Generator Aux

FIELD QUALITY PLAN
FOR
TURBO GENERATOR & AUXILIARIES

(ERECTION & COMMISSIONING)
4 X 250 MW THERMAL POWER PROJECT, RAIGARH

M/s JINDAL POWER LIMITED
DOC No. QPX-TG-001
REVISION 01
REVISION Date 12.01.2007
ISSUED TO: ISSUED BY
DGM (Quality)
BHEL: PSWR: NAGPUR
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR: WESTERN REGION
NAGPUR – 440001
DOC NO.: QPX-TG-001
REV No.: 01
PSWR-QUALITY TABLE OF CONTENTS
REV Date: 12.01.2007
SHEET: 01 OF 01
Sr. No. DESCRIPTION NO. OF SHEETS
1.0 DOCUMENTS REFERRED IN QUALITY PLAN 01
2.0 AUTHORIZATION FOR DIFFERENT CLASSES 01

OF CHECKS AND NONCONFORMITY
DISPOSITION
3.0 STATEMENT OF CHECKS 21
3.1 GENERATOR
3.2 BRUSHLESS EXCITER
3.3 SEAL OIL SYSTEM
3.4 GAS SYSTEM
3.5 WATER PIPING FOR HYDROGEN COOLERS
3.6 STATEMENT OF CHECKS FOR GENERATOR

COMMISSIONING
5.0 LOG SHEETS (L-00 TO L-40). 59

DOC NO.: QPX-TG-001
DOCUMENTS REFERRED REV No.: 01
PSWR-QUALITY
IN
FIELD QUALITY PLAN REV Date: 12.01.2007
SHEET: 01 OF 01
Sr. No. Reference Document Issuing Authority
01 WELDING MANUAL PSWR, NAGPUR

PSQ-WDM-COM REV-00
02 HEAT TREATMENT MANUAL PSWR, NAGPUR

PSQ-HTM-COM REV-00
03 NDE MANUAL PSWR, NAGPUR

PSQ-NDM-COM REV-00
04 GENERATOR ERECTION MANUAL. PSWR, NAGPUR
05 PROCEDURE FOR OIL FLUSHING. PSWR, NAGPUR
06 TECHNICAL INSTRUCTION FOR AIR LEAK PSWR, NAGPUR

TEST OF BUSHINGS
07 ERECTION DRAWINGS. BHEL, HARIDWAR
08 SHOP TEST CERTIFICATES / TEST BHEL, HARIDWAR

PROTOCOLS
DOC NO.: QPX-TG-001
AUTHORISATION FOR CHECKS REV No.: 00
AND
PSWR-QUALITY
NONCONFORMITY DISPOSITION REV Date: 27.04.2006
SHEET: 01 OF 01
Class of Agency Inspection Accepting Agency Disposition Authority
Check Authority
Task performer/ Head of Section Engineering Centre/
CRITICAL BHEL FQA Engineer Head (Quality), PSWR
Task performer Head of Section Engineering Centre/

MAJOR BHEL Head (Quality), PSWR
Task performer Task performer Engineering Centre/

MINOR BHEL Head (Quality), PSWR
LEGENDS
CLASS OF CHECK: A – CRITICAL CHECK, B – MAJOR CHECK, C – MINOR CHECK
TYPE OF CHECK: R – RECORD VERIFICATION, V – VISUAL CHECK,
P – PHYSICAL CHECK, M – MEASUREMENT, T – TEST
NOTE
1. Disposition authority within BHEL shall be as under:
Product nonconformity: Engineering Centre.
Process/System nonconformity: Head (Quality), PSWR.
2. Wherever log sheet is not called for, suitable record shall be maintained in logbook/protocol.
3. In case of nonconformity, accepting authority shall ensure disposition of nonconformity

before acceptance and disposition shall be reflected in log sheet/protocol.
4. QAE (if posted at site) shall witness ‘A’ category checks. He is also authorized to carry out
surveillance in any of B & C category of checks at his discretion.
5. BHEL shall ensure that instruments with valid calibration are used for measurement.
6. Quantum of check shall be 100% for all characteristics unless otherwise mentioned in QP.
MANUFACTURER’S NAME & ADDRESS FIELD QUALITY PLAN
SYSTEM: Turbo Generator & Auxiliaries DOC NO.: QPE: TG 001 CLIENT: M/S JINDAL POWER LTD
REV. NO.: 01 CONSULTANT: M/s D.C.P.L
SUB-SYSTEM: GENERATOR DATE: 12.01.2007 PROJECT: 4 x 250 MW THERMAL POWER
PROJECT, RAIGARH
PS-WR: 345, KINGSWAY, NAGPUR
PAGE: 01 OF 21 CONTRACTOR: BHEL-PS-WR, NAGPUR
Sr. TYPE CLASS QUANTUM / REFERENCE DOCUMENT/ FORMAT OF REMARKS
OF OF FREQUENCY ACCETANCE STANDARD RECORD
No. CHARACTERISTICS / ITEM INSTRUMENT
CHECK CHECK OF CHECK
1.0 Foundation Taking over & Preparation:
1.1 Ensure foundation is clean, and free from oil, Tape B Once Generator Outline Protocol
grease etc., and dimensions are as per drawing. Drawing
1.2 Ensure foundation is free from cracks, surface R B 100% Guidelines BHEL- Protocol / Testing By
defects etc. PS-TS-T-37 dated UT report MSEB.
Note: Review Ultrasonic reports available with 02.03.05, Health
client. checking of TG
foundation.
1.3 Review foundation frequency values measured R B 100% Testing By
by Shaker test at all the crossbeam locations of MSEB.
bearings, and compare with design values.
1.4 Ensure permanent benchmark is made V B 100% Marking By

somewhere outside the TG foundation. MSEB.
1.5 Check elevation at different points on the M B 100% Civil Drawing

foundation with respect to permanent
benchmark.
A– CRITICAL, B– MAJOR, C– MINOR CHECK
R– RECORD VERIFICATION, V– VISUALLY, P– ERECTION
PHYSICAL CHECK, M– MEASUREMENT, T– TEST
REVIEWED APPROVED
BHEL-PSWR, NAGPUR LEGENDS AREA M/s MSPGCL / M/s DESEIN
PROJECT, RAIGARH
2.0 Assembly of foundation plate:
2.1 Ensure that machined surfaces of foundation V -- B Once -- Logbook
plate and base plates are free from corrosion.
Note: Blue match / machine the plate surfaces,
wherever required to get minimum 80% surface
contact area.
2.2 Positioning, elevation, levelling of the foundation M Plumb bob, B 100% Drawing & Turbine Protocol
plates over the foundation. Ensure levelling of Spirit Level, Catenary’s Data.
foundation plate over the base plate with respect Water Level,
to permanent benchmark. Measuring
Tape
2.3 Ensure foundation plate flatness by surface plate M Surface plate / B Once
/ straight edge such that 0.03mm feeler gauge straight edge/
does not pass. Feeler gauge
2.4 Ensure the distance between centre of M Measuring B Once Generator Outline Protocol
foundation bolt holes and centre line of Tape Drawing
generator.
2.5 Ensure that dimensions (including diagonal M Measuring B 100% - do - Protocol

distances) are maintained as per drawing. Tape
REVIEWED APPROVED
PROJECT, RAIGARH
3.0 Placing of Stator on foundation:
3.1 Handling of stator as per manual. V C 100% Erection Manual
3.2 Contact between the footing of the stator and the V B Once
foundation plate not less than 85%.
3.3 After placing the stator, ensure that all the V C Once
packers are loaded/tight properly by slight
hammering
4.0 Record thickness of each shim and the overall M Vernier/ C 100% Logbook
thickness of shims put together. Number of Micrometer
shims should not exceed as specified in drawing.
5.0 Stator Winding:

5.1 Check cleanliness of joining surfaces before V C 100%
assembly of output leads.
5.2 DC resistance and IR value of each phase M Micro Ohm B 100% Shop test certificate L-02
before assembly of output lead. Meter & 1 KV
Megger
5.3 Check all body fasteners for proper locking V B 100% Drawing
including overhang winding.
5.4 Ensure tack welding of tension bolt nuts. V C 100% Drawing

REVIEWED APPROVED
PROJECT, RAIGARH
6.0 Assembly of output leads:
6.1 Check cleanliness of joining surfaces. V C 100%
6.2 Check the fasteners and washers for non- M Magnet B Once Drawing
magnetic property as per drawing.
6.3 Ensure proper flow of soldering material all V C Once
around the joint surface.
6.4 IR value of each phase after assembly of output M 2.5 or 1 KV B 100% L-02
leads. IR should not be less than (KV + 1) M Megger
Ohm at 40o C.
6.5 DC resistance after assembly & bolting of output M Micro Ohm B 100% Shop test certificate L-02
leads. Meter
7.0 Terminal Bushing:
7.1 Check IR value by motorized Megger. IR value M 2.5 or 1 KV B 100%
should not be less than (KV+1) Mega Ohms. Megger
7.2 Air leak test of terminal bushing at 4kg/cm2 for 3 M Pressure B Once Technical Instruction L-01
hours before its assembly on the stator casing. Gauge
7.3 Visual inspection for cracks & damage. V C Free from cracks &
damage.
REVIEWED APPROVED
PROJECT, RAIGARH
8.0 Resistance Thermometers & Thermocouples:
8.1 Check DC resistance & IR value of RTD. IR M 250 V Megger, B 100% Shop test certificate L-03
should be greater than 1 M Ohm. Multi Meter
8.2 Check continuity for thermocouples in the core. Multi Meter B 100% Shop test certificate L-03
9.0 Rotor:
9.1 Check IR of the winding. It should not be less M 500 V Megger A 100% Shop test certificate L-02
than 1.3 M ohms at 40o C.
9.2 Record DC resistance of the rotor winding. Also, M Micro B 100% Shop test certificate L-02
measure impedance of the rotor winding with Ohmmeter
220 V, 50 Hz AC supply.
9.3 Journal diameter both on TS & ES. Check M Vernier B 100% Drawing L-16
visually their surface or any scratch marks. /Micrometer
9.4 Locking of balancing plugs / screws / weights. V B 100% Drawing L-05
9.5 Locking of fan blades. Check visually for any V B 100%
damage to fan and retaining-ring surface. Check
locking of fan blades by angular rotation.
9.6 Cleaning of axial and radial ventilating holes in V C 100%
rotor.
REVIEWED APPROVED
PROJECT, RAIGARH
9.7 Check all radial ventilating holes on the rotor slot V B 100%
wedge for any blockage by slot liner / inter turn
insulation.
9.8 Check for any axial movement of unlocked slot V B 100%
wedges.
10.0 End shield:
10.1 Cleaning of pre-chamber. V C 100%
10.2 DPT of seal oil inlet pipe weld joints. V B 100%
10.3 Cleaning of all sealing grooves. V C 100%
10.4 Check thoroughness of holes provided for filling V C 100%
of sealing compound by blowing compressed air.
11.0 Bearing & their Assembly.
11.1 Check for any damage and looseness to the V B 100%
Babbitt surface visually.
11.2 Contact at the parting plane of the bearings. V C Once Drawing
Min. contact 80% by blue matching.
11.3 IR value between the bearing support ring and M 1 KV Megger B 100% L-06
end shield not less than 25 M Ohms before rotor
placement and 10 M Ohms after rotor placement.
REVIEWED APPROVED
PROJECT, RAIGARH
11.4 Contact between bottom half bearing liner & V B Once
support ring of spherical seating. It should have
80% contact area in the 60º arc of lower half
bottom most area.
11.5 Check against blockage of jacking oil pipeline. V C 100%
11.6 Measure ID of bearings. M Micrometer B Once Drawing Protocol
11.7 Record radial clearances of oil catchers on M Feeler gauge C 100% Drawing
Turbine Side and Exciter Side.
12.0 Rotor Insertion as per prescribed procedure and V B Erection Manual, L-07
checks to be carried before insertion and after Rotor Insertion
insertion as per “Rotor Insertion Protocol”. Procedure
13.0 After rotor placement on bearings, check side M Feeler gauge B Drawing Logbook
gap between bearing and support ring, both on
Turbine Side and Exciter Side.
14.0 Rotor Alignment to be carried out after alignment
of Turbine Rotors and check following:
14.1 Axial & radial run outs of the half-coupling flange. M Dial gauge A Erection Manual L-19
14.2 Radial run outs of the rotor journals. M Dial gauge A -do- L-19
14.3 Alignment with LP rotor & check slope of rotor M Dial gauge/ A Drawing/ Erection L-20
journals. spirit level Manual
REVIEWED APPROVED
PROJECT, RAIGARH
15.0 Grouting of spacers and foundation plate (F.P.) V B 100% Drawing
after final alignment.
16.0 Ensure tightening, stretching and locking of V B 100% Drawing Logbook
foundation bolts. Ensure tack welding of the bolt
and nuts with anchor plate.
17.0 Ensure setting of magnetic axis and maintaining M Vernier / Tape A 100% Drawing
its offset after air gap setting.
18. Check air gap on both TS & ES. M Feeler gauge A 100% Drawing L-08
19. Check all Axial & Radial clearances between M Feeler gauge A 100% Drawing Log sheets
stator and rotor. Maintain records as per log
sheet Nos. L-10, L-11, L-12, L-13, L-15, L-16, L-
17 & L-18.
20.0 Assembly of insert cover. V C 100% Drawing
21.1 Labyrinth Rings & their Assembly.

21.1 Contact at the parting planes of the Labyrinth V/M Feeler gauge C Once
should not be less than 80%.
Note: 0.03 mm feeler should not pass.
21.2 IR Value between inner labyrinth ring and end- M 500V Megger B 100% L-06
shield should not be less than 10 M Ohm.
REVIEWED APPROVED
PROJECT, RAIGARH
22.0 ID of the seal ring on both TS & ES. Check M Micrometer B 100% Drawing L-15
visually seal ring surface or any scratch marks.
23.0 Check condition of MULTI-KONTAKT assembly. V C Once
24.0 Seal Ring Holder:
24.1 Check cleanliness of seal ring holder & all V C 100%
grooves.
24.2 Check Run out of end shield surface where seal M Dial gauge B 100% L-14
body rests.
24.3 Measure thickness of seal ring holder. M Micrometer B Once Drawing L-14
24.4 Check contact between joining surface of two V/M Feeler gauge B Once
halves. Contact area should not be less than
80% and 0.03 feeler gauge should not pass.
24.5 IR between seal ring holder and end shield. IR M 1 KV Megger B 100% L-06
value should not be less than 25 M Ohm.
24.6 Ensure there is no blockage of ring relief oil and V C 100%

