Name : HTWT600007 Rev : C Release : 2021/06/22 09:34 AM

Hydro Technical Standard HTWT600007

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Test Instruction
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C 17/06/2021 1/8

Responsible department: Written by: Checked by: Approved by:

CoE Large Generator K. Rathore J. Poux S. Ali
Derived from: Replaces: Established date: Language:
- Rev B 17/06/2021 English

Visual checking on various assembly parts

1 Objective ................................................................................................................................................... 2
2 Scope of application ................................................................................................................................ 2
3 Responsibility ........................................................................................................................................... 2
4 Place and timing of carrying out ............................................................................................................ 2
5 Application of the visual checking ......................................................................................................... 2
6 Metallic parts: ........................................................................................................................................... 2
6.1 Machined Metallic parts ................................................................................................................. 2
6.2 Raw parts not machined ................................................................................................................ 3
6.3 Pre-machined assembly parts ....................................................................................................... 3
6.4 Welded assembly parts, vessels and pipelines ............................................................................. 3
7 Winding parts ........................................................................................................................................... 4
7.1 Stator winding bars ........................................................................................................................ 4
7.2 Stator winding coils........................................................................................................................ 4
7.3 Stator terminals, insulated bus bars .............................................................................................. 5
8 Temperature sensor................................................................................................................................. 5
8.1 Temperature sensor general ......................................................................................................... 5
8.2 Temperature sensor ready for installing for winding ..................................................................... 5
9 Stator ......................................................................................................................................................... 5
9.1 Stator laminated or stator laminated core ..................................................................................... 5
9.2 Stator or stator- laminated core with winding ................................................................................ 6
10 Pole .................................................................................................................................................... 6
10.1 Field coil .................................................................................................................................... 6
10.2 Pole complete ............................................................................................................................ 7
11 Finished insulation parts................................................................................................................. 7
11.1 From laminated material (e.g. slot wedges) .............................................................................. 7
11.2 From extruded material (e.g. Insulating caps) ........................................................................... 7
12 Guide - and thrust bearing parts, apparatuses, devices, coolers, cooling equipments ........ 7
13 Rotor complete ................................................................................................................................. 8
14 Revision History ............................................................................................................................... 8

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1 Objective

Fixing up criteria and guidelines for the visual checks.

2 Scope of application

Visual checks, for which this test instruction is prescribed.

3 Responsibility

For the definition of the checks, the engineering dept. is responsible; for the implementation the
concerned departments are responsible.

4 Place and timing of carrying out

The visual checks are done, as a rule, according to the I & T plan or parts list. They are to be
planned as follows and carried out.
- by the sub-suppliers, before delivering
- at the GE receiving department, during the incoming inspection
- in the factories, before further processing or delivering
- at erection sites, while delivering and during the assembly operations, as well as before
handing over to the customers.

5 Application of the visual checking

The visual checking is to be always carried out on all surfaces of finished parts.
In case of series production parts, the scope of inspection is to be fixed up by the
responsible engineering / factory.

6 Metallic parts:

6.1 Machined Metallic parts

- The surface must be free from contaminations, rust and defects as well as mechanical
damages.
- The surface finish must conform to the drawing.

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- Radii and their transitions as well as thread runouts and edges to be dressed are to be specially
in spected.
- Special bores are to be examined with the help of an Endoscope for defects.
(e.g. central bores in rotor parts, water boxes and brazed-in nipples for water-cooled bars
and main current leads).

6.2 Raw parts not machined

The forged or rolled assembly parts must have a surface corresponding to process and conform to
the following requirements:
- Surface defects, overlappings or similar are admissible only if they can be removed by working
on the machining allowance
- Repair weldings are allowed only for weldable materials and with approval of the
competent engineering dept.
- Painting or rust protection must be carried out according to drawing or purchase order.

6.3 Pre-machined assembly parts

The pre-machined assembly parts must fulfil the following requirements during the visual checking
before further processing:
- Surface defects like notches, cracks, overlaps or similar are not admissible; in borderline cases,
the engineering dept. will decide.
- for parts that are checked for cracks or with Ultrasonic, the surfaces must be pre-processed as
required for the corresponding checking process.
- Painting or rust protection must be carried out according to drawing or purchase order.

