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WATER AND ELECTRICITY DEPARTMENT

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ENGINEER .. MERZ AND MCLELLAN
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ABU D~1AB T j". PROJECT

CUSTOMER DWG. No . 176-VO~7510-M-1000-8

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JOHNBROWN
I John Bro'Wn Engineering Limi ted
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C Lydebank. Dunbartonshire G8l lYA
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J. B. E. DRAWING No : 1820 - :r~
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JOHN BROWN ;

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- DRAWN MA 11-04-95
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GENERATOR ROTOR WITHDRAWAL

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 ROTOR DISASSEMBLY

Generally speaking, one should not disassemble a part without first marking it and without making sure that
it is not fastened with bolts and nuts to neighboring parts and that it does not bring with it any conductor wire,
cable, etc. that has not been released.

Refer to engineering drawing 39-601 416 for the various handling steps.

Preliminary steps
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CD Exciter side: Open end doors. Disassemble cross-member on floor.
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- Remove shell from exciter.
,....
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0) - Remove stator from exciter
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Remove bearing ventilation.

Remove all equipment installed on bearing.

Remove bearing feed and oil return

Remove end flange

Remove end bell.

Reduction gear side: Remove rotor grounding system

Remove end flange.

RemO\/e end bell

Remove coupling bolts.

Remove all equipment Installed 011 the bearing.

Remove feed and 011 return

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DES. RED 0811092 M PHEULPIN GENERATOR ROTOR WITHDRAWAL
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PHASE 1

Use two jack screws 39-402 353 to disengage and spread coupling by 15 mm.

Remove all screws and pins fastening bearing casing and riser located under bearing casing.

Coupling side:

- Slide rotor lifting tool under the 350 mm dia, section of the shaft:
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I() • a: the two wooden wedges (item P)
o • b: mounting 39-405 082
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•.... • c: wedge 39-405 068
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(f)
• d: I-iron (item R)
• e: Install jack (item F), following an F

Use jack to lift by 5 mm.

Insert 200 x 200 x 5 mm wedge (item M) under mounting 39-405 082.

Put jack on other side.

Lift rotor by 10 rnrn.

Insert 200 x 200 x 10 mm wedge (item N) under mounting 39-405 082.

Put jack on other side.

Lift by 10 mm.

Wedge With item N.

Repeat above steps to lift rotor by 40 mm

Fit lifting rings on riser.

Remove riser and sheet metal adjusting plates msertrnq a wooden wedge to replace them

Remove bearing cap

Remove top bearing half-shell.

Hook bearing casing onto lifting system With lift In] hooks

~ :=. :J Lower Remove beanng casing. disengaging It on the Side

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MPHEIJLP~N
VERI,,'E
DES REO GENERATOR ROTOR WITHDRAWAL
08/10'92
OA 3 Dates Noms

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 Exciter side:

- Follow the same steps, inserting tool under the 420 mm dia. section, along with wedge 39-405 070 (see
View G).

- Alternatively lift on one side then on the other to lift the rotor evenly on both sides.

PHASE 2

- Insert 3,000 x 600 x 2 mm glossy cardboard insertion (item C) in stator.

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Coat top surface of sliding plate 39-405 069 with grease. Install plate in bore of stator on glossy cardboard
<:> insertion.
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••••
en On the reduction gear side, slide hinged friction pad 39-405 083 in the bore of the stator, under the barrel.
M
as close as possible to the coupling side band. Hold it in place with 2 mm dia. string (item 0).

On the reduction gear side, install end friction pad 39-303 077 under 315 mm dia. section.

- Wedge the bearing race (customer supply).

Install the bearing race 39-201 106, centering it in relation tc the axis of the rotor and fastening it to the base
plate with NO.5 clips (item F)

Put truck 39-100 590 under barrel.

Slide wedge 39-402 896 onto truck.

Lower rotor actuatinq the hooking devices to lay It on Incnon pads and truck.

