H-6745 00 MKB 000 81 DC

POWER SYSTEMS
MODIFICATIONS TABLE
REV PREPARED CHECKED APPROVED DATE MODIFICATIONS STAT.
A M.SUBRAMANIAN ANURAJ SHARMA VIBHU RATHORE 29th MAY-14 FIRST ISSUE GFE
H-6745 00 MKB 000 81 DC _ A 2 of 118

ERECTION MANUAL Element: 0
Rev.: A
APPLICATION AND PRECAUTIONS
HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm
INDEX
1. PURPOSE
2. SCOPE
3. SAFETY PRECAUTION
4. STATOR FRAME, CORE ASSEMBLY AND WINDING
5. ROTOR ASSEMBLY
6. ASSEMBLY OF UPPER BRACKET IN ERECTION BAY
7. INSTALLATION OF LOWER BRACKET
8. ASSEMBLY OF LIFTING / BRAKING JACKS AND ITS PIPING
9. PREPARATION OF PIT FOR STATOR ERECTION
10. LOWERING OF LOWER SHAFT
11. INSTALLATION OF STATOR AIR COOLER AND ITS PIPING
12. INSTALLATION OF PHASE AND NEUTRAL CONNECTION AND GUARDS
13. INSTALLATION OF UPPER BRACKET
14. INSTALLATION OF THRUST BEARING ASSEMBLY
15. ASSEMBLY OF UPPER GUIDE BEARING
16. INSTALLATION OF LOWER GUIDE BEARING PIPING
17. INSTALLATION OF COLLECTOR RING AND CONNECTION WITH FIELD WINDING
18. INSTALLATION OF UPPER AND GUIDE BEARING PIPING
19. INSTALLATION OF FIRE PROTECTIONS & INSTRUMENTATIONS
20. INSTALLATION OF FLOOR AND COVERS
21. INSTALLATION OF MISCELLANEOUS DEVICES.
22. CHECKS BEFORE GENERATOR OPERATION
23. MECHANICAL TEST AND BALANCING

H-6745 00 MKB 000 81 DC _ A 3 of 118
Rev.: A
REFERENCE DOCUMENTS
• ANNEXURE 1 - 1ECR100844
• ANNEXURE 2 - HTWT 620242

• ANNEXURE 4 - HTZW 23292
• ANNEXURE 5 - HTAE 60012

• ANNEXURE 8 - HTAE660145
• ANNEXURE 13 - HTZW23204
• ANNEXURE 14 - EP310,HTZW23232
• ANNEXURE 15 - HTWT620280
H-6745 00 MKB 000 81 DC _ A 4 of 118

Rev.: A
1. PURPOSE
The purpose of this document is to define general erection guidelines to be followed at site by erection team;
General assembly drawings are the final reference for installation.
Note: Erection supervisor at site based on site condition can change this erection procedure.
2. SCOPE
This document is applicable for HULU TERENGGANU HYDROELECTIC PROJECT only.
3. SAFETY PRECAUTION
- Prior start of erection works, ensure following safety:
- To be Ensured by TENGA NASIONAL BERHAD:
- Trouble free access to the working fronts.
- Ensure that all the required reinforcement bars are bended.
- No activities are going above working fronts to avoid any object falling.
- No activities should be taken under working fronts to avoid any miss-happening.
- Working fronts should be dry and clean.
- Removal of all naked cables if any around working fronts.
- All the gas cylinders opening are properly tight and chained to avoid any fire.
- All the loose material on roof to be removed prior start of erection.
- Advance information to be given in case of any blast or radiography.
- No gas cylinders near generator area to avoid any fire hazard.
- Noise and pollution to be controlled as per standard.
- All the dangerous area to be marked properly.
- No blast in the vicinity.
- All the opening to be plugged and fenced.
- Alstom will also ensure above applicable safety precaution in his working area during execution.
H-6745 00 MKB 000 81 DC _ A 5 of 118
Rev.: A
PREPARATION
Client is to ensure all benchmarks. Unit axis, X & Y and Elevation
Alstom to ensure that all benchmarks are punched on properly fixed plates to avoid any
Misalignment during the course of execution.
H-6745 00 MKB 000 81 DC _ A 6 of 118

ERECTION MANUAL Element : 0
Rev. : A
STATOR FRAME ASSEMBLY , CORE AND WINDING
4. STATOR FRAME ASSEMBLY , CORE AND WINDING
4.1 ASSEMBLY OF STATOR SEGMENTS
• Mark the position of pedestal stools for stator frame segments in service bay.
• Bring all four stator frame segments one by one and place it on service bay by using slings, rope D-
shackles and lifting device supplied for lifting of stator frame segment.
• Remove the packing material carefully so that it may not damage the stator segment.
• Remove the packing material from service bay.

• Thoroughly inspect the stator segments for any damage during transportation.
• Place the stator stools in position marked in service bay.
• Assemble the lifting arrangements with the stator segment as per drawing.
• Lift the stator segment and place it on stools as per drawing.
• Repeat the same process for other segments.
• Prepare the matching surfaces removing the anti-corrosive material applied for the purpose of
transportation where stator segments need to match.
• Clean and apply oilstone on plate matching area.
• Joint all stator frame segments temporarily to check the gap between stator frame segments for shim
packing.
• Make final Assembly of the stator frame segments using bolts and pins.
• Check out dimension of all four segments after finishing of with torquing of bolts.
• After bolting, centre and level the Stator.
• After the stator is centred and levelled, go ahead with the welding of Stator joints.
• After final welding & Torquing check the centring and level of complete Stator and record the same.
H-6745 00 MKB 000 81 DC _ A 7 of 118

Rev. : A
Measurement Report:
MR 1 LEVEL OF STATOR SUPPORT BLOCKS
MR 2 STATOR FRAME ROUNDNESS BEFORE BOLTING
MR 2a STATOR FRAME ROUNDNESS AFTER FINAL BOLTING
MR 3c HORZANTIALTY OF STATOR FRAME LOWER FLANGE
Ref Drawing:
H-674500MKB11201TW STATOR FRAME FRBRICATED
H-674500MKB11200TM STATOR FRAME MACHINED
H-6745 00 MKB 000 81 DC _ A 8 of 118

Rev. : A
• For Stator core erection refer the STATOR CORE ERECTION PROCEDURE 1ECR100844
After final completion of stator core Perform El CID Test.
Measurement Report:
MR 3 ADJUSTMENT OF KEY BARS BEFORE WELDING

MR 3a ADJUSTMENT OF KEY BARS AFTER WELDING
MR 5 HEIGHT OF MAGNETIC CORE DURING CLAMPING
MR 6 MAGNETIC CORE ROUNDNESS
MR 7 STATOR CORE HEIGHT
MR 8 LOW INDUCTION TEST
MR 19 INSULATION RESISTANCE MEASUREMENT OF MAGNETIC CORE CLAMPING STUDS
Ref Drawing:
H-674500MKB12000TC STATOR CORE ASSEMBLY

H-674500MKB61201TC STATOR CORE AND WINDING RTD ARRANGEMENT
H-674500MKB12001TC STATOR CORE STACKING & PRESSURE ARRANGEMENT
H-6745 00 MKB 000 81 DC _ A 9 of 118

Rev. : A
4.2 PREPARATION OF STATOR PARTIAL WINDING IN SERVICE BAY.
4.2.1 PREPARATION OF TEMPORARY TOOLS
• Prepare the tools for insertion of bars (Belt, wedges, mallets hammer, Bakelite blocks….)
• Prepare the dust free closed chamber for winding.

• Make sure the absence for any foreign material in the slots.
• Clean the slots carefully, take care not to damage the slot punching
• Arrange to prepare the round packing machine for different thickness of silicon coating on semi conducting
tape and make a role for taping on the bar.
• Prepare temporary device for elevation setting of bars.
• Prepare platforms for partial winding.
H-6745 00 MKB 000 81 DC _ A 10 of 118

Rev. : A
4.3 PREPARATION OF CONSUMABLES
4.3.1 COLD POLIMERISATION EPOXY RESIN FOR TAPE IMPEGRATION
- Fitting of HIME 450560 tape with epoxy resin NBT 401839 and NBT 401842 between layers of connection
junctions
- Formulation
Component Part by weight Remarks

HIME 450560 TAPE
NBT 401839 100 A
NBT 401842 50 B
• Preparation:
• Pour part B into part A
• Make sure that both parts are thoroughly blended together since correct hardening depends upon the
uniformity of the mixture.
• Lifetime after preparation. : 2 Hours at 23 ºC.
• Storage before Mixing: at ambient temperature.
• Application: According to Manufacturing instruction HTZW23204
4.3.2 COLD POLIMERISATION FILLING PUTTY
• Fitting of gap left between connection pieces.

• Formulation

CEMENT J11 HIME 450663 2.5 A
CEMENT J11 HIME 450664 1 B
………. ……………… ……………
• Preparation:
• According to manufacturing instruction HTAE 660520.
• Make sure that both parts are thoroughly blended together since correct hardening depends upon the
uniformity of the mixture.

H-6745 00 MKB 000 81 DC _ A 11 of 118
Rev. : A

Note:
• It is advisable to use the full capacity of mixture to facilitate the mixing process.
• Use complete mixture before lifetime.
• Application: According to manufacturing instruction HTZW23204.
4.3.3 FELT, CHORD AND TAPE IMPREGNATION
• Pre-impregnation of wedge cord, tape and felt used for end winding and connections wedging.
• Formulation

NBT 401839 100 A
NBT 401842 50 B
HZN 451493(HTAE 60021) ……………… FILLER
• Preparation:
• According to Manufacturing instruction HTZW23204 and HTAE 660596.
• Make sure that all parts are thoroughly blended together since correct hardening depends upon the uniformity
of the mixture.

• Note:
• It is advisable to use the full capacity of mixture to facilitate the mixing process.
• Use complete mixture before lifetime.
• Application: Manufacturing instruction HTZW23204 and HTAE 660596.
H-6745 00 MKB 000 81 DC _ A 12 of 118

Rev. : A
4.3.4 EPOXY RESIN
Scope of application is filling of insulation caps and impregnation of round cord.

(I) TOP SIDE END CAPS
Formulation

CEMENT J11 HIME 450663 2.5 Resin A
CEMENT J11 HIME 450664 1 Hardener B
• Preparation:
• According to manufacturing instruction HTAE660520.
(II) Application
• Application according to manufacturing instructions HTAE 660520.
• Fitting the space between the bars using spatula.
• Cover the junction until a volume of resin equal to that of hood has been applied.
• Filling of the end caps at the bottom and on the sides
• Invert the cap on the junction.
(III) BOTTOM SIDE END CAPS
- Formulation

HZN 451484 (HZN02643) 856 Resin 09
HZN 451484 (HZN02645) 143 Hardener 86
………………
According to manufacturing instruction HTZW23241.
H-6745 00 MKB 000 81 DC _ A 13 of 118

Rev. : A
4.3.5 IMPEGRATION OF ROUND CHORD (SURGE RING)
- Formulation

EPE 19A HZN 451580 67 Resin Comb EPE 19A
EPE 19B HZN 451580 33 Resin Comb EPE 19A
NBT 401843 .976 ACCELERATOR
HZN 450838 .024 DYE STUFF
Preparation:
- According to manufacturing instruction HTZW23232.
- Equipment used:
- Pneumatic injector.
- Hardening time: 8 hours at 23 ºC.
- Curing time: Hot curing 16 hours at 100 ºC
- Application: According to specification.
Ref Drawing:
H-674500MKB13001TC GENERATOR STATOR WINDING DIAGRAM

H-674500MKB13000TC STATOR WOUND AT SITE
4.4 PAINTS
- Scope of application is protection surface and finishing treatment.
4.4.1 ANTI-CORONA PAINT
- Scope of application is protection of both sides of end winding bars.

- Formulation

LL16 HIFE 450018 100 Conductive varnish
103 HIFE 450021 10 Hardener
15 Thinner
H-6745 00 MKB 000 81 DC _ A 14 of 118

Rev. : A
Preparation:
- According to manufacturing instruction HTAE660108, HTAE660145.
- Conductive varnish must be carefully mixed with hardener before using.
- If required paint must be diluted with thinner 8 NBT 402845, HZN02544.
Application:
- Must be applied with brush or spray gun.
4.4.2 FINISHING PAINT
- Painting of stator core and winding as per drawing.
4.5 SILICON COMPOUND
- Scope of application is filling of round packing tap around the bars.

- Formulation

S52 HIFE 450070 9 Resin 52
105 HIFE 450071 1 Hardener 105
………………
Preparation:
- According to manufacturing instruction HTAE660556.
- RESIN must be carefully mixed with hardener before using agitator.
- Apply with the specified equipment.
Application:
- According to specification HTAE 660556.
H-6745 00 MKB 000 81 DC _ A 15 of 118

Rev. : A
4.6 LUBRICANT
- Scope of application is lubrication of ripple springs.

- Formulation

PTFE TR GLEIT (VYDAX) 100 Lubricant
WHITE SPIRIT 10
………………
Preparation:
- According to Manufacturing instruction
Application:
- Apply with brush on ripple springs.
Ref Drawing:

4.7 SLOT IDENTIFICATION AND PREPARATION
- Mark the axis on stator (Up stream and down stream).

- Identify the slots repeatedly along the core with permanent marker to easy identification of RT D’s slot and
various types of bars in different slots.
- Mark slot no 1 to 228
- Locate and mark the slots with RT D’s according the winding diagram.
Measurement Report
MR 25 Bar / Slot reference No
Ref Drawing:

H-6745 00 MKB 000 81 DC _ A 16 of 118

Rev. : A
4.8 INSPECTION OF BARS
- Check each bar for any physical damage. Remove dust, sticky particles and irregularities from bar surface.
- Visual checking of bar as per drawing.
- Conduct insulation resistance test of each bar.
4.9 ASSEMBLY OF STATOR PARTIAL WINDING
4.9.1 INSTALLATION OF BOTTOM BARS

FOR ROUND PACKING TAPE FOLLOW INSTRUCTION HTWT 620172
- Brazing surfaces on the bottom bars must be polished and cleaned (free of damages, dust and grease) prior to
the bottom bar insertion. Remove any grease with White spirit.
- Clean the bars with a clean and dry cloth (non abrasive).
- Check the core for any physical damage.
- Wrap the bar with round packing tape.
a) Install and clean the device for bar round packing.

b) Measure the slot width (Ws)
c) Measure the bar width (W b)
d) Calculate the mounting gap (Ws – W b)
e) As a double-layer folded round packing tape has a thickness of 0,22 mm, then the total thickness both
sides is 0,44 mm. Define then coating thickness of the silicone compound for round packing according
to the following gaps:
Clearance between bar and slot wall Applicator setting

0,5 mm 0,10 to 0,15 mm
0,6 mm 0,20 mm
0,7 mm 0,20 mm
0,8 mm 0,20 to 0,25 mm
0,9 mm 0,25 to 0,30 mm
1,0 mm 0,30 mm
NOTE: deviation from these values can be made under the following conditions:
- The bar sits too loosely in the slot: increase the amount of silicone compound, as air bubbles can form inside
the compound
- The bar sits too tightly in the slot: this happens if silicone compound is pushed out when the coil is inserted.
Reduce the amount of the compound
H-6745 00 MKB 000 81 DC _ A 17 of 118

Rev. : A
- Realisation of Resin: thoroughly mix the resin and hardener in the mixing equipment. The scope of delivery
covers the resin and the required amount of hardener. The pot life of the compound is 2 hours at a
temperature of 23 °C. This period can be prolonged by cooling the components before and after mixing
- Set the applicator (round packing device) for the calculated thickness
- Prepare the required quantity of semiconductor tape and store it in the magazine
NOTE: protect the tape from dirt contamination. It must not be dirty before being treated.
Wrap the tape around the bar as shown below

- Check the left core slots for cleanliness
- Cover the sharp edges of stator core with electrical tape to prevent any damage of round packing tape during
installation.
- Install the bottom bar.
- Remove electrical tape and the excessive silicone compound from the stator core.
- Check the alignment of bottom bar by measuring winding overhang at NDE and DE side as per drawing.
- Check for minimum air gap in the overhang between two bars and maintain as per drawing value.
- Install temporary wedge to hold bottom bars in the slot using hard wood as a substitute of the air gap before
polymerization of silicone paste.
- Mark the axial position of the spacer blocks on the bottom bar overhang part by using a template.
- Install spacer blocks wrapped with a felt impregnated with LL16 to be wound to each other with ½ over
lapped and 2 throttle turns of tape on the both DE and NDE side as per drawing.
- The cords will be varnished with Resin EP139 and impregnated with Resin using an injection machine after
final installation and wedging with bottom bars layer at DE and NDE side as per drawing.
- Apply necessary Corona protection paint on the winding overhang portions taking care to avoid the droplets
on brazing part. Limit of corona paint is 50 mm below brazing lug.
- Conduct Insulation Resistance and High Voltage test of bottom bars in a group as per test plan and record
results & observation in control sheet.
- Stator winding insulation resistance test at 20 ºC and 70% humidity
H-6745 00 MKB 000 81 DC _ A 18 of 118

Rev. : A
Description Acceptance limits Applied specifications Remarks

44.4 MΩ for 3 Phase
Under 5000 V DC. for 1
Insulation resistance 88.8 MΩ for 1 Phase HTAE 60012
minute
Polarization index HTAE 660183
(i) Dielectric Test.
Description Applied voltage Applied specifications Remarks

Dielectric test (AC) 36.6 kV - AC - 50 Hz HTAE 60031
1 minute
Or
Dielectric test (DC) 62.22 kV – DC HTAE 60031
1 minute
PREPARATION AND INSTALLATION OF R T D’s

- Put each RTD in specific spacer. Equip the wiring with varnished sheath silicone diameter 4.
- Prepare araldite and fill the cavities.
- After drying to make sure that there is no extra thickness, if there is any extra thickness adjust by grinding.
- Make a continuity check and insulation test of RTD
- Make the correspondence no of slot on each RTD.
- Paint the spacer with conductive varnish.
- Install stator winding temperature detector (RTD.
- Mark each RTD wires with their corresponding number of the terminal box according to drawing.
- Measurement of Resistance and Dielectric test as per instruction.
Measurement Report
MR 21 PARTIAL DIELECTRIC TEST

MR 23 STATOR ELECTRIC CHECKS BEFORE DIELECTRIC TESTS.
MR 23a STATOR ELECTRIC CHECKS AFTER DIELECTRIC TESTS.
MR 24 RTD TESTING
H-6745 00 MKB 000 81 DC _ A 19 of 118

Rev. : A
Ref Drawing:

H-674500MKB13211TC STATOR SLOT (WEDGING SYSTEM)
H-674500MKB61201TC STATOR CORE AND WINDING RTD ARRANGEMENT
4.9.2 INSTALLATION OF TOP BARS

- Brazing surfaces on the top bars must be polished and cleaned (free of damages, dust and grease) prior to the
installation. Remove any grease with White spirit.
- Clean the bars with a clean and dry cloth (non abrasive).
- Wrap the bar with round packing tape.
- Remove the temporary wedges from the bottom bars and check core slots for cleanliness.
- Install spacer as per drawing.
- Cover sharp slot edges of stator core with electrical tape to prevent any damages of round packing tape
during installation.
- Install the Top bar. Remove electrical tape and the excessive silicone compound from the stator core.
- Check the alignment of Top bar by measuring/matching winding overhang at NDE and DE side, realign to the
brazed part of bottom bar.
- Check for minimum air gap in the overhang between two bars and maintain as per drawing value.
- Mark the axial position of the spacer blocks on the bottom bar overhang part by using a template.
- Measure for installing filler strip and install protection strip, filler strip ref drawing. Apply rhodorsil paste on
ripple spring and install ripple spring.
- Install counter wedge and wedge.
- Install slot wedge stopper before the first wedge and after the last wedge impregnated with varnish as per
drawing.
Check before wedging

- Check the closing wedge profiles. The wedge must slide with a slight friction against the slot walls of
magnetic core.
- Dimensional check of ripple spring.
- Neither crack nor sign of lack of cohesion is to be noticed on the ripple springs when they are used. Any spring
with these defects must be rejected.
H-6745 00 MKB 000 81 DC _ A 20 of 118

Rev. : A
Wedging preparation and installation:

- Insert the protection strip in contact with the bar.
- The sliding strip in contact with the protection strip bore side is made of laminated epoxy glass material.
- Insert all the wedges as per drawing and Instruction document HTWT620280.
- When fitting the closing wedge make sure that the ventilation notches match the core‘s ventilation duct.
- If necessary adjust the length of wedge.
- Verify the slot wedges with the Knocking hammer.
- Tie the End wedges with impregnated cord with top and bottom bars.
- Install spacer blocks wrapped with a felt to be bound to each other with ½ over lapped and 2 throttle turns of
tape on the both DE and NDE side.
- Apply necessary Corona protection paint on the winding overhang portions taking care to avoid the droplets
on brazing part.
- Conduct Insulation Resistance and High Voltage test of Air Gap (Top) bars in a group as per test plan and
record results & observation in control sheet
44.4 MΩ for 3 Phase Under 5000 V DC. for 1

Insulation resistance HTAE_60012
88.8 MΩ for 1 Phase minute
Polarization index …………………….. HTAE_660183
(I) Dielectric Test

Dielectric test (AC) 32.0 kV - AC - 50 Hz HTAE_60031
1 minute
OR
Dielectric test (DC) 54.4 kV - DC HTAE_60031

1 minute
H-6745 00 MKB 000 81 DC _ A 21 of 118

Rev. : A
Fill the surge in with EP310

The surge ring has to be filled with EP310 to solidify the surge ring
Please Note:
- Check the air gap of the bars between the phases separations, minimum measure must be guaranteed.
- Pre-wedging can be removed the next day and re-used for further bar installations.
- Adjust thickness of spacer blocks, by splitting the blocks or by adding additional felt.
- Pointed ends on the fibre glass tape must be removed to prevent hand injury and point discharge on the
stator winding.
- The bars must be completely wedged within the curing time (normally three to four hours) of the silicone
compound.
- All R T D’s must be earthed properly.
- Proper earthing of Generator Frame.
Don’ts:
- Do not strike the bar directly with a hammer during installation.
- Only taps with a plastic hammer on a fibre plate padded with felt to be used.
- Do not use conductive (Lead pencil) or ball pen to prevent damage on the bars.
- Do not install the spacer blocs too tight, to avoid stress of the bars.
OPERATIONS:
Installation of the air gap (top) bars:
Prepare the round packing according instruction HTWT 62 0172 § 3
Wrap the round packing tape around the bars according HTWT 62 0172 § 4.2
Remove the temporary wedging of bottom bars
Put the spacer (with conductive varnish)
Insert the air gap bar in the slot according HTWT 62 0172 § 4.3 and HTZW 23338
H-6745 00 MKB 000 81 DC _ A 22 of 118

Rev. : A
Measurement Report:
MR 21 PARTIAL DIELECTRIC TEST
MR 24 RTD TESTING
Ref Drawing:
4.9.3 TOP AND BOTTOM BAR CONNECTION
- Identify top and bottom bars that are to be connected with bar to bar. Clean and prepare the surface of bars
connecting to suit the requirement for induction brazing.
- Connect bottom side of bars by induction brazing.
- Connect top side of bars already identified for bar to bar connection.
(i) Brazing operation:
- Put a sheet of brazing material in space between 2 surfaces to braze.

- Tighten the joint to be brazed using a suitable tool.
- Set the inductor of brazing.
- Heat the junction to cast of brazing (710 ºC Approx.) and maintain a few secondly adding brazing if
necessary.
- The gap between two surfaces must be filled.
(ii) Warning:
- Total time of heat must be short ideally it should be 2 minute.
- Cool the joint at the end of operation.
- Clean the joint
- Make a visual inspection of all brazing. Remake the brazing of joint with crack.
- Cleaning of joint with white spirit only.
Ref Drawing:

Specification applied for Brazing: HTWT 620242
H-6745 00 MKB 000 81 DC _ A 23 of 118

Rev. : A
4.9.4 JUMPER AND CIRCUIT RING CONNECTIONS
- Make sure the bar ends and the jumper / connector ends are cleaned.
- Remove the paint where the metallic support will be welded.
- Put all the support of circular connections on the frame
- Fix the insulating supports.
- Weld the support with frame and paint it after applying a coat of red-oxide.
- With the help of winding connection diagram associate each bar with proper connector type.
- Assemble parallel connection with supports and insulators as per drawing.
- Install parallel connection in sequence and complete brazing as per drawing and site conditions. Wherever
induction brazing is not possible, flame brazing to be adopted.
- Install the terminal insulator on stator frame.
- Install the terminal on both phase and neutral side. Tight them with insulators mounted on stator frame.
- Conduct visual checks on all brazing joints.
- After brazing but before insulation fill all cavities with compound.
- Insulate bare portion of the conductor as per drawing (insulation thickness of 2.6mm).
4.10 PRILIMINARY TESTS

(i) TEST OF WINDING R T D’s
100Ω at 0º C ± 0.2
Resistance
IBF 24401
Insulation Resistance >100 MΩ minute
Note: For subsequent test RTD must be grounded.

(ii)WINDING INSULATION TEST

Insulation resistance HTAE_60012
Polarization index
minute/10 minutes
HTAE_660183
H-6745 00 MKB 000 81 DC _ A 24 of 118

Rev. : A

Dielectric test (AC) 30.0 kV - AC - 50 Hz 2.1 Un + 1 kV - AC - 50
1 minute Hz - 1 minute
Or
Dielectric test (DC) 51.0 kV - DC 1 minute (2.1 Un + 1 kV) x 1.7 –
DC - 1 minute
4.11 INSTALLATION OF END CAPS
- Install end insulating cap at NDE side temporarily without filling material, mark the position, match with
other caps, rap adhesive tape on the mark to block bottom of the cap for holding the filling material.
- Install end insulating cap at NDE side fill with resin and level with other caps.
- Check for voids by hammering softly on the outside of the caps. If required fill the filling material through the
hole provided on top of the cap.
- Install end insulating cap at DE side temporarily without filling material, mark the position.
- Install end insulating cap at DE side filled with resin. Hold the end cap with temporary support till the filling
material cures and become hard.
- Check for complete filling of cap with filling material. If required top up the filling material.
- Make sure that the caps will cover properly the end of the bars, overlapping the bar insulation.
- Refer the drawing and Document before filling the caps
- *Note: While filling caps be sure there is no air bubble formed.
Measurement Report:
MR 24 RTD TESTING
Ref Drawing:

H-6745 00 MKB 000 81 DC _ A 25 of 118

Rev. : A
4.12 STATOR FINAL PROTECTION
- Checks all the screw is locked.

- Clean the stator core winding, and frame.
- Apply a corona protection with the spray gun on both ends of stator winding.
4.13 PAINTING AND COMPLETION OF STATOR WINDING
- Apply first coat of paint on exposed winding surface (only winding portion done at site) except end caps with
paint specified in drawing.
- Apply intermediate coat of paint on exposed winding surface including end caps with paint specified in
drawing
- Apply paint on stator core complete with paint specified in drawing.
4.14 FINAL ACCERPTANCE HIGH VOLTAGE TEST OF STATOR WINDING:
- Conduct Insulation Resistance and final AC High Voltage test of complete Stator winding as per inspection
and test plan and record results & observation in control sheet.

Insulation resistance
Polarization index …………………….. HTAE_60012
minute
(i) Dielectric Test.

Dielectric test (AC) 28.6 kV - AC - 50 Hz 2.0 Un + 1 kV - AC - 50
1 minute Hz - 1 minute
Or
Dielectric test (DC) 48.62 kV - DC 1 minute (2.0 Un + 1 kV) x 1.7 –
DC - 1 minute
H-6745 00 MKB 000 81 DC _ A 26 of 118

Rev. : A
- Cover the wound stator properly after final HV test and earth properly.
Measurement Report:
MR 22A FINAL DIELECTRIC TEST

MR 24 RTD TESTING
H-6745 00 MKB 000 81 DC _ A 27 of 118

Rev. : A
ROTOR ASSEMBLY
5. ROTOR ASSEMBLY
5.1 PREPERATION
- Position and adjust the elevation, centring and flatness of rotor laying support on the rotor erection bay.
- Shift the Rotor spider from store to service bay.
5.2 POSITIONING OF ROTOR SPIDER IN SERVICE BAY.
- Clean the surface of rotor laying plate & check the level.
- Remove the packing material carefully so that it may not damage the shaft journal.
- Remove the packing material from service bay.
- Thoroughly inspect the Rotor Spider for any damage during transportation.
- Clean the Rotor spider and place it on the pedestal as per drawing.
- Keep the verticality and horizontality of Rotor spider with in 0.05 mm by provision of shims or adjustment of
jacks.
Measurement Report:
MR 30 HORIZONTALITY OF ROTOR SPIDER SUPPORT RINGS ON ERECTION BAY.
Ref Drawing:
H-674500MKB20000TC GENERATOR ROTOR ARRANGEMENT

H-674500MKB83101TC RIM STACKING ARRANGEMENT
H-674500MKB83401TC ROTOR BUILDING PEDESTAL ANCHORING ARRANGEMENT
H-674500MKB24000TC ROTOR SPIDER COMPLETE
Preparation for rim stacking:

- Install the stacking tooling devices according to the drawing.
H-6745 00 MKB 000 81 DC _ A 28 of 118

Rev. : A
ROTOR ASSEMBLY
5.3 STACKING OF RIM /CLAMPING AND KEYING.

- Install the rotor rim bottom pressing plates on the levelling jacks and level according to the drawing.
- Install centring compass.
- place the rim keys as per drawing.
- Place the DE rim end plates around the Rotor and level it with the help of rim jacks.
- Ensure that the DE rim end plates are properly levelled.
- Distribute packets of rim around the rotor.
- Begin stacking the rim as per stacking diagram using locating dowels.
- Stack approx 100mm insert the clamping bolts according to drawing.
- Check that the 100mm height is correctly centred with the help of centring compass. Keep check of the rim
centring during complete operation of stacking.
- Perform first clamping as per drawing instruction.
- Check height of core in front and back at the location of poles.
- Insert compensation lamination wherever necessary and continue clamping until second, 3rd and final pressing.
- Perform final pressing by hydraulic tensioner as per drawing.
Warning:
- Do not remove Pedestal Jack during stacking operation.
- Perform all checks as per first pressing and continue stacking and pressing as per drawing until the last
pressing.
- Install the lower & upper fans as per drawings. Tighten the nut & bolts with the specified torque & lock them
properly.
- The marking on Jacking Bolts has to be removed for Proper levelling of End Plate at site.
H-6745 00 MKB 000 81 DC _ A 29 of 118

Rev. : A
ROTOR ASSEMBLY
Note:
- It is very important to check the diameter of core and position of core from the point on spider arm. Where
necessary make adjustments.
- Check the rotor fan over the core bolts and ensure its fitting.
- Check the height of rim in front and back at the pole location.
- Check the rotor core is properly centred prior to keying at each arm.
- Perform final keying of the rim.
- Checking the centring of the rim after keying.
Measurement Report:
MR 31 HORIZONTALITY AND VERTICALITY OF ROTOR SPIDER
MR 32 ROTOR RIM KEY CONCENTRICITY
MR 40f HIGHT OF ROTOR RIM AFTER CLAMPING.
MR 42a ROTOR RIM CENTRING AFTER KEYING.
Ref Drawing:

H-674500MKB83101TC RIM STACKING ARRANGEMENT
H-674500MKB83401TC ROTOR BUILDING PEDESTAL ANCHORING ARRANGEMENT
H-674500MKB25000TC ROTOR RIM ASSEMBLY
H-674500MKB25101TC RIM STACKING DIAGRAM
H-6745 00 MKB 000 81 DC _ A 30 of 118

Rev. : A
ROTOR ASSEMBLY
5.4 PREPARATION AND INSTALLATION OF POLES
- Check the Rim key slots remove the burr if necessary.

- Prepare the pole unload unpack according to the drawing.
- IR value before inserting poles is to be taken at 500 V
- Position the pole according to the polarity, their weight so that they would be balanced as well as possible and
making them as per drawing.
- Position two poles 180 degree apart according to the pole locating drawing by using pole turning and handling
device.
- Check the diameter of the rotor poles after inserting poles.
- Install the rest of the poles (Always in opposite position).
- Put height adjustment block before installation of Poles.
- Adjust elevation relative to shaft (to be check with optical level and record)
- Check the roundness on each pole.
- Check polarity of Rotor poles (polarity can be checked by magnetic compass used in laboratories).
- Perform final keying i.e. locking of keys
- Install the connection between field coils.
- Check that the connections and locking plates are dually screwed with the locking plates.
- Install the damper connection
- Perform high voltage test of complete rotor.
- Install lower and upper fan blades.
Note:
- In case of difficulty of pole insertion local grinding up to 1mm on rotor rim OD is allowed.
- Measure pole centring, pole axis and field winding insulation resistance, polarity test, pole impedance test and
High voltage test.
- Check the rotor fan over the core bolts and ensure its fitting.
- Install Perform clamping and check the final
Measurement Report:
MR 47 POLES CENTRING
MR 48 POLE AXIS POSITION
MR 51 POLE IMPEDENCE TESTS
MR 52 FIELD POLES POLARITY TEST
MR 53 ROTOR DIELECTRIC TESTS
MR 53a ROTOR FINAL DIELECTRIC TEST
H-6745 00 MKB 000 81 DC _ A 31 of 118

Rev. : A
ROTOR ASSEMBLY
Ref Drawing:

H-674500MKB26306TC POLE LOCKING ARRANGEMENT
H-674500MKB26430TC DAMPER WINDING CONNECTION ARRANGEMENT
H-674500MKB29200TC FIELD LEADS CONNECTION ARRANGEMENT
H-674500MKB28101TC DE AND NDE FAN ARRANGEMENT.
H-674500MKB83350TC POLE HANDLING ARRANGEMENT
5.5 INSTALLATION OF UPPER SHAFT
- Remove centring compass.
- Install the upper shaft and tighten as per drawing instruction.
- Make sure the concentricity and parallelism are ok before coupling of Rotor and upper shaft.
5.6 INSTALLATION OF COLLECTOR RING CONNECTION
- Installation of the collector ring leads on hub.

- Positioning of hub inside the upper shaft.
- Carry out marking of the leads through the shaft.
- Remove leads from the shaft along with hub and carry out necessary drilling and tapping.
- Relocate the hub and complete all the connections.
- Install the connection as per drawing taking care for the insulation on the clamping area. Check that all the
joints are firmly tightened with support.
- Check all the screw are tightened with specified torque and locked as per drawing.
- Final varnishing of the connections with the varnish.
- Touch up paint of the rotor.
Measurement Report:
MR 53 ROTOR DIELECTRIC TESTS
Ref Drawing:

H-6745 00 MKB 000 81 DC _ A 32 of 118

Rev. : A
ROTOR ASSEMBLY
5.7 INSTALLATION OF UPPER FAN, LOWER FAN AND BRAKE TRACK
- Install the upper and lower fan and tighten to specified torque in drawing
- Install the brake track and tighten to required torque as per drawing specification
5.8 PREPARATION OF CONSUMABLE
5.8.1 RESIN PREPARATION
- Fitting of gap left between connection pieces with resin impregnated felt, joints of connections.
- Formulation

RESIN 15120 HGST 906101 100 A
RESIN 15174 HGST 906101 55 B
………. ……………… ……………
Preparation:
- Mix part B in part A with the help of agitator.
- Make sure that both parts are thoroughly mixed together, since correct hardening depends upon the uniformity
of the mixture.
- Lifetime after preparation. : 2 Hours at 23 ºC.
- Storage before Mixing: at ambient temperature.
Note:
- It is advisable to use the full capacity of mixture to facilitate the mixing process.
- Use complete mixture before lifetime.
- Application: According to manufacturing instruction.
5.8.2 ARALDITE PUTTY PREPARATION
- Fitting of gap left between connection pieces. Joints of connections.

- Formulation
H-6745 00 MKB 000 81 DC _ A 33 of 118

Rev. : A
ROTOR ASSEMBLY

HGST 906303 100 ACITATE D ETHYLE A
AEROSOL 18466 20 AEROSOL B
………. ……………… ……………
Preparation:
- Mix part B in part A with the help of agitator.
- Make sure that both parts are thoroughly mixed together, since correct hardening depends upon the uniformity
of the mixture.
- Lifetime after preparation : 30 minutes Hours at 20 ºC.
- Storage before Mixing: at ambient temperature.
Note:
- It is advisable to use the full capacity of mixture to facilitate the mixing process.
- Use complete mixture before lifetime.
- Application: According to manufacturing instruction.
H-6745 00 MKB 000 81 DC _ A 34 of 118

ERECTION MANUAL Element :0
Rev. : A
UPPER BRACKET ASSEMBLY IN ERECTION BAY
6. ASSEMBLY OF UPPER BRACKET IN ERECTION BAY
- Prepare and clean the erection bay.
- Mark out the position of stools for the assembly of arms.
- Install the supporting stools according to the marking references.
- Adjust the elevations.
- Unpack the upper bracket hub and its arms and position them on the stools w.r.t. the final position in the
pit as per drawing.
- Bolt the arms according to the drawing.
- Connect pipes and wiring as far as possible.
- Install the electrical box on the arm as per drawing.
- Check all the fasteners are firmly tightened and locked.
Ref Drawing:
H-674500MKB31201TB UPPER BRACKET HUB WITH FLANGE(FABRICATED)

H-674500MKB31202TM UPPER BRACKET HUB MACHINED
H-6745 00 MKB 000 81 DC _ A 35 of 118

Rev. : A
ASSEMBLING AND LOWERING OF LOWER BRACKET
7. INSTALLATION OF LOWER BRACKET
- Foundation plate should be delivered screwed and pinned together with bracket and with inserted shims
for later adjustments, whenever possible.
7.1 LOWERING AND ASSEMBLY OF LOWER BRACKET.
- Check good operation of travelling cranes.
- Make sure that all the lifting devices are correctly assembled and tightened
Follow the procedure given in the lower bracket lifting arrangement drawing H-674500MKB84240TC
- Place the plates for the adjusting bolts.
- Put down of Lower bracket along with the lower counter part and partly tight the nut. Adjust axis, angle,
and level according to drawing.
- Pre stress anchor bolts according to specific instructions after pouring of foundation plates. (Attention to
be paid for curing time).
Note: Take reference elevation of Turbine shaft for all measurements.

Ensure that the shrink hose is wrapped around the anchor bolts.
The sequence of activity can be changed by supervisor at site.
Measurement Report:
MR 60 EVENNESS OF TURBINE SHAFT COUPLING FLANGE
MR 62 EVENNESS AND LEVEL OF THE LOWER BRACKET
MR 63 LOWER BRACKET CENTERING RELATIVE TO THE TURBINE AXIS
Ref Drawing:
H-674500MKB36300TC LOWER BRKT SOLE PLATE ANCHORING ARRANGEMENT

H-674500MKB32201TM LOWER BRACKET MACHINED
H-674500MKB84240TC LOWER BRACKET LIFTING ARRANGEMENT
H-6745 00 MKB 000 81 DC _ A 36 of 118

Rev. : A
INSTALLATION OF LIFTING / BRAKING JACKS AND
PIPING
8. ASSEMBLY OF LIFTING / BRAKING JACKS AND ITS PIPING, SPACE HEATERS AND ACCESSORIES.
- Install the brake jacks as per drawing on the lower bracket.
- Install the air piping for the brake jacks and make pressure test of the piping
- Install the oil piping feeding to the jacks on the lower bracket as per drawing.
- Verify there is no leakage at 1.5 times to designed pressure for 30 minutes.
- Check the height of all brake jacks and record.
- Install fire protection piping at the lower part of generator
- Install the space heater according to drawing
Measurement Report:
MR 64 LEVEL AJUSTEMENT OF BRAKE AND LIFTING JACK
Ref Drawing:

H-674500MKB55001TC BRAKE JACK AND DUST COLLECTOR MOUNTING
H-6745 00 MKB 000 81 DC _ A 37 of 118

Rev. : A
STATOR LIFTING AND INSTALLATION
9. PREPARATION OF PIT FOR STATOR ERECTION
- Preparing of the cutout for pouring the grout. (Rough surface, no cement residues, adequate watering.)
- Make sure the shrunk on hose is on the anchor bolt (or equivalent solution).
- The shrunk on hose enables proper elongation of the anchor, when pre-stressing.
- Install the sole plates on the concrete reinforcement take care of orientation and match marking with the
stator feet.
- Level and adjust the height with the relevant screws.
- Level the sole plate and record.

(200)
(250)
(1150)
(290)
Measurement Report:
MR 65: ELEVATIONS AND LEVELING OF STATOR SOLE PLATE
Ref Drawing:

H-674500MKB16000TC STATOR SOLE PLATE ARRANGEMENT
H-6745 00 MKB 000 81 DC _ A 38 of 118

Rev. : A
STATOR LIFTING AND INSTALLATION
9.1 ASSEMBLY OF STATOR LIFTING DEVICE.
- Shift the stator lifting device components from store to power house service bay.
- Assemble the stator lifting device in service bay as per drawing.
9.2 LOWERING OF WOUND STATOR IN PIT
- Preparation of stator for handling according to the drawing.
- Check good operation of travelling cranes.
- Make sure that all the lifting devices are correctly assembled and tightened.
- Hold the stator and lift up to approximately 10 mm above the stool
- Shift the wound stator from service bay to pit.
- Check the position of stator with the axis reference i.e. Upstream axis, down stream axis, rotation axis and
horizontally.
- Check that the stator is resting on all of its sole plates.
- Adjust the centre and magnetic axis of stator w.r.t turbine flange.
- Check that all the fastening screws and dowel pins are correctly installed and locked according to drawing.
- Pour in foundation plate with shrink free concrete according to specification. Do this after definitive
alignment of the Stator including level.
- Priestess anchor bolts according to specific instructions after pouring of foundation plates. (Attention to be
paid for curing time).
- After complete installation of stator frame install the lower air guide at the lower part of stator frame.
Note: measure level of magnetic axis, stator centring with respect to turbine shaft.
Measurement Report:
MR 66 LEVELS OF MAGNETIC CORE AXIS AND CENTRING
Ref Drawing:

H-674500MKB16000TC STATOR SOLE PLATE ARRANGEMENT
H-674500MKB81201TB MAIN LIFTING BEAM
H-6745 00 MKB 000 81 DC _ A 39 of 118

Rev. : A
ROTOR LOWERING AND COUPLING
10.1 LOWERING OF LOWER SHAFT
- Lift the lower shaft as per the handling drawing.
- Lower the shaft and place it on the thrust bearing.
- Match the R/R position of Generator and Turbine shaft and adjust the concentricity of both shafts.
- After desired level and concentricity is achieved, couple generator and turbine shaft and slip in 2
Coupling bolts in opposite direction. (Turbine erection team)
- Tight the 2 coupling bolts and than put all the coupling bolts one by one.
- Perform the pre stress of the coupling bolts as per drawing.
- Check the level and elevation at the top of Generator lower shaft after coupling.
10.2 LOWERING OF ROTOR.
- Before lowering of rotor check elevation and flatness of Generator lower shaft.
- Set the lifting jacks height so that rotor lower coupling face is at the theoretical level + 20mm over the
upper coupling face of lower generator shaft.
- Keep the lifting jacks in positions by using their blocking nuts without maintaining oil pressure.
- Check the good operating condition of the traveller crane.
- Prepare the rotor-handling device and install on the rotor as per drawing.
- Trials lift the rotor and check that it is perfectly levelled.
- Lift up the rotor approximately 10mm above the pedestal during one hour before shifting the rotor in to the
pit.
- Lift up the rotor and shift above the stator pit, and lift down the rotor taking care the air gap clearance.
Guide the rotor inside the stator bore by using wood guides with appropriate thickness.
- Keep wooden spacers after alternate pole between Rotor and Stator in order to avoid any damage.
- Lower the rotor until its jacking track comes in touch with the lifting jacks fitted with the protective plate.
- R/R marks of Generator lower shaft and Rotor should match.
- Check the concentricity and parallelism of the Generator lower shaft flange w.r.t.Rotor coupling face.
H-6745 00 MKB 000 81 DC _ A 40 of 118
Rev. : A
ROTOR LOWERING AND COUPLING
- Lift generator lower shaft by means of coupling bolts fitted with the hydraulic jacks.
- Install the coupling bolts and tighten them with required pre stress force by means of hydraulic jacks.
- Lock the nuts as per drawing.
- After the coupling of Lower shaft is completed install the upper shaft.
- Perform the pre stress of coupling bolts of upper shaft and rotor as per drawing.
Pre-attention
Rotor and lower shaft can be coupled even without the turbine shaft and latter complete Generator
shaft line can be coupled with Turbine shaft line
When the complete shaft line is resting on jacks and is concentric with Turbine shaft ( after shaft
free), the shaft distance w.r.t the brackets at the bearing portion should be recorded, for future
reference.
Ref Drawing:

H-674500MKB83200TC ROTOR HANDLING ARRANGEMENT
Measurement Report
MR 60 EVENNESS OF TURBINE SHAFT

MR 60 a EVENNESS OF LOWER SHAFT
MR 68 ROTOR CENTERING RELATIVE TO TURBINE SHAFT
MR 69 EVENESS OF UPPER SHAFT TOP FACE
H-67 45 00 MKB 000 81 DC _ A 41 of 118

Rev.: A
STATOR AIR COOLER
11. INSTALLATION OF STATOR AIR COOLER AND ITS PIPING.
- Cleaning the stator frame thoroughly.
- Pressure testing of coolers in service bay.
- Sticking foam rubber / Gasket according to seal area on stator frame.
- Clamping the cooler on stator frame Protect the external surface of cooler with plywood supplied from
workshop.
- Install the valves on each cooler.
- Install the piping support and install the pipes inside the pit as per drawing and tack weld them.
- Remove the pipes and weld as per welding specification.
- Pressure testing of pipes as per standard
- Final assembly of pipes.
- Check the pipes for any leakage.
Ref Drawing:
H-674500MKB51001T0 STATOR AIR WATER COOLER

H-674500MKB61200FF GENERATOR INSTRUMENTATION & MONITORING DIAGRAM
H-6745 00 MKB 000 81 DC _ A 42 of 118

Rev.: A
PHASE AND NEUTRAL CONNECTION
12. INSTALLATION OF PHASE AND NEUTRAL CONNECTION AND GUARDS.
- Installation of generator leads protection guard according to the instruction.
- Installation of partial discharge analysing system according to the drawing. .
Ref Drawing:
H-674500MKB45002TB PHASE AND NEUTRAL TERMINAL COVER ARRANGEMENT
H-674500MKB61200FF GENERATOR INSTRUMENTATION & MONITORING DIAGRAM
H-6745 00 MKB 000 81 DC _ A 43 of 118

Rev.: A
INSTALLATION OF UPPER BRACKET IN PIT
13. INSTALLATION OF UPPER BRACKET.
- Clean all the components of upper bracket thoroughly clean the shaft and all surfaces of Upper bracket
(Assembled) and embedded plates matching surface.
- Fit the slings according to lifting lugs with the upper bracket.
- Install the upper bracket foundation plates by using key and bolts on upper bracket arms.
- Shift the upper bracket and place on the stator.
- Centring, levelling and level adjustment of upper bracket in according with the generator shaft.
- Measure the clearance between stator upper base plate and upper bracket arms in 4 points.
- Match all the levels with the help of shim (INTERMIDIATE PLATE) according to clearance.
- Fitting of each arm in position in its correspondence to location, bolting and pinning in position as per
drawing. (final torque of upper bracket bolts after complete adjustment of Upper bracket)
Measurement Report:
MR 70 UPPER BRACKETS CENTRING LEVELING AND HEIGHT

MR 77 UPPER BRACKET LEVELING PLATE THICKNESS
Ref Drawing:
H-674500MKB31201TB UPPER BRACKET HUB WITH FLANGE (FABRICATED)

H-674500MKB36200TC UPPER BRACKET SOLE PLATE ANCHORING ARRANGEMENT
H-674500MKB84251TC NDE BRG OIL POT ASSLY & DISMANTLING ARRANGEMENT
H-674500MKB84200TC UPPER BRACKET HANDLING ARRANGEMENT
H-6745 00 MKB 000 81 DC _ A 44 of 118

Rev. : A
THRUST BEARING ASSEMBLY
14. INSTALLATIONS OF THRUST BEARING ASSEMBLY.
The bearing assembly should be done as per Drawing.
For bearing assembly follow document HTWT 620337
NOTE:
- Clean the area properly. There should not be any foreign material inside the pot.
- Installation of oil and water piping according to drawing.
- Lower the shaft line on thrust pads.
- Install the air guide assembly as per drawing and measure the gap between fan and air guide.
- Check the alignment (RUNOUT) of unit.
- Set the Lower guide bearing clearance.
Measurement report:
MR 71 LOWER GUIDE BEARING CLEARANCE

MR 74 SHAFT LINE ALIGNMENT CONTROL
Ref Drawing:
H-674500MKB32001TL COMBINED BEARING LAYOUT

H-674500MKB32300TC LOWER COMBINED BEARING ARRANGEMENT
H-674500MKB32004TB LOWER THRUST PAD SEGMENT
H-6745 00 MKB 000 81 DC _ A 45 of 118

Rev. : A
ASSEMBLY OF UPPER GUIDE BEARING
15. ASSEMBLY OF UPPER GUIDE BEARING.
- Clean all the components of Upper bracket thoroughly clean the shaft and all surfaces of lower bracket
and guide bearing exposed to oil.
- Don’t use cotton waste because particle left behind may cause trouble.
- All loose packing and protective coating must be removed.
- Assemble the bottom cover and assemble the oil cooler on it.
- Pressure testing of oil cooler as per drawing.
- Installation of Guide bearing pad support ring, and bolting with lower bracket.
- Assembly of Guide bearing pad and locking.
Note
- Installation of oil pumping ring and bolting with lower bracket.
- Assemble the oil tank with cooler and sleeve around the shaft.
- Lifting of oil tank bottom with sleeve and cooler and bolting with lower bracket.
- Check the gap between sealing ring and shaft journal bottom with the help of putty.
- Lower the oil tank bottom with sleeve and cooler and make the gap of 2mm between sealing ring and
shaft journal.
- Assemble the oil tank bottom with sleeve and cooler with lower bracket as per drawing
Note
Refer drawing for the final assembly of oil bottom cover with sleeve and cooler strictly.
- Adjust the pad clearance.
- Place the pads in contact with shaft journal with the help of adjusting bolts or taper keys.
- Check the measurement and machine the distance plate of pad by maintaining clearance as per drawing.
- Install the back distance plate and remove the temporary packing.
H-6745 00 MKB 000 81 DC _ A 46 of 118

Rev. : A
ASSEMBLY OF UPPER GUIDE BEARING
- Check the clearance at each pad.
- Check all the bolts are tightened and locked properly.
- Install the instrumentation as per drawing and dressing them.
- Install the sealing ring cover.
- Install the upper oil tank cover.
Important
Tightness of all oil joints shall be carefully checked as per drawing.
Before BTD assembly fill half the cavity of pad with oil.
Install Sealing ring and sealing cover as per drawing.
Measurement Report:
MR 72 UPPER GUIDE BEARING CLEARANCES
Ref Drawing:
H-674500MKB32300TC LOWER COMBINED BEARING ARRANGEMENT

H-6745 00 MKB 000 81 DC _ A 47 of 118

ERECTION MANUAL Page:
Element : 0
LBB PIPING Rev. : A
16. INSTALLATION OF LOWER GUIDE BEARING PIPING.
- Provisional positioning of oil and water piping as per drawing.
- Position the supports and set the different parts of piping as per drawing.
- Tack welds the different parts of piping.
- Dismantle all parts of pipes after marking match marks on the flanges.
- Weld the pipe sections and flanges.
- Perform the pressure test of the water pipes.
- Perform the chemical cleaning of the oil pipes.
- Reinstall the piping.
- Install the oil level indicator and oil level pipes according to the drawing.
- Filling of oil pipes with oil as soon as possible after installation.
- Perform oil flushing of pads with oil by means of oil circulation pump.
- Install oil mist pipe according to the drawing.
- Perform painting as per painting specification.
H-6745 00 MKB 000 81 DC _ A 48 of 118

Rev. : A
INSTALLATION OF COLLECTOR RING AND BRUSH
HOLDER ASSEMBLY
17. INSTALLATION OF COLLECTOR RING AND CONNECTION WITH FIELD WINDING.
- Clean the collector ring.
- Install the collector ring on the shaft with the help of bolts and insulation washers and sleeve as per
drawing.
- Install the collector ring connection with field winding connection inside the shaft.
- Check that all the connections and bolts are firmly tightened as per drawing.
- Lock all the fastened items as per drawing.
Check:
- Measure the Insulation resistance of collector ring before connecting with field winding.
17.1 INSTALLATION OF BRUSH HOLDER ASSEMBLY
- Clean and smooth the contact surface with the Brush holder support on the upper part of upper bracket.
- Assemble the brush holder assembly in service bay as per drawing.
- Install the Brush holder assembly on the Upper bracket with the help of bolts as per drawing.
- Centre the brush holders compare to the collector ring.
- Check the setting of brush holder. (Also check the setting at running level)
- Connection of brush holder with the field input and assembly of brushes.
- Checking that all the electrical contacts and all the fastenings are firmly tightened and locked.
- Let the commissioning engineer install the cables for excitation system. Install the collector ring covers.
Ref Drawing:

H-674500MKB41000TC COLLECTOR BRUSH GEAR ARRANGEMENT
H-674500MKB41201TB COLLECTOR RING COVER
H-6745 00 MKB 000 81 DC _ A 49 of 118

Rev. : A
UBB PIPING
18. INSTALLATION OF UPPER GUIDE BEARING PIPING
- Provisional positioning of oil and water piping as per drawing.
- Position the supports and set the different parts of piping as per drawing.
- Tack welds the different parts of piping.
- Dismantle all parts of pipes after marking match marks on the flanges.
- Weld the pipe sections and flanges.
- Perform the pressure test of the water pipes.
- Perform the chemical cleaning of the oil pipes.
- Reinstall the piping.
- Install the oil level indicator and oil level pipes according to the drawing.
- Filling of oil pipes with oil as soon as possible after installation.
- Perform oil flushing of pads with oil by means of oil circulation pump.
- Install oil mist filtration pipe according to the drawing.
- Perform painting as per painting specification.
H-6745 00 MKB 000 81 DC _ A 50 of 118

Rev. : A
FIRE PROTECTION
19. INSTALLATION OF FIRE PROTECTIONS & INSTRUMENTATIONS
- Install heat detectors and smoke detectors.
- Install the fire station.
- Install the fire control box.
- Install the Fire protection piping between station and generator pit.
H-674500MKB01002TL GENERATOR AUXILIARIES SYSTEM LAYOUT

H-674500MKB61200FF GEN INSTRUMENTATION & MONITORING DIAGRAM
H-6745 00 MKB 000 81 DC _ A 51 of 118

Rev. : A
INSTALLATION OF FLOOR AND COVERS
20. INSTALLATION OF FLOOR AND COVERS
- Arrange and install the generator cover supports over the upper bracket arms.
- Temporary arrange the floor and covers over the supports. And mark as per drawing.
- Remove the covers and make necessary drilling and welding. Take care during the work that nothing
should fall on generator. Take special care for weld chips and drill burrs.
(Magnet stick may be used for collecting weld chips & burrs)
- Reinstall the covers over the supports and tighten all the screws.
- Always use the spring washers with bolts at vibrated area.
Ref Drawing:
H-674500MKB43200TC GENERATOR TOP COVER ARRANGEMENT