6.4 Welded assembly parts, vessels and pipelines

Checking of the parts at the sub-supplier's premises regarding

- mechanical damages, cracks etc.
- Cleanliness / Rust formation, in case of vessels and pipes in the inside also
- Painting and /or rust protection treatment according to the purchase order/ drawing
specifications
- Completeness according to the purchase order/ drawing specifications.
The visual checking of the welded joints is to be done according to the drawing and / or the I & T
plan.

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7 Winding parts

7.1 Stator winding bars

Before applying the main insulation

On the finish-formed bars, before applying the main insulation, the following criteria must be
verified:
- every bar is numbered on the connecting side.
- the strand insulation on the entire bar length is without damages
- the pressed, pre-compacted bar has no excess cementing compounds at the edges
- insulating tapes and/or insulating foils are neatly removed
- the bar ends are metallic bright or tin plated according to drawing and are cleaned.
After applying the main insulation
The bars finished for installing, are to be verified for execution conforming to drawing and must
comply with the following requirements:
- the surface of the main insulation should not have over the entire bar length any damages,
protruding resin accumulations and no sharp edges
- bars with corona protection coating or corona protection bandages are likewise without damages,
the bandages are free from folds and neatly bonded (no loose tapes)
- the bar ends are produced neatly according to drawing and cleaned.
- the brazing places at the bar connection lugs are neatly dressed, doubtful brazing places must
be examined further
- the welding places at water-cooled bars are neatly dressed.

7.2 Stator winding coils

Before applying the main insulation

The finish-formed and pre-compacted coils have to conform to the following requirements before
further processing:
- no damage on the strand insulation, especially in the coil radii and at the rolling
- neat stripping of insulation at the coil ends according to drawing
- no excess resin at the edges from the hot-pressing of the interturn insulation
- isolating tapes and/or isolating foils are neatly removed
- Every coil is numbered at one coil end.
After applying the main insulation
The coils ready for installing are to be verified for execution conforming to drawing and must
comply with the following requirements:
- the main insulation should not have any damages over the entire coil length
- the top bandage is applied free from folds, especially in the coil radii and at the rollings
- Coils with corona protection coating or bandage should not have any damages and no folds if
tape is used
- the coil ends are metallic bright or tin-plated according to drawing and cleaned.

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7.3 Stator terminals, insulated bus bars

For these current-carrying assembly parts, it is to be ensured by visual inspection that:

- the insulation is applied evenly, free from folds and with neat terminations on both side
- the corona protection coating or the corona protection bandaging has been produced as per
drawing and the latter has been applied free from folds
- The connecting ends are produced metallic bright, or tin-plated according to drawing, with or
without bores and cleaned
- the assembly part has no damages over the entire surface.

8 Temperature sensor

8.1 Temperature sensor general

In the visual inspection of the temperature measuring elements e.g. for assembly in windings
(before insulating), in laminated cores or in other assembly parts, care is to be taken to ensure that
- Measuring rods / measuring heads, supply cable, terminal housing, connecting threads etc. are
not damaged
- the transition of the supply cable in the measuring rod / measuring head is executed carefully
- the temperature measuring elements are conforming to the drawing and are complete.

8.2 Temperature sensor ready for installing for winding

The elements insulated with protection jacket must conform to the following requirements:
- for the baking, escaped adhesive must be removed
- the corona protection coating must be neatly and evenly applied
- the supply cables must be free from damages.

9 Stator

9.1 Stator laminated or stator laminated core

It is to be verified that:
- the entire laminated core is neatly cleaned, especially the winding slots and existing air slits
- The laminated core does not have any mechanical damages or stacking defects
- The paint treatment is carried out neatly according to drawing.

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9.2 Stator or stator- laminated core with winding

Before inserting the coils or bars the stator laminated core must be checked as follows
- for mechanical damages and paint damages
- for cleanliness of the laminated core, especially the winding slots and existing air slits .
After assembling the coils or bars, wedges installed, connections and
main current leads fitted, completely made ready must be checked as follows:
- for uniform assembly of the winding (coils or bars), in particular, attention is to be given to the
bow portions and the end winding support
- that slot wedges, spacer pieces, connections, main current leads and cord fastenings are
assembled or executed neatly and as per drawing
- that end wedges are assembled as per drawing and are secured
- that the brazing spots are neatly cleaned before insulating and visually promise a good brazed
joint; doubtful brazing places must be further investigated
- that insulating caps are assembled as per drawing, neatly potted, cemented or fixed with cords
and dressed
- that all tapes and cords are applied without any distant fringes, loose tapes and protrusive
insulation material is not allowed
- that especially in Micadur-Compact execution, no non-permissible resin accumulations are
adhering to the stator as drips, drops or in any other form.
- that the finish-taped stator / stator laminated core is neatly cleaned and is paint-treated as
per drawing.
After running trials in the works and after the commissioning in the plant it is to be ensured
in the final inspection that:
- the end winding, the supports or other parts do not have any inadmissible deformations
- Bolts and /or nuts are re-tightened and secured

