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Rotor removal and installation


4.5-9913-0002/1 0410

Exploded view

Cooler

Cover

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

Sheet: 01/14

End wall segment EE


End wall segment TE

Stator

Rotor

Cover

Longitudinal
section

Bearing
pedestal EE
Bearing cover

Air guide baffle ring EE


Bearing
pedestal TE
Bearing cover

End wall segment TE

End wall segment EE

Exciter - Set

Exciter set

TE

Rotor

Air guide baffle ring TE


Bearing pedestal
EE
Bearing cover

Bearing pedestal TE
Bearing cover

Bearing pedestal
EE
Base

Stator

EE

Bearing
pedestal TE
Base
Intermediate frame TE

Bearing
pedestal EE
Base
Shaft bushing TE

Shaft bushing EE

Intermediate frame EE

EE
View Z

Bearing
pedestal TE
Base

Intermediate frame EE

Labyinth ring
EE

TE

Cover

Rotor

End wall
segment TE
Bearing pedestal TE
Bearing cover

Bearing pedestal TE
Base

Shaft bushing EE

Z
Intermediate frame TE

Labyrinth ring TE

Shaft bushing TE

Base frame

Intermediate frame TE

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Front wall segment TE

Rotor removal and installation


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Stator

Rotor

Cover

End wall segment EE


Bearing
pedestal EE
Bearing cover

Bearing
pedestal TE
Bearing cover

Exciter set

TE

EE

Bearing
pedestal TE
Base

Bearing
pedestal EE
Base
Shaft bushing EE

Intermediate frame TE
Shaft bushing TE

Intermediate frame EE

Equipment required:
In the Siemens scope of delivery following items are included:
1 x slide plate
2 x sliding shoe
1 x slide pedestal
2 x set-down trough
Slide grease
The generator operator has to provide:
- gantry crane and hitching gears (sling equipment for jacking the rotor)
- chain or rope hoists
- securing devices
- foil
- wire reels
- water level
- height-levelling supports
Not all of the tools and equipment included in this description are part of the standard scope of
supply included with the generator. The agreed scope of supply must be checked. If necessary,
various parts, tools, and equipment may have to be ordered separately.

Sheet: 02/14

Step 1: Safety precautions


Only skilled personnel is authorized to perform any disassembly or assembly work on the generator. The accident prevention regulations applicable on the construction site must be complied with.
The valid safety regulations must be observed when working on platforms.
Lifting equipment and hitching gear must be of a size and strength adequate for the required loads. Round slings must be used as hitching gears.
Suitable measures must be used to secure the rotor against unintended movements during every step, as well as after the rotor is in its resting position after having been removed.
Removed parts must be safely stored outside marked walkways. They must be stored in such a way that it is impossible for the parts to unintentionally change position or topple over.
Do not store any tools or component parts in the area of base frame and generator windings.
Suitable aids or materials (e.g., foil) must be used to protect uncovered openings from soiling and to prevent foreign particles from entering them.
Openings must be adequately marked and blocked in line with operator protection requirements.

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Front wall segment TE

Rotor removal and installation


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Stator

Cover

Rotor

End wall segment EE

Warning!
1) If any oil leaks from the bearings during the work being carried out, use adequate means to
capture it.

Lagerbock
Bearing ES
Lagerdeckel
pedestal EE
Bearing cover
Bearing
pedestal TE
Bearing cover

Erreger
Exciter -set
Set

TS
TE

ES
EE

Bearing
pedestal TE
Base
Intermediate frame TE

Lagerbock
Bearing ES
Unterteil
pedestal
EE
Base
Shaft bushing TE

Shaft bushing EE

2) While jacking apart the half couplings, observe the maximum axial clearance values as
specified in the dimensional drawing on "Axial and radial rotor play". Only jack apart until the
coupling overhang is located at a maximum distance of 10 mm outside the coupling face. A
bigger distance between the half couplings will impede rotor later lifting in the area of cap /
toothed end packets.
3) After opening, the bearings must be immediately protected from mechanical damage with
suitable measures (e.g., covering).
4) The fan blades must be removed if the fans diameter is greater than the rotor retaining ring's
diameter. The corresponding dimensions can be found in the Axial and radial rotor play
Section. The blades must be removed according to the instructions made for assembly group
1345.
5) The fan blade ends should be bandaged using soft protective material to protect the threads
before they are placed down.

