COMPANY PROPRIETARY

NOT TO BE REPRODUCED OR DISCLOSED WITHOUT SPECIF IC

WRITTEN PERMISSION OF MITSUBISHI ELECTRIC CORPORATIO N

1. Preface

In this repair work of generator on GECELCA 3 POWER PLANT, MELCO attended to the generator
assembly work as the assembling adviser from 12th Apr. 2018 to 9th May. 2018.
This document describes the assembly records and the recommendation about the generator
assembly work.

2. Work schedule of assembly work

Regarding the generator assembly work, actual schedule is shown in attachment-1.

3. Replacement items for assembly work

Regarding the each parts for generator assembly, replacement (supplied by customer or MELCO) or
reuse items are shown in Table-1.

Table 1
Replacement
No. Item Reuse
MELCO Customer
1 Rotor blade ○
2 Brower shroud ○
3 Inner shield ○
4 Outer shield ○
5 Gas seal ring ○
6 Oil seal for bearing ○
7 Bearing ○
8 Bearing pedestal ○
9 Oil piping ○
10 CT ○
11 Flexible lead for IPB ○
12 Collector ring ○

4. Record of assembly work

The work records for the generator assembly are described as follows.

・Record list
Fig 1: LP TURBINE AND GENERATOR ROTOR ALIGNMENT (BEFORE ADJUSTMENT)
Fig 2: LP TURBINE AND GENERATOR ROTOR ALIGNMENT (AFTER ADJUSTMENT)
Fig 3: GENERATOR & TURBINE COUPLING RUN OUT
Fig 4: AXIAL ADJUSTMENT AND CONNECTION FOR COUPLING BOLTS
Fig 5: INSULATION RESISTANCE FOR GENERATOR BEARING
Fig 6: GENERATOR BEARING CLEARANCE
Fig 7: SIDE CLEARANCE FOR GENERATOR BEARING
Fig 8: AXIAL SET OF GENERATOR ROTOR
Fig 9: AIR GAP BETWEEN GENERATOR STATOR AND ROTOR
Fig 10: GAP BETWEEN OIL SEAL AND ROTOR FOR #5 BEARING
Fig 11: GAP BETWEEN OIL SEAL AND ROTOR FOR #6 BEARING
Fig 12: GAP BETWEEN GENERATOR GAS SEAL RING AND SHAFT JOURNAL
Fig 13: GAP BETWEEN GENERATOR FAN BLADE AND BLOWER SHROUD
Fig 14: RADIAL GAP AROUND COLLECTOR RING
Fig 15: THICKNESS OF LINER UNDER BEARING PEDESTAL FOR GENERATOR ROTOR
Fig 16: GAP BETWEEN BRUSH BOX AND COLLECTOR RING
Fig 17: GENERATOR ROTOR BLADE POSITION AT TURBINE SIDE
Fig 18: GENERATOR ROTOR BLADE POSITION AT COLLECTOR RING SIDE

AIC-TG0-18029
2
 COMPANY PROPRIETARY
NOT TO BE REPRODUCED OR DISCLOSED WITHOUT SPECIF IC
WRITTEN PERMISSION OF MITSUBISHI ELECTRIC CORPORATIO N

5. Recommendation
Regarding the generator assembly work, MELCO would like to inform following recommendations from
standpoint of quality and safety.

5.1. Labyrinth of gas seal ring (both Turbine side and collector ring side)
We confirmed the damage such as contact trace at labyrinth of gas seal ring.
The clearance between gas seal ring and shaft does not satisfy the criteria of original manufacture’s
design due to damage of labyrinth. Therefore there are possible risks for operation with this gaps as
follows.
A) Foreign materials such as dusts might invade inside of generator.
B) Generator temperature might be affected by the outside air flowed into generator.
We recommend to replace with new one in next inspection.

Gas seal ring

Labyrinth is damaged

The situation of gas seal ring

5.2. Assembly of the generator rotor

In this assembly work, we confirmed that the rotor was inserted being supported by the bearing
pedestal which was assembled temporary.
And then, the pedestal slid and moved along with rotor by rolling the piping located under it.
MELCO considers that this method takes much time and is not safety.
Therefore, MELCO recommends using the crane instead of bearing pedestal for support the rotor at
collector ring side to improve the workability and safety.
In this case, supporting tool for placing under the rotor temporarily are required when assembling
the collector ring side pedestal.
MELCO can provide it in accordance with customer's inquiry.

Piping

Insertion of generator rotor

AIC-TG0-18029
3
 COMPANY PROPRIETARY
NOT TO BE REPRODUCED OR DISCLOSED WITHOUT SPECIF IC
WRITTEN PERMISSION OF MITSUBISHI ELECTRIC CORPORATIO N

5.3. Field lead for collector ring

We confirm that field lead was loosen because it is not fixed at inside of collector ring bed.
Field lead should be fixed by collector ring bed to prevent the continuous impact by vibration in
operation.
So, we recommend that fixation department of field lead will be repaired at next inspection.

Field lead is loosen

Field lead

5.4. Air gap between stator core and generator rotor

Measurement of air gap took much time and was difficult because the space for measurement is
narrow.
We consider that the workability of the air gap measurement can be improved by using the special
tool designed by MELCO as shown in below Fig.
So, we would like to recommend that the special tool is purchased for next inspection.

Air gap

Ex.) Gap gauge

Inner flame

Gap gauge

Rotor Measurement position

Image of using the gauge (Cross section)

AIC-TG0-18029
4
 COMPANY PROPRIETARY
NOT TO BE REPRODUCED OR DISCLOSED WITHOUT SPECIF IC
WRITTEN PERMISSION OF MITSUBISHI ELECTRIC CORPORATIO N

5.5. Record before the disassembly

We recommend that record for each gap (Oil seal, gas seal ring, Collector ring fan etc…) and run
out data after decoupling are measured before disassembly.
Because, it need to compare the value after the assembly with the value before disassembly.

5.6. Measurement of generator fan blade gap

In this work, measurement of generator fan blade gap for using filler gauge took much time.
We consider that using the taper gauge instead of filler gauge makes workability improved.
So, we would like to recommend that the taper gauge as below is purchased from MELCO at next
inspection.
※specification of taper gauge(measurement range)：0.5 ~ 3.0mm, 3.0 ~ 5.0mm

Measurement position
Taper gauge

5.7. Gap between fan blade and blower shroud(collector ring side)
Measurement value of fan blade gap is satisfied in this work.
However, we were not able to adjust to lower side because holes for inner shield interfered with
bolts (collector ring side).
If inner shield is moved to lower side at next inspection, we recommend some work as below. In
the same way about turbine side, if inner shield cannot adjust in the different direction it need to
work as below.

1. The size of the hole for inner shield are extended according to situation.
2. If necessary, L-shaped key is machined contact surface at inner shield (Depend on value of
movement for inner shield).

Size up for hole

Machining of L-shape key

AIC-TG0-18029
5
 Attachment-1
Apr,2018 May,2018
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9
D D D D D D D D D D D N D N D D D D D D D D N D N D N D D D D D D
Generator assembly
Coupling machining BY GECELCA
Instalation work of TSI
BY GECELCA
Assembly of gear box BY GECELCA
Coupling between LP and GEN
BY GECELCA
Turning for 8 hrs BY GECELCA
Initial run for balancing
Preparation of assembly for generator
rotor
Assembly for generator rotor
Assembly around bearing
Alignment and coupling between
generator and turbine
Adjustment of air gap between stator
core and rotor
Assembly of blade for generator rotor
Assembly of inside shield & wind
guiding
Assembly of outer shield & gas seal
ring
Assembly around collector ring
Assembly of oil piping
Assembly of main lead(Flexible lead)
Replacement of CT
※ ： Actual work
： Preparation
 LP TURBINE AND GENERATOR ROTOR ALIGNMENT (BEFORE ADJUSTMENT)
VIEWING
DATE 23-Apr-18 From Turbine　side
DIRECTION
UNIT It is 1/100 except entry
SIGNATURE H.TERUYA
MEASURING Dial Indicator
ROOM TEMP. - ℃ APPARATUS Outside micrometer

