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G E o P
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5A4, 6A6 & LM6000 Rotor Assembly and Disassembly

(For Industrial Turbines)

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1996 GENERAL ELECTRIC COMPANY

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I. DISASSEMBLY A. Frame Assembly

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The following parts must be disassembled to remove the rotor. 1. Disassemble vent piping, if applicable, and other devices attached to the roof of the exciter compartment. 2. Remove exciter end compartment air inlet silencer, if applicable. NOTE It is not necessary to remove frame end caps to remove rotor. 3. Remove the exciter housing and the non-rotating portion of the exciter, including the base. Refer to exciter assembly for detailed instructions. 4. Remove all the instrumentation on the pedestal at both ends of the unit. 5. Remove the grounding brush assembly and coupling guard from the turbine end of the unit. 6. Remove the hardware and sealing around the pedestal at both ends. 7. Remove the hardware securing the outside walls of the outer frame structure and remove the walls at both ends. 8. Remove the air shroud on the inner wall. Remove the top half and rotate the lower half around and remove it over the pedestal. B. Preparation of Rotor for Removal (Refer to Figure 1) 1. Remove both inner and outer oil deflectors at both pedestals. 2. Remove the upper-half pedestal at the turbine end of the unit. Remove the upper-half bearing at this location. Lifting provisions are provided at the 12:00 oclock position on the frame to allow the use of a hoist to aid in the removal. CAUTION These lifting provisions are for lifting portions of the pedestal and bearing only and are never to be used to support the weight of the rotor. 3. Remove the bolts securing the exciter end pedestal to the base. Remove the dowels. NOTE Do not remove the upper-half pedestal and bearing on the exciter end. 4. Assemble the wood block (6) at the location shown in Figure 1. This block will be used to support the pedestal while it is being skidded during the first stage of rotor removal.

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Turbine End

Connection End Hyd. Jack Supplied By Customer 4 3 2 5 6

Hyd. Jack Supplied By Customer

NOMENCLATURE LIST 2. Protective shim 3. Rotor pan 4. Rotor shoe 5. U shaped shim 6. Wooden block

Figure 1. Preparation of Rotor for Removal. 5. Remove the coupling bolts and separate the couplings, using the jacking bolt hole provisions in the generator portion of the coupling, until a .75 in. separation is achieved. 6. The rotor axial movement should not exceed dimensions as specified on mechanical outline drawing. CAUTION Ensure that the oil deflector shoulder on the shaft does not make contact with the bearing during separation of the coupling. 7. Slide the protective shim (2) and the steel rotor pan (3) down the length of the unit by inserting it from the exciter end at about the 12:00 oclock position. Rotate the protective shim and pan around to the 6:00 oclock position. Insure that the pan and protective shim project beyond the end of the core on both ends of the unit. NOTE Coat the steel shim with paraffin or hard wax on the inner surface prior to assembly into the unit.

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8. Secure the rotor pan securely at the turbine end of the unit to prevent movement. 9. Locate a 25,000 lbf [111MN] [11.3 Mg] jack (not provided) under the shaft at both ends of the unit adjacent to the pedestals as shown. Use of a protective pad between the jack head and the shaft is very important to prevent scratches and dents in the shaft surfaces. 10. Jack the shaft at both ends taking care to insure the shaft does not slip. Jack the shaft up until the retaining ring is within 0.0150.030 [0.380.76 mm] of the core. This will allow the insertion of the rotor shoe (4) between the retaining ring and the rotor pan on the turbine end of the unit and the U shaped shim under the pedestal on the exciter end of the unit. NOTE When raising the exciter end of the shaft, the rotor will make contact with the top half of the bearing and will lift the pedestal off its seat on the base. 11. Insert the rotor shoe (4) and insure that it is seated properly on the rotor pan and is positioned in front of the retaining ring as shown in Figure 1. 12. Remove the shims under the exciter end pedestal and insert the U shaped shim (5). The edge of the shim is intended to hook onto the back end of the pedestal base and on the front end of the wood block (6) which has already been positioned. The shim is installed from either side of the pedestal. 13. Lower the shaft at both ends. The rotor will rest on the rotor shoe (4) on the turbine end of the unit and exciter end pedestal will rest on the shim (5). Remove jacks. 14. Assemble the shaft pulling/lifting device (8 & 9) to the exciter end of the shaft. The device mounts on the outboard side of the pedestal with the offset on the ID fitting between the journal and the oil deflector surface. The device which is in two sections, is to be mounted with its joint in the horizontal position and with two of the three ears located on the top half. Secure the two sections and torque the bolts once the device is well seated on the oil deflector surface. Secure the device to the pedestal using the oil deflector bolt holes. 15. Remove the lower-half bearing in the turbine end pedestal. 16. