Document vyYXbX1KzYvqz5E0MMOy7de5w

1 /?ft<ltstuciic4c C=3 oo 600 KW TURBINE GENERATOR UNITS Turbine, Reduction Gear, Generator, Exciter and Regulator lor HULLS 1053 & 1054 THE INGALLS SHIPBUILDING CORPORATION Paseagoula, Mississippi Ingalls Hull No. 1053 Customers Order No. CCY-2 Westinghouse Order No. BH-69181-T2 Ingalls Hull No. 1054 Customers Order No. CDE-2 Westinghouse Order No. BH-71041-T2 January, 1959 x5-A1403 MH-729-B ______________________________________________________________ (g WESTINGHOUSE ELECTRIC C O R P O R A T I South Philadelphia Works - Steam Division - Essington, Pa. INSTRUCTION BOOK 1430-C95 pjE`0G03s2r Printed In U.S.A. TURBJNE-GENERATOR UNITS Serial Number Assignments INGALLS HULL NO. 1053 S/S Unit No. 1 Unit No. 2 Turbine Generator 15-A-1404-1 15-A-1404-2 1-S-58-P-316 2-S-58-P-316 INGALLS HULL NO. 1054 S/S Exciter 1-S-58-P-317 2-S-58-P-317 . Turbine Generator Exciter Unit No. 1 Unit No. 2 15-A-1404-3 15-A-1404-4 1-S-57-P-994 2-S-57-P-994 1-S-57-P-995 2-S-57-P-995 NOTE: Hie letter "S" in Generator or Exciter Serial Number, means "Stator*. Hie rotor bears the same Serial Number with the letter *R" in place of "S". . Communications Should communications be desirable or necessary regarding the unit instal lation covered by this instruction book, or an individual device included in the installation, replies will be greatly facilitated by citing tbe Westinghouse General Order Number for tbe complete equipment and tbe nameplate readings for the detail apparatus involved. Do not fail to give the turbine and/or generator stator and rotor serial number and the complete nameplate reading, when information is desired. The turbine data and serial number are stamped on the nameplate, mounted on the turbine exhaust end cover. The generator stator serial number is stamped on the generator nameplate, and also on the metal under the nameplate and on the machine foot. The generator rotor serial number is stamped on the end of the shaft. Should any particular information be desired, please be very careful to state clearly and fully the question for consideration, and the associated con ditions. Communications should be addressed to the nearest Westinghouse Electric Corporation Sales Office. Local sales, engineering or service representatives are usually available for quick consultation. Ordering Repair or Renewal Parts When ordering repair or renewal parts, give the name of the parts, the illustration or drawing and item numbers which apply and the nameplate reading of the machine, including the serial number. 2 r;-0003'2-: 1430C95 TURBINE AND REDUCTION GEAR Table of Contents Page Serial Number Assignment ...................................................................................... Communications ......................................................................................................... Order Repair Parts ................................................................................................. 2 2 2 Chapter 1 - Turbine &-Reduction Gear . Chapter 2 - Ships Service A-C Generator Chapter 3 - D-C Rototrol Exciter . . . Chapter 4 - Generator Voltage Regulator Red Tab 1 2 3 4 n--n m 1430C95 HbE-00038229 3 TURBINE-GENERATOR UNITS Serial Number Assignments INGALLS HULL NO. I0S3 S/S------------------------ 1 Turbina Generator Eiciter (bit NO. 1 Unit No. 2 15-A-1404-1 15-A-1404-2 1-S-58-P-316 2-S-58-P-316 1-S-58-P-317 2-S-58-P-317 INGALLS HULL NO. 1064 S/S Turbine Generator Exciter Unit No. 1 Unit No. 2 15-A-1404-S 15-A-1404-4 l-S-57-P-994 2-6-57-P-994 1-6-57-P-995 2-S-57-P-995 NOTE: Tbe letter *S* In Generator or Exciter 8erlal Ntaber, hui 'Stator". The rotor beam the sue Serial Number with the letter *R* In place of *6*. Communications Should cooiunicatlons be desirable or necessary regarding tbe unit Instal lation covered by this Instruction book, or an Individual device Included in the Installation, replies sill be greatly facilitated by citing the Nestlnghouse General Order Number for the complete equipment and the nameplate readings for tbe detail apparatus Involved. Do not fall to give the turbine and/or generator stator and rotor serial number and the complete nameplate reading, when Information is desired. Tbe turbine data and serial number are Btamped on the nameplate, mounted on the turbine exhaust end cover. Tbe generator stator serial number is stamped on tbe generator nameplate, and also on the metal under the nameplate and on the machine foot. The generator rotor serial number is stamped on the end of the shaft. Should any particular Information be desired, please be very careful to state clearly and fully the question for consideration, and the associated con ditions. Communications should be addressed to the nearest Nfestlnghouse Electric Corporation SaleB Office. Local sales, engineering or service representatives are usually available for quick consultation. Ordering Repair or Renewal Parts When ordering repair or renewal parts, give the name of the parts, the Illustration or drawing and item numbers which apply and the nameplate reading of the machine. Including the serial number. 2 1430C95 Table of Contents Serial Number Assignment Communications ............... Order Repair Parts . . . Chapter 1 - Turbine ft-Reduction Gear . Chapter 2 - Ships Service A-C Generator Chapter 3 - D-C Rototrol Exciter . . . Chapter 4 - Generator Voltage Regulator TURStKE ARD REOUCTIOH GEM Page 2 2 2 Red Tab 1 2 3 4 oc m: 3 3! 1430C95 t=* m mHOOU'l! 3 t 1430COS TURBINE AND REDUCTION GEAR Table of Contents Subject list of Turbine and Reduction Gear Illustrations Section 1.1 - Turbine Details ............................. Turbine & Reduction Gear Characteristics . . . General Description ................... . ................... Cylinder .................................................................. Rotor ..................................................................... Curtis Blading ....................................................... Rateau Blading ....................................................... Interstage Seals ................................................... Curtis Wheel Chamber Labyrinth Seals ..... Turbine Glands ....................................................... Bearings .................................................................. Oil Seal Rings ....................................................... Stean, Drain and Gland Piping .......................... Thrust Bearing ....................................................... Rotor Position Indicator .................................... Coupling .................................................................. Throttle Valve ....................................................... Stean Chest ........................................................... Factory Valve Settings ........................................ Governor .................................................................. Speed Changer ....................................................... Section 1.2 - Reduction Gear ...................... General Description ................................. Pinion and Gear Bearings ......................... Alignment of Pinion and Gear .................. Main Oil Punp ............................................ Oil System ................................................... Auxiliary Oil Punp ..................................... Oil Strainer ................................................ Oil Cooler ................................................... Lubricating Oil ........................................ Quality of Oil ............................................ Section 1.3 - Description of Safety Devices Overspeed Trip ............................................... Lo Oil Pressure Trip ................................. Atmospheric Relief Valve ............................. Testing of Safety Devices ......................... Page 100.3 101 101 101 102 102 102 102 103 103 103 103 104 104 104 105 105 106 106 107 107 110 Ill 111 111 111 112 112 112 113 113 113 113 116 116 116 117 117 Is Go fen F Oi & lrt-ODM23f too. TURBINE-GENERATOR UNIT Subject Page Section 1.4 - Installation of Turbine .................................................. Alignment of Unit and Setting ofTurbine Rotor ............................... Pipe Connections.................................................................................... 118 118 119 Section 1.5 - Instructions for Operation ofTurbine ............................. To Start................................................................................................... To Parallel................................................................................................ To Shut Down............................................................................................ Precautions................................................................................................ 120 120 120 120 1$1 Section 1.6 - Care and Maintenance ofTurbine .................................... Inspection............................................................................................... eights....................................................................................................... Rotor Clearance Diagram ......................................................................... Rotor Lifting Gear ................................................................................. Rotor Lifting Device for Removing BearingShells ........................... Tools and trenches................................................................................. Repair Parts ............................................................................................ 122 122 122 122 122 122 123 123 Section 1.7 - Appendix............................................................................. 124 Index................................................................................................... ... . 124 List of Repair Parts............................................................................. 125 to 130 Turbine and Reduction Gear Illustrations ................................. White Tabs 1-28 100.2 MM0JH231 1430C85 TURBINE MO REDUCTION GEAR LIST OF ILLUSTRATIONS Fig. No. Title T-l Outline of Turbine, Gear and Generator ............... T-2 Longitudinal Section through Turbine and Pinion T-3 Curtis and Rateau Blading ................................. . T-4 Interstage Diaphragm Seal Rings .......................... T-S Turbine Bearings ........................................................ T-S T-7 T-8 T-8 T-10 Rotor Glands and Labyrinth Seal Rings . . . Steen, Drain and Gland Piping Diagram . . . Thrust Bearing ................................................... Rotor Position Indicator .... ................... Turbine end Pinion Coupling .......................... T-Il T-12 T-13 T-I4 T-15 Throttle Valve............................................. Governor and Speed Changer............................. Servo-aotor, Steaa Chest Operating Mechanism Steaa Chest Linkage and Valves ...................... Reduction Gear, Longitudinal Asseably . . . T-16 T-17 T-18 T-19 T-20 Reduction Gear Bearings Oil System Diagram . . , Main Oil Pump . . . . . Oil Strainer................. Oil Cooler....................... T-21 T-22 T-23 T-24 T-25 Oil Cooler By-Pass Valve Overspeed Trip ................ Lo Oil Pressure Trip . Rotor Clearances .... Atmosphere Relief Valve T-26 T-27 T-28 Rotor Lifting Gear ................................................... Rotor Lifting Device for Removing Bearing Shells Tools and Wrenches ................................................... White Tab C=3 1 2 3 4 5 oc 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 C=^ 1430C95 00.3 1430C05 CHAPTER 1 - TURBINE AND REDUCTION GEAR G=H Section 1.1. Turbine Details TURBINE AND REDUCTION GEAR CHARACTERISTICS J. Each unit consists of a high-speed con densing turbine, arranged to drive an a-c gen erator and d-c exciter, through the nedlun of a reduction gear, ahlch reduces the high speed required lor efficiency in the turbine to the lover practicable generator speed. The tur bine, gear and generator are bounted on a.coaaon bedplate, to vhich is secured also the oil cooler, etc. An outline arrangement plan of the unit is shown in Figure T-l. 2. Two identical units are supplied for each ship. The noainal rating of each unit is 600 kv, on s 750 kva, 801 power factor, 3 phase, 60 cycle, 450 volt, a-c generator; and a 120 volt, d-c exciter. 3. The turbine is designed and tested to op erate with steaa at a throttle pressure of 585 psig, with 845 FIT. The turbine is also capable of delivering rated load with satis factory operation in all respects when sub jected to pressure and temperature variations as defined in the NEMA Standards for Marine Propulsion Steaa Turbines and Gears. The tur bine will also operate satisfactorily at re-' duced capacity when exhausting to the atmos phere. GUARANTEED PERFORMANCE Load Lotd Percent KW Throttle Steaa Plow Lb/hr Rate Lb/kw/hr. Vacuum In. Hg. Abs. 125 750 7868 100 600 6294 75 450 4892 50 300 3501 10.40 10.40 10.87 11.67 1.5 1.5 1.5 1.5 4. The turbine exhausts into an auxiliary condenser at 1.5 inches Hg exhaust pressure. 5. The normal operating speed of the turbifi is 9,018 rpa and that of the generator 1,200 rpa. 6. The pinion and'gear are of the doubl helical type, and the gear is designed transmit anormal load of 888 brake horsepow with the pinion operating at 9,018 rpa a:0~: the gear at 1.200 rpa. under these conditio the gear bearing pressure is 80.0 pounds pirjr^j square inch of projected area, the piniq bearing pressure is 190 pounds per souare inq of projected area, and the tooth pressure 89 pounds per inch face, per inch pitch circl diameter. 7. The turbine bearing pressures are 90J and 72.4 pounds per square inch of proJecteB area, andthe turbine and pinion Journal speeds are 78. 7 and 108 feet per second, respectively. The gear Journal velocity is 21.0 feet per second. 8. The oil system capacity--at high level 80 gallons; normal level 76 gallons, and low level 72 gallons. GENERAL DESCRIPTION 1. The turbine, of straight-iapulse type, longitudinal section of which is shown i __ Figure T-2, consists of a combination tJf-') Curtis and Rateau stages. The Curtis elemenfip) consists of one pressure stage with two veloqu| lty stages. The Curtis stage is followed byc3 six Rateau stages. 2. The steam, after passing through the -- throttle valve and the steaa chest valves^^ enters the first stage nozzles where it lei'~, expanded to the pressure existing in the lm^--^ pulse chamber. The velocity energy acquireS^ in this expansion is converted into rotative energy by the impulse blades. The steaa is then expanded successively through the Rateau HUE-COD3E2:: 101 TURBI HE--GENERATOR UNIT stages to the pressure maintained in the con denser, thus inparting further rotative energy to the rotor. 3. Hie turbine cylinder is supported at the gear end by lugs on the cylinder base at the level of the turbine centerline, which rest on the gear bousing and are restrained from axial movement relative to the housing by keys set half in'the lug and half in the bousing. The lugs can slide transversely on the keys, thus allowing for differential expansion, but transverse movement of the turbine as a whole is prevented by a vertical key on the end of the cylinder base, held between gibs on the gear housing. The thrust end Is supported by two transverse plates which are bolted to tbe cylinder and the bedplate. Tbe web of the transverse plates provide the necessary flex ibility for longitudinal expansion and con traction of the cylinder. CYLINDER 1. The turbine cylinder consists of a base and cover, bolted together on tbe horizontal Joint, and each Bade In two pieces. The hor izontal and vertical Joint flanges are care fully nachlned to a full bearing surface which provides a true aetal to aetal Joint. These four pieces are Bade froa ahigh grade of cast steel, the steam chest being cast integral with the cylinder cover, high pressure end. ROTOR 1. The turbine rotor is nachlned from asolid alloy-steel forging. Tbe auto-stop body is screwed onto one end and the other end is coupled to the reduction-gear pinion through a flexible coupling. After the blades are Installed, the entire rotating assembly is dynamically balanced. chest valves it enters the nozzle block. This block is made of forged corrosion resistant steel, and is secured to the turbine cylinder by means of caulked wedges and screws. The steam is expanded through round passages in. the block to the pressure existing in tbe Curtis wheel chamber. The blades are milled froa bar stock of corrosion resistant steel and are provided with shrouds, riveted over tenons on the ends of the blades, thus forming a closed passage for the steam flow. 2. The rotating blades are secured to tbe turbine rotor by a type of fastening consist ing of a *T*-root with lugs aachlned on tbe blade shank which straddle and hold In tbe sides of tbe groove, thus resisting the tend ency of the blade-pull to spread tbe side of the blade-groove. Tbe blades are held against the top of groove by half-round segaents, caulked In place at the bottom. With tbls type of fastening it Is, of course, necessary to widen the groove at one point In order to enter the blades in tbe aT* shaped groove. The row Is completely filled with blades and the last blade at this starting point Is se cured by pins. The stationary blades are se cured In straight-sided grooves by a series of short keys which fit In auxiliary grooves, cut In the blade shank and in the side of the main groove. 3. Blade shields are secured to the cylinder and extend around that portion of tbe wheel circumference which Is not utilized for the steam admission nozzles. These shields isolate the blade paths from the remainder of the steam space and thus decrease tbe windage loss due to the blades rotating In the conparatively dense steam. In order to prevent any accumu lation of condensation in tbe bottom of the shields, holes are drilled at the bottom on the vertical centerline, to allow any conden sation to flow to drain. CURTIS BUD I NO 1. Tbe Curtis blading is shown in detail in Figure T-3. The Curtis eleaent consists of one pressure stage with two velocity stages. After the steam has passed through the steam RATEAU BLADING 1. The Curtis element is followed by six Ratean stages, divided from tbe foraer and from each other by Interstage diaphragms. The Rateau blading is illustrated In Fig. T-3. The nozzles for the Rateau stages are aachlned 102 fNE-00CJE23* 1430C95 1430CSS TURBINE AND REDUCTION GEAR units welded into inner and outer rings to pressure. The leakage is carried away through Bake acoaplete diaphragm assembly. The latter the 'dummy leakoff pipe", and re-enters the are Bade in halves and extend completely around turbine cylinder at the fifth stage ofbladi tbe rotor. Tbe second, third, and fourth and it. therefore, gives up most of its aval stage nozzles, however, occupy only a portion able energy in the low pressure end of turbf of tbe circumference, varying in area in suc before passing to the condenser. ceeding stages in accordance with the increase in the volume of the progressively expanded steam. The Rateau blades are similar in de Turbine glands sign and method of fastening to the Curtis wheel blades described previously. 1. At the point where the turbine rotQ^ shaft extends through the ends of thecylindq leakage of steam from, or air into cyllnd INTERSTAGE SEALS is prevented by Beans of glands of the stepp tooth labyrinth type. These glands consi|> 1. Steam leakage froa stage to stage between of a group of tbree rings, each fitted wit the stationary diaphragms and the rotating ten rows of Integrally aachlned labyrin shaft is alnlnlzed by Beans of Interstage strips. Bade in four segments, set in _ seals. These consist of stepped-tooth laby shaped grooves in the gland cases, and heftttj-, rinth strips Bschlned Integrally in rings, against the shoulder of the *L* by Beans aade in four segments, and aounted in "L* flat springs. As shown in the illustratio shaped grooves in the diaphragms. The rings Figure T-6. the rings are prevented from turj are held in position of alnimua clearance by ing by tbe pins. aeans of garter springs as indicated in tbe illustration. Figure T-4 and are prevented 2. The radial clearance between the rotdT froa rotating by Beans of tbe pins. and the gland seal rings are indicated in the illustration. Figure T-24. These radial 2. ' Tbe radial clearances between the rotor clearances are the designed 'cold* clearances. and the interstage seals are indicated in the In addition to the radial clearances, the illustration Figure T-24. These radial clear alloy aetal seal rings have small gaps betwef ances are tbe designed 'cold' clearance and tbe segments, when cold, to provide for eft in addition, tbe seal rings have snail gaps pension and the segments are matched marlufS^ between the segments as shown in the illustra so they may be re-assembled correctly. ' tion Figure T-4. to provide for expansion. The seal rings are Batched marked so that they may be reassesbled correctly. BEARINGS ' CURTIS WHEEL CHAMBER LABYRINTH SEAL 1. In order to minlalze leakage of high pressure steam from the Curtis wheel chamber and to lighten the load on the gland at the high pressure end of the turbine, a group of three seala, aounted in tbe cylinder base and cover is provided between tbe Curtis wheel chamber and the inlet end gland, as shown in Fig. T-6. 2. Each of these three seals is fitted with twelve rows of integrally eachined labyrinth strips by whicb the steaa escaping outward along the shaft is throttled to a much lower 1. The rotating element consists of the tu'r bine rotor, flexible coupling and piniq carried in four bearings which are similar lustrated in Figure T-5. They consist steel shells made in halves, and lined wiiffjj genuine tin base babbitt. Tbe two halves of each bearing are doweled together with pins--'1 and the bearing is prevented from rotating within the housing by a stop dowel which pn@S) Jects into a notch cut in the housing. OiXr^. is admitted on the vertical centerline at tftfeb^ top. the babbitt being relieved to provide^: ample space for the distribution of oil aloitr'-' the Journal surface. On the inner end of the turbine bearings, the shell is grooved into 103 TURBINE-GENERATOR UNIT which in oil baffle is installed, forming an oil pocket. A slot is cut at the bottom of this pocket on the vertical centerline, by neons of which oil bleeding from this end of the bearing is remitted to flow to drain. The turbine bearings have a normal clearance of .005 to .007 inch with a aaxlaum clearance before rebabbitting of .015 inch. 2. The turbine bearings, if removed, nay be measured for wear by cheeking the cron thick ness in four specific longitudinal planes. 3/8 inch in from the end of the bearing. Ra dial lines scribed on the bearing end, as shown in Pig. T-S. designate the neasuring planes. The value of these dimensions at the tine of aanufaeture is stamped on the end of each bearing. Any change in these neasnrenants indicates sear and if excessive, the cause should be Investigated. 2 psig. It will be noted that the nain steaa inlet line, and the lapulse chamber of the cylinder have drains, controlled by valves. These valves should beopened during the start ing periods in order to reaove the condensa tion resulting froa heating of the turbine parts. Further reference to these drains and this illustration will be found under 'Opera tion*. THRUST BEARING > 1. The portion of the end thrust on the rotor, which is not counter-balsnced by the stesa pressure acting against the Curt is Wheel Labyrinth Seals, is transaltted to the sta tionary parts by means of a thrust bearing of the 'Kingsbury* type, illustrated in Figure T-B. It is located on the exhaust end of the turbine shaft and is also shown in Figure T-2. OIL SEAL RIN6S 1. The grooved oil seal rings which are used to prevent the escape of oil along the shaft frat the bearing housings, consist of bronze rings nade in halves, and brass baffle plates also aade in halves. Any oil which creeps along the shaft is caught in the grooves in the oil ring and floss through a series of radial drain boles in the pocket, in the lower half of the ring. Roles are drilled in the baffle which pernlt the oil to flow to drain. These holes are drilled at sufficient height to nalntaln an oil level in the pocket, thus preventing the escape of oil vapor through the drain hole. The oil rings nay be seen in Figure T-2. STEAM DRAIN AND GLAND PIPING 2. The bearing is ofthe single thrust type, having babbitted thrust shoes on one side of the collar, which is a separate piece mounted oo the shaft. As the thrust is in the dlrectlon of the steaa flow, this side of the bearing is provided with four shoes, while a .thrust ring secured to the end of the journal bearing is used on the opposite side of the collar to locate the rotor axially. 3. On the thrust side, the shoes (8) are supported on the leveling blocks (or plates) (6) and (11). which by rocking upon each other allow the shoes to move relatively to one another so that the babbitted faces are all pressed against the collar with equal force. Hence, each shoe takes an equal share of the load. The upper leveling plates (11) rest upon the loser leveling plates (6) which in turn are carried in the base ring (5) which is aade in halves. 1. The diagram of the steaa drain and gland piping is shown in Figure T-7. Sealing steaa for the glands is supplied froa a separate source at approxlaately 10 pslg and a valve and gauge are supplied for controlling the sealing steaa. Approxlaately 80 pounds per hour of steaa will be required at no load to seal the turbine, above 125 Kw the turbine is self sealing. The steaa pressure at the UP. gland should be nalntalned at not sore than 4. As aay be seen in Figure T-2 the base ring is supported in the housing. It is cen tered by the key (4) shown in Section A-A of Figure T-8. The thrust ring is located by a liner between it and the Journal bearing. 5. The correct axial position of the thrust bearing, and hence the correct axial location of the rotor, is determined by the thickness of the filler piece, shown in Figure T-2, and 104 NH-0MM2!' 1430C95 1430C95 TURBINE AND REDUCTION GEAR in Figure T-8 between tbe base ring (S) and the bousing. The thickness of this filler piece Bust be such that with the rotor barred toward the exhaust end as far as it sill go, the clearance between the nozzle block and the first row of Curtis blades is as shown on.the clearance diagram, Figure T-24. 6. The actual Internal clearance ofthe bear ing should be between .008 and .012 inch in order to permit establishment of a proper oil film between the collar and tbe shoes. After tbe filler piece of correct thickness (as described previously) has been installed, the proper running clearance is obtained by ad justing the thickness of the liner which is located between tbe thrust ring and the tur bine bearing. This clearance should be checked by rolling the rotor and barring it froa one extreae axial position to tbe other, and then measuring tbe end travel with a dial type in dicator. 7. If tbe bearing has been disasseabled for cleaning or repair, the following notes will assist in simplifying reasseably. 8. First clean and Inspect all parts care fully. Oil the bearing surfaces when assem bling. 9. All bearing parts are to be assembled ra dially with tbe housing cover removed. See Figure T-8; with the shaft in position, first rotate loner half of brass oil control ring (14). into place under collar. 10. Place the leveling plates (6) and (11) and four shoes in position on the split halves of tbe base ring (S), and secure by screws, (12) and cotter pins as shown. Rotate the lower half of the base ring into place on inner side of collar, with parts attached and follow with upper half and its key (4). 11. Bolt under half (1) of oil control rings to lower half (14). the halves of the thrust ring (16) and (17) are secured to the upper and lower halves of the Journal bearing. As semble end cover. 12. Turn base ring (5) to bring Joint vertical, and test end-play by jacking shaft end-wise and aeasuring tbe amount of movement with feelers. Adjust thickness of one or both tenxin filler pieces, by shimming or machining, -" make total end-play between.008 and.012 in maintaining Curtis blade clearance as notfd above. When found to be correct, turn fagse, ring to bring key (4). to top center, and housing cover down. 13. Do not force when assembling. If parts do not go together easily, somethingis out of place. 