Planed value
Concentricity：
0.01mm ±0.03mm*1 in vertical direction
(Generator upper side)
0.0mm ±0.03mm*1 in horizontal direction
Parallelism ：
0.0mm ±0.03mm*1 in vertical and horizontal direction
LP GEN ※1 : These value is MELCO's standard
CONCENTRICITY PARALLELISM

45.0 0.00

LP COUPLING 0
28.0 17.0 3.00 4.00

0.0 9.00

LP COUPLING 180

AVERAGE

VERTICAL DIFFERENCE VERTICAL DIFFERENCE

0.225mm GEN Down 0.09mm Lower side open

HORIZONTAL DIFFERENCE HORIZONTAL DIFFERENCE

0.055mm GEN Right side 0.01mm Right side open

FORM NO
FIG. 1
 LP TURBINE AND GENERATOR ROTOR ALIGNMENT (AFTER ADJUSTMENT)
VIEWING
DATE 24-Apr-18 From Turbine　side
DIRECTION
UNIT It is 1/100 except entry
SIGNATURE H.TERUYA
MEASURING Dial Indicator
ROOM TEMP. - ℃ APPARATUS Outside micrometer

Planed value
Concentricity：
0.01mm ±0.03mm*1 in vertical direction
(Generator upper side)
0.0mm ±0.03mm*1 in horizontal direction
Parallelism ：
0.0mm ±0.03mm*1 in vertical and horizontal direction
※1 : These value is MELCO's standard
LP GEN
CONCENTRICITY PARALLELISM

0.0 2.00

LP COUPLING 0
1.0 2.0 1.00 1.00

3.0 0.00

LP COUPLING 180

AVERAGE

VERTICAL DIFFERENCE VERTICAL DIFFERENCE

0.015mm GEN UP 0.02mm Upper side open

HORIZONTAL DIFFERENCE HORIZONTAL DIFFERENCE

0.005mm Left side 0.00mm

Judge good FORM NO

FIG.2
 GENERATOR & TURBINE COUPLING RUN OUT

VIEWING
DATE 21-Apr / 29-Apr-18 From turbine
DIRECTION
UNIT 1/100mm
SIGNATURE By customer
MEASURING
Dial Indicator
ROOM TEMP. - ℃ APPARATUS

GENERATOR TURBINE

RUN OUT ( Before connection)

2.0

0.0 1.0
1(A) 1(A)
２ ２

0.0 ３
GEN 2.0 ３
LP

1.0 2.0

4.0

RUN OUT ( After connection)

3.0 0.0

2.5 4.5 1.0 0.5

1(A) 1(A)
２ ２

３
GEN LP 1.0
0.0 3.0 2.0 ３

0.0 2.0 1.5 0.0

0.0 0.0

FORM NO
FIG.3
 AXIAL ADJUSTMENT AND CONNECTION FOR COUPLING BOLTS

DATE 1-May-18 ROOM TEMP. - ℃

VIEWING
SIGNATURE H.TERUYA DIRECTION
View form turbine

View from Turbine

Allowable value for coupling bolt elongation : 0.14～0.18mm

Bolt Bolt Bolt Bolt

number elongation number elongation

1 0.17 7 0.16

2 0.16 8 0.14

3 0.17 9 0.14

4 0.16 10 0.14

5 0.16 11 0.16

6 0.17 12 0.16

FORM NO
FIG.4
 INSULATION RESISTANCE FOR GENERATOR BEARING

UNIT MΩ
DATE 20-Apr-18
MEASURING
1000V Megger
APPARATUS
SIGNATURE H.TERUYA

INSULATION RESISTANCE

Allowable value : More than 1MΩ

#5 Bearing #6 Bearing
Insulation Resistance Insulation Resistance
speacer (MΩ) speacer (MΩ)
1# 2000 1# 1100
2# 2000 2# 1700
3# 1100 3# 1200
Judge Good Judge Good

FORM NO
FIG. 5
 GENERATOR BEARING CLEARANCE

VIEWING
DATE 23-Apr-18 From Section
DIRECTION
UNIT mm
SIGNATURE H.TERUYA
MEASURING
Filler gauge
APPARATUS

