Generators - Particular Technical Specification

Generators / SECTION 6
Part02
SECTION – 6 GENERATORS
TABLE OF CONTENTS
SECTION - 6 GENERATORS...........................................................................................................1
6-01 SCOPE...............................................................................................................................1
6-02 TYPE AND RATING............................................................................................................2
6-03 TEMPERATURE RISE.........................................................................................................7
6-04 ELECTRICAL CHARACTERISTICS........................................................................................9
6-05 MECHANICAL CHARACTERISTICS...................................................................................14
6-06 STRUCTURAL DETAILS....................................................................................................16
6-07 HOUSING........................................................................................................................20
6-08 STATOR..........................................................................................................................22
6-09 ROTOR............................................................................................................................28
6-10 GENERATOR MAIN AND UPPER SHAFTS........................................................................33
6-11 COMBINED SHAFT ALIGNMENT.....................................................................................36
6-12 BEARINGS.......................................................................................................................37
6-13 AIR COOLING..................................................................................................................41
6-14 LUBRICATION.................................................................................................................43
6-15 HIGH PRESSURE OIL SYSTEM.........................................................................................44
6-16 BRAKES AND JACKS........................................................................................................46
6-17 PIPING............................................................................................................................49
6-18 WINDING TERMINATIONS AND NEUTRAL GROUNDING ASSEMBLY.............................50
6-19 TEMPERATURE DETECTORS...........................................................................................52
6-20 MACHINE CONDITIONING MONITORING......................................................................53
6-21 INSTRUMENTATION.......................................................................................................53
6-22 CURRENT TRANSFORMERS............................................................................................58
6-23 HEATERS.........................................................................................................................58
6-24 PROVISIONS FOR GOVERNOR ACCESSORIES.................................................................58
6-25 INSULATION AGAINST STRAY CURRENT........................................................................59
6-26 GENERATOR TERMINAL BOX.........................................................................................59
6-27 FIRE EXTINGUISHING SYSTEM.......................................................................................60
6-28 SPECIAL TOOLS AND MAINTENANCE EQUIPMENT........................................................66
6-29 SHOP ASSEMBLY AND TESTS..........................................................................................66
6-30 INSTALLATION................................................................................................................69
6-31 FIELD TESTS....................................................................................................................70
6-32 SPARE PARTS..................................................................................................................70
6-33 LIQUIDATED DAMAGES FOR SHORTFALL IN OUTPUT AND EFFICIENCY........................70
RUFIJI HYDROPOWER. PROJECT – E&M PACKAGE Particular Technical Specification

For Major Equipment/Part02
SECTION - 6 GENERATORS
6-01 SCOPE
A. This Part specifies the detailed requirements for the design, manufacture, testing at the
manufacturer’s works, delivery to the project site, storage before installation, erection,
testing at the site and commissioning of nine 276.47 MVA (with 10% continuous overload
capacity) generators and appurtenances to be furnished complete in accordance with these
Specifications.
B. Complete generators shall be provided by the Supplier, designed in accordance with

current accepted standards and suitable for operation in a hydroelectric powerhouse as
indicated on the Drawings. Unless otherwise specified, all accessories required for a
complete operational generator shall be provided, whether or not such items are specifically
mentioned in these Specifications by the Supplier.
C. The following paragraphs written in the singular form for one generator shall apply
equally to other generator furnished, except where requirements differing there from are
specified.
D. The basic materials and methods shall be in accordance with Part-02, Section 1-07. The
excitation systems shall be in accordance with Part-02, Section - 7. Installation and field
testing shall be in accordance with Part-02, Section - 08.
 Nine (9) hydro-generators with 10% continuous overload capability each to match
the turbines as per Part -02 Sectiona-03 of the specification, including lifting devices.
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RUFIJI HYDRO POWER PROJECT. PROJECT-E&M PACKAGE
Particular Technical Specification
For Major Equipment/VOLUME 5
 Nine (9) sets of static excitation and voltage regulation equipment.
 Nine (9) sets of auxiliary systems/ equipment for generating units and plant such as
firefighting system, high-pressure (HP) lubrication system, cooling system, air drying,
equipment for brakes and jacks, brush dust collection equipment, monitoring
equipment, etc.
 One (1) lot of spare parts and special tools for a), b), c) and d)
 Shop and field tests
 Manuals and full documentation of supplied equipment including as-built drawings
The scope shall include all components which are required for performance, durability and
satisfactory operation of the hydro-generators even though not individually or specifically
stated in these specifications.
6-02 TYPE AND RATING
E. Type: The generator shall be of the vertical-shaft, hydraulic-turbine driven synchronous

type complete with bearings, neutral grounding assembly, fire extinguishing system, and a
closed system of ventilation with surface air coolers.
F. Arrangement
1. The Specifications are written on the basis of a preferred arrangement whereby a

combined lower guide and thrust bearing is mounted on a lower bracket. An upper
guide bearing may also be furnished above the rotor, mounted on an upper bracket.
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2. Alternative offer with combined thrust and guide bearing above the rotor and guide
bearing below the rotor may be furnished by the supplier if otherwise found
suitable by him along with suitable justification.
3. The vibratory analysis of the unit required in this Section under 6-10. D, Analysis of
Unit Rotating System, shall confirm the adequacy of the proposed design. All these
elements shall be furnished by the generator manufacturer.
G. Rating
The generator rating shall be as follows:
1. Continuous rated capacity at 0.85 power factor, 276.47

MVA
2 110% Continuous maximum capacity at 0.85 305.0

power factor, MVA
3. Power factor (lagging) 0.85
4. Rated frequency, Hz 50±10% ( IEC-60041-1)
5. Number of phases 3
6. Rated voltage between phases, kV 15.75 (+/-10%)
7. Rated speed, rpm 150
8. Stator winding connection Wye (neutral Yes

suitable for both grounded and ungrounded
operation)
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9 Rated speed 150 rpm

10 Direction of rotation Clockwise when viewed from top
290 rpm -To co-ordinate with turbine
Runaway speed
11 manufacture*
12 Transient speed rise To coordinate with turbine manufacturer*
13 Short circuit ratio ≥1.1
14 Moment of inertia of the whole ≥40000 tons m2:
15 generating unit GD2 inertia-constant H = 4.4 kWs/kVA)
16 Stator-winding connection Star (Y)
Star point grounded through grounding
Generator grounding
17 transformer
Ratio of quadrature axis sub
transient reactance to direct axis <1.10
18 sub transient reactance x”q/x”d
Transient reactance xd’, (assumed
for power system stability 0.25
19 analysis)
IM 8221, combined thrust and
guide bearing below the rotor and
Type of Construction
an upper guide bearing
20 (W 42 acc. to DIN 42950
Method of cooling (acc. to IEC
IC 9 A7 W7
21 60034-6)
Generator Cooler Cooling water
30 degree Celsius
22 inlet temperature
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H. Plant Operating Mode
1. The units will be used for base and peak load generation, depending on the season
of the year. The generator units will be used principally for peaking load during 12
to 16 hours daily in average, with a power rating adapted to the hydraulic conditions.
2. The generator shall be designed to be started and loaded not less than 5 times in
every 24-hour period and not less than 1500 times in the period of a year.
3. The units shall be designed for both local and remote operation.
I. Design Stresses: All parts of the generator, including bearings, shall be designed to
withstand all electrical, mechanical, and structural stresses resulting from operation of the
generator under rated operating conditions, including stresses caused by temporary
conditions of over speed and short-circuits, as specified in these Specifications.
J. Stator Assembly
1. Stator core assembly and installation of winding shall be done at the manufacturer’s
works to the extent possible however stator core stacking and bars assembly can
also be done at site to meet the final assembly requirements. Stator shall be
dispatched in minimum number of sections consistent with the transport limit. The
maximum number of stator sections shall be 4.
2. The stator core shall be of laminated construction. Core lamination sheets with a
loss co-efficient of not more than 1.1W/kg at one (1) Tesla shall be used.
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3. The phase and neutral terminals shall be suitable for connection to isolated phase
bus ducts. The terminals shall have sealed non-magnetic metal barriers for
preventing air exchange between inside and outside of generator housing
4. Stator assembly of partly assembled stator sections and winding work between
stator sections, if applicable, shall be performed at site under the direction of the
manufacturer's supervising erector. The stator core shall be tested at site before
start of winding for hot spots. Core magnetization Test (loop test preferable) or
electromagnetic core imperfection (ELCID) test shall be done at the site and hi-pot
testing of the completed winding shall be performed after completing the assembly.
K. Rotor Assembly
1. Rotor assembly shall be performed at the site. Field poles shall be shipped from the
factory fully assembled and tested.
2. Rotor assembly shall be performed under the direction of the manufacturer's

supervising erector in the erection bay and shall include the following:
a. Assembly of the rotor spider sections (if applicable) and brake ring segments.
b. Complete assembly of rim laminations to form a homogenous ring without butt

joints.
c. Installation of field poles, including interpole connectors.
The design and construction of the rotor shall be in accordance with best
modern practice. The pole winding inter-turn insulation shall be of special
epoxy impregnated mica/synthetic paper and insulation to ground of glass
laminates, both corresponding to IEC 60085 class F insulation.
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The field poles shall be provided with adequate damper windings to improve
stability under fault conditions and to reduce voltage distortions under condi-
tions of single phase to ground fault.
The slip rings shall be made of stainless steel and shall have helically grooved
surface. These shall be well insulated with epoxy glass insulation and designed
for use with carbon brushes. The slip rings shall be so located as to be easily
accessible for inspection during operation and for maintenance.
The slip rings and brush gear shall be separately enclosed from the generator
housing. The rotating parts and brush gear shall be protected by a dust
collector to prevent brush dust from circulating in the slip ring housing.
The slip ring and brush gear shall be provided with an exhaust fan and filter
which will operate whenever the unit is running.
The rotor shall be provided with a suitable brake ring with which the brake
shoes shall make contact. The wearing surface of the brake ring shall be made
in segments which shall be easily removable and renewable.
As far as possible, parts of the rotor shall be balanced statically in the
manufacturer’s shop according to ISO 1940, class G 6.3. The finished rotor shall
be designed and assembled in order to achieve balance quality according ISO
1940, class G 6.3.
L. Standards: Ratings, tests and characteristics shall be in accordance with the latest
approved standards of ANSI, IEEE, IEC, and NEMA, each as they apply, unless otherwise
definitely specified.
6-03 TEMPERATURE RISE
M. Winding Temperature Rise
The stator and rotor pole windings shall fulfill all requirements for class "F" insulation. At
rated output the generator stator and rotor winding temperature rises at any voltage and
frequency in the specified operating range shall not exceed the limits of IEC 60085 class B
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insulation, while at overload conditions (110 % of rated output) maximum generator stator
and rotor winding temperature shall not exceed the limits of IEC 60085 class F insulation,
with consideration of the required temperature reduction due to the generator voltage
higher than 15.75kV.
1. Winding insulation shall be class F. The temperature rises when delivering the
continuous rated output of 276.47 MVA and continuous maximum output 305.0
MVA at rated voltage, rated speed, 0.85 power factor (lagging), and rated
frequency, with one cooler out of service and with cooling air leaving the air coolers
at not more than 40°C, shall not exceed the following values:
At Rated At Maximum
Output Output
a. Stator Winding 70°C 80°C
b. Field Winding 80°C 90°C
c. Collector Rings 75°C 75°C
d. Core and Mechanical parts in 70°C 70°C

contact with or adjacent to
insulation
2. The generator shall be capable of operating continuously at any voltage not more
than 10% above or below rated voltage when delivering the rated or maximum
MVA output specified in this Section under 6-04, A, 1 (Capacity) under the
conditions specified therein, at rated power factor (lagging) and rated frequency
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without exceeding the limiting temperatures specified above and with cooling air
leaving the air coolers at not more than 40°C.
3. The temperature of the generator shall be determined in accordance with the

procedures specified in IEEE 115, “Test Procedures for Synchronous Machines.”
N. Bearing Temperature
1. The temperature of the thrust bearing shoes and the guide bearing shoes shall not
exceed 70°C and 60°C respectively, when operating under any load from 0 to 110%
of the rated Voltage at rated speed.
2. The temperature of the bearings shall be determined by RTDs located in the bearing
shoes.
6-04 ELECTRICAL CHARACTERISTICS
O. General Characteristics
The electrical characteristics of the generator shall be as follows:
1. Capacity
a. The generator continuous rated capacity of 276.47 MVA and continuous

maximum capacity of 305.0 MVA, at 0.85 power factor shall be achieved with a
temperature rise increase in the stator and field windings that is below the
maximum indicated in this Section under 6-03 (Temperature Rise), with one
cooler out of service.
b. The continuous generator output capability when charging a transmission line,

under-excited, at rated frequency and voltage, without exceeding a stator
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winding temperature rise of 70°C or being completely self-excited or unstable,

shall not be less than 183.0MVAr.
2. Reactance’s (per unit value based on rated voltage and rated capacity).
a. Guaranteed direct-axis, unsaturated, transient reactance, not greater than 25%.
b. The calculated ratio of the quadrature-axis, unsaturated, subtransient

reactance to the direct-axis, unsaturated, subtransient reactance (rated voltage
values), not more than 1.1
3. Short-Circuit Ratio. Not less than1.1.
4. Wave Distortion Factor
a. The balanced telephone influence factor (TIF) of the line-to-line voltage when
measured according to IEEE Std. C50.12. on an open circuit at rated speed and
rated voltage, shall not be greater than 70
b. The residual component of TIF when measured according to IEEE Std. C50.12
on an open circuit at rated speed and rated voltage, shall not be greater than
50
c. Deviation factor of wave form, measured in percent of open-circuit line-to-line

voltage, at rated voltage and frequency, not more than 10%.
5. Natural Frequency: Generator natural frequency at 0 to 50% load at 0.85 to 1.0

power factor including the effect of the power transformer, when connected to the
electrical system and driven by a hydraulic turbine having an estimated flywheel
effect (GD2) of ≥40000 t-m2 (including water), shall not be less than 1.07 Hz nor
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more than 1.50 Hz. However, these values can be rechecked during details
Engineering.
6. The generator and its associated excitation system shall be capable to charge Two
transmission line circuit and its compensation systems (if connected).
7. The generator shall be capable of safely withstanding maximum stresses during

normal operation, runaway-speed conditions, two phase and three phase short-
circuit conditions, single phase ground fault, 180 degrees and 120 degrees out of
phase synchronization, magnetic unbalance.
P. Efficiency
1. The guaranteed generator efficiency, at rated MVA, power factor, voltage and
speed, shall not be less than 98.66%. The generator losses shall include I 2R losses in
armature and field windings, friction and windage losses, core losses, stray losses,
and excitation system losses (such as excitation power transformer, rectifier, and
voltage regulator losses) and portion of the thrust bearing loss produced by the
weight of the rotating parts of the generator itself according to ANSI C50.12.
2. The efficiency of the generator as determined from the losses and calculated from
the corresponding generator efficiency at 60%, 70%, 80%, 90%, 100% of rated
output & at maximum output, at rated voltage, speed, and power factors of 0.85
and 1.0 shall be provided.
3. Guarantees on Efficiency & Output Rejection Limit
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The rated and maximum output of the generator shall be guaranteed (within
the limits of temperature rise specified) at rated power factor and at any
voltage and frequency in the specified operating range. Also, the efficiencies of
the generator shall be guaranteed at specified output levels up to the maximum
continuous overload output of 305.0 MVA with terminal voltage of 15.75 kV and
power factor (lag) of 0.85 Individual losses shall be established using suitable
method as per IEC 60034-2 and the efficiencies shall be determined according
to IEC 60034-2. The static excitation equipment losses shall be included in the
generator losses. No tolerance in the quoted efficiency for guarantee purpose
shall be permitted. The Tenderer shall propose in his tender the method to
determine the losses and efficiencies.
The weighted average efficiency shall be determined from the individual

guaranteed efficiencies and test figures at the loads specified below:
hgaw= 0.2 x h 100 + 0.3 x h 90 + 0.3 x h 80 + 0.15 x h 70 +0.05 x h 60

where
hgaw = Weighted average efficiency
h 100 = Efficiency at 100 percent rated MVA and 0.85 p.f
The minimum acceptable weighted average efficiency shall be ≥98.66 %.
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The equipment is liable for rejection if the test values of rated and maximum
output or the weighted average efficiency is less than for corresponding
guaranteed values by one (1) % or more, and also if either of stator or rotor
winding temperature exceeds the specified limits under maximum output
conditions.
The Contractor shall have to make good and meet the guarantees in case of
shortfall in test values in relation to guaranteed values. A maximum period of
six (6) months will be given to the Contractor for rectification before application
of penalties or rejection. For more details,
Q. Special Requirements
1. The generator shall be capable of withstanding, without harmful deformation or

injury, a 3-phase short circuit or any other short circuits in accordance with the
procedures specified in IEC 60034-1at its terminals when operating at maximum
MVA and power factor, at 110% rated armature voltage, and with fixed excitation.
2. The generator shall be capable of withstanding 150% of rated current in accordance

with the procedures specified in IEC 60034-1without harmful deformation,
mechanical injury, or other damage, near rated voltage, without exceeding the
temperature rise for rated conditions.
3. The field windings shall be designed to safely withstand 2 times field current
corresponding to rated conditions for not less than one minute.
4. The generator shall be capable of withstanding, without injury, the effects of a

continuous current unbalance corresponding to a negative phase sequence current
of 15% of maximum stator current provided the rated output is not exceeded and
the maximum current does not exceed 105% of maximum current in any phase at
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rated power factor and voltage. The specified temperature rise shall not be
exceeded during this unbalanced operation.
5. Under unbalanced fault conditions, the generator shall be capable of withstanding,

without injury, a per-unit negative-sequence-current (I 2), expressed in terms of
rated stator current for a duration of the fault in seconds (t), such that the
integrated product (I2)2t is not more than 20 s, as per IEC 60034-1.
R. Phase Sequence: The generator terminals shall be marked with the subscripts U, V, and
W which indicate the order in which the voltages at the terminals reach their maximum
positive values (phase sequence) with counterclockwise electrical phasor rotation. When
viewed from above and from the center of the rotor they shall be arranged in the horizontal
order U, V, and W reading from left to right.
6-05 MECHANICAL CHARACTERISTICS
The generator shall have the following mechanical characteristics:
S. Flywheel effect (GD2 in t-m2) of rotating parts of the generator excluding the turbine
rotating parts and water, not less than 40000 t-m2 (Direction of rotation, viewed from
above clockwise)
T. Maximum runaway speed, not more than 290 rpm
U. The generator shall be capable of withstanding the maximum runaway speed for 30
minutes without harmful deformation or injury, and without overheating of the
bearings above 90 ºC.
V. The elevation of the coupling face between the generator shaft flange and the turbine
shaft flange shall be determined by the Supplier, subject to approval by the Purchaser.
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W. The elevation of the turbine distributor centerline shall be as required at 61.0 msl
X. The generator shall be designed mechanically to continuously withstand stresses within

the limits specified in Part-02, Section 1-06, Allowable Stresses.
Y. The generator shall be designed mechanically to withstand temporary overloads of up to

the turbine output at maximum net head and maximum gate opening with stresses
within the limits specified in Part-02, Section 1-06, Allowable Stresses.
Z. The generator noise level, as measured at points one meter vertically above the upper
cover plate of the generator, shall not exceed 80 dB(A).
AA. The maximum deviation in the air gap in any horizontal plane as formed by the stator
inner circle and the rotor outer circle shall not exceed ±5% of the average value, after
the complete assembly of the stator and the rotor.
BB. The maximum deviation in the air gap in any vertical plane between the stator and the
rotor shall not exceed ±5% of the average value. When the generator is operating, the
respective heat expansion of the stator and the rotor shall be essentially concentric and
uniform to prevent harmful deformation of the stator frame and rotor spider.
CC. After the assembly of the generator and the turbine, the first critical speed of the
combined turbine and generator rotating parts shall be at least 125% of the specified
maximum runaway speed.
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6-06 STRUCTURAL DETAILS
DD. A. The generators shall be capable of safely withstanding maximum stresses during
normal operation, runaway speed conditions, earthquake, two phase and three phase
short circuit conditions, single phase earth fault, 180 deg out of phase synchronization,
magnetic unbalance with 50% of poles short circuited within the speed range of 1.3 times
the rated speed, brake application etc. The stator frame shall be supported on soleplates
embedded in the concrete foundation and constructed as part of the powerhouse
structure. Bolts shall be provided to ensure that the stator frame will remain on the
soleplates at all times, even under conditions of earthquake, short circuits or faulty
synchronization while allowing the stator to expand freely on the soleplates. A radial pin,
rectangular key or spring leaf plate shall be provided between the frame lower shelf plate
and each soleplate in order to allow radial expansion only while at the same time
preventing any undue movement of the stator frame on the soleplates when the
generator is subjected to stresses resulting from earthquake, short circuits or faulty
synchronization conditions. Additionally,
 Continuous operation at any speed from 90% to 110% of rated speed.
 Operation for a period of at least 15 minutes under maximum runaway conditions

with cooling water in operation.
 Operation for a period of at least 15 minutes at maximum allowed load and rated
speed without cooling water followed by safe shut-down.
 Operation for a period of at least 30 minutes at any speed between zero and rated
speed (including creeping
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EE. The thrust bracket, supporting the upper or lower combined thrust and guide bearing
assembly, shall support the weight of the entire rotating element of the generator
together with the turbine runner and shafts and shall have adequate rigidity and strength
for safe operation under conditions of unbalanced hydraulic thrust of the turbine runner.
FF. The upper and lower guide bearings and support brackets, combined as applicable, shall
have sufficient radial stiffness to withstand the unbalanced magnetic pull force resulting
from a half field fault such that contact between the rotor and stator is prevented.
GG. The lower bearing bracket shall be designed and constructed for removal through the
stator and to maintain bearing concentricity during periods of thermal expansion. The
lower bracket shall be drilled and tapped for hanger bolts for supporting a platform
which shall be furnished with the generator. The platform shall provide access to the
lower bearings and to the area between the bearing bracket arms for inspection of
bearing bracket, brakes, bottom of field winding and stator winding, and other
accessories located in the area. All necessary accessories for the platform and the access
shall be furnished. The platform shall be removable with the lower bracket and shall be
designed for assembly and maintenance of lower bearing components and for a
minimum uniform load of 1000 kg/m2. The design of the platform shall be coordinated
with the turbine manufacturer's requirements. Anchorage of the platform and its access
layout shall not interfere with removal and maintenance of the equipment in the turbine
pit.
HH. The upper bracket will support the upper bearing(s), as applicable, the collector ring
housing, and the generator cover which shall be designed for a minimum live load of
1000 kg/m2. It shall be designed to be supported on the stator frame and on the air
housing concrete walls of the generator pit, as required for horizontal stability. The
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upper bracket shall be so designed such that the oil cooler of the guide bearing shoes, if
provided, can be taken out without removing the collector ring.
II. The generator brakes shall be mounted on the lower bracket under the rotor, and they
shall also act as jacks to lift the rotating parts for removal of the thrust bearing shoes.
The foundations for the brackets or supports shall be designed so as not to reduce the
clear opening for removal of turbine parts through the stator bore. The clear opening
shall be defined to be not less than the area established by the turbine pit diameter.
JJ. The generator manufacturer shall coordinate with the turbine manufacturer for
attaching the circular track of the electric monorail hoist in the turbine pit to the
generator lower bracket or the lower guide bearing radial support if required by the
turbine manufacturer. All necessary bolts, supports, and hardware for this attachment
will be furnished by the turbine manufacturer. Drilling and tapping on the lower bracket
or the lower guide bearing radial support shall be performed by the generator
manufacturer.
KK. A steel plate barrier which may be combined with the lower bracket shall be provided at
the bottom of the generator to confine the circulation of air within the generator
enclosure. If access to the generator brakes is from below the steel plate barrier, at least
2 adequately sized openings with hinged covers shall be provided at an approved
location for such access. The cover of the opening shall be secured by latches operable
from both sides and shall open toward the generator side.
LL. Soleplates and foundation bolts for the stator frame and for the bearing brackets and
supports shall be furnished.
MM. The design of the generator brackets, supports, frame, floor plates, and structures in
which resonance might become objectionable shall be so proportioned that any
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possibility of synchronism with the natural frequency, or any of its multiples, of the
turbine or of the rotor and stator core vibration during all operating conditions will be
avoided. The natural frequency of the generator parts shall be verified with the turbine
manufacturer.
NN. Necessary platforms and supports, access hatches, stairways (or removable stairways),
and hand railings shall be provided for ready access to and for inspection of the collector
rings and brushes, bearings, brakes, and speed signal generator and for access from the
passageway around the stator frame to the top of the generator. Hand railing shall be
aluminum alloy pipe railing conforming to ASTM-B241, “Specification for Aluminum-Alloy
Pipe,” alloy GS 11A or GS 10A, condition T832 (6063-T832). Handrail joints and
connections shall be welded and ground smooth. Aluminum surfaces which will be in
contact with other materials shall be painted with zinc-chromate primer conforming to
U.S. Fed. Spec. TT-P-645, “Primer: Paint, Zinc-Chromate, and Alkyd Type.” All handrails
shall have a waxed satin finish.
OO. Suitable guards over or around all live and moving parts shall be provided.
PP. Provision shall be made for readily handling all parts during assembly or disassembly of a
unit. Adequate provisions shall be made for attaching lifting devices, rails, slings,
eyebolts, and other devices required for maintenance equipment.
QQ. Provisions shall be made for connecting, in 2 locations to the station grounding system,
the stator frame, upper and lower brackets, supports, oil and air coolers, and all other
metal parts of the generator that require grounding. All grounding connections,
terminals, and bolts shall be furnished.
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6-07 HOUSING
RR. A steel top cover and an adapter ring for grouting into the concrete walls of the
generator air chamber shall be furnished so that an air-tight joint is made between the
ring and the concrete and between the ring and the generator top cover plates. Top
cover shall be of pleasing appearance, neatly constructed, and sufficiently rigid to
prevent vibrations. The top cover shall be designed for a minimum live load of 500 kg/m 2.
The top cover shall be provided with removable panels over the air coolers to permit
removing the coolers from above and with a pressure relief door designed to coordinate
with the CO2 system. The top cover shall be divided into a number of sections. Each
section shall have provisions for lifting with the powerhouse crane. The lifting devices
shall be concealed when the covers are in place to provide a flat surface without
projections.
SS. The design of the generator shall provide for 2 metal access doors to be installed in the
generator air housing concrete pit. A clear passageway around the stator frame with 750
mm or more between the outside of the air coolers and the inside surface of the
generator air chamber shall be provided. Double pole position switches suitable for 220 V
DC shall be furnished and installed for each access door to provide indication that the
door is not fully closed and as an interlock with the CO2 system. The doors shall have
flush locks, master keyed, with suitable handles and inside panic release bars.
TT. A pressure-relief door of such size and design as to relieve excessive internal pressure
from the operation of the CO2 system shall be provided. The pressure-relief door shall
open and reclose automatically at pressures determined to suit the conditions, so that no
part of the generator will be distorted or damaged.
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UU. The top cover of the generator housing shall be provided with removable panels to
provide access to the generator collector rings, the bearing assembly and the top of the
stator. A ladder or stairway shall be provided to facilitate access.
VV. A complete lighting system shall be designed and provided inside the generator air
housing. The lighting system shall consist of an adequate number of fluorescent or
incandescent lighting fixtures with guards arranged to provide lighting in the passage
around the stator frame, in the areas of the bearing supports, around the collector rings
and brushes, at the bearing reservoirs, and at other appropriate areas. The fixtures shall
operate at 230 V AC, 50 Hz, and shall provide a minimum illumination of 150 lx on
vertical and horizontal working surfaces inside the housing. Duplex receptacles and
lighting switches shall be arranged at appropriate locations. Wiring shall be routed in
conduit and terminated in the generator terminal box. A 400/230 V AC, 3-phase, 4-wire
power supply for the lighting system to the generator terminal box. shall be provided
under Part-02, Section - 1, General Technical Requirements of Electrical Work. Wire and
conduit from the generator terminal box to lighting fixtures shall be furnished as part of
the lighting system. The lighting fixtures, guards, receptacles, and switches shall be of
heat-resistance and vibration-proof type.
WW. All base members, embedded frames, foundation bolts and nuts, trench covers, etc.
shall be furnished with the housing. In addition, a continuous copper ground bus 6 mm
by 50 mm shall be provided around the inside perimeter of the generator air housing for
connection at 2 points to the powerhouse ground grid.
XX. Two floor drains of the ball-float type shall be furnished for embedding in the concrete
floor of the air housing. The drain piping shall connect to the drain trench located in the
turbine floor.
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YY. All control valves, switches, and gages inside the air housing shall be in a location
permitting safe and convenient operation and inspection.
STATOR
ZZ. Stator Core
1. The stator core shall be built up with high-grade, high-permeability, low specific
loss, non-aging, cold-finished, thin, silicon-steel laminations. Each lamination shall
be deburred and finished after punching and then coated on both sides with
insulating varnish, or other approved equivalent material, to minimize eddy current
losses.
2. The stator core shall be assembled at the factory for shipment to the site in a
maximum of 4 sections for final assembly there. A thin layer of insulating material
such as Nomex paper shall be inserted between sections during assembly. The
sections shall have the maximum amount of stator coils inserted in the core in order
to minimize the field erection time required. If the transportation limits within the
country prohibit shipment of the 4 preassembled stator core sections, then the
stator frame with core stacked shall be sent in a maximum of 4 sections and the
core shall be stacked in the Supplier workshop, and the following requirements will
apply:
a. The laminations shall be furnished ready for stacking in the stator frame to
form a continuous integral core with all joints between laminations overlapped.
b. The clamping system shall be such that correct clamping pressure is maintained
during stacking and the core laminations will not become loose during service
life. Intermediate clamping pressure shall be applied homogeneously to
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successive layers of laminations while being stacked. After cold pressing and
core loss testing, the stator clamping bolts shall be re-tightened to
recommended values. If stator through bolts are used (rather than back-of-core
bolts), these shall be provided with insulating sleeves to ensure that no contact
occurs between the bolts and the laminations. The clamping pressure shall be
such that there shall be no abnormal buzzing of laminations during operation.
3. The laminations shall be adequately keyed or dovetailed to the stator frame and
securely held in place by clamping plates and tightening nuts at each end of the
core. The core clamping bolts shall be made of high-yield-point steel to provide an
elasticity reserve which maintains the required pressure to the core laminations.
Ventilation spacers shall be of “I-beam” or rectangular cross section. Sheared sheet
or similar types of spacers will not be permitted. The use of aluminum for
ventilation spacers, or for any load-bearing item in the stator, will not be permitted.
4. The air ducts in the stator core shall be arranged to make the flow of air smooth and
quiet; to make the core evenly, efficiently and thoroughly cooled; and to minimize
air friction losses.
5. To minimize buckling and stress of the stator core, thermal expansion shall be
considered in its design. Free radial thermal expansion shall be accommodated in
the design to assure roundness and concentricity of the stator core during normal
and overload operations. The cross-sectional area of the stator frame shall not be
larger than that of the core, and the upper bearing bracket shall not restrict the
expansion of the stator.
6. All stator end support rings, clamping plates and fingers, through bolts, nuts, and
washers shall be of non-magnetic material.
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AAA. Stator Frame
1. The stator frame shall be made of rolled steel sheets and divided into a minimum
number of sections/segments consistent with transportation limitations. The sections
shall be designed for field assembly by bolting and welding to form a solid continuous
frame. The stator frame shall be designed to keep the core in an isotropic cylindrical
shape; to decrease the thermal stress under all generator operating conditions; and to
provide adequate rigidity and strength against forces caused by out-of-phase
synchronizing and short circuits, including short circuits of one-half of the field windings.
If the frame is designed for free radial movement on the soleplate, then provisions shall
be made to prevent torsional movement and undue radial movement in an inward
direction caused by single-directional magnetic pull arising from unbalanced conditions
such as a short circuit of one-half of the field windings or from eccentricity between the
stator and rotor. Leveling screws and openings for grouting shall be provided on the
soleplates.
BBB. Stator Winding
1. The stator winding shall be wye connected, suitable for both grounded and
ungrounded operation, consisting of single-turn coils with conductors completely
(360°) transposed in the slot portion of the coils by the Roebel method, in order to
reduce the voltage and temperature differential between conductor strands. Only
bar winding shall be provided. Both main and neutral leads and terminals shall be
insulated for full line potential and routed within the generator air housing to the
locations specified under Winding Terminations and Neutral Grounding Assembly,
herein.
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2. The maximum possible amount of stator coils shall be inserted into the factory
preassembled core sections. All remaining stator coils shall be furnished ready for
inserting into the stator slots at the site. All material necessary for making a
complete stator winding and termination shall be furnished. All necessary
conductors, connectors, terminals, and materials for forming the generator neutral
and connecting the generator windings to the neutral equipment and to the main
lead buses shall also be furnished.
3. The windings shall be insulated with Class “F” thermo-setting insulation, or better as
defined in ANSI C50.10/IEC 60085, but the maximum temperature rise of the
windings including their main and neutral leads shall not exceed the value specified
in this Section under 6-03, Temperature Rise. Insulation systems using asphaltic
compounds will not be accepted. The coil insulation shall be impregnated by use of
the vacuum-pressure method with epoxy or solvent-free resin, or equal, so that the
insulation becomes a dense and homogeneous mass, free from air pockets. The
coils shall be treated so as to prevent permanent injury from exposure to
dampness, oil, and other contamination.
4. The stator coils shall be provided with an outer protective tape of glass fiber, and
the slot portions shall be treated with a semi-conducting paint to provide corona
shielding. The corona shielding shall extend a sufficient distance beyond the stator
core and shall be graded to non-conductive paint at the ends to ensure the desired
linear potential distribution. Individual bars shall not create apparent corona at 1.5
times rated line-to-line voltage and it can be discussed during detail engineering.
The insulated caps enclosing the ends of coils shall be sufficiently separated from
the adjacent caps and the interconnecting ring busbars to prevent corona.
Sufficient separation shall also be provided to prevent corona between the out-of-
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slot portions of the upper and lower bars from different slots, particularly when
bars of different phases cross each other. Means of preventing corona at these
points, such as inserting solid insulation or bar ties shall be provided where needed.
The coil outer protective tape shall be heat-resisting and shall not deteriorate under
high temperature.
5. The coils shall be form prepared to assure uniformity of dimensions and shall be
interchangeable. The coils may have a flexible outer layer so that they are inserted
under pressure in the slots, or may use fillers or liners. Slot liners, if used, shall be
fabricated of an approved semi-conducting material and of such design as to keep
the semi-conducting coating on the coil in close contact with the iron core
throughout the entire slot, and to ensure the continuity of corona shielding of the
coils. Two-piece coil slot wedges or ripple springs shall be used to apply and
maintain a high positive outward radial pressure on the coils during all operating
conditions and to prevent the coils from becoming loose. Slot wedges shall ensure
uniform pressure on the coil and shall be of a design whereby wedge tightness can
be verified by measuring the deflection of the wedge surface.
6. The winding shall minimize losses and heating due to circulating currents. Stator
coil conductors shall be of annealed copper, with conductivity in accordance with
approved standards, free from splinters, flaws, rough spots, or sharp corners. The
end portions of the coils and the connections shall be rigidly supported and braced
to prevent vibration and distortion under stresses caused by the most severe short-
circuit conditions to which the generator may be subjected. The whole supporting
system of the coil ends shall be of adequate strength, well-ventilated, and made of
non-magnetic materials, and it shall be designed to allow for inspecting the stator
end-winding and core and for measuring their vibration.
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7. The stator winding shall be so designed as to permit the removal and replacement
of the coils without mechanical damage to the stator.
8. After brazing the ends of the bars, a fiberglass insulating cap shall be placed over
each connection and filled with an epoxy compound. Soft soldering connections
will not be acceptable for brazing. All brazing of joints and connections including
ring busbar and coil jumper connections shall be made by using a silver bearing
allow solder to ensure adequate mechanical strength and conductivity. All bolted
busbar connections shall have silver-plated surfaces. Bolts shall be made of non-
magnetic material.
9. Stator windings shall be fully symmetrical and equally distributed throughout the
perimeter of the stator in phase angle and voltage phase sequence. In selecting a
winding arrangement, minimizing the harmonic component of the magnetic field in
the air gap shall be considered.
CCC. Assembly Platforms: Assembly platforms and associated embedded parts required
for assembling the factory preassembled stator core sections, stacking the laminations (if
required), and inserting the stator windings shall be furnished. The platforms shall not
interfere with the installation and handling of the turbine components. Drawings shall show
all necessary foundation materials, including details of embedded parts and components.
DDD. Lifting Device: The lifting device and hardware required for lifting the completely
assembled stator assembly and core shall be furnished. Drawings shall show all necessary
hardware and attachment requirements.
Page 27 of 45
6-08 ROTOR
EEE.Poles
1. The pole pieces shall be built up of high-grade, cold-finished, thin steel laminations
(with oxidizing treatment), stacked under pressure and held together by means of
end-plates and bolts, fastened to the rotor rim by means of dovetail(s) or T-head (s),
and secured in place by means of tapered keys. The design of the end plates shall
reduce the heating on their surface in front of the stator. The keys attaching each
pole shall be locked in place on both sides of the rotor rim to prevent the keys from
coming out in the event they become loose.
2. The poles shall be replaceable without lifting the rotor and dismantling the upper
bracket.
FFF. Rotor Rim
1. The rotor rim shall be constructed of high-strength, cold-finished, steel laminations

assembled to form a solid structure. The laminated rim shall be clamped together
to form a compact ring between solid segmented end-plates by means of axial bolts
in reamed holes, ensuring a positive connection between the adjacent segments of
any 2 layers for the transmission of the tensile forces. The high precision of the
punching and of the clamping bolt diameter shall eliminate the need of reaming the
holes in the rim during stacking at the site. After the rotor rim is assembled, the
difference between the actual height of the rotor rim and the design height shall
not be more than 10 mm. The pressure on the laminations shall prevent slippage of
the laminations at all speeds including runaway speed. The safety factor due to
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friction against slippage at the runaway condition after considering the loss of
pressure due to Poisson’s modulus shall not be less than 1.5.
2. The rotor rim shall be free to expand uniformly around the periphery without
constraint from the spider, but it shall be either heat-shrunk or friction held type
rim, however, heat-shrunk type would be preferred. The rotor rim shall be fitted to
the spider to assure roundness and concentricity during normal and temporary
overload operations, to prevent a shift in the center of gravity, and to effectively
transmit the torque. The shrink-fit or friction held type rim shall be effective at all
speeds up to full load rejection speed.
3. Sufficient air ducts and air baffles shall be provided in the stator core and frame,
and along the closed loop air circuit. They shall act together with the webs of the
rotor spider if radial (rim) ventilation system is provided or with fan blades mounted
on the rim to provide passage of cooling air as required by the closed cooling
system. These ducts shall be evenly distributed over the rim to provide a uniform
air flow. Special provision shall be made to prevent deformation and breakage of
the air baffles. The addition of separate motor-driven fan ventilation or vent baffles
mounted on the poles will not be accepted. The design of the baffles shall ensure
that sufficient air is directed for cooling of the stator winding coil ends and circuit
rings.
GGG. Field Winding: The field winding shall be insulated with Class “F” insulation as
defined by ANSI C50.10/ IEC-60034 and shall consist of copper strips wound edgewise.
Insulation systems using asphaltic compounds will not be accepted. The turn insulation shall
be thoroughly cemented to the adjacent turns. Heat treatment under pressure shall be
performed to assure a compact assembly of the field winding. Insulated supporting plates
shall be provided at the top and bottom of each field coil and shall be adequately supported
Page 29 of 45
at all points. Means shall be provided to compensate for shrinkage in the insulation and to
maintain adequate pressure on the field coil. Special care shall be taken to prevent the
winding end from deforming or slipping due to the centrifugal force on the interpole links
and to prevent the field winding from slipping on the pole body. The field windings and their
insulation shall be capable of withstanding vibration, thermal displacement, and stresses at
maximum runaway speed and shall be capable of withstanding short-circuit and unbalanced
current without mechanical and electrical failures. Field winding supports located at mid-
height between poles shall be provided if needed, so that the windings do not distort at any
speed including runaway conditions.
HHH. Damper Windings: The damper bars in the poles shall be of low resistance and
rugged construction. They shall be designed in order to obtain an appropriate value of ratio
of quadrature-axis subtransient reactance to direct-axis subtransient reactance as applicable
for un-connected damper winding. The damper windings including their connections shall
be adequately supported to prevent mechanical failure due to vibration, thermal
displacement, and stresses at maximum runaway speed and shall be capable of withstanding
short-circuits and unbalanced currents. The interpole links shall be designed to permit easy
disconnection and removal of each pole and shall be sufficiently flexible to avoid failure due
to vibrations and thermal displacement, but they shall be firmly attached to the damper
short-circuiting bars of each pole to withstand the runaway speed.
III. Braking: A brake ring shall be provided at the bottom of the rotor rim or spider. The
wearing surface of the brake ring shall be made of a heat-resisting and wear-resisting
material for a high number of braking operations, and it shall have an adequate safety
margin to allow braking under emergency conditions. It shall be made up of segments which
are easy removable and renewable. Adequate provision shall be made for dissipation of the
heat resulting from brake application and for thermal expansion of the brake ring segments
Page 30 of 45
without deformation. The fixing system of the braking rim segments shall ensure that the
segments remain in position under all conditions and it shall have a safety factor of at least
1.5 at runaway speed.
JJJ. Rotor Spider
1. The rotor spider including a central hub shall be a welded structure, subdivided into
a minimum number of sections to facilitate handling, transporting, and assembling.
Machining and heat treatment shall not be necessary at the site. The number of
rotor spider segments to be assembled at the site shall be a maximum of 3. If only
one guide bearing is provided under the rotor, the spider shall be of an asymmetric
or dropping-arms design in order to get the guide bearing closer to the center of
gravity of the rotor.
2. Fitted bolts, keys, and other similar devices as required by the design shall be
provided for assembly of the main shaft and the upper shaft of the generator to the
lower and upper flanges of the rotor hub at the site.
3. The spider shall have adequate tangential and vertical rigidity to prevent undue
deformation, to ensure centering of the rim and the poles, and to blow enough
cooling air to the rim, if the design of the cooling system uses radial (rim)
ventilation.
KKK. Collector Ring and Brush
1. The collector rings shall be mounted above the rotor in a separate enclosure. They
shall be sufficiently spaced or barriered and insulated with Class F insulation.
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2. Brushes shall be arranged to allow only visual inspection while the generator is
running. The brush holder shall be arranged so that the brush can be easily and
safely removed and reinserted into the holder during shut down period of machine.
3. The brush pressure acting on the ring shall be constant without requiring adjusting
during the lifetime of the brush. The structure and arrangement of the brushes and
holders shall facilitate ventilation. The collector ring and brushes shall be made of
highly wear-resistant material.
4. The abrasive value of the brush shall be less than 2 mm per 1,000 hours of
operation. The abrasive value of the collector ring shall be less than 1 mm per 7,500
hours of operation, and the service life of the collector ring shall not be less than 20
years.
5. The ring assembly shall be so designed that its surface can be repolished at the site.
Maximum run out of the collector rings shall be less than 0.5 mm. Means shall be
provided to prevent the circulation of carbon dust within the generator ventilation
system and to prevent dust from accumulating on the windings. Insulation for the
rings and leads shall be oil and moisture-resistant.
6. The brush leads shall be silver-brazed, woven copper braids and have at least 30%
extra cross-section of copper over the amount required for maximum field
excitation.
7. Field cables or insulated bus shall be furnished continuously from the terminals of
the field brushes to the field bushing terminals located at the air housing in a
manner specified in this Section under 6-18, Winding Terminations and Neutral
Grounding Assembly. The field terminals shall be suitable for connecting to metal-
enclosed bus or cable furnished with the excitation system specified in Part-02,
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Section – 7: Static Digital Excitation System. An extra set of collector ring brushes,
brush holders, and terminals shall be furnished for testing and monitoring
equipment.
LLL. Flywheel Effect: The specified value of GD 2 flywheel effect shall be incorporated into the
rotating parts of the generator. A separate flywheel will not be permitted.
MMM. Erection Pedestal: One erection pedestal to be used for rotor assembly and
maintenance in the erection bay shall be furnished.
6-09 GENERATOR MAIN AND UPPER SHAFTS
NNN. General: The generator shall be provided with main (lower) and upper shafts.
Depending on the design selected, the upper shaft may have to be rigid enough for the load
imposed by an upper guide bearing, if that is provided or even for the total vertical weight
and hydraulic thrust load, if the thrust bearing is located above the rotor. If there is no upper
guide bearing, the upper shaft may be built from a prefabricated tubular section of alloy
steel and connecting flange to the rotor spider with sufficient rigidity to maintain its shape at
all speeds up to 1.25 times the runaway speed, but the requirements below regarding
materials will not be applicable to it.
OOO. Lower Shaft: The lower shaft shall be made from forged, vacuum-degassed, open-
hearth carbon or alloy steel properly heat treated. They shall be of ample size and strength
to operate safely in combination with the turbine shaft at any speed up to the maximum
runaway speed without harmful vibration or distortion. They shall be able to operate at the
Page 33 of 45
rated speed with the guaranteed maximum turbine output without exceeding the maximum
allowable stresses for normal operation specified in Part-02, Section 1-06, Allowable
Stresses, except that stresses may be increased as allowed therein for temporary overloads.
Under generator unbalanced conditions, such as short circuit of one-half of the field
windings, stresses may be increased as allowed therein for generator maximum unbalanced
transient forces. The critical speed of the combined rotating parts of the turbine and
generator shall be verified by both the turbine and generator manufacturers. The first
critical speed shall be at least 25% above the maximum runaway speed. The generator
manufacturer shall coordinate with and provide the turbine manufacturer with Drawings and
all details relative to the generator bearings and rotating parts for use in the critical speed
calculation. The lower shaft shall be provided with a guide journal surface and a thrust
runner, while the upper shaft shall be provided with a guide journal surface, if an upper
guide bearing is provided. These surfaces shall be highly polished to the finish indicated in
this Section under 6-12, Bearings
PPP. Upper Shaft: A suitable upper shaft shall be furnished above the rotor for use with
the upper guide bearing, or for the weight and hydraulic thrust load, as applicable, for
mounting the generator field collector rings, and for connecting the speed signal generator
furnished by the governor manufacturer to the shaft. The bolts, nuts, and nut guards for
connections of these parts shall be furnished. The upper shaft shall meet the same
requirements as described for the main shaft above except that its dimensions shall be
determined by the generator manufacturer.
QQQ. Shaft grounding and shaft monitoring
Suitable shaft grounding has to be ensured. A shaft current monitoring system shall be
provided and installed in the excitation cabinet. The system shall be equipped with an
interface for connection to the power plant control and monitoring system.
Page 34 of 45
RRR. Analysis of Unit Rotating System: The dynamic stability, rigidity, and critical speeds
of the unit shaft system, complete with its bearings and including all superimposed loads,
shall be analyzed. The analysis shall demonstrate that the bearings, their supports, and
established oil films are adequate for both normal operation and transient conditions. An
analysis shall also be made to verify that the natural frequency of the unit components is
sufficiently separated to avoid resonance with the frequency of the electrical grid and with
the draft tube pressure pulsations and to avoid resonance with the frequency of the
vibration of the generator components. A detailed report, accompanied with related
calculations and data, shall be submitted for the Purchaser's review.
SSS. Main Shaft Dimensions: The diameter and length of the generator main shaft shall be
coordinated with the turbine shaft diameter. The generator main shaft shall be of proper
length and shall have coupling flanges at both ends, one for connection to the underside of
the generator rotor hub and the other for connection to the turbine shaft flange. The
elevation of the face of the flange at the turbine coupling shall be determined by the
Supplier, subject to approval of the Purchaser. The shaft coupling for connection to the
turbine shaft shall be designed in cooperation with the turbine manufacturer to provide a
precision fit between the 2 coupling halves. The coupling dimensions and corresponding
internal and external shaft diameters shall conform to ANSI/IEEE 810, "Standard for
Hydraulic Turbine and Generator Integrally Forged Shaft Couplings and Shaft Runout
Tolerances." All bolts, nuts, nut or bolt guards, keys for the coupling, and all tools and
devices for fit-up of the coupling and tightening the bolts shall be furnished by the
manufacturer responsible for the combined shaft alignment. The tools and devices required
to connect and disconnect the coupling will become the property of the Purchaser.
TTT.Machining and Runout Tolerances: The generator shafts shall be accurately machined
and finished throughout to obtain a smooth finish and shall be polished at the bearing
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surfaces and at bands provided at suitable and accessible locations for shaft runout
verification. If the shafts are made of solid forgings, they shall have a concentric hole at least
150 mm in diameter bored axially throughout their entire length, machined sufficiently
smooth to permit visual inspection of the metal in the shaft interior, or the interior material
shall be inspected by other suitable means subject to the Purchaser's approval. The entirety
of the shafts shall be subjected to ultrasonic examination as specified in Part-02, Section 1-
10.3, Nondestructive Testing. The amount of shaft runout shall be verified in the shop by
rotating the finished shafts in a lathe or aligning device, and it shall not exceed the
tolerances recommended for generator shafts in ANSI/IEEE 810, “Standard for Hydraulic
Turbine and Generator Integrally Forged Shaft Couplings and Shaft Runout Tolerances,”
Paragraph 4, “Shaft Runout Tolerance-Factory Check.”
UUU. Upper Shaft Extension: If an upper bearing is provided, a suitable upper shaft
extension shall be furnished for mounting the generator field collector rings, and for
connecting the speed signal generator furnished by the governor manufacturer to the shaft.
The bolts, nuts, and nut guards for connections of these parts shall be furnished.
6-10 COMBINED SHAFT ALIGNMENT
VVV. General: The fitting and aligning of the combined turbine and generator main shafts
shall be performed in either the turbine or generator manufacturer's factory at the option of
the Supplier.
WWW. Method of Alignment: The manufacturer assigned the shop alignment of the
combined shafts shall assemble the mating shaft to his shaft, match the shafts in a way to
obtain the best combined alignment, match-ream the coupling bolt holes, fit the bolts in the
coupling, bolt the shafts together, check the alignment, fit the coupling guards, match mark
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the couplings, paint identifying marks designating the unit number on each shaft near the
coupling, disassemble the shafts, pack the shafts for shipment, and ship them to the site.
The shop alignment check of the combined shafts shall conform to ANSI/IEEE 810. The shop
alignment check will be witnessed by the Purchaser and shall be approved in writing by both
manufacturers. Any necessary corrections to either of the shafts for proper alignment shall
be made immediately; both manufacturers shall cooperate to affect this so as to minimize
any delays and to adhere to the shipping schedules.
6-11 BEARINGS
XXX. All bearings shall be capable of operating continuously without injury, with the
machine rotating at any speed from 50% to 110% of rated speed
YYY.The thrust bearing shall have ample capacity to support the combined weight of the
rotating parts of the generator and turbine, including the maximum unbalanced hydraulic
thrust of the turbine. The thrust bearing shall have a removable one-piece runner and shall
be arranged to permit easy inspection, adjustment, dismantling, and assembly of the thrust
bearing shoes without disturbing the rotor, stator, or bearing bracket other than jacking the
rotor to remove the load from the bearing. The thrust runner shall be removable after lifting
the rotor and the shaft from the pit. Hardness and surface finish of the runner working faces
shall be in accordance with the following table:
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Hardness Parallelism Planeness Roughness Rest

Difference of
Hardness * **
HB HB mm mm μm μm
>200 <30 <0.02 <0.01 <0.4 <1.6
* Indicates the roughness of the mirror surface.
** Indicates the roughness of the rest of the surfaces such as the coupling face
between the runner and collar and the faces of inner and outer circles of the runner.
ZZZ. The thrust bearing metal temperature shall not exceed the value specified in this Section
under 6-03, Temperature Rise. The safe, stable, and continuous operation of the bearing
shall be guaranteed without harmful thermal distortion and mechanical deflection of the
bearing's lubricating face under various operating conditions. The design and structure of
the bearing shall meet the following requirements:
1. The load and the temperature rise on all the shoes shall be even and stable under
all steady operating conditions. The design of the supports of the thrust shoes shall
be of the self-equalizing or spring types so that an adequate wedge of oil film is
formed at the bearing surface and that differences in loading of the shoes are
minimized during operation.
2. The thrust bearing shoes shall be of the tilting pad type. The oil film between the
runner and shoes shall be adequate under all normal operations.
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3. The maintenance, dismantling, and assembly of the bearing shall be convenient and
easy.
4. Starting at normal operating temperatures, the thrust bearing shall be capable of

operating without bearing cooling water for 15 minutes, without injury, at the rated
Maximum output of 305 MVA followed by normal stopping.
AAAA. A high-pressure oil injection system will be provided for the thrust bearing as
required in this Section under 6-15, High Pressure Oils System, to lubricate the area of
contact between the thrust shoes and the thrust runner when starting and when stopping
the unit. However, under emergency conditions, the bearing shall be capable of starting or
stopping without jacking or external oil pressure. The thrust bearing shall also be capable of
operating without injury and without high-pressure oil lubrication under the following
conditions:
1. Continuously at any speed from 50% to 110% rated speed.
2. For at least 1/4 hour at any speed from 110% rated speed to the specified maximum
runaway speed with cooling water on.
3. For at least 1/2 hour at low speed from 4% to 5% of rated speed (only for stopping
condition).
BBBB. The guide bearing(s) shall meet all normal and unbalanced operating requirements
of the generator, including the unbalanced loads caused by a short circuit of one-half of the
field windings. The metal temperature of the guide bearing(s) shall not exceed the value
specified in this Section under 6-3, Temperature Rise. The lower or upper guide bearing, as
applicable, may be combined with the thrust bearing in the same oil reservoir on the
bracket. The guide bearing(s) pads shall be of the segmental, screw-adjustable, oil
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immersed, Babbitt type. The bearings shall be designed and constructed so that they can be
easily dismantled, assembled, and adjusted without disturbing the thrust bearing, the rotor,
or the collector ring. Viewports shall be furnished for each guide bearing to facilitate
maintenance measurements and observations. The surface finish of the working face of the
guide bearing shall have a roughness no greater than 0.8 m.
CCCC. Bearing oil lubrication shall be performed by oil circulation which is achieved by
shaft or runner rotation without an auxiliary pump.
DDDD. An oil-to-water cooler of copper-nickel alloy cooling coils shall be provided for each
bearing oil reservoir. Copper to Nickel Ratio shall be as 90:10 in Cuprous-Nickel Tube alloy.
Each cooler shall have sufficient capacity to cool its oil with cooling water as specified in Part-
02, Section 1-07.9, Station Service Compressed Air and Water Supply. The combined thrust
and guide bearing oil cooler may be located outside or inside the generator housing, but
outside of the oil reservoir, and shall be designed so that the oil will be circulated through
the cooler by the action of the shaft rotation alone, and the cooler tubes shall be easily
removable for replacement. The coolers shall be designed to prevent accumulation of
sediment. Provisions shall be made for effective removal of flux deposit and dirt. The
pressure drop through the coolers shall not exceed 0.7 kg/cm 2. The individual coils shall be
so mounted that any one coil can be removed and replaced without dismantling the bearing
assembly. Separately valved water-supply and water-discharge lines to and from each oil
reservoir and oil-overflow lines shall be furnished. The bearing oil cooling system shall be
designed so that the unit can rotate at any speed from 110% of rated speed to the maximum
specified runaway speed for 30 min., without reaching a bearing metal temperature of 100
ºC in any bearing after that period of time.
EEEE. The bearing assemblies and their housings shall be provided with means for
pressure equalization so that a sudden pressure rise inside the generator enclosure, caused
Page 40 of 45
by discharge of the CO2 gas will not affect the configuration of the bearing lubricating oil
surface to the extent that it would have any adverse effect on the thrust bearing or the guide
bearing operation. The design shall be such as to prevent damage to the bearings resulting
from unequal pressures in the event the pressure-relief door in the air housing should fail to
operate.
FFFF. Bearing shoes and segments shall be furnished complete with thermo wells for
insertion of RTDs specified in this Section under 6-19, Temperature Detectors. Thermo wells
shall be placed in locations that will produce the hottest spot metal temperature readings.
The size of all thermo wells used for RTDs shall be identical. Remote bulb, thermometers
with built-in thermal relay functions, shall also be provided as specified in this Section under
6-21, Instrumentation.
GGGG. Oil and water piping for the reservoirs shall be furnished in accordance with Part-02,
Section - 1-07.4, Piping and Fittings.
HHHH. Insulation shall be provided at least in two points in series in the path to ground
from the upper shaft to the upper bracket, in order to prevent the circulation of shaft
currents that may damage the bearings. All conduits and piping reaching that bracket must
be provided with double insulation.
6-12 AIR COOLING
IIII. The generator shall be provided with air-to-water coolers spaced symmetrically around
the periphery of the stator frame for a closed, recirculating air cooling system. The
circulation of air shall be by means of the fan or action of the generator rotor, which shall
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provide adequate air flow for cooling all generator parts. The air flow through the air coolers
shall be in an outward radial direction. Cold air return air ducts may be placed in the
concrete below the stator, and along the arms of the upper and lower brackets, so their
expansion is minimized.
JJJJ. The air coolers shall have sufficient cooling capacity to maintain the temperature of the
air leaving the coolers at 40°C, or less, with the generator delivering continuously 110% of
the rated MVA at rated speed, 0.85 power factor, and rated voltage, with one cooler out of
services and with the cold water entering the generator coolers at the temperature
determined by the closed loop water cooling system. The Supplier shall inform the generator
manufacturer of the maximum cooling water temperature. Provisions shall be made to
clean the cooler tubes. The water pressure drop through the coolers and headers shall not
exceed 0.7 kg/cm2 measured from the coupling flange of the common supply header to the
coupling flange of the common discharge header. The coolers shall be designed for operating
water pressures based on the range selected by the Supplier.
KKKK. Each air cooler shall be of the plate-fin type with stainless steel/cupric-nickel alloy
(Copper to Nickel Ratio shall be as 90:10 in Cuprous-Nickel Tube alloy) tubes expanded into
and fixed to non-ferrous or SS corrosion-resisting tube sheets. The water boxes shall be non-
ferrous or SS and constructed with removable cover plates to permit access to all tubes, and
they shall be arranged to permit free thermal expansion and to permit removal of any cover
for inspection or cleaning of the tubes without disturbing the water pipe connections.
Adequate provisions shall be made to avoid transmitting the magnetic core vibrations to the
tube bundle. A valve and hose connection shall be provided to permit complete draining of
each cooler. Automatic air vents shall be provided at the top of each cooler and at other
locations in the system as required. The air vents shall be connected through valves to a
common header. Aluminum-bronze water headers shall be furnished with the coolers. The
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connection to the cooling elements shall be arranged in such a way that the cooling water
always remains fully in the coolers. All connections between the coolers and the headers
shall be of the flanged or victaulic type and a valve shall be provided in each connection
between each cooler and the headers so that any cooler on the generator can be readily
disconnected and removed for maintenance or repair without interfering with the operation
of the remaining coolers. The outlet valve for each cooler shall be globe type for use in
balancing flows in the various coolers. The discharge header shall have a vented standpipe
to ensure that coolers will always be full of water. A gauge cock with a 6 mm tapered-pipe-
thread female connection shall be provided at the inlet and outlet of each cooler for use with
pressure gage. Handling devices and an air blow off device shall be provided on each cooler.
LLLL. All water piping for the coolers shall be furnished in accordance with Part-02,
Section 1-07.4, Piping and Fittings.
6-13 LUBRICATION
MMMM. The generator shall be provided with a complete, self-contained, oil

lubricating system for the bearings which shall include the latest improvements to eliminate
the throwing of oil and the escape of oil vapor from the bearings and lubricating system.
Adequate provisions shall be provided, if necessary, to prevent excessive churning or
aeration of the oil. The lubricating system for the upper bearing, if furnished, shall be
separate from that of the lower one.
NNNN. Each lubrication system shall include suitable oil reservoirs, oil piping, valves, filters,
and necessary appurtenances. Two oil-level gauges for each oil reservoir shall be furnished
as specified in 6-21, Instrumentation.
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OOOO. Lubricating oil required for initial filling of all of the equipment plus 10% reserve
shall be furnished. The oil for the generator lubricating system shall be the same type and
grade as the lubricating oil furnished for the turbine.
6-14 HIGH PRESSURE OIL SYSTEM
PPPP. A high-pressure oil lubricating system shall be furnished to provide high-pressure oil
to the thrust bearing surfaces during starting and stopping of the generator. Under normal
conditions, the high-pressure oil lubricating system will be automatically put into operation
in the starting and stopping sequences. The high pressure oil system shall automatically
start when unit creeping is detected. An adequate thickness of the oil film between the
runner and the shoes shall be built up within 5 sec after the pump starts. The high pressure
oil lubricating system shall be cut-off 5 sec after the unit has come to complete stop.
QQQQ. The high-pressure oil lubricating system shall have One Main AC driven pump and
One Standby DC driven pump. The Main AC pump and the Standby DC pump shall
individually be of full-capacity and shall independently be able to generate required high-
pressure oil. All controls, motor starters, instrumentation, gauges, valves, filters, regulators,
and protective devices shall be included to provide a fully automatic system in which the
standby DC pump starts in the event the main pump fails to start or to maintain pressure.
The DC driven pump motor set should be provided for standby duty in case of failure of main
pump.
RRRR. The system shall include, but not be limited to, the following instruments:
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1. One pressure switch, pressure gauge, filter, and check valve at the discharge piping
of each pump. Switch contacts shall be provided for automatic lead-lag operation
of the pump motors.
2. One flow indicating switch, pressure switch, pressure surge limiter (to avoid
pulsations), pressure relief device, and pressure gauge in the common supply
header from the 2 pumps. Switch contacts shall be provided. Each pressure and
flow switch shall be provided with a minimum of 2 electrically independent,
adjustable, single-pole, double-throw, and contact circuits.
SSSS. A control cabinet shall be provided for manual and automatic control of the pump
motors. The cabinet shall include the following control devices:
1. Motor starters in accordance with the requirements of Part-02, Section 1-07.2,

Auxiliary Equipment
2. Two “MANUAL-OFF-AUTO” maintained-contact selector switches
3. Two sets of red and green indicating lights.
4. One “LEAD-LAG” maintained-contact selector switches for selection of the main and
stand-by pumps.
5. Relays, timers, and other devices required to automatically start the stand-by pump
in the event that the main pump fails to start during “AUTO” mode of operation. A
Programmable Logic Controller (PLC) may be supplied and is preferred instead of
relay logic.
6. Two electrically-independent, single-pole, double-throw contact circuits.
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TTTT. The high pressure oil lubricating system including control cabinet shall be located
outside the generator air housing.
6-15 BRAKES AND JACKS
UUUU. The generator shall be provided with air-operated brakes of sufficient capacity to
bring the rotating parts of the generator and turbine, under normal operating conditions, to
a stop from 25% rated speed within 5 minutes after the brakes are applied, without injurious
heating of the braking surface on the rotor, without field excitation on the generator, and
with the leakage torque through the turbine wicket gate seals not exceeding an amount
which will produce 2% of the full rated turbine torque . The air brakes shall be suitable for a
maximum air pressure of 8 kg/cm 2, but shall be designed for braking operation with initial air
pressure of 7 kg/cm2, and shall be operated between 5 kg/cm 2 and 7 kg/cm2. The brakes
shall also be designed to serve as hydraulic jacks to lift the generator rotor and the turbine
runner for assembly, dismantling, or adjustment of the thrust bearing. The amount of lift
shall be between 10 and 15 mm. All parts of the generator shall be so constructed as to
permit this lift without dismantling or disconnecting any parts. An approved provision shall
be made for blocking the rotor in the fully raised position and in an intermediate position
suitable for bearing inspection. The blocking device shall be such that it will be unnecessary
to maintain hydraulic pressure on the jacks while the rotor is in the raised position.
Materials used shall be such that galling will not occur during braking.
VVVV. A loop header for oil and air supply shall be provided and arranged to drain the oil
and to prevent oil entry into the air system. High-pressure, lock-shield valves shall be
provided in the oil and air supply lines to the loop header. All piping used in connection with
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the air brakes and hydraulic jacks shall be capable of withstanding the maximum oil pressure
required to lift the combined weight of the rotating parts of the generator and turbine. The
air piping shall be furnished complete between the brake cylinders and the air receiver,
including all fittings, valves, and supports required for a complete system. A type of brake in
which oil is present in the brake cylinder during braking operations will not be acceptable.
WWWW. The brake shoes shall be provided with suitable friction wearing surfaces (free
of metal and asbestos) which shall be easily renewable. The brake shoes and wearing
surfaces shall be keyed or otherwise securely fastened to the jack pistons. The brake shoe
wearing surface shall have a guaranteed useful life of at least 10 years, based on 2 stopping
operations per day with the brakes applied at 25% rated speed.
XXXX. Control equipment for automatic and manual admission and release of air from the
brake system will be furnished by the governor manufacturer. The brake air piping shall be
of sufficient size and free of restrictions to permit complete release of the brake shoes after
completion of the braking cycle. Each brake cylinder shall be provided with a position switch
with 2 electrically-independent, single-pole, and double-throw contact circuits. The position
switches shall change position when the brake shoe reaches the reset or release position.
Each brake shoe shall be spring reset to disengage the shoe from the brake ring when the air
pressure is off.
YYYY. The rotor jacking device shall include a pump, for providing high pressure oil to the
hydraulic jacks, driven by an ac motor. All controls, motor starter, protective equipment,
high-pressure piping, flexible hose, piping connectors, strainer, regulator, pressure gauges,
check valves, oil sump, and all other accessories and appurtenances required for a complete
system shall be provided. Motor starter, in accordance with the requirements of Part-02,
Section 1-07.2 Auxiliary Equipment, shall be provided for the pump complete with the
following accessory devices:
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1. One “ON-OFF” maintained contact selector switch.
2. One set of red and green indicating lights.
Controls shall be arranged to start and stop the pump for normal jacking during maintenance
and inspection. All the equipment shall be mounted on a common base in an accessible
location on the outside of the generator foundation.
ZZZZ. The station compressed air system will furnish compressed air at a minimum
pressure of 7 kg/cm2. One air receiver shall be furnished for the generator brakes for each
generator. The tank shall be of adequate size to permit a minimum of 2 braking cycles
without recharging. The tank shall be of welded steel construction, designed, fabricated, and
tested to standards equal to the ASME Boiler and Pressure Vessel Code, Section VIII, Division
1. The tank design pressure shall be for 8.8 kg/cm 2 maximum compressed air system
operating pressure. The tank shall be provided with an inspection opening with bolted cover,
a drain hole in the bottom with its valve, necessary piping connections, moisture trap with
automatic drain, manometer, check valves, safety relief valve, lifting lugs, and a foundation
base with all required anchor bolts and materials. Pressure switches shall be furnished on
the tank for automatically controlling admission of compressed air into the tank. An
electrically operated valve for this purpose shall be furnished. Data indicating the total air
volume required for the number of brake applications involved in a single stopping sequence
as specified above shall be submitted to the Purchaser.
AAAAA. A dust collection system shall be provided for removal of brake dust produced
during application of the brakes. The dust collection system shall include electrostatic filters
for trapping particles produced from wearing of the brake shoes. The system, including a
control cabinet, shall be complete with all necessary ductwork, piping, instruments, filters,
and suction air units mounted in an accessible location outside the generator air housing.
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Individual air suction units shall be installed near each brake, sized to collect all the brake
dust generated during a normal braking operation. The control cabinet shall be designed for
the manual and automatic control of the complete system and shall include the following
control devices:
1. Motor starters in accordance with the requirement of Part-02, Section 1-07.2,

Auxiliary Equipment.
2. One “MANUAL-OFF-AUTO” maintained-contact selector switch.
3. One set of red and green indicating lights.
4. Relays, timers, and other devices required to automatically start the system when
the brakes are applied and stop the system, after a time delay, when the brakes are
disengaged.
5. Two electrically-independent, single-pole, double-throw contact circuits.
6-16 PIPING
BBBBB. All piping systems for the coolers, bearings, brakes, and fire protection system,
including ring headers for surface air coolers, valves, nozzles for a carbon dioxide system,
and fittings, shall be designed and furnished with the generator. All piping shall be clean
inside, and where ending in open connections for other work, ends shall be capped for
protection. Valves and other operating devices shall be easily accessible, and gages and
other indicating devices shall be located where they can be conveniently read from the floor
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or walkways. All technical specifications for pipes and fittings shall be in accordance with
Part-02, Section -1, -07.4, Piping and Fittings.
CCCCC. Water piping, where dripping would be objectionable, shall be insulated to prevent
all exposed cooling water piping, valves, expansion joints, and fittings from sweating.
Insulation shall consist of one 25-mm thick layer of cellular plastic or expanded polyurethane
material which shall be securely held in place. A jacket of 0.4 mm thick aluminum adhesive,
without paper or asphalt, shall be provided to cover the piping insulation. The jackets shall
be furnished with 50-mm wide aluminum butt straps. An insulation shield shall be provided
for hanger and support contact areas and shall cover the bottom 150 degrees. The minimum
shield length shall be 230 mm. Shield materials between the insulation jacket and hanger
shall be 1.5 mm (minimum) thick aluminum alloy.
DDDDD. Arrangement of piping and location of valves and joints shall be such that there will
be a minimum disturbance of piping and interference with other services when the
generator is dismantled or parts are removed for inspection or repairs.
6-17 WINDING TERMINATIONS AND NEUTRAL GROUNDING ASSEMBLY
EEEEE. General
1. Generator line-end and neutral-end armature windings and field windings shall be
routed outside the generator housing and shall terminate at bushing assemblies
mounted in seal-off plates located on the walls of the air housing.
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2. The generator neutral point will be made-up outside of the air housing. Insulated
copper terminals shall be brought outside the housing for connection to the bus
ducts and formation of neutral outside. The neutral end of the winding shall be
insulated for 15.75 kV minimum. The neutral point will be connected to the neutral
grounding equipment outside the housing by the bus duct supplier.
3. Bushing assemblies mounted on seal-off plates shall be provided for the armature
and field windings. The horizontal axis of the armature winding bushings and the
phase-to-phase axis distance shall be coordinated with the arrangement of the
segregated-phase bus.
4. The surface area of all copper terminations to be joined by bolting shall be silver
plated. All bolting hardware, including bolts, nuts, and approved lock washers, shall
be provided.
5. The seal off plates at line and neutral ends shall be provided with a flange to receive
the segregated phase bus enclosure, which shall be sized and drilled in coordination
with the bus supplier.
FFFFF. Armature Windings
1. The main and neutral leads shall be insulated copper busbar and all the six
terminals shall be brought out of generator housing for connection to segregated
phase bus ducts at line and neutral ends.
2. The terminations of the line-end armature windings will connect to segregated-

phase bus provided under Volume - 5, Section - 9. The details of this connection
shall be coordinated with the segregated-phase bus manufacturer. The hardware
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and connectors required to connect the bushing terminals to the segregated-phase

bus will be provided under Part-02, Section-9.
GGGGG. Field Windings
1. The field windings shall be led-out in a direction and at a height suitable for the
conditions.
2. The terminations of the field windings shall connect to bus provided under Part-02,
Section-9. Insulated cable on tray may also be used. All hardware and connectors
required for a complete interconnected system shall be provided.
6-18 TEMPERATURE DETECTORS
HHHHH. Type and Locations: Resistance temperature detectors (RTDs) shall be dual
platinum, 100± 0.1 Ω at 0°C, and shall be provided in the locations shown below:
1. 36 RTDs, equally distributed, located in the generator stator winding in accordance

with ANSI C50.10.
2. 36 RTDs, equally distributed, located in the generator stator Core in accordance

with ANSI C50.10
3. 8 RTDs, minimum, located near the hottest-spot metal of the thrust bearing shoes.
The RTDs shall be spaced equidistant from one another.
4. 8 RTDs for each guide bearing spaced equidistant from one another.
5. Two RTDs located in each bearing oil reservoir.
6. One RTD located in the hot air side of each surface air cooler
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7. One RTD located in the discharge air from each surface air cooler.
IIIII. Connections: Each platinum detector shall be connected by 3 leads to terminal blocks
located in the generator terminal box. One wire from each detector shall be connected to a
common point or bar on the terminal block. The common point for the bearing temperature
detectors shall be separate from that for the stator winding temperature detectors. The
common points shall be insulated from ground, but provisions shall be made for a grounding
connection on or near each terminal block. All wiring between the terminals and the
individual temperature detectors shall be furnished and installed.
6-19 MACHINE CONDITIONING MONITORING
The equipment and devices specified under Volume – 7, Section - 9 shall be furnished with
each generator.
6-20 INSTRUMENTATION
The following equipment and devices shall be furnished with each generator:
JJJJJ. Oil Level Gauges: Each bearing oil reservoir shall be equipped with one indicating
oil level gauge in an accessible and readable location near the reservoir. Each gauge shall
have 4 level switches, each with 2 electrically independent contact circuits set to close their
contacts at the following levels:
1. At and above high level (alarm)
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2. At and below minimum normal oil level
3. At and below low level (alarm)
4. At and below extreme low level (trip)
The oil level at which each contact operates shall be independently adjustable. The range of
the gauge shall be adequate to indicate the oil level at rest and at all operating conditions.
KKKKK. Cooling Water Flow Indicating Gauges and Transmitters: A cooling water flow
indicating gauge and transmitter shall be furnished in the discharge line from each bearing
oil reservoir cooler and each air cooler of the generator. The flow indicating transmitter shall
indicate the cooling water flow rate over a range of 25% to 125% of maximum flow, and it
shall include an externally powered, 2-wire, external, 4-20 mA dc signal to be wired to the
generator terminal box. The external flow signal shall be linear over the full flow rate in the
specified range. The flow indicating gauge shall be for local indication to facilitate
maintenance. Each flow indicating transmitter and gage shall be complete with valves,
tubing, standard stainless steel orifice plates, and flanges.
LLLLL. Cooling Water Switches: Besides the cooling water flow gauges and transmitters the
Supplier shall supply cooling water flow switches for the oil and air cooling water circuits,
which will be used in the automatic starting sequence of the unit. Each switch shall have two
independent C-form contacts of adequate rating for the circuit in which they will be used.
The flow switches may be integrated in the indicating gauges and transmitters specified in
the previous paragraph.
MMMMM. Vibration Detectors: The following vibration detectors shall be provided:
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1. Bearing and Main Shaft Vibration Detectors: Seven vibration detectors shall be
furnished with the generator, 2 mounted on each bearing bracket or radial support
for X and Y direction vibrations (run-out) of the main shaft, one mounted on each
bearing bracket or radial support for horizontal vibration of the bearing housing,
one mounted on the lower bearing bracket for vertical vibration of the rotating
parts. The leads from the vibration detectors shall be terminated in the generator
terminal box.
2. Stator Core Vibration Detectors: Three vibration detectors shall be furnished and
arranged, equally-spaced, in the core fastenings. The leads from the vibration
detectors shall be terminated in the generator terminal box
3. Stator Frame Vibration Detectors: Two vibration detectors for X-Y directions shall
be furnished and arranged, in the pit for the stator frame. The leads from the
vibration detectors shall be terminated in the generator terminal box.
NNNNN. Oil Pressure Gauges and Switches: Pressure gauges and switches shall be provided
as described below:
1. Pressure gauges and switches for the high-pressure oil system shall be as specified
in this Section under 6-15, High Pressure Oil System.
2. Pressure gauges and switches for the rotor jacking system shall be as specified in
this Section under 6-16, Brakes and Jacks.
3. One differential pressure gauge and one differential pressure switch shall be
provided across each strainer/filter furnished for the generator oil and water
systems.
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All necessary interconnecting piping, tubing, and fittings between sensing elements and
gauges shall be provided. Each switch shall have 2 electrically-independent, adjustable
contact circuits.
OOOOO.Water-in-Oil Detectors: One detector shall be provided in each bearing oil reservoir
to detect the leakage of water into the bearing. Each detector shall be provided with 2
electrically-independent contact circuits.
PPPPP. Thermometers: 4 remote bulb thermometer with built-in thermal relay function,
vapor-pressure type, 144 x 144 mm case, for the thrust bearing, for the thrust bearing oil
reservoir and for the guide bearings. The thermometer shall be provided with a leakage
alarm contact circuit, and adjustable, electrically-independent, ungrounded, alarm and
tripping contact circuits. The thermometer bulb shall be located so as to indicate the
temperatures of the hottest parts. The thermometer dials for the bearings and the bearings
oil reservoir will be mounted on the governor cabinet by the governor manufacturer. The
bulbs and the capillary tubing shall be insulated to prevent stray currents as required.
QQQQQ. Dials: Dials for thermometer indicators and for pressure gauges shall be
white, with black scale markings and numerals and black pointers. The dials shall also be
provided with a color band alongside the gage scale, clearly visible from the face side of the
gage, arranged in accordance with the following color code:
1. Green range for normal operation
2. Orange range for operation requiring caution or attention, but not of highest
emergency
3. Red range for abnormal operation requiring immediate corrective action
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RRRRR. Online Condition Monitoring Devices:
The On Line Condition Monitoring System shall be programmable microprocessor based