seal oil passages.
25.0 Check tightness of bolts between fan-shield top V B 100% Drawing
half & end shield by hand and its locking.
REVIEWED APPROVED
PROJECT, RAIGARH
26.0 Check that while assembling seal body on to the V B 100% Technical Instruction
end-shield, the parting plane bolts are tightened
in sequential manner to avoid fouling.
27.0 Contact between journal & bearing liner along V C 100% L-09
with uniform band OF 210 + / - 10 mm.
Note: Angle of contact 52.85o + / -2o.
28.0 Gap between the top half of the bearing shell M Feeler gauge B 100% L-10 & L-
and its support in the upper half of the end 11
shield.
29.0 Gap between stopper of bearing & parting plane M Feeler gauge B 100% L-10 & L-
of support ring. 11
30.0 Check rotor shaft IR with end-shield after final M 1 KV Megger B 100%
assembly of bearing, seal ring and labyrinth ring
on both sides. It should not be less than 1 M ? .
31.0 Check the generator internals as per “Generator V B 100% L-21
Box-Up Protocol”
32.0 Reaming of coupling holes:
32.1 Diameter of reamed holes and matching bolts. M Vernier/ B 100% Drawing L-04
Micrometer
32.2 Weight of bolts & nuts for all the coupling holes. M Weighing B 100% L-04
balance
REVIEWED APPROVED
PROJECT, RAIGARH
32.3 Ensure locking of nuts after required elongation V B 100% Drawing L-04
of coupling bolts is achieved.
32.4 Ensure balancing of coupling by putting bolts & M Weighing C 100%

nuts of approximately equal weight (+ / - 5 g) in balance
diametrically opposite holes.
33.0 Ensure proper filling of sealing compound after V C 100% Drawing
assembly of the end-shields
34.0 Check terminal chamber for any foreign material V C 100% No foreign material
before assembly of the manhole cover. should be left.
35.0 Assembly of coolers:
35.1 Before insertion of coolers, hydraulic test the M Pressure B Once Drawing / Erection L-01
hydrogen coolers. No leakage is allowed. Gauge Manual / Procedure
35.2 Check tightness of the tube bundle. No V C 100%

looseness is allowed.
35.3 Check the cooler chamber for presence of any V B 100%

foreign material before insertion
36.0 Carry out hot air blowing through stator casing till V A 100% Erection manual
the machine is ready for hydrogen filling.
REVIEWED APPROVED
SUB-SYSTEM: BRUSHLESS EXCITER DATE: 12.01.2007 PROJECT: 4 x 250 MW THERMAL POWER
PROJECT, RAIGARH
1.0 Bed Plate:
1.1 Check foundation / levelling & Centring. M Dumpy level / B 100% Drawing
Tape
1.2 IR between bearing pedestal and bed plate. M 1KV Megger B 100% Erection Manual L-22
2.0 Exciter Rotor Assembly:
2.1 With armature shaft resting on support bearing & M Dial gauge B 100% Drawing L-29
normal bearing, check journal run-out & face run-
out on coupling.
2.2 Check for proper condition of MULTIKONTAKT V C 100%
assembly and proper fixing of pins.
2.3 Alignment with Generator Rotor. Record the air V/M Feeler gauge B 100% Drawing L-29 & L-
gap between poles and armature. 26
2.4 With exciter rotor coupled to the TG rotor, check M Dial gauge A 100% Erection Manual L-30
run out and carry out Swing Check.
2.5 Ensure contact area between bearing pedestal & V B Once
its seating surface on bed plate is minimum 80%.
Blue match if required.
2.6 Ensure contact area between bearing spherical V B Once
and its seat is 60% minimum in the 60º arc of
lower half bottom most area. Blue match if
required.
REVIEWED APPROVED
PROJECT, RAIGARH
3.0 Bearing Assembly:
3.1 Check condition of Babbitt for any crack V B 100%

looseness visually.
3.2 Shaft diameter on journal and bearing ID. M Micrometer B Once Drawing
3.3 Side, top clearances & bearing arc length for M Feeler Gauge B 100% Drawing L-23
load bearing area.
3.4 Blue matching between top & bottom half (not V B Once
less than 85%).
3.5 Check lube oil inlet, outlet and jacking oil holes V C 100%
against any blockage.
3.6 Ensure proper mounting of vibration pick-ups. V C 100% Drawing

They should not foul with rotor shaft after axial
expansion of the exciter. Also, the cabling should
not ground bearing insulation.
3.7 IR check on bearing insulation. Minimum IR M 1KVMegger B 100%

value is 3 Mega Ohms.
REVIEWED APPROVED
PROJECT, RAIGARH
4.0 Record the following axial clearances between:
4.1 Fuse & Rotating Rectifier Cover. M Feeler Gauge B 100% Drawing L-25
4.2 Ø Balancing ring & TE Air Guide Cover, M Feeler Gauge B 100% Drawing L-27
Ø Blower and Air Guide Cover at Exciter End.
Ø Air Guide Cover and Armature end,
Ø Brush end and slip ring edge.
4.4 Ø Bearing axial clearances, M Feeler Gauge B 100% Drawing L-24
Ø oil wiper ring & step near measuring slip ring,
Ø oil wiper ring and step near Blower,
5.0 Permanent Magnet Generator (PMG):
5.1 Air gap between permanent magnet and stator M Feeler Gauge B 100% Drawing L-28
frame.
5.2 IR & DC resistance of armature. IR value should M 250Vmegger, B 100% Shop test certificate L-02
not be less than 1 Mega Ohm. Micro ? Meter
6.0 IR & DC resistance of field winding. IR value M -do- C 100% Shop test certificate L-02
should not be less than 1 Mega Ohm.
7.0 Check continuity and IR of Quadrature axis coil: M 250Vmegger, C 100% L-02
Multi Meter
8.0 Ensure assembly of air vent flaps and coolers. V C 100%

REVIEWED APPROVED
SUB-SYSTEM: SEAL OIL SYSTEM DATE: 12.01.2007 PROJECT: 4 x 250 MW THERMAL POWER
PROJECT, RAIGARH
1.0 Check for proper cleaning of Seal Oil Tank V C 100%
(SOT), Seal Oil Storage Tank (SOST), Pre-
Chamber, and Intermediate Oil Tank (IOT).
2.0 Check for proper condition of float valves in IOT V C 100%
& SOT.
3.0 Seal Oil System Inter Connecting Piping, Check
and ensure following:
3.1 A slope of 40 mm / m is maintained. M Water level C 100% Drawing & FWS
Note: Ensure NDT Examination of site welds.
3.2 Hydraulic test of seal oil lines at 1.5 times M Pressure B Once Drawing L-31
working pressure. Gauge
3.3 Leak test during air tightness test. V B 100% Drawing L-32
3.4 Thoroughly inspect oil pipelines for any rust V C 100% Procedure Logbook
formation. Note: Acid cleaning should be
performed only in case of rust formation.
3.5 Ensure Oil flushing of the seal oil system. V B 100% Procedure L-31
3.4 During normalisation of the system, ensure that V C 100% -do-

all blanks provided in seal oil piping are
removed.
4.0 IR value of both AC & DC motor windings. IR M 500Vmegger B 100% L-31
Value should be more than (KV + 1) M ohms.
REVIEWED APPROVED
SUB-SYSTEM: GAS SYSTEM DATE: 12.01.2007 PROJECT: 4 x 250 MW THERMAL POWER
PROJECT, RAIGARH
No. CHARACTERISTICS / ITEM CHECK
INSTRUMENT CHECK OF CHECK
1.0 Leak test during generator air tightness test. V B 100% Erection Manual L-32
2.0 IR of CO2 Vapour exhauster motor winding and M 500Vmegger B 100% Logbook
Gas dryer motor. Minimum IR value is (KV+1)
mega ohms.
3.0 Layout of gas piping & hydrogen cooler piping. V B 100% Drawing & Field Logbook
Note: Ensure Welding & NDT as per FWS. Welding Schedule
4.0 Check the liquid leakage detection lines for V C 100% Drawing / Erection Logbook
proper slope. Manual
5.0 Hydraulic test of the pipelines at a pressure of 4 M Pressure B 100% Drawing / Erection L-01
KG/Cm2 for 30 minutes. There should not be any gauge Manual
leakage.