Intermediate frame EE

Sheet: 03/14

Step 2: Preparatory work


The transportation safety devices and safety tools delivered with the generator must be prepared when starting work. Depending on the actual generator design, cooling elements, a sound-absorbing hood, and, if
necessary, the fan blades may have to be removed as part of the dismantling procedure. Loosen all cable couplers before lifting off the sound-absorbing hood without fail.
The remaining work steps must be carried out in the following order:
Align the rotor coupling vertically (transport position marking 0 or 12 on the coupling must face upwards)
Remove the static excitation device (slip ring housing, connecting cables, plug-in brush holder, and brush yoke) / the exciter
Removal of the TE and EE front wall segments.
Removal of the labyrinth rings and the upper TE and EE shaft bushings
Remove all bearing pedestal connections, (oil flanges, cables, shaft vibration pickups, etc.)
Mark and remove the TE and EE air baffle rings
Remove all tightness rings, vibration detectors and temperature sensors at the TE or EE bearing pedestals
During all crane work, make sure that the hitching gears are not placed on the rotor retaining rings, on the bearing points, or in the area of the sealing surfaces.

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Rotor removal and installation


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Stator

Rotor

Bearing
pedestal EE
Bearing cover

Sliding shoe

Special
tool
Screw
eyelets
The picture shows a section of the
special tool used for removing rotors.
The brackets that can be seen in the
background are mounted on the
bottom of the sliding block with
hexagonal bolts. The sliding block is
placed in the area of the bearing or
near the bearing in the direction of
the generator center. The copper
shim is inserted in between in order
to protect the bearing.

Bearing
pedestal EE
Base

Bearing
pedestal TE
Bearing cover

ES
EE

TE

Copper shim
for bearing
Bearing
pedestal TE
Base

Sliding block,
U-brackets

Intermediate frame TE

Sliding block,
Base

Intermediate frame EE

Step 3: Disengaging the rotor on the turbine end


The rotor must be disengaged on the turbine end.
The drive-side coupling half must be jacked apart from the coupling recess with the help of the original clamping bolts.
It might be necessary to remove the fan blades on both rotor ends as preparation for the following step.
The fan blades must be removed if the fans diameter is greater than the inner diameter of the rotor retaining ring or if the is the danger that the fan blades will interfere with the housing.
The corresponding dimensions can be gathered from the Axial and radial rotor play specifications.
The blades must be removed according to the instructions made for design group 1345.

Sheet: 04/14

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Stator

Slide plate

Bearing
pedestal TE
Bearing cover

Rotor

Bearing
pedestal TE
Bearing cover
Bearing
pedestal TE
Base

Slide plate,
Inserting position

TE

EE
Caution!
The slide plate must be inserted carefully. Damage to
the rotor and stator must be prevented without fail.

Bearing
pedestal EE
Base
Intermediate frame TE

Slide plate, final position

The picture shows the slide plates required final


position. The rotor has already been removed in the
picture.

Intermediate frame EE

Step 4: Insert the slide plate


Clean the slide plate, apply a thin film of slide grease to the top side, and wrap it in sheeting.
The slide plate, covered in foil, must be slid in through the generator gap between the rotor and stator, above the EE bearing. It must be placed centrally underneath the rotor by guiding it on both sides.
After this, the foil between the rotor and the slide plate must be removed.