1 n ROTOR POSITION INDICATOR 1. The rotor position indicator whichu bolted to tbe end of the thrust bearing horn ing is shown in Figure T-9. A reading}* taken by pushing lightly on the pad *A'i the pointer (10). until the ball (4) mas contact with the end oftbe rotor. Immedlatp after Installation, the rotor should be bar toward the exhaust end and while in this sltion, the pointer should be set at zero, loosening the clamp screw in the pointer to adjust it and then tightening up securely, and pinning. Thereafter when a reading is taken, the displacement of the pointer from , zero, will indicate an axial displacement^ the rotor, one division on the graduated sell (13) representing a displacement of the rofei of .002 inch. A small spring (6) holds tjj ball out of contact with the turbine roc when the indicator is not being used. It/ obvious that readings should be taken, eltn with tbe unit carrying load or with the roe barred toward the exhaust end. OtherwlJ the clearance in the thrust bearing may gkve_2 an erroneous reading. COUPLING % lrc3 1. The turbine rotor and the reduction gear pinion are connected by means of a couplijjtg^ of the Sier-Bath type, illustrated in Figure-s T-10. 2. As may be seen in detail in the lllustrW^ tion the coupling is of the internal, iovolut^?, toothed type. The coupling beads are pressed and keyed to the turbine and pinion shafts respectively and the two halves of the sleeve ME-0M3BJ1 05 TURBIRE-GEHERATOR UNIT are bolted together to sake the driving con nection. 3. Lubrication is supplled by means of sprays of oil directed into the lip of the sleeve, from nipples in the pinion and turbine bearing ends and a positive circulation of oil, to prevent sludging of the tooth clearances, is alntained by virtue of a number of outlet holes on the periphery of the sleeve flange. Additional Information *111 be found under 'Installation* and under 'Maintenance*. 6. The valve disc (3). and seat (2). are provided with cobalt-chromium contact surfaces to prevent erosion and the valve is held on the stem (7), by the disc flange (5). Leakage along the valve stem lsminimized by the leakoff bushing (8). 7. The steam strainer basket (43). is carried in the body which is welded to the throttle valve body (1). It is made of corrosion-re sistant steel and is held in pjace by the bonnet (40). THROTTLE VALVE 1. Steam is admitted to the turbine by a horizontally disposed throttle valve which is shorn in Figure T-ll. This valve is manually operated by a handwheel, but can be closed automatically by a compression spring, when the trip release latch is tripped by the over speed trip mechanism. 2. The valve is of the unbalanced, single seat type. It is guided in a cylindrical re cess in the bonnet (10), and secured to the spindle (19). by neans of the stem (7) and a slotted coupling (IS). Thrust washers (13) and (14) serve to eliminate clearance in the coupling. 3. The handwheel spindle (19) is threaded through a sliding valve stem nut (17). sub jected to compression of the sprint (18). and prevented from turning by the guide (16), which is welded to the yoke (20). The nut (17). is normally held out against the spring force by the trigger shaft (30). which is con nected to the overspeed trip device. 4. When the overspeed trip functions, the trigger shaft is rotated, thus freeing nut (17) and permitting the spring to push the valve stem in the closing direction, thus closing the valve.5 5. To reset the device, it is necessary first to turn the wheel all the say in the closing direction, thus forcing the sliding nut (17). outward until the trigger shaft (30), is re engaged through the tension of the relatch spring (35). STEAM CHEST 1. The governor and servo-motor Operating mechanism is shown in Figures T-12 and T-13, the latter showing the connections for the arrangement of the steam chest linkage. The steam chest body is an integral part of the turbine cylinder, and the cover serves also as a linkage support. The turbine is provided with four valves, which are arranged in par allel within the steam chest; that is all valves are surrounded with steam at approxi mately throttle pressure. The valves are numbered, 1, 3, 2, and 4 beginning atthe stud and continuing in aclockwiae direction, look ing from the top of the valve stems. The steam chest is shown in Figure T-14. 2. These valves are of the single seated, plug type. The seating surfaces are spherical and the seats are of the diffuser type. The seats are pressed in the steam chest body and seal welded, but can be renewed if necessary. As shown in the illustration, the valves are carried by a flange formed on the end of the valve lifting rod. This lifting rod is con nected to the operating mechanism by tbe trunnion and the links. It is guided in the steam chest cover by the bushings, and is held against rotation by the stud. As the operating mechanism raises and lowers the lifting rod, the rod in turn raises the valves by engaging the adjusting nuts. The adjusting nuts are threaded on the valves and hence the point at which each valve opens and the amount of opening can be varied by means of these adjusting nuts. Of course, there is an un balanced steam force, tending to close tbe valves, but in addition, a positive closing force is obtained by tbe lower edge of the 106 -000!S2!` 1430C95 1430C95 TURBINE MO REOUCTION GEAR lifting-rod flange, engaging the lower shoulder on each valve. 3. For establishing the proper lifts for the several valves a special fixture is provided, the application of which is shown an the tool illustration. Figure T-28. It coaprises a temporary cover to be bolted in place on the steam chest Instead of the steam chest cover; .an Indicator aounting rod; and a rod to be set up on the valve stea. 4. To nse this fixture proceed as follows: Disconnect the governor linkage and remove the steaa chest cover. Bolt in its place, the valve setting fixture assembly as shown in Figure T-28, setting it so that four holes in the cover coae over the four valves, and set up the rod (8). Drop the rod (6) through the proper hole in cover plate (7), so that it restB on top of No. 1 valve. Claap two dial Indicators to the rod and set one against the top of the valve lifting stea, and the other against the top of the rod (6) compress ing then sufficiently to Insure positive re sponse when the stea is lifted. 5. Set both indicator dials at zero. Lift the valve lifting stea until a reading shows on each of the indicators. The difference of the two readings will be the clearance for No. 1 valve. Three or four check readings should be taken and the differences should be the saae in every instance. 6. Next shift the rod <6) to No. 2 valve and repeat the above process. Do thiB with each of the four valves. Be sill then have a series of differences, thus for example:-7 Reading No. 1 No. 2 No. 3 No. 4 Stem Valve Rod Difference 0.022* 0.009* 0.013* 0.110" 0.018" 0.092- 0.181- 0. 205' 0.055- 0.050' 0.126" 0.155' 7. These differences are the clearances of the several valves between the valve lifting plate and the valve nuts and should be the saae as listed in the tabulation of valve settings under the serial nuaber of the unit in question. 8. The amount the valve lifting stem is raised in the above operation is immaterial as lmugj] as it is enough to obtain readings on lath n Indicators, and that successive trials spqfr^j the same difference between the stem and vaTVe" readings. FACTORT VALVE SETTINGS 1. This is the clearance between the vwF^ stea nut and valve lifting plate with ?he turbine in a static1 condition. 2. The actual values determined during fact tests sill be found staaped on the plate (ljj located on the governor lever (10) of Fig T-14. The actual values nay vary slight froa the design values shown in Fig. 7-14.( 3. The opening, through which valve lifts rod (41) extends into the steam chest[ sealed against escape of steam to ataosphe by the provision of close fitting busbig (18) and (22) and two leakoffs, one betw& the two bushings and one near the top of the outer bushing, whence the leakage is carried away. The steam from the inner leakoff is led to a zone of lower pressure in the cyl inder, while the outer leakoff is connected , to the gland condenser. GOVERNOR 1. The governor as shown in the illustration. Figure T-12 is of the vertical shaft flybffij type, in which the revolving weights move KXZj dlally in response to changes in centrifuge^ force, resulting from changes in turbis^2 speeds. The changes in centrifugal force aW' thus the position of the weights, are tradSe) aitted to a cup valve, in the sub-assemboyn (10), the position of which determines ti5 amount of H.P. oil that is permitted to pass through the variable orifice to drain. jjnr-- balance of the H.P. oil being directed to the-', operating servo-aotor mechanism as "control oil*. <39 2. H.P. oil from the aaln pump discharge from the auxiliary hand pump) is directed through passages in the governor housing, to the filter inlet, item (16) of Figure T-12; HWE-000JS23? 107 TURBINE-GENERATOR UNIT and through external piping to the relay. Item seat to the cup valve (10). When the governor (2) of Figure T-13 entering the servomotor at is at rest, the strap spring holds the governor the flanged inlet as shown. weights (8). in their innermost position. 3. The H.P. oil passing through the filter. Figure T-12, is directed by internal passages to the space Just above the cup valve (10). which forms a variable orifice permitting the portion of oil that passes through the cup valve to drain back to the oil reservoir, and as mentioned earlier the balance passes to the servo-motor mechanism in the capacity of 'control oil'. 4. The portion of the H.P. oil that is piped to the servo-motor operating mechanism from the pump discharge, enters the servo-motor housing to a neutral position of the relay (2). Examination of the Figure T-13 shows that this relay, seated on a spring (1), is forced upward, hut restrained through linkage from moving except as permitted fay a movement of the bellows and stem assembly. Thus, the control oil leaving the governor and entering the servo-motor housing as shown, acts upon this bellows and stem assembly: closing the bellows and moving the stem upwards arainst the action of tbe spring (38) with an increase in the pressure: and allowing the bellows to expand with the spring action and moving the Bten downward with a decrease In oil pressure. 5. Tbe movement of tbe stem and bellows as sembly permits tbe movement of tbe relay (2) In a similar direction. The movement of tbe relay allows tbe H.P. oil to flow through passages to either the upper or lower surface of the piston (7) causing tbe piston and pis ton rod (13) to move. 6. The piston rod (13), Is connected by linkage to the steam chest valves.7 7. Referring to Figure T-12. the governor hub which holds tbe weights assembly, is driven frcm tbe end of the main gear wheel shaft by means of spiral gears. The governor weights are securedtoa strap of spring steel, mounted across the diameter of the hub. that is in the form of a ring. The spring is formed into a *U* at the center and the forces acting upon the weights, flex the strap spring, thus transmitting the forces through tbe spring 8. The entire rotating element is carried in four bearings. The governor bearings (4) and (42) (Figure T-12) are combined journal and thrust bearings. Tbe main oil pump bearings (bushings) shown in Figure T-18 are Journal wear and all are mounted in the bearing bracket and main oil pump housing. This bearing bracket is located on, and bolted to the oil reservoir base. The vertical position of the governor hub (8) and thereby the proper posi tion of the follower gear (2). can be adjusted by tbe final machining of the liner (40) so that tbe designed clearances can be obtained between tbe governor bub and tbe sleeve (43), at the thrust bearings (4) and (42). 9. Tbe cup valve rests upon a button sup ported in the center of the governor weight strap. 10. Tbe space within the cup valve seat is supplied with H.P. oil as described above in paragraph 3 and the cup valve proportions the amount of oil permitted to drain, to the cen trifugal force of the governor weights, and thus controls the oil pressure acting under the cup valve seat, and hence the pressure of the 'control oil'. 11. The balance of forces for any given op erating condition, couslstsof the centrifugal force of the governor weights acting upward, through tbe strap, button and cup valve: op posed by the governor oil pressure acting downward on the cup valve. The value of the governor oil pressure is determined by the annular area of the variable cup valve orifice and the part of tbe centrifugal force of the governor weights not balanced by the force of tbe spring: hence, every turbine speed (and consequent value of centrifugal force on the governor weights) determines a definite value of governor oil pressure. 12. Tbe operation of tbe governor and steam chest is as follows: With the turbine at rest, tbe governor weights (8) of Figure T-12 are held in their 108 11*6-0005:210 1430C95 1430C95 TURBINE AND REDUCTION GEAR lnneraost position by tbe strap spring, and tbe steaa chest valves (26) and (27), of Fig ure T-14, are held closed through linkage connected to the operating piston (7), of Figure T-13, which is held in its uppermost position when no oil pressure is available, by the action of the spring (38) pressing downward in step and bellows assembly, and hy the action of the spring (13) of Fig. T-14 against the lever (10). The Figure T-13 shows the steaa chest servo-wotor operating aechanlsa in a position with the turbine at rest. The spring (38) in the stea and bellows asaeably has expanded the bellows to tbe aaxiana with the stop nut (33) seating on the cover (36). The operating piston (7) is held in the upperaost position and the relay (2), is in a position Just past neutral, with the relay closing the upper ported passage leading to the upper surface of the piston (7). Tbe lover ported passage leading to the lover sur face of the piston is open. 13. in order to start the unit, it is first necessary to start the auxiliary hand oil puap to insure turbine journal bearing lubrication. This auxiliary oil puap, not being designed to operate the governor and aervo-aotor nechanlsa should be operated until the aain oil puap can take over. Tbe can lever lteas (19), (23) of Figure T-14 should be raised to tbe horizontal position, which will raise No. 1 steaa chest valve (26) approxlaately .060 inch, sufficiently to allow steaa to be adnltted to the turbine. With the auxiliary oil puap operating, the cam lever in the hor izontal position, the throttle valve band wheel can be slowly opened until the unit starts to rotate. 14. As the turbine speed increases to approx laately 25% of the no-load value, the aain oil puap discharge oil pressure exceeds tbe pressure of the auxiliary puap which say be then shut down. As the aain oil puap pressure Increases, supplying tbe governor and servo motor aecbanlsa with H.P. oil, tbe oil pres sure builds up in tbe space above the cup valve (10) of Figure T-12; and in tbe center of the relay (2) of Figure T-13. The H.P. oil leaving the governor as 'control oil* di rected to the servo-aotor, surrounds the stea and bellows asseably and as the oil pressure Increases the bellows closes against the acticn of the spring (38). The H.P. oil that has entered tbe relay cavity bleeds to the side of the piston (7), but as the belf and stea aove upward, permitting the rq (2) to also aove upward, the lower ported" passage closes and the upper ported pasf is opened allowing H.P. oil to flow toSJej upper side of tbe piston (7). As the oil pressure increases, the bellows and asseably aove upward, the relay (2) also aSvT upward and the piston (7) moves downward. *( 15. Tbe action of the piston (7) moving df] ward results in the steaa chest valves opened by neans of the connecting link4 After tbe unit has been checked for satlsf tory operation, the speed nay be increase? further opening of the throttle valve, the turbine approaches normal speed, the trlfugal forces will begin to aove the govern nor weights outward. Tbe unit is now co under control of the governor as i t approajj full, no load speed, the cam lever item of Figure T-14, will then drop to tbe Id position, clear of the steam chest operating linkage. 16. As load is applied to the unit, the tur bine speed decreases, and the centrifugal f acting on the governor weights is redug The governor spring force being constant./Zte reduction in centrifugal force is balanceioiy an increase in governor oil pressure, results in an upward aoveaent of the cup val (10), reducing the annular opening of variable orifice and increasing tbe pres? of the 'control oil" to the servo-motor snism. Tbe increase in 'control oil* press acts upon the bellows and stem assembly (j aovlng them upward, the relay (2) following in a similar direction in proportional amoflitt and opens the upper ported passage permlti^ the H.P. oil to flow to the upper surface of the piston (7), the aoveaent of which in a downward direction, opens the steaa cn5T valves (by neans of connecting linkage) ^5) ficlently to nalntaln the required speed. 17. If the load decreases, the turbine sntejf accelerates, increasing the centrifugal f<M/ on the governor weights, and thus Increases the annular opening of the cup valve (10), ni"-ooo;s:: 109 TURBINE-GENERATOR OMIT which permits a treater aaount of H.P. gov erning oil allowed to drain and hence a re duction in the 'control oil* presaure. The reduction in control oil pressure, reducing the pressure upon the stew and bellows assem bly (39); pernits the bellows to expand by the acticn of the spring (38). Examination of Figure T-13 shows that the relag (2). would then be aoved in a downward direction closing the upper ported passage and opening the lower port, permitting H.P. oil to flow to the lower surface of the piston (7), the aovenent of which in an upward direction closes the stean chest waives (hr means of connecting linkage) sufficients to maintain the required speed. 18. Thus it can be seen by examination of Figures T-12 and T-13 that the governor is capable of closing the steam chest valves.in minimum time, in the event of total loss of load. In the event of total loss of oil pres sure, the action of the stem and bellows as sembly (39), moving downward under forces from the spring (38), and the action of the spring (13) of Fig. T-14 upon the lever (10), would also close the steam chest valves, by means of the connecting linkage in minimum time. SPEED CHARGER 1. The hand and motor-operated speed changer, by means of which the speed or load of the unit can be varied is shown in Figure T-12. The principal parts of the electrically op erated portion are:--The motor shafts, worms, and worm wheels. The principal parts of the hand operated portion are:--The hand-wheel and shaft. Both the electrically operated and hand operated portions act to regulate the turbine speed by means of changing the position of the valve seat (37).2 2. The electric motor, connected to the shaft (S3) drives the worm (54) which in turn drives the worm gear (46) and worm gear (31). The worn gear (31) drives the collar (27) fay fric tion caused by the spring (33) acting against spring seat (34). The collar (27) is secured to the shaft (21) which is threaded in the bushing (25) in the top of the speed changer housing (18). Since the bushing (25) is sta tionary, rotation of the shaft (21) by the won gear (31) screws the shaft either upward or downward through the bushing (25) and hous ing (18); thus changing the position of the valve seat (37). and hence the speed or load corresponding to a given governor weight po sition. 3. For band operation, rotation of the hand knob is transmitted directly through the shaft (21) in the manner described above to the cup valve seat (37) moving it upward or downward. The clutch collar (27) with spring (33). and washer (32) form a friction type clutch which is held in engagement by the spring (33). This clutch slips when the hand operated fea ture is used and also serves as a safety de vice, in the event of overtravel of the speed changer motor. 4. The hand adjustment knob, (20) mounted on the shaft (21) has an Indicating arrow direct ing counterclockwise rotation for an Increase in turbine speed or load and hence clockwise rotation for a decrease in tnrblne speed or .load. The adjustment of the shaft (21) by the hand knob or speed changer motor is not Identical with the adjustment (or change in position) of the valve seat (37). The shaft (21) is threaded with B.H. threads 11-1/2 threads per inch at the bushing (25) and 11 threads per inch at the cup valve seat (37). Hence, one revolution of the hand knob in a counterclockwise direction causes the shaft to travel upward approximately .087 inch through the bushing (25). (1.000 * 11.5* = .087 inch). The cup valve seat being pre vented from turning by the screw (12) will move in a downward direction, with shaft move ment, approximately .091 inch. Thus the new position of the cup valve seat is the differ ence between the two or a movement of .004 inch in the downward direction. The same figures apply to the adjustment of the knob in the opposite direction causing the cup valve seat to move in the upward direction. The aaount of the cup valve seat travel is identical per revolution of the shaft (21) for the band adjustment knob or for the speed changer motor hy remote control from the con trol panelboard. 110 ME-C!0>M<: 1430C95 1430C95 TURBINE AND REDUCTION GEAR Section 1.2 Reduction Gear GENERAL DESCRIPTION 1. The longitudinal section through the pin ion shaft is shown in Figure T-2 and the lon gitudinal section through the reduction gear is shown in Figure T-15. The gear wheel is pressed and keyed onto the gear shaft. The shaft is carried in the gear bearings (Figure T-16) the bearing on the turbine end acting also as the thrust bearing. Machined collars on the shaft act as the thrust-bearing collars and liners are provided by Beans of which the axial location of the gear wheel any be ad Justed. The gear wheel and generator rotor are dynamically-balanced after being bolted together. 2. The gear-housing base is aounted in the bedplate and forms the oil reservoir for the unit. An oil-level gage is provided to show the aaount of oil in the reservoir. The Bain oil puap, which is driven by the spiral gears, takes its suction froa the reservoir as shown. 3. Between the generator-end gear bearing and the coupling, there is an oil thrower collar on the shaft and an oil-ting, the lab yrinths of which drain back into the tear housing. Mounted on the coupling flange there is a second oil-ring, the labyrinths of which also drain back into the gear housing, to prevent the possibility of oil vapor escaping into the engine room. 4. The gear teeth are lubricated by weans of oil sprays which discharge oil between the pinion and gear teeth. PINION AND GEAR BEARINGS 1. The pinion and gear bearings, shown in Figure T-16. consist of steel shells, babbittlined. sinllar in general design to the tur bine bearings described in paragraph 10 except that the pinion bearings, being enclosed by the gear housing do not require oil baffles, as do the turbine bearings.2 2. The pinion bearings have normal clearance of .007 to.009 inch with aaxlaua of .015 inch before rebabblttlng. The gear bearings .006 to .008-inch noraal with maximum of . inch before rebabblttlng. The turbine aaln gear bearing is provided with bolted-on thrust rings at either end. 3. Shoulders on the gear shaft servefonf] thrust collars so that this bearing is a <Hgj bined journal and thrust bearing. Split lirfi/s between tbe bearing shell and the thrust rings peralt adjustaent of the locatlonjro'i the aain gear wheel in the bousing and of \pten axial clearance of the bearing. 4. The pinion and gear bearings, if reao aay beaeasured for sear by checking the cr&n^ thickness in four specific longitudinal'" planes, S/8 inch in froa the end for the pftos/J ion bearings and one inch in from tbe end IreS-C the gear bearings. Radial lines scribed"5rT" the bearing end, as shown in Fig. T-16, dSp-Q) lgnate the aeasurlng planes. Tbe value di1 these dinensions at the tine of nanufacture is stamped on the end of each bearing. Any change in these measurements Indicates wear and if excessive, the cause should be inves tigated. ALIGNMENT OF PINION AND GEAR 1. For proper operation of the unit, t pinion and gear shafts should be parall^ This condition exists when tbe pinion and g{ shaft centerlines lie in the same plane are equidistant at both ends. The critert of proper alignaent is uniform tooth contd to ensure a balanced pinion-gear tooth loq lng. This condition aay be checked by cla lng the pinion journals so that they will rg hard down on the bottom half of the bearings. The pinion teeth should be coated with slon Blue and the pinion and gear rotated totether. The resultant aarklng on the geffic) teeth will indicate any adjustment that is^, necessary to produce a uniform tooth contact^ which may be made by carefully scraping ofo?\ or more of the babbitt faced Journal bearings!:'-'' This scraping should be limited to the toler ance of tbe bearing bore. RM-OOOJtlC III TURBIME-6ERERAT0R UR IT HAIM OIL PUMP 1. Tbe Bain oil pump, which is shown in Pig. T-18 and in the reduction gear assembly. Fig ure T-15, is located in the turbine end of the gear-housing base. It is of the gear-type and is driven from the governor body, which in turn is driven from the wain gear shaft through spiral gears. 2. The pump body is bolted to an Internal bracket in the gear-housing base. The suction is taken from close to the bottoa of the res ervoir through s short intake pipe. The puap is driven hy Beans of a vertical shaft spllned at both ends. The upper end engages the gov ernor body sleeve nut, which is secured to the governor body. The lower end engages splines in a hollow shaft or driving sleeve to which the puap gear (driver) is keyed and which rotates in the puap-bearing bushings. Tbe driven puap gear is keyed to a short, idler shaft. The bushings which serve as bearings for the gears are Bade of tin-base babbitt aetal. 3. The ptng> takes oil froe the reservoir and discharges into a line leading to the duplex strainer and thence to the oil cooler. and servo-motor mechanisms to operate the steam-chest valves. The remainder is led through external piping through the strainer and cooler to lubricate the bearings and re duction-gear teeth. The maximum permissible temperature of oil leaving any bearing is 180F. The temperature rise of oil passing through any bearing is not to exceed 50F. 4. The flow of the oil through the bearings is regulated by orifices Installed in each of the bearing oil supply passages in the hous ing. 5. A relief valve, connected to the bearing oil supply line, is set to discharge a part of tbe oil directly to the reservoir if the pressure at the bearings exceeds 10 psig. A by-pass valve. Figure T-21, around the cooler, is provided so that tbe cooler can be tem porarily taken out of service for cleaning or repair while the unit is still running. CAU TION - THE VALVE IN THE OIL COOLER LINE MUST BE OPBI WHEN THE BY-PASS VALVE IS IN OIL-TO* OOOLER POSITION. SEE FIGURE T-17. OR OIL CAN NOT CIRCULATE THROWS! THE SYSTEM. The cooler is normally by-passed when starting the unit, until the normal lube oil teoperature has been established. OIL SYSTEM 1. The arrangement of the oil system is shown dlagraasatlcally in Figure T-17. This system consists essentially of a reservoir foraed by the reduction-gear housing, a main oil pump described above, a duplex strainer, a cooler, a hand-operated auxiliary puap for use when starting and stopping the unit, and the con necting piping. 2. The level of the oil in the reservoir is shown by the bayonet type gage which is lo cated on the turbine end of the gear bousing. The oil level should be maintained so that It is between the high and low-llalt Barks on the gage plate with the Bachine in operation.3 3. In noraal operation, the Bain pump dis charges at approximately 70 sounds per square inch gage pressure. A part of this oil is led through cored passages to the governor 6. The hand-operated auxiliary pump takes its suction from the reservoir and discharges through a check valve into the strainer and thence to the lubricating system. This pump should be operated when starting the unit until tbe speed increases sufficiently for the main pump to supply the lubricating re quirements. This pump should also be operated when slowing down the unit until the shaft is at rest. AUXILIARY OIL PUMP 1. The manually operated auxiliary oil pump which is used to supply oil for the system when starting up is manufactured by the Blackmer Pump Company of Grand Rapids. Michigan. The pump is operated by turning the hand crank in a clockwise direction and will deliver 10 gpm when operated at us rpm. 2. The crank is connected to a abaft upon which is mounted a rotor enclosed within the 112 flk'E-0:0.'S24l 1430C95 1430CSS TURBINE AND REDUCTION GEAR puap cylinder. The rotor, which is eccentric to the pump cylinder bore contains three spring positioned, self-adjusting vanes which operate with.small axial clearance and follow the Inner surface of the puap cylinder, the vanes being pressed radially outward by springs. Oil entering iron the suction side is impri'sooed between consecutive vanes and is carried around to the discharge side. The snail axial clearance between the vanes and the puap 'cylinder prevent oil froa returning to the suction side except for a very saall aaount of leakage. OIL STRAINER 1. The oil strainer is shown in Pigure T-19. It is of the duplex type and the basket, through which the oil aust flow, is Bade with sides of wire aesh and perforated sheet. 