REVIEWED APPROVED
PROJECT, RAIGARH
1.0 Check proper direction of rotation of AC & DC V C 100% O&M Manual L-31
seal oil pumps motors.
2.0 Gas tightness test along with gas and seal oil M Pressure A 100% O&M Manual L-32
system at a pressure of 3.5 kg/cm2 for 48 hrs. Gauge
Leakages < 2.4 M3 during 24 hours.
3.0 Ensure end-shield pre-chamber is cleaned V B 100% O&M Manual Logbook
manually after oil flushing in order to remove any
foreign material entrapped. Also, check that
during normalisation of seal oil system, all the
blanks provided in seal oil piping and end-shields
have been removed.
4.0 Prior to first mechanical run, check the following:
4.1 Check that Seal Oil pressure is 1.2 kg/cm2 above M/V Pressure B 100% O&M Manual Logbook
the casing pressure. Ring relief flow is adjusted gauge
to 12 to 15 litres per minute.
4.2 Check for proper flow of seal oil at both the ends. V C 100% O&M Manual Logbook
4.3 Check for proper functioning of DPRV ‘A’ & V B 100% O&M Manual
DPRV ‘B’ and also float valves in SOT & IOT.
4.4 Check for Auto changeover of seal oil pumps. In V C 100% O&M Manual
case AC pump trips / seal oil pressure drops, DC
pump must take over automatically.
R– RECORD VERIFICATION, V– VISUALLY, P– COMMISSIONING
REVIEWED APPROVED
PROJECT, RAIGARH
4.5 IR value of each phase. Also check PI value. M 2.5KVmegger A 100% Instruction Manual L-02
Note: (motorized)
Ø IR value > (KV+1) Mega Ohms,
Ø PI value should not be less than 2.0.
4.6 IR value of the following with 500VMegger: M 500VMegger B 100% IR should not be
Ø Bearing shell to Earth (EE, TE), less than 1 M? .
Ø Seal Body to Earth (EE, TE).
5.0 During first mechanical run, check the following:
5.1 Vibration of bearings on the end-shield at V Vibration B 100% Shop protocols L-31
Soaking speed and 3000 RPM Analyzer
Note: Critical speeds are to be quickly passed.
5.2 Terminal Voltage of PMG. M Multi meter B Shop protocol
5.3 Temperature of following: M Control panel B Shop protocol L-34 &
Ø Bearing metal, L-38
Ø Seal oil inlet & outlet,
Ø Hot Gas & Cold Gas,
Ø Water inlet & outlet,
Ø Stator winding & core.
6.0 Dry out of the stator winding if IR value is less M Dry-out Kit B O&M Manual
than (KV+1) M Ohms / PI is less than 2.0.

REVIEWED APPROVED
PROJECT, RAIGARH
6.0 Filling of casing with hydrogen as per H2 filling V B O&M Manual Logbook
procedure. Ensure casing Pressure is 3 KG/Cm2.
7.0 Short Circuit Test:
7.1 Short Circuit Characteristics at 25%, 50%, 75% & M Control panel B Once Test Protocols L-35
100% load current.
7.2 At 100% load current, check rotor current M Control panel B Once Test Protocols L-35
indication and correct to the required value.
7.3 Ensure that current based protections are V/M Control panel B 100% Drawing Protocol
functional and measure the current at the relay
terminals.
7.4 Verify short circuit characteristic curve. V B Once Test Protocols L-35
7.5 Check healthiness of diodes. V Stroboscope B 100%
7.6 Rotor current, if provided for. M/V Control panel B 100% Test Protocols L-35
7.7 Check operation & stability for all differential V Control panel B 100% Test Protocols Protocol
relays. Also check operation of over-current relay
& record current in all relays at 0%, 25%, 50%,
75% & 100% load current.
7.8 Operation of all earth fault relays. In case of V Control panel B 100% Test Protocols Protocol
microprocessor based relays, relay current
shown in display to be used.
REVIEWED APPROVED
PROJECT, RAIGARH
8.0 Open circuit Test:
8.1 Ensure that voltage based protections are V/M Multi meter B 100% Drawing Protocol
functional. Measure the voltage at all voltage
terminals of concerned relays.
8.2 Check Vibration on bearings under following M Control panel B 100% O&M Manual L-33
conditions:
Ø Without excitation,
Ø With excitation.
8.3 Plot OCC. V/M Control panel B Once O&M Manual L-36
8.4 Check correctness of rotor current indication M Control panel C 100%
8.5 Check residual voltage matches with shop value M/R Multi meter B 100% Shop protocol Logbook
for brushless exciter by PT measurement.
9.0 Check phase sequence of the stator winding. M Control panel B Once O&M Manual
10.0 Check for Maximum temperatures of following: M Control panel B 100% O&M Manual L-38
Ø Stator winding.
Ø Bearing drain oil.
11.0 Check Shaft voltage and compare with shop M Control panel A 100% Shop protocol L-37
protocols.
REVIEWED APPROVED
PROJECT, RAIGARH
12.0 Check healthiness of synchronising circuit. V B 100% O&M Manual / Protocol
Schematics
13.0 Check that Voltage, frequency and phase V/M Control panel B 100% O&M Manual L-39
sequence is in synchronisation with grid at the
time synchronization with the grid.
14.0 After loading the machine as per turbine loading
schedule, measure the following parameters:
14.1 Bearing Vibration. M Control panel B 100% O&M Manual L-33
14.2 Ø Active and reactive power. M Control panel B 100% O&M Manual L-40
Ø Stator current & power factor.
Ø Voltage of all three phases.
14.3 All temperatures indicated by RTD. M Control panel B 100% O&M Manual L-38
14.4 Healthiness of all diodes. M Control panel B 100% O&M Manual Logbook
14.5 Ø Hydrogen pressure in casing. M Control panel B 100% O&M Manual Logbook
Ø Hydrogen purity.
Ø Hydrogen consumption for 24 hours.
Ø Functioning of thermostat controls of
hydrogen drier.
14.7 Excitation current. M Control panel B 100% O&M Manual L-40
14.8 Shaft voltage M Control panel B 100% O&M Manual L-37
14.9 Performance of auxiliary systems. M Control panel B 100% O&M Manual
REVIEWED APPROVED
INSTRUMENT REGN.NO.
DATE OF INSPECTION
PSWR-QUALITY
DRAWING / DOCUMENT NO.
RECORD OF QUALITY CHECKS

SHEET CHECK RESULTS DRAWING / FORMAT OF INSPECTED BY CLEARED BY REMARKS
NO. OF QPI NO. ACHIEVED DOCUMENT RECORD SIGN. & DATE SIGN. & DATE
OK / NOT OK REFERENCE
Note: Any protocol made is to be numbered & mentioned in “Format of Record” column.
DOC. NO.: QPX-TG-001
SYSTEM SUB-SYSTEM AREA
PROJECT REV NO. : 01
UNIT NO. LOG SHEET NO.: L-00
RATING SHEET: 01 of 01
INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
DRAWING / DOCUMENT REF.
HYDRAULIC TESTING OF HYDROGEN COOLERS
Pressure gauge details:

Rating: Make: Sl. No.:
Instrument Reg. No. Calibration Date Calibration Next due date
Testing Actual Starting Ending

Hydrogen Duration
Date pressure pressure time time Remarks
Cooler No. (min)
(kg/cm2) (kg/cm2) (hours) (hours)
NO LEAKAGES WERE OBSERVED.
Coolers and cooler spaces in generator casing were thoroughly cleaned and inspected. No
foreign material was left inside. Subsequently all four hydrogen coolers were inserted in
respective cooler spaces on date_______________________
NAME SIG. / DATE DOC. NO. QPX-TG-001
PROJECT CHECKED BY REV NO.: 01
UNIT NO. ACCEPTED BY LOGSHEET NO. L-01
RATING CUSTOMER SHEET 1 / 3

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
HYDRAULIC TESTING OF PIPING FOR H2 COOLERS

Testing Actual
Starting time Ending time Duration
Date pressure pressure Remarks
2 2 (hours) (hours) (min)
(kg/cm ) (kg/cm )
Circuit taken:

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
AIR LEAK TEST OF TERMINAL BUSHINGS BEFORE ASSEMBLY

Testing Actual
Starting time Ending time Duration
Date pressure pressure Remarks
2 2 (hours) (hours) (min)
(kg/cm ) (kg/cm )
Circuit taken:

INSTRUMENT REGN.NO.
DATE OF INSPECTION
PSWR-QUALITY
TESTS ON STATOR & ROTOR WINDING
STATOR ROTOR
DC Resistance corrected at 20oC IR value corrected at 40oC PI DC IR value Impedance
(m? ) (Mega Ohms) VALUE Resistance (M? ) (Ohms)
Stage Corrected at
U V W U V W 20oC
(Ohms)
Erection
(Before assembly of
output leads)
Erection
(After assembly of
output leads)
Commissioning
*** ***
Note: Shop test values are standards where specified values are not indicated.
NAME SIGNATURE / DATE DOC. NO. QPX-TG-001

PROJECT
CHECKED BY REV NO.: 01
UNIT NO. ACCEPTED BY LOG SHEET NO. L-02

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
IR value and Impedance Measurement of Generator Rotor
Date: Ambient temperature:

Details of multi meter:
Make: Sl. No.:
Details of Variac:
Make: Sl. No.:
Details of Digital Tong Tester:

Make: Sl. No.:
Details of Megger:
Make Sl. No. Range Calibration Due date Certificate No.
date
IR value of generator rotor:

Before rotor insertion After rotor insertion
Impedance measurement:
S. Voltage Current Frequency Impedance (M? )
No. (Volts) (Amp) Hz Shop value Before insertion After insertion
1.
2.
3.
4.
5.
6.
7.
8.
9.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY

OHMIC RESISTANCE AND IR VALUES OF EXCITER
A. MAIN EXCITER
Digital micro-ohmmeter details
Make: Range: Model No.:
Calibrated on: Calibration due on: Sticker No.:
Winding resistances:
Date: Ambient Temp:
Field winding
Q axis coil -1
Q axis coil -2
Space heater-1 Space heater-2
IR values:
Date Ambient Temp: Megger used:
Between IR values
Rotor winding Rotor shaft
(including RR wheel)
Quadrature axis coil-1 Stator frame
Quadrature axis coil-2 Stator frame
Space heater-1 Stator frame
Space heater-2 Stator frame

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
OHMIC RESISTANCE AND IR VALUES OF EXCITER

B. PILOT EXCITER
Digital micro-ohmmeter details
Make: Range: Model No.:
Calibrated on: Calibration due on: Sticker No.:
Winding resistances:
Date: Ambient Temp:
U-N
Armature winding V-N
W-N
IR values:
Date Ambient Temp: Megger used:
Between IR values
Stator winding Stator frame
combined
U-V
Stator Winding V-W
U-W

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
TEST ON RTD / THERMOCOUPLES

Ambient Temperature:
A. SLOT RESISTANCE THERMOMETERS (SIMPLEX RTDs)
RTD-A RTD-B
SLOT
NO. RESISTANCE IR VALUE RESISTANCE IR VALUE
(IN OHMS) (MEGAOHMS) (IN OHMS) (MEGAOHMS)
B. CONTINUITY OF CORE THERMOCOUPLES: All thermocouples are showing continuity.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
TEST ON RTD / THERMOCOUPLES

C. COLD / HOT GAS TEMPERATURE MEASUREMENT (DUPLEX RTDs)
IR VALUE(MEGA
SL.NO. DESIGNATION RESISTANCE (OHMS)
OHMS)
REMARKS:

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY

FINAL DIMENSIONS OF COUPLING HOLE / BOLT AFTER HONING
(LP-GENERATOR)
BOLT + NUT
HOLE BOLT COUPLING HOLE BOLT
BOLT DIA WEIGHT
NO. NO. DIA ELONGATION
(Kg)
NOTE:
1. BOLT ELONGATION TO BE KEPT AS PER DRAWING.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
BALANCING WEIGHTS/PLUGS
NO. OF WEIGHTS LOCKING

SL.NO. AREA
PROVIDED OK / NOT OK
1. ROTOR BARREL
2. FAN HUB
3. RETAINING RING
4. EXCITER
5. ANY OTHER
REMARKS:

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
IR MEASUREMENT ON GENERATOR
Without Rotor With Rotor

Measure No. Position
(without LP & TG Coupling) (without LP & TG Coupling)
(1) 01 TS
02 ES
(2) 01 TS
02 ES
(3) 01 TS
02 ES ***
(4) 01 TS
02 ES

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY

ROTOR INSERTION PROTOCOL
(A): BEFORE ROTOR THREADING, CHECK THE FOLLOWING :
SL NO. CHECK Completed (4) Remarks
1. All electrical tests (dc resistance, IR value and
impedance) are carried out on rotor. (Log sheet No.
____________ )
2. Assembly of terminal bushings (output leads) and
soldering to be completed before electrical tests on
stator.
3. Stator is thoroughly cleaned and free from foreign
elements like dust, oil/water, spanners, screwdrivers etc.
4. Overhang portion of the stator winding is thoroughly
cleaned and absence of erection tools, fixtures and other
foreign materials. While checking for absence of foreign
material, use magnet base of dial gauge for removing
magnetic objects.
5. All electrical tests (dc resistance, IR value) are carried out
on stator. (Log sheet No. ____________ )
6. Check healthiness of thermocouple/RTD of stator core
/winding.
7. Check locking/ tack welding of bolts and nuts of steel
brackets supporting the winding overhang. Check bus bar
supports and spacers for intactness and tightness by
hand feel.
8. Check tightness of bus bar spacers and winding
overhang braiding by hand feel.
9. Tightness of fan blades for angular rotation is checked
10. Check and ensure for locking of all balancing weights to
be checked visually / hand feel.
11. Ensure locking of nuts on retaining rings (axial direction)
which are spring loaded by prick punching.
12. Ensure tightness of rotor overhang partition wall
assembly for axial / radial movement is checked visually
or by hand movement only. No opening of sealing wall is
required.
13. Vacuum cleaning of all ventilating holes is carried out and
transportation packing & blower protection cover on rotor
is removed.
14. Ensure exciter end half coupling of rotor is fitted with
moisture protection cover to protect contact pins on rotor.
15. Measure and record mail spigot/journal dimensions of
rotor on both ends
INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
ROTOR INSERTION PROTOCOL

