than one year Drain the bearing Place a Silicagel gag inside the bearing oil sump it is necessary to open the bearing housing to proceed Place an adhesive strip along the parting lines of the housing Pour the recommended protecting agent through the oil filling hole of the bearing around 50 cc Turn the shaft several times in order to spread the product evenly throughout the bearing CAUTION A VISIT OF THE BEARING research of corrosion marks MUST BE DONE AT LEAST ONCE PER YEAR CAUTION BEFORE START UP IT WILL BE NECESSARY TO REMOVE THE SILICAGEL BAG AND TAPES 2 4 3 Oil circulation installation Refer to chapter 2 6 2 4 4 Start up of Sleeve bearings a General check before start up To identify your bearing characteristics refer to section 1 This verification must be carried out upon the first start up during periodic inspection of the bearing or as soon as any part of the bearing alignment is changed coupling After a long shutdown period proceed following the used storage procedure refer to chapter 2 4 2 Check that the shaft has not corrod
93. tor winding 16 Rotating resistances 8 Stator ribs 17 Rotating diodes 9 Stator lamination 18 Diode bridge cover S 4 5 6X7 8 9 10 114 124 13 14 15 3 i 16 2 17 Sys 63 SERVICE AND OPERATING MANUAL ALTERNATORS 10 1 2 Machine type A53 A54 o o N Rotor 10 Polar wheel Bearing drive end 11 Balancing disc Fan hub 12 Exciter field Drive end shield 13 Exciter armature Fan 14 Non drive end shield Fan screen 15 Bearing non drive end Stator winding 16 Rotating resistances Stator ribs 17 Rotating diodes Stator lamination 18 Diode bridge cover en 0020000 db d2 O88 rd v L pa SX 64 SERVICE AND OPERATING MANUAL ALTERNATORS 10 1 3 Machine type A56 A58 1 Rotor 10 Polar wheel 2 Bearing drive end 11 Balancing disc 3 Fan hub 12 Exciter field 4 Drive end shield 13 Exciter armature 5 Fan 14 Non drive end shield 6 Fan screen 15 Bearing non drive end 7 Stator winding 16 Rotating resistances 8 Stator ribs 17 Rotating diodes 9 Stator lamination 18 Diode bridge cover SERVICE AND OPERATING MANUAL ALTERNATORS 10 2 FLANGED SLEEVE BEARING 10 2 1 Self lubricating bearing o gt Top half of the housing Positioning pin hole Positioning pi
94. trip The heating resistor is switched on as soon as the machine is shut down It is located at the back end of the machine The electrical characteristics are provided in Section 1 Technical Characteristics b Stator winding temperature sensor The temperature sensors are located in the active part of the stack They are located in the zone assumed to be the hottest part of the machine The sensors are connected to a terminal box Depending on the temperature rise of the machine the temperature of the sensors should not exceed a maximum of TEMP RISE ALARM TRIP class Power KVA lt 5000 gt 5000 lt 5000 gt 5000 To improve the machine protection the alarm set point may be reduced following effective site information Alarm temperature Highest recorded temp 10 K Trip temperature Alarm temperature 5 do not pass over the values of the previous chart Highest recorded temp Temperature measured at the site in the worst temperature condition at the stator temperature sensor E g a class B machine reached 110 during a facto ry heat run test Set the alarm temperature to 120 in stead of 130 as indicated in the previous chart Set the emergency shutdown to 115 C instead of 1356 as indicated in the previous chart C Stator air sensor As an option an RTD or thermostat can measure the stator air inlet temperature cold air Stator air inlet temperature Alarm points
95. tures sold under various trademarks which often contain white spirit which evaporates too slowly or chlorinated products which are likely to become acidified CAUTION DO NOT USE ALKALINE PRODUCTS THEY ARE DIFFICULT TO RINSE AND CAUSE REDUCTION OF INSULATION RESISTANCE BY FIXING THE HUMIDITY b Cleaning products Use pure de greasing and volatile agents which are well defined such as Gasoline without additives Toluene slightly toxic inflammable Benzene or benzine toxic inflammable Ciclohexaire non toxic inflammable Soft water 60 SERVICE AND OPERATING MANUAL ALTERNATORS 7 4 2 Cleaning the stator rotor excitation system and diodes a using specific chemical product The insulation and the impregnation system are not damaged by solvents see the list of authorized products above It is essential to avoid entry of cleaning agents into the slots Apply the product with a brush sponging frequently in order to avoid accumulation in the housing Dry the winding with a dry cloth Allow the traces to evaporate before reassembling the machine CAUTION AFTER CLEANING THE GENERATOR DRYING IS IMPERATIVE TO RECOVER THE CORRECT WINDING INSULATION b Rinsing using soft water Hot soft water less than 80 C used under pressure less than 20 bars can be used CAUTION AFTER CLEANING THE GENERATOR DRYING IS IMPERATIVE TO RECOVER THE CORRECT WINDING INSULATION Sx ovs 7 5 DRYING THE WIND
96. unding panel if compound regulator The compounding panel is located in the terminal box The three current transformers TI 01 TI 02 TI 03 fitted in the terminal box on three power supply conductors supply the compounding panel Rectifier bridges CR 01 CR 02 rectify the alternating current coming from these three transformers An RC circuit R 01 C 01 acts as a filter CR 03 protects the system from high voltage spikes R 02 is an assembly of two adjustable resistors adjusted at the factory Refer to the regulator manual L 01 is an adjustable self inducting coil comprising three coils The different positions of the jumpers are shown on a plate attached to the self inducting coil L 01 is adjusted to supply excitation with no load Refer to the regulator manual b Booster plate if shunt booster regulator The booster plate is located in the terminal box The three current transformers TI 01 TI 02 TI 03 fitted to three power supply conductors supply the booster plate Rectifier bridges CR 01 CR 02 rectify the alternating current from these three transformers An RC circuit R 01 C 01 acts as a filter CR 03 protects the system from high voltage spikes R 02 is an assembly of two adjustable resistors adjusted in the factory Refer to the regulator manual section Principle of Excitation Regulation 41 SERVICE AND OPERATING MANUAL ALTERNATORS 2 18 2 Automatic voltage regulator 3 VOLTAGE REG
97. upply and return lines have been rinsed as instructed in the chapter 2 4 3 Ensure that the installation instructions have been followed refer to chapter 2 4 3 such as filtering unit return line properly inclined etc Proceed as for the self lubricated bearings and then start the oil supply system pump etc To adjust the oil flow as recommended in section 1 Machine stopped adjust the pressure reducing valve A to get the bearing oil level at the middle of the glass And then run the generator Machine running and oil at the operating temperature the oil sight glass level should be within 1 3 and V2 of the glass If necessary readjust the pressure reducing valve A B U U V During generator operation the oil level in the bearing must comply with the indications in Chapter 2 4 5 20 SERVICE AND OPERATING MANUAL ALTERNATORS e Oil circulation bearing with accurate oil flow 4596 10 To identify your bearing characteristics refer to section 1 This chapter typically applies for bearings engineered for heavy thrust tilting pads as for bearing types E Z A CAUTION THE OIL FLOW MUST BE CARREFULLY ADJUSTED TO THE REQUESTED VALUE The oil circulating bearings are delivered with a breather an oil inlet flow regulating system The oil inlet regulating system consists of an adjustable pressure reducin
98. wing visit should be forecasted following the observed dust level b Cleaning Stop the machine Cut off the power supply by isolating the inlet and outlet lines and drain the water Disconnect the leak sensor option with double tube cooler and make sure that there are no leaks Remove the water boxes on each side of the machine Rinse and brush each water box NOTE Do not use a hard wire brush as this will remove the protective oxidation layer which has formed on the surfaces of the water boxes Clean each tube with a metal scraper Rinse in soft water Keep the leakage chamber dry double tube water cooler only Proceed to a gasket change C Leak detection for a double tube exchanger If a leak is detected it is necessary to ascertain its origin immediately and repair it Remove the two water boxes apply a slight positive pressure in the leakage chamber and thus between the two tubes only concerns double tube coolers If a tube is damaged plug it at BOTH ends Use a tapered plug The plug should preferably be made of salt water resistant aluminum bronze or of a synthetic material AS 2 7 4 Servicing the water cooler a Cooler removal The cooler unit is slid into its housing It is possible to remove the cooler from the housing without removing the water boxes The cooler is fastened to the housing via a series of screws on the housing Remove the supply and return pipes Provide two supports t

Download Pdf Manuals

Related Search

Related Contents

AP エアベルトサンダー10mm 取扱説明書  ISR-AC ITR-AC - E  フュージング  ATF VI  Interactions User Manual  Reguladores - Leroy Somer  Samsung LA40C630K1R راهنمای محصول  1 Canadá - InFocus  Acer Aspire Z3-615  

Copyright © All rights reserved. Failed to retrieve file