H-674500MKB43300TC TURBINE PIT COVER ARRANGEMENT
H-6745 00 MKB 000 81 DC _ A 52 of 118

Rev. : A
INSTALLATION OF GENERATOR AUXILIARIES
21. INSTALLATIONS OF MISCELLANEOUS DEVICES
• Complete installation of whole electrical auxiliaries of generator viz intermediate boxes, RTD, Space
Heater, Lighting, Oil mist exhauster, oil injection pump, all remote sensing devices… As per drawings
• Boxing-up of the generator.
• Checking of good operation of oil injection pump, oil mist pump, breaking system, jacking system…
• INSTALLATION OF EXCITATION CUBICLE AS PER DRAWING.
H-674500MKB01002TL GENERATOR AUXILIARIES SYSTEM LAYOUT

H-674500MKB61200FF GEN INSTRUMENTATION & MONITORING DIAGRAM
H-6745 00 MKB 000 81 DC _ A 53 of 118

Rev. : A
CHECKS BEFORE GENERATOR OPERATION
22. CHECKS BEFORE GENERATOR OPERATION
- Check that all bolts /screws are locked.
- Check that there is no oil or water leakage from pipes or bearing vats.
- Check that all air coolers are clean. Remove plywood from coolers.
- Check that collector ring are clean and movement of brushes in brush holder is correct.
- Check the cleanliness.
- There should not be any loose item over generator.
- Check there may not be any conducting foreign material inside generator barrel.
- No person left inside the generator barrel.
- Lock the door of Generator Barrel during and before operation.
H-6745 00 MKB 000 81 DC _ A 54 of 118

ABCD ALSTOM POWER Ltd. 1ECR100844
Responsible department: Take over department: Revision: Doc. Type: File No.:
HGT HGT - Erection procedure 1ECR100844.doc
Prepared: Checked: Approved: Language: Page:
17.01.02 J.F. Milette 24.01.2002 Group 06.03.2002 W. Morgante en 1/15
Valid for: Derived from: Replaces: Classify No.: Date set:
Hydro Power Segment 29.03.2002
Stator Core
Erection Procedure
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties
without express authorization is strictly forbidden. ã ALSTOM POWER (Switzerland) Ltd. Switzerland 2002.
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List of Contents
1 SUMMARY............................................................................................................................................ 3
2 VALIDITY.............................................................................................................................................. 3
3 LIST OF ALTERNATIVES.................................................................................................................... 3
4 SCOPE OF TYPES............................................................................................................................... 3
5 TECHNICAL DESCRIPTIONS ............................................................................................................. 3

5.1 DEFINITIONS ....................................................................................................................................... 3
5.2 INSTALLATION OF THE KEYBARS ........................................................................................................... 4
5.2.1 Preparation ............................................................................................................................................. 5
5.2.2 Installation of the resting plates.............................................................................................................. 5
5.2.3 Preliminary installation of the master keybars ....................................................................................... 5
5.2.4 Preliminary installation of the intermediate keybars.............................................................................. 6
5.2.5 Final installation of the keybars ............................................................................................................. 6
5.3 STATOR CORE STACKING ..................................................................................................................... 7
5.3.1 Preparation for stacking ......................................................................................................................... 8
5.3.2 Stacking................................................................................................................................................... 8
5.4 ERECTION TOLERANCES .................................................................................................................... 11
6 REFERENCES: .................................................................................................................................. 13
Abbreviations
DE Driven end
NDE Non driven end
ALSTOM POWER – Hydro Power Segment – Generator Technology Centre
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1 Summary
This text proposes an installation sequence of the stator core and its connection to the stator
frame. Special cases where the stator is stacked in two or more segments in the workshop and
assembled on site or with clamping system on the back of the core are not covered in this
procedure.
The installation sequence and tolerances given in this text are guidelines. Each project engineer
is responsible to verify if the client has imposed erection tolerances, to verify if the tolerances
can be met and to optimize the installation sequence and tooling with its local installation team.
The tolerances given in this procedure are for reference. The tolerances given by the designer
or stated on the drawings always prevail.
2 Validity
This erection procedure is valid from the date of receipt of the approved edition, sent by letter
from the Generator Technology Centre and signed by the technology director. This document
will be revised when major changes make it necessary.
3 List of alternatives
• Stator core and keybars installed at site.
This procedure does not cover the installation of the auxiliary equipment
4 Scope of types
The presented erection procedure is valid for all vertical hydro generators and pump storages,
except small standard generators. It includes high, medium and low speed machines, as so as
all output ranges.
All machine types for which this instruction is not valid, like specific refurbishments and bulbs,
must be installed according to other specific criteria.
5 Technical descriptions
5.1 Definitions
Concentricity: area defined by a circle of radius t, the tolerance, which center corresponds to the
stator reference axis.
Circularity: area defined by two concentric circles separated by a distance t, the tolerance. The
two circles have their centers on the best center of the stator core.
Horizontality: area defined by two horizontal plans separated by a distance t, the tolerance.
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5.2 Installation of the keybars

Figure 1 shows a complete stator core, including the keybar system that connects the stator
core to the stator frame.
Figure 1 - Complete stator core
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5.2.1 Preparation
1. A compass (stator bore radius measuring tool) shall be installed concentric with the turbine
axis.
• Concentricity tolerance : 0.05mm
• Verticality tolerance : 0.05mm
2. Verify that the stator frame lower ring flatness tolerance is respected.
5.2.2 Installation of the resting plates
1. Mark the position of the keybars on each flange. If the clamping bolt holes on the lower ring
are already drilled, make sure that the position of the keybars will match the clamping bolt
positions. The keybars position should also match the center of the phases and neutral
connections.
2. Using c-clamps, install two resting plates. One on the stator flange above the lower ring and
the other on the flange below the top flange. These two resting plates will determine the
radial position of the reference keybar.
3. Adjust the radial position of the two resting plates to respect the radial position tolerance of
the keybar. The erection team has to take into consideration the welding deformations to
obtain the appropriate radial position of the resting plate after welding. If MIG/MAG welding
(CO2) is used, the welding deformation should be zero.
4. Weld the two resting plates.
5. Select a keybar with a good geometric shape (straightness, torsion,…). This keybar will be
called the reference keybar.
6. Temporary install the reference keybar.
7. Verify the radial distance to the centerline of the reference keybar. Correct the position of
the two resting plates, if required, until the radial tolerance is met.
8. Install and weld all the other resting plates.
9. Verify their radial position.
5.2.3 Preliminary installation of the master keybars
1. Grind the paint on the stator frame flanges at the location of each stirrup weld,
2. Install the mounting angles on the resting plates: the mounting angles should be on a
slightly larger radius than the bore radius of the resting plates,
3. Temporary dispose the keybars around the inner periphery of the stator frame and mark the
position of the stirrups at the height of each stator flange,
4. Remove the keybars. Slide on the stirrups and install them at their position using c-clamps,
5. Determine the quantity of master keybars: this quantity should be such that the chord
between each master keybar is about 2000mm and at maximum 4000mm. The quantity of
master keybars should be a multiple of the total quantity of keybars. If not possible, the last
master keybars should overlap the first master keybar,
6. Dispose the master keybars, equally spaced around the periphery: the first master keybar
should be installed on the reference resting plates. This master keybar is called the
reference keybar,
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7. Bolt the master keybars to the stator frame. In order to prevent bending of the keybars, do
not tighten the mounting angles too hard. The keybars shall rest against the resting plates,
8. Adjust the lateral verticality of the reference keybar,
9. Verify the radial position of the reference keybar at all stator frame flange elevation,
10. Tack weld all the stirrups of the reference keybar,
11. Verify that there is no clearance between the reference keybar and the stirrups,
12. At all stator frame flange elevation, measure the chords between each master keybar.
Determine the average chord at each stator frame flange height,
13. Adjust the chords between each master keybar such that at all stator flange height the
difference between the measured chord and the average chord is 0.25mm maximum and
that the sum of the errors per elevation is below +-0.25mm. The difference between the sum
of errors between each elevation should be below 0.25mm,
14. Verify the radial position of the master keybars at all stator frame flange elevation,
15. Tack weld all the stirrups of the master keybars.
5.2.4 Preliminary installation of the intermediate keybars
1. Install the intermediate keybars at equivalent interval between the master keybars,
2. Bolt the intermediate keybars to the stator frame. In order to prevent bending of the keybars,
do not tighten the mounting angles too hard. The keybars shall rest against the resting
plates,
3. Using the positioning template and the compass, adjust the position of the intermediate
keybars to respect the radial and the chord tolerances,
4. Verify the radial position of the intermediate keybars at all stator frame flange elevation,
5. Tack weld all the stirrups of the intermediate keybars,
6. Verify that there is no clearance between the keybars and the stirrups.
5.2.5 Final installation of the keybars
1. If the mounting angles can be used for stacking the next unit, remove and store them. If they
cannot be used for the next unit, secure the bolts by tack welding.
2. Stack two layers of lamination and verify that:
• There is no gap between the keybars and the stirrups.
• The back of the laminations rest against the keybars.
• The bore radius is within the circularity and concentricity tolerances
• There is a gap between each lamination, thus the laminations do not overlap.
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3. Weld the stirrups. The welding of each stirrup should be made to minimize the welding
deformation, as shown in Figure 2. The stirrups should be welded following the sequence
described in Figure 2. Complete the welding of the stirrups on a stator flange before starting
at another level. MIG/MAG welding (CO2) is recommended to minimize the distortion of the
stator frame.
Figure 2 - Welding of the Stirrups

4. 100% of the stirrup welds should be visually inspected and 10 % should also be inspected
with magnetic particles or liquid penetrant. The acceptance criteria for the weld inspections
are described in the standard EN 25817 – Quality Level C.
5. Install the keybar locking plates.
6. Clean the stator frame and paint the welds.
5.3 Stator core stacking

Figure 3 shows all the components used for clamping the stator core.
Figure 3 - Clamping system
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5.3.1 Preparation for stacking
1. When the stator frame is made in sections and welded on site, the welding distortion could
locally affect the position of the holes, thus some designer could decide that it is better to
drill the clamping holes at site. If this is the case, use the laminations as a template to mark
and drill the clamping bolt holes on the lower ring.
2. Remove the laminations.
3. Install the DE press plates. If press fingers with strips are used, the extremity of the press
fingers (at the inner diameter) should be 2mm higher than the elevation at the outer press
finger diameter. Adjusting shims should be welded under the press fingers to obtain the
horizontality and elevation tolerances.
5.3.2 Stacking
1. Start the stacking. The end packages are usually made of stepped laminations.
2. At the middle height and final height of each lamination package, tap the laminations bore
radius using a plastic hammer to make sure that the laminations rest against the keybars.
3. Install the piling guides at each slot facing the keybars. The stacking guides will ensure a
smooth surface in the slots. The piling guide thickness should be 0.1mm smaller than the
theoretical slot width. The tolerance on the pilling guide thickness is +0.03mm, -0mm. The
first set of pilling guide set should be pulled up as the stacking goes on until the height of the
piling guide is reached, than a second set of pilling guides is used. The second set is pulled
up as the stacking goes on, until the complete height is reached. For high stator core (more
than 2m) it is a good practice to use an intermediate set of pilling guide. This intermediate
set can be made of only one pilling guide per lamination instead of 2.
4. At each layer, move forward the lamination by one keybar to overlap the joints. Always place
the first lamination of each package at the same position. Use the reference keybar as a
positioning guide. This procedure is not applicable for the lamination layers where stator
core RTD have to be installed, since the RTD slots have to be coincident.
5. Once a package is stacked, clamp the lamination package and measure its thickness on the
bore and the outer diameter using a vernier caliper. Try to distribute the thicker and thinnest
laminations and the equalizing segments to respect the thickness tolerance.
6. Install the ventilation segments and the insulating bushes as per drawing.
7. At 100mm from the bottom and 100mm from the top and at every stator frame flange take a
set of measurements in order to insure that the circularity, concentricity, verticality and the
straightness tolerances are met. The minimum number of reading per set of measurement is
based on the bore diameter, see Table 3. The first reading should always be taken at the
same angular position.
8. During stacking, proceed with intermediate pressing at approximately every 500mm of
stacked height. The last intermediate pressing is done two or three packages before the
core height is reached.
• The intermediate pressings must always be carried out after a final stacked core
package. It is not permitted to carry out a pressing within the stacking process of a
package. The ventilating segment should not be installed.
• Install the NDE press plates, the clamping bolts, the spacer tubes, the steel washers and
nuts.
• Grease with a non-conductive grease the bearing surface of the nuts and the threads
and tighten the nuts following a pattern similar to Figure 4. The proposed pattern consists
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in separating the stator core in equal segments and all the first nut of each segment is
tightened at the same time and so on. To do this a hydraulic pump equipped with a
manifold is used with hydraulic hollow cylinder jacks. Limit the force to 80% of the
nominal value. As the stacking goes on, the stretching length of the clamping bolts will
increase.
• Measure the core height around the circumference on the inner and outer radius. From
these measurements, the stator core will be equalized in the next package using
equalizing laminations.
• Using a sharp knife check each core tooth for compactness. Mark non-compact areas
with chalk. Determine the thickness of the required inserts.
• Check the slot dimensions and smoothness using the slot control device.
• After intermediate pressing, loose the nuts in a crosswise pattern.
• Remove the NDE press plates and the clamping bolts.
Figure 4 - Clamping bolts tightening sequence

9. Because of the manufacturing process of the laminations, the fingers of the laminations are
usually slightly thicker. This small difference in thickness creates difference in height
between the inner and the outer diameter of the laminations as the stacking goes on. To
compensate this effect, it is necessary to install equalizing segments, see Figure 5.
• The equalizing segments must be interlocked with the keybars.
• The equalizing segments can be installed in stepped.
• Only one equalizing segment shall be installed between two normal laminations.
• The installation of equalizing segments in the end packages is not permitted.
• The equalizing segments must be installed in the middle of a package.
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Figure 5 - Installation of equalizing segments
10. To have a uniform core, it could be necessary to have special equalizing segments that do
not interlock with the keybars. In this special case, use Nomex paper and glue it with epoxy
to the laminations.
11. Once the final stator core height is reached, proceed with the final pressing.
• Install the NDE press plates
• Fix the insulating tubes in the insulating washers. The insulating tubes shall be
introduced up to the middle of the insulating washers.
• Install the clamping bolts, spring plate, press washer, insulating tubes and insulating
washers, plain steel washers, and the nuts.
• Grease with a non-conductive grease the bearing surface of the nuts and the threads
and tighten the nuts in a sequence similar to Figure 4. A hydraulic hollow cylinder must
be used. Stretch the studs to their nominal elongation within ±5% of their nominal
calculated value.
• Try to insert a sharp paper knife on the inner and outer diameter of the core. Non
compact areas must be marked with chalk and corrected by loosening the clamping bolts
and inserting equalizing segments. Do not take off the whole pressure on the clamping
bolts. Stop loosening the clamping bolts as soon as you are able to insert the equalizing
segment. Tighten the loosened clamping bolts the nominal value.
• Verify the horizontality and the elevation tolerances.
• Measure the height of the core.
• Remove the piling guides and verify the slot dimension using the slot control device.
12. Measure the insulation resistance of the clamping bolts. Use a 500 V d.c. Megger. The
insulation resistance should be at least 10 MΩ.
13. Paint the stator core using a 2 components epoxy resin paint:
• Apply 1 coat (1 x 40 microns) on the stator bore and on the back of the core
• Apply a second coat (1 x 40 microns) on the back of the core
• Apply a thin coat (1 x 20-30 microns) in the stator core slots
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14. Perform the loop test.
15. Verify the tightening of the clamping bolts. Re-tighten the clamping bolts if required.
16. At each end of the stator core, the bore diameter of the last lamination package will be
coated with two components wiping epoxy.
17. There is no need to lock the nuts. The pre-stressing of the clamping bolts locks the nut by
itself.
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HTWT 620242
File No.:
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98.01.06 Senn 98.01.06 Klamt 98.01.06 Förster en 1/4
Hydro Power Segment 14. 08.2002
Manufacturing Instruction
Preparation of Brazing Joints from the Roebel-Type Stator Bar Ends with
Brazed Tabs
General
This manufacturing instruction describes the preparation of brazing joints, after the
stator bars are installed in the stator core by Hydro-generators or special machines.
Roebel-type stator bars with brazed tabs are used.
2002-12-19 EN Approved
Lng. Status
List of Contents Page

Rev. Released
1 Preparation 1
A
Type
2 Design of Roebel-Type Stator Bar Ends with Brazed Tabs 2

CQ
3 Deviations 2
3.1 Axial Deviation 2
9461 HTWT620242
Dept. Document No.
3.2 Tangential Deviation 3

3.3 Radial Deviation 3
3.4 Plane - Parallelism 4
3.5 Brazing Surface 4
1 Preparation
The brazing surfaces of the brazed tabs must be clean, plain and free of grease,
prior to the stator bar installation.
The stator bars must be wedged into the stator core, and the filler blocs in the
winding overhangs must be installed, before it is allowed to align the brazed tabs to
each other.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without
express authority is strictly forbidden. © ALSTOM POWER (Switzerland) Ltd. Switzerland 2002.

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2 Design of Roebel-Type Stator Bar Ends with Brazed Tabs

The design of a Roebel-type stator bar end with brazed tab is shown in Picture 1.
The conductor strands are brazed together to a solid conductor, and a tab
(connector between bars) is brazed to it.
When all stator bars are finally installed, there should be no clearance between the
brazed tabs (brazing joint) from the lower- and upper bars,(see Picture 2). The
brazed tabs must be aligned, if the brazing surfaces are not parallel to each other.
brazed T ab
Conductor strands
Lng. Status
Rev. Released
A
Type
CQ
Picture 1 Picture 2
9461 HTWT620242
Dept. Document No.
3 Deviations
3.1 Axial Deviation

The maximal allowed axial
deviation, between the brazed tab of
the upper- and lower bar is 10%
from the tab height, but not more
than 4mm. (see Picture 3).
Picture 3
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3.2 Tangential Deviation

The maximal allowed tangential
deviation, between the brazed tab of
the upper- and lower bar is 10% from
the tab width, but not more than
3mm. (see Picture 4).
Picture 4
Lng. Status
Rev. Released
3.3 Radial Deviation

A
Type
The maximal allowed radial

CQ
clearance between the brazing

surfaces is 1.5mm. (see Picture 5).
9461 HTWT620242
Dept. Document No.
A copper shim must be inserted,

when the gap exceeds 1.5mm.
During brazing, the brazed tab from

the upper- and lower bar must be
pressed together with a clamping
device.
Picture 5
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3.4 Plane - Parallelism

The gap of the brazing joint
must be perfectly parallel
(see Picture 6).
A custom-made copper plate

must be inserted to correct
large deviations in plane -
parallelism and brazing gap.
Lng. Status
Picture 6
Rev. Released
A
Type
CQ
3.5 Brazing Surface

9461 HTWT620242
Dept. Document No.
The allowed deviations of the brazing surface are specified under number 3.1
through 3.3. The brazing surface must be greater than 80% of the theoretical
brazing surface (no deviation between brazed tabs). If this requirement is not
accomplished, then the design department must be notified.
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Hydro Power Segment 14. 08.2002
WORKING INSTRUCTION
Installation of bars, round packing
General
This Working Instruction describes the procedure for installing the stator winding in
the slots using the round packing technique. This Instruction applies to all stator
windings of water-powered, diesel-powered and special generators with Roebel
bar windings and MICADUR or MICADUR SILAST insulation systems.
CONTENT Page no.

