OPERATING AND MAINTAINNING

INSTRUCTION
FOR TURBO-GENERATORS
OF WX21Z SERIES

0JS461397

TRANSLATOR
CORRECTOR

SHANDONG JINAN POWER EQUIPMENT FACTORY

THE PEOPLES REPUBLIC OF CHINA

JPEF

Operating and maintaining Instruction

Code

0JS.461.397

For Turbo-generators of WX21Z Series

Total 14

The 0th

Content
Introduction
1. Operating instruction
2. Maintaining instruction
3. Overhaul content
3.1 Stator maintenance and overhaul
3.2 Rotor maintenance and overhaul
3.3 Pedestal bearing maintenance and overhaul
3.4 Air-coolers maintenance and overhaul

JPEF

Operating and maintaining Instruction

Code

0JS.461.397

For Turbo-generators of WX21Z Series

Total 14

The 1st

Introduction
The instruction was worked out according to original instruction for WX
series air-cooled turbo-generator of ABB. It can be divided into two parts for
convenience.
The first part, whose code is 0JS.461.401C, is the INSTALLING
INSTRUCTION consisting of General, Installation site and working
conditions, Structure introduction, Installation etc.. The second part is the
OPERATING

AND

MAINTAINNING

INSTRUCTION,

which

is

described in detail as follows:

1. Operating instruction
1.1 The generators of this series are all three-phase, two-pole, synchronous
generators with static excitation systems. Driven by steam turbines, no
special restrictions are applied on the start-up and shutdown of them except
those on the start-up and shutdown of the turbines.
1.2 During normal operation, the load of generator is adjusted by automatic
voltage regulator (AVR) matching with the generator. The use of AVR is
described in the Operating instruction for AVR. The generators are capable
of continuous rated output with the stator voltage being (1005)% of the
rated value and the exciting current not exceeding the rated value.
1.3 During operation, the voltage regulating, switching on or off, putting the
generator into grid, load regulating etc. shall be carried out according to the
corresponding specifications in the Operating rules for power.
1.4 Besides the normal operation stated above, there are still some points needed
to be noted:
1.4.1 To protect the generator rotor windings from overheating, the exciting
current must be less than rated value during lower power factor operation.
1.4.2 If the generator operates with the three-phase load out of balance, the
current of each phase should not be larger than the rated stator current
(IN) and the ratio (I2/IN) of negative sequence current component (I2) to

the rated current (IN) should be no more than 8%.

1.4.3 The operation time should be less than 30s if the stator current is 1.5
times of the rated value. Such case should not occur more than two times
per year.
1.4.4 The permissible value of the negative sequence current and the
corresponding duration time may be obtained from the following
formula:
(I2/IN)2 . t=10
where INstator rated current . ttime , in seconds .

JPEF

Operating and maintaining Instruction

Code

0JS.461.397

For Turbo-generators of WX21Z Series

Total 14

The 2nd

1.5 The generator may be put into trial operation if it has been installed and
has passed the inspection. For the sake of safer and more reliable
operation, please carry out the following checks before starting.
1.5.1 Measure the insulating resistance of the electrical parts to see if they
meet the requirements or not.
1.5.2 Make sure if the wiring of the electrical circuits is correct and reliable
or not (no short circuit, looseness, etc. should exist).
1.5.3 Make sure if the switches can work correctly and reliably and the
protecting settings of relays meet the requirements.
1.5.4 The air circuit of the cooling system as well as the generator and the
chambers for air coolers must be sealed well. In order to prevent the
entrance of outer dust, please re-check the sealing condition after the
starting of generator.
1.5.5 Check the oil circuit and ensure it clean and unblocked.
1.5.6 Check the clamp bolts in the foundation or for the end covers, bearings,
etc. again to see if they have been fastened well.
If the generator successfully passed the checks mentioned above, then
it may be started.
1.6 Pay attention to the following points when starting the generator.
1.6.1 All the switches in electrical circuits should be in their normal state,
that is, the ones that should be switched off should be switched off
(e.g.: the switches in buses, etc.), the ones that should be switched on
should be switched on (e.g.: the switches for the control source,
measuring meters, etc.)
1.6.2 Switch on the oil circuit. The lubricating oil pressure, which is
0.15MPa before going into the bearings, becomes 0.08MPa after going
into the bearings. (Watching the pressure gauge mounted on the flange
cap against the inlet oil pipe.) When the oil pressure is lower than
0.15MPa at the inlet and lower than 0.08MPa in the bearings, the inlet

oil hole of the limiting oil plate should be enlarged to make the oil
pressure reach 0.08MPa in the bearings. Located between the flange of
inlet oil pipe and the flange of bearing oil inlet, the limiting oil plate
can be removed by dismantling the clamp bolts for the flange at oil
inlet. If the high pressure jacking oil unit for rotor has been adopted, it
should be started when the oil pressure reaches 1030MPa. After the
barring has been finished, the unit may be shut off (Whether there is
high pressure jacking oil unit for rotor or not depends on the starting
requirements of the turbine).

JPEF

Operating and maintaining Instruction

Code

0JS.461.397

For Turbo-generators of WX21Z Series

Total 14

The 3rd

1.6.3 Monitor the vibration of bearings during the run-up of generator.

Normally its value is no more than 0.05mm. As larger vibration may
appear when the generator operates at the critical speeds, please run
through those speeds quickly.
1.6.4 During the course of stepping-up and rated operation, the inlet and
outlet oil temperatures should be monitored from time to time to keep
the inlet oil temperature lower than 45 and outlet oil temperature
lower than 70. The oil pressure in bearings shall be no less than
0.05MPa.
1.7 The electrical measurement and the bringing into operation of the
generator etc. should be carried out according to the operation rules
drawn up from the Power operation instruction, this instruction as well
as the technical data supplied together with the generator we supplied
etc..
1.8 The data we supplied for each generator include the electrical data, the
capability curve, the drawings supplied together with the generator, the
ex-works, etc..
1.9 For the technical requirements that are not specified in this instruction,
please see relevant sections in GB/T 7064 Requirements for turbine type
synchronous machines or IEC34-3 Technical requirements for turbinetype synchronous machines.
2. Maintaining instruction: It is necessary to maintain the generator for safe
and reliable operation. In order to help power plants carry out the job
successfully, the following points are recommended for reference.
2.1 Monitoring and maintaining during normal operation.
2.1.1 The generator and its surroundings should be kept clean.
2.1.2 The temperatures of the stator windings, inlet cooling air and outlet oil
of bearing, which should be watched from time to time (one time per
hour), should not exceed the corresponding limits. Were there any

exceeding, measures must be taken.

2.1.3 Bearings and frames should be watched frequently to avoid abnormal
vibration.
2.1.4 When the inlet water temperature of air-cooler is over 33 , the inlet air
temperature of generator is over 40 and the temperature rise of stator
is beyond the upper limit, the load of generator should be reduced to
ensure the stator temperature rise not exceeding the upper limit.
2.1.5 The replacement air filters on the end covers should be inspected
frequently. If there is much dust, the filter materials in them should be

JPEF

Operating and maintaining Instruction

Code

0JS.461.397

For Turbo-generators of WX21Z Series

Total 14

The 4th

cleaned or washed or replaced by new ones. The filter materials may be

removed by only dismantling the caps of the filters. It is not permissible
to dismantle the complete filters from the end covers during the operation
of generator to prevent the entrance of foreign matter.
2.1.6 During normal operation, the abrasion of grounding brushes and
brushes at the slip rings shall be inspected regularly. The abraded ones
may be replaced during the course of operation, but this work must be
done by experimental skilled workers.
2.1.7 The matters, which are found and cannot be solved during operation,
should be recorded and solved during the shutdown or regular overhauls
of the generator.
2.1.8 If the air coolers leak during operation (the float switch acts), checks
should be carried out to identify which cooler leaks, then switch off the
inlet and outlet valves of this cooler. In this case, the load of generator
should be adjusted or the water-flow of other coolers be increased (the
water pressure should be kept below the permissible working water
pressure) to ensure the inlet air temperature of generator not exceeding
40during operation. The fault should be eliminated during the regular
shutdown of generator.
2.2 Regular shutdown for minor overhaul (rotor not removed) and major
overhaul (rotor removed). The time intervals may be decided by the
following recommended formula or chosen from the following chart.
Te=Teff+ns (Ts+20)
Where:
Teequivalent operation hours Teffeffective operation hours
nsnumber of starts

Tstime needed for one start-up

Sequence and intervals of regular overhauls

No. of Overhaul

Value of Te (Hours)

Years of Installation

1st minor overhaul

800012000

Max.4 years

1st major overhaul

2200028000

Max.8 years

2nd major overhaul

4700053000

Max.15 years

2nd minor overhaul

7200078000

Max.20 years

3rd major overhaul

97000103000

Max.25 years

Note: 1. Minor/major overhauls should be carried out alternatively approx. 25000 EOH
(Te) after the third major overhaul.
2. The regular overhauls of generator should be carried out simultaneously with
those of the turbine.