Sheet: 05/14

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Gantry crane

Rotor removal and installation


4.5-9913-0002/6 0410

Stator

Hitching gear

Rotor

Rotor

3. Lowering

1. Lifting

Bearing
pedestal TE
Base

TE

EE
2. Removal

Lifting

Bearing
pedestal TE
Base
Intermediate frame TE

Intermediate frame
TE in installation
position
Sliding shoe

Base frame

Intermediate frame
TE in parking
position

Supports adjustable
in height

Slide plate, final position

Sheet: 06/14
Step 5: Removing the intermediate frame on the turbine end (TE)
The first step is to release the TE bearings intermediate frame from the base frame. To do this, remove the bearing pedestal bolts and alignment pins from the base frame.
DANGER:
Danger of injury from heavy loads falling.
The rotor must NOT be suspended from the suspension eyelets on the bearing cover.
After this, the hitching gears are attached to the rotor shaft near the bearing. The bearing is lifted a few millimeters with the intermediate frame + shaft still attached to it.
The goal behind this is to place thin rolls (welding wires) underneath the intermediate frame. These rolls are used as aids for transportation. Alternatively, a lubricated slide pad may be used.
Once these aids have been positioned, the bearing is lowered together with the intermediate frame. The intermediate frame must now be released from the bottom part of the TE bearing block.
Remove the screws and dowel pins.
After this, the rotor must be lifted with the crane until the intermediate frame can move freely and can be pulled out from the side. The intermediate frame must be safely stored.
During the next step, the sliding shoe is inserted between the centrally aligned slide plate and the rotor, flush with the edge of the retaining ring.
Once the sliding shoe has been positioned, the rotor can be lowered until it is bearing on the sliding shoe.
Finally, the TE bearing is supported with the help of height-adjustable elements.

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Bearing
pedestal TE
Bearing cover

Rotor removal and installation


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Gantry
crane

Stator

Rotor

Bearing
pedestal EE
Bearing cover

Bearing
pedestal TE
Bearing cover

Hitching gear

View B

Caution!
Disassembly

Bearing
pedestal EE
Base

If a hydraulic jack is used


instead of a crane, the jack
must be placed underneath
the coupling or between the
bearing
block
and
the
coupling.
Insert
suitable
material for shaft protection
between shaft and jack (e.g.,
copper or aluminum sheets).

Bearing
pedestal EE
Base

Lifting

TS

ES
Rotor

Supports adjustable in height

Sliding shoe

Slide plate, final


position

Supports adjustable in height

Bearing
pedestal TE
Base

Intermediate frame EE

Sheet: 07/14

Step 6: Removing the TE bearing cover and the top bearing shell
The TE bearing covers threaded connection must be completely disassembled.
The hitching gears are attached to the bearing covers eyelets. The bearing cover must be carefully lifted off.
The bearing cover is placed in its resting position with the crane. It must be safely put down on a suitable soft support pad (wood, rubber, or similar). The slinging ropes are removed.
The bearing shells screw couplings must be unscrewed. After this, the measuring cable for the bearing insulation monitoring system is removed and the top bearing shell is removed.
The bearing shell must be packed up and stored safely.

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Gantry crane

Rotor removal and installation


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Stator

Bearing support

Rotor
Bearing
pedestal TE
Bearing cover
Hitching gear

TE

EE

Rotor with
coupling on the
turbine end

Bearing
pedestal TE
Base

Lifting

Bearing
pedestal TE
Base
Support adjustable in height

Sliding shoe

Slide plate, final


position

Support adjustable
in height

Sheet: 08/14

Step 7: Removing the lower bearing block section and the lower bearing shell on the turbine end (TE)
The shaft must be lifted by 0.1 to 0.3 mm on the turbine side. For this purpose, the hitching gears must be attached in the immediate vicinity of the bearing block. If the space available allows, the attachment
should be made on the side facing the fan hub. The high-pressure hose and the oil line for the jacking oil (if any) that are located underneath the bearing shell must be removed. The grounding cable must be removed.
Once the shaft is lifted, the lower bearing shell can be swiveled out.
After this, two eye bolts must be placed on the bottom of the TE bearing block. These must be placed diagonally opposite to each other.
Lower the rotor until the rotor rests on the slide shoe.
The hitching gears must be attached to the eyelets. After this, the height-adjustable support must be removed.
The lower bearing block section can now be lowered, removed sideways and safely stored.