SL NO. CHECK Completed (4 ) Remarks
16. Rotor overhang area below the retaining ring is
thoroughly inspected for any foreign material.
17. Locking of rotor slot wedges and all other fasteners
is checked.
18. Check that all spacers provided in the core pocket
ventilation area is fully tight.
19. Check that insulating paint is properly applied over
stator core / winding area.
20. Check visually, the condition of retaining ring and
journal surface.
21. Check cleaning of bottom half end shield and
ensure that it is placed in position before start of
rotor threading
22. Check megger value of bearing housing with end
shield (without rotor )
23. Check that M-8 counter sunk screws (used for fixing
of PVC insulating sheet) of sliding pedestal and skid
shoe are not protruding and are not damaged.
24. Ensure visually that all fasteners of stator and rotor
are properly locked either by tack welding or by
bending lock washers.
25. Hydrogen cooler fasteners are properly locked.
26. Ensure rotor lifting on pole face only.
27. Only polythene sheet should be used to cover the

rotor
(B): AFTER ROTOR THREADING, CHECK THE FOLLOWING :
1. IR value of stator winding.
2. IR value of rotor winding
3. All fixtures used for rotor insertion are removed.
4. Ensure the stator with rotor is well preserved with

temporary covers.
Additional point, if any:

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
GENERATOR ROTOR – RADIAL AND AXIAL ALIGNMENT
Measure No. Position Nominal Value Actual value

1 01
2 01
3 01
4 01
5 01 Top
02 Right
03 Bottom
04 Left
6 01 Top
02 Right
03 Bottom
04 Left
7 01
8 01
02

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
BEARING RADIAL CLEARANCES
Measure Position Nominal Actual value

No. value TE(front) TE(Rear) EE(Front) EE(Rear)
1 Top
2 Right
3 Left
4 Bottom Contact
Area
NOTE : 1. WAY OF MEASURING : LEAD / THICKNESS GAUGE
2. BEARING CLEARANCES ARE MEASURED ON FIRMLY TIGHTENED BEARING
3. FOR LEFT AND RIGHT READINGS, FEELER GAUGE TO BE INSERTED 10 mm BELOW OF

PARTING PLANE.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
RADIAL CLEARANCES – BEARING OILWIPER RINGS

(TURBINE END)

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left
3 01 Radial (Top)
4 01 Radial (Left)
02 Radial (Right)

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
RADIAL CLEARANCES – BEARING OILWIPER RINGS

(EXCITER END)

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left
3 01 Radial (Top)
4 01 Radial (Left)
02 Radial (Right)

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
BLOWER – RADIAL CLEARANCES

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
LABYRINTH RING INSIDE – RADIAL CLEARANCES

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
AXIAL RUNOUT MEASUREMENT ON ENDSHIELD SEAL BODY SEATING SURFACE
Measure Axial Run-out (T.E.) Measure Axial Run-out (E.E.)

No. No.
1 01 2 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
Permissible Axial Run-out is not greater than 0.2mm
1. Axial run-out exceeding 0.2 mm is neutralised by counter machining of seal body flange.
2. This logsheet is only for counterchecking. In case of any doubt, concurrence from
manufacturing unit is to be obtained for machining.
3. Location numbers are counted while looking from T.E. & E. E. respectively.
INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
SEAL RING HOLDER ONLY FOR

REFERENCE
MEASUR SHOP ERECTION
E NO. ACTUAL, BEFORE TAPER NOMINAL ACTUAL, AFTER TAPER

MACHINING ± 0.1 MACHINING
01
02
03
04
05
06
07
08
09
10
NOTE: This reference logsheet is to be filled up from shop records.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
SEAL RING – RADIAL AND AXIAL CLEARANCES
T.E. Seal Ring

Measure No. Position Actual Value
1 01 Vertical
02 Horizontal
2 01 Vertical
02 Horizontal
5 01
E. E. Seal Ring
Measure No. Position Actual Value
3 01 Vertical
02 Horizontal
4 01 Vertical
02 Horizontal
6 01
REMARKS:

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
SEAL RING – RADIAL AND AXIAL CLEARANCES
Measure No. Position Nominal Value Actual Value

11 01 AXIAL (TE)
12 01 AXIAL (EE)

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY

SEAL RING – RADIAL CLEARANCES

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left
3 01 Top
02 Right
03 Bottom
04 Left
4 01 Top
02 Right
03 Bottom
04 Left
5 01
6 01

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY

SEAL RING HOLDER – RADIAL AND AXIAL CLEARANCES

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left
3 01 Top
02 Right
03 Bottom
04 Left
4 01 Top
02 Right
03 Bottom
04 Left
5 01
02
6 01
02

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
LABYRINTH RING OUTSIDE – RADIAL CLEARANCES

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
GENERATOR ROTOR - RADIAL RUNOUT
Measure Actual Value Measure Actual Value

No. No.
1 01 1 09
02 10
03 11
04 12
05 13
06 14
07 15
08

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
LP-GENERATOR COUPLING ALIGNMENT

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left
a) Top & Bottom and
Note: The difference between Should be within 0.02 mm
b) Left and right
BEARING No. Bearing No. 5 Bearing. no. 6 Bearing. No. 7
SLOPE IN mm/m

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
BOXING-UP PROTOCOL
BEFORE BOXING UP (FINAL ASSY. OF TOP HALF END SHIELDS & MANHOLE CLOSING) OF GENERATOR,
CHECK THE FOLLOWING :
SL. CHECK Completed Remarks
NO. (4 )
1. Overhang portion of stator winding is clean and free from
any foreign material like dust, oil/water and tools.
2. Cleaning of stator casing including end shield area for
water/oil, dust, foreign material.
3. Cleaning of gas cooling duct/canal for water/oil, dust and
foreign material.
4. Cleaning of all casing drain pipes.
5. Recheck locking of all the approachable fasteners on
stator winding overhang & rotor etc.
6. Ensure through-ness of all drain holes provided on the
end-shield as per drawing.
7. Check proper dimension of all grooves provided on the
endshield.
8. Ensure proper location of flange connection on the end
shield with openings on seal body like ring relief oil supply,
oil drain and seal oil supply.
9. Ensure assembly of all plugs provided on end shield as
per drawing.
10. Check that all fasteners of stator / end shield joints, end
shield parting plane joints and insert cover fasteners are
properly tightened and lock washers locked properly.
11. Assembly of insert cover supports have been completed
as per drawing & its lock washers locked.
12. All dowel pins from inside of generator to be removed from
position.
13. Inspection of individual cooler for proper cleanliness
before insertion if sent separately / removed at site.
ADDITIONAL POINTS, IF ANY:

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
IR MEASUREMENT ON EXCITER
BEARING PEDESTAL TO BASE FRAME

( without shaft contact with flanged pipes)
Measure No. Nominal value Actual value

1 01
NOTE: IR value should not be less than 3 MΩ.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
EXCITER BEARING RADIAL CLEARANCES
Measure Position Nominal value Actual value

No.
FRONT REAR
1 Top
2 Right
3 Left
4 Bottom Contact
Area
NOTE : 1. WAY OF MEASURING : LEAD / THICKNESS GAUGE
2. BEARING CLEARANCES ARE MEASURED ON FIRMLY TIGHTENED BEARING
3. FOR LEFT AND RIGHT READINGS, FEELER GAUGE TO BE INSERTED 10 mm BELOW

PARTING PLANE.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
BEARING – RADIAL AND AXIAL CLEARANCES
NOTE:
Axial dimensions are to be taken at site during erection when machine is at standstill and LP-
generator and Generator –Exciter rotors are coupled with no gap.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
BEARING – RADIAL AND AXIAL CLEARANCES

1 01 Top
02 Right
03 Left
2 01 Top
02 Right
03 Bottom
04 Left
3 01 Top
02 Right
03 Bottom
04 Left
4 01 Top
02 Right
03 Bottom
04 Left
5 01 Top
02 Right
03 Bottom
04 Left
6 01
02
03
04
05
06
07
7 01
02

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
ROTATING RECTIFIER WHEEL – RADIAL AND AXIAL ALIGNMENT

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Axial
02 Axial
03 Axial
04 Axial
05 Radial
06 Radial
07 Height of Centres

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
MAIN EXCITER – RADIAL ALIGNMENT

D.E. N.D.E.
1 01
02
03
04
05
06

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
MAIN EXCITER – RADIAL AND AXIAL ALIGNMENT

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left
3 01 Axial
02 Axial
03 Magnetic Shift
04 Axial
05 Axial
06 Axial

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
PILOT EXCITER – RADIAL AND AXIAL ALIGNMENT

1 01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
PILOT EXCITER – RADIAL AND AXIAL ALIGNMENT (CONTD.)