Insert second wedge 39-402 896 on rotor. Fasten It with assembly flange 39-403 897. Iastenmn It with
M20 x 600 threaded rods (item E) and nuts (1I.M20)

Remove rotor lifting tool

Fasten TU16 cable-puller to cross-member 39-301 515

Hook 11.5 mm dra, 12 mm long cable under truck with shackle M30 4000

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DESRED 08/10/92 M.PHEULPIN GENERATOR ROTOR WITHDRAWAL
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 PHASE 3

Actuate cable-puller to pull out rotor until the end friction pad is near the end of the stator bore. without going
past it.

Remove hinged friction pad 39-405 083. Replace it by barrel protector 39-403 017 and 300 x 200 x 2 mm
glossy cardboard insertion (item K). securing them with 2 mm dia. string (item 0)

Use 12-lon force jackscrew 10 lift rotor.

- Install surbased truck (item G) under barrel of rotor. as near as possible to the coupling side band. inserting
it in the 900 x 200 x 2 mrr, glossy cardboard insertion (item J) and 200 x 150 x 10 mm wedge (item II) so
that when the rotor is lowered. end friction pad 39-303077 no longer rests on the sheet metal plate.

PHASE 4

The rotor can be extracted from the alternator until its center of gravity is sufficiently out to allow It to be lifted
(approximately 4 meters).

PHASE 5

ASSEMBL Y OF ROTOR

With the rotor In phase 4. Install barre! protector 39-403017 and 300 x 200 x 2 mm glossy cardboard insertion
(item K) under barrel of rotor. as near as possible to the coupling side band (detail X). holding them In place
with 2 mm dia. string (item 0); also install end friction pad 39-303 077. both these installations being carried
out under the 315 mm dia. section Then run cable on cable-puller In pulley on pulley-holder cross-member
39-301 514. with the hooked strand In the axis of the bearing race

Refer to engineering drawing 39-601 416 for the various steps entailed In handling.

Phase V

Bring In the rotor until end friction pad 39-303077 -s .n t~~'::'

stator at the level of sLcmg plate 3S--:.>:; '=e: j

Use Jackscrew with a minimum force of 12 tons to I,ft rotor Remove surbased lruck.,',e.j,)lng ci1·::; c'd:<Jt:'Ci1rC
Insertion Install rotor on end Inction pad.
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Remove Jackscrew. barrel protector 39-40301 -: aneJ Ins"r1,-_'·r.
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In Its place install hinged tnction pad 39-405 083 and see ••re i1 ·.'.Ith 2 mrn 'j:" s!~;ng 'item :"i.

Finish bringing In rotor. usmo the cable-puller UD to chase .:

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VERIF!E
DES REi:' ;:OHEUL.PIN
GENERATOR ROTOR WITHDRAWAL

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08.'10;92 M
OA 3 Dilles Noms
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Position II

With rotor brought in:

Install rotor lifting tool.

Unciamp truck. Remove top wedge 39-402 896

Lift rotor by 40 rnm

- Remove truck 39- 100 590.

Remove end friction pad 39-303 079.

Remove hinged friction pad 39-405 083.

Remove sliding plate 39-405 069 and 3.000 x 600 x 2 mm glossary cardboard Insertion (item C)

The rotor is then in phase I.

Phase I

Fit bearing casing With bottom bearing half-shell Place assernblv unde: rotor Use lifting system to ;I~
assembly until It cernes into contact wrth the rotor

Install top bearing half-shell and bearing cap The beann-; .s then hanging 011 the rotor

Install riser and sheet metal adjusting plates

Fit rotor in secondary shaft of reduction gear. '.1·,1:1" the :1\)(,"1;;9 devices and makln'J sure that 1"'" ::-e.';':n-;
IS correctly placed on the base.

Fasten bearing to base of generator

Remove hooking devices

Check concentricity and alignment around CGUr:;;,I']

- J.S.E. No. 1 8 2 0 - 3 3 8 0 - 0 3 6
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GENERATOR ROTOR WITHDRAWAL

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 Final steps

Exciter side:
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Install end bell.
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Install end flange i,
Assemble bearing feed and return
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011

Install all equipment on beanng

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Assemble bearing ventilation. r
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Assemble stator and exciter shell.
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o Close end doors. f
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Reduction gear side: Install end bell.
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Install end flange.
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Assemble rotor earthing system
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Install all equipment

Assemble ventilation
on bearing
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GENERATOR ROTOR WITHDRAWAL

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