compact, modular & multi-channel units complete with Transducers, Processors, Display
modules (MMI), Communication port, Special cables &other standard peripherals. This
system shall be provided for all the units. The processor/data acquisition unit together with
Display unit shall be installed preferably in the Central Control Room. The Signal
Conditioner/ Repeater, if any, required for reliable reproduction of signals from the sensors
installed at the strategic locations shall be included in the scope of supply. The system shall
include relay modules which can activate alarms or shut down of the machine when
programmable thresholds are exceeded. The system shall be integrated with the protection
logic of units and shall be coordinated with Control & Monitoring System. However, the
protection system shall be such as to restraint the operation during transient conditions that
normally arise during start up/shut down of the machine to avoid unwarranted
alarm/tripping of the machine.
The measurement principle & modularization for the Condition Monitoring System shall be
as per the standard practice of the manufacturer.
On line condition monitoring system shall be provided to monitor the following parameters
of generating units
i. Measurement of air gap
ii. Vibration Monitoring both for Static and Rotating parts
iii. Partial Discharge Monitor
iv. Shaft Current Monitor
v. Moisture Detector
vi. Bearing Temperature Monitor
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The Suppliers shall submit details of the online condition monitoring system with the bid.
6-21 CURRENT TRANSFORMERS
SSSSS. The CT’s for protection and metering will be located in the run of the segregated
bus as specified in Part-02, Section-9.
TTTTT. Shaft Current Detection CT: A shaft current CT shall be supplied if two guide
bearings are provided, which shall be installed along the upper shaft at a convenient point
between the two generator guide bearings.
HEATERS
An adequate number of thermostatically-controlled electric heaters shall be furnished within

the generator housing to prevent condensation of moisture or sweating when the generator
is idle. Heaters shall be in 2 or 3-kW units and shall be wired in delta for operation on a
400/230 V, 50-Hz circuit. The wiring shall be extended to the generator terminal box as
specified in this Section under 6-26, Generator Terminal Box.
PROVISIONS FOR GOVERNOR ACCESSORIES
The governor manufacturer will furnish a speed signal generator for the governor and also
overspeed and underspeed switches. Proper space and provisions for mounting these
devices and the necessary wiring and concealed conduit to the generator terminal box shall
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be provided with the generator. The installation shall include necessary pull boxes and
intermediate terminal boxes.
INSULATION AGAINST STRAY CURRENT
The generator conducting parts such as stator, brackets, all supporting parts, seals,
thermometer bulbs, and detectors shall be adequately insulated against stray currents which
could be set up by the field of the generator and cause injury to the generator or turbine
bearings, if so required. The insulation materials shall be designed to safely withstand all
mechanical stresses incurred under operating conditions as specified in the Specifications.
The insulation shall be arranged to break the possible paths of such currents in not less than
2 places in series so that positive tests for ground currents can readily be made.
6-22 GENERATOR TERMINAL BOX
UUUUU. All wiring within the generator air housing shall be routed in rigid metal conduit.
The conduits shall be arranged, as far as practicable, to make removal unnecessary when the
generator is dismantled.
VVVVV. Wiring required for connection to devices outside the generator air housing,
including wiring from spare contact circuits, shall be routed to a generator terminal box
located on the outside of the air housing except wiring for the generator fire extinguishing
equipment which shall be wired to the test stations.
WWWWW. Barriers shall be provided inside the terminal box to separate the
instrumentation, control, and power terminations.
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XXXXX. Intermediate terminal boxes shall be arranged inside the generator air housing, as
required by the design, and shall be mounted in accessible locations with ample working
space.
6-23 FIRE EXTINGUISHING SYSTEM
YYYYY. General: A high-pressure type CO2 fire extinguishing system shall be furnished for
the generators, and it shall conform to NFPA 851, "Recommended Practice for Fire
Protection for Hydroelectric Generating Plants". The system shall consist of 2 banks of 45 kg
capacity CO2 cylinders for the initial discharge, 2 banks of 45 -kg capacity CO 2 cylinders for
the extended discharge, pressure trips, directional valves, initial and extended discharge
piping, pressure switches, remote control stations, discharge nozzles, manual releases,
automatic releases, thermostats, cylinder racks, saddles and guards, hangers, supports,
inserts, expansion anchors, and all appurtenances specified herein, or required for a
complete operating system. The cylinders shall be capable of being recharged locally. Each
bank of cylinders shall be adequate for all three units of generator, and one bank of each
type shall be connected as a reserve. The design shall be based upon the generator housing
air volume and deceleration time for the generators. The quantity of CO 2 to be used shall be
in accordance with NFPA requirements. The CO 2 shall be scented to allow personnel to
detect the gas when it is released. Piping shall be as specified in this Section under 6-17,
Piping. Electrical conduit and wiring between the various components of the system will be
furnished under Part-02, Section 1-07.3 Electrical Accessories.
ZZZZZ. Arrangement of System: The change-over from main to reserve protection, or

reserve to main, shall be accomplished by manual switches. The rate of discharge of CO 2
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shall be determined by the nozzle orifices and the pipe size so as to provide a high initial
concentration with a continuous extended discharge and maintaining a 30% minimum CO 2
concentration throughout the generator deceleration period or for a period of 20 minutes,
whichever is longer. The discharge from the cylinders shall be routed to the appropriate
generator by the operation of the directional valves. All cylinders shall be located in the
powerhouse at a convenient location.
AAAAAA. Controls: The system shall be so designed that it can be discharged by action
of the generator differential relays, by fixed-temperature type and rate-of-rise heat
detectors and smoke detectors located inside the generator housing, by manual operation of
remote emergency pushbuttons, or by direct manual operation of directional valves and
cylinder releases. Pressure switches in the line to each generator shall actuate signal lights in
the master control box and also shall actuate the station annunciator system and initiate the
shut-down of the affected unit. All electrical equipment shall be suitable for 110-V DC
ungrounded service. A DC control power switch for each generator shall be provided in the
master control cabinet so that electrical operation of the directional valves for any generator
may be prevented by opening the DC control power switch.
BBBBBB.Equipment
1. General: The CO2 system shall be capable of having all component parts, other than
those involved in the actual discharge of cylinder contents, tested without requiring
any replacement of parts.
2. Cylinders: The cylinders shall have a nominal capacity of 45 kg of CO 2 and shall have
suitable dimensions to suit the layout. The cylinders shall be interchangeable. Each
cylinder shall be provided with a safety cap for protection during shipment. The
serial number, weight empty, and weight full shall be stamped on each cylinder, and
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a weight record chart in a suitable holder shall be provided for each system. Each
cylinder shall be provided with a refillable type valve and safety pressure release. If
a puncture type disc seal is used for safety relief in place of a valve, 10 additional
disc seals shall be furnished for each bank. The cylinders shall stand in their normal
upright position and shall be protected from being accidentally discharged. The
cylinders shall be mounted in a floor-type open rack to hold them securely in place.
All cylinders shall be fitted with discharge valves which are free of exposed lines,
cables, or falling weights which might cause fouling or accidental operation of the
system. The cylinders shall be furnished charged with CO 2 gas as required for the
complete system ready for operation. In addition, the amount of CO 2 gas required
for the tests shall be furnished.
3. Directional Valves: Directional valves shall be of such design that no external levers
or falling weights are required for operation. The 2 valves, initial and extended, for
each generator shall be arranged for simultaneous operation by one electric
actuating device. Each valve shall have a minimum bursting pressure of 425 kg/cm 2
and shall be given a thorough shop test under simulated operating conditions and
pressures before shipment. The bodies, discs, seats, plungers, and all moving parts
of the directional valves shall be made of a corrosion-resistant material. Each valve
shall be provided with a nameplate similar to that provided for the control station.
The valves for each generator shall be labeled "Initial Discharge" or "Extended
Discharge", as required.
4. Blocking Valves: Manually operated blocking valves at each of the two entrance
doors of each of the generator air housing shall be provided to prevent CO 2 release
while work is being done in the generator housing. Valves shall be provided with
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auxiliary contact circuits for position monitoring and alarm. Means for padlocking in
each position shall be provided.
5. Extended CO2 Release: Extended CO2 release to the generators shall be from the
extended discharge cylinder bank. All cylinders in the extended discharge cylinder
bank shall be released simultaneously. The reduced rate of discharge shall be
obtained by the use of restricting orifices and properly sized extended discharge
piping.
6. Break Glass Control Stations: Two remote control stations shall be furnished for
each generator. These stations shall be of the break-glass type with a hammer
chained to the case suitable for flush mounting. The stations shall be of pleasing
appearance. Each control station shall be furnished with a nameplate with the
designation of the generator which it serves inscribed thereon. Each control station
shall be complete with switch and red and green pilot lights. The green lamp shall
indicate that the current supply is on. The red lamp shall light only when the
pressure-operated switch closes by action of CO 2 to give positive indication that the
gas has been released to the respective fire hazard area. The design of the remote
control stations shall be included in the record Drawings.
7. Master CO2 Control Cabinet: The master control cabinet shall be located at the CO 2
cylinder frames. The cabinet shall contain the following equipment for each
generator: dc control power circuit switch; pushbutton and pilot lamp for circuit
continuity test for the CO2 trip circuit; pushbutton and pilot lamp for circuit
continuity test of the directional valve circuit; red lamp for CO 2 discharge; and green
lamp for control power indication. The cabinet shall also contain the following
common equipment: pushbutton and pilot lamp for circuit continuity tests of the
initial and of the extended cylinder releases, cut-out switch for the extended
Page 63 of 45
discharge bank; transfer switch for transferring control between the main CO 2 bank
and the reserve CO2 bank; and ground test pushbutton and pilot lamps. Terminal
blocks shall be provided as required for connection for all internal and external
controls and devices.
8. Test Station: One test station complete with manual release switch and red and
green indicating lights shall be provided for mounting on the outside of the
generator housing The red lights shall indicate operation of the CO 2 fire
extinguishing equipment and the green light shall indicate availability of control
power to operate the system. The test station shall also contain a power supply
cut-out switch, and pushbuttons and indicating lights for circuit continuity testing
and indicating lights for position monitoring of the door blocking and directional
valves. Circuits shall be provided for automatic release of the fire extinguishing
system. The smoke or the heat detectors shall also initiate an alarm. Provisions
shall be made to prevent malfunction of the electric solenoid valve.
9. Discharge Nozzles: The nozzles for discharging the CO 2 to the generators shall be of
the unshielded type. All nozzles shall be of correct size and shape to effectively
spread the gas without freezing. They shall be of corrosion-resistant material,
preferably Monel metal, and shall be threaded to fit standard pipe fittings and
shaped to permit easy removal with a standard wrench without damage to the
nozzles.
10. Manifold Piping: The cylinders of each bank shall be piped into a manifold by means
of a flexible metal tube to prevent breakage due to vibration and to permit easy
connection and removal of cylinders. Each manifold shall be equipped with a
pressure relief device operable at a pressure not less than 170 kg/cm 2 and not
Page 64 of 45
exceeding 210 kg/cm2. Pressure relief devices shall be designed and located so that
their operation will not subject personnel to injury.
11. Heat Detectors: Heat detectors shall be fixed-temperature and rate of rise type, set
to operate at a temperature selected to suit the conditions. The temperature-
sensing and contact-actuating element shall be tubular, hermetically sealed, and
shall have a corrosion-resistant metal shell. The contacts shall be normally open,
designed to close on increase of temperature.
12. Smoke Detectors: Smoke detectors shall have a corrosion-resistant metal shell. The
contacts shall be normally open, designed to close on the presence of invisible
combustion products. The sensitivity shall be adjustable. No adjustment, resetting,
or replacement of moving parts shall be required to restore the system to normal.
13. Sleeves: Sleeves shall be provided for piping passing through generator pit concrete
walls. Pipe shall be caulked into sleeves to prevent leakage of CO 2 gas from
generator housing.
14. Weighing Device: A device for weighing the cylinders shall be provided in the
cylinder rack without disconnecting cylinders from the system.
15. Enclosure: An enclosure of suitable height shall be provided for the gas cylinder
assembly. It shall consist of a structural steel or pipe frame with wire mesh or
expanded metal panels and shall be equipped with a hinged door. The door shall
have a heavy-duty tumbler type lock.
16. Air Housing Door Interlock: A door-activated micro switch with double-pole, double-
throw contacts shall be furnished for mounting at each generator door to disable
Page 65 of 45
the CO2 fire protection system while work is being performed in the generator
housing. The micro switches shall be wired to the generator terminal box.
6-24 SPECIAL TOOLS AND MAINTENANCE EQUIPMENT
For Special Tools & Maintenance Equipment’s , refer Annexure – 2A
6-25 SHOP ASSEMBLY AND TESTS
CCCCCC. General
1. Assembly: The manufacture and fabrication of the generators and other equipment
shall be in accordance with best engineering practice and quality control at every
stage. Complete shop assembly of the generators will not be required but part
assemblies of the generator to the maximum extent shall be done and match-
marked in the shop for convenience of site assembly. These sub-assemblies,
accessories and equipment shall be subjected to the routine test in the shop as
specified herein.
2. Material Tests: The metallic materials shall be tested as specified in Part-02, Section
1-10.2, Test of Materials. The insulation material shall be tested in accordance with
ANSI-C29. No Material Tests need to be performed at Supplier’s Lab. However,
Supplier shall submit the Material Manufacturer’s and Mills TCs for EIC’s approval.
3. Dimensional Check and Pre-Assembly: All components and parts of the generator
shall be pre-assembled and inspected, and important critical dimensions shall be
recorded, and the records submitted to the Purchaser.
Page 66 of 45
4. Thrust Bearing Tests: Tests shall be performed in the shop to demonstrate the
adequacy of the thrust bearing design to meet the performance requirements
specified. Tests may be performed on a complete bearing, on one or more bearing
shoes, or on a bearing model. In lieu of these tests, the Purchaser may accept
certified field test reports demonstrating satisfactory operation of a similar thrust
bearing to the bearing proposed. A similar thrust bearing shall be defined as one
being of comparable design having a load capacity equal to, or greater than, the
proposed capacity and having a temperature rating equal to, or less than, the
proposed rating.
5. Stator Core Magnetization Test: The stator core segments (maximum of 4) shall be
completely assembled in the shop, and a core magnetization test (loop test) shall be
performed. The core under test shall be magnetized by wrapping insulated cables
around the core with sufficient number of turns to produce the maximum flux
density expected under the maximum or rated conditions. The core under test shall
be energized until the temperature of the core has stabilized, but not less than 2
hours. The test shall be terminated if the temperature difference between the core
and frame exceeds 30°C or if the core temperature exceeds 80°C. The temperature
of the core shall be periodically checked for development of hot-spot temperatures
during the test. Hot-spot temperatures in excess of 10°C above the average core
temperature shall be repaired. The test shall be repeated until no hot-spot
temperatures exceeding 10°C above average core temperature are detected. The
stator core test shall be done at the site after assembly of the stator sections or if
the core is stacked there.
6. Stator Coil Tests: The following tests shall be performed on each individual stator
coil, including spares:
Page 67 of 45
a. AC Dielectric Test: Each coil shall safely withstand a power frequency test
voltage of 2U+1000V for a period of one minute.
b. Insulation Power Factor Test: The loss dissipation factor (tan-δ ) shall be
measured at 40%, 80%, and 120% of the rated phase-to-phase voltages. The
tan-δ  at 40% rated phase-to-phase voltage shall not be greater than 0.04; the
tan-δ difference (tip-up) between the values at 80% and 40% rated phase-to-
phase voltages shall not be greater than 0.005; and the tan-δ  difference
between the values at 120% and 80% rated phase-to-phase voltages shall not
be greater than 0.01.
c. Strand-to-Strand Dielectric Test: The insulation between strands shall be