2 01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
3 01 MAGNETIC OFFSET
REMARKS, IF ANY:

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
EXCITER COUPLING ALIGNMENT

1 01 Top
02 Right
03 Bottom
04 Left
2 01 Top
02 Right
03 Bottom
04 Left
a) Top & Bottom and

Note: The difference between Should be within 0.02 mm
b) Left and right

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
EXCITER ROTOR- ALLOWABLE RUNOUT DEVIATION AT SWINGING
RATING CUSTOMER SHEET 1 / 2 SHEETS

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
EXCITER ROTOR – COUPLING CHECK & SWINGING
1&2 RADIAL RUN-OUT TEST :

For actual measures, run-out is entered corresponding to the position by graduation.
Measure No. Allowable value Actual value
1 01
2 01
3 SWING OF THE EXCITER ROTOR: During this inspection, generator and exciter
rotors are coupled as prescribed. The exciter bearing is replaced by an auxiliary
bearing hanging freely in the crane. Allowable values are as per sheet 1/2.
Measure No. Actual Value Measure No. Actual Value
3 01 08
02 09
03 10
04 11
05 12
06 13
07 14
4 TIGHTENING TORQUE OF THE COUPLING BOLTS :
Measure No. Nominal Value Actual Value
1 01

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Seal Oil System Flushing

A. Trial run of following pump-motor units:
Name plate details Motor Pump
MAKE MAKE
FRAME TYPE
VOLT FLOW
Air side AC-SOP-1 CURRENT HEAD
KW SPEED
SPEED SL.NO.
SL.NO.
MAKE MAKE
FRAME TYPE
VOLT FLOW
Air side AC-SOP-2 CURRENT HEAD
KW SPEED
SPEED SL.NO.
SL.NO.
MAKE MAKE
FRAME TYPE
VOLT FLOW
Emergency DC-SOP CURRENT HEAD
KW SPEED
SPEED SL.NO.
SL.NO.
MAKE MAKE
FRAME TYPE
VOLT FLOW
Vacuum Pump CURRENT HEAD
KW SPEED
SPEED SL.NO.
SL.NO.
Parameter Air side AC-SOP-1 Air side AC-SOP-2 Emergency DC-SOP Vacuum Pump
Discharge
pressure
Motor Current
Remarks:
INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Seal Oil System Flushing
1. Seal oil storage tank , seal oil tank & intermediate oil tank cleaned on _________________ (date)
2. Temporary pipes are acid cleaned on ____________(date)& neutralised
on______________(date)
3. Trial run of AC SOP-1 completed on: _____________________(date)
4. Trial run of AC SOP-2 completed on: _____________________(date)
5. Trial run of vacuum Pump completed on: _____________________(date)
6. Trial run of Emergency air side DC SOP completed on: _____________________(date)
7. Heating arrangement(as applicable) for seal oil provided on _____________________(date)
8. Fire fighting system of lube-oil & seal-oil system commissioned on ___________________(date)
i) Oil flushing of seal oil piping with seal oil rack excluded
Date & time of start Date & time of finish No. of thermal shocks Type of thermal shock
Circuit:
ii) Oil flushing of seal oil system

Date & time of start Date & time of finish No. of thermal shocks Type of thermal shock
Circuit:
Completion Criteria:
1. No foreign particle and material present at the filtering elements after 24 hours of operation.
OIL FLUSHING OF SEAL OIL SYSTEM COMPLETED SUCCESSFULLY

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Hydraulic test on Seal Oil piping
A. Hydraulic testing of seal oil piping excluding rack(may be conducted along with lube oil system)
Date Pressure Time duration
Circuit taken:
Note:
1. Above test to be conducted at 1.5 times working pressure for 30 minutes.
2. No leakage allowed
HYDRAULIC TEST OF SEAL OIL SYSTEM COMPLETED SUCESSFULLY

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Generator Air tightness test
Preparation:
1. Commissioning of Seal oil system completed on ______________________(date)
2. Generator terminal bushings connected on __________________________(date)
3. Assembly of gas system piping completed on _________________________(date)
4. Instrument air drier put in service on ______________________(date)
5. H2 gas cooler inserted on ________________________________(date)

Ensure H2 coolers are not charged with water.
6. Thermostat checking of hydrogen dryer heater done on ___________________(date)
7. Direction of rotation of gas dryer fan checked on ___________________(date)
8. Gas rack unit carbon filter direction and locking of internals checking on_________________(date)
9. Mercury manometer mounted on ______________________(date)
10. Precision test pressure gauge is mounted on ____________(date)

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Air Tightness test
Barometric
Casing pressure in Atmospheric
Activity Date & Time pressure mm of
kg/cm2 temp in °C
Hg column
Start
Finish
Parameter Value Remarks

Pressure drop during test period (24
hours ):
Temp drop during test period (24
hours ):
Equivalent loss of air in 24 hours as
per calculation:
Permitted loss of air in 24 hours at Allowed Actual
__________ pressure
Loss of air in m3:

V=((0.2694*24)/z)*Vg)*(((p1+pb1)/(273+t1)-((p2+pb2)/273+t2))
Vg = Generator Volume in m3
z = duration of leakage test in hours
p1 =gauge pressure within the system at beginning of leak test, mbar
p2 =gauge pressure within the system at end of leak test, mbar
pb1=barometer reading at beginning of leak test, mbar
pb2=barometer reading at end of leak test, mbar
t1= temperature of the gaseous atmosphere at beginning of leakage test, °C
t2= temperature of the gaseous atmosphere at end of leakage test, °C

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY

Air Tightness Test
S. No. Time Casing pressure(mm Hg) Casing pressure(Kg/cm2) Hot/Cold gas
Temp(°C)

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
VIBRATION DATA
Details of instruments used :

DATE BEARING VIBRATIONS (in mm/sec)
& SPEED CONDITION FRONT BEARING REAR BEARING EXCITER
TIME BEARING
H V A H V A H V A
MECHANICAL RUN
At Soaking speed
At 3000 rpm
During Dry out

(If applicable)
DURING S.C.C.
At 50% Load
At 100% Load
DURING O.C.C.
With Excitation
UNDER LOADING
MW MVAR
PROJECT CHECKED BY REV. NO. R 00

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
TEMPERATURE DATA DURING FIRST MECHANICAL RUN
Hot GENERATOR BEARING

SPEED & Winding Core
SL. gas/Cold BABBIT METAL SEAL OIL
TIME temp temp Remarks
NO. gas T. E. E. E. INLET OUTLET max/min max/min

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Short Circuit Characteristics
S. No. Stator Current

Field Field Main Exciter Main Exciter
Voltage Current R Y B voltage Current
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
NOTE:
The above values of Stator current (in steps of 1 KA) and Excitation Current to be plotted on L3/3 and
compared with SCC of shop protocols.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Short Circuit Characteristics Curve

Stator current
Excitation current

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Open Circuit Characteristics Test

Details of Instruments used :
Whether OCC is taken with or without Generator Transformer :
Q-axis Coil Calculated Rotor Stator Voltage

S.
Voltage (Volts) Current (Amps) Remarks
No. R-Y Y-B B-R
NOTE: The above values of Stator voltage (in steps of 10%) and Field Current to be plotted on
sheet 3/3 and compared with SCC in shop protocols.