2. The flow of oil to the strainers is con trolled by the valve plug which is so designed that when turned on its seat by aeans of the changeover lever it will direct the oil to either strainer, but will prevent the oil from being conpletely cutoff during changeover froa one strainer to the other. The indicator on the changeover lever points toward the side of the strainer which is in use. 3. In order to clean a strainer it is only necessary to swing the changeover lever to the opposite side, back off the handle, reaove the cover, and lift out the strainer basket. OIL COOLER 1. Pigure T-20 shows the oil cooler with its pipe connections. The oil enters the cooler shell at the bottoa and passes around the outside of the tubes, being directed back and forth across then by the baffles and leaves the cooler by the outlet connection at the top of the shell. The water enters the water bonnet and passes through the tubes on one side to a reversing bonnet and back through the tubes on the other side to the outlet. The tubes are rolled into both tube sheets. 2. Provision is Bade in the shell, by means of a 'floating* reverse end tube plate relative expansion of the shell and tube bdft1"" dle, the reverse end tube plate being seal against leakage by twin *0* ring seals and gland spacer. The gland spacer is fitted with an annular groove and radial drain passag^ hence any minute amount of oil or water whl might bleed past the *0* ring seals is Bitted-to drain off rather than mix one the other. Both water chambers are provided-" with zinc pencils`attached to pipe plug These zinc pencil electrodes should be exsj lned at least once each month and cleaned replaced If their condition so warrants. He-ji^, aoval of the zinc pencil from the reverse ejp^ ' chamber cover permits full drainage from tube side. I 3. The dry weight of the complete cooler | 405 pounds. The cooler has 56 tubes and designed to cool 24 gallons per minute of from 143.3tol30P with 5.5 psi pressure dr when supplied with 33 gallons per minute water at 85F with0.5 psi water-pressure dropT LUBRICATING OIL 1. A suitable lubricating oil is of utmos importance and its selection should be givb very careful consideration. Oils confonnifi to the requirements of the following Speciff cation may be purchased in the open marke and have been found to perform satisfactorily QUALITY OF OIL 1. The oil shall be a refined mineral oil highest quality and uniformity. It sha{ contain no grit. Inorganic acid, alkali, wat4 soap, asphaltum, pitch, resinous substances or any other substance which will interfer with the lubricating properties of the oil or that will be detrimental to the oil. or to the metals with which the oil will come Ijh-- contact, in service. 2. The oil shall be capable of preventliyg^, the formation of rust on steel parts bathetic1 with oil, should small quantities of watejF^ enter the oil during service. (See paragraph5'"^ III, following, 'Corrosion in Lubrication Systems'). 13 TURBINE-6ENERAT0R UNIT I. For Circulation Systems (See Table) II. Physical and Cheeicsl Properties NOTE l: The values shown in the table below are based on tests nade in accordance witb the latest approved standards of the American Society for Testing Materials: Basel lng.......................... Plash Point ................... . . Viscosity carbon Residue ............... ASTM D92 Neutralization No. ... , Sulphur Content . . . . .. . ASTM D129 Corrosion Resistance . . ,. . ASTM D665 NOTE 2: There is a present trend on the part of various interests in Marine propulsion geared units to specify viscosity at 130F as 171 to 189. with a Dean & Davis Viscosity Index of 50 minimum. Such oils are quite sat isfactory tor this service. NOTE 3: The reeoonended values in the table spply. of course, to new oil only. NOTE 4: Some Merchant Marine Interests spec ify that the oil shall pass the corrosion test with a synthetic sea water Instead of the distilled water normally used in this test. (See Table at bottom of page) III. Corrosion in Lubrication Systems In the operation of a steam turbine it is impossible to entirely exclude moisture from lubricating oil systems. The presence of very small quantities of moisture, in a system using unsuitable oil, has been found respon sible for serious corrosion, which Interferes with governor system operation and jeopardizes bearings. The ASTM has developed and pub lished the ASTM Specification D-665 (latest revision or issue) entitled 'Rust Preventing Characteristics of Steam Turbine Oil in the Presence of Water. Test for*. It is recom mended that turbine lubricating oil be pur chased to successfully pass this test, and that the purchaser verify the oil prior to its use. IV. Inhibited Oils; Purification Systems It is known that some types of oil puri fication systems using fuller's earth or similar filter materials nay remove the cor rosion or oxidation inhibitors that were added to the oils by the supplier. It is recommended that before such systems are applied, the oil supplier be consulted on this point. APPARATUS Plash Point, F .......................... . Saybolt viscosity Seconds at: 100P ..................................... . 210P..................................... . Carbon Residue .......................... . DIRECT* CONNECTED TURBINE UNITS 330 Min. 140-to 250 40 to SO 0.10% Max. SINGLE RE0UCT. GEARS TO 3000 HP (2250 KW> 350 Min. 250 to 350 47 to 60 1.0% Max. LARGE GEAR UNITS MARINE PROPUL SION UNITS 350 Min. (See Note 2) 350 to 550 52 to 66 1.0% Max. Neutralization Number ............... . 0.10 Max. 0.10 Max. 0. 10 Max. 0.50 Max. Corrosion Resistance Test . . . . Shal1 Pass Shall Pass (See Note 4) Shall Pass M8-OOC312<: 1430C95 TURB1HE AKD REDUCTION GEAR V. Replace Parts Some of the corrosion inhibitors added by the suppliers are of the plating type, that is they 'plate out* from the oil to the petal surfaces to fora a.protective coating. It is quite possible, then, to find that an o'll which passes the rusting test before being placed in the turbine, nay after a short tine in service fail to pass the test due to its loss of the inhibitor. Under such conditions, should a nee part be Installed, for instance. In the governor system, this part aay nist If water is present, due to the lack of proper protection. It is recommended that new parts, be treated by immersion in new. inhibited (fit--J at a temperature of 140-150F. for severferi hours before installing in order to start tM={] development of a protective coating. VI. For Bal I Bearings Lubricate ball bearings on pumps afftJc similar equipment with the same oil as usi in the main lubricating systea. ss 3 1430C95 DJ t=i m R-:O03!2<; 115 TURBINE-GENERATOR UNIT Section 1.3 Description of Safety Devices OVERSPEED TRIP 1. The .overspeed-trip necbanlsm which trips the throttle valve and thus shuts down the turbine'in case it overspeeds is shown in Figure T-22. The actuating device consists of a weight located transversely in a hole in the body which is screwed onto the end of the turbine rotor. The weight Is located with its center of aass slightly off the axis of rotation and is held in place by the spring and the retainer which is secured by the screw. As the speed of the rotor increases the cen trifugal force of the eccentric weight becoaes greater until at a pre-deteralned speed (10 to 12% above noraal full-load speed) the cen trifugal force is sufficient to overcone the resistance of the spring, whereupon the weight aoves outward radially until it cones into contact with the trip lever. This lever is struck sharply by the weight and the resulting aoveaent disengages the latch froa the reset handle, these latter pieces being held in engageaent by the hardened plates, then the reset handle is released the tension spring pulls the trip rod saartly toward the throttlevalve trip lever, to which one end of the spring is attached, and through which the trip-rod end aoves until the shoulder engages the lever with a hammer-blow effect which is sufficient to actuate the throttle valve trip ping nechanisa and close the valve as described in the section on throttle valve. The speed at which the auto-stop will function can be adjusted by aeans of the liners. Increasing the thickness of the liners Increases the tripping speed. Decreasing the thickness of the liners decreases the tripping speed.2 2. A Halt switch, (lten (32) of Figure T-ll), aounted on a switch bracket, (Itea (33) of Figure T-ll) 1b actuated by the operation of the throttle valve. The closing of the throt tle valve, either manually or by overspeed tripping, results in the closing of the Halt switch which in turn is connected to a trip ping device for the naln generator circuit breakers. Thus the llait switch circuit is open when the throttle valve Is open and closed when the throttle valve is closed. 3. then this nechanisa has operated it Bust be reset by band. This is accoapllshed by returning the reset handle to the horizontal position when the latch plates will again be engaged. This resetting cannot be done until the turbine speed has decreased sufficiently to allow the overspeed-trip weight to return to its noraal position which will occur at slightly below noraal turbine speed (approxi mately 1,000 rpn of generator). 4. A special wrench (S) is furnished, as shown in Figure T-28. by aeans of which the overspeed-trip retainer nay be renoved when asking a change in the setting or overhauling of these parts. LOW OIL PRESSURE TRIP 1. The function of this nechanisa (shown in Figure T-23) is to shut down the turbine if. for any reason, the oil pressure drops below a predetermined ainiaua. it operates in con junction with the overspeed trip linkage which is described previously. 2. As shown in the illustration, the necbanisn is in its latched (or starting) posi tion, with no oil pressure established. The latch pin (3) and latch (l) are engaged to hold the piston (7) in its inner position, compressing the spring (8). 3. The chamber in front of the piston (7) is connected to the bearing oil supply line by drilled passages as shown. As pressure is established in this chamber the piston moves inward, further compressing the spring (8). This piston movement also aoves the latch (1) inward and the pin (3) is noved upward by the spring (2) thus disengaging the latch com pletely. The oil pressure now holds the pis ton (7) and latch (1) in the extreme Inner position. 4. If the bearing oil pressure drops to the point atwhlch the aecbanism is set to operate, the oil pressure against the piston drops and the spring (8) aoves the piston and rod out ward. causing the latch (1) to strike the 116 MHS'.Hil: 1430CSS TURBINE AND RE9UCTI0N GEAR overspeed trip lever. Moveaent of this trip lever shuts down the turbine ss described under 'Overspeed Trip Mechanise*. 5. After this mechanism has tripped, the oil trip latch and also the overspeed trip linkage, aust be reset by band. STEP 1 Push the latch (1) inward and push the pin (3) downward until the pin engages the 'latch to bold it in its inner position. STEP 2 Reset the overspend trip linkage as described previousIt. ATMOSPHERE RELIEF VALVE 1. The ataospbere relief valve shown in Fig ure T-2S is noanted on the cylinder cover at the exhaust end, as shown in Fig. T-2. This valve, when operating, pemlts excess pressure within the turbine cylinder to be discharged to the ataospbere. The valve is water sealed and spring loaded, and is adjusted to start opening when a pressure of 10 psig exists within the turbine cylinder exhaust end. Jt will be wide open and release full throttle flow at 30 lbs. gage. . 2. The spring loading of the valve is pre set at the factory and cannot be adjusted ex ternally. 3. The handwheel (11) is provided to annually check the operation of the valve. Remove the locking pin (16) froa stem lock (8) and the valve stea (10) before turning the handwheel. After the annual operation check has been perforaed; replace the locking pin in its proper position. TESTING OF SAFETY DEVICES 1. overspeed say result froa a variety of causes such as dirt or scale lodging under the steaa valve; daaage to seats so that the leakage is aore than the steam requirement is at light loads; excessive friction in the gov ernor parts due to foreign natter; or damage to working parts. Consequently, all parts should be kept in good condition at all timbe^-'J Periodically, about once each nonth, the op--eration of the safety devices should be cheafe&i as follows: (with generator disconnected from " the line and neters). p___ * 2. The operation of the overspeed trip shoK be tested as follows: jggj Referring the Figure T-14 (Steam Cheftf disconnect the steam-chest valve-lifting Kid link from the lever by removing pin, block the valves in the open position by m- n sorting s suitable block between crossbegr^: and bushing. Then start the turbine A ' gradually Increase the speed to the trippi point. The .overspeed trip should function^ 10 to 12S above normal generator speed (1,3 to 1,350 rpa). The throttle valve should! opened very gradually. During this test, speed of the unit should be watched contl| uously with a hand tachoaeteron the generat and the operator should be ready to trip t^ valve instantly Incase the overspeed governor does not trip at the proper speed. 3. The low oil pressure trip aechanism shown in Plgure T-23. aay also be checked when shutting down the unit by noting the moves of the latch (1) when it moves outward und the Influence of the spring (S) and at d) same time observing the reading of the beaY-n lng oil pressure gage. The low oil pressra^j trip mechanism has been adjusted at the fa tory, to operate when the decreasing bearih supply oil pressure reaches a value of 3k Psig. 4. The spring loading of the ataospbere rb lief valve can be tested with compressed aip) when the unit is shut down. However, thi procedure requires that the valve be removedci froa the turbine cylinder. A aore desirable arrangement is to test the valve with the un|ri operating at no load and a built up back presjps sure. The unit can be started without tlfe-y condensing equipment in operation which allogs^ the back pressure to build up. Natch the e^--^ haust pressure gage to see at shat pressure,, the relief valve starts to open. 1430CSS KIE-00038;:; I 17 TURBIHE-6EHERAT0R UR IT Section 1.4 Installation of Turbine ALI8RMERT OF (WIT AND SETTIN6 OF TURBIRE ROTOR 1. The bedplate of the unit is supported on, and secured to. longitudinal seating pads that are bolted to the ship's structure by the shipbuilder. 2. Chen erecting tbe unit at tbe factory, the bedplate is set level and tbe gear-bousing base is set in place and supported an chocks. The pinion and gear bearings are checked for plane and parallelise by using nandrels. The generator stator is then set up and the gen erator outboard bearing is brought into align ment with the gear bearings. Next the tur bine-cylinder base is set up and the turbine bearing is aligned with the pinion bearings, using liners under the turbine supports as necessary. 3. Tbe turbine rotor is then placed in tbe turbine cylinder cover and is located axially in order to obtain the proper clearance dimen sion between the nozzle block and the first rotating row of Impulse blades, as shown on the rotor clearance diagram. Figure T-24. Tbe distance from the low-pressure end of the cyl inder cover (inside gland face), to the face of tbe turbine rotor, is then measured. This dimension is recorded and is also stamped on the turbine cylinder-base horizontal-joint flange at the low-pressure end. Tbe turbine rotor is then placed in the cylinder base. The thrust bearing cover and the upper half of the turbine bearing (pinion end) and the bearing cover are assembled and bolted in place. The rotor is then moved as may be nec essary to obtain the 1/8- inch dimension between the coupling faces as shown in Figure T-24 and tbe cylinder base is adjusted in an axial direction, until tbe dimension from the face of turbine rotor to the cylinder end is in agreement with that stamped on tbe cylinder base horizontal flange. The cylinder base is thee doweled and keyed to tbe bedplate in this position. The thickness of tbe thrust bearing filler piece (9) Fig. T-2 and also shown in Fig. T-B, is machined to suit and assembled. Then tbe thickness of the bearing thrust ring liners shown in Figs. T-5 and T-8 is adjusted to maintain the clearance shown in the diagram. Fig. T-24. The gear and pin ion are adjusted to drawing clearances by shifting the liners (see Figure T-1S) in back of the gear bearing-thrust faces as necessary. 4. If it should became necessary to install a spare turbine rotor, the following procedure should be followed: ` 5. Vlth the new rotor placed in the cylinder cover, the dimension from the face of the rotor to tbe cylinder-cover end should be determined as described above. Then Install tbe new rotor in tbe cylinder base and locate it axially to agree with the dimension from tbe cylinder end to*the face of the rotor, as found in tbe cylinder cover. Then measure the axial clearance at the outboard end of tbe thrust bearing in order to obtain the proper thickness for the rotor-locating filler piece, shown in Figure T-2 and T-8. Ilth this filler piece Installed, the turbine rotor will be in its proper running position. Then measure the thrust-bearing clearance and if .this is not found to be within the prescribed limits, change the thickness of tbe liners behind the thrust ring to provide the proper clearance. 6. With the rotor in place, check the align ment as outlined above. 7. The method of checking the Internal alignment of the reduction gear has been de scribed under 'Reduction Gear*. To check the alignment of the pinion and the turbine rotor, disconnect the flexible coupling between them and check the angular alignment by taking feeler-gage readings between the faces of the coupling hubs at top, bottom, and both sides. Also cbeck the horizontal and vertical align ment of the coupling hubs at the periphery on top and at the sides. The pinion and turbine should be in line. 8. Check the alignment of the gear and gen erator. To do this, roll out the bottom half of the turbine-end gear bearing and measure tbe amount that the gear shaft Journal drops 118 nk:-DCCISri! 1430C95 TURBINE MID REDUCTION GEAR when not supported. This drop should be .0040 inch, measured on the shoulder just outside the Journal. Replace the turbine-end bearing and roll out the generator-end gear bearing. This journal should drop .0025 inch, measured on the shoulder adjacent to this journal on the generator side. Recheck these readings by rolling the gear-shaft and generator rotor over 180 degrees and repeating the operation. Note: It is wore Important to obtain a correct ratio of these deflections rather than a specific value of either because the above values are subject to a tolerance of plus or ninus .001 inch. The.deflection of the gen erator-end gear shaft bearing, should be 61% of the turbine-end gear shaft bearing deflec tion. If the proper values are not obtained, the outboard generator bearing pedestal should be adjusted upward or downward as necessary to produce the desired value. PIPE CONNECTIONS 1. The steaa pipe connected to the turbinethrottle valve nust not be rigid because, if it sere, it sight aove the unit out of alignsent. It should be nade with long radius bends and should be supported at a point near the turbine, in Baking this condition, the pipe should never be sprung into place. The connection should be Bade so that the Joints Batch properly. 2. The exhaust line should have a flexible expansion-joint close to the turbine, prefer ably at the turbine exhaust flange. The --] haust pipe should be supported Just beyonf) the expansion-joint to prevent the weight fro daaaging the expansion-joint or the turbine. The expansion-Joint should have enough flexin__ n bility to insure that no undue strain will b\PQ imposed on the turbine exhaust. pn gi) 3. Before connecting the steam pipe to thg c turbine, the line should be thoroughly blown out with high-pressure steam to remove anfc-^_ foreign aatter such as dirt, scale, joint cornKS'' pounds, etc., which if carried into the tur|---- r; bine. Bight prevent the closing of the steam chest valves and cause over-speeding or plugs--i up part of the nozzle throat, thus reducln^Cj the capacity and efficiency of the unit. 4. Wet steaa is objectionable as it causeg auch aore rapid erosion of the blades an4 nozzles than dry steam, it also reduces botf efficiency and capacity of the unit. Slugsp^j, of water, whether from priming of the boileTsJj2l or the picking up of condensation in the pipe line, if carried through the turbine causes serious shocks, vibration and speed fluctua tions or aay trip the overspeed trip mechanism. If the pipe connections are such as to allow condensation to collect in the turbine or___ steam pipe, drains must be installed for use-- ` when starting up. (Q) 4 p_/l 1430C95 me-ocojsis'. I 19 TURBINE-GENERATOR UNIT Section 1.5 Instructions for Operation of Turbine TO START STEP 1 See that circuit breaker and nain switch are open. STEP 2 Cut In all resistance in the field rheostat. STEP 13 Adjust the rheostat tor nornal volt age of the generator. STEP 14 Eoonect tbe generator to the line and put on load. TO PARALLEL STEP 3 See that the throttle reive is In Its closed position with the throttle waive trip latch in place. Hake sure that the orerspeedtrip mechanism is In operating condition. STEP 4 Check the oil level in the reservoir and aake certain the valve in the oil cooler line is OPEN if the by-pass valve is in ollto-cooler position. 1. To put one aachlne on the line when the other unit la in operation: STEP l Bring the unit up to nornal no-load speed as described above. STEP 2 >ltb the speed-changer, bring the speed down to tbe synchronous speed of the systea. STEP 5 Drain the steaa and exhaust piping. STEP 6 Open the throttle valve, steaa strain er. gland seal nanlfold and cylinder drains. These drains are shown in Figure T-7. STEP 3 Observe tbe synchroscope and aanlpulate the speed-changer until synchronise is Indicated. STEP 4 Throw tbe unit oc the line. STEP 7 Turn steaa on glands, using not aore than 3 pounds pressure. STEP 8 Start the circulating puap and the condensate puap. STEP 9 Prime the unit thoroughly, with the auxiliary oil puap before atteopting to start the turbine. STEP S Beadjust tbe speed-changer until each unit takes its share of the load at the proper speed. STEP 6 The proper voltage to obtain before throwing one generator in parallel with the other, can be found best by trial. It nay vary slightly from line voltage, depending upon local conditions. STEP 10 Open the steaa-chest valve by aeans of the jacking lever under the governor op erating piston rod. Then open the throttle valve, starting the turbine rolling iaaediately so that the turbine rotor will heat evenly. Bring up to about l.000 rpo on the generator, in 5 to 10 ainutes. Then bring speed up until the governor controls tbe speed. This can be deteralned by observing the steaa-lnlet gauge, as the inlet pressure will drop when tbe gov ernor throttles steaa to tbe turbine, see that bearing oil pressure is naintalned be tween 8 and 10 pounds. STEP 11 Close all drain lines. TO SHUT DOWN STEP l Reduce the load to practically zero by aanipulating the speed-changer. STEP 2 Throw off the load by opening circuit breaker, and then open, finally, the nain generator snitch, if work is to be done on the generator. STEP 3 Close the turbine throttle valve. This can be done by striking the overspeedtrip latch shown in Plgure T-22. STEP 12 Circulate water through the oil STEP 4 Operate the auxiliary oil pump when cooler. slowing down until shaft is at rest. 120 s-0tC3:S; 1430C95 TURBINE AMD REDUCTION 6EAR STEP S Shot off the rater to the oil cooler. STEP 6 Shut off the steam to glands. STEP 4 Keep the throttle stem and the steamchest valve-lifting rod clean, free of erosicm__ or corrosion. (Do not paint these stems.) L--J STEP 7 Clean the machine and put It In read iness for the next run. STEP S Keep the bearing oil pressure betvee 8 pounds and 10 pounds gauge. STEP 6 Keep the oil level in the reservoirs) PRECAUTIONS STEP l Avoid passing steam through the tur bine with the rotor at rest. Kith the throt tle and steam-chest valves closed, the steamstrainer drain should be open. STEP 2 Avoid air being dravn through the glands with the rotor at rest. STEP 3 Periodically (about ooce each month) Inspect the overspeed-trip Might to see that it vorks freely in the body. Also teat all safety devices to see that each one functions properly. between the limits Indicated on the 'Oil-Level!---- r| Gauge*. oo STEP 7 Keep the oil strainer clean. ` STEP 8 Keep the oil cooler clean. Note - Th^>>' valve In the oil cooler line must be open wtaefprz! the by-pass valve is in oil-to-cooler posioc!/ tlon, or oil cannot circulate through thrpj system. _____ .L bill' B Leave all switches open when machlnf Is not running. STEP 10 At the least sign of trouble. stoA machine laaiediately. Investigate and correct the trouble before starting the machine again. --n P *3 1430C95 ms-oome:!- 121 TURBINE-GENERATOR UNIT Section 1.6 Care and Maintenance of Turbine INSPECTION 1. About once each year, depending on the nature of the service, the unit should be dismantled and thoroughly Inspected and cleaned. Erosion of the blades, nozzles and valves, wear of bearings (including the Kings bury thrust hearing), and changes in clear ances, are the nain points to be inspected. The gear-case cover should be reaoved to per mit Inspection of the gear teeth. If the gear-tooth bearing is not sell-distributed over the tooth surfaces, the parallelism of the pinion and gear bearings should be checked. 2. The oil cooler, oil strainer, and steaa strainer should be cleaned. All oil piping should be disconnected and thoroughly washed and cleaned. A light coat of shellac should be applied to the flange faces in asking up the Joints. WEIGHTS (APPROXIMATE) 1. The approximate weights of the principal parts of the units, which nay require handling are as given in the table below: 2. The approximate weight of one complete set of tools is 70 pounds. - 3. For the assistance of the operator in checking the condition of the unit and in perforaing such repairs as any become neces sary. the following information and aaterials are furnished. ROTOR-CLEARANCE DIAGRAM 1. Figure T-24 shows the normal clearances and the clearance Halts throughout the tur bine. These clearances should be checked whenever an inspection of the turbine is being aade. ROTOR-LIFTING GEAR 1. Figure T-26 shows the arrangeaent of the rotor-lifting gear. The lifting gear is fab ricated froa pipe and plate. The slings fit around the rotor as shown and then over the collars. The hanger is welded to the pipe at a point which balances the two ends and thus keeps the rotor level while it is being lifted. Nane of Part Pounds One Unit (Assembled Complete) .... A-C Generator and Exciter (Coaplete)......................................... Turbine (Coaplete) .............................. Turbine Rotor (Bladed) ...................... Cylinder Cover..................................... Cylinder Base ......................................... Gear-Housing Base and Bedplate . . . Gear-Case Cover..................................... Gear-fheel and Shaft .......................... Gen. and Exciter Rotors (Inc. Shaft)..................................... Gen. and Exciter Stators................... Governor................................................ Throttle Valve ..................................... Oil Cooler............................................ Oil Strainer......................................... 18.028 8,625 4.280 640 1,100 1.090 2.610 285 675 3,310 5,318 131 240 405 87.5 ROTOR LIFTIN6 DEVICE (FOR REMOVING BEARING SHELLS) 1. In order that the turbine bearings may be reaoved for exaaination or replacement with out the necessity of lifting the turbine cyl inder cover, two rotor lifting jacks are fur nished as shown in Figure T-27. By slipping these Jacks into place as indicated in the figure and setting up on the nuts, the rotor nay be raised sufficiently so that the lower halves of the bearings nay be rolled out. Care should be taken when using these Jacks to sake sure that the rotor is raised Just enough to take its weight off the bearings, because with the use of these Jacks, the rotor night be lifted sufficiently to dsaage the thin Beal strips around the blading and dummy seals. 