1 Applicable instructions ..................................................................................................... 1

Lng. Status
2 List of materials ................................................................................................................ 2

3 Preparatory work, general information ............................................................................. 2
3.1 Arrangement of the winding device and the workplace ................................................ 2
Rev. Released
3.2 Thickness of the silicone coating.................................................................................. 3

3.3 Silicone compound ....................................................................................................... 3
E
Type
3.4 Applicator...................................................................................................................... 3
CQ
4 Installing the bars in the slots........................................................................................... 3

4.1 Tape wrapping device................................................................................................... 3
9461 HTWT620172
4.2 Wrapping ...................................................................................................................... 4

Dept. Document No.
4.3 Inserting the bottom bar................................................................................................ 5

4.4 Voltage test of the bottom layer .................................................................................... 5
4.5 Inserting the top bars .................................................................................................... 5
4.6 Voltage test of the complete winding ............................................................................ 5
1 Applicable instructions
1ECR 100846: Stator Winding Instruction, Design Instruction
_______________________________________________________________________________________________________________
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden. © ALSTOM POWER (Switzerland) Ltd. Switzerland 2004.
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2 List of materials
Follow the instruction: 1ECR 100846 Stator Winding Instruction
3 Preparatory work, general information

Follow the instruction: 1ECR 100846 Stator Winding Instruction
3.1 Arrangement of the winding device and the workplace

Lng. Status
Rev. Released
E
Type
CQ
9461 HTWT620172
Dept. Document No.
(1) bar support

(2) applicator for silicone compound (V-6876 0001-V) or similar
(3) tape magazine for treated tape
(4) round packing tape
(5) floor covering to protect the tape from dirt contamination
(6) bar
(7) tape wrapping device (V6876 0001-X) or by hand
(8) fixed points for securing the bars
The applicator for the silicone compound, item 2, is adjustable for coating
thicknesses of 0.1, 0.2, 0.3 and 0.4 mm.
The silicon compound container can be cooled with water if it is desired to prolong
its potlife.
The item can be cleaned by allowing the silicone compound to harden and then
removing it solid mass.

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3.2 Thickness of the silicone coating

Measure the slot width bn
Measure the coil width bbar
The difference bn and bbar gives the clearance between the bar and the slot wall.
A double-layer folded round packing tape has a thickness of 0.22 mm. The total
thickness (both sides) is 0.44 mm.
Table as a guideline for the coating thickness of the silicone compound for round
packing:
Clearance between bar and slot wall Applicator setting

0.5 mm 0.10 - 0.15 mm
0.6 mm 0.20 mm
0.7 mm 0.20 mm
0.8 mm 0.2 - 0.25 mm

Lng. Status
0.9 mm 0.25 - 0.30 mm

1.0 mm 0.30 mm
Rev. Released
Deviations from these values can be made under the following conditions:
E
Type
CQ
a) The bar sits too loosely in the slot:

Increase the amount of silicone compound, as air bubbles can form inside the
9461 HTWT620172
compound.
Dept. Document No.
b) The bar sits too tightly in the slot:

This happens if silicone compound is pushed out when the coil is inserted.
Reduce the amount of the compound.
3.3 Silicone compound

Thoroughly mix the resin and hardener in the mixing equipment. The scope of
delivery covers the resin and the required amount of hardener. The potlife of the
compound is 2 hours at a temperature of 23 °C. This period can be prolonged by
cooling the components before and after mixing.
3.4 Applicator
Set the applicator for the calculated thickness. Prepare the required quantity of
semiconductor tape and store it in the magazine.
Important !
Protect the tape from dirt contamination, it must not be dirty before being treated.
4 Installing the bars in the slots

4.1 Tape wrapping device
Clamp the bar in the wrapping device.

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4.2 Wrapping
Wrap the tape around the bar as shown in the illustrations below.
semiconductor tape
bar / coil
coil with corona protection

Lng. Status
silicone compound
Rev. Released
semiconductor tape
E
Type
CQ
Round packing tape secured with Scotch Electrical

tape FE – 500 – 0393 – 7
9461 HTWT620172
Dept. Document No.
unless otherwise specified

on the drawing
end of laminated
stator core

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4.3 Inserting the bottom bar

Position the bar axially as shown in the drawing (place the bar on a suitable
underlay). Insert the bar into the slot until is rests flush on the slot bottom.
Remove the surplus silicone compound from the stator after inserting the bar.
Check that no cooling ducts are blocked by surplus silicone compound.
Insert the intermediate packing or resistance elements as shown in the drawing.
After installing the bottom bar, insert an intermediate piece of the same height as
the top bar. This is needed for the provisional wedging and replaces the top bar. It
may be made of wood. Next, wedge the bar using the normal wedge and the
counter-wedge. The distance between the provisional wedges must be about
500 mm. The slots must be completely wedged before the gel time of the silicone
compound expires.
The bar must be left undisturbed in the slot for the hardening time of the silicone
compound (5 to 10 hours).
Lng. Status
If the bar only goes into the slot with difficulty, it may be driven in by means of
careful blows on a piece of plastic backing placed over the straight portion of the
bar.
Rev. Released
4.4 Voltage test of the bottom layer

E
Type
CQ
Earth all the resistance elements before the test.
Test all the bottom bars to earth with the test voltage in accordance with the test
9461 HTWT620172
plan.
Dept. Document No.
4.5 Inserting the top bars

Insert the top bars in the same way as described in Section 4.3.
The slot must be completely wedged before the gel time of the silicone compound
expires.
Wedging, supporting and soldering/brazing must be carried out as shown in the

drawing.
4.6 Voltage test of the complete winding

Earth all the resistance elements before the test.
Test all the bottom and top bars to earth with the test voltage in accordance with
the test plan.

H-6745 00 MKB 000 81 DC _ A 74 of 118
abcd ALSTOM (Switzerland) Ltd HTZW 23292
Responsible department: Take over department: Revision: Doc.-type: File no.:
TSDXH / ICC G 04-09 CJ HTAE660117
04-06-25 Haas 04-06 Bindert 04-06 C.-E. Stephan en 1/3
Valid for: Derived from: Replaces: Classify no.: Data set:
same no HTZW\23292en.G__.doc
Test Instruction for Components (PA)
Testing of resistance temperature detectors (RTD’s)
Designation text: PA_resistance temp. detec. Document number: HTZW 23292
Index of contents Page

1 Purpose................................................................................................................................................ 1
2 Scope of application............................................................................................................................. 1
3 Test conditions ..................................................................................................................................... 1
4 Carrying out the tests on RTD's for installation in windings................................................................. 2
5 Carrying out the tests on RTD's for other components than windings ................................................ 3
6 Test facilities ........................................................................................................................................ 3

Lng. Status
7 Documents to be used ......................................................................................................................... 3

8 Personnel qualification......................................................................................................................... 3
Rev. Released
9 Responsible departments .................................................................................................................... 3

G
Type
CJ
1 Purpose
This test instruction describes the procedure for the stage-by-stage checking of the dielectric strength and
9612 HTZW 23292
Dept. Document No.
the insulation resistance of resistance temperature detectors (RTD’s) in windings and other components
of generators and motors during the assembly. It serves, among others, for the detection of defects
during the assembly operations.
2 Scope of application
This test instruction is applicable for insulated RTD's in all electrical rotating machines. The instruc-
tion is not applicable for RTD’s that are fitted uninsulated on metallic parts.
3 Test conditions
The resistance temperature detectors (RTD’s) are checked for their resistance value as well as their
measuring accuracy and dielectric strength before installing.
For carrying out the respective voltage test all RTD’s are to be short-circuited and connected to one
another.
During the high voltage test on the stator winding all RTD’s are to be short-circuited and earthed.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties with-
out express authority is strictly forbidden. Copyright © 2004 by ALSTOM (Switzerland) Ltd.
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4 Carrying out the tests on RTD's for installation in windings

a) Tests after the production of the RTD's, by the supplier or in the workshop
Test Test criteria
4.1 RTD’s ready for assembly in the winding

After the production of the RTD’s (including corona
protection), the following tests are to be carried out
on the RTD’s against the corona protection:
4.1.1 Voltage test
Test voltage 2500 V, 50/60 Hz, for 1 Min. No breakdown
4.1.2 Insulation resistance
Measuring voltage 2500 VDC , for 1 Min. ≥ 10'000 MΩ
4.1.3 Resistance of the RTD’s According to EN 60751 class B
or according to order,
Deviation among themselves <0,5%
b) Tests on the RTD's during assembly of the winding

Test Test criteria
Lng. Status
4.2 Supply wires in drawn-in condition

(without RTD’s, main current bushings and connection
terminals)
Rev. Released
4.2.1 Voltage test against earth

G
Type
CJ

Measuring voltage 2500 VDC , for 1 Min. ≥ 2000 MΩ
9612 HTZW 23292
4.3 RTD’s with supply wires soldered and tied up to the

Dept. Document No.
winding components
This test is to be carried out after the assembly of the
bottom bars or coils.
Measuring voltage 1000 VDC , for 1 Min. ≥ 2000 MΩ
4.3.3 Resistance of the RTD’s Deviation among themselves <1,5%
4.4 Testing of the RTD’s after the winding installation

(optional for hydro generators)
After the voltage test at the top-bars of the stator

winding, a further test according to pt. 4.3 is to be
carried out on the RTD's without main current
bushings and connection terminals. As for pt. 4.3
4.5 Final checking of the RTD’s in windings

Measuring voltage 500 VDC, for 1 Min. ≥ 100 MΩ
4.5.3 Resistance of the RTD’s Deviation among themselves <1,5%
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5 Carrying out the tests on RTD's for other components than windings
Insulated RTD's in other components, e.g. stator core, press plates, cooling pipe nipples,
bearings etc., are to be tested follows:
a) Tests after the production of the RTD's, by the supplier or in the workshop
Test Test criteria
5.1 RTD’s ready for installation

5.1.2 Resistance of the RTD’s According to EN 60751 class B
or according to order
b) Tests after the installation of the RTD's

Test Test criteria
5.2 Tests on the installed RTD's:


Lng. Status
5.2.2 Resistance of the RTD’s Deviation from nominal value <1,5%,

(Take special care about temperature variations) Deviation among themselves, if in-
stalled in the same system <1,5 %
Rev. Released
G
6 Test facilities
Type
CJ
The following measuring and test equipments are needed for carrying out the measurements/tests:
• Isolation resistance measurement: Megger up to 2500 VDC with following ranges:

9612 HTZW 23292
Dept. Document No.
≥1'000 MΩ at 500 V, ≥2'000 MΩ at 1000 V,

≥10'000 MΩ at 2500V test voltage
• High voltage test: AC-test transformer 2500 V, 50 or 60 Hz
• Measurement of RTD-resistance: Ohmmeter
7 Documents to be used
Inspection and Test plan or the test protocol of the corresponding inspection dept.
8 Personnel qualification
The tests are to be performed by appropriately trained and authorized personnel.
9 Responsible departments
The responsibility for carrying out the measurements/tests 4.1and 5.1 lies with the manufacturer or
supplier of the RTD's.
The responsibility for carrying out all other measurements and tests (Pt. 4.2 - 4.5 and 5.2) lies with
the project- or assembly management.
The general safety and heavy current regulations are applicable.
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same no HTAE\60012en.J__.doc

Measuring the insulation resistance of rotating electrical machines
Destignation text: PA-Insulation resistance Documentation no.: HTAE 60012
Content
1 General informations............................................................................................................................ 1
2 General specifications ......................................................................................................................... 1
3 Insulation resistance measurement on stator windings of all types, except those with direct
liquid cooling......................................................................................................................................... 3
4 Insulation resistance measurement on stator windings with direct liquid cooling ....................... 3
5 Insulation resistance measurement on field windings ..................................................................... 4
6 Insulation resistance measurement on the rotor (armature) windings .......................................... 4

Lng. Status
Rev. Released
1 General informations
J
Type
The test methods and minimum insulation values to be used when measuring the insulation
ND
resistance of stator and rotor windings of electrical machines ready for operation are prescribed for
the purpose of standardization.
9612 HTAE 60012
Dept. Document No.
As basis serve internal ALSTOM documents as well as IEEE-Standard 43, edition 2000.
Information concerning the test procedures and insulation resistances to be complied with for the
different machine windings is set out below.
2 General specifications
2.1 Application
- Before commissioning an electrical machine or after longer shutdown periods.
- Before and after carrying out a high voltage test.
- In conjunction with the winding diagnosis for assessing the winding as regards dirt contamination
and the effects of moisture.
2.2 Principle of measurement

Apply a d.c. voltage between a part of the winding and the earthed housing or winding support (other
parts of the windings without a voltage applied, and temperature measuring detectors, should also
be earthed) and read the resistance value 1 minute after applying the voltage.
Earth the winding part concerned immediately after the measuring voltage is switched off.
express authority is strictly forbidden. Copyright © 2002 by ALSTOM (Switzerland) Ltd.
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2.3 Measuring voltage

500 - 5000 V d.c. voltage, depending on the available measuring instruments. (The level of the
voltage in this range will in practice not yet act on the resistance value).
Rated voltage of test object Guide for test voltage

< 1000 500
1000-2500 500-1000
2501-5000 1000-2500
5001-12000 2500-5000
>12000 5000-10000
Table 1 Guide for test voltage during insulation resistance measurement
500 V is recommended as preferable, and is prescribed as compulsory for low-voltage windings

(UN < 1000 V).
The test should be carried out using a stabilised d.c. voltage source using a high-quality commercial
resistance measuring instrument (open circuit voltage max. up to approx. 650 V).
Lng. Status
2.4 Influence factors

The insulation resistance of rotor and stator windings will in the first instance depend on the
insulation system, size of the machine and surface characteristics. The following factors above all
Rev. Released
will be of major importance in insulation resistance measurements:
- surface condition of the winding (dirty)

J
- moisture
Type
ND
- temperature
9612 HTAE 60012
The temperature has a decisive effect on the insulation resistance. If the winding temperature differs
Dept. Document No.
considerably from the room temperature (> 5 °C), the measured value used in the assessment
should be converted to a reference temperature of 20 °C as follows:
R1 min (20 °C) = R1 min (t) . K
R1 min (t) = Resistance reading at temperature t
K = Temperature coefficient, Appendix page 5
Example: R1 min measured at 60 °C : 50 MΩ

R1 min (20 °C) = 50 . 10 = Ω
500 MΩ
The correction curve shown on page 5 can normally be used for all ALSTOM insulation systems.
Resistance measurements at winding temperatures below the dew point of the ambient air should be
avoided if at all possible.
2.5 Assessing the measured results of the insulation resistance

- The measured 1 min insulation resistance values with respect to 20 °C must satisfy the minimum
values specified under paragraph 3-6.
- If the minimum insulation resistance is not achieved, the cause must be ascertained before
recommissioning or carrying out a voltage test. Cleaning the critical parts of the insulation or
drying at increased temperature (approx. 80 °C) will normally suffice to produce an improvement.
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2.6 Certificate
The results of the resistance measurement should be logged. The measuring voltage and winding
temperature as well as the measuring instrument used should be stated, as well as the type of
winding circuit.
The test certificates HTAE 667002 for stator windings and HTAE 667003 for rotor windings are
preferably to use.
3 Insulation resistance measurement on stator windings of all types, except

those with direct liquid cooling
The following shall apply to the measurement of the complete winding with respect to earth
before and after the voltage test is carried out:
- Minimum resistance value
R1 min (20 °C) > 3 (n + 1) in MΩ

(n = rated voltage of machine in kV)
Example: UN = 18 kV → R1 min = 3 (18 + 1) = 57 MΩ

Lng. Status
a) If the resistance condition is complied with, a machine may be commissioned.
b) It is generally not considered to be necessary to measure the resistance of each phase.