#5 Bearing #6 Bearing
Out board In board In board Out board

b1 b2 b2' b1'

Allowable vertical clearance :

Designed dimension : 0.52mm ~ 0.65mm

#5 Bearing #6 Bearing
Mesuremant Mesuremant Mesuremant Mesuremant
No. No. No. No.
Value(mm) Value(mm) Value(mm) Value(mm)

b1 0.63 b2 0.63 b1' 0.59 b2' 0.59

Judge Good Judge Good

FORM NO
FIG. 6
 SIDE CLEARANCE FOR GENERATOR BEARING

VIEWING
DATE 22-Apr-18 From Section
DIRECTION
UNIT mm
SIGNATURE H.TERUYA
MEASURING
Filler gauge
APPARATUS

#5 Bearing #6 Bearing

c1 c2 c2' c1'

a1 a2 a2' a1'

Out board In board In board Out board

Allowable value(MELCO standard) :
Difference of "a1" and "a2" within 0.03mm
(Similarly "c1" and "c2" , "a1'" and "a2'" , "c1'" and "c2'")

#5 Bearing #6 Bearing
Mesuremant Mesuremant Mesuremant Mesuremant
No. No. No. No.
Value(mm) Value(mm) Value(mm) Value(mm)

a1 0.53 c1 0.51 a1' 0.49 c1' 0.50

a2 0.55 c2 0.50 a2' 0.49 c2' 0.50

Judge Good Judge Good

FORM NO
FIG.7
 AXIAL SET OF GENERATOR ROTOR

ROOM TEMP. - ℃
DATE 28-Apr / 30-Apr-18
UNIT mm
SIGNATURE H.TERUYA

#5 Bearing #6 Bearing

S d e h d e h

DESIGN VALUE 28±2 42±2 0～0.1 28±2 42±2 0～0.1

MEASUREMENT
VALUE
101.0 29.0 41.5 0.04 29.0 41.0 0.05

S: THICKNESS OF GEAR SPACER

FORM NO
FIG. 8
 AIR GAP BETWEEN GENERATOR STATOR AND ROTOR
ROOM TEMP. - ℃
DATE 26-Apr-18
UNIT mm
SIGNATURE H.TERUYA

Turbine side
View from Turbine
79.90

Judge

80.05 80.00 Good

80.10

Collector ring side

79.80
View from collector ring

Judge

79.90 80.10 Good

80.30
FORM NO
FIG.9
 GAP BETWEEN OIL SEAL AND ROTOR FOR #5 BEARING
ROOM TEMP. - ℃
DATE 30-Apr-18
UNIT mm
SIGNATURE H.TERUYA

① ②

①Outboard side
View from turbine
0.43

Judge

0.50 0.07 Good

0.13

②Inboard side
0.55
View from turbine

Judge

0.49 0.12 Good

0.11
FORM NO
FIG.10
 GAP BETWEEN OIL SEAL AND ROTOR FOR #6 BEARING
ROOM TEMP. - ℃
DATE 28-Apr-18
UNIT mm
SIGNATURE H.TERUYA

② ①

①Outboard side
View from collector ring
0.61

Judge

0.11 0.48 Good

0.19

②Inboard side
0.44
View from collector ring

Judge

0.15 0.50 Good

0.15
FORM NO
FIG.11
 GAP BETWEEN GENERATOR GAS SEAL RING AND SHAFT JOURNAL
ROOM TEMP. - ℃
DATE 9-May-18
UNIT mm
SIGNATURE H.Shibukawa

Turbine side
1.85
View from turbine

Judge

0.9 1.69 Not good

Refer to the third page

clause 5.1 of the report.

1.6

Collector ring side

0.5
View from collector ring

Judge

0.2 0.45 Not good

Refer to the third page

clause 5.1 of the report.