JPEF

Operating and maintaining Instruction

Code

0JS.461.397

For Turbo-generators of WX21Z Series

Total 14

The 5th

2.3 During maintenance, the generator should be dismantled and assembled

according to method listed in the Installing instruction.
2.3.6.1

Overhaul instruction

3.1 Stator maintenance and overhaulDescribed in the following text

3.2 Rotor maintenance and overhaulDescribed in the following text
3.3 Pedestal bearing maintenance and overhaulDescribed in the following
text
3.4 Air-coolers maintenance and overhaulDescribed in the following text
Note: For the details of AVR part, see the Instruction for AVR.
3.1 Stator maintenance and overhaul
Minor

Major Machine Checked Items and Requirements

overhaul overhaul

parts

Winding
End

1) If there is dust on the surface, it shall be cleaned using

vacuum.
2) If there is still some dirt left after cleaning with vacuum,
cleaning agent or gasoline should be used.
3) Check binding ropes for looseness or breaks. If such
phenomenons exist, please replace the old binding ropes
and paint epoxy resin varnish on the new ones and dry
them after fastening them tightly.
4) Check the clamp bolts of winding supports for looseness.
The bolts that are loosened should be re-fastened.
5) Check the connecting joints of cases (combining the
corresponding ends together) and connection wires on the
winding end to see if overheat exists (the changes of
insulation color, etc.). Were there any overheat points, the
corresponding insulation should be cleared to identify
whether the joints are not well welded or the clamp bolts
are loosened. If the joints are not well welded, the oxide
on them should be cleaned first and then re-insulate them
after welding them together properly. If the clamp bolts
are loosened, fasten them tight.

Stator
core

1) Check the wedges for looseness. The looseness may be

eliminated by inserting filler strips under the loosened
wedges or replacing the loosened wedges.

2) If there is dust in the stator core, the upper housing

should be dismantled first, then vacuum may be used to
clean the dust on the inner and outer surface. The
ventilation paths of the core should be cleaned too.
During the cleaning, observe the outer surface of core and
the inner surface of the housing to see if there are

abnormities in welding seams, seal strips etc.).

JPEF
Minor

Major

overhaul overhaul

Operating and maintaining Instruction

Code

For Turbo-generators of WX21Z Series

Total 14

Machine

0JS.461.397
The 6th

Checked items and requirements

parts

Stator
core

3) Observe the teeth to see if there are overheat points (where

the surface varnish changes black). Such overheat points
are formed due to short circuit between silicon steel
segments caused by the damage of the insulation on the
silicon steel segments in the teeth part. If overheat points
are found, insulating varnish or insulating sheets should be
poured or inserted between the silicon steel segments. The
thickness of the insulating sheets should be 0.1 0.2mm
and it should be wide enough to be pressed by the wedges
to avoid emersion.
If it is convenient, iron loss test should be carried out by
qualified personnel to verify if the overheat points have
been eliminated.

Stator
windings

1) Measure the DC resistance of every phase: If the

difference between the measured value and test value
(measured before leaving the factory) or the value
measured when installed exceeds 2%, the cause should be
found and eliminated. The test values are measured at the
end of terminals when leaving our factory. For
convenience of comparison, power plant should measure
these values at the same points.
2) Measure insulating resistance : If the insulating resistance
measured with 2500V M megger (hand-cranked megger)
is lower than 1M per 1000V (calculated according to the
rated voltage of generator) at common temperature (about
20) , the reason that leads to this condition should be
analyzed and absorptance test should be carried out. If the
absorptance is less than 1.3 , it may be caused by humidity
and should be dried to make the insulating resistance no
less than 3M per 1000V .
3) Withstand voltage test: Only when the insulating resistance
reaches the above requirements, the withstand voltage test
may be carried out. The AC withstand voltage should be
lower than 1.5 times of rated stator voltage, while the DC
withstand voltage should be lower than 2.5 times of the
rated stator voltage. During the course of this test, the
corresponding safety rules must be obeyed to avoid body
electric shock etc..

Resistance 1) Using a 250V hand-cranked megger measure the

temperature
detector

insulating resistance , the measured value should be higher

than 0.5 M .

2) Verify the DC resistance of temperature detector Pt100 :

the value should be (1000.2) at 0.