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Rotor removal and installation


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Stator

Rotor

Removal direction

Gantry crane
Bearing
pedestal EE
Bearing cover
Bearing
pedestal EE
Base

TE

EE

Adapter plate
Z

Slide
pedestal
Sliding shoe

Slide plate, final


position

Intermediate frame
EE

Adapter plate for


attaching the rope hoist

Slide pedestal

Rotor

Detail Z

Sheet: 09/14

Step 8: Assembling the sliding block on the turbine end (TE) and the adapter plate on the exciter end (EE)
The sliding block must be assembled on the TE bearing point. In order to ensure that the bearing is protected, the assembly process must be carried out only while using the copper shims included in the scope of supply.
It is necessary to assemble the sliding block perpendicularly to the rotor axis. Use a water level to check the horizontal alignment.
The EE bearing must be held securely by the transportation securing device. Attach a rope sling to the bearing to pull out the rotor.
A rope hoist or a chain hoist must be used as the pull mechanism. This hoist must be attached to an appropriate and sufficiently stable anchor point.
As an alternative to this procedure, the rotor can be moved out from the coupling end (TE) with the help of hydraulic jacks or equivalent tools.
Before starting to pull out the rotor, it is necessary to remove the bolts with which the EE intermediate frame is bolted onto the base frame.
The crane is attached to the rotors exciter side with the use of suitable hitching gears (round slings). If the space available allows, the attachment should be made on the fan side, next to the bearing point.
It is necessary to position the crane perfectly perpendicular to (and above) the center of the rotor. The rotor must be carefully lifted until the EE bearing is no longer bearing a load.

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Rotor removal and installation


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Stator

Rotor

Gantry
crane

Bearing transportation
securing , Assembly
Drawing

Bearing
pedestal EE
Bearing cover

Top bearing shell

Separating joint
Bearing
pedestal EE
Base

TE

EE
Pulling direction

Rotor
Bottom bearing shell

Slide pedestal

Sliding shoe

Slide plate, Final


position

Intermediate frame EE

Adapter plate for


attaching the rope
hoist

10 axial securing (divided)


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

Sheet: 10/14

Step 9: Travel out the rotor (start)


The rotor is pulled out from the stator by exerting an axial pull while continuously guiding the crane.
The force required to pull out the rotor is equal to the frictional force that must be overcome. The latter can be approximated with FR = x FN. The normal force is calculated as follows: F N = F G = m x g.
where m is the shaft mass that can be gathered from the dimension drawing text and g equals gravitational acceleration. For comparison purposes, bear in mind that the coefficient of static friction for steel
steel is = 0.15. If this value is used for the calculation, the result obtained is approximately the maximum force that the attachment point of the chain or wire rope used to pull out the rotor must hold.
A suitable anchor points must be selected according to this information. Since the slide plate is lubricated, the coefficient of friction will decrease significantly as soon as the rotor is moving.
In order to be able to transmit the axial tensile force onto the rotor, the EE bearing is fixed using the transportation securing device.
As part of another step that has already been carried out, the rotor was lifted until the EE bearing was no longer bearing a load.
On the turbine end, the rotor is still bearing against the sliding shoe.

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Rotor removal and installation


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Stator

Rotor

Cover

Gantry crane

Other stages in the removal process

Bearing
pedestal EE
Bearing cover

TE

EE

Bearing
pedestal EE
Base

The sliding block comes


into contact with the slide
plate
Removal of the
sliding shoe

Pulling direction

Slide pedestal

Sliding shoe

Slide plate, final


position

Intermediate frame EE

Adapter plate for


attaching the rope
hoist

Sheet: 11/14

Step 10: Travel out the rotor (continued)


Continue to pull out the rotor until the sliding block comes into contact with the slide plate. When continuing the process, the sliding shoe will reach the leading edge of the slide plate on the exciter end, at which point it
can be removed.
No attachment points other than the points specified for attaching the axial pull mechanism must be used. In particular, no forces must be exerted on the slip rings while removing the rotor.
This also applies to the fan blades if they have been left on the rotor due to there being enough space available.
Moreover, it is absolutely necessary to ensure that the applied tensile forces act solely in an axial direction. Avoid any oblique or a skew pulling. Do not use the crane to carry out any axial pulling movements.
The rotor and stator components must not come into contact with each other while the rotor is being removed.