122 ihH30!S<5i 1430C95 TURBINE AND REDUCTION 6EAR TOOLS AND WRENCHES REPAIR PARTS 1. Figure T-28 is shorn for the purpose of enabling the operator to familiarize himself with the special wrenches and tools and the purposes for which they are Intended. Those tools, the use of which is not immediately obvious, are referred to at appropriate points in the foregoing text. 1. The lists, which face the several turbid illustrations have been compiled to facilita ordering spare or renewal parts by name number. Whenever parts are ordered, it is utmost importance to give the serial numb< of the turbine or gear on which the parts ai to be used. oo 1430CSS 4 C=^ m IHE-0MJ825: 123 TUNSINE-6ENERAT0R UNIT Section 7 -- Appendix INDEX Itn Page . Alignment of Pinion and Gear .................................................................. Ill Alignment of Unit and Setting of Turbine Rotor ................................. 118 Atmospheric Relief Valve ......................................................................... 117 Bearing, Turbine Thrust ............................................................................. 104 Bearings, Pinion and Gear .................................................................. . . 'Ill Bearings, Turbine ........................................................................................ 103 Blading, Curtis Stage .................. ..... ........................................ 102 Blading, Bateau Stages . ......................................................................... 102 Characteristics, Turbine and Reduction Gear ........................................ 101 Coupling, Turbine and Pinion .................................................................. 105 Curtis Wheel Chamber Labyrinth Seals ................................................... 103 Cylinders......................................................................... ............................. 102 Factory Valve Settings ............................................................................. 107 General Description, Turbine . . ........................................................... 101 General Description, Reduction Gear ....................................................... Ill Glands, Turbine ............................................................................................ 103 Governor....................................................................................................... 107 Inspection................................................................................................... 122 Interstage Seal Rings ................................................................................ 103 Low oil Pressure Trip ................................................................................ 116 011 Cooler............................................ ...................................................... 113 Oil, Lubricating........................................................................................ 113 011 Pump, Auxiliary..................................................................................... 112 Oil Pump, Main............................................................................................ 112 Oil Seal Rings............................................................................................ 104 011 Strainer................................................................................................ 113 Oil System................................................................................................... 112 Oil, Quality of............................................................................................ 113 Overspeed Trip Mechanism ......................................................................... 116 Pipe Connections........................................................................................ 119 Precautions................................................................................................... 121 Repair Parts ............................................................................................... 123 Repair Parts, List of.................................................................................125 to 130 Rotor.............................................................................................................. 102 Rotor Clearance Diagram ............................................................................. 122 Rotor Lifting Device forRemoving Bearing Shells ............................... 122 Rotor Lifting Gear.................................................................................... 122 Rotor Position Indicator ....................................................................... 105 Safety Devices, Test of............................................................................. 117 Speed Changer................................................................................................ 110 Steam Chest................................................................................................... 106 Steam Drain and Gland Piping .................................................................. 104 Throttle Valve ............................................................................................ 106 Tools and Wrenches..................................................................................... 123 To Shut Down Unit........................................................................................ 120 To Start Unit................................................................................................ 120 To Parallel Unit........................................................................................ 120 Weights........................................................................................................... 122 124 fl;-OOC!S25: 1430C95 TORBIHE AND REDUCTION GEAR List of Repair Parts (Use Group 7) WESTINGHOUSE. ELECTRIC. COR.P rafcMtTURBiNL GENERATOR SLT |T,n.ESPARE. PARTS LIST SHEET I [sWi B. CtTFM WT jfrRl |ga.R |GR3 |gg~ (ORi NAME. AUTO STOP GOVERNOR REFERENCE 1 |r*-TtsC rT.naoxrua MATT. SPEC. SPRING IA-H-SS7I SPRING SO-1" IS SPR INC SPRING 0-118 SI 0-3-29 IS C=3 D^JG MOTTO SCA.Lt J P"6- G40 D 36< lAVor REG'D FOR I SHIF BEARING - THRUST ( KINGSBURY) COLLAR SHOE A N-Ilt HOC BABBITT At ONI UHIT SHOE SUPPORT J 90-T- 3t BEARIHg -TURBINE (THRUST EMP) TURBINE BEARING COMPLETED* J4Sl| l BEARING -TURBIRE (COUPLING EMP ) TURBINE BEARING COMPLETE!* Z* JMJl 14 BEARING - PlHICH (COUPLING EWP ) PINION BEARING COMPLETE )CZ9 J4S0I2O BEARING - PINION (.GENERATOR EHD ^ PINION BEARING COMPLETEIM5 J4SS|2S| BEARING -GEAR (TURBINE ENP) GEAR BEARING CO MPLETElsi 9 0441 KB] BEARING -GEAR (GENERATOR ENP) GEAR BEARING COMPLETE t9 J4*j|sd as* i. A ' Im 3 'U II -fg 1430C95 125 TURBINE-GENERATOR UNIT List of Repair Parts (con't) (Use Group 7) TITLt SPARE PARTS LIST sheet z |sub. G4-0 D 366 1. NAME, 33 COUPLING RE.FEREMCE | SWrvTO\HlXSmNo SPtC. V REQ'D TOR l SHIP ft 4a Onf 1i7r 1fa*7t c0*7 34 Smoulder screw 36 FCEx-ni/t 36 SICR-Btfl 6 CZ64BI 7 16 10 10 10 10 10 10 10 10 to to to 10 i'o 1C |0 37 m 31 40 GEAR HOUSING HORIZONTAL JOINT 41 .TAPER POWEL - /s 760104 3 1556-1 1 1 t I 1 t 1 1 42 BOLT -*/ X ttys LG 16462 - 4115 2 2 z E t 2 2 2 43 BOLT - Vj 4 Vj LG. 16462 - 5115 I 1 1 1 1 1 t / 44 BOLT - *// X Z *4 LG 14462 - 5115 1 \ l 1 1 l 1 1 45 CAP SCREW (*0C. H0.)V*I>H6 W-H-462 46 NUT-HEX. -f# 16534 - 47 NUT - HE*. - 751444 * 6653-1 1 1 l 1 t 1 1 7607-0 2 z z z 2 2 2 2 7405-0 1 1 1 1 1 1 1 / 41 44 <0 51 NEAR WHEEL SHAFT COUPLING SI BOLT FITTED l`P X 3>fe LG. 751503 511 5 fc 6 6 6 6 fo 6 Si NUT HEX. I`44 lockwasmck I1? 55 751453 * 747 50 - 7405-0 6 6 6 6 6 6 4 6 2042-2 5 6 & 6 6 6 6 6 54 47 56 57 60 GLANOS - SPINDLE (THRUST END) 61 BLAND ASSEMBLY 50-F-I07 \k. 1 t11 Ii 1 62 43 4 GLAmds - spindle (coupling end ) 65 GLAND ASSEMBLY J F 147 IT 64 \1 lti 1 47 1430- 126 HNE-0003E260 C95 TURBINE AND REDUCTION GEAR List of Repair Parts (con't) (Use Group 7) E=3 1430C95 M6-OCC38?i: 127 TUB INE-6ENEMT0R UNIT List of Repair Parts (con't) (Use Group 7) TjT ^SPARE PARTS LIST sheet a SUB OWG 64-0 D 366 5 NAMt 104 TURBINE CYLINDER JOINT BEFERENCE . MATl REQ'D roh $H|P| ttOSMMtNQ 1 t SPEC. STTILMO v M *0 &3 4 & in * 17 9* OC \S r t \J * X U1 see NITtS I0S BOLT -VtU V4 LO lot BOLT -Vi X 3 Vi L<<. IB*** I44tt - 107 DOWEL ftOLTfAM'S.C.lS.L-tJ) 9-H-30* - (OB STUD 17% iq 14470 - in STUD - I1? X It '/. LO. 14474 - no 00 WEL -STUD * 7/a * 3 '/* 1.0 9-H-134 - in BOLT - */4 X 3>V ut NUT-HEX - y. Its NUT - HEX - A 14467 16594- 16534 - IK CAP SCREW tSOC.Mo)56xi3jS 10- I0-H-7S - 115 EXTENSION NUT - I**" X >4 L4 VM-Z7J - UC BOLT - yo X Ji LC 16407 - 117 DOWEL BOLT-A* l7i,C.4y#,l.. >4 9-M-197 - m DOWEL STUD - l`/2 X 4'* LV 119 STUD BOLT -1^X7% 1$ S-H-724 - Its EXTENStoM NUT - 1 >* X 3 % l6- M-H-TOS - t( NUT-HEX - l' I4S* - itt NUT- HEX VO to STUD - I'-' X 11*/# Lq. 14534 O-H-709 - l TAPER DOWEL - Vs 125 NUT-HEX - V# 7SOI04 3 751459 - Ur ui ut SIlS t i i1 1 1 B 5115 1 1 7011 1 \ SB II 1 till 1 \ 7011 l 1 !11 1 t1 11 l i111 i i1 1 1 1l\ B B B B B sue l 1 111 B 7S0S-0 \ \ \ 111 B 27609-0 2 7 2 2 2z7 B 4553 \ l V 1 1 1 Aft IS55I 1 \ I1111 a 7630 1 t 1 i \ 1 1 1 A S3S7 \ \ 1 t i 1 1 1 A *337 \ \ 1 t l 1 1 1 A B337 1 i l 1 l 1 1 1 A 771* ( i 1 1 i 1 1 A 7403-4- 1 i t \ 1 1 1 1 7009 \ \ 1 1 i 1 1 1 0337 l i t \ 1 1 1 1 A A A IS56-I 1 i 1 1 l 1 1 1 76 09-0 1 i 1 1 1 J 1 A A IW 130 \S\ 37 133 IM 135 I3t 137 138 1430128 C95 TURBINE AND REDUCTION GEAR List of Repair Parts (con't) (Use Group 7) 1430C95 IHE-C0H521: 129 TUR8INE-GEHERATOR UNIT List of Repair Parts (con't) (Use Group 7) r^SPARE PARTS U5T 2. h NAMt ns STEAM CHEST COVER ELIUKAGE 116 VALVE 177 VALVE Of VALVE SEAT IT9 VALVE SEAT esheet sue *> 64003 66 REFERENCE MATV. MAMIMC 2 C PSTWVoLTJaELNHONs SPEC. REQ'D FOR 1 iHIP os3r fv or *n $ $ tn 9 ttcs or VT s U- (COUTD FI? ITEM-07) 98J IT8 8 98J 178 9 -- - - --- - 2-- 2- 98JI78 10 98 J178 II -- -- 22- i MOTES NOTE 4: LOCATED IN HORS 20NTAV. JOINT OF H R CYLINDER. NOTE B": LOCATED SN HO*-tZONTAL JOINT OF L.P CYLINDER. G, ITEMS TO BE ORDERED BY HEAT T'RANSFER APPARATUS DIVISION. !.,170,(71,17?, 78 < (* 1430- 130 nE-0:3!:2t; C95 - a <s O u tlin e o f T u rb in e , Gear and G enerator L o n g itu d in a l S e ctio n th ru T urbine and P inion - - FIG. T-2 MHOQ362U FIGURE T-2 LONGITUDINAL SECTION THROUGH TURBINE AND PINION Item Name of Part 1 .Auto Stop Gov. Body 2 Bearing Turb. (Thrust End) 3 Bearing Turb. (Coupling End) 4 Bearing Pinion (Coupling End) 5 Bearing Pinion (Generator End) 6 Bearing Housing Cover 7 Bearing Housing Base 8 Bearing Cover (Pinion) 9 Filler Plate (Thrust End) 10 Bearing Thrust Ring 11 Bearing (Thrust) 12 Bed Plate 13 Baffle - 1st Stage 14 Blading - 1st Stage 15 Blading - Stages 2 thru 6 16 Blading - 7th Stage 17 Coupling 18 Cylinder Base (L.P. End) 19 Cylinder Cover (L.P. End) 20 Cylinder Base (H.P. End) - 21 Cylinder Cover (H.P. End) 22 Turbine Support 23 Gear Housing Base 24 Gear Housing Cover 25 Nozzle Block 26 Nozzle Diaphragm (2nd Stage) 27 Nozzle Diaphragm (3rd Stage) 28 Nozzle Diaphragm (4th Stage) 29 Nozzle Diaphragm (5th Stage) 30 Nozzle Diaphragm (6th Stage) 31 Nozzle Diaphragm (7th Stage) 32 Oil Rings (Turbine) 33 Oil Ring (Thrust Bearing) 34 Pinion 36 Rotor 37 Rotor Glands (H.P. End, L.P. End, & Dummy) 38 Rotor Gland Cover (H.P. End) 39 Rotor Gland Cover (L.P. End) 40 Rotor Position Indicator End Cover 41 Steam Chest Cover . 42 Valve Stem Leakoff Pipe 43 Sentinel Valve (When Specified) 44 .Blank Flange (When Specified) 45 Atmospheric Relief Valve (When Specified) t y p ic a l r a t e a u rc BLADE ASSEMBLY C u r tis and Rateau B la d in g - F IG . T -3 HH00382W CURTIS STAGE BLAD E ASSEMBLY .x a o r R al uj v> -p uj i? z < ;< -R>5 Q H 34?0Uz-7 g <5Ou' ztW~ iz tp a ui c--c cyc Hx w> JJSsa5S5 zi- Q F < -- uj _ f?gQ^ |o-5'FI>-- Hoa oqg:' 85. "~ i? w o b2Sg <=!iSb- cQcjDSUz.<zdy2j y2rcl I LU *r In te r s ta g e D ia p h ra g m S e a ls - - F IG . T-*4 CYLINDER RING\ CYLINDER Q Z LlJ I-- in W D cc i zo cc t- LU W o 5 m 2 Q Z Ui UJ in in < O z -I CL D O U _l o ? ZK LU o< LinJ LinU h- < z o$ x in i<n in oz a. it o. m > *" D Z < _J o R o to r G lands and la b y r in th S e a ls - - F IG . T-6 MAIN STEAM INLET -Steam , D ra in and G land P ip in g D ia g ra m a f |G , 7 .7 HVB-0003S271 FIGURE T-8 TURBINE THRUST BEARING Item 1 2 3 4 5 6 7 8. 9. 10 11 12 13 14' 15 16 17 Name of Part Oil Control Ring (Upper Half) Collar Base Ring Key Sere* Base Ring Key Base Ring (In Halves) Lower Leveling Plate Base Ring Dowel Disc Shoe (Body) Shoe (Babbitt) Shoe (Support) Upper LevelingPlate Leveling Plate Set Screw Base Ring Shoe Dowel Oil Control Ring (Lower Half) Oil Control Ring Screw Thrust Ring (Upper Half) Thrust Ring (Lower Half) T h ru s t B e a rin g -- FIG. R otor P o sitio n In d ic a to r -- FIG. T-9 HiB-OOQ'WJ FIGURE T-9 ROTOR-POSITION INDICATOR Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Name of Part End Cover End Cover Bolt End Plug Contact Ball Contact Ball Retainer Contact Ball Retainer Spring Spindle Spindle Bushing Spindle Bushing Set Screw Pointer Pointer Screw Pointer Pin Graduated Scale Plate D OIL DISCHARGE MB-0005521 FIGURE T-10 TURBINE - PINION COUPLING Item Name of Part 1 Flange Sleeve 2 Flange Sleeve 3 Special Hub 4 Retainer 5 Lock Ring 6 Shoulder Screw 7 Hex Nut sr ) ) FIGURE T-ll THROTTLE VALVE ASSEMBLY Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Name Throttle Valve and Stream Strainer Body Throttle Valve Seat Throttle Valve Disc Throttle Valve Disc Pin Throttle Valve Disc Flange Throttle Valve Disc Cap Screw Throttle Valve Stem Leakoff Bushing Gasket Bonnet Hex Nut Stud Coupling Washer Coupling Thrust Washer Coupling . Coupling Guide Sliding Nut Spring Screw Spindle Yoke Yoke Bushing Key Handwheel Reference Plate Washer Hex Nut Tripping Lever Latch Insert Latch Shaft Bushing Latch Shaft , Cap Screws Switch Switch Bracket Spring Pin Spring Hex Nut Slotted Machine Screw Stud ' Hex Nut Strainer Bonnet ' Gasket - Steam Strainer T h ro ttle Valve -- FIG. T - ll GOVERNOR AN D SPEED CHANGER G o v e rn o r and Speed. C hanger CLEARANCES .008 WAX. .005 MIN. TOTAL .006 MAX. .004 MIN. ON DIAMETER 'c* .005 MAX. .002 MIN. ON DIAMETER V .004 MAX. .002 MIN. ON OlAMETER f -.0045 MAX. 025MIN. ON OlAMETER SECTION "A-A'  9T Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 FIGURE T-13 GOVERNOR SERVO-MOTOR Name of Part Spring (Relay) Relay Base Socket Head Screw Socket Head Screw Elastic Stop Nut, (piston rod) Piston Piston Ring Gasket Bushing, Inner - Cover, (piston cylinder) Bushing, outer Piston Rod Taper Pin Rod Extension Set Screw* Taper Pin Bearing Pin, shouldered Link Link, (relay) Links, (slotted) Roller Bearing Washer . Item 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Name of Part Spacer Bolt Nut Spacer Stem Locknut Trunnion Guide Stop Stop Nut > Socket Head Screw Socket Head Screw Cover, (Bellows Assembly) Gasket Spring, (Bellows) Bellows Assembly Body Flange Bearing Washer Spacer Bolt Cotter Pin - Relay Bushing (Assembly of Top, Center and Bottom Bushings) Governor Servo-M otoi STEAM CHEST LINKAGE CLEARANCE^ 4 CLEARANCE CLEARANCES A MAX. .004 MIN.002 ONOIA. S* MAX. .033 MIN..027 ONDIA. C' MAX .0025 MIN..002 ONDIA. D MAX. .004 MIN. .0035 ON DIA. E' MAX .0035 MIN. .00050NDIA. F* MAX .006 MIN. .002 TOTAL ItIl * M11 \\Y\ !C> IUO. MmIiMn CoVilli TuO>T>-AxiI. I M HIM lull-1 I ir I | >i CONTROL OIL INLET CONN. .EAKAGE-DRAIN CONN. Hw wa wu a a o S <y WH c je o GU ^ i D ** J4C>-a*> 4>>). b z ifi J 4>1 .* -ocfHc. HaUc HacW dAB-*) > u a a ta ^ N P) >f O O) o M M n V Id so <so 9 > *J i^l !33 la*> fog* *4o*) c B 4> SJS . c2 JtCb3H* t-4a>1 Mjs *4fc*)- ; a3 2 &5 u3 41 V4>) JV3 > >o 4 4a4J> *94J> QW t) 3 *SJ U 10J (7 U is 3 is n n o e> pi o -! Steam C hest L in k a g e and V alves FIG U R E T -1 5 T R eduction Gear L o n g itu d in a l PINION BEARINGS SECTION j - J . SEC TIO N `H -I ag ram II A 5* f0 0 n 0 d w of *5 -Q~ < --tt*X X<^X r-r" 1 w*;- safi l ~l ... L Lsi > <^hJ 1*1- ...\ i)': ii ol* sH! ,,*sHS $: $tc Jipnqg ^usis fxc*k29*fiOfSiJ- 5S^s? oz-'hwa*. itl ji"-2ch At |! I i$L ' ?> n zi 31 aj! i *1 4 / *** U i* if hi sS < *i ?* d5 z - ^ O c ? S' S Saa 5 2 nt>J| j * a- j f! t a i S ) u , ! " jL # Vi j- * <J fd< ? 'f; iJ ij j g. 9 .2 1 7 ~ tf 4 6i < <i jy idiig? i ?F r 3M* N abc J .'Ei 9 9 R! O fjfl B F M ain O i1 Pump FIGURE T-18 MAIN OIL PUMPS Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Name of Part Oil Pump Assembly Pump Body Complete Cover Pin Driver Gear and Shaft, Complete Gear. Driver Shaft Driver Key Gear, Driven Shaft. Driven Driven Gear & Shaft, Complete Shaft, Drive Bushing Set Screw Spacer & Pin Complete Spacer Studs Locknuts , . FIGURE T-19 OIL - STRAINER Item Name of Part 1 Body 1C Locating Pin 2 Valve Plug 2A Stop Pin 3 Straining Compartment Cover 4 Valve Bonnet 4A Stud and Hex Nut 4D Stop Pin for Jack Lever 5 Gland 5A Stud and Hex Nut 6 Jack Lever 6A Jack Screw 6B Washer 6C Hex Nut 7 Plug Turning Lever 7A * 7B 9 9A 10 Turning Lever Cap Machine Screw (Hex Head) Packing Packing Support Ring Gasket 10A Gasket 10B Gasket 13 Clamp 14 Set Screw 15 VI 15 V2 15 D1 Vent Tap and Plug Vent Tap and Plug Drain Tap and Plug Item 16 16A 16B 16C 16D Name of Part Support Collar Sidewall (Perforated) Bottom Plate Handle Bail and Pressure Spring Bow Rivets 16F-G 16J 16M 16f* (United) Union Nut Positioning Pins ' Sidewall (Wire Mesh) Bottom Plate 16S Support Collar 18 Bottom Plug Cover 18A Stud and Hex Nut 19 Indicator Plate 20 Inlet Plate 21 Name Plate 22 Caution Plate ' 23 Drive Screws SF Support Flange STAYRODS JU3-000J32fJ HANDWHEEL GLAND CAP GLAND-- STEM PACKING PACKING SEAT RING 0=3 VALVE STEM O0 G0 VALVE BONNE`S OIL INLET OIL TO COOLER yf % % i X/ Yz. OIL FLOW BY- PASSING COOLER -VALVE BODY .VALVE SEAT B C=3 c=* S) Oil Cooler By-Pass Valve -- FIG. T--21 KiB-00038285  Xo pu X t3r* oa w w aLO cn W > O > *o & -o5 -O4) *dJ >&>i w-a*iJ CU 53 V 0) tl I s MO 4fJi 4o) H N Z ZZ * K U U 11 N D< j3c a S <c a fi a ff 3* 3 3 tc1 k n M CO CO sv> n c_ i flu a* i Ur U *i 4> 4> 0J) . 4-> *i . uo .uo I H M S. S *H .* K CON D.I 33 ^ ~zz *9> <A 4K) Z K 3 U i i**t 1 H i9o CO ^OH "s, os re * O "* 60 X 3 * SU 4> 4i H -4)3w ta +*U C U \re j#< , - , 3 S t4a> uO 0) m cUa u4) - *- ta ^cOa Otco OtUa.O*o1sQt^a. n r> i/i a> $ u u u b ou u. . 4e> e4> s e S. ** 3 3 3 3 3 W( 4(^)du, eu u u u Sit s caa. 3 caatau (oiisfl vH-4 *J srt c- x a o w n if ift 3 i3 tX5 ,, u u " eLi. 4>> >4> 4>) * 33231: to t* a ci c moss IsU 4> OS U 1 NNMN 1 m2 5 a ft. IS sa i( FIGURE T-23 LOW-OIL-PRESSURE TRIP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Name of Part Trip Latch Trip Latch PinSpring Trip Latch Pin i Trip Latch Bracket and Cover Gasket Trip Rod Trip Piston Trip Spring Trip Cylinder Trip Rod Nut Trip Spring Seat Trip Spring Adjusting Bolt Locknut Trip Spring Adjusting Bolt OVERSPCELD T R IP I 5 \ Atmosphere R e lie f Valve R otor L iftin g Gear -- FIG. T-26 HK8'000J82?0 S L IN G IUB*OQOJ82?1 T o o ls and Wrenche kaa<>t --c9ai Pi C O' o n ; sbo s> sa axvoo dOOa -sehM cowu. uas >*> &. a>v ss +J I* Oe i-oVi 6 w 23235 53322 *2 pj O O H i m n v to is t* a a o 1430C95 Subject SHIP'S SERVICE OBCRATOR SCTION 2.1 - OBSCRIPTION OP GENERATOR (BBRAli INFORMATION............................ Purpose ............................................ Machine Identification sad Data Ratine ................................................ Nameplate Data................................ Generator Classification .... DESCRIPTION OP APPARATUS................ Illustrations ................................ General Arrangement ...... PTaae and End Covers'...... Air Cooler ........................................ Bearlncs ............................................ Stator Core .................................... Terminals . . , ............................ Armature (Stator) findins . . . Shaft and Spider ............................ Field (Rotor) Poles .................... Bloeers and Loser Coll Supports Field (Rotor) llndins ................ Collector ........................................ Brush Rigsing and Brushes . . . Mechanical Rotation .................... Phase Rotation ................................ Space HeaterB ................................ Stator Tenperature Detectors . . Spare Parts ................................ . Ordering Renewal Parts ................ Communications ................................ SECTION 2.2 - INSTALLATION OP SMERAT0R (BBRAL INSTALLATION............................ 8torage ................................................ Handling and Unpacking .................... INSTALLATION AND ERECTION .................... General ................................................ Examination of Bearing and Journal Cleaning of Collector Rings . . . Alignment of Equipment .................... Page 201 201 201 201 201 201 201 201 201 201 202 202 202 203 203 203 203 203 203 203 204 204 <3 204 204 204 204 204 204 205 206 206 206 c= 206 206 206 206 206 206 IMB-00038233 200.1 TURB1ME-6EMERAT0R UNIT Subject Page Ventilation and Cooling.....................................................................................207 . . Power Connections (Stator Leads) ............................................................ 207 Control Siring and Rotor Leads ................................................................ 207 . Lubrication................................................................................ fECTICN 2.3 - OPERATION OF GENSRATQR................................................................ 208 REUUNART STARTING............................................................................................ 208 . Brush Adjustment.................................................................................................208 - Initial Check on Insolation Resistance ................................................... 208 Drying-Out findings............................................................................ .* . .. 208 Pinal Check Before First Start................................................................ 209 StARTINO OBBRATOB................................................................................................210 Check Daring First Start................................................................................. 210 General...................................................................................... Explanation of Synchronizing Leap Circuits ........................................... 210 Determining Proper Phase Sequence .............................................................. 211 Synchronizing Generators with Laaps .......................................................... 212 Synchronizing Generators with a Synchroscope . ..................................... 212 OPERATION OF GENERATORS.................................................................................... 213 Single Generator ............................................................................................ 213 Parallel Generators................................................................................ . 213 SHOTTING DORN OF GENERATOR................................................................................ 214 Removing froa Service .................................................................................... 214 Extended Shutdown ............................................................................................ 214 SECTION 2.4 - MAINTENANCE CP GEJCRATGR............................................................ 215 <UERAL MAINTENANCE............................................................................................ 215 Temperature........................................................................................................ 215 Possible Sources of Collectorend Brush Trouble .................................. 215 Dirty or Oily Collector Ringsor Brush Rigging .................................. 215 UNUSUAL OEERATING CONDITIONS............................................................................ 217 Excessive Current Densities Due to Overloads .................................... 217 Extended Operation with a LowValue of Brush Current ...................... 217 CORRECTIVE MAINTENANCE........................................................................................ 217 Insulstloo Resistance .................................................................................... 217 Annual Inspection ............................................................................................ 218 Cleaning Generator ........................................................................................ 219 Cleaning Air Cooler ........................................................................................ 219 Rebnbblttlng Bearing .................................................................................... 219 Repair of Air Cooler .................................................................................... 219 207 210 200.2 flkE-00038274 1430C95 A-C GENERATOR Illustrations Index (Ship's Service A-C Generator Only) F`9 Title G-l Connections for Drying-Out findings with D-C Welder .................... G-2 Topical Behavior Curve of Insulation Resistance during Dry-out Run................................................................... ........................................... G-3 Connections far Synchronizing A-C Generators Dsing, Leaps . . . 6-4 Synchroscope for Synchronizing A-C Generators ................................ G-5 Diagraa of Connections for Measuring Insulation Resistance . . G-6 Generator Outline................................................ ....................................... G-7 List of Spare Parts and Tools ................................................................ 1430C95 RM-000SM9S 200.3 1430C95 HAPTER 2 - 600 KW, 450 VOLT SHIP'S SERVICE A-C GENERATOR m Section 2.1 Description of Generator GENERAL INFORMATION Purpose 1. These Instructions are Intended to de scribe the construction and to guide in the installation, operation and aaintenance of the ship's service generators. Machine Identification and Oata 1. It is reconended that the naaeplate red ings of the nee equipment be reviewed and flee copies of these readings be nade avaiMe!) able. This inforsation sill be found useffil0 in subsequent correspondence on the equipment. 2. Always refer to the serial ntuber stamp on the naaeplate of the nachine when corr spending with the aanufacturer for this the nuaber which identifies the nachine. fcn RATING Generator Classification 1. These generators are rated 600 KN (750 KVA), 80%power factor; 450 volts, 901 aaperes, 3 phase, 60 cycles, 1200 Rpn; Excitation 120 volts, 50.5 aaperes d-c; teaperature rise per Table I. Table I Itea Teaperature Else Degrees Centigrade Theraoaeter Resistance Armature Windings Insulated Field Windings Collector Rings Bearings Cores h Mechanical Parts in contact with Insulation 40 40 55 35 40 50 50 - - (a) Reference Aabient Teaperature . . (b) Table and Method of Measuring Teaperature Rise: ..................... Tabled (c) Class of Insulatlao.....................Clss (d) Degree of Enclosure . . Totally Enclosed (e) Method of Cooling.................Water Cooler (f) Manufacturer's Type Designation ................. Special 6-39-16 (g) Means of Excitation . 120 volt,1200 Rp direct current excited directly connected toC generator (h) Prime Mover . . Steam Turbine South Philadelphia (*t$j DESCRIPTION OF APPARATUS 11 lustrations 1. Reference to the outline drawing. Pi 6-6, will be found useful in suppleaentl the following description. NAMEPLATE DATA 600 KW (750 KVA) 450 Volts 961 Aaperes 80% Power Factor 3 Riaae 60 Cycles 1200 Rpm 120 Exciting Volts 50.5 Exciting Aaperes Stator Serial - IS - 2S - 58P316 Rotor Serial - 1R - 2R - 58P316 General Arrangement 1. The a-c generator is coupled to the speed" reducing gear by a forged flange couplindSc) The shaft is supported between the generato*^, and exciter by a split sleeve bearing mounteM^' on the bracket of the generator and at thSwJ coupling end by the speed reducing gear cou^=^ pllng. The stator fraae is aounted on the sob base. The rotor of the exciter is over 201 TURBIRE-6EHERATQR URIT bung on the abaft and tbe exciter fraae is connected to tbe generator bracket. Ibe ex citer baa its own shaft which bas a pilot fit and threads into tbe a-c generator shaft. Frme and End Covers 1. The fraae is famed of welded, hot-rolled steel aeabers. Heaovable cowers on tbe upper side of tbe stator fraae fnrnisb access to lifting logs on tbe inside of tbe fraae and heavy steel feet are welded to tbe loser por tion of the fraae. These feet are aachlned parallel to tbe shaft and are drilled for foundation bolts, dowels, and Jscksciwws. 2. Tbe stator core laalnatloas are staaped froa special silicon steel. They are stacked on transverse bolts and are claaped hy steel end rings bolted together. Ventilating spaoes are provided by fingerplate spacers permitting air to circulate through tbe core. Terainels of tbe araatnre are brought out at the bottoa of the fraae to a condnlt box mounted on the bottoa of tbe fraae. 