JPEF
Minor

Operating and maintaining Instruction

Code

For Turbo-generators of WX21Z Series

Total 14

Major

overhaul overhaul

Machine

0JS.461.397
The 7th

Checked items and requirements

parts

Resistance 3) Take out the discharge protector for resistance temperature

temperature

detectors from the measuring terminal box on the frame

detector

and check it with 250V hand-cranked megger. If it cannot

be broken down, it is in good condition.

Air filters

The filter materials of the air filters on end covers should be

taken out to be cleaned or replaced by new ones.

Recheck the
operation

Check and eliminate the problems recorded during operation.

records

Stator core If the paint on the surface is broken off seriously, it should be
and
windings

re-painted with self-dry epoxy resin magnetic paint [e.g.: 1361

(H31-31)].

3.2 Rotor maintenance and overhaul

3.2.1 Before removing the generator rotor in major overhaul, all the fan blades
shall be taken off from the axial fans. The special tools and method used to
withdraw the rotor are listed in the installation instruction whose code is
0JS.461.401. During minor overhaul (the rotor is not drawn out), only the
upper bearing pedestal and the upper inner and outer covers need to be
dismantled. The lower part of inner and outer covers shall be dismantled
only when it is necessary.
Minor
overhaul

Major

Machine

overhaul

parts

Checked items and requirements

Fan blades 1) Clean the dust, oil pollutants and corrosion on the surface

and
retaining
rings

of them.
2) Check blades, retaining rings and other parts to see if there
is scars on the surface and the angle of blades have
changed.
3) Check the fastening nuts below the blades to see if they
have been loosened. Were there any looseness, please
fasten them with a torque wrench.
4) The stop screws (shown in fig.3-1.) should be tightened
with a torque of 100Nm applied by a socket head cap
screw torque wrench.

Windings

1) The insulating resistance of rotor windings, measured by a

hand-cranked megger (lower than 500V) at the slip rings
on the non-drive end, should be larger than 0.5M. During
the course of the measuring, the diodes or the two slip
rings should be short-circuited to protect the diodes from
being destroyed.
2) Measure the DC resistance: The difference between the
measured value and test value (measured before leaving
the factory) or the value measured when installed in power

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Minor

Operating and maintaining Instruction

Code

For Turbo-generators of WX21Z Series

Total 14

Major

Machine

overhaul

overhaul

parts

Windings

0JS.461.397
The 8th

Checked items and requirements

plant should not exceed 2%. If there are rectifiers, the

polarity of the meters and the slip rings should be
identical.

Journal

Check the surface between the journal and the bearing bush to
see whether there are scars on it.

DE
coupling

1) Check the surface of flange to see whether there are cracks

or scars on it.
2) Check the connecting bolts to see if they are loosened.

Rotor

1) Clean the dust and dirt on the surface of rotor body etc..
2) Check the screws on the wedges to see if some of them
have projected out of the surface of wedges. Were there
any projections, the corresponding screws should be
screwed to below the surface of wedges and fixed by
punching.
3) As the generator is cooled by a closed cycle air-cooling
system, the cooling air entering the rotor windings is free
of dust (thus the ventilating ducts are seldom affected by
dust. Despite of this, the air outlets in the wedges should
still be checked and cleaned because slight dust may still
enter the generator due to un-tight sealing. If the air outlets
are seriously covered with dust, please clean them
according to fig.3-2.
4) Check the surface of retaining rings and fan blades to see
whether there are cracks or scars on them. Carry out the
check with die dialysis method if necessary.
5) Check the surface of journals and shaft couplings to see
whether there are cracks or scars on them.
6) Check the paint on the surface, clean and re-paint it if it is
broken off seriously.

JPEF

Operating and maintaining Instruction

Code

0JS.461.397

For Turbo-generators of WX21Z Series

Total 14

The 9th

Fig. 3-1 Installation of the fan blades

A Label of the fan blades D Rotor shaft
1 Fan hub 2 Fan blades 3 Nut 4 Stop screw 5 Stop screw
6 Washer 7 Anti-movement washer 8 Hex nut

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Operating and maintaining Instruction

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0JS.461.397
The 10th

Fig. 3-2 Drawing of wind road for cleaning

the dust in rotor windings conductors

1. Blow clean and dry compressed air (0.6 MPa 1MPa) into every
ventilation hole in the rotor wedges to clear the dust in the linear holes of
the conductors. Conduct the compressed air into one of the ventilation slots
(shaped like a crescent moon) on both sides of the big tooth to clean the
dust in the conductors of the end windings while blocking the other
ventilation slots (This method can only be carried out with the existence of
retaining rings).
2. The dust will be blown out from the space between retaining ring plate and
the shaft. To protect other parts from being polluted, a vacuum is
recommended to be used to collect the dust at the vent.