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
Open Circuit Characteristics Curve

Stator voltage
Excitation current

INSTRUMENT REG. NO.
DATE OF INSPECTION

PSWR-QUALITY
MONITORING SOUNDNESS OF BEARING INSULATION BY SHAFT VOLTAGE

Details of Instruments used:
Voltage Voltage between Shaft & Earth

Sl. No. Condition at between Shaft Without Oil With Oil Film Remarks
Measurement Ends Film Shorted Shorted
NOTE: The voltage difference between voltage with/without oil film shortened should be within
10% in case of healthy bearing insulation

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
TEMPERATURE DATA
SL Time Condition Generator Bearing Gas Temperature Indicated by Stator

No. Babbit Drain Oil RTDs Winding
Temp Remarks
EE TE EE TE COLD HOT
Max.
o
( C)

INSTRUMENT REG. NO.
DATE OF INSPECTION
PSWR-QUALITY
SYNCHRONISATION OF GENERATOR
SL No. DESCRIPTION REMARKS

1. Type of synchronisation :
(Check Synchronisation / Semi - Auto Synchronisation /
Auto synchronisation )
2. Details of synchronising check relay :
i) Phase angle difference
ii) Percentage Voltage difference
iii) Percentage Slip
iv) Time Setting

NOTE : Ensure shorting between relay terminals
No. 11&12 (For English Electric Make relay)
3. Details of matching parameter during synchronisation
i) Location of Generator PT before or after Generator
Transformer
ii) Phase Sequence at Generator PT / Bus PT
iii) Bus PT Voltage as measured at synchronising panel

a. When charged from Generator
b. When Charged from grid
c. Check voltages of different phases between
generator PT and bus PT.
d. Confirm voltages between R-R, Y-Y & B-B
indicate zero when synchronoscope is at 12 O’
clock position to check correct phasing of
both the voltages.
REMARKS:

INSTRUMENT REGN.NO.
DATE OF INSPECTION
PSWR-QUALITY
GENERATOR SYNCHRONISATION - TEST DATA
S. Date Time MW MVAR Freq. Power Bus Stator Voltage Stator Current Rotor Q-axis Remarks
No. Factor Voltage U V W U V W Current coil
Voltage
NAME SIGNATURE / DATE DOC. NO. QPX-TG-001

UNIT NO. ACCEPTED BY LOG SHEET NO. L-40

Generator Aux

Uploaded by

Generator Aux

Uploaded by

FIELD QUALITY PLAN

TURBO GENERATOR & AUXILIARIES

4 X 250 MW THERMAL POWER PROJECT, RAIGARH

REVISION Date 12.01.2007

ISSUED TO: ISSUED BY

BHARAT HEAVY ELECTRICALS LIMITED

2.0 AUTHORIZATION FOR DIFFERENT CLASSES 01

3.2 BRUSHLESS EXCITER

3.3 SEAL OIL SYSTEM

3.4 GAS SYSTEM

3.5 WATER PIPING FOR HYDROGEN COOLERS

3.6 STATEMENT OF CHECKS FOR GENERATOR

5.0 LOG SHEETS (L-00 TO L-40). 59

Sr. No. Reference Document Issuing Authority

01 WELDING MANUAL PSWR, NAGPUR

02 HEAT TREATMENT MANUAL PSWR, NAGPUR

03 NDE MANUAL PSWR, NAGPUR

04 GENERATOR ERECTION MANUAL. PSWR, NAGPUR

05 PROCEDURE FOR OIL FLUSHING. PSWR, NAGPUR

06 TECHNICAL INSTRUCTION FOR AIR LEAK PSWR, NAGPUR

07 ERECTION DRAWINGS. BHEL, HARIDWAR

08 SHOP TEST CERTIFICATES / TEST BHEL, HARIDWAR

Task performer Head of Section Engineering Centre/

Task performer Task performer Engineering Centre/

3. In case of nonconformity, accepting authority shall ensure disposition of nonconformity

1.4 Ensure permanent benchmark is made V B 100% Marking By

1.5 Check elevation at different points on the M B 100% Civil Drawing

2.5 Ensure that dimensions (including diagonal M Measuring B 100% - do - Protocol

5.0 Stator Winding:

A– CRITICAL, B– MAJOR, C– MINOR CHECK

6.1 Check cleanliness of joining surfaces. V C 100%

21.1 Labyrinth Rings & their Assembly.

24.6 Ensure there is no blockage of ring relief oil and V C 100%

32.4 Ensure balancing of coupling by putting bolts & M Weighing C 100%

35.2 Check tightness of the tube bundle. No V C 100%

35.3 Check the cooler chamber for presence of any V B 100%

3.1 Check condition of Babbitt for any crack V B 100%

3.6 Ensure proper mounting of vibration pick-ups. V C 100% Drawing

3.7 IR check on bearing insulation. Minimum IR M 1KVMegger B 100%

A– CRITICAL, B– MAJOR, C– MINOR CHECK

3.4 During normalisation of the system, ensure that V C 100% -do-

A– CRITICAL, B– MAJOR, C– MINOR CHECK

A– CRITICAL, B– MAJOR, C– MINOR CHECK

8.4 Check correctness of rotor current indication M Control panel C 100%

DRAWING / DOCUMENT NO.

RECORD OF QUALITY CHECKS

DRAWING / DOCUMENT REF.

HYDRAULIC TESTING OF HYDROGEN COOLERS

Pressure gauge details:

Instrument Reg. No. Calibration Date Calibration Next due date

Testing Actual Starting Ending

NO LEAKAGES WERE OBSERVED.

NAME SIG. / DATE DOC. NO. QPX-TG-001

PROJECT CHECKED BY REV NO.: 01

UNIT NO. ACCEPTED BY LOGSHEET NO. L-01

RATING CUSTOMER SHEET 1 / 3

DRAWING / DOCUMENT REF.

HYDRAULIC TESTING OF PIPING FOR H2 COOLERS

Pressure gauge details:

Instrument Reg. No. Calibration Date Calibration Next due date

NO LEAKAGES WERE OBSERVED.

NAME SIG. / DATE DOC. NO. QPX-TG-001

PROJECT CHECKED BY REV NO.: 01

UNIT NO. ACCEPTED BY LOGSHEET NO. L-01

RATING CUSTOMER SHEET 2 / 3

DRAWING / DOCUMENT REF.

AIR LEAK TEST OF TERMINAL BUSHINGS BEFORE ASSEMBLY

Pressure gauge details:

Instrument Reg. No. Calibration Date Calibration Next due date

NO LEAKAGES WERE OBSERVED.

NAME SIG. / DATE DOC. NO. QPX-TG-001

PROJECT CHECKED BY REV NO.: 01

UNIT NO. ACCEPTED BY LOGSHEET NO. L-01

RATING CUSTOMER SHEET 3 / 3

DRAWING / DOCUMENT NO.

TESTS ON STATOR & ROTOR WINDING