measured during fabrication of the coils and it shall withstand a test voltage of
at least 50 V.
d. Corona Test: Each coil shall not produce apparent corona at 1.5 times rated
phase-to-phase voltage.
7. Field Pole Tests: The following tests shall be performed on each individual field pole,
including spares. The test records shall be submitted to the Purchaser.
a. Megger test of each pole.
b. Ac dielectric test: Each pole coil shall safely withstand a power frequency test
voltage to ground (the pole body) of 10 times rated excitation voltage (but not
less than 1500 V) for a period of one minute.
Page 68 of 45
c. Turn-to-turn dielectric test: Pulse tests shall be performed. The insulation

between turns shall withstand a test voltage as selected to suit the conditions,
but no less than 50 V.
8. Cooler Tests: All oil and air coolers shall be subjected to a hydrostatic test pressure
of 1.5 times the rated pressure for a period of not less than one hour without
showing leaks.
9. Grounding Transformer Assembly and Tests: The grounding transformer shall be

completely shop assembled and shall be subjected to the routine tests in
accordance with IEC.
10. Resistor Tests: The dielectric test at 2,200 V, AC and measure of AC resistances shall
be performed on each resistor in accordance with procedures outlined in IEEE 32.
11. Miscellaneous Equipment Tests: All other electrical equipment, such as motors,
relays, meters, sensors, detectors, devices, etc., shall be tested individually in
accordance with applicable standards at least equivalent to ANSI/IEEE/IEC
standards, except that where the parts are in quantity production and routine tests
are made, and such routine tests are in accordance with standards at least
equivalent to the ANSI/IEEE/IEC standards, individual tests of such parts will not be
required; however, in either event, certified test data covering each part shall be
submitted.
INSTALLATION
Installation of generators shall be in accordance with Part-02, Section -08
Page 69 of 45
6-26 FIELD TESTS
Field tests shall be as specified in Part-02, Section -08.
6-27 SPARE PARTS
DDDDDD. Mandatory Spare Parts
Refer the attached annexure-2A for the spare parts and special T&P
EEEEEE. Optional Spare Parts
The Supplier shall furnish in his Bid a list of recommended additional spare parts, including
prices, and shall indicate the time required for delivery of each item to the Site, after receipt
of purchase order.
6-28 LIQUIDATED DAMAGES FOR SHORTFALL IN OUTPUT AND EFFICIENCY
For any shortfall in the tested values of rated output and the weighted average efficiency of
generator the corresponding guaranteed values respectively, shall be computed as follows:
Functional Guarantees
The functional guarantees the Contractor warrants are as follows:
• Rated output at rated voltage, frequency and power factor

• Efficiencies from 60 to 100 % of the rated output at rated voltage, frequency and power
factor
Page 70 of 45
• Segregated losses from 60 to 100 % of the rated output at rated voltage, frequency
and power factor.
Failure to obtain Guarantees and Liquidated Damages
If the generator rated power attained in the guarantee tests is less than the guaranteed
value the Supplier shall repair at his own cost within a certain period of time, in order to
achieve the guaranteed values. In case the Supplier, after this period, fails achieving the
guaranteed rated power, the Employer could reject the generator.
If the weighted average efficiency is lower than the guaranteed Value but the actual weighted
average efficiency attained in the guarantee test, is not lower than 1% (one point of percent), and
the Contractor elects to pay liquidated damages to the Employer in lieu of making changes,
modifications and/or additions to the woks, then the Contractor shall pay liquidated damages for
such default. For efficiency default equal to 1% (one point of percent) the Contractor shall pay
liquidated damages of 5% (five percent) of the Contract Price of the Generator.
For fractional values between 0 (zero) and 1% (one point of percent) of efficiency default,
the Contractor shall pay the Employer the corresponding fraction, rounded to the upper 0.1%
(one tenth of one percent) of the indicated liquidated damages.
Contractor's aggregate liability to pay liquidated damages for failure to attain the functional
guarantees shall not exceed five percent (5%) of Contract Price of the Generator.
Rejection limit-
The Employer reserves the right to reject the generator if the tested values of either
weighted average efficiency or the rated output falls short by one (1) percent of the
corresponding guaranteed values during field acceptance tests.
Page 71 of 45
Annexure-2B
Special Tools Requirement
SN Item Description Specification Unit Qty
1 Device for stator frame Sets 1

Assembly and welding
2 Device for Dovetail bar Sets 1

installation
3 Stator Core Clamping device 2
4 Stator core Magnetic Test 1

Device
5 Stator roundness measurement 2

device
6 Stator lifting device including 2

accessories
Generator
7 Stator winding assembly device 2
8 Rotor Poles Assembly Special 2

tools
9 Rotor Lifting device 2
10 Tools Box 2
11 Polishing Tools for slip ring 1
12 Various Lifting eyes and slings 2

up to maximum requirement
13 Electric Barring device 1
14 Shaft lifting and tilting device 1
15 Hydraulic Tensioner –Up to Pcs Each
Page 72 of 45
maximum Requirement One pc
16 Rotor Rim Tensioner device Pcs Each

One pc
17 Stator core Tensioner device sets 2
18 Tools for connecting shaft with Sets 1

rotor hub
19 High Pressure jacking device
20 4 Jacks of 100 Tons loading sets 1

capacity each
21 Rotor shrinkage heaters and Sets 1 set

accessories ( Including Panels
and Cables)
22 Rotor air gap measurement sets 2

device ( digital)
23 Shaft and thrust collar heating Sets 2

Electrical pads with insulating
wires and MCCB
24 Surface Plates with fine Sets 2

accuracy for the measurement
and Retaining ring Scraping
works
25 Straight Edge up to stator Set 1

diameter
26 Master level with 0.01mm/m Sets 2
27 Block level Sets 2
28 Micrometer 3.0m lengthy Sets 2
Page 73 of 45
Spare Tools for Generator
S. No Descriptions Nos Qty.

50% stator winding
complete with
Stator winding complete with wedges, packing, bracing, wedges, packing,
1
tying and insulating materials (For 9 Units) bracing, tying and
insulating materials
(For 9 Units)
2 universal field poles assembled with windings set Four (40) universal
3 field coils complete with insulation and collars Set 10
4 Set of thrust bearing pads Set 2
5 thrust bearing runner Set 2
6 set of upper guide bearing pads Set 2
7 set of lower guide bearing pads Set 2
8 bearing oil cooler of each type set 1
9 brake / jacking cylinders complete set 2
10 sets of brake shoes Set 3
11 complete air/water coolers Set 2
12 set of slipping brush holder assembly set 2
13 sets of slip ring brushes set 16
auxiliary brush holder assembly for rotor temperature
14 set 2
measurement
sets of auxiliary brushes for rotor temperature
15 set 6
measurement
16 grounding brush holder set 1
17 sets of grounding brushes set 6
set of seals for one generator and its associated
18 set 1
equipment
19 vibration transducers complete with cable set 3
10% set – RTD auxiliary relays, switches sensors of each
20 % 10%
type
21 dial type thermometers of each type Set 4
S. No Descriptions Nos Qty.
Page 74 of 45
22 pressure transducers of each type set 2

23 pressure gauges of each type set 2
24 flow transducers of each type set 2
25 Bearing Oil 20% of total Oil (for all 9 units) % 20%
26 oil level probes of each type set 2
27 oil level sight glasses set 2
28 water contamination detector for bearing oil set 1
29 solenoid coils of each type set 2
module of each type for vibration monitoring
30 set 1
equipment
31 module of each type for shaft current monitoring set 1
module of each type for rotor temperature evaluation
32 set 1
device
set of high pressure lubrication system components
33 set 1
(including motor/pump unit)
34 set of brake system components set 1
35 set of brake dust collection components set 1
36 brush gear exhaust fan set 1
37 sets of brush gear filters set 3
38 set of air dryer components set 1
39 set of CO2 fire protection components set 1
40 each type of fire detectors set 2
volume of CO2 gas sufficient for one refill after release of
41 As per Requirement
the fire protection system
42 lighting fixtures of each type set 2
sets of miniature circuit breakers, fuses, contactors,
43 set 2
auxiliary switches etc.
6-34 Generator Technical Guaranteed Data sheet
Page 75 of 45
Item Designation Unit Required Value Remarks
1 General
a. Manufacturer -
b. Place of manufacture -
c. Number of Units Nos 9
Vertical shaft,
Type designation -
Water wheel
driven
d. alternating
current
synchronous
generator
Applicable standards - IEC

e.
IEEE
2 Main data
a. No. of phases - 3
b. Rated voltage kV 15.75kV
c. Rated Current Amps 10135.0
d. Rated power factor p.u. 0.85
Page 76 of 45
Guaranteed rated generator 276.47

output within temperature
2.1
rise limit class “B” at rated
power factor (lagging)
 at 90 % Un MVA 276.47
 at 100 % Un MVA 276.47
 at 110 % Un MVA 276.47
Guaranteed continuous 110 %

overload generator output
2.2
within temperature rise limit
class “F”at rated power factor
(lagging)
 at 90 % Un MVA 305
 at 100 % Un MVA 305
 at 110 % Un MVA 305
Voltage range at which rated

2.3
output is available % ±10
2.4 Rated frequency Hz 50
2.5 Service factor 1.0
Page 77 of 45
As per Contract
Range of frequency variation %
±10% but Same
2.6 should be
respected as
per IEC60034-1
2.7 Number of poles 40
2.8 Rated synchronous speed Rpm 150
Direction of rotation (viewed

2.9
from top) Clockwise
290.0 ( As per
Design runaway speed RPM
contract same
2.10
should be ≤275
RPM)
Lowest factor of safety

(referred to yield strength) for
2.11 0.667
a generator rotating part at -
runaway speed
Maximum peripheral speed at

2.12 143.2
runaway speed m/s
Page 78 of 45
Flywheel effect of the

≥40000 for n=
2.13 generator rotating parts,
150 rpm
excluding turbine wheel (GD2) tons m²
Minimum Moment of Inertia t-m2

2.14 (J-GD2/4) of rotating parts of ≥9000
the whole machine
2.15 Inertia constant (H) kWs/kVA 4.4
2.16 Accelerating Time Sec 8.9
3 Bearing Arrangement
Lower guide bearing Yes/No

a Yes
combined with thrust bearing
b Upper Guide bearing Yes/No Yes
4 *Stator Winding
a Type of winding Lap
Number of parallel paths 4

b
/phase
Page 79 of 45
c Coil Pith ( Slot 1 to Slot n) 1-11
Design Temperature rise ( at K 75

d
Rated MVA )
Design Temperature rise at K 85

e
110% over load
Dimension of individual mm 7.5x1.8

f
elementary conductors
g Current per coil A 2494
h Current density in conductors A/mm2 3.15
i Insulation Type F
Capacitance per phase of the µF

j 1.22
winding
Number and type of 72 RTD-OK ( 36

k temperature detectors in in Winding and
stator 36 in Core )
5 *Rotor
a Number of poles 40
Page 80 of 45
b Type Cu Insulation
c Insulation Type F
Safety Factor ( Yielding Point)

d N/mm2 345
for rotor space
Safety Factor ( yielding point )
e N/mm2 550
for rotor rim
Safety factor ( yielding point) N/mm2
f for dovetail part of pole 400
piece )
g Rotor Spoke materials Steel Plate
Magnetic Thin
h Rotor Rim Materials
steel plate
Dovetail part of pole piece Magnetic Thin

i
materials steel plate
j Rotor spoke design stress Kgf/cm2 ≤2300
k Kgf/cm2 ≤3667
Rotor Rim Design Stress
Kgf/cm2
Dovetail Part of pole piece
l ≤1500
design stress
6 Efficiency
6.1 ≥98.6
Guaranteed generator
efficiency at rated voltage and
rated power factor (the static
Page 81 of 45
excitation system losses are

included in the generator
losses)
 at 110 % continuous rated

a 98.68
output (MVA) %

b 98.65
output (MVA) %
c 98.61
output (MVA) %
d 98.55
output (MVA) %
e 98.45
output (MVA) %
f 98.32
output (MVA) %
Weighted average efficiency

h ≥98.66
%
6.2 Max Temp Shall be

Generator losses at rated
75℃- Refer Stator
load, rated voltage and rated
Page 82 of 45
winding Temperature
power factor:
at 100 % load
a  Constant losses kW 1066
b  Load losses kW 1833
c  Excitation circuit losses kW 50
d  Additional load losses kW 267
Max Temp Shall be