3. Air shields and end cower, which are bolted to the fraae, enclose and direct tbe ventilating air. and protect tbe araatnre winding. The front cower is split on the horizontal center line. Ibe upper half bas a reaovable window giving access to tbe brushes. The rear end cower is split along the hori zontal centerline. A reaovable cower is pro vided around tbe coupling flange to give ac cess to coupling bolts. Air Cooler 1. The air cooler for tbe a-c generator is located at the top of tbe generator fraae. It is a double tube type of cooler furnished hr tbe Harrison Radiator Division of tbe Gen eral Motors Corporation.2 2. The purpose of tbe double-tube construc tion is to enable leaks in tbe water tubes to be detected before serious failure of a tube occurs. Each double tube consists of a water carrying tube surrounded by a close-fitting outer tube. Axial grooves in the inside sur face of the outer tube extend the full length of tbe cooler tubes. 3. The grooves in the outer tubes open into a `tell-tale" cbaaber at each end of tbe cooler. IRien a leak occurs in the sain water carrying tube, tbe leakage runs into tbe grooves in tbe outer tubes and into tbe afore mentioned `tell-tale* cbaaber. Tube leakage can be detected only if tbe lower 1/8* pipe plug is opened permanently to permit tbe leak age from tbe `tell-tale* cbaaber to be ob served. The upper 1/8' pipe plug should also be permanently removed to vent tbe 'tell-tale* cbaaber. Treat tbe upper and lower 1/4* pipe pings as conventional tube sheet header cbaaber vents and drains. Flanged connections are provided on .the inlet and outlet for connec tion to the sea mater lines. Either connec tion may be used as tbe inlet. Care must be used to install tbe piping in such a way that tbe cooler will be full of water at all tlaes during operation. The cooler will not operate properly if all tubes do not contain flowing water. 4. Strainers or filters, if used to exclude foreign natter or solids, ansi be Installed on the inlet side. The cooling water aust be free of foreign natter larger than .250 inch screen openings. Strainers or filters are essential if liquids circulated through tbe cooler contain foreign natter larger than specified. 5. This cooler requires 35 gallon per alnute of water at 8SF. This water will cool tbe air circulated in tbe cooler to 50F. Bearing (Fig. 6-6) 1. Tbe sbsft is supported by a bracket-type split sleeve bearing at tbe collector end. Lubrication is provided by tbe forced-feed systea of the prlae aover. A fixed orifice at tbe bearing inlet supplied by tbe priae aover limits the oil flow through tbe bearing to 1/2 gallon per alnute. 2. In addition to oil throwers nachined on tbe shaft, front and rear oil seals are pro vided to prevent leakage of oil from tbe bear ing. Tbe seals consist of 4 seal-circular washers of alualnua which are bolted to the bracket end bearing cap. The snail clearance between tbe shaft and the inner periphery of 1430- 202 IIMe-00038297 C95 1430C95 A-C GENERATOR the seals prevents leakage of oil along tbe shaft away froa the bearing. Stator Core strands deep of double cotton covered copper wire. The strands are .072 inch thick; fha q width of the strands is .204 inch. 1/--u 2. blearta wedges are used to hold the cot 1. The core of the Machine is built up of in place in the slots. The colls are roppd ,, circular segmental laminations of silicon steel to an Insulated steel ring on each end of Utygl stacked on nine transverse stnds. Each cir cular laalnatlon consists of four and one half segsents. Ventilating spaces are foraed "between tbe fraae. rings and the ends of the winding to prevent distortion in case of show^-' circuit. Shaft and Spider oc core tar finger-plate spacers, and between the packages of ponchlngs by vent-plate spacers 1. The shaft for the a-c generator is wachi*fel at seven positions along the length of the froa a steel forging and is provided with Bn ,, core. Ibis arrangeaeht furnishes a weans for integral flange on the rear end for coup111 dissipating heat froa the core fay permitting to the speed reducing gear. The exciter shsj cooling air to enter the inner portion of the core. The laainatioos are insulated froa one another with a surface coating of sodlun sil icate (water glass). Finger-plates at each is threaded to the sain shaft at the fro end of the aachlne. Tbe spider which carrlj the field poles is built up of steel laalnn tlons riveted together, the assenbly belli end of tbe core prevent loosening of the teeth. pressed on and keyed to the shaft. The spid The stater punchlogs have 72 slots each hav laminations are punched with a dovetail slji ing a finished sine, after stacking, of 0.S5S far nounting the field poles. inch vide by 2.585 inches deep. Field (Rotor) Poles Terminals 1. The six poles are constructed of laainated 1. The a-c generator stator leads are brought steel ponchlngs which are securely bound to out at the bottoa of the fraae. The rotor gether by through rivets. Each field pole Is leads are brought out the bottoa of tbe a-c fastened to the spider by a dovetail, shill generator fraae to a botton-aounted conduit is held in place hy four tapered keys. box. 2. Seven 1/2* diameter copper damper bar!f>i Araature (Stator) Winding extend axially Just beneath the face of ea&3j Tabulation of Winding pole. These bars are brazed at each end erg, the pole to an end ring. These end rings are-^ all connected between poles. R Coil Grouping: 4 Colls per group repeated 18 tiaes - 1 Group per pole Blowers and Lower Coil Supports per phase - 3 Groups per pole - 18 Groups total 72 Colls 1. Six, scoop type, unidirectional blowefajp) are aounted on each end of the rotor assemblKji These blowers are suitable only for clockwisfTS Throw of Coils: Slots 1 to 12 - 6 Poles 3 Phase 6 Parallels Delta1 rotation facing the collector end. Sheet steel, slotted coil supports are aounted nnd<y--^ each pole on both ends of the rotor assembly^--, to ensure a tightly fitting field coil. (pQ) 1. The stationary araature has a bore of 27.5 Inches and has 72 slots, each of which Field (Rotor) Winding has a finished size of 0.555 Inches wide by 2.585 Inches deep. The araature coll is of 1. Each field coil consists of one sectioi the dlaaand-type and consists of 6 conductors, coaposed of 177 turns of .162 x .182 inch each of which is two strands wide by two double cotton covered copper, wound on a mould. MB-0MJ8U8 203 TOKBIRE--CEDEKATOR UNIT The dimensions of the bodId ere 5*3/4 Inches in eldth by 17-1/2 Inches in length with s redias of 5/8 inch it the corners. As the coll is sound, each layer is brushed elth synthetic resin and the coll is pressed in both the turn and layer directions. The in side of' the coll is blocked, and claaps are applied daring the pressing operations. 2. After the coll is renored froa the aould, the coil is Insulated froa the pole with D- shaped pieces of reinforced alca placed inside the coll and turned out over the top and bottaa edges of the coll. The coll is asseabled on the pole with Micarta uashers; after assembly it is treated three tines in aolstnre and ollr resisting Tarnish. , 3. Bach coll is secured in Its position os the pole by the upper coll support, sedge uashers and the loser coll support. The upper coll support is aade froa alualnua laalnatlons and is rireted to the pole. The sedge washer is aade of fishpaper-and is under the Mlcarta bottom washer. The lower coll support is made of steel and two slotted bolt holes alios it to be pressed tightly against the bottom washer. A Mlcarta coll brace is held to the' spider with 2 Insulated bolts between ewery pole and its neighbor. . Col lector 1. The collector asseably is shrunk on the shaft between tbe rotor assembly and the froot Journal. It consists of two bronze collector rings shrunk onto a length of steel bushing around which a sleeve of mica has been built up with the entire bushing used as a aandrel. Two brass studs, one threaded into each ring, pass through Mlcarta insulating tubes connect ing tbe rings to tbelr respective field leads. Mechanical Rotation 1. The blowers ou the generator are suitable for clockwise rotation facing collector end. Phase Rotation 1. When the necbanlcal rotation of the gen erator is clockwise as viewed froa tbe collec tor end, the ears Inducted in the phases sill reach positive aaxlnua valhes in the follow ing order: Space Hesters 1. Four 250 watt, 115 volt (Style 11215854) apace heaters are located in the bottoa of the aacblne frame. These heaters are con nected in parallel for 115 volt, single phase operation. The total power requirement is 1000 watts. The leads are brought out to a conduit box located on the bottaa of the gen erator. Stator Temperature Detectors 1. The temperature detectors consist of ten oha resistance colls eabedded between the upper and lower coll sides in the stator slots. The seven detectors are equally spaced around the circunference of the generator. The leads are brought out to a conduit box located on the bottoa of the generator. Spare Parta 1. The spare parts furnished for the a-c gen erator are given on the 'List of Spare Parts and Tools* which is Fig. G-7 of this Instruc tion Manual. Brush Rigging and Brushes 1. The two brushholders are supported on an Insulated steel stud mounted on the bracket cap. Bach brushholder contains two brushes 1-1/4 inch thick by 3/4 inch wide by 2 inches long. Each generator requires four brushes. For replaceaent brushes, order by lestlngbouse Style No. 1295005. Ordering Renewal Parts 1, When ordering renewal parts, give the name of the part, tbe drawing and ltea numbers which apply, and the nameplate reading of the aacblne. Including the serial number. The stator serial number will be found staaped on the nameplate, under the naaeplate and on tbe machine foot. The rotor serial ia staaped on the end of the shaft. M-oooitm Iw 1430CSS A-C GENERATOR Conaunicatlens 1. Should coatunlcaticn be desirable or nec essary regarding the Installation covered by this Instruction Book, or an Individual device included in the installation, replies sill be greatly facilitated by citing the General'Or der (G.O.) nuaber for the complete equipment and the naneplate readings of the detail ap paratus Involved. 2. Do not fail to give the stator and/or rotor serial nuaber and the canplete naneplate read ing when intonation is desired for a rotat ing aachlne. The stator serial nnaber is staaped on the aachlne naneplate and in the netal under the naneplate and on the aachlne foot. The rotor serial nuaber is stempef the end of the shaft. 3. Should any particular information be de sired, be very careful to state clearly[ fully the question for consideration, and( associated conditions. 4. Coaaunications should be addressed totfcSe nearest >estlngh,ouse Electric Corporation Sales Office, local sales. engineerlngQo^ service representatives are usually available for quick consultation. frirv 1430COS <3 *3 m HHB-0003B100 205 TURBINE--GENERATOR UNIT Section 2.2 Installation of Generator 6ENERAL INSTALLATION Storage . INSTALLATION AND ERECTION y 6eneral 1. The' generator is shipped with the windings well protected froa noisture. At the destina tion, the rotor and stator should be placed in locations protected froa the weather and froa wecfaanical injury. Rain, snow, water or steaa froa leaking pipes, or condensation froa the ataosphere should be excluded. It Is particularly laportant to keep the windings dry for aolsture lowers the Insulation re sistance and Increases the likelihood of a breakdown. If the aachlne Is brought froa cold surroundings Into a aara rooa, it should be kept cowered until Its teaperature has risen to rooa teaperature In order to prevent the condensation of aolsture an the windings and other parts. 1. The principal external dinenslons of the generator set and the provisions for nounting it on the base of the prine nover are shown on the outline drawing, which appears as Fig. 6-6 of these Instructions. > Exaainatlon of Bearing and Journal 1. Before the aachlne Is placed In service, the surfaces of the bearing and journal should be exaalned for Injuries accidentally sustained during or after sfalpaent. Scratches on the surface of the babbitt should be saoothed out, and scratches or rust on the journal should be polished off before the aachlne Is asseabled. 2. When storage over a period of tine Is anticipated, the aachlne should be coapletely enclosed by a tarpaulin or a covering of wood, aetal or roofing paper unless the aachlne Is In a protected location. Also, the space heaters should be energised. Handling and Unpacking Cleaning of Collector Rings 1. Rewove the protective coapound covering the rings. A cloth dipped In benzine or car bon tetrachloride will be useful In reaovlng this coapound. Alignaent of Eguipaent 1. It Is easily possible, by rough handling or careless use of bars or hooks, to do aore daaage to a aachlne before or during erection than would be done in years of regular serv ice. 2. Care should be taken in transporting and handling the aachines to see that the windings are not daaaged. A blow upon any part of the windings is likely to injure the Insulation and result in the burning out of a coil. The generator fraae should be lifted by placing hooks in the lifting lugs provided on the side of the generators.3 3. In lifting the rotor, it is preferable to use rope slings looped around the shaft. If chains are used, they should not be looped around the journals unless the latter are properly protected. In no case should the ropes or chains be allowed to exert pressure on the windings or collector rings. 1. Once the a-c generator has been approx!lately located on the turbine sub-base with the coupling loosely fitted, the final alignaent should be undertaken. The feet of the generator are provided with jackscrews which permit either side of the stator to be raised so that sheet-aetal liners nay be Inserted between the feet and the sub-base to correct the alignaent. 2. The fit at the face of the coupling is the guide for the alignaent of the electrical equipment with the prine nover. Liners should be Inserted under the stator feet as needed to cause the faces of the coupling to fit to gether as specified In the instructions for the prise nover. The coupling bolts should then be tightened. 3. The position of the generator should be adjusted so that the following conditions are 1410- 206 MMOMBJJl CDS 1430COS A-C generator et after the frame feet bolts are polled tight: a. The proper axial clearances exist at the Journal between the Journal oil throwers and the bearing. The clearances at the ends of the bearing should be such that the; will be approximately equal after the coupling bolts are tightened. b. .The air gaps are equal around the bore within 1/64 inch. It is particularly impor tant that the air gap between the araatnre core and the pole faces be unifora, for any Inequality in the gap will cause unnecessary friction and heating in the. bearings as well as unequal heating of the iron in the arnature. During these adjustments, the air gap should be gaged froa both ends of the nachlne at different points around the rotor. Oases for the purpose should extend to the center of the care. . The feeler gage should be Inserted along the core between the poles and then sored over into the space between the pole face and the stator core. This procedure reduces the likelihood of reading too snail a value for the air gap at a point near the end of the nachlne where a high punching is most likely to exist. If accurate readings of the air gap are required, the varnish should be renoved froa both the rotor and stator punchlngs at the air-gap surface. c. The coupling outage is less than .001 inch as aeasured at the flange with s dial indica tor after the coupling bolts have been tightened. The presence of burrs, nicks, or other results of poor handling will be noticed in this check. d. The rotor should be centered axially in the stator bore. That is, the pole tips on the rotor nust extend equal distances beyond the stator core at both ends of the nachlne. hen the proper allgnaent of all parts is ob tained, rean holes for dowels and Install dowels and foundation bolts. Ventilation and Cooling 1. The generator is ventilated with sirjjax^ culated through the machine by the bio action of the field poles and blower vanq the rotor. 2. Air fron the outer end bells is djf axially into each end of the machine near! shaft. Part of the air ventilates the|( turns of the stator and passes through open ing through the finger plates, into the space between the stat&r core and the frame co The remainder of the air enters the space tween the field poles, crosses the air and flows radially through the stator clj Pros there, all the air is directed lntof1 cooler through an opening at the top off generator frame. After passing through[ cooler, the air is returned to the gener* through ducts which are integral parts ofiCtb*' frame. Power Connections (Stator Leads) 1. The main generator terminals are brought out to a conduit box located on the bottom of the frame. Control Wiring and Rotor Leads 1. The leads from the generator field brought out to a conduit box located on bottom of the a-c generator frame. From tljj they can be connected to the leads broug out of the exciter conduit box. The si^ heater and stator temperature detector lsa are brought out to separate conduit boxes K cated on the bottom of the a-c generator fra* Lubrication , 1. The bearing is connected to the forces* feed lubricatioo system of the speed reducing gear. An orifice at the bearing inlet re-, duces the oil pressure at the bearing tT" value which permits an oil flow through bearing of 1/2 gallon per minute. 2. The lubricant recommended is engine Ojifc>,having a viscosity of 180 to 250 seconds SA*1^' bolt at 100P. MH0M8JC? 207 T TURBINE-GENERATOR UNIT Section 2.3 Operation of Generator PRELIMINARY STARTIN6 Brush Adjustment .3. Further information on insulation resist ance is given under the Section on "Maintenance of Generator", page 215. 1. Brashes snd brashholders should be exam ined before the machine is started up to make sure that the brushes are in the proper posi tion, that there is a proper fit between the collector and the brashes, and that the brushes are free in the bolder. If the faces of the brushes do not conform to the curvature of the collector, it is necessary to grind them to shape. Ibis operation is always required when new brashes are installed. 2. When fitting new brushes or damaged brashes, the operator should use sandpaper, "Grade 1-1/2* for the roughing cut, and "Grade 0* for the final fitting. The sandpaper should be drawn in the direction of rotation under the brashes. Rounding of the brash edges can be avoided fay releasing pressure as the paper is drawn back and by being careful to keep the ends of the paper as close to the collec tor as possible. Bach brash should be treated in turn, and it will be found that by this means a satisfactory contact is quickly se cured. 3. An initial brush pressure of 2.4 lbs is recommended. Once the machine is in service, the pressure may be altered as necessary. Initial Cheek on Insulation Resistance Orying-Out Windings 1. If the insulation resistance indicates that the windings have absorbed moisture dur ing shipment, the generator should be dried out before any high-potential test is made or before the generator is initially run. Once the windings have bees dried out, the space heaters should be placed in operation whenever the machine is not running. The windings may be dried either by the use of external beat or by the circulation of current through the winding themselves. 2. When external heat is to be applied, it is advisable to use resistance heaters or steam coils as sources of heat. The space heaters located inside the generator are not of sufficient capacity for use in drying out the machine; so additional heaters are re quired. The apace heaters nay be used as supplementary sources of heat. The machine should be covered, and the heaters should be placed near the bottom of the enclosure. Care should be taken to protect the machine against direct radiation from the heaters. Effective drying cannot be accomplished unless means are provided to circulate the air so as to remove the moisture. The circulation of heated air can be improved by the following; 1. The insulation resistance of an electrical machine gives an indication of whether the machine is in a suitable condition for opera tion or potential tests. If the Insulation resistance of a winding is below the minimum acceptable value for a new machine, the wind ing should be dried out.2 a. Forcing air into the bottom of the enclo sure with small fans. b. Having the enclosure sufficiently close fitting to cause most of the heated air to pass through the ventilating spaces in the machine. 2. Once the windings are in a satisfactory condition for operation, it is recommended that initial readings be taken for both the armature and field windings so as to provide a basis for later comparison. c. Providing an opening at the top of the enclosure for the escape of moisture-laden air. 3. (hen the heating is to be accomplished fay the circulatlao of current, a d-c welding set may be used to provide the current. The cur- MB-0003130! 1430- 208 C95 A-C GENERATOR 1430CSS FI6. 6*1 -- Connections for Drying-Out Winding* With D-c Welder rent In any part of the winding should not exceed the rated value. Refer to Fig. fl-1. 4. Another eethod of elrcnlatlng current through the stator winding of the generator without subjecting then to toll voltage Is to drive the aacfalne at a convenient speed with the stator windings short-circuited and with, the proper value of excitation applied to the field to give somewhat less than rated arma ture current. FIG. 6-2 -- Typical Behavior of Inauiati Resistance During a Dry-Out Run 5. Regardless of the method of heating used. It Is essential that the heat be brought up gradually at first, the aim being to allow the water vapor to find its way out naturally through the insulation. Too rapid heating Is likely to develop such steam pressure In local portions that escape passages are forced through the Insulation, Injuring It perma nently. It Is generally desirable to consume 15 to 20 hours in bringing the temperature up to the value required.6 6. The total temperature of any part of the machine should not exceed 75C during the early part of the drying-out period. Later, after the Insulation resistance has passed Its minimum value and has become nearly stable, the temperature may be raised to 125C or slightly higher. If the windings are heated by passing current through them, the tempera ture of the stator colls should be determined by thermometers, and the temperature of the field windings may be determined by comparison of the winding resistance with Its resistance at a known temperature. Refer to the para graph on 'Temperature* page 21S for the method of measuring temperature by change of real ance. 7. During the drying-out process, measiJ^f nents of Insulation resistance should be at regular intervals and it is recommen__ dfiSthat the results be plotted in the fora curve of 'Insulation Resistance vs. Tlme*f=^ typical curve of this kind is shown as ' 0-2. Tbe initial drop in insulation resij ance can be attributed to the effect of rid temperature, and the subsequent rise In , sistance is caused by the removal of moistq The drying-out process should be contln until tbe insulation resistance becomes ap proximately constant at a high value. --.1 Final Check Before First Start [CJ .J>1. Before the unit is started the foll< checks should be made: a. Be sure that all necessary work of in stallation and erection has been completed. MHB-0003B104 209 V -r - TURBINE-GENERATOR UNIT b. Carefully exaaine the interior of the cenerator for loose objects such as bolts, nuts, and tools. Such iteas should be reaoved froa the aachine, and care should be taken to prevent their being drawn into it by aagnetlc attraction. b. Watch teaperature whenever possible to be sure that none is excessive. c. Check the brush rigging to be sure that the brushes ride properly on the collector rings. c. Check to be sure that the brushes are free in their holders and that the brush pres sure is about 2-1/2 psl (roughly 2.4 lb per brush for this aachine). Oice the aachine is in service, the pressure aay be altered as necessary. d. Cheek the wiring and piping to be sure that all connections hsve been asde properly. e. Check to see that the proper electrical clearances exist between conductors. Do not allow brush shunts to touch each other. f. Be sure that all aoving parts have suffi cient clearance with respect to adjacent sta tionary parts. g. Check to see that the windings are free from dirt and aolsture. h. Measure the insulation resistance of the windings, and dry out the windings if the test shows this to be necessary. 1. Be sure that all cover plates have been installed over the openings in the fraae and end bells. STARTING GENERATOR Check During First Start General 1. When generator units are to be paralleled, the starting of subsequent units is siallar to that for a single generator, but additional care is required in order to synchronize the units. 2. In order that synchronous generators aay be connected to a systea already in operation, the voltage of the incoalng aachine and that of the systea Bust be spproxiaately the saae at each instant. This requires that the two voltages be of tbe saae frequency, have the ssae aagnltude and phase rotation, and be in phase with each other. 3. Voltaeters indicate whether the aagnltudes of the voltages are the saae, and frequency aeters or tachoaeters indicate whether tbe frequencies are approximately the saae. Aether tbe voltages are exactly in phase and of exactly tbe aaae frequency is indicated fay a synchroscope or fay a synchronizing lasp cir cuit. Explanation of Synchronizing Laap Circuits 1. Although the indication of synchronism given fay a synchronizing laap circuit is less precise than the indication given fay a syn chroscope, the frequent use of the laap cir cuit Justifies an explanation of its operation. 1. When the unit la first started, the fol lowing observations should be Bade: a. Before starting the generator, the cool ing water valves to the generator air cooler Bust be opened to give the rated flow (3S GPM of water at 85P) of cooling water to the gen erator air cooler. The air cooler will not operate satisfactorily if the flow of cooling water is insufficient. Therefore, any throt tling should be done on the cooling water out let piping only. 2. Lamps should be connected between the leads which will be joined together when the generators are synchronised. The leaps should be adapted for the highest voltage which they will receive. This voltage will be twice the noraal value and will occur when the aachine voltages are in phase-opposition. When the voltage of the systea is too high for tbe synchronizing apparatus, it is usual to place voltage transforaers between the aaln circuits and the synchronizing circuits so as to re duce tbe voltage at the switchboard to a safe 1430- 210 MB-0003S305 C95 1430CSS A-C GENERATOR S. When the frequencies of the incoming gen erator and the system are equal and the volt ages are equal but out-of-phase, the frBpg glow with a steady brilliancy. The degr{ brilliancy depends upon the amount of displacement between the two voltages. 6. When voltage transformers are requirq the lamp circuit because of high line ages, it is possible for the transformer |__ nectioos to be made in such a manner thatohhe lamps burn with maximum brilliancy when the two voltages in question are in-phase rafegc than out-of-phase. It is preferable to[)s? DARK LAMPS TO INDICATE SYNCHRONISM instedjfc^ FIB. 6-3 -- Connection! for Synchronizing A-c Generators Using Langs mine. Figure 6-3 ebons such connections be tween two of the phases of two 3-phase gen erators. cue generator nay be considered as representing a systea nhlch is already in op eration. 3. As the voltage of the incasing generator and the voltage of the systea change froa a condition of phase-coincidence to one of phase-opposition, the floe of current through the laaps changes froa a nininun to a aaximun. When the voltages are exactly equal and in phase, the current through the leaps is zero. A phase difference between the voltages causes current to flow through the laap circuit and illuminate the laaps.4 4. If there is a saall difference between the frequency of the lncoaing generator and that of the systea. the laaps increase in brilliancy until the voltage of the aachlne and that of the systea are in exact opposition. Proa this condition, the laaps decrease in brilliancy until they are completely dark (if the voltages are equal in nagnltude), indicat ing that the voltages are again in phase. The frequency with which the laaps alternate be tween the bright and dla conditions is propor tional to the difference between the generator and systea frequencies. 