JPEF

Operating and maintaining Instruction

Code

For Turbo-generators of WX21Z Series

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0JS.461.397
The 12th

3.3 Pedestal bearing maintenance and overhaul

Minor

Major

Machine parts

Checked items and requirements

overhaul overhaul

High pressure Check the joints and oil pipes by applying a certain oil
oil pipe and

pressure to see if they leak.

joints

Bearing
metal

1) Check the surface of bearing metal to see whether there

are scrapes or not.
2) Measure the inner diameter of bearing bush. If it has
exceeded the diameter of journal by 2, measures must
be taken.
3) Check the cohesiveness of the wolfram lining to the
bearing bush by supersonic wave test and dye
permeation test if necessary.

Bearing

Check the insulation between the bearing and bearing

insulation

pedestal. If short-circuit occurred, the following points

should be checked:

1) Check the insulating pads between the bearing ring and

bearing pedestal to see if they are all right.

2) Check the insulating washer in the joint between the

high-pressure oil pipe and bearing ring to see if it is all
right.

Inner and

Check the abrasion of oil baffle plates inner holes. By

outer oil

measuring their diameters. If the dimension is 0.6mm

baffle plates

larger than that of the journal, the corresponding oil baffle

plate should be replaced. (The new plate, which will be set
in the slot that is 2mm wide and 4mm deep, should be
made according to the old one. After smearing epoxy resin

on it, the new plate is inserted into the slot and its inner
hole machined to a dimension 0.20.3mm larger than that
of the journal.)

3.3.2 Before fastening the bearings , a compression value of 0.03 0.05mm

between the upper cover 1 and bearing block 3 should be left (See fig.3.3-1).
This intention may be realized by the method of pressing lead thread (See
fig.3.3-2). The lead thread 7 whose diameter is 0.5 0.8mm is inserted
between the bearing ring 4 and adjusting plate 5 first, then the clamp bolts
between the upper cover 1 and bearing block 3 are fastened tight so that there
is no gap is left between upper cover 1 and bearing block 3. Loosen the clamp
bolts and take out the lead thread 7. According to the dimension of lead thread
7 before and after compression, you may decide how thick the pad to be
inserted needed to be. E.g.: If the dimension [k] (after compression) is
0.27mm, you may get a compression value of 0.03mm(0.3-0.27=0.03)
by

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Operating and maintaining Instruction

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Total 14

0JS.461.397
The 13th

placing a pad whose thickness is 0.3mm on the adjusting washer 6 that

locates under adjusting plate 5.
3.3.3 If there are clearances between the adjusting plates 8 on both sides and
bearing ring 4 and if the lower adjusting plate needed to be adjusted,
changing the washers under the adjusting plates please. Note that the
changing of washers shouldnt lead to eccentricity of the bearing.

Figure 3.3-1

Figure 3.3-2
3.4 Air-coolers maintenance and overhaul (After the generator has been
stopped)

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Operating and maintaining Instruction

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0JS.461.397
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3.4.1 Clear the dust in air coolers and the cooling room with vacuum.
3.4.2 Check all the sealing carefully to ensure no leakage of the cooling air.
3.4.3 Dismantle the water chamber and check the cooling pipes. If there is rust
in them, clear them immediately to ensure the cooling effection.
3.4.4 Test the float switch to see whether it can act reliably and Check the
liquid level (oil level) below the switch to see if its depth is within the
normal value 80 mm110mm. Besides, check the valve outside of the
drainage to see if it is flexible and the drainage if it is unblocked.
3.4.5 Water pressure test:
If there is no leakage when the water pressure (higher than 1.5 times of the
working water pressure) is applied for 30 minutes, the air coolers are
considered to be qualified coolers. The expanding pipes method must
be used if the leakage points exist between the cooling pipes and
supporting plates bearing the pipes. But if the leakage points exist on
the pipes of coolers and cannot be repaired temporarily, the fault pipes
must be blocked up with wood plugs on both ends. In no case should
more than two pipes leak for one cooler. Plans should be made to carry
out the next repair or replacement for the second case mentioned above,
however, the inlet air temperature should be kept lower than 40
during the operation of the period from the time when the fault appears
to the time it is eliminated.
3.4.6 If the anticorrosive paint on the some parts of coolers has come off, they
shall be cleaned and repainted correspondingly.