10 Pole

10.1 Field coil

On the finish-brazed or wound, insulated and baked field coils, the following points must be
verified:
- the brazings of the longitudinal and transverse conductor as well as the joints are neatly
executed and dressed
- the interturn insulations are correctly installed
- the paint treatment is carried out as per drawing.

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10.2 Pole complete

Before fitting the coils on the pole it must be checked that:

- all sharp edges are deburred
- existing welded joints and weld beads are neatly de-slagged and dressed
- damper bars are secured against axial displacement, as per drawing.
- the brazing spots of the damper winding are neatly executed
- the paint treatment is carried out as per drawing
Before delivering the complete poles it must be ensured that:
- the insulations between pole coil and iron are correctly assembled
- Securing welding spots are neatly produced and dressed
- the paint treatment and / or preservation is carried out in accordance with the drawing
- Gaps between field coil and pole body are closed with adhesive tape (Scotch tape).
To protect against dust and foreign matters (protection during storage and transport)

11 Finished insulation parts

11.1 From laminated material (e.g. slot wedges)

These parts must be verified for the following points:

- Compressed and machined surfaces are smooth, free from visible contaminations and from
parting compounds, free from porous spots, cracks and damages
- The quality of the surfaces, radii and edges conform to the drawing specifications.
- External and internal threads on machined parts (e.g. from Hm 34) are neat and without broken-
out areas.

11.2 From extruded material (e.g. Insulating caps)

These parts must be verified for the following points:

- Compressed and machined surfaces are smooth, free from visible contaminations and from
parting compound, free from porous spots, cracks and damages
- The quality of the surfaces, radii and edges conform to the drawing specifications.

12 Guide - and thrust bearing parts, apparatuses, devices, coolers,

cooling equipments

The relevant assembly part is to be visually checked at the sub-supplier's works for the
following:
- Removal of machining burrs and inadmissible sharp edges
- Cleanliness and freedom from rust, for vessels and pipe systems also in the inside
- Pipelines, valves and other assembly parts are blown out and cleaned, before closing the
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openings
- Clean surfaces in case of metallic bright, painted and/or otherwise treated parts
- Clean, protected cable guiding in case of electrical devices or devices
- Completeness of the delivery according to the drawing and /or purchase order.
During the incoming inspections at GE, the relevant assembly part is to be checked
regarding:
- Transport- and paint coating damages
- Cleanliness and freedom from rust, for vessels and pipe systems also in the inside; if these are
delivered closed, as random samples.
- Completeness of the delivery according to the drawing and purchase order

13 Rotor complete

Before the overspeed testing of the rotor or before the first start-up in the plant, it is to be
ensured through a visual inspection that:
- bearing and seat portions for the test set-up are proper
- all the parts necessary for the testing in the overspeed test rig are fitted
- bolts and nuts are tightened and are also secured in the plant
- the rotor is cleaned and has no mechanical damages or other defects.
After the tests in the overspeed test rig
before the assembly of the rotor in the generator in the works or in the plant, it is to be
ensured through a visual inspection that:
- no parts have inadmissible deformations
- bearing-, sealing- and seat portions are in order and not damaged
- the rotor is completed, i.e. all parts are fitted as per drawing, bolts and/or nuts are re-tightened
and secured
and the pole wedging to the rotor is re-wedged, if necessary
- Paint treatment and /or preservation is carried out as per drawing.
After running the tripping speed in the plant it is to be ensured through the final inspection that:
- no parts have inadmissible deformations
- bearing-, sealing- and seat portions are in order and not damaged
- bolts and/or nuts are re-tightened and secured and the pole wedging to the rotor is checked
and re-wedged if necessary.

14 Revision History

C 17/06/2021 K. Rathore J. Poux S. Ali Change to GE Template

B 15/01/2003 R. Schibli H. Zanoli M. Foerster Change to Alstom logo, improvements
A 13/11/2002 R. Schibli B. Karrer B. Karrer -
Rev Date Written by Checked by Approved by Modifications

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