If such a measurement is carried out in special cases (e.g. large generators), the following
Rev. Released
condition applies:
J
Minimum resistance value : R1 min (Phase) > 2 . R1 min (complete winding)

Type
ND
d) The resitstances measured before and after the high voltage test should not differ more than
20%.
9612 HTAE 60012
Dept. Document No.
4 Insulation resistance measurement on stator windings with direct liquid

cooling
The following shall apply to the measurements of the complete winding with respect to earth before
and after performing a voltage test:
R1 min (20 °C) > 3 (n + 1) in MΩ

(n = rated voltage of the machine in kV)
Example: UN = 18 kV → R1 min = 3 (18 + 1) = 57 MΩ
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The following additional conditions shall also apply:

• The resistance measurement should be carried out immediately before and after the voltage test,
provided that the coolant has not yet been filled. The resistance value after the voltage test may
then not drop below the minimum value and the difference between the two values should be less
than 20%.
• The above specifications shall apply irrespective of whether the cooling system is filled or not
when oil is used as the coolant.
• If water is used as the coolant, the above conditions will only apply before the coolant is filled.
Once the water has been filled in the winding, the insulation resistance will be < 1 MΩ if and will
practically only be dependent on the conductivity of the water.
If the resistance condition is complied with, a machine may be commissioned.
Generally speaking it is not considered necessary to perform a resistance measurement on each

phase separately. If such a measurement be carried out in special cases (e.g. large generators),
the following condition shall apply:
- Minimum resistance value: R1 min (phase) > 2 . R1 min (whole winding)

5 Insulation resistance measurement on field windings

Lng. Status
- The resistance measurement with respect to earth should be carried out on all field windings
before and after each voltage test.
Rev. Released
R1 min (20 °C) = 1 MΩ

J
Type
ND
a) If this resistance condition is satisfied, a machine may be commissioned.

b) For windings cooled directly by liquid, and where the coolant has already been filled
(applicable to water), the insulation resistance is < 1 MΩ. It is then practically only dependent
9612 HTAE 60012
Dept. Document No.
on the water conductivity.

c) When resistance measurements are taken before and after a voltage test, the resistance
value after the voltage test should not differ by more than ± 20 % from the first value.
d) In the case of brushless excitation with rotating diodes, the rectifier set should be bridged out
during the resistance measurement.
6 Insulation resistance measurement on the rotor (armature) windings

- The following shall apply to the measurement of the whole winding with respect to earth before
the voltage test is carried out:
R1 min (20 °C) > n in MΩ, but with a minimum of 1 MΩ

(n = Dimensionig voltage of the machine in KV)
Example: UN = 1.2 kV → R1 min = 1.2 MΩ
If this resistance condition is satisfied, a machine can be commissioned.
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Insulation resistance, temperature coefficient as a function of the winding temperature, for insulations of
temperature classifications F and H
1000
100
Temperature coefficient K
Lng. Status
10
Rev. Released
J
Type
ND
9612 HTAE 60012
Dept. Document No.
K = 0,3162 e0,0576 T
0.1
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Temperature [°C]
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abcd ALSTOM (Switzerland) Ltd. HTAE 660183
Responsible dept.: Take-over dept.: Revision: Doc. t y p e : File no.:
TEDH5 / ICC B 02-10 CJ HTAE60000
Translated: Checked: Approved: Language: Page:
02-10-22 Bindert 02-10 Wirsching 02-10 C.-E. Stephan en 1/4
Valid for : Derived from: Replacement for : Classification no.: Datei:
Same no. HTAE\660183en.B__.doc
Testing instruction for components (PA)
Determination of the polarisation index on windings of rotating electrical machines
Designation text: PA-Polarisation index Document number: HTAE 660183
1 General information 1
2 General stipulations 2
2.1 Application 2
2.2 Preparatory operations 2
3 Measuring principle, measuring protocol 2
3.1 Measuring principle 2
3.2 Measuring protocol 2
4 Carrying out the measurement 3
4.1 Measurement voltage 3
4.2 Measuring device and circuit 3
4.3 Measuring action, data recording 4
4.4 Influencing parameters 4
4.5 Evaluation of the polarisation index 4
4.6 Protocol 4
1 General information
For the sake of uniform handling, the procedure for the determination of the polarisation index of
ready for operation rotor- and stator windings of electrical machines is being prescribed.
Applicable instructions
ALSTOM-internal documents as well as IEEE-Standard 43, issue 2000 serve as basis.
without express authority is strictly forbidden. Copyright © 2002 with ALSTOM (Switzerland) Ltd.
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2 General stipulations
2.1 Application
Before the commissioning of an electrical machine or after longer shut down periods as well as in
connection with the winding diagnosis for the evaluation of the winding w.r.t. contamination and
effect of humidity, in case demanded by the customer.
2.2 Preparatory operations

• Before beginning the measurement, the temperature of the test object should be approximately
in the normal ambient temperature level (< 30 °C).
• If the test object to be investigated pertains to a direct water-cooled winding, then the following
points are to be taken into account:
- Cooling circuit filled: No polarisation index measurement possible.

- Cooling circuit drained: Provided that the cooling circuit is drained and the residual humidity
is drawn out by means of vacuum (Check through resistance meas-
urement), the measurement can be carried out in the normal way.
• If the test object has a fire protection (CO2), then it is to be blocked or switched off before com-
mencement of the measurement.
• In case of exciter windings with brushless excitation, the rectifiers (Diodes) must be protected
from over-voltages by short-circuiting. In this, all terminal connections at the cooler modules
row-wise are to be connected to one another throughout with high contact stability with a bare or
tinned copper wire. After completion of the investigations, the wires are to be again removed
carefully.
• For carrying out the measurement, all safety-engineering measures according to the applicable
safety regulations are to be complied with (set up barriers, visible earthing rods, warning notices
etc.).
3 Measuring principle, measuring protocol
3.1 Measuring principle

Between the winding of the object to be tested and the counter-electrode (e.g. the earthed rotor
shaft or the stator laminated core) a stabilised direct current of prescribed magnitude is to be ap-
plied. The insulation resistance is to be determined as per a precisely defined time program and
entered in a protocol. After that, from the quotients of the 10min- and 1min- insulation resistance,
the polarisation index is to be calculated.
After the completion of the measurement the winding is to be immediately earthed.
3.2 Measuring protocol

About the carried out insulation resistance measurement and determination of the polarisation index
a protocol is to be kept, which contains the measured values as well as all relevant details of the
test object and the measuring conditions. Preferably the measured values are to be entered in the
measuring protocol HTAE 667019.
The protocol preparation can be done manually or according to relevant computer program.
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4 Carrying out the measurement
4.1 Measurement voltage

As a rule, 500 - 5000 V d.c. voltage, depending on the measuring device available and the meas-
urement voltage of the test object (In this range the magnitude of the voltage does not yet affect
practically the insulation resistance and polarisation index of dry insulations).
Table 1 reproduces the maximum permissible measuring voltages.
Measurement voltage of Guidance values for

the test object [V] test voltages [V]
< 1000 500
1000-2500 500-1000
2501-5000 1000-2500
5001-12000 2500-5000
>12000 5000-10000
Table 1 Guidance values for d.c. test voltage for the insulation resistance measurement.
500 V is preferably recommended and for low voltage windings (U N < 1000 V) mandatorily pre-
scribed.
4.2 Measuring device and circuit

The test should be carried out with the help of a stabilised dc voltage source or with a qualitatively
good commercially available resistance measuring device (No-load voltage ≤ 650 V).
Illustration 1 shows the test circuit to be used. In this example, a rotor winding serves as test object.
IL
+
Ug
- Ug = stabilised DC-
voltage source
(500/1000 V)
l
A1
IL = Charging current
S
A1 = Ammeter
S = Changeover switch
A Measurement
data recor-
ding unit
Illustration 1 Circuit diagram

for insulation resistance
measurement
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4.3 Measuring action, data recording

• Between the winding section to be tested and the earthed frame or winding support (further
winding sections not having voltage supply and temperature measurement probes are likewise
to be earthed) a constant, if possible negative charging voltage UL (as a rule 500 - 5000 VDC,
see also Table 1) is to be applied.
• As soon as the selected charging voltage is reached, the time measurement is to be started and
depending on the measuring device used, the resistance or charging voltage values after the
relevant time periods are to be read out and protocolled.
• After reading out the 10-min value, the measuring voltage is to be switched off and the corre-
sponding winding section is to be immediately earthed.
• After that (if not directly measured) the insulation resistance values after 1 min as well as after
10 min are to be calculated (RINSUL = UL / IL) and entered in the protocol. The ratio of the 10min-
to the 1min -insulation resistance yields then the polarisation index PI.
4.4 Influencing parameters

The polarisation index of rotor- and stator windings is primarily dependent on the insulation-/ corona
protection system, machine size / winding geometry and -circuit as well as the surface conditions.
During measurements for determining the polarisation index above all the following factors are of
considerable significance
- Surface condition of the winding (degree of contamination / type of contamination),
- Humidity / Temperature.
Measurements for determining the polarisation index at winding temperatures below the dew point
of the ambient air are therefore to be avoided as far as possible.
4.5 Evaluation of the polarisation index

The polarisation index has mainly informative character and can if need be serve as comparison
basis for later measurements. Compulsory limit values will not be prescribed but should be referred
to merely as recommendations (see table 2).
As long as the absolute values of the 1min insulation resistance satisfy the relevant specifications, a
winding is regarded as fit for operation. If the insulation resistance is > 5000 MΩ even after 1 min-
ute, the polarisation index is regarded in general as insufficient evaluation criterion.
Temperature class of the insulation system Guidance value PI

Class A 1,5
Class B 2,0
Class F 2,0
Class H 2,0
Table 2 Guidance values for PI during the insulation resistance measurement
4.6 Protocol
The results of the measurement for determining the polarisation index are to be protocolled, for
which the protocol sheets HTAE 667002 and HTAE 667019 are suitable. Preferably the protocol
sheet HTAE 667019 is to be used. Besides the type of the winding circuit, the winding temperature
and the measuring voltage as well as the used measuring instrument are to be indicated. In addi-
tion, under remarks details are to be given about the external winding condition with regard to con-
tamination type and extent as well as, where applicable, humidity indications.
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Voltage test on stator windings of electrical machines with rated voltages

> 3.3 kV in manufacturers’ works (without global impregnation / MC-System)
Designation text: TI_Voltage test Stator Document-number: HTAE 60031
1 General information................................................................................................................... 1
2 Test principle, protocol .............................................................................................................. 2
3 Carrying out the test.................................................................................................................. 4
4 Turbogenerators: A.C. voltage tests on stator windings............................................................. 7
5 Hydrogenerators and special machines: A.C. voltage tests on stator windings.......................... 9
6 Turbogenerators: A.C. voltage tests on winding connections and terminal leads..................... 11
1 General information
This instruction describes the voltage tests on stator windings of rotating machines with rated volt-
ages > 3.3 kV.
• In connection with the winding manufacturing of rotating electrical machines and for checking
during the production of the individual winding elements, installing or assembly and after the
completion of the winding, voltage tests are to be planned.
• ALSTOM-internal documents as well as the latest IEC-Publication 60034-1 serve as basis. In

principle, testing is always done starting from the rated voltage UN of the machine (or details
of the electrical calculation).
• The instruction fixes up the timing and voltage for the testing of the various winding elements
taking into account the insulation system.
• For winding operations outside the manufacturer’s works if required, additionally the details
given in TI HTAE 60057 are to be observed.
• The present instruction will be matched regularly with the latest knowledge levels and is valid
from the date of issue of the last revision index.
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2 Test principle, protocol
2.1 Test principle

• The prescribed test voltage is to be applied, depending on the production and assembly stage
between the winding section to be checked, i.e. stator bars or coils and the earthed stator casing
or earth coatings. Further winding sections, not connected to voltage and temperature measur-
ing probes are to be shorted and always to be earthed.
• Before connecting or after switching off the voltage, the corresponding winding section or phase
is to be immediately earthed visibly. Further the relevant safety precautions for working with high
voltage are to be observed.
• In the normal case before and after every high voltage test, an insulation resistance measure-
ment is to be carried out according to HTAE 60012. The high voltage test should normally be
done, only if the minimal insulation resistance values are complied with.
When testing individual elements (bars, coil), the insulation resistance measurement may be
omitted in the normal case (subject to customer requirements). However it is recommended to
carry out this measurement as random sampling on the first 10 bars or coils for checking per
winding type.
• The test voltage is a sinusoidal A.C. voltage with a frequency between 40 Hz and 60 Hz, with a
ratio of peak value to effective value 2 ± 5 % : 1. Normally testing is done with a 50 Hz-A.C.
voltage, irrespective of the rated frequency of the test object. The test voltage should not vary
by more than ± 5 % of the rated test voltage within the testing time.
At rated voltages from 6 kV, after consultation with the responsible technical department or the
approval of the customer respectively, even a testing with D.C. voltage is permissible. The test
voltage UDC to be applied is then determined as follows:
UDC = UAC eff x 1.7
• The test voltages are entered in the present instruction under the respective section as a func-
tion of the rated voltage UN and are valid for a customer acceptance test voltage UAP = 2UN+1kV
according to IEC60034-1.
If the customer acceptance test voltage UAP is exceptionally higher than 2UN+1kV, the test volt-
ages of the levels 4 and 5 are to be increased by the difference of the acceptance test voltage to
2UN+1kV. The following is applicable:
UP ' = UP + UAP − (2UN + 1kV )
• The voltage test should be begun with a sufficiently small voltage (less than 50 % of the pre-
scribed test voltage) and then raised evenly with a velocity of 1-2 kV/s (Normal case), or in
steps of not more than 5 % of the planned test voltage (same total voltage regulation period as
in normal case). The time for the voltage increase from half to the full test voltage value should
be minimum 10 s. The full test voltage is, unless other specifications are there, to be held for 1
minute (for special tests on unimpregnated winding elements according to curve 0 only 10 s!).
After that, the voltage is to be regulated back as evenly and as quickly as possible to zero.
• At voltages greater than about 1.1 × UN/ 3 or 1.1 UN (between phases) fine corona discharges
can occur. This is permissible, provided at the test voltage no creepage paths or pronounced
spark-overs arise.
If distinct spark discharges or creepage path formations occur, the testing is to be immediately
aborted. The cause is to be clarified and action measures taken for preventing them. In case of
creepage path formations repairs are to be carried out.
• The tests of the levels 1 - 5 are done normally at ambient conditions, irrespective of cooling me-
dium or the subsequent installing height.
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• The customer acceptance test (Level 6) is done according to IEC60034-1 on completely assem-
bled generator under normal operating conditions.
• In case of direct-fluid cooled machines, with filled-in cooling medium, a minimal circulation of the
same during the voltage test is to be taken care of (min. 20 % of the rated throughflow quantity
of the cooling medium).
If the cooling medium is not filled, the stator winding must be dry (check through insulation resis-
tance). If earlier a winding leak-tightness test had been carried out by means of Helium, the
cooling circuit must first be flushed with N 2 because of the Teflon hoses.
• A voltage test should usually not be repeated in the same magnitude.
• After treating the end windings with corona protection varnishes (e.g. Phase separations) or af-
ter drawing in of pre-impregnated cords, their drying time is to be observed, before a voltage test
is permitted to be done. Normally, the drying time at an ambient temperature of 18 - 23°C is
at least 24 h.
• A voltage test is considered passed if no disruptive discharges, flash-overs or creepage path tra-
ces have formed.
2.2 Protocol
About every voltage test carried out a protocol is to be maintained, which should contain the follow-
ing details:
• Insulation type, rated voltage, customer acceptance test voltage, test voltage according to electri-
cal calculation
• Winding condition
• Winding -/ambient temperature
• Voltage type (AC or DC)
• Voltage magnitude/velocity of the voltage increase
• Test duration
• Finding
• Observations, if any (Discharges/Temperature rises)
• Insulation resistance, before and after the voltage test
• Inspector, Date.
Preferably the following test protocol sheets are to be used:
• HTAE 667010 - AC Voltage test

• HTAE 667011 - DC Voltage test
• HTAE 667012 - AC Voltage test, 3-phase
• HTAE 667013 - DC Voltage test, 3-phase
2.3 Safety measures
Electrical tests should be carried out only by trained personnel observing the general and local
safety measures.
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HTAE 60031
3 Carrying out the test

• The test voltages to be applied at the different production stages are dealt with in the following
chapters:
• Chapter 4 : valid for turbo generators

• Chapter 5 : valid for hydro generators and special machines
• Chapter 6 : valid for winding connections and terminal leads of turbo generators
• It is to be noted that differentiation is made between testing the entire winding against earthed
frame or the individual phases respectively, as well as individual winding elements.
• During the testing of double Roebel bars (transposed conductors) both bar halves must be con-
nected at both ends conductively with one another!
• For the individual bar tests depending on the insulating system different, suited test voltages
come to be applied (Curves 1 – 1e).
The test voltages during the winding assembly (curves 2 - 6) are valid for all insulation systems
(Exception: Global impregnation technique / MC-System).
• For the individual bar testing of hydro generator bars at test voltages ≥ 60 kV the corona pro-
tection sleeves and stress grading layers are to be protected by means of shunt-arranged resis-
tors.
For the individual bar testing of Turbo generator bars with corona protection sleeves, a shunting
of the end control must be done only at test voltages ≥ 80 kV. For turbo generator bars without
sleeves, a shunting of the end control must be carried out, in case the following is applicable:
• End control from PETP/GlGwb Leit 10 and UN > 11kV

• End control from Leitlack LL16 and UN > 15kV
This can be achieved acc. to variant A or B.
H-6745 00 MKB 000 81 DC _ A 90 of 118

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HTAE 60031
Shunting variant A (with voltage-independent resistors)
The shunting of the end corona protection in the end winding region is done through a parallel circuit
of high voltage-/ high power resistors (lattice network). The coupling is done according to Fig. 1a
with special tension springs.
Fig. 1a: Test arrangement variant A for the shunting of the voltage stress grading length.
Control boxes placed insulated against earth (on insulating blocks).
Control boxes
Connection
sockets
1. to 6.
E D C B A
Metal Insulation Coupling tension Stress grading End of slot corona Corona protection Slot corona
springs coating protection coating sleeve *) protection coating
*) Maximum permissible temperature rise of the sleeve when testing: ≤ 50°C

R1...R5 Resistances, value based on the resistors installed in the control boxes.
Divide the control paths between end of slot corona protection coating (under the sleeve) and end of
the insulation so, that each of the parts A, B,...E in fig. 1a have a mean electrical field strength of
max. 4kV/cm. For subdivision of control paths see table below.
Each control box is dimensioned for a voltage of up to Urms = 45 kV and consists of 10 resistors
100 kΩ / 250 W connected in series. Between two adjacent connecting sockets the resistance is
200 kΩ (2 resistors in series).
When using n control boxes, every “n“th connecting socket (from earth terminal) is used. The other
sockets remain open (see Fig. 1a as example for 3 control boxes).
Sub-division of the control paths [cm]

No. of control boxes Test voltage A B C D E
2 UZP ≤ 90 kV 5 6 7 8 Rest
3 90 kV < UZP ≤ 135 kV 7 8 9 10 Rest
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Shunting variant B (with voltage-dependent resistors)
The shunting is based on H-VL VB 65/233 or ZWT PB 219556. Resistance characteristic and build-
up of the so-called control boxes are defined in PB.
The connection of the 6 terminals of the control boxes at the bar-bows is done by means of ≤ 5 mm
wide, copper strips fitted over the corona protection according to Fig. 1b.
Fig. 1b: Test arrangement variant B for the shunting of the voltage stress grading length.
Control boxes placed insulated against the earth (on insulating blocks).
lA ~ 0.15 ⋅ U lA = Length between connecting points in mm

U = Bar periphery in mm
Sleeve Stator bar Stress grading coating
Slot corona protection
The corona protection layers must be clean.
The couplings (Strips, springs) must in each case lie in a plane, perpendicular to the test piece axis
and pulled taut.
The connecting cables with the control boxes must have adequate distance from one another.
The control boxes must, before using for the test be checked for being free from dust, for the pur-
pose of preventing creepage path formation. The control box resistors are to be checked with Ohm-
meter from time to time, in order to detect interruptions, if any.
The control boxes must be installed well insulated, for the purpose of preventing flash-overs to
earth.
After every test series, the resistors in the control boxes are to be scanned for uniform temperature
rise.
• Special phase bars with built-in potential coatings in the overhang must be additionally tested
with 2 x UN for 1 minute prior to installation in the overhang. In this, the slot corona protection in
the slot region and the Cu-conductor are to be earthed; the slot corona protection in the over-
hang region is to be connected to voltage.
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HTAE 60031
4 Turbo generators: A.C. voltage tests on stator windings
Legend for the curves sheet Diagram 1 on the following page
Special test:
0* Testing of the bars before impregnating (corona protection already applied).
Normal tests, winding elements ready for installing:

1 Testing of the coils or bars before installing; applicable for MICADUR (E ≤ 2.5 kV/mm).
1a Testing of the coils or bars before installing; applicable for MICADUR (2.5 kV/mm < E ≤ 3.0 kV/mm).
1b Testing of removed, as new bars before re-installing; applicable for MICADUR.
1c** Testing of the coils or bars before installing WITHOUT shunting; applicable for MICADUR.
1d Testing of the coils or bars before installing; applicable for MICADUR-Silast, Semicadur,"Resin-rich"-
insulation, etc.
1e Testing of removed, as new bars before re-installing, applicable for “remaining insulating systems“.
Normal tests, winding elements installed:

2*** Testing after installation of bottom layer with bar windings or individual sectors with coil windings dur-
ing the assembly.
3**** Testing after the installation of the top layer with bar windings or after the installation of the coils after
provisional wedging, cord application etc., prior to possible heating up process.
• For H2-cooled stators, in which the winding will be additionally pressed into the slots at elevated
temperature, this testing takes place with provisionally fixed winding with connections. After the fi-
nal wedging then checking is to be done according to curve 4.
4**** Testing the winding after brazing, heat treatment, if applicable, final wedging and connections are
fitted.
5**** Acceptance test in the factory, if testing with 100 % UAP is required in the plant, and for corset ma-
chines after clamping the winding overhang, application of flooding resin, mounting of terminal con-
nections and assembly with the housing.
6**** Acceptance test voltage
Test duration
Curve 0: 10 s; other curves: 1 min
Additional hints
E Operating field strength [kV/mm];
* Special test: e. g. When changing the production place or during first time production of MICADUR-
bars. For the testing, the bars must be prepared as follows:
• Clamp the bars between 2 metal strips placed on the broad sides (provided bars are not assembled
in L-strips), which are spaced exactly at distance equal to the SPECIFIED width of bar. The length of
the strips should correspond to that of the core (slot). The strips must be connected with earth dur-
ing the test.
• In the case of no stress grading protection (stress grading varnish applied after VPI-process) a tem-
porary voltage stress grading must be applied (with PETP/Gl Gwb leit 10 tape; 1/3 overlapped),
which has to be removed after the HV-test.
► Minimum length = 30 mm x UN [in kV]
► Overlapping with slot corona protection: 25 mm
** Testing is done only if already earlier testing as per curve 1 has been done with a test voltage
≥ 80 kV with shunting variant A or B. --> 3 U N Test
*** Testing of the bottom layer and connections against the frame.
**** Phase-wise testing with the connections.
H-6745 00 MKB 000 81 DC _ A 93 of 118

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A.C. voltage tests on stator windings of turbo generators

Curve 1 to 6: The coils or bars have been impregnated or calibrated and
cured before the assembly.
120 1
110
1a
1b
100
90
1c
80
2
1e 3
70
4
Test voltage UP [kV]
5
60 6
1d 0
50
40
30
20
10
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Rated voltage UN [kV]
Diagram 1: A.C. voltage tests on stator windings of turbo generators
Calculation formulae:
Curve 0: UP = 2 UN Curve 1e: UP = 2.68 UN + 1.5 kV

Curve 1: UP = 4 UN Curve 2: UP = 2.58 UN + 1 kV
Curve 1a: UP = 3.6 UN Curve 3: UP = 2.4 UN + 1.1 kV
Curve 1b: UP = 3.5 UN Curve 4: UP = 2.23 UN + 1.2 kV
Curve 1c: UP = 3 UN (valid for UN ≥ 7 kV, Curve 5: UP = 2.1 UN + 1.3 kV
UP max = 80 kV) Curve 6: UP = 2 UN + 1 kV
Curve 1d: UP = 2.8 UN + 1.4 kV
Legends for the curves - see previous page
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abcd K 09-01 en 9
HTAE 60031
5 Hydro generators and special machines: A.C. voltage tests on stator windings
Legends for curves sheet Diagram 2 on following page
Normal tests, winding elements ready for installing:

1*** Testing of the coils or bars before installing; valid for MICADUR up to operating field strength of
2.5 kV/mm.
1a Testing of the coils or bars before installing; valid for MICADUR with reduced insulation thickness up
to a maximum operating field strength of 3.0 kV/mm.
1b Testing of removed, as new bars before re-installing; valid for MICADUR.
1d Testing of the coils or bars before installing; valid for MICADUR-Silast, Semicadur,"Resin-rich"-
insulation, etc.
1e Testing of removed, as new bars before the re-installing, valid for “other insulating systems“.
Normal tests, winding elements installed:

2* Testing after installation of bottom layer with bar windings or individual sectors with coil windings dur-
ing the assembly.
4** Testing of the winding after brazing, final wedging and connections fitted.
5** After transporting the completely winded stator or stator-sector from the manufacturing factory to
power station, should undergo a transport control.
6** Acceptance test voltage on completely assembled generator at the final site.
Test conditions
Curves 1 - 5: Ambient conditions
Curve 6: Operating conditions
Test duration
Curves 1 - 6: 1 min
Additional hints
* Testing the bottom layer against the frame.
** Phase-wise testing with the connections.
In the case of single-phase machines with twin-layer concentric windings and insufficient transformer
power, subdivision is not allowed within one pole to ensure that the air gap between the two layers
will not be overstressed.
*** In case the rated electrical field strength E is remarkably lower than 2.5 kV/mm the pseudo rated volt-
age U’N has to be taken as base for the calculation of the test voltage for the single bar. The U’N is
calculated according the rated insulation thickness and the electrical field strength of 2.5 kV/mm:
kV
U ' N = 3 * d iso * 2.5
mm
Increased customer acceptance test voltage
If the customer acceptance test voltage UAP is exceptionally higher than (2UN+1kV), the test voltages of the
levels 4 and 5 are to be increased by the difference of the customer acceptance test voltage to (2UN+1kV).
Then the following is applicable:
UP ' = UP + UAP − (2UN + 1kV )
Special tests
If required, the tests according to curves 0, 1c and 3 from chapter 4 also come for application to hydro-
generators. When installing the winding at the erection site, if required, additionally the details in
TI HTAE 60057 are to be followed.
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HTAE 60031
A.C. voltage tests on stator windings of hydro generators

and special machines
Curve 1 to 6: The coils or bars have been impregnated or calibrated and
cured before installing.
120 1
110
1a
1b
100
90
80
2
1e
70
4
5
60 6
1d
50
40
30
20
10
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
rated voltage UN [kV]
Diagram 2: A.C. voltage tests on stator windings of hydro-generators and special machines
Calculation formulae:
Curve 1: UP = 4 UN Curve 2: UP = 2.58 UN + 1 kV

Curve 1a: UP = 3.6 UN Curve 4: UP = 2.23 UN + 1.2 kV
Curve 1b: UP = 3.5 UN Curve 5: UP = 2.1 UN + 1.3 kV
Curve 1d: UP = 2.8 UN + 1.4 kV Curve 6: UP = 2 UN + 1 kV
Curve 1e: UP = 2.68 UN + 1.5 kV
Legends for the curves - see previous page
H-6745 00 MKB 000 81 DC _ A 96 of 118

abcd K 09-01 en 11
HTAE 60031
6 Turbogenerators: A.C. voltage tests on winding connections and terminal

leads
6.1 Connections without earthed surfaces
All winding and terminal lead connections of machines with acceptance test voltages UAP ≥ 37 kV
are to be tested individually before installing in the stator with the test voltage listed on the next
page in Diagram 3.
For testing, the connection conductors must be provided up to the distance l from the insulation end
(see next but one page, Diagram 4) with an earth electrode, e.g. made of aluminum foil which must
be widely wound with binding wire. In order to avoid surface discharges the connections must be
coated with overhang stress grading over the entire length.
6.2 Winding connections in compact version without grounded surfaces
The test refers to the connection groups which are manufactured, assembled and cured outside the
machine (compact connections).
• Testing phase against phase
Test in each case one input and output of one phase (according to drawing) against the remain-
ing outputs and inputs to be grounded with 1.25 • UAP for 1 minute.
Apply insulating barriers (plate material made of Hgw, Nomex etc.) to all uninsulated connection
ends if the minimum distances from points of different potential are less than 200 mm.
6.3 Testing of the complete connection unit in the installed condition against frame
Test voltage: 1.3 × UAP; Test duration: 1 min
6.4 Terminal lead connections with earthed surfaces
• Stator winding connections with earthed surface and controlled ends are to be tested, before in-
stalling in the machine for the phase-side connections with 4 × UN and the neutral point side
connections with 3 × UN for 1 minute.
• To the extent connections are put together before the assembly in the stator, these are to be
tested against one another with 1.25 × UAP for 1 minute. In this, all not yet insulated connection
ends are to be provided with insulating barriers (sheet material from Hgw, Nomex, etc.), in case
these ends do not have minimum distances of 200 mm to points of different potentials.
• At test voltages UZP ≥ 80 kV shunt-connected resistors are to be used according to details under
chapter 3 for shunting the control paths.
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HTAE 60031
A.C. voltage test on winding connections and terminal leads

of turbo-generators before installing: Test voltage
(Applicable for MICADUR®-insulated windings with U AP ≥ 37 kV)
56
54
52
50
48
46
44
42
40
38
36
34
32
18 20 22 24 26 28 30
rated voltage UN [kV]
Diagram 3: A.C. voltage tests on winding connections and terminal leads

of turbo-generators before installing: Test voltage
Calculation formula: UP = 1.74 UN + 2.2 kV
H-6745 00 MKB 000 81 DC _ A 98 of 118

abcd K 09-01 en 13
HTAE 60031
A.C. voltage test on winding connections and terminal leads

of turbo-generators before installing: minimal distances conductor/earth
(Applicable for MICADUR®-insulated windings with U AP ≥ 37 kV)
Applied electrode Insulated terminal lead connection
Conductor without insulation
56
54
52
50
48
46
44
42
40
38
36
34
32
160 180 200 220 240 260 280 300
Minimum necessary distance l Earth electrode-conductor [mm]
Diagram 4: A.C. voltage tests on winding connections and terminal leads

of turbo-generators before installing: Minimum distances conductor / earth
Calculation formula: l = 5.5 mm x UP [in kV] –15 mm
H-6745 00 MKB 000 81 DC _ A 99 of 118

=>> ABB Industrie AG HTAE 660145
Responsible department: Take over department: Revision: Doc.-type: File no:
CHIND-IME B 00-02 CQ HTAE 60000
00-02-04 Camastral 00-02 Herzog 00-02 Lanz en 1/2
Valid for: Derived from: Replaces: Classify no: Data set:
same no HTAE\660145en.B__.doc
Manufacturing Instruction (FA)
Conductive varnish LL 16 (Winding overhang varnish) HIFE 450018
Designation text: FA-Cond. varnish LL 16 Documentation no.: HTAE 660145
1 General
LL 16 is a grey, 2-component solvent-containing varnish on a epoxy resin base with voltage-
dependent conductivitiy. It consists of the varnish component with carborundum as the conductive
pigment and the curing component (hardener).
LL 16 is used as conductive varnish for controlling the surface voltage potential, mainly as a stress
grading varnish on stator winding bars and coil exits and winding overhangs of high voltage
machines. Required layer thickness: Min. 50 µm (0.05 mm).
2 Varnish composition
For painting and rolling:
100 parts by mass Varnish component LL 16 HIFE 450018 R ...
10 parts by mass Hardener Härter 103 HIFE 450021 P ...
For spraying purposes:

100 parts by mass Varnish component LL16 HIFE 450018 R ...
10 parts by mass Hardener Härter 103 HIFE 450021 P ...
15 ... 20 parts by mass Verdünner spez 8 NBT 402845 P1
or
15 ... 20 parts by mass Verdünner Universal 3 HZN 453289 P ...
3 Preparing of mixture
The mixing of the components has to be done just before using the varnish. The varnish component
LL16 must be thoroughly stirred before adding the hardener, in order to make sure that no sediment
remains. After having added the hardener, the mixture must be stirred until a homogenous mixture is
obtained.
Attention: the solvent may evaporate due to too long mixing cycles in open containers.
We reserve all rights in this document an in the information contained therein. Reproduction, use or disclosure to third parties
without express authority is strictly forbidden. Copyright © ABB Industrie AG 2003.
HTAE660300 19990319MP
H-6745 00 MKB 000 81 DC _ A 100 of 118

=>>
HTAE 660145
B 00-02 en 2
4 Properties of the mixture
4.1 Pot life
At room temperature (≤23°C), the pot life is maximum 2 hours.
4.2 Curing
According to the corresponding prescription, resp. at least 24 h at 23°C.

To reach quickly a constant resistance value, the object may be cured after 2 h of air drying at 23°C
in an oven:
at 110°C: at least 5 h or at 120°C: at least 2 h
5 Processing
5.1 Application
With brush, roller, spraying
5.2 Remarks
− Both components are supplied normally in cans, both filled up in the right mixing proportion.
− During processing, LL 16 must be stirred frequently in order to prevent the precipitation of
sediments.
− LL 16 must be dried for a minimum of 24 hrs at 23°C before any electrical tests ( or at least 2 h at
120°C)
− For a thorough mixing of the components poured together it is recommended to use a shaking
equipment (for example about 10 minutes in the "Red-Devil" shaking equipment)
− The conductive varnish LL 16 is continuously tested during production and before delivery through
technique insulation system (ABB CHIND, Dept. IME). Therefore, a incoming test of the
components by the end user is not necessary.
6 Storage
The single components may be stored in well-sealed cans at room temperature (≤ 25°C) maximum
12 months.
7 Safety precautions
When working with synthetic resins adequate protection precautions according to local regulations
should be observed and the protection measures acc. to HTZW 23200 should be followed.
H-6745 00 MKB 000 81 DC _ A 101 of 118

ABB ABB Industrie AG HTAE 660146
Responsible department: Take over department: Revision: Doc.-type: File no:
CHIND-IME A 00-02 CQ HTAE 60000
00-02-04 Camastral 00-02 Herzog 00-02 Lanz en 1/2
Valid for: Derived from: Replaces: Classify no: Data set:
same no HTAE\660146en.A__.doc
Conductive varnish LL 17 (slot varnish), HIFE 450019

Designation text: FA - Leitlack LL 17 Documentation-No. : HTAE 660146
1 General
LL 17 is a black, 2-component solvent-containing varnish on a epoxy resin base. It consists of the

varnish component with graphite as the conductive pigment and the curing component (hardener).
LL 17 is used as conductive varnish for slot corona protection in stator windings. Required layer
thickness: min. 50 µm (0.05 mm).
Lng. Status
2 Varnish composition
Rev. Released
For painting and rolling (usual case):

100 parts by weight Varnish component LL 17 HIFE 450019
10 parts by weight Hardener Härter 103 HIFE 450021
A
Type
ND
3 Preparing of mixture
9612 HTAE660146
The mixing of the components has to be done just before using the varnish. The varnish component
Dept. Document No.
LL17 must be thoroughly stirred before adding the hardener component, in order to make sure that
no sediment remains. After having added the hardener, the mixture must be stirred until a
homogenous mixture is obtained.
Attention: the solvent may evaporate due to too long mixing cycles in open containers.
4.1 Pot life
At room temperature (≤ 23°C), the pot life is maximum 2 hours.
4.2 Curing
According to the corresponding prescription, resp. at least 24 h at 23°C. To reach quickly a constant
resistance value, the object may be cured after 2 h of air drying at 23°C in an oven:
at 110°C: at least 5 h or
at 120°C: at least 2 h
We reserve all rights in this document an in the information contained therein. Reproduction, use or disclosure to third parties
without express authority is strictly forbidden. Copyright © ABB Industrie AG 2002.
HTAE660300 19990319MP
H-6745 00 MKB 000 81 DC _ A 102 of 118

ABB A 00-02 en 2 HTAE 660146
5 Processing
5.1 Application
With brush or roller. The varnish has to be stirred during processing to prevent the precipitation of
the pigment.
The varnish may be sprayed only in exceptional situations. Only small insulation pieces may be
sprayed only in well ventilated spraying cabinets.
Composition for spraying:

100 parts by weight Varnish component LL17 HIFE 450019 R ...
10 parts by weight Hardener Härter 103 HIFE 450021 P ...
15 - 20 parts by weight Verdünner spez 8 NBT 402845 P1
or
15 - 20 parts by weight Verdünner Universal 3 HZN 453289 P ...
5.2 Remarks
• Both components are supplied normally in cans, both filled up in the right mixing proportion.
• During processing, LL 17 must be stirred frequently in order to prevent the precipitation of

sediments.
Lng. Status
• LL 17 must be dried for a minimum of 24 h at 23°C before any electrical tests (or at least 2 h at
120°C)
• For a thorough mixing of the components poured together it is recommended to use a shaking
Rev. Released
equipment (for example about 10 minutes in the "Red-Devil" shaking equipment)

A
• The conductive varnish LL 17 is continuously tested during production and before delivery through
Type
ND
ABB Industrie AG, Dept. IME. Therefore, a incoming test of the components by the enduser is not
necessary.
9612 HTAE660146
Dept. Document No.
6 Storage
The single components may be stored in well-sealed cans at room temperature (≤ 25°C) for
maximum 12 months.
should be observed and the protection measures acc. to HTZW 23200 should be followed.
H-6745 00 MKB 000 81 DC _ A

UM660300P4
103 of 118
Dept. Document No. Type Rev. Released Lng. Status
9612 HTAE660520 CQ - 2003-03-03 EN Approved
H-6745 00 MKB 000 81 DC _ A

104 of 118
TEDH5 / ICC _ 04-08 CQ HTAE 660117
04-08-17 Keser 04-08 Widmer 04-08 C.-E. Stephan en 1/1
HTAE\660556en.___.doc
Resin combination SI 628, HIME 450348
Designation text: FA Resin comb SI 628 Documentation no.: HTAE 660556
1 General
Resin combination SI 628 is made of basic resin SI 52 and the hardener 105. It is a castable, cold-
to hot-curing silicone elastomer, used as filler material mainly for round-packing.
2 Ingredients
9 parts by weight Basic resin SI 52 HIFE450070P
1 part by weight Hardener 105 HIFE450071P
3 Mixture
Lng. Status
Mix the two components and stir thoroughly until a homogenous mass in produced.
Rev. Released
4 Pot life
>2d at –15 °C
-
or 4h at 5 °C
Type
CQ
or 2h at 15 °C
or 70 min at 23 °C
or 30 min at 30 °C
9612 HTAE660556
Dept. Document No.
5 Curing
at least 12 h at 23 °C
or 1h at 35 °C
or 20 min at 70 °C
or 10 min at 100°C
or 5 Min. at 150°C
6 Safety measures
During mixing and processing safety measures as per HTZW 23200 must be observed.
7 Validity
This prescription is valid from the date of issue.
H-6745 00 MKB 000 81 DC _ A 105 of 118

TSDXH / ICC A 05-05 CQ HTAE 60000

05-05-12 Keser 05-05 Hutter 05-05 Carl-Ernst Stephan en 1/2

same no HTAE\660569en.A__.doc
Resin combination EP 214; HIME455145 (cold curing, filled pad varnish)
Designation text: FA-resin comb. EP 214 Documentation no.: HTAE 660569
1 General
EP 214 is a filled, solvent-containing cold curing resin combination. The product is used to
impregnate PETP fleece.
2 Resin composition
Lng. Status
18.7 g Basic resin EP 03 NBT 401839

21.8 g Acetone NBT 400407
Rev. Released
50.1 g Filler 69 HZN 451493

9.4 g Hardener 30 NBT 401842
A
Type
100.0 g Total
CQ
9612 HTAE660569
Dept. Document No.
3 Production of resin combination

The 4 components have to be mixed in the above-mentioned order.