7. The following check can be used to Bgfcg] certain that the laaps will be dark whenSffi' voltages are in phase. Disconnect the ftmin leads of the incoming generator at the isfr* erator. and throw in the main switch of RMS'' generator so that its bus work will be egjg^ glzed from the systea. Both voltage truneQ formers will then be energized from the S3$ei voltage source, and the lamps will be dars-W the transformer connections are correct. If the laaps burn brightly under these conditions, the two connections to one of the primaries or to one of the secondaries of the voltage transformers should be reversed. Determining Proper Phase Sequence 1. When a generator is to be syncbrooggfil with a system already in operation, the pha^v sequence of the generator must be the saa^b that of the system. To check the phase fjaquence, the following procedure is recommenAwfc Refer to Fig. 0-3, and assuae that generator^ *D* is to be synchronized with the systajT represented by generator **. Note that syn chronizing equipment is required in Wi phases, when the phase sequence is tdr^ checked. Check the two laap circuits sepa rately, aa described in the preceding section^ to be sure that the laaps in each circuitVre dark when the voltages being compared (ajrth equal and in phase. Once the circuits hne been checked, the proper phase sequence the incoming generator nay be determined. five?'. 2. To check the phase sequence, observe both sets of laaps when the voltage and frequency ME-OMJMM 211 < (. k TURBINE-GENERATOR UNIT of the incoming generator have been aade ap proximately equal to that of the systeo. If both sets of lamps become bright and dark in unison when the frequency of the incoming generator is slightly different from that of the system, the phase rotation of the generator is the same as that of the system. 3. If one se.t of lamps is bright while the other is dark, the phase sequence of the in coming generator is opposite to that of the system. To make the phase sequence of the generator agree with that of the system, in terchange any two of the three line connectors between the generator and the bus. It is well to make a confirming check on the phase se quence after changing the connections, but first the lsmps should again be checked to be snre that they will be dark when the corre sponding voltages are equal and in phase. Synchronizing Generators with Leapt ' FIG. G-4 -- Synchroscope 1. Synchronizing lamps are recommended for nse as a check on the operation of the syn chroscope and for emergency use in case the synchroscope is inoperative. Separate volt age transformers should be used for the syn chroscope and lamps. If the phase sequence of the incoming machine is known to be correct, lamps need to be connected between only one phase of the generator and one phase of the system. 2. The lamps should be connected so as to be dark at synchronism and to be at maximum brilliancy when the generator and system volt ages are 180 degrees out-of-pbase. Zero po tential is applied to the lamps at synchronism. However, an Incandescent lamp appears dark even though a considerable potential is ap plied. For this reason, lamps do not give as definite and accurate an indication of syn chronism as is obtained with a synchroscope. Nevertheless, they msy be used satisfactorily if proper care is exercised.3 3. With the generator frequency slightly greater than that of the system, adjust the speed of the generator so that the bright and dim sequence of the lamps becomes slow and constant. Anticipate the tine required tor the breaker to close its contacts, and throw the breaker so that its contacts will close at the middle of the dark period. Synchronizing Generators with a Synchroscope 1. A synchroscope is an instrument which is used to indicate the Instantaneous difference in phase between the voltage of the incoming generator and the voltage of the system with which the generator is to be synchronized. Refer to Fig. G-4. The voltage of the system is used as a reference, and its voltage vector can be represented as a stationary pointer in the *12 o'clock* position on the dial of the instrument. The voltage vector of the incom ing generator is represented by the movable pointer. The number of mechanical degrees between these 'vectors* on the synchroscope dial is the oumber of electrical degrees by which the generator and system voltages are out of phase. 2. When the pointer is in the left-hand por tion of the dial, the voltage of the incoming generator is considered to be lagging the voltage of the system. When the pointer is in the right-hand portion of the dial, the voltage of the Incoming generator is considered to be leading the voltage of the system. M6-00038301 212 1430C95 1430C95 A-C GENERATOR 3. Hie speed of rotation of the pointer is proportional to the difference between the frequency of the generator and that of the systea. If the generator frequency is higher than the systen frequency, the pointer will rotate in the 'PAST* (clockwise) direction, indicating that the generator is running too fast. If the generator frequency is less than the systea frequency, the pointer will rotate in the 'SLOW* (counter clockwise) direction, ' indicating that the generator is running too slowly. 4. Before the incoming generator is connected to the systea, a check should he aade on the synchroscope to be sure that the pointer of the instruaent rotates when the generator frequency is known to be soaewhat different fraa the systea frequency. OPERATION Of GENERATORS Single Generator 1. then a synchronous generator opef alone and is not paralleled with other gen erators, the field current aust be adjfeep for each change in load in order to eaiStaii rated voltage. This adjustment can beCssfe through aanual control of the regulatorliaEdl it is preferable for this to be done witfi ?be regulator set for autoantic operation tonkeep the voltage constant even though the|Q^)J varies rapidly. No change in the power of the generator can be affected by chaij the field current of the generator, ad power factor for a single generator is de alned entirely hy the characteristics ojj .load. 5. Bhen the lncoalng generator and the sys tea are in exact synchronise, the following conditions exist: a. The voltage at the generator Is equal to the voltage of the systea. then this condi tion exists, the generator and systea voltaeter readings are equal. b. The frequency of the generator Is equal to the frequency of the systea. then this condition exists, the pointer of the synchro scope reaalns stationary. c. The voltage of the generator is in phase with the voltage of the systea. then this condition exists, the pointer of the synchro scope is In the *12 o'clock* position.6 6. In practice, the best results In synchro nizing a generator with a systea are obtained by closing the line breaker when the pointer is rotating slowly In the 'PAST* direction and approaching the *12 o'clock* position. By observing tbe synchroscope carefully and tlning the closing operation properly, the circuit nay be coapleted at the exact point of synchronism, or at least within a very few degrees of it. Paulty synchronizing will cause a disturbance on the power systea and any result In automatic tripping of the cir cuit breakers. Parallel Generators REQUIREMENTS FCR SUCCESSFUL PARALLEL OPERATION 1. The following paragraphs give the general requirements for successful parallel operation of synchronous generators. 2. The speed regulation of tbe prime movers should be alike. That is, the per centl in speed for a given percent increase in( should be the saae for all units. Theri in speed from no-load to full-load nay be' two percent or less, but if it is the ( for all of the generators which are in( allel, the total load will be divided bef tbea In proportion to their ratings. 3. The speed governors of the prime noyessi should be free from `hunting* and should bmig the machines quickly to a steady speed. /f5hy oscillation of the governors will result rtfijja transfer of load back and forth between"n3chloes and a fluctuation of the voltage. C=^ LOAD DIVISION AND POWER FACTOR CONTROL 1. Vhen synchronous generators are operating In parallel, the power factor of each depeSSt/ upon the relative excitation and upon the7M5, vision of tbe total kilowatt-load between tfee machines. It is preferable for all the gen erators to operate at tbe saae power factor. RIB-OOD3J30J 213 TURBINE-GENERATOR UNIT 2. In the following dlscusnion, let it be sssuned that the total load Is to be divided between two generators of equal rating. In addition. It will be assuned that the regulator is set for 'MANUAL* operation. The kilowuttload aar be divided equally between the gen erators hy adjusting the governor settings of the two prise aovers. When the two generators are carrying equal loads, their wattaeter readings will' be equal. Ibis redivlslon of load nay be affected without any appreciable change in the frequency of the power systea (noraally SO cycles) by asking each governor adjustment very slight and by Baking the ad justments alternately on the two machines. 3. After the load is balanced, the power factor and line current of the two generators nay be equalized by properly adjusting the annual control unit of the regulator. This any be accoapllsbed without appreciable change in the ship's service voltage (noraally 450 volts) hr slight and alternate adjustments of the `MANUAL CONTROL* handles of the two reg ulators. Refer to the Chapter on 'Voltage Regulator*. 4. With the kilowatt-load divided equally between the two generators, the machine op erating at the lower lagging power factor has the higher line-cnrrent aaaeter reading. If the 'MANUAL CONTROL* handle for the generator having the higher line current is turned slightly toward the'LOWER* position (in order to decrease excitation), the power factor of this machine will increase and the line-cnrrent aaaeter reading for this machine will decrease.5 reactive-load whereas the other nachine is carrying only its share of the kilowatt-load. 6. When the voltage regulator is set for autoaatic control, during the power-factor adjustaents, the same equalization of current say be obtained. In this case it is necessary to vary the `VOLTAGE ADJUSTING* Instead of the 'MANUAL CONTROL*. The regulators will continue to maintain the proper division of reactive-load by Beans of cross-current conpensators, regardless of changes in load. Refer to Chapter on 'Voltage Regulator*. SHUTTING DOWN OF GENERATOR Removing froa Service 1. Mien a generator is operating in parallel with other generators of a systea, and it is desired to remove the generator froa service, the operator should reduce the load on the generator. When all the load has been shifted to the other machines, disconnect the genera tor from the line, and turn on space heaters to keep generator wan and dry. Extended Shutdown 1. During an extended shutdown, the follow ing protective neasures should be taken unless the generator unit can be started periodically and run for a fen ninutes: a. Apply slushing compound to the shaft journals to prevent rusting. 5. In an extreae condition of iaproper `MAN UAL CONTROL* setting, one generator nay be op erating at a low lagging power factor while the other generator is operating at unity power factor. Under this condition, the aa aeter reading of the lagging-power factor ma chine will be considerably higher than that of the other nachlne. This is due to the fact that the one generator is carrying all of the b. Reaove the brushes froa the rings and wipe the rings with paraffin as the machine is coming to a stop with the rings still warm. Be sure that the generator has first been dis connected froa the line and that the excita tion has been removed before the brushes are raised. c. Turn on the space beaters. HUB-00031101 M30- 214 C95 1430C95 A-C GENERATOR Section 2.4 Maintenance of Generator GENERAL MAINTENANCE IMPROPER BRUSHHOLDER SPRING TENS I Temperature 1. The appearance of excessive teaperatnre In an; part of the machine Is an Indication of trouble. The situation should be Investi gated immediately and the cause of the trouble removed. Routine checks on temperature are recommended so that such conditions may be discovered before serious damage is done. 2. The bearing thermostat warns of excessive bearing temperature. If the alarm sounds, the oil supply should be checked. Shut down the unit if the temperature cannot be reduced immediately. 3. The teaperatnre of the field windings is measured by the change in resistance of the field winding Itself. 1. The spring tension should be sufficient to maintain contact between the brush and i collector ring in spite of small vibratis of the brash rigging and collector ring However, the pressure should not be such|( to cause undue mechanical wear. It has bgeg- found that a brush pressure of 2-1/2 psi of brush area gives the best brush performance^ This is equivalent to approximately 2.4 for this machine. p--1 BRUSHES REQUIRING REPLACEMENT 1. As the brushes become shorter from wea the springs should be tightened so as to mat tain the proper brush pressure. Brush should be replaced before they reach the li| of their travel. 4. Vheo the change of resistance of a copper winding is used to measure the average total temperature of the winding, the following equation can be used: t2=R2 ( 234.5 4t,) 234 g R1 in which the resistance values (R) are both in the same units, and the total temperatures (t) are in degrees Centigrade. Subscript (1) refers to the known condition. Subscript (2) refers to the condition at which the resistance is known but the temperature is to be calcu lated. This equation is satisfactory for the range of temperatures normally obtained in electrical machines. Possible Sources of Collector and Brush Trouble1 1. One of the principal indications of im proper brush and collector performance is sparking. The following list presents possi ble causes of brush and collector trouble. USE THIS INFORMATION TO PREVENT TROUBLE as well as to remedy it. UNEQUAL CURRENT DISTRIBUTION AMONG BRUSHES 1. Sparking nay result from an unequal dis tribution of current among the brushes on one ring. The spring tension should be lieved temporarily on the brush carrying excessive current. Readjustment of the spri^ tension may be necessary for all the brushe on the ring to cause each brush to carry it proper share of the current. (c Dirty or Oily Collector Ringa or Brush Rigging 1. Imperfect contact results when dirt, oiQD) or particles broken from the brush are pressed between the brush and the ring. Furthermore, dust between the brush and the holder nay n conduct sufficient current to fuse the brush-- to the holder. 2. The collector rings, brushes, and brus^2) holder should be kept clean and free fro dirt, carbon dust, and oil. A piece of canv^ dipped in a grease solvent is recommended for cleaning these parts. RKB-OOOJI'IC 215 TURBINE-GENERATOR UNIT IMPROPER BRUSHES 1. Brushes of the proper grade are furnished with the sachine. other types nay give un satisfactory performance. See 'Brush Rigging and Brushes', page 204. '2. Brushes of the proper sire nust be used. If the brushes are too snail, they nay faecone edged.at an angle in the holders. If they are too large they will stick in the holders, but this can he remedied by rubbing the sides of the brush with fine sandpaper. ing lightly with fine sandpaper. It is very lnportant that this be done; for while these spots are not serious in thenselves, they will lead to pitting of the rings and the necessity for regrinding. However, no harm is done to the rings if the condition is cor rected at once. If the rings are very rough, they should be ground and polished with the rotor turning. This should not be done at standstill or hy hand, for under these cir cumstances, tbe rings may be made eccentric and uneven. CORRODED RINGS IMPROPER ALIGNMENT OF BRUSHHOLDERS ~ 1. The alignment of the brushes on the ring should be checked occasionally to be sure that a brush does not overhang the edge of .the ring. If tbe brush is allowed to overhang. ' the overhanging part develops a thin edge which chips and breaks off. VIBRATION OF THE BRUSH RIGGING 1. Any loose parts of the brush rigging should be tightened. UNBALANCE IN THE ROTOR OR ECCENTRICITY OF THE COLLECTOR RINGS 1. Either of these conditions can cause the brushes to leave the rings and draw an arc once every revolution. This repeated arcing at the sane place on the ring in tine burns the imprint of the brush on the ring.2 1. Brush imprints nay he burned on the sur face of the rings as a result of causes other than unbalance and eccentricity. Ibis burn ing also occurs when the rings have been left unprotected during an extended shutdown. Ibis usually occurs on a machine which is subjected to corrosive fumes, fhen the machine is shut down, the fumes act upon the surface of the rings except where they are covered by the brashes. Tbe difference in surface caused by this action produces a slight burning as the rings rotate after tbe machine has been re turned to service. Brush imprints due to corrosive fumes can appear at any point on the rings, depending upon tbe position in which the rotor happens to stop. Refer to the Instructions on 'Extended Shutdown', page 214, for protective measures. 2. Corroded rings may require grinding and should always be polished before being re turned to service. 2. Tbe 'truth* of tbe rings can be checked with a dial indicator on the back of a brush while the unit is running at low speed. If the rings are eccentric on the shaft, they should be turned, or ground, and polished. These operations nust be done when the rotor is turning, for if they are dene at standstill or by hand, the eccentricity of the rings nay actually be increased. ROUGH OR HARKED RINGS I. Any black spots that appear on the surface of the collector should be removed by polish UNEVEN HARDNESS OF RING 1. If a ring is not of uniform hardness around the periphery, uneven wear results, and the performance becomes unsatisfactory. ELECTROLYTIC ACTION 1. Because there is an electrolytic action at the surface of the rings,1 their performance is improved by reversing their polarity occa sionally. In some cases, it has been found useful to do this as often as once a week. 216 IWWMKJU 1430C95 1430C95 A-C GENERATOR UNUSUAL OPERATING CONDITIONS Excessive Current Densities One to Overloads 1. The mechanical contact between the brush and the ring is never absolutely perfect, and high current density at the contact surface can cause sparking with brush fits that would be sufficiently accurate for normal densities. Extended Operation with a Low Value of Brush Current e. Increased temperature of the insulation. (The effect of temperature on insulation re sistance is great, the resistance at 25^5^3 being six to fourteen times that at 750C, pending upon the type of machine.) 4. Measurements of Insulation resistance lowered fay the following factors: a. Increased magnitude of the test voltjgg used. (Variations of test voltage as smelt as 2:lor 3:1 make po appreciable difference). 1. Brash `chatter*, accompanied fay sparking, has been found to result from this practice, as when machines are run without load in a standby capacity. b. Decreased tine of application of tf voltage. SIGNIFICANCE OF TESTS CORRECTIVE MAINTENANCE Insulation Resistance GENERAL 1. The insulation resistance of a winding is the resistance of tbe insulation to a d-c voltage tending to produce leakage current through the insulation and over its creepage surfaces. Although it is not a measure of the dielectric strength of the insulation, the insulation resistance indicates whether the machine is in a suitable condition for operation or far high-potential tests. 2. Insulation resistance is affected by a number of conditions, and often an apparent inconsistency in a group of readings can be attributed to variations in one or more of tbe test conditions which have been Incorrectly assumed as constant.3 1. Insulation resistance varies widely am&jt^ machines of different sizes and voltagS^ Therefore, measurements of this quantity ~ useful chiefly for comparison with those at other times on the same machine. MO ~ TESTS OF INSULATION RESISTANCE ARE RECOMMENfflR) for detecting changes in the insulation mare^ rial or creepage surfaces. In order for these tests to be correlated properly, each test should be made under the same conditions. 2. A trend toward lower insulation resists is a warning that failure of the insulatfc is possible. For this reason, the readings.' obtained at any particular time should' compared with the previous readings in on| to be of maximum significance. 3. The behavior of insulation resistari while the windings of a machine are being? dried out is discussed in the section on *Diy=' lng out Windings*, page 208. fo; CONDITIONS FOR TEST 3. Tbe actual insulation resistance is lowered by the following conditions: a. Aging of the Insulation. b. Mechanical damage to tbe insulation. c. Presence of dirt in tbe machine. d. increased moisture content of the insula tion. 1. In order for all the tests to be made under approximately equal conditions of teaperature and moisture, it is suggested thK"" the Insulation resistance be measured in dlately after shutdown while tbe machine still hot. It is preferable to use the sa method and the same circuit for all tests . In any case, the records of Insulation ra slstance will be more valuable for future reference if the conditions of temperature. MB-M035312 217 I TURBINE-GENERATOR UNIT aolsture, etc., and the test circuit and volt age are noted along with the insulation realatance. D-C CIRCUIT 500 TO 400 VOLTS METHOD OF TEST 1. The insulation resistance of a winding war be aeasured by using either an instrunent called a aegger or a d-c test circuit. In either, case, one connection is Bade to the fraae (for stator windings) or to the shaft (for rotor windings), and the other connection is aade to a coaaon terainal to which all leads of the winding in question are attached. VOLTMETER / ok V. THIS SWITCH CLOSED FOR / READING LINE VOLTAGE / TO RESISTANCE TO BE MEASURED h------- 2. When the d-c circuit is used, readings are taken with a high resistance d-c voltaeter. first with the aeter connected directly across a 900 or UOO volt o-c power supply, and nest with the unknown insulation resistance in series with the aeter and power supply. A recoaaended test consists of 500 volts d-c applied for 60 seconds. Refer to Fig. 0-5. . 3. The insulation resistance nay be calculated froa the following forwula when the d-c.test circuit has been used: (R1 - <B-E') ) R = (1.000.000 E' ) *"*" R = Insulation resistance in aegohas R'= Resistance of voltaeter in ohas FI6. 6-6 -- Diagraa of Connections for Measuring Insulation Resistance 2. Reaove the end bells and the bearings. 3. Exaalne the stator core and stator colls for loose sedges, coils, or coil bracing or any other unusual condition. Check the ap pearance of the coll Insulation. 4. Check the rotor for loose dasper bars and loose connections. If a field coil la not tight on the pole, the pole and coil should be reaoved, and Mica plates Inserted between the coll and pole to take up space in width. A collar the sane size as the bottoa coll washer should be used to take up space in depth. E = Voltage of d-c power supply B'= Voltage read on aeter when insulation resistance is in series with the voltaeter.4 4. If the readings of Insulation resistance are low, the leads should be disconnected and the aeasureaent repeated separately on the winding and on the leads in order to deteralne whether the trouble is in the winding or in the leads. 5. Inspect the collector rings, being sure that they are tight. If the rings are rough, narked, or corroded, polish then as described in the section on 'Possible Sources of Collec tor and Brush Trouble*, page 215. If rings are loose, the collector aust be replaced. 6. Inspect tbe bearing and saooth out any rough places in the babbitt. Inspect tbe journal. Its surface MUST be saootb. Polish out scratches which are found. Annual Inspection 1. It is recoaaended that after one year of operation, and once a year thereafter, the generator be thoroughly Inspected. 7. Bring to the attention of a Vestinghouse service representative any condition which cannot be repaired by tbe aalntenance crew. mib-ooohuj 218 1430C95 '> ) ' A-C GENERATOR Claming Generator 1. At the annual shutdown period, the gen erator should be cleaned. It Is advisable to renove the dirt from all accessible parts of the generator, but particularly froa the wind ings, collector, brush rigging, ventilating spaces, and parts adjacent to the electrical windings and connections. Cleaning Air Cooler 1. Die strainers in the sea-water inlet line should be cleaned as frequently as required to provide unrestricted flow. 2. Ibe inside of the water tubes should be cleaned as frequently as necessary to provide unrestricted flow of sea water. The unit should be Inspected at long intervals to see if the fins on the outside of the tubes re quire cleaning froa deposits of oil and grease froa leaky bearings, or csrbon froa brush wear. 3. The cooler is provided with zinc electrodes to centralize electrolysis. These electrodes should be exaalned regularly at 30 day inter vals to see that size of electrode is still adequate. 4. The following procedure should be used in cleaning the air cooler: Step 1 - Close valves in pipe connections to and froa the cooler; drain water, and reaove the unit froa the piping. Step 6 - Reassemble in reverse order, using new gaskets where necessary. Rebabbitting Bearing 1. In case it is necessary to rebabbitt an old bearing on a ship, nelt out the old[bald bltt and prepare a suitable mandrel, ^gtai the bearing is split, each half shouljd-hS babbitted individually. The mandrel sijij consist of a half-cylinder with shoulders <Whning along its length so that the sides of the bearing may >rest on them and form a safes fit. Pieces of felt should be placed aijpufu: the ends of the bearing shell to prevencpcEc) babbitt from running out at the ends. Rezpw bearing insulation and replace after be^Jjfig] is rebabbitted. 2. Only a good tin-base babbitt (Restln Allay No. 46-1) or an approved lead-base [taW bltt (Westlngbouse Alloy No. 25) shoul^S osed for such work. The melted babbitt sIMStW be poured into the gate until it begin%jj) overflow. Sufficient time should elapse after the pouring and before the mandrel is removed from the bearing to allow the babbitt to be come quite hard. 3. The bearing should then be bored or reterf to the proper size. Holes for the introdua(] tion and draining of oil from the beai2hg should be drilled and the proper nachlimg done to provide grooves at the splits Cm eccentric chambers for the oil in the center of the bearing.' The finishing operationsvjmr be done with a suitable scraper. Step 2 - Disconnect inlet and rear covers to expose inside of tubes. Step 3 - Clean inside of tubes by application of steaa jet and use rods where necessary. Repair of Air Cooler 1. The Harrison Radiation Division makes following comment on emergency repair of air cooler: Step 4 - Clean outside of tubes by use of steaa jet, drying with compressed air. Step 5 - Clean any foreign natter from Inside of inlet and rear covers. 2. 'Approximately 5S of the tubes aayn.be. blocked off and the generator air cooler nj still operate efficiently. Thus a leak tube nay be blocked off by inserting plju into each end*. 1430C95 IWWM5HH 219 WESTINGHOUSE ELECTRIC CORPORATION - OIVISION L.R.A. title_________________ Spake Parts List______ DWfl 17/ A 530 SUB 1 PLANT LOCATION PGH- O S .f pare' List Parts And Tools MANUFACTURER - WESTINGHOUSE ELECTRIC CORP APPLIANCE - GENERATOR SPARES application - auu.tpn (QOlH 5 IU 20 Sjduj NAME OF PARTS OR TOOL D </) 3CL<o 2 . manufacturers data CATALOG OR MANUf ACTURERS IO O SERIAL DWG 4 PIECE NO- ORDERING OATAl PC. DRAWING NO. 1 Va G FIELD COILS 2I 1 BEARING 3 V* 2 BRUSH HOLDER 4 *4 4 BRUSH HOLDER SPRING S*I6343U S#372P95K0lj 5* 1359452-B S*25S3iO B 5I I BRUSH RIGGING INSUL. ITS Gf 7, 4 12 G I 4 BRUSH 5*1295005 7I ZINCS AND GASKETS (COOLE^j FR HARRI50N RADIATOR DIV. OF GEN MOTORS E 8519632 16 C4969 I B 9175 8BII46 19 D 7411 350C678 29D284 IS 57m Uyl/ B G.O.-BH-69181-TP SPARE PARTS ;S.O. 55P3I9 SPARE PARTS FOR USE WITH I BRG. AG TURBINE GENERATOR 50584316 LEGEND: S- STYLE NO. C=i 11 WHEN ORDERING ALWAYS REFER TO MACHINE 5ERIAL NUMBER 171 *53o.K List of Spare Parts and Tools -- FIG. G-7 HUB-00038316 Rating: Type SK 6-83: 7.S KW: 120 Volts; 62.5 Anps; 1200 RPM Characteristics Enclosure ................ finding .................... Duty......................... Rotation ...... Aablent Teapemture Teaperature Rise . Class of Insulation Drive ........................ Bearings .................... Lubrication . . . , Mounting .................... Dripproof Protected Shunt Continuous Cl froa Coco. Did 50C 40C 100B 24 hours 55C 1251 2 hours A Direct-Quill Type None None Horizontal For Maintenance Instructions See EMS-141 following this page. Outline Drawing is 21-C-8236 which follows EMS-141. oo 1430-C65 Sect. 3 m NIB-00036317 V V Unpacking....................................................... X Inspection........................................................1 Handling........................................................... 1 Electrical Connections.................................... 2 A-C Motors ................................................2 D-C Generators............................................2 General........................................................... 2 Connections - Fig. 1................................ 2 Operation............................................................... 3 Before Starting............................................3 On D-C Generators.................................... 3 On D-C Motors............................................3 Starting Generators.................................... 3 Starting Motor-Generator Sets .... 3 Starting D-C Motors.................................... 3 Stopping Generators....................................3 Stopping Motor-Generator Sets .... 3 Stopping D-C Motors................................ 3 Brushes........................................................... Commutator.............................................. . Sparking at Brushes.................................. Flashover ....................................................... Bearings - Sleeve - Ball and Roller . Causes of Insufficient Voltage - Generators................................................... Causes of Underspeed (Motors) .... A-C Motors.............................................. D-C Motors............................................... Heating of: Field Coil................................................... Armature................................................... Rotor........................................................... Commutator............................................... Cleanliness................................................... Reassembly of Machines (on bedplate)...............................................6 Disassembling of Machines (on bedplate)...............................................8 GENERAL INSPECTION To obtain long satisfactory service from ro tating electrical equipment, it is necessary to properly install, operate and maintain such equipment. The following gives the simple precautions and instructions for such care. Properly maintained equipment will require very little care other than periodic inspections and lubrication. The most important factor is to keep the apparatus clean and free of oil, water and other foreign material. INSTALLATION UNPACKING When unpacking, be sure and protect any ex posed windings from damage. Never pry against a winding nor strike It a blow with a hammer. Do not allow sharp instruments to come in con tact with the coils. Avoid damage to the shaft. Keep it free from bumping which will cause burrs and interfere with the coupling or pulley fit. Do not bend shaft as it will cause mis alignment. As soon as the apparatus is unpacked givtQ) it a thorough Inspection. Look especially for^l any loose field connections, bolts, covers,1^} broken brushes or brushholders and .any no-i ticeable damage to coll insulation. Repair im-1 mediately any damage found. If machine been in storage some time or has been expose to dampness, the insulation resistance should be checked. See instructions under nance" - Insulation. See that name plate read ing agrees with the voltage and frequency pro-(fjB) vided for the motor. lrS HANDUNG Electrical equipment can be damaged whei=_ dismantled. If the machine is dismantled and theafcs windings are exposed, care is necessary to^y properly protect these windings from damage. 6 In handling the armature, do not allow the com- ^ mutator or coil ends to be bumped as this will /jte; damage them. Support the rotor or armature by rope slings about the shaft or steel punchings. Use a spreader to keep the ropes from tiM m USA- (Jammty, 1951) (OctvhM. Il) MMMJIJ1J 1 i> f INSTALLATION--OPERATION--MAINTENANCE pressing against the coil ends or commutator. Never sup port it by pressure on the coil ends or on the commuta tor, either when using a rope sling -or when resting on blocks. Never use any sharp instruments on any coils as the insulation may be punc tured. ELECTRICAL CONNECTIONS AC Motor* Connection of Motor to Power Circuit with Standard Number of Terminals. Three-Phase (Three Ter minals). Connect any lead to any motor terminal. To reverse the direction at the motor, interchange any two leads. Two-Phase, Four Wire (Four Terminals). Connect the leads from one phase to motor terminals T1 and T3 and the leads from the other phase to motor terminals T2 and T4. To reverse the di rection of the motor, inter change the leads of one phase. Two-Phase, Three Wire (Four Terminals). Connect the two outside leads to motor terminals T1 and T2 and the common lead to T3 and T4. To reverse the rotation of the motor, interchange the two outside leads. Connection of Motor with more than Standard Number of Terminals. Refer to the connection plate on the motor or to the connection sheet filed in the instruction envelope. DC Motor* Connect the motor and starter by referring to the diagrams furnished with the starter and as given in dia grams 1, 2, 3 or 4. Motor Connection*--Rotation Facing Commutator End 1DUORAH Bo. --SHORT WOURD HOTOR. WITHOUT COHPIRSATIRG COILS Clockwise Rotation 3______t A! And P to -- Lint 3 toConnect A to starting resistance. then + lane Connect Fl to + line 2Covntee.Clocxwise Rotation Connect A And Pa to -- line * Connect Al to etArtinc resistance. then to + line Connect Fi to + line - 2Vise* or Moron Tumimau** DIAGRAM Ho. --SHUNT WOUHD MOTOR/WITH COMFtNSATtHG COOS. AKD COMPOUND WOUHD 3 2Clockwise Rotation Connect S end P to -- line 2Connect Al to Si Connect A to stertag renounce, thence to + line Connect Pi to + line ` Comma^ucivitt Rotation 2 2Connect S end P to -- line 2 6Connect A to l Connect Al to starting reneionre thence to + line Connect Pi to + line DIAGRAM He. I--BURTift WOUHD MOTOR Clockwise Rotation 3Connect S to -- line toConnect At Si 2Connect A to ourtinf resistance. thence to + line Cowra-CLocrmti Rotation 82Connect to -- hoe 2Connect A to SI to_ Connect Al emetine resistance. thence to + hoe View nr Moron Tsucnai*** ____ 4DIAGRAM Ho. --TIP* ST RtRVATOR MOTOR 1COMPOUND WOUHD--CIAIW S D AlfD m (See note) (for cleat I ctoei nee dnina No. I) 82 2Clockwise Rotation. Connect nod F to -- lint - 2ff--At to SI Connect A to etarting resistor, thence to + line Connect Pi to + line 2 2CotorTaa-Clockwise Rotation Connect Slnnd P to -- has Connect A to Si Connect Al to starting rename, thence to + Knc. Connect Pi to + has _____________j for stnrtiat, the foil eeriw field baina in circuit. Coder norma) bf 3 3 83--------------------------the series Add is short circuited. !o daeaasliaadlllaeton. tbeaencetdd mar be cot oat in two steps Aervdfcdtiai S and S , than Si end . Generator Connections 8DIAGRAM Ho. (-COMPOUND WOUHD OXH RATOR CbocKwtu Rotation 2Connect A to + line 2 82Connect Al end F to 81Connect to -- tine Coneset Pi to Add rheostat. thence to + line. Coontw-Clockwiss Rotation 2 2 82Connect Al to + has Cinmed A to P to 4View or Gsnkkatok Tbkmimalc** Connect SI to line Con_n_e_c_t PI to fidd rbooctet. thence to < - line. 0mean am He. --SHUNT WOUHD OXHXRATOR /,/^qpy~A2 Vnw nr OnnsnATos TnooMtiM Clockwise Rotation 2Connect A to + tine 2Connect Al end F to -- line Cortnert Pi to fidd rheostat, thews to + boe Comma-Clogcwiss Rotation 2 2Connect Al to + line Cnnmrt A to P to -- has Connect PI m fid'd rheostat, thence to + line. Above twmmal location ere for leads oat right bend ddo looking At When lends are oat left hand dde ** r---- ----- Connect the generator and field rheostat by referring to diagrams furnished with the field rheostat as given in dia grams S and 6. 1Pm. --Unaw or CMoaenwo Moron to Lmg 0=3 2 IWM003831I INSTALLATION--OPERATION--MAINTENANCE General Install all wiring and fusing in accordance with the National Electric Code, and local re quirements. A conduit box is supplied, but conduit and conduit fittings are not furnished with the ma chine. These items may be purchased from any Electrical Dealer, or Plumber's Supply Bouse. When the machine is mounted on a bedplate, or on slide rails for belt adjustment, flexible metallic conduit should be used to protect the leads. In making this connection a squeete connector should be used for attaching the flex ible conduit to the conduit box, as shown in Fig. 1. Squeeze connectors may be straight, 45, or 90. In order to connect a squeeze connector to the conduit box first remove the cover of the box. Run a locknut well down the threads of the connector and place the connector in the hole in the bottom of the conduit box. Screw a conduit bushing over the end of connector, swing the connector to the desired position and draw the locknut up tight against the box. Fol low the same procedure with rigid conduit or reducing bushing. . OPERATION BEFORE STARTING Check to see that all connections are made and all joints are tight. Examine the brushes and brushholders. The brushes should be free to slide in the holders and should be bearing against the surface of the commutator or slip ring. If any broken brushes are found they should be replaced. (See instructions under "Maintenance" - Brushes). The holders should be providing approximately two pounds per square inch pressure and should be located 1/16 to 1/8 inch from commutator surface. If brush rig has been disturbed during installation it should be returned to the correct position as set at the factory and which is marked by means of a dowel bolt. Always keep the rig in this position. Examine air gaps and re move any foreign material found therein. See that rotating members turn freely. The following instructions cover various types of electrical apparatus. Be sure to know which type you have. If you have: D-C Motors use paragraphs 2, 3, 4 D-C Generators use paragraphs 1, 5, 6 A-C to D-C M-G Set use paragraphs 1, S, 6 D-C to D-C M-G Set use paragraphs 1, 2, 9,6 On DC Generators Keep field rheostat turned to the all in" ilrn! sition (position of minimum voltage) and line switches should be open. (I) ON DC MOTORS Keep field rheostat (if there is one) turnip) q! to the "all out" position (position of mininufiix speed) and all line switches should be open.f ~ Q Slotting Generator and Motor Generator Se On initial starting proceed slowly and note especially for any evidence of rubbing. Cl) for heating in the bearings. Alter set is up to speed raise voltage turning field rheostat. If polarities are right - adjust for rated voltage and close main switclbpn Generator is then ready to be loaded. (J'C' Alter load is applied to d-c generators lodwj^-1 for evidence of sparking at the commutator^ ,, The generator should carry rated load witj little sparking. If severe sparking occurs, comments under "Maintenance". !| STARTING DC MOTORS On initial starting proceed slowly and note especially for any evidence of rubbing. Check for heating in the bearings. After motor is up to speed, check speed. OK, motor is ready to be loaded. After load is applied to DC motors look fotpN evidence of sparking at the commutator. Thlt^y motor should carry rated load with little spark'll lng. If severe sparking occurs, see comments^) under "Maintenance". Stopping Generator and Motor Generator Set When stopping, gradually reduce load on gen erator as much as possible before tripping cir cuit breaker. Turn rheostat to minimum volt age and stop prime mover. STOPPING DC MOTORS When stopping, gradually reduce load as much as possible before tripping circuit breaker. MAINTENANCE INSULATION Keep machine free of dirt, oil and water at all times. One of the greatest enemies of coil' .ON insulation is dirt, and if the equipment is kept1 clean less trouble will result. The best way to check for excessive dampness in. the windings is to make an insulation resistance measurement. W-M03eJ20 3 INSTALLATION--OPERATION--MAINTENANCE This can be done directly by a "megger". If a megger is not available, the measurement can be made using a 100 to 500 volt direct cur rent (the higher voltage available the more ac curate the results) and a direct current volt meter,. of which the resistance in ohms is known (generally marked on label inside the instrument cover)^ The method of making a resistance measure ment with the voltmeter is to first read the voltage of the line, then connect the resistance to be measured in series with the voltmeter and take a second reading. The measured resistance is calculated from the formula: Rrr * --r -,V--*--V-> onrr 7 (V-v) V First voltage reading, v e Second voltage reading. R = Resistance of insulation in ohms, r Resistance of voltmeter in ohms. If a grounded circuit is used in malting this measurement, care must be taken to connect the grounded side of the line to the frame of the machine. The voltmeter should be connected between the windings and the other side of the circuit. The Insulation resistance with the machine cold (at room temperature) should be at least: one megohm (1, 000, 000 ohms). When the windings are hot it should be at least: 3 (rated voltage) ., KW * 1000 0 megohms) If the resistance is low, the generator should be dried out before it is started into regular service. It can be done by, (1) using a sep arate heater (such as a lamp bulb) Inside the generator (do not place too near the coils and in general the machine should be partially en closed for the best results), (2) circulating current through the windings, or (3) dismantling and removing the armature and coils and baking them in an oven (at not over 105C). This should be done in extreme cases. If the second method is used, run the gener ator with a low voltage output, adjusting the load to. a current value which will raise the temperature to approximately 70C. This tem perature should be maintained during the drying process by raising or lowering the current as required. Careful attention should be given to the ma chine during this drying-out process. There is always danger of overheating the windings when drying by circulating current through them. The inner parts which cannot quickly dissipate the heat generated in them may get dangerously hot. while the exposed and more easily cooled por tions are still at a comparatively moderate temperature. Therefore, the temperature of the hottest part accessible should always be observed during the drying-out process, and should not be allowed to exceed 80C total tem perature. If It is found that the generator is in a very damp condition, it may require several hours or even days to dry it out because the insula tion is. more easily injured when damp then when it is comparatively dry. In such extreme cases, it is better to bring up the tem perature slowly at first, not allowing the max imum temperature to be reached until part of the moisture is expelled. BRUSH POSITION The correct brush position has been located at the factory and the rocker ring is locked to the magnet frame to prevent any movement. The brushholder should be adjusted to be ap proximately 1/16 inch from the face of the commutator. BRUSHES The ends of all brushes should be fitted to the commutator so that they make good contact over their entire bearing face. This can best be accomplished after the brushholders have been adjusted and the brushes inserted. Lift a set of brushes sufficiently to permit a sheet of sandpaper to be inserted. Draw the sand paper in the direction of rotation under the brushes releasing the pressure as the paper is drawn back. Be careful to keep the ends of the paper as close to the commutator surface as possible as this will avoid rounding the edges of the brushes. It will be found that by this means a satisfactory contact is quickly secured. Use sandpaper grade 1-1/2 for the roughing out and grade 0 for the final fit. Make frequent inspection to see that: 1. Brushes are not sticking in holders. 2. Shunts are properly attached to brushes and holders. 3. Tension Is changed as brush wears. Main tain approximately two pounds per square inch. 4 MB-OOOISJH INSTALLATION--OPERATION--MAINTENANCE 4. Worn out brushes are replaced before they reach their limit of travel and break contact with the commutator. 5. Remove the free copper picked up by the face of the brush. COMMUTATOR The commutator is perhaps the most impor tant part of the whole machine because it is most sensitive to abuse. Under normal con ditions, it should require very little attention beyond frequent inspection. The surface should always be kept smooth. If, through extreme carelessness, neglect or accident, it becomes badly roughened, the armature should be re moved and the commutator turned down in an engine lathe. Sometimes a little sandpapering is all that is necessary. Emery cloth or paper should never be used for this purpose because of the continued abrasive action of the emery which becomes embedded in the copper bars and brushed. Even when sandpaper is used the brushes should be raised and the commutator wiped clean with a piece of canvas. Cotton waste should never be used. All commutators are thoroughly baked and tightened before leaving the factory, but if a bar should work loose it should be attended to promptly. The same may be said of flat spots or "flats" which will sometimes occur, due to a loose bar, unusually soft copper or even too sever flash or short circuit. Under normal conditions the commutator should become dark and highly polished after a few weeks' operation, and remain unchanged for years. There should never be any lubricant used on the commutator. Trouble is sometimes experienced from the burning out of mica insulation between segments. This is most commonly caused by allowing the mica to become oil soaked or by the bars loosening between them. It is rarely, if ever, definitely traced to excessive voltage between bars. When this burning does occur, it may be effectively stopped by scraping out the burned mica and filling the space with a solution of sodium silicate (water glass) or other suitable insulating cement. Even with the most careful workmanship, high mica sometimes develops and starts sparking, which burns away the copper and aggravates the difficulty. By prompt action, serious damage can be prevented by cutting away the mica to a depth of one-sixteenth of an inch below the adjacent copper. SPARKING AT BRUSHES Sparking at the brushes may be due to any of the following causes: a. Machines may be overloaded. b. The brush may not be set exactly on neutraliQP) c. The brushes may be wedged in the holdersr - or have reached the end of their travel. l[2]l d. The brushes may not be fitted to the cir-u=>ca cumference of the commutator. 0 e. The brushes may not bear on the commu-n tator with sufficient pressure. f. The brushes may be burned on the ends. g. A commutator may be rough; if so, it' should be smoothed off. h. A commutator bar may be loose, or mavp^ project above the others. Lrjnj i. The commutator may be dirty, oily or worriS^ out. j. The carbon brushes may be of an unsuitable>^ grade. k. The brushes may not be equally space around the periphery of the commutator. l. Some brushes may have extra pressure may be taking more than their share of current. m. High mica. n. Vibration of the brushes. o. Incorrect brush angle. There are other causes, but localized sparking may be due to an open circuit or loose connection in the armature. This trouble is indicated by" a bright spark which appears to pass completely^ around the commutator and may be recognized^) by the scarring of the commutator at the point'---' of open circuit. If a lead from the armaturec^l winding to the commutator becomes loose or'^J broken it will draw a bright spark as the breakuTD) passes the brush position. This trouble cany readily be located, as the bars adjacent to the P) disconnected bar will be more or less pitted. P) FIASHOVER jQf A flashover happens when arcing occurs be-/fjp\ tween adjacent brushholder brackets. In general,'jJ-' it is caused by excessive voltage, or by ab-C-S normally low surface resistance on the com mutator between brushholders of opposite polar-n__^ tty. Any condition tending to produce poor com-I,----mutation increases the danger of flashover. rs-s Among other causes are the following: 1. Rough or dirty commutator. 2. A drop of water on the commutator from leaky steam pipes or other source. (Oo 3. Short circuits on the line producing ex cessive overload. MMoojajtt S > INSTALLATION--OPERATION--MAINTENANCE BEARINGS, SLEEVE When machines are Installed, put a good grade of light dynamo oil in each bearing housing. Use oil of a viscosity of from 185 to 212 sec onds at 40C. This oil is satisfactory for normal temperature down to 0C or 32F. For oils suitable for lower temperature secure special engineering recommendations. The correct level of the oil is one-eighth inch below top of combination over gauge and filling device. Close down cover when through oiling. When machines are first started, feel bear ing housings occasionally to see that bearings are not overheating. The frequency of bearing inspection depends on the conditions surrounding your application. Do not add oil unless the oil level has dropped more than one-eighth inch below the top of the combination overflow gauge and filling device. Do not oil bearings while the motor is running. Do not flood with oil. Do not spill oil over the housing or the bracket. Old oil should be drained from the housing once a year and replaced with new oil. BAU AND ROLLER BEARINGS-- OPERATION AND CARE OF Quietness and life of ball and roller bearings depends largely on cleanliness and proper lu brication. Inspection 1. When the machine is installed make certain that the rotor turns easily, particularly if the machine is not installed until some months after being shipped. 2. Never open the bearing housing under con ditions which would permit entrance of dirt. 3. External inspection of the machine at the time of the first greasing soon after it is put into operation will determine whether the bear ings are operating quietly and without undue heating. Further inspection will not be neces sary except at frequent intervals, probably at greasing periods. 4. If practicable, it is desirable for the most satisfactory service, to open the bearing hous ings once a year, or after every 5,000 hours' operation, to check the condition of the bear ings and grease. If difficult to inspect the pulley or pinion end bearing, the condition of the bearing at the opposite end will usually be representative of both. 5. If grease deterioration has occurred or if dirt has gained entrance to the housing, the bearing and housing parts should be thoroughly cleaned out and new grease added. Grease Lubrication 1. Grease is generally used as a lubricant. Ordinary cup greases are not satisfactory be cause of great tendency to deteriorate under the severe churning action of the bearings. To be suitable for ball or roller bearing lubrication a grease should be compounded from a pure mineral oil and a sodium base soap. It should be free from dirt and fillers, such as powdered mica, flake graphite, etc. It should be free from acid or alkali or from ingredients which will form these compounds. It should not melt at the highest operating temperature of the bear ings and it should maintain a fairly uniform con sistency over a large temperature range. Westingfaouse grease meets these requirements. Keep grease clean by using only closed containers. Do Not Over Lubricate 2. A small amount of lubricant is essential, sufficient to maintain a film of lubricant over the surface of the balls and races. Too much grease will cause churning, overheating and grease leakage. If grease leakage occurs the bearing has been over filled, or the grease used is not suitable for the particular applica tion. If high pressure guns are used, great care should be used to avoid over lubrication. When shipped from the factory, grease lu bricated ball and roller bearing machines have sufficient grease of the right grade to last for a limited period. However, a charge of grease should be added soon after the machine is put in operation, and thereafter at suitable intervals, as determined by experience. As a guide, it is suggested that grease should be added every three months of operation in amounts as indi cated in the following table. If experience in dicates that these quantities result in a surplus of grease in the bearing, the quantity should be reduced or the greasing periods lengthened or both. The ideal condition is that the bear ing housing be from 1/3 to 1/2 full of grease. As the shaft extension diameter is easily de termined and is roughly proportional to the bearing size the following table for grease ad ditions is prepared on this basis. C=3 oo 6 M8-00038313 INSTALLATION--OPERATION--MAINTENANCE Shaft Extension Diameter Amount of Grease to be added 3/4 to 1-1/4" Above 1-1/4 to 1-7/8" Above 1-7/8 to 2-3/8" Above 2-3/8 to 3" Above 3 to 4" Above 4 to 5" 1 cu. in. 1-1/4 cu. in. 2-1/2 cu.' in. 4 cu. in. 7 cu. in. 10 cu. in. 1 6z. = 1-1/4 cu. in. 3. When surplus grease sump below bearing is supplied, this should be kept empty at all times. Rcreating (nor pr*-lubricoted type) 4. When the bearing housing has been disas sembled and the bearing thoroughly cleaned with a suitable solvent it should be immediately regreased with Westinghouse grease alter first spraying or flushing with good lubricating oil. Apply the new grease either from a tube or by band, over and between the balls or rollers. Do not use more than the amount specified in the table. Westinghouse Grease - Ordering Data 8 os. tube -- Style No. 1360876 1 lb. can----- Style No. 1248911 5 lb. can----- Style No. 1248912 10 lb. can----- Style No. 1248913 25 lb. can----- Style No. 1380877 Refer to the nearest district office of the Company for Westinghouse Grease packed in larger containers. CleanlineH Ball and roller bearings are especially sen sitive to even a small amount of dirt. Hence, they must be protected from it at all times. If necessary to disassemble the bearing housing, first thoroughly remove dirt from all adjacent parts so that dirt will not fall into bearing or interior of housing. A grease having high stability is permanently sealed in these bearings by the bearing manu facturer. Both laboratory tests and years actual service have proved that this grease w^ give long service. Bearings from several suppliers are used in Life-Line motors; for a given sise motor, tlft--1 bearings of all suppliers are interchangeabldHPj The details of the seal construction varv somef_n what depending upon the bearing manufacturer]^ cqi but each type of seal is equally effective iftaeil keeping out foreign material and retaining th@ 0 lubricant. CAUSES OF INSUFFICIENT VOLTAGES (GENERATORS) The following causes may prevent generator^H from developing their normal voltage: a. The speed of the generator may be beli normal. b. The switchboard instruments may be correct and the voltage may be different fro; that indicated, or the current may be dilfe: from that shown by the readings. c. Part of the shunt field may be reversed o! short circuited. d. The brushes may be incorrectly set. e. The part of the field rheostat or other un necessary resistance may be in the field cir cuit. CAUSES OF UNDERSPEED (MOTORS) AC Motors The switchboard instruments may be Incorr rect.and the voltage and/or the frequency ma)P^ be different from that indicated, or the curreo may be different from that shown by the read logs. DC Motors a. The switchboard instruments may be in-^}< correct and the voltage may be different front]--; that Indicated, or the current may be different from that shown by the readings. PRELUBRICATED BEARINGS b. If shunt field is separately excited the volt age and field current may be high. Some motors are supplied with pre-lubricated bearings which do not require servicing. These motors are identified by a decal near the bearing housing and usually by the omission of grease fittings and drains. c. The brushes may be incorrectly set. d. If field rheostat is necessary for rated(^3 speed part of rheostat may not be in circuit and as a result the field current is high. MHOOJ832I 7 INSTALLATION--OPERATION--MAINTENANCE HEATING OF HELD COILS Heating of field coils may develop from any of the following causes: In extreme cases clean machine using carbon-tetracholordie on a cloth. Use sparingly and in a well ventilated place as the fumes are toxic. Do not scrape coils with any instrument. a. Operating at too low a speed, requiring more than normal field current. b. Too high voltage. c. Partial short circuit of one coil. After several years of operation it is good practice to coat all coils with a coat of good insulating varnish. A baking varnish is much superior to air-drying varnish, and should be used il possible. d. Overload. HEATING OF ARMATURE OR ROTOR Heating of the armature may develop from any of the following causes: - a. Too great a load. b. A partial short circuit of two coils with heating of the two particular coils affected. c. Short circuits or grounds on armature or commutator. DISASSEMBLY OF MACHINES-- ON BEDPLATE If, far any reason, a machine must be re moved from a bedplate, the following procedure should be followed: 1. Remove coupling bolts to disengage shaft from other units. 