Generator losses at
85℃- Refer Stator
continuous overload, rated
6.3 winding Temperature
voltage and rated power
at 110 % load
factor:
a  Constant losses kW 1066
b  Load losses kW 2052
c  Excitation circuit losses kW 55
d  Additional load losses kW 317
7 Class of Insulation
a  Stator Class F
For Coil –Class

b  Rotor
F
Page 83 of 45
8 Temperatures
Maximum generator
temperature rise above inlet
cooling air temperature (40°C)
8.1
with the generator delivering
rated output continuously at
rated power factor:
 Stator winding, measured

a by embedded
temperature detectors
 at 90 % Un K ≤85
 at 100 % Un K ≤75
 at 110 % Un K ≤70
 Field winding, measured

b
by resistance method
 at 90 % Un K ≤80
 at 100 % Un K ≤85
 at 110 % Un K ≤90
Page 84 of 45
Maximum generator
temperature rise above inlet
cooling air temperature (40°C)
8.2
with the generator delivering
continuous overload at rated
power factor:
 Stator winding, measured

a by embedded
temperature detectors
 at 90 % Un K ≤95
 at 100 % Un K ≤85
 at 110 % Un K ≤75
 Field winding, measured

b
by resistance method
 at 90 % Un K ≤85
 at 100 % Un K ≤90
 at 110 % Un K ≤95
8.3 Maximum temperature rise

above cooling water inlet
temperature (30°C) with the
Page 85 of 45
generator delivering rated

output continuously:
From CW Temp -30 °C

 Thrust bearing pad,
measured by resistance ≤40
temperature detectors K
From CW Temp -30 °C

 Guide bearing segments,
measured by resistance ≤35
temperature detector K
Temperature limit assigned by

8.4
the Bidder to the generator:
 Stator winding insulation °C 155 (Class-F)
 Rotor winding insulation °C 155 (Class-F)
9 Electrical characteristics
9.1 Generator short-circuit ratio p.u. ≥1.1
Generator synchronous
9.2
reactance:
 Direct axis (xd) p.u. ≤1.1
 Quadrature axis (xq) p.u. 0.624
Page 86 of 45
Generator transient
9.3
reactance:
 Direct axis (x’d) p.u. ≤0.30
 Quadrature axis (x’q) p.u. 0.624
Generator sub transient

9.4
reactance:
 Direct axis (x”d) p.u. ≥0.18
 Quadrature axis (x”q) p.u. 0.203
Generator negative phase

9.5 0.196
sequence reactance (x2) p.u.
Generator zero phase

9.6 0.073
sequence reactance (x0) p.u.
9.7 Ratio of x”q to x”d - <1.1
Maximum I2/In value for -

9.8 ≤8%
continuous operation
Maximum (I2/In)2 * t for -

9.9 operation under fault 40
conditions
9.10 ≤1.5
Telephone harmonic factor as
Page 87 of 45
specified in IEC-60034 %
9.11 Waveform deviation factor % ≤5
Symmetrical Short circuit

10 Current at generator
Terminals, at Rated load
a Three phase kA 55.25
b Two Phase kA 47.06
c kA 68.50
One phase to neutral
Surge Impedance of
11
generator
a One Phase Ohm 3.68
Comprehensive value for Ohm

b 1.23
three phases
12 Characteristic Curve
a Power chart Submitted
Submitted
No load saturation and three
b
phase short circuit curve
Submitted
c V Curve Sheet
13 Continuous Output when MVA

operating as Synchronous
Page 88 of 45
Condenser over excited at

rated voltage
Capacity for Condenser

13.1
Operation at rated voltage
a Lag MVA 166
This value is
MVA
not in To be defined the
b Lead
overexcited reason
condition
Voltage Rise in case of
14
sudden Load Rejection
a At p.f. 0.85 % 28.3
b At p.f. 0.10 % 19.9
15 Excitation conditions
Maximum admissible
continuous generator output
when charging a transmission
a line without the generator 180
becoming unstable or self-
excited, at rated frequency MVAr
and rated voltage
16 Weight
Page 89 of 45
Weight of generator rotating

a 590
parts including shafts tons
Weight of heaviest assembly

or part of the generator to be
b 570
lifted by the powerhouse tons
crane
Weight and name of heaviest

part or assembly of the
c 75T/stator(1/4)
generator, as prepared for tons
shipment
Weight of lifting device on tons

d 80
crane
17 Dimensions
Minimum required crane

hook clearance above
erection bay floor elevation,
17.1 for erection, dismantling or 9000
maintenance of the generator
by means of the powerhouse mm
crane
17.2 Overall dimension of largest Thrust bearing

generator part or assembly, as reservoir of
Page 90 of 45
prepared for shipment: lower bracket-

ok
a  Length mm 5490
b  Height mm 1600
c  Width mm 5490
Standards or Mechanical Properties

code (BS),
Part Rm KCV- KCV-
ASTM, etc) and Re ( Mpa) A% HB
( Mpa) 20C 0C
grade
EN10106 M250-
Stator Core
50A
ASTM A283-13
Stator Frame 235 370-500 25
Gr-D
ASTM A633-13
Rotor spider 345 470-630 19
Gr-D
EN1010265400-
Poles 400 500 18
TF180
ASTM A668
Generators Shaft 260 515 20 ≥47 149-207
Class D
ASTM A668
Thrust Collar 260 515 20 ≥47 149-207
Class D
Thrust bearing ASTM A283-13
235 370-500 26
bracket Gr-D
ASTM A283-13
Thrust Pads, Base 235 370-500 26
Gr-D
Thrust Pads , White ASTM B23 Alloy
66 88 6 ≥27
metal No03
Guide Bearing Pads, ASTM A283-13
235 370-500 26
Base Gr-D
Guide bearing Pads , ASTM B23
66 88 6 ≥27
White metal Alloy No03
Page 91 of 45
ASTM A633-13
Slip rings 345 470-630 19
Gr-D
ASTM A633-13
Brake Ring 345 470-630 19
Gr-D
ASTM B75
Air water Coolers 275 310 10 ≥65
C1200(H80)
Page 92 of 45
Instruments List- Tentative and will Finalize during details Engineering.
Location
Sl.
Type of Abbre. Purpose Qty Indicating/ Recording
No. Sensor/ Transducer/
Instrument instrument
transmitter
1 (a) Resistance Temperature PT100-RTD Stator Winding Temp. 16 Nos Embedded in stator Winding between SCADA
Detectors bars
(b) Resistance Temperature PT100-RTD Stator Core Temp 16 Nos Embedded in stator core SCADA
Detectors
(c) Resistance Temperature PT100-RTD Stator teeth Temp. 16 Nos Embedded in stator teeth SCADA
Detectors
(d) Resistance Temperature PT100-RTD Air Coolers cooled air Temp. - Each air cooler outlet air circuit SCADA
Detectors
(e) Resistance Temperature PT100-RTD Air Coolers hot air Temp. - Each air cooler inlet air circuit SCADA
Detectors
(f) Resistance Temperature PT100-RTD Thrust Bearing pad temperature - Embedded in all the pads SCADA
Detectors
(g) Resistance Temperature PT100-RTD Upper guide Bearing temp. - Embedded in all the pads SCADA
Detectors
(h) Resistance Temperature PT100-RTD Lower guide bearing temp. - Embedded in all the pads SCADA
Detectors
(i) Resistance Temperature PT100-RTD Thrust Bearing oil temp. 2 Nos ln combined oil tank for the SCADA
Detectors thrust & lower guide bearing
(j) Resistance Temperature PT100-RTD Upper bearing oil temp. 1 No In upper bearing oil tank SCADA
Detectors
(k) Resistance Temperature PT100-RTD Cooling water Inlet temp. to air 1 No ln inlet pipe line SCADA
Detectors cooler
(l) Resistance Temperature PT100-RTD Cooling water outlet temp. from - In outlet pipe line from each cooler SCADA
Detectors air cooler
(m) Resistance Temperature PT100-RTD Temp. Of Cooling Water Inlet & 2 Nos In Pipeline SCADA
Detectors Outlet from Thrust-cum-lower
Guide Brg. Cooler
(n) Resistance Temperature PT100-RTD Temp. Of Cooling Water Inlet & 2 Nos In Pipeline SCADA
Detectors Outlet from upper guide Brg.
Cooler
2 (a) Dial Type Temperature DTT Thrust Bearing Pad temp. 4 Nos Embedded in pads M & D System
Detector M & D System
(b) Dial Type Temperature DTT Upper Bearing Pad temp. 2 Nos Embedded in pads
(c) Dial Type Temperature DTT Lower Bearing pad temp. 2 Nos Embedded in pads
(d) Dial Type Temperature DTT Thrust cum lower guide Bearing oil 1 No ln oil tank
Detector temp. M & D System
(e) Dial Type Temperature DTT Upper Bearing oil temp. 1 No ln oil tank
Detector
Page 1 of 45
Dial Type Temperature DTT Air Inlet temp to coolers Alternate air cooler inlet side M & D System
(f)
(g) Dial Type Temperature DTT Air Outlet temp. from coolers Alternate air cooler outlet side
(h) Dial Type Temperature DTT Water Inlet & Outlet from upper 2 Nos In pipe line
Detector G.B. cooler M & D System
(i) Dial Type Temperature DTT Water Inlet & Outlet temp.from 2 Nos In pipe line
Detector L.G.B. cooler M & D System
(j) Dial Type Temperature DTT Water Inlet & Outlet from 2 Nos. In pipe line
Detector Thrust cum lower Guide
Bearing Coolers.
3 Temperature Indicator T.I Rotor temperature 1 No Insulated brushes across slip rings Digital excitation regulator
Location
Sl.
Type of Instrument Abbre. Purpose Qty Indicating/
No. Sensor/ Transducer/
Recording
transmitter
4 (a) Pressure Gauge PG Cooling water pressure at generator 2 Nos Local instrument
Indication
inlet & Outlet
(b) Pressure Gauge PG Cooling water pressure at upper 2 Nos Local Indication
bearing Inlet & Outlet
(c) Pressure Gauge PG Cooling water pressure at Thrust 2 Nos Local Indication
Bearing cum lower guide bearing
Cooling Water Inlet
(d)
/ Outlet
Pressure Gauge PG Inlet water for fire protection system 1 No Pipe line Indication
(e)
Pressure Gauge PG H. P. Oil System 1 No Local Indication
(f)
Pressure Gauge PG Compressed air supply for brakes 1 No Local Indication
5 (a) Oil level indicator and controller LIC Thrust bearing oil level 1 No Combined thrust & lower guide M & D System
bearing Oil tank
(b) Oil level indicator and controller LIC Upper bearing oil level 1 No Upper bearing Oil tank M & D System
6 (a) Oil level sight gauge LG Thrust bearing oil level 2 No Combined thrust & lower guide M & D System
bearing Oil tank
(b) Oil level sight gauge LG Upper bearing oil level 1 No Upper bearing Oil tank M & D System
7. Water flow meter indicator WFM Water flow inlet / outlet Generator 1 No each Cooling water inlet & outlet piping M & D System
with(4- 20mA output) air coolers, thrust cum lower
bearing & upper bearing oil coolers
8 (a) Moisture detector MD Thrust cum lower Bearing Oil tank 1 No Bearing tank M & D System
moisture monitoring
(b) Moisture detector MD Upper Bearing Oil tank moisture 1 No Bearing Tank M & D System
monitoring
Page 2 of 45
9 (a) Vibration Monitor VM Upper and lower generator bearing 2 each Displacement pickup M & D System
(b) Vibration Monitor VM Shaft Vibrations 4 nos (2 Non- Contact pickup M & D System
on each
bearing)
10. Shaft Current Monitor SCM Shaft Current Detection 1 no Shaft M & D System
11 Creep Detector CD Creep detection 1 no Shaft M & D System
12 Limit switches LS Brake release & rotor jacking - Each Brake shoe M & D System
13 Pickup transducer On line air gap monitoring As per T.S Air gap As per T.S
14 Partial discharge coupler with On line partial discharge detector As per T.S stator terminals As per T.S
Online Measurement
Page 3 of 45

Generators - Particular Technical Specification

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Generators - Particular Technical Specification

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Generators / SECTION 6

RUFIJI HYDROPOWER. PROJECT – E&M PACKAGE Particular Technical Specification

B. Complete generators shall be provided by the Supplier, designed in accordance with

 Nine (9) sets of static excitation and voltage regulation equipment.

 Shop and field tests

 Manuals and full documentation of supplied equipment including as-built drawings

6-02 TYPE AND RATING

E. Type: The generator shall be of the vertical-shaft, hydraulic-turbine driven synchronous

1. The Specifications are written on the basis of a preferred arrangement whereby a

The generator rating shall be as follows:

1. Continuous rated capacity at 0.85 power factor, 276.47

2 110% Continuous maximum capacity at 0.85 305.0

3. Power factor (lagging) 0.85

4. Rated frequency, Hz 50±10% ( IEC-60041-1)

6. Rated voltage between phases, kV 15.75 (+/-10%)

7. Rated speed, rpm 150

8. Stator winding connection Wye (neutral Yes

9 Rated speed 150 rpm

H. Plant Operating Mode

2. Rotor assembly shall be performed under the direction of the manufacturer's

b. Complete assembly of rim laminations to form a homogenous ring without butt

c. Installation of field poles, including interpole connectors.

6-03 TEMPERATURE RISE

M. Winding Temperature Rise

a. Stator Winding 70°C 80°C

b. Field Winding 80°C 90°C

c. Collector Rings 75°C 75°C

d. Core and Mechanical parts in 70°C 70°C

3. The temperature of the generator shall be determined in accordance with the

6-04 ELECTRICAL CHARACTERISTICS

The electrical characteristics of the generator shall be as follows:

a. The generator continuous rated capacity of 276.47 MVA and continuous

b. The continuous generator output capability when charging a transmission line,

winding temperature rise of 70°C or being completely self-excited or unstable,

a. Guaranteed direct-axis, unsaturated, transient reactance, not greater than 25%.

b. The calculated ratio of the quadrature-axis, unsaturated, subtransient

3. Short-Circuit Ratio. Not less than1.1.

4. Wave Distortion Factor

c. Deviation factor of wave form, measured in percent of open-circuit line-to-line

5. Natural Frequency: Generator natural frequency at 0 to 50% load at 0.85 to 1.0

7. The generator shall be capable of safely withstanding maximum stresses during

3. Guarantees on Efficiency & Output Rejection Limit

The weighted average efficiency shall be determined from the individual

hgaw= 0.2 x h 100 + 0.3 x h 90 + 0.3 x h 80 + 0.15 x h 70 +0.05 x h 60

1. The generator shall be capable of withstanding, without harmful deformation or

2. The generator shall be capable of withstanding 150% of rated current in accordance

4. The generator shall be capable of withstanding, without injury, the effects of a

5. Under unbalanced fault conditions, the generator shall be capable of withstanding,

6-05 MECHANICAL CHARACTERISTICS

The generator shall have the following mechanical characteristics:

T. Maximum runaway speed, not more than 290 rpm

X. The generator shall be designed mechanically to continuously withstand stresses within

Y. The generator shall be designed mechanically to withstand temporary overloads of up to

6-06 STRUCTURAL DETAILS

 Continuous operation at any speed from 90% to 110% of rated speed.

 Operation for a period of at least 15 minutes under maximum runaway conditions

ZZ. Stator Core

AAA. Stator Frame

BBB. Stator Winding

FFF. Rotor Rim

1. The rotor rim shall be constructed of high-strength, cold-finished, steel laminations

JJJ. Rotor Spider

KKK. Collector Ring and Brush