• Pot life at a temperature < 30°C: approx. 6 hrs.
• Curing (soaked fleece and installed): approx. 24 hrs.
• The filler sediments quite rapidly after the mixing.
5 Processing
The resin combination has to be painted on both sides of the fleece. It has to be ensured that the
fleece is soaked completely with the resin.
The resin has to be stirred frequently during processing since the filler sediments quite rapidly
Safety measures for processing according to HTZW 23200.
without express authority is strictly forbidden. Copyright © 2005 by ALSTOM (Switzerland) Ltd.
H-6745 00 MKB 000 81 DC _ A 106 of 118

abcd HTAE 660569
A 05-05 en 2
6 Storage
The resin combination should not be stored more than 6 hrs in closed container after mixing.
Single components to be stored acc. to HTZW 23175:
• EP 03: 6 years (≤ 25°C)
• Hardener 30: 3 years (≤ 25°C)
7 Safety measures
Follow local safety regulations for blending and operating of this resin combination and meet
protection measures according to HTZW 23200.
Lng. Status
Rev. Released
A
Type
CQ
9612 HTAE660569
Dept. Document No.
H-6745 00 MKB 000 81 DC _ A 107 of 118

=>> ABB Industrie AG HTZW 23204
Responsible department : Take over department : Revision : Doc.-type : File no.:
CHIND-IME C 98-08 CQ HTAE 660117
Prepared : Checked : Approved : Language Page :
98-08-03 Hutter 98-08 Gasparini 98-08 Lanz en 1/1
Valid for : Derived from : Replaces : Classify no.: Data set :
same no. HTZW \23204EN.C__
Manufacturing Instruction (MI)
Resin combination EP 139, GMN 598100 R211; (Cold-curing bandaging resin)
Designation text: MI - Resin comb EP 139 Documentation no.: HTZW 23204
1 General
The resin combination EP 139 is an unfilled, cold-curing epoxy resin containing solvent. Application:
Mainly as brushing resin for insulating connection lugs, winding connections and phase bus bars with
narrow space conditions.
2 Formulation
100 parts by weight Grundharz EP 03 NBT 401839
50 parts by weight Härter 30 NBT 401842
10 parts by weight Acetone(chemicaly pure) NBT 400407
3 Mixture
Pour the three weighed components together and mix thoroughly.
4 Processing
Pot life approx. 4 hours at 18°C to 23°C
Curing approx. 24 hours at 18°C to 23°C
5 Storage
The single components acc. to HTZW 23175.
should be observed respectively acc. to HTZW 23200 should be followed.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden. Copyright © ABB Industrie AG 2003.
UM660300
H-6745 00 MKB 000 81 DC _ A 108 of 118
H-6745 00 MKB 000 81 DC _ A 109 of 118
H-6745 00 MKB 000 81 DC _ A 110 of 118
abcd ALSTOM Power HTWT620280
Responsible department: Take over department: Revision: Doc. type: File no.:
9461 - CQ
2004-02-12 krathkl 2004-02-18 kraant1
2003-12-01 kraros14 en 1/3
Valid for: Derived from: Replaces: Data set:
Manufacturing Instruction
Wedging of Stator Winding with Parallel Wedge and Ripple Spring
1. Application
This manufacturing instruction is valid for all electrical machines, in which the stator
winding is wedged with parallel wedges and ripple spring.
2. Tools and Consumption Material

Lubricant Vidax GMN 598026 P0351
Nylon Hammer ∅ 40mm
Wedging Tool GMN 590534 P--- Industrial Laminated, Hard Fabric, Hgw 37,5
3. Determination of Prestress for Ripple Spring

Lng. Status
Rev. Released
-
Type
CQ
9461 HTWT620280
Dept. Document No.
thickness unpressed (2.65 mm)

- material thickness (0.90 mm)
-------------
= (1.75 mm)
prestress = 0.85 x 1.75 mm = ca. 1.5 mm
4. Wedging of Stator Winding

4.1 General
The stator bars or stator coils are installed in the stator slots according to the drawing
(“Round Packing“ or “Side Filler“ method).
By the “Round Packing“ method, the stator bars or stator coils must be wedged within the
gel time of the “Round Packing“ compound.
express authority is strictly forbidden.  ALSTOM 2004
H-6745 00 MKB 000 81 DC _ A 111 of 118

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HTWT620280
4.2 Wedging Directions

Electrical machines with horizontal shafts, and a stator core length of < 2 meters, should
be wedged from the non-connection side to the connection side of the winding.
Electrical machines with horizontal shafts, and a stator core length of ≥ 2 meters, should
be wedged from the center of the stator core in both directions.
Electrical machines with vertical shafts must be wedged from the driven end side to the
non-driven end side.
4.3 Determination of spacer thickness
For the determination of the spacer thickness, one ore more of the spacers are used as a
gauge.
Protection strip is fixed to the stator bar (length of slot)
Wedge, ripple-spring, and sliding strip must be installed in the stator slot, according to the
left drawing below.
Insert the spacers between ripple-spring and sliding-strip, until the ripple spring is slightly
Lng. Status
pressed.
Remove the spacers and determine the necessary thickness of the spacers as follows:
Rev. Released
prestress of ripple spring (1.5 mm)

+ thickness of gauge (1 … 1.5 mm)
- thickness of counter wedge (2.5 mm)
-
Type
CQ
-----------------
necessary thickness spacers = (0 … 0.5 mm)
=======
9461 HTWT620280
Dept. Document No.
whereas prestress of ripple spring is calculated according to paragraph 3.
For the first wedge only, add additional ca. 0.2 mm spacers, to insure that the bars are
firmly pressed into the slot
H-6745 00 MKB 000 81 DC _ A 112 of 118

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HTWT620280
4.4 Wedging
Insert the necessary spacers between the sliding strip and the protection strip. Lubricate
the counter-wedge with lubricant and drive it in its final position (flush with wedge) by using
the wedging tool and the Nylon hammer.
Make sure that the chamfered side of the counter wedge is on the side of the bar.
In case, there is not enough space to apply a sliding strip, do the following:
Insert the nessary spacers between wedge and ripple spring and drive the counter wedge
in its final position (flush with wedge) by using the wedging tool and the Nylon hammer.
Make sure that the chamfered side of the counter wedge is on the side of the bar.
See drawing below.
Lng. Status
Rev. Released
-
Type
CQ
9461 HTWT620280
Dept. Document No.
H-6745 00 MKB 000 81 DC _ A 113 of 118

=>?@
Responsible department: Take over department:
ALSTOM Power
Revision: Doc. type:
HTWT600018
File no.:
9461 C CB
2003-02-05 krabeka 2003-02-05 krabeka
2003-02-06 kraros14 en 1/4
Valid for: Derived from: Replaces: Data set:
DELIVERY INSTRUCTION
Manufactoring, classification and packing of rim lamination sheets
1. Objective
Ensure that all rim lamination sheets are manufactured according to

drawing in order to guarantee the assembly of the rotor rim.
The rim lamination sheets have to be duly protected against rust, and
sorted, marked and packed according to weight-classes.
Lng. Status
2. Scope
All rim lamination sheets which are punched or laser-cut.

Rev. Released
C
3. Responsibility
Type
CB
The supplier is responsible for the correct execution.

9461 HTWT600018
Dept. Document No.
4. Manufacturing
4.1 General conditions
Gloves must be worn all the time by working with the rim lamination sheets
and/or base material to prevent hand injury and corrosion initiated by hand-
sweat.
The pilot production for rim lamination sheets can be started only after successful
sample approval of all order-positions. It requires a pilot production approval
by the customer (notification min. 1 week before acceptance inspection).
The series-production for rim lamination sheets can be started only after suc-
cessful approval of the stacked sample rim. It requires a series-production ap-
proval by the customer (notification min. 1 week before acceptance inspection).
The supplier of rim lamination sheets is responsible for the sample approval and
the continuous production checks. The punched or laser-cut rim lamination
sheets have to be packed continually in order to prevent corrosion.
express authority is strictly forbidden.  ALSTOM 2003
H-6745 00 MKB 000 81 DC _ A 114 of 118

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HTWT600018
4.2 Sample approval of the first rim lamination sheets of all order positions with
acceptance inspection and pilot production approval by the customer
- Manufacturing of 3 rim lamination sheets of all order positions
- Checking the 3 rim lamination sheets:
ù Flatness according to drawing
ù Burr height according to drawing, checking of bore diameter with dowel pin
(the dowel pins must be supplied by the rim lamination sheets manufacturer)
the dowel pin diameter = bore diameter minus 0.10 mm
ù Laser starting points not in claws area
ù Rim lamination sheet symmetry with a turned around rim lamination sheet
between two others, lying in normal position (if possible)
ù Dimensional check with precision measuring instruments, acc. to drawing
ù Measuring of all dimensions of the 3 rim lamination sheets, according to
drawing, with a coordinate-measuring machine or with a scanner.
The origin of coordinate is marked on the drawing.
- Correction of the laser-program, respectively adjusting of the punching tools,
must be carried out, if the measurements are out of tolerances.
In this case, the above mentioned works by pct. 4.2 have to be repeted.
Lng. Status
The pilot production can be started only after the successful sample approval of every
order position and submitting the measurement records to the customer.
Rev. Released
4.3 Sample approval of the stacked sample rim (pilot production of all order posi-
C
tions) with acceptance inspection and series-production approval by the cus-

Type
CB
tomer
The sample rim guarantees the assembly of the rotor rim, including interlacing of the
rim lamination sheets according to drawing.
9461 HTWT600018
Dept. Document No.
The production of rim lamination sheets can be started only after the successful
approval of stacked sample rim.
Performed by rim lamination sheets manufacturer: manufacturing of the sample rim,

as following:
ù Levelness (max. permissible deviation 2 mm on the whole surface)
ù The sample rim must be stacked with 1 lamination sheet per layer. The
interlac ing of each individual layer must be carried out acc. to drawing. The
stacking of stacking of the sample rim is completed, when the interlacing
sequence of the layers repeats. The rim lamination sheets have to be stacked with
4 stacking pins per lamination sheet.
Performed together with the customer: sample rim checking, as following:

ù Erection of sample rim : check for correct interlacing of rim lamination sheets
ù Flatness of the whole sample rim
ù Lamination sheets alignment with dowel pins into the bores for the press bolts,
it must be possible to stick through the bolts effortlessly
(dowel pin diameter = bore diameter minus 0.10 mm)
ù Measuring of inside diameter of the simple rim (radial measuring with fix center),
3 diameters equal espaced checks pro lamination sheets
ù Complete profile checking of the sample rim, special attention must be paid to
the axial slots for pole claws and rim keys.
ù Recording of measuring results
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4.4 Series-production of the rim laminations sheets

The series-production can be started only after the successful approval of the sample
rim by the customer.
Continuous checking during the production for all order positions:

- 100% congruency of the rim lamination sheets , stack of rim
lamination sheets aligned by stacking pins
- Dimensional control of rim lamination sheets on random sampling basis, in
order to guarantee the dimensional requirements:
ù Burr height according to drawing
ù Flatness according to drawing
ù All dimensions of rim lamination sheets according to drawing
- No corrosion
These checks have to be recorded and submitted to the customer.

5. Classification
Lng. Status
Every order position must be classified by the manufacturer and every rim
lamination sheet have to be weighed and sorted into weight classes.
Rev. Released
Class 1 White:
C
Type
CB
Rim lamination sheets weight < Nominal weight - 0.3 kg
Class 2 Yellow:
9461 HTWT600018
Dept. Document No.
Nominal weight - 0.3 kg ≤ Rim lamination sheets weight< Nominal weight - 0.1
kg
Class 3 Red:
Nominal weight - 0.1 kg ≤ Rim lamination sheets weight< Nominal weight +

0.1kg
Class 4 Green:
Nominal weight + 0.1 kg ≤ Rim lamination sheets weight< Nominal weight + 0.3 kg
Class 5 Blue:
Rim lamination sheets weight ≥ Nominal weight + 0.3 kg
Every rim lamination sheet has to be marked with the corresponding colour at the
edge of cut of the outside radius.
The rim lamination sheets have to packed separately according to the weight classes.
H-6745 00 MKB 000 81 DC _ A 116 of 118

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HTWT600018
6. Packing
The stacking rim lamination sheets have to be packed according to Alstom

Working Instruction HDST 600688 and project specifications.
Without any special requirements, the boxes, lined with corrosion inhibitor paper,
have to contain stacks of rim lamination sheets with approx. 600 mm height
and max. 1500 kg weight.
For seaworthy packings special conditions apply, they must be laid down
in the purchase order.
Every crate must contain only one weight-class and one order position of
rim lamination sheets.
Rim lamination sheets of different Units (Generator 1, 2, etc) must be packed

separately.
Lng. Status
On the outside of the crate has to be printed the order number, the order
position, the color code according to weight-classes as well as the machine No.
Rev. Released
C
Type
CB
9461 HTWT600018
Dept. Document No.
H-6745 00 MKB 000 81 DC _ A 117 of 118

Rev.: A
MECHANICAL TESTS AND BALANCING
23. MECHANICAL TESTS AND BALANCING
OPERATIONS:
• Install sensors and recorders for balancing tests on both generator bearings.
• Test rotor balancing.
• Insert balancing weights as required by measurements according to drawing.
• Ensure that weights are firmly in position prior any run test.
• After over speed tests, check the keying of the poles, rotor rim, etc… (Refer to the instruction manual).
• After final balancing test, weld all balancing weights.
H-6745 00 MKB 000 81 DC _ A 118 of 118

H-6745 00 MKB 000 81 DC

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POWER SYSTEMS

REV PREPARED CHECKED APPROVED DATE MODIFICATIONS STAT.

H-6745 00 MKB 000 81 DC _ A 2 of 118

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

4. STATOR FRAME, CORE ASSEMBLY AND WINDING

6. ASSEMBLY OF UPPER BRACKET IN ERECTION BAY

7. INSTALLATION OF LOWER BRACKET

8. ASSEMBLY OF LIFTING / BRAKING JACKS AND ITS PIPING

9. PREPARATION OF PIT FOR STATOR ERECTION

10. LOWERING OF LOWER SHAFT

11. INSTALLATION OF STATOR AIR COOLER AND ITS PIPING

12. INSTALLATION OF PHASE AND NEUTRAL CONNECTION AND GUARDS

13. INSTALLATION OF UPPER BRACKET

14. INSTALLATION OF THRUST BEARING ASSEMBLY

15. ASSEMBLY OF UPPER GUIDE BEARING

16. INSTALLATION OF LOWER GUIDE BEARING PIPING

17. INSTALLATION OF COLLECTOR RING AND CONNECTION WITH FIELD WINDING

18. INSTALLATION OF UPPER AND GUIDE BEARING PIPING

19. INSTALLATION OF FIRE PROTECTIONS & INSTRUMENTATIONS

20. INSTALLATION OF FLOOR AND COVERS

21. INSTALLATION OF MISCELLANEOUS DEVICES.

22. CHECKS BEFORE GENERATOR OPERATION

23. MECHANICAL TEST AND BALANCING

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

• ANNEXURE 2 - HTWT 620242

• ANNEXURE 3 - HTWT 620172

• ANNEXURE 7 - HTAE 60031

H-6745 00 MKB 000 81 DC _ A 4 of 118

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

This document is applicable for HULU TERENGGANU HYDROELECTIC PROJECT only.

- Prior start of erection works, ensure following safety:

- To be Ensured by TENGA NASIONAL BERHAD:

- Trouble free access to the working fronts.

- Ensure that all the required reinforcement bars are bended.

- No activities should be taken under working fronts to avoid any miss-happening.

- Working fronts should be dry and clean.

- Removal of all naked cables if any around working fronts.

- All the loose material on roof to be removed prior start of erection.

- Advance information to be given in case of any blast or radiography.

- No gas cylinders near generator area to avoid any fire hazard.

- Noise and pollution to be controlled as per standard.

- All the dangerous area to be marked properly.

- No blast in the vicinity.

- All the opening to be plugged and fenced.

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

Client is to ensure all benchmarks. Unit axis, X & Y and Elevation

H-6745 00 MKB 000 81 DC _ A 6 of 118

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

4. STATOR FRAME ASSEMBLY , CORE AND WINDING

4.1 ASSEMBLY OF STATOR SEGMENTS

• Remove the packing material from service bay.

H-6745 00 MKB 000 81 DC _ A 7 of 118

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

H-6745 00 MKB 000 81 DC _ A 8 of 118

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

MR 3 ADJUSTMENT OF KEY BARS BEFORE WELDING

H-674500MKB12000TC STATOR CORE ASSEMBLY

H-6745 00 MKB 000 81 DC _ A 9 of 118

HULU TERENGGANU 2 x 125 MW 147 MVA – 214.3 rpm

4.2 PREPARATION OF STATOR PARTIAL WINDING IN SERVICE BAY.

4.2.1 PREPARATION OF TEMPORARY TOOLS

• Prepare the dust free closed chamber for winding.

• Prepare temporary device for elevation setting of bars.