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Rotor removal and installation


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Stator

Cover

Rotor

Gantry crane

Bearing
pedestal EE
Bearing cover

Equipment of set-down trough

Bearing
pedestal EE
Base

TE

Body setdown trough

EE
Pulling direction

Set-down
trough
Bearing area

Slide plate, final


position

Slide
pedestal

Set-down
trough

Height-levelling
supports

Intermediate frame EE

Adapter plate for


attaching the rope
hoist

Sheet: 12/14

Step 11: Placing of the rotor exciter end (EE) on the set-down trough
The rotor continues to be moved out until its attachment position (geometrical center of the rotor) is located outside the stator and the attachment area is freely accessible.
As soon as the position just described has been reached, the rotor body is placed down. A support trough must be used for this purpose. The trough must be placed near the EE retaining ring, centrally under
the rotor body. The height difference in relation to the hall floor must be compensated for with stable pad elements.
The support trough and pad elements must be placed in such a way that the required hitching gear rope spread for the following crane work can be achieved.
Basically, the rotor must be put down in such a way that a safe resting position that completely prevents any subsequent sliding or settling movements from occurring after the crane is removed is maintained.
The aids used for axially pulling the rotor can now be removed.

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Rotor removal and installation


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Caution!
Stator

Cover

Rotor

Gantry
crane

A rotor, which is not suspended horizontally, will reduce the clearance in


the air gap needed when the rotor is moved out. This makes it possible for
the stator and rotor to come into contact with each other. Due to the large
mass of the rotor, this contact will most probably result in heavy damage.
Because of this, the rotor must be balanced with great care.

Rope spreading 600 mm

TE

EE

Bearing
pedestal EE
Bearing cover

Bearing
pedestal EE
Base

Alternative
support

Slide plate, final


position

Slide
pedestal

Rubber pad

Set-down
trough

Height-levelling
supports

Alternative support

Sufficient rope spreading

Intermediate frame EE

Step 12: Suspending the rotor horizontally


The hitching gears for the crane are placed approximately in the geometrical center of the rotor. Basically, the attachment points must be separated by a minimum of 600 mm.
The rotor must be slung in such a way that it is hanging in a horizontal position after being lifted. (Please observe the bearing weight.) A water level must be used in order to
ensure that a perfectly horizontal position is achieved. The rotors position is monitored by observing, from both bearing points, how the rotor lifts off during the crane lifting operation.
Both ends must lift off their supports at the same time.
In order to be able to perform corrections, the rotor must be put down again in the same position. The correction is made by moving the slings by a few centimeters. They are moved
in the direction of the end that came up later than the other. This procedure must be repeated until the rotor is in a perfectly horizontal position.
It is absolutely necessary to ensure that the rotor is moved out as evenly as possible. Any sudden braking or accelerating movements by the crane can cause uncontrollable rotor movements,
which in turn can lead to damage to the stator and/or rotor.
As long as the rotor is still in the proximity of the stator, the rotor ends must be carefully guided by hand. This way, small displacements can be corrected.

Sheet: 13/14

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Energy Sector

Rotor removal and installation


4.5-9913-0002/14 0410

Stator

Cover

Rotor

Caution!

Gantry
crane

Bearing
Pedestal EE

TS

Bearing
pedestal EE
Base

If the EE bearing has to be


disassembled,
the
procedure
followed is the same as that used
for the bearing on the turbine end.

ES
Set-down
troughs

Slide plate, final


position

Slide
pedestal

Rubber pad

Height-levelling
supports

Intermediate frame EE

Step 13: Put down the rotor onto the final position
The rotor must be removed completely.
Once removed, the rotor must be safely put down on the support trough or in a shipping crate.
The rotor may not be supported on the cap and the slip rings. This also applies to the fan blades if they were left on the rotor.
These components must not be used for support or securing purposes either.
Once all work is done, a visual inspection of all gaps and openings must be carried out. Moreover, it must be ensured, once again, that all removed parts are safely stored.
These steps must be followed in the opposite order in order to install the rotor.
If it becomes necessary to disassemble the EE bearing, the procedure to be followed is the same as that for disassembling the bearing on the turbine side.

Sheet: 14/14