1.04
FORM NO
FIG.12
 GAP BETWEEN GENERATOR FAN BLADE AND BLOWER SHROUD
ROOM TEMP. - ℃
DATE 2-May-18
UNIT mm
SIGNATURE H.TERUYA

Turbine side
3.0
View from turbine

Judge

2.5 2.2 good

2.7

Collector ring side

3.15
View from collector ring

Judge

2.2 2.35 good

1.85
FORM NO
FIG.13
 RADIAL GAP AROUND COLLECTOR RING
ROOM TEMP. - ℃
DATE 3-May-18
UNIT mm
SIGNATURE H.TERUYA

Air shield gap(without collector cover)

View from collector ring
1.15

Judge

0.85 1.15 good

0.85

Collector fan blade gap

2.65
View from collector ring edge

Judge

2.0 2.5 good

1.55
FORM NO
FIG.14
 THICKNESS OF LINER UNDER BEARING PEDESTAL FOR GENERATOR ROTOR

DATE 24-Apr-18 Unit mm

SIGNATURE H.TERUYA

#5 Bearing #6 Bearing

Before alignment
#5 Bearing #6 Bearing

Thickness(mm) amount Thickness(mm) amount

0.06 1 0.28 4
0.28 2 0.48 3
0.48 2 0.9 1
0.9 1 2 1
1.78 1
total 4.26 total 5.46

After alignment
#5 Bearing #6 Bearing

Thickness(mm) amount Thickness(mm) amount

0.28 1 0.28 3
0.45 1 0.48 2
0.48 2 0.9 1
0.9 1 2 1
1.78 1
total 4.37 total 4.70

FORM NO
FIG.15
 GAP BETWEEN BRUSH BOX AND COLLECTOR RING

DATE 2-May-18 ROOM TEMP. - ℃

VIEWING
SIGNATURE H.TERUYA DIRECTION
View form turbine side

Turbine Side Shaft End Side

① ② 4 5

3 6

2 7

1 8

Slipring
View from Turbine side

We confirmed that the brush touched contact surface of collector ring.

Unit:mm
① ②

Measurement Measurement
No. No.
value(mm) value(mm)

1 4.2 1 4.2

2 4 2 4.2

3 4 3 4.6

4 4.2 4 4.2

5 4.2 5 5

6 4.3 6 4.5

7 4.3 7 4

8 4.2 8 4.5

Only for reference

FORM NO
FIG.16
 GENERATOR ROTOR BLADE POSITION AT TURBINE SIDE

VIEWING
DATE 20-Apr-18 DIRECTION From Turbine side

SIGNATURE H.TERUYA Unit g

Ｔ－２７ Ｔ－１

Ｔ－２１ Ｔ－８

View from turbine side

Counter Clockwise direction

Blade Blade
Weight(g) Weight(g)
position position
T-1 1263 T-15 1261.6
T-2 1263.1 T-16 1262
T-3 1262.2 T-17 1262.7
T-4 1262.2 T-18 1261.5
T-5 1262.2 T-19 1262.5
T-6 1261.4 T-20 1262.9
T-7 1261.2 T-21 1262.6
T-8 1263 T-22 1261.5
T-9 1262.3 T-23 1262.4
T-10 1262.5 T-24 1261.5
T-11 1262 T-25 1261.5
T-12 1261.8 T-26 1262.2
T-13 1262 T-27 1261.4
T-14 1262.5

FORM NO
FIG.17
 GENERATOR ROTOR BLADE POSITION AT COLLECTOR RING SIDE

VIEWING
DATE 20-Apr-18 DIRECTION From collector ring side

SIGNATURE H.TERUYA Unit g

Ｓ－２７ Ｓ－１

Ｓ－２１ Ｓ－８

View from collector ring side

Clockwise direction

Blade Blade
Weight Weight
position position
S-1 1263.4 S-15 1261.1
S-2 1261.9 S-16 1261.7
S-3 1265.2 S-17 1264.1
S-4 1264.9 S-18 1264.4
S-5 1261.7 S-19 1264.9
S-6 1261.6 S-20 1261.4
S-7 1262.8 S-21 1262.2
S-8 1262.6 S-22 1263.5
S-9 1264 S-23 1261.6
S-10 1264 S-24 1265.1
S-11 1261.8 S-25 1263.6
S-12 1263.9 S-26 1261.7
S-13 1264.3 S-27 1263.4
S-14 1263.7

FORM NO
FIG.18