2. Remove dowel in feet of machine to be re moved from bedplate by tightening nut on dowel pin until entire dowel can be removed. There should be two dowels per frame located diago nally opposite each other. HEATING OF COMMUTATOR Heating of commutator may develop from any of the following causes: 3. Remove holding-down bolts in feet, being careful to observe and maintain correct shims under each foot for reassembly. a. Overload. b. Sparking at the brushes. c. Too high brush pressure. REASSEMBLY OF MACHINES-- ON BEDPLATE After a machine has been removed from a bedplate, reassemble as follows: d. Lack of inherent lubrication of brushes. 1. Place machine on bedplate with same shims under each foot as when disassembled. CLEANLINESS 2. Start holding-down bolts, but do not tighten. Particular care should be exercised towards keeping all parts of the machine reasonably clean. High rotative speed draws air into the armatures and the other parts with a velocity sufficient to carry with it particles of dirt or oil vapor that may be in the air. The rotating part must be cleaned periodically or the ma chines will ultimately short circuit between com mutator necks or break down to ground over insulation surfaces. Stationary windings should be well cleaned for the same reason. 3. Install dowel bolts, and drive down as far as possible. 4. Tighten holding-down bolts, and drive dowels all the way in. 5. Install coupling discs and bolts. Machine is ready to run. 6. Observe the rules for starting as given under "Operation". 0=3 oo *3 MMMJIJ25 GENERAL INFORMATION EMS 151 1A. FOREWORD a) Careful reading of these Instructions will provide Information for the proper care and handling of the generator voltage regulat ing equipment and avoid damage to the equip ment which may impair its performance when placed in operation. b) when corresponding regarding the equipment described herein refer to--Type *SRAN-3" Voltage Regulating Equipment. Use Westlnghouse identification data given on title page. Com plete identification of parts is contained on page II. lations it is considered advisable, due to exciter field characteristics, to use an aw.-n clter field resistor to limit the range regulating resistance and improve the seni_r. tivity. foe,: 133 l-- oc d) The resistance,is varied by the value of the current in the coil circuit. Nor( operating range of the coil current var^ from .125 to .140 ampere d-c from the reef tier. 10 e) With this value of coil current in regulator circuit, proper voltage reguia^ tion will be obtained. jQc^. c) Address inquiries to the nearest Westinghouse Service Facility-see list at end of this book--or to Westlnghouse Electric Cor poration; Switchgear and Control Division; East Pittsburgh, Pennsylvania, U.S. A. IB. DESCRIPTION OF GENERATOR VOLTAGE REGULATING EQUIPMENT a) The purpose of the automatic voltage regu lator is to maintain the terminal voltage of the alternating-current generators at, or very close to, rated volts regardless of load variations. b) The voltage regulator controls the voltage of the alternating-current generator by varying the resistance in the exciter field circuit. This regulating action is of a semi static nature and hence the device operates only when a correction in voltage is necessary. Since the regulator acts directly on the ex citer field resistance, no intermediate con tactors, levers or linkages are necessary. c) The "SRAN-3" type of voltage regulator has two regulating resistance plates which can be connected in parallel, series-parallel or series. These in turn are connected directly in the exciter field circuit. On some instal 1C. VOLTACE REGULATOR CONTROL ELEMENT | a) The regulator coil is wound with 3000 tuk of No. 25 enameled copper wire with a re sistance of 65 ohms. It is identified by Westlnghouse Style No. 1173224. bj An adjustable resistance is connected series with the coll of the voltage ref lator to set the range covered by the volta adjusting rheostat, so that rated general voltage is obtained with the voltage adjusting!] rheostat in the mid-position. This internallyJ mounted resistance consists of two 750-oty tubes each identified by Westlnghouse Sty No. 1115103. c) The spring-mounted moving arm of the regu lator is supported so that the armature' passes within the fixed air gup in the magnet^ circuit. The pusher pins are located nt outer end of the moving arm and arranged to press against the silver buttons which are mounted at the free end of the leaf springs made of conducting material. d) The fixed end of each silver-button le^fCj spring is attached to consecutive sterns^ of the regulating resistance plates. TliesgC' plates have resistive wire embedded in vitreous Mi-KHIJU I '.A SMS 151 GENERAL INFORMATION to prevent excessive voltage and hunting. When the a-c voltage rises.the regulator operates, due to increasing coil pull.to insert resist ance in the exciter field circuit and thereby decrease the exciter field current and armature voltage. The primary of the damping trans former is subject to this change and induces a voltage in the secondary which causes a momentary reduction in the normal regulator coil current. Thus, the coil pull is reduced by this impulse from the damping transformer, and the regulated voltage is not decreased excessively. Conversely, when the a-c voltage falls and the regulator operates, due to de creasing coil pull, to short-out resistance in the exciter field circuit,the Impulse from the damping transformer aids the normal coil current. Thus the regulated voltage is not increased excessively. c) The 3-phase, full wave, Rectox rectifier. rectifies the 3-phase a-c voltage to pro vide d-c current for the main coil of the volt age regulator control element. The basic element of the Rectox rectifier is a copper disc, on one side of which a layer of cuprous oxide has been formed. This disc allows cur rent to pass freely in the oxide-to-copper direction but with difficulty in the opposite direction. In this installation the discs are assembled on six separate supporting studs. The six stacks of discs each Identified by Westinghouse Style No. 1106396, are connected so that all positive half-waves of the impressed alternating-current energy will send current to the regulator coil in one direction through one half of the rectifier stacks; all negative half-waves will return to the potential trans former through the other half-stack which previously opposed passage of the positive half waves. The result is a d-c output from the rectifier to the control element coil. This output depends on the average of the 3phase voltages. IF.. VOLTAGE ADJUSTING RHEOSTAT a) Turning the handle of this rheostat raises or lowers the value at which the regulator holds the generator voltage. Changing the resistance varies the current in the coil cir cuit of the regulator.which changes the posi tion of the regulator moving arm and results inachange in resistance in the exciter fiffir--] circuit. Hence the regulated value of eene| ator voltage can be adjusted by the positi, of this rheostat. This rheostat has approxi mately 203 equal steps of resistance.225 ohms i total. IF. CROSS-CURRENT COMPENSATOR jgSJj 0c a) This piece of apparatus consists of an adjustable auto-transformer connect&d^ across a resistor-reactor combination. TM^- insulating transformers transmit energy in__~ proper phase relation to the potential circuljJ^3 of the regulator. This causes the regulator--n to droop the regulated voltage in proporciejr/^j to the magnitude and phase angle of the active load current. IG. A-C POTENTIAL TRANSFORMER a) Two potential transformers arc used step down from rated a-c generator voltagi to approximately 115 volts, the voltage ap plied to the regulating equipment. b) The potential transformers are connected as follows; n-- 1 PRIMARY - Connected open-delta receives 3-- phase, 3-wire, 60-cycle, generat^ volts. ^ SECONDARY - Connected open-delta gives 3-pha^gE 3-wire, 60-cycle, 115 volts. 1H. CURRENT TRANSFORMERS a) One current transformer is supplied with-. each a-c generator that operates in parahiy lei with other generators. It is connecte^Pg in line "B" of the generator and its energy is supplied to the cross-current compensator,!__ The ratio of this current transformer depend^ upon the kw rating of the generator. II. REGULATOR CUTOUT SWITCH far'' 'Sb' /C.c:. i) The regulator cutout switch is of tllW7s*WZ rotary type provided with three positions flK-00Q5831fc 3 US 1S1 HANDLING-STORAGE-INSTALLATION C43 2A. STORAGE . a) The regulating equipment was carefully Inspected and checked and then packed for shipment with the object of providing protec tion during the necessary handling and storage. The unit will withstand reasonable atmospheric and temperature conditions. A metal case en closes the moving element of the regulator to afford protection against dirt and dust. How ever it is recommended that the shipment should be checked immediately for loss or damage. If any such shortage or damage is found.lt should be reported to the transportation company with out delay. ZB. HANDLING AND UNPACKING a) Care should be taken not to kink or bend the hinge-spring assembly. The moving-arm assembly should not be forced In any direction otherwise the performance of the regulator is likely to be unsatisfactory. ZC. INSTALLATION AND ERECTION a) When the regulator is placed in position prior to the installation of other large apparatus nearby, the electrical equipment should be protected by box or crate parts, or sections of plywood. 2D. TEMPERATURE AND VENTILATION a) Provision for cooling has been made by leaving the resistance plates exposed to the atmosphere and yet protected from harm by the use of a metal shield. These resistance plates are vertically mounted which assures rapid removal of heat from the unit. Free movement of air around the unit should be per mitted for proper dissipation of the heat de veloped In the resistance plates. Leads should be connected as shown in the schematic end connection diagram. Due re^afft", should be given to the polarity of the damjfitig-'1 transformer otherwise the moving armaturdiot" the magnet will swing violently. ISei) oc 2F, ADJUSTING AND TESTING a) The regulator has been carefully adjuit(f[ and tested at the factory and no readjust-- ment should be required other than voltage-1, adjustment by means of the voltage adjusting-' rheostat. (s''-' b) The following precautions are deslr before actually operating the unit. Ctmck-- for the free operation of the moving armature^" The clearances are approximately .013 + .pSisj of an inch on each side of the moving armatiivq^i This armature must be exactly centered for Its travel in the air gap of the magnet. Suf ficient clearance In the hinge spring holes permits centering the armature. If the arma ture should be out of center, thus causing a binding or rubbing against the bumpers, it necessary only to loosen the blnge-spr{ screws, center the armature with a feeler ease " to insure proper clearance and then tlghtsji/ the hinge-spring screw thus locking the arma ture in position. Check to see that there at/ no bent or kinked hinge springs, as this w@i cause the armature to shift out of position-; The leaf springs should under no condition^; loose or bent. ir^' _ c) The limit of travel for the moving aw should be Just sufficient to permit ^12) silver buttons to open and close. This travaT can be adjusted by loosening the stop screws1 at the bottom of the moving arm, adjusting to permit all buttons to open and close, and retlghtenlng the locknuts. 2G. LUBRICATION 2E. CONTROL CONNECTIONS a) Each piece of apparatus has clearly marked terminal blocks or studs for connections. a) Positively no form of oil or lubricating substances are required on this regulator^ There are no bearings as all movement Is ac complished through springs. KH-0003IJ3E TYPE SRAN-3 VOLTAGE REGULATOR Contents Description CONTRACT IDENTIFICATION............................................................... Machine Identification ........................................................... Voltage Regulator Identification and Drawings .... GENERAL INFORMATION....................................................................... Foreword ...................................................................................... Description of Equipment ....................................................... Voltage Regulator Control Element .................................... Daaping Transformer and Recto* Rectifier Assembly . . Voltage Adjusting Rheostat ................................................... Cross Current Compensator ................................................... A-c Potential Transformer ................................................... Current Transformers ............................................................... Regulator Cutout Switch .................................... ................ HANDLING. STORAGE, INSTALLATION............................................... Storage................... .................................................................. Handling and Unpacking ........................................................... Installation and Erection ................................................... Temperature and Ventilation ............................................... Control Connections ........................................ , ................ Adjusting and Testing ........................................................... Lubrication ............................................................................... OPERATION AND MAINTENANCE........................................................... Starting up an A-c Generator ............................................... Compensator Adjustment ........................................................... Example of Operation ............................................................... Non-Parallel ....................................................................... Parallel ........................................................................... . Shutting Down ........................................................................... Maintenance ............................................................................... What To Do In Case of Trouble ........................................... DRAWINGS AND DIAGRAMS................................................................... Westlnghouse Service Facilities <see List at Back of Book) Page iii iii iii 1 1 1 1 2 3 3 3 3 3 5 5 5 5 5 5 5 5 7 7 7 8 8 8 9 9 9-10 Hi oc P--n 0 H EMS MB-0001EJ27 151 ') CONTRACT IDENTIFICATION Purebater INGALLS SHIPBUIL0IN6 CORP. Manufacturer WESTIN6HOUSE ELECTRIC CORP. 6.0. BH-69I8I-TY and BH-7I04I-TY S.O. 23-Y-2533 MACHINE IDENTIFICATION ANO RATINGS A.C GENERATOR - S.O. 67-P-99`1 and E8'P>3I6 75 KVA. 450 Volta, 0.8 PF. 3 Fbase. 60 Cycle. 1200 RH D-C EXCITER - 3.0. 67-P-996 and 68-P-3I7 7.S K. 120 Volt. 1200 RFM IDENTIFICATION ANO DRAWINGS Apparatua Identification 8CHBIATIC AND CONNECTION DIAGRAM................................................................... 1S-D-91B0 TYPE BRAN-4 REGULATOR CONTROL ELBENT . . Outline A Drilling Plan ........................ Internal Diagram .................................... DAMPING TRANSFORMER AND RECTIFIER ASSEMBLY Outline and Drilling plan .................... VOLTAGE ADJUSTING RHEOSTAT . . . Assembly Deg. (Assy. No. 1) SI 1584350 B-D-1805 13-D-6243 SI 1736122 7-D-8980 SI 1736119 97-C-67 CROSS CURRENT COMPENSATOR . Outline A Drilling Plan Internal Dlag.................. St 1114839 l-D-4638 l-D-4637 REGULATOR CUTOUT SNITCH.................................................... Outline A Drilling Plan Pig. 3 A 7 Lines 5 A 15 CURRENT TRANSFORMER .... Outline A Drilling Plen SI 1173289 13-B-8976 SI 1304227 88-C-763 POIBfTIAL TRANSFORMER . . . Outline A Drilling Plan SPARE PARTS LIST.................... SI 1304463 2-C-3864 127-A-323 C=3 ISS 01 2 2 n--n 7- - 1430C95 M8-OOOJS329 Hi * GENERAL INFORMATION 31-260C60 1A. FOREWORD . a) Careful reading of these instructions will provide information for the proper care and handling of the generator voltage regulat ing equipment and avoid damage to the equip ment which may impair Its performance when placed in operation. b) ben corresponding regarding the equipment described herein refer to--Type * SRAN-4" Voltage Regulating Equipment. Use Westlnghouse identification data given on title page. Com plete identification of parts is contained on page II. lations it is considered advisable, due exciter field characteristics, to use an citer field resistor to limit the range regulating resistance and improve the sen tivity. d) The resistance,is varied hy the value | the current in the coil circuit. Nor operating range of the coll current varij from 0.145 to 0.165 ampere d-c from the recti fier. S3 e) With this value of coil current in tlfte^ regulator circuit, proper voltage reguljfj^; tion will be obtained. c) Address inquiries to the nearest Westinghouse Service Facility--see list at end of this book--or to Westlnghouse Electric Cor poration; Switchgear Division; East Pittsburgh, Pennsylvania, U.S.A. IB. DESCRIPTION OF GENERATOR VOLTAGE REGULATING EQUIPMENT a) The purpose of the automatic voltage regu lator is to maintain the terminal voltage of the alternating-current generators at, or very close to, rated volts regardless of load variations. b) The voltage regulator controls the voltage of the alternating-current generator by varying the resistance in the exciter field circuit. This regulating action is of a semi static nature and hence the device operates only when a correction in voltage is necessary. Since the regulator acts directly on the ex citer field resistance, no intermediate con tactors, levers or linkages are necessary. c) The "SRAN-4" type of voltage regulator has four regulating resistance plates which can be connected in parallel, series-parallel or Beries. These in turn are connected directly in the exciter field circuit. On some instal 1C. VOLTAGE REGULATOR CONTROL EL] a) The regulator coil is wound with 3000 turns of No. 25 enameled copper wire with a re sistance of 65 ohms. It is identified by Westlnghouse Style No. 1173224. b) An adjustable resistance is connected series with the coil of the voltage re&T later to set the range covered by the voltsj adjusting rheostat, so that rated generatopi voltage is obtained with thevoltage adjustified rheostat in the mid-position. This internaU3t\ mounted resistance consists of nine 750-omt' tubes identified by Westlnghouse Style NttZT 1115103. jC^} c) The spring-mounted moving arm of the reg lator is supported so that the armature^) passes within the fixed air gap in the magnetic^ circuit. The pusher pins are located at tifeS outer end of the moving arm and arranged to press against the silver buttons which mounted at the free end of the leaf springs.^, made of conducting material. -j d} The fixed end of each silver-button leafSJ' spring is attached to consecutive sten^L of the regulating resistance plates. Thest"^ plates have resistive wire embedded in vitreous HwB-0003SIIv I 31-260 060 GENERAL INFORMATION to prevent excessive voltage and hunting. When the a-c voltage rises, the regulator operates, due to increasing coll pull, to insert resist ance in the exciter field circuit and thereby decrease the exciter field current and armature voltage. The primary of the damping trans former is subject to this change and induces a voltage in the secondary which causes a momentary reduction in the normal regulator coll current. Thus, the coll pull is reduced -by this impulse from the damping transformer, and the regulated voltage is not decreased excessively.. Conversely, when the a-c voltage falls and the regulator operates, due to de creasing coil pull, to short-out resistance in the exciter field circuit, the impulse from the damping transformer aids the normal coil current. Thus the regulated voltage is not increased excessively. c) The 3-phase, full wave, Rectox rectifier, rectifies the 3-phase a-c voltage to pro vide d-c current for the main coil of the volt age regulator control element. The basic element of the Rectox rectifier is a copper disc, on one side of which a layer of cuprous oxide has been formed. This disc allows cur rent to pass freely in the oxide-to-copper direction but with difficulty in the opposite direction. In this Installation the discs are assembled on six separate supporting studs. The six stacks of discs each identified by Westlnghouse Style No. 1253324. are connected so that all positive half-waves of the impressed alternating-current energy will send current to the regulator coil in one direction through one half of the rectifier stacks; all negative half-waves will return to the potential trans former through the other half-stack which previously opposed passage of the positive half waves. The result is a d-c output from the rectifier to the control element coil. This output depends on the average of the 3phase voltages. IE. VOLTAGE ADJUSTING RHEOSTAT a) Turning the handle of this rheostat raises or lowers the value at which the regulator holds the generator voltage. Changing the resistance varies the current in the coil cir cuit of the regulator, which changes the posi tion of the regulator moving arm and results in a change in resistance in the exciter f^bVd-l circuit. Hence the regulated value of - ator voltage can be adjusted by the posH^^j of this rheostat. This rheostat has approx!^ mately 203 equal steps of resistance, 225 total. Irjr IF. CROSS-CURRENT COMPENSATOR a) This piece of apparatus consists of"an adjustable auto-transformer connecitqd across a resistor-reactor combination. insulating transformers transmit energvsfn proper phase relation to the potential cir^O.C of the regulator. This causes the regul to droop the regulated voltage in propor to the magnitude and phase angle of the active load current. 1C. A-C POTENTIAL TRANSFORMER a) Two potential transformers are usedcHestep down from rated a-c generatorvolt^jge^ to approximately 115 volts, the voltage ap plied to the regulating equipment. b) The potential transformers are connected as follows: PRIMARY volts. Connected open-delta receives phase. 3-wire, 60-cycle, generd SECONDARY - Connected open-delta gives3- 3-wire, 60-cycle, 115 volts. il^ r--.1 1H. CURRENT TRANSFORMERS (hie current transformer is supplied jtT a) each a-c generator that operates in pai^aft lei with other generators. It is connected in line "B" of the generator and its enelffii is supplied to the cross-current compensator. The ratio of this current transformer depepas^ upon the kw rating of the generator. fa il. REGULATOR CUTOUT SWITCH a) The regulator cutout switch is of thq. rotary type provided with three positions'' 3 Schematic and Connection Diagram Drawing 18-D-9190-3 tl*e-0003S33f |L^ PANEL t-45 C=3 * Cl 9 i 'B1l r-5 5--H 8r 7"? m oc Icfe ss 13 fe 7e 1* CUTOUT DRILL H+4H (8 HOLES) p fr=i 6 Outline Drawing and Drilling Plan Drawing 9-D-1805-3 MH00JI3I0 SERIES PARALLEL CONNECTED PLATES (REAR VIEW) SILVER BUTTON ASSEMBLY Internal Diagram Drawing 13-D-6243-3 MB-00M8M1 Dwg. 7-0-8980-1 Outline and Drilling Plan (BS Voltage Adjusting Rheostats Assembly Drawing (e^ Drawing 97-C-67-2 MS-00018343 Cross-Current Compensator -- Outline and Drilling Plan c= m Drawing l-D-4638-1 MB-000MJ44 WIRING DIAGRAM (REAR Y/W) C CO SC/tMAT/C DMGRAM DIALS FAR xcohkma r/oAf Cross-Current Compensator -- Internal Connection Diagram <4 c=a Drawing l-D-4637-7 IUE-OC01SM5 Regulator Control Switch - - Outline Drawing and Drilling Plan Drawing 13-B-8976-6 WB-OMMJW C=3 oc Outline and Drilling Plan <3 r SIB-00058S47 Drawing 89-C-763-2 1st. 0* LIST OF REPAIR PARTS NAME OF PIECE MF6R s DATA (STYLE NO. SHOP 01 TYPE SRAN-4 CONTROL ELEMENT A SILVER BUTTON AS SE *4BO( 1 Main spring 2 SHORT HI NOE SPRING 2 LONG HINGE SPRING 1 MAIN COIL 2 RANGE SETTING RESISTOR 4 REGULATING resistance plate 1313989 11(AGIO 1166944 1313985 UT3224 III5I03 1296910 .1 B23Y2534 P VOLTAGE ADJUSTING RHEOSTAT 8 rheostat 1736119 CROSS CURRENT COMPENSATOR RESISYOR II15144 a TYPE"*" regulator control sw. 10 3 CONTACT 5EGIAENT 11 3 CONTACT SEGMENT 12 i STOP FINGER 13 12 CONTACT FINGER 1041505 545626 II14883 1087203 A REPAIR PARTS LIST FOR TYPE SRAN-4 VOLTAGE regulating equipment Spare Parts List WHEN REORDERING REFER TO 5T7LE NUMBER AND SHOP ORDER Is) C=3 & & MHOOJBW Drawing 127-A-323-2  WESTING HOUSE REPRESENTATIVES IN FOREIGN COUNTRIES--Cont'd Nicaragua Panama . See Mexico See Mexico C=fl Paraguay See Argentina Peru . . Philippine Islands Cable Address--WEMCOEXPO Westinghouse Electric International Company, Attention of Regional Representative Casllla 1635, Avenida Wilson B-90, 7th Floor, Lima, Peru. Cable Address--WEMCOEXPO > Westinghouse Electric Company, Ltd. Attention of Regional Engineer 301 Myers Building, Port Area, Manila, Philippine Islands. 0c Puerto Rico . See Cuba San Salvador See Mexico South Africa Cable Address--WEMCOEXPO (Johannesburg) Westinghouse Electric Company, Ltd. Attention of Regional Supervisor, P.0. Box 6067, 308 Union Corporation Building 78 Marshall St., Johannesburg. South Africa. Spain Gable Address--WEMCOEXPO Westinghouse Electric International Company, Attention of Zone Director, (Avda. Jose Antonio 7). Madrid, Spain. Surinam . . Seeden . . Switzerland See Venezuela See Prance See Prance Trinidad . Turkey . . See Prance Cable Address--WEMCOEXPO Westinghouse Elec. Inti. Co. Attn: Project Representative c/o Taclco, 59 Baylndlr Sokak Yenisehlr, Ankara. Uruguay . . Cable Address--SERRACAS Westinghouse Elec. Inti. Co. Attn: Regional Supervisor c/o Serratosaft Qastells. S. A. 18 de Julio 1110. Montevideo, Uruguay. Venezuela . Cable Address--WEMCOEXPO Westinghouse Electric Company, S. A., Attention of Zone Director. Apartado 1889, EMeflcio la Ceiba 3er Pisa Sociedad a San Francisco 8. Caracas, Venezuela. MIE-OE3383SI rh i Kt DOMESTIC PORTS (Continued) Port Everglades............................ Sales Office--731 Ingraban Bldg., Miaul, Fla. Portland. Me.................................... Sales Office--9 Bowman Street, Augusta, Maine Portland. Ore.................................. PORT ENGINEER--309 S. W. Sixth Avenue. Portland 4. Oregon Sales office Providence.................................... Sales Office--51 Elnpire St., Providence 3. R. I. San Diego........................................ Sales Office--861 Sixth Avenue, San Diego 1, Calif. San Francisco................................ PORT ENGINEER-- 1 Montgomery Street, San Francisco 4. California ' Sales Office Savannah........................................ Sales Office--1299 Northside Drive, N. W. P.0. Box 4808. Atlanta 2. Georgia ' Seattle............................................ PORT ENGINEER--3451 East Marginal lay. Seattle 4. Wash. '' Sales Office Tacoma............................................ port ENGINHR--1830 Pacific Avenue. Tacoma 2. Wash. Tampa................................................ Sales Office--608 Tampa St., Tampa, Fla. Toledo............................................ Sales Office--245 8omalt Street. Toledo 4, Ohio Wilmington, Cal.............................. PORT SRSInrat--600 St. Paul Ave.. Los Angeles 17, Calif. Wilmington. Del.............................. PORT ENGINEER--3001 Walnut Street, Philadelphia 4. Pa. Wilmington, N. C............................ Sales Office--210 E. Sixth Street, Charlotte 1. North Carolina C=3 WESTINGHOUSE REPRESENTATIVES IN FOREIGN COUNTRIES Africa ................................................................ See Egypt and South Africa Argentina........................................................ Cable Address--WEM00EXPO Westlnghouse Electric Company, S. A., Attention of Zone Director Paseo Oolon 221, Buenos Aires, Argentina. Australia Brazil British Guiana Ceylon .... Chile .... China .... Cable Address--WSOOEXPO (Sydney) Westlnghouse Electric International Company, Attention of Zone Director, Box 23, Waterloo, N. S. W., (Joynton Avenue), Sydney, Australia. Cable Address--WBKXEXOP (Rio De Janeiro) Westlnghouse Electric Company of Brazil, Attention of Zone Director, Calxa Postal 1320, (Av. Grace Aranha 182-10 Andar) ' Rio de Janeiro, Brazil. Cable Address--WENCOEXPO (Seo Paulo) Westlnghouse Electric Company of Brazil, Attention of Regional Engineer, Calxa Postal 5156, Rua 15 de Novembro 200-3 Andar - Sala 1 Sao Paulo, Brazil. See Venezuela See India See Uruguay See Philippine Islands u-- Repair Shop he-ooo:s:;2 r1- <' X * MEMORANDUM oc So' TP-SW C=i & Mt'OWSISS* MEMORANDUM MM0HJJ56 MEMORANDUM 15=3 & hUB-OMUSSBt MEMORANDUM C=3 9S me-ODO]B36C