1.

Purpose
The purpose of this procedure is to describe all activities and define the sequence of work for the rotor removal of MV generator with capacity 1750 KVA installed at Ariguanabo site.

2. Scope
The scope of this procedure covers the activities during rotor removal of MV generator with capacity 1750 KVA. It is the responsibility of the plant manager and safety officer to ensure this Method Statement and Safety Procedures are followed during the execution of the work.

3. References
Plant safety manual Local authority safety standards and practices Generator Operation and Maintenance Manual Bearing dismantling manual

4. Tools and equipment

Cranes, Fork Lifts, lifting belts, slings and other necessary tools and tackles for rigging & material handling Shaft extension Guide bolts Hand Tools

5. Rotor Removal Procedure

Before any disassembly, study the generator assembly drawing and other drawings appended to the Technical Documentation. Dismantling should be carried out carefully, with all applicable work safety regulations observed. The sequence of work will be as follows: Uncouple the shafts Disconnect all external cables from the terminals Unbolt the stator from the foundation plate Remove the dowel pins. Transport the generator to a dismantling place Dismount the covers opposite the exciter from both sides of the stator frame. Disconnect exciter stator cables from the terminals on the inside of the bearing endshield. Dismount the front cover and top part of the bearing housing on the exciter side; remove the temperature sensor from the bearing.

Mount a shaft extension of appropriate length and support it at the end. Remove the bearing labyrinth seal and bearing shell from the bearing housing. Unscrew the bolts securing the bearing endshield. To protect the exciter windings against possible damage, screw 4 guide bolts of length enabling shifting of the endshield to such a distance that the exciter stator gets shifted from its rotor, via the bearing endshield into the holes in the frame.

While moving out the bearing endshield use the jacking bolts screwed into the endshield and the eye-bolts screwed into the bearing housing.

Slide the endshield out together with the exciter stator and the bearing housing to the end of the shaft extension. Perform this task very carefully. Until the exciter stator is shifted out of the rotor, the radial movements of the endshield with respect to the generator axis cannot exceed 1 mm.

Support the shaft extension at its mid-section. Remove the shaft extension end support. Remove the bearing endshield together with the bearing housing and the exciter stator.

Support the shaft at the coupling end. From the bearing at the drive end, dismount the top cover, layrinth sealing, sleeve and thermometer Screw an eye-bolt into the bottom section housing dismount it. Unscrew the bolt securing the bearing endshield. Screw the jacking screws into the endshield holes and suspend the endshield on slings. Remove the bearing endshield if the dimensions of the coupling permit this. If it is not possible, secure the endshield to the shaft and coupling in such a way that it does not slide while removing the rotor.

Put a 2 mm thick pressboard insert between the stator and the rotor. Mount hemp slings at the end of the shaft extension and at the end of coupling and cautiously move out the rotor as far as possible towards the coupling. Support the rotor in this position and transfer the slings to the pole part near the centre of gravity of the rotor and remove the rotor from the stator.

The assembly procedure will be with activities performed in reverse sequence.

6. Health and Safety

Toolbox talk shall be carried out to keep the team-mates aware of job activities before starting any work, identification of all hazards and control measures of it. Emergency evacuation contingency plan shall be known to work performing crew members. Safety equipments, warning devices and signboards shall be in position at work site. All work performing personals shall be provided with PPE and ensure proper use of it. The plant management, supervisors and safety officers will closely supervise and monitor all phases of activities in connection with the compliance of safe working models. All equipment like Cranes, Forklifts, Chain pulley blocks, lifting belts, slings and other necessary tools and tackles for rigging & material handling operation, electrical equipment etc. shall be inspected by competent personnel prior to use at site.

Any accident, Injury, or near miss shall be reported immediately to appropriate authorities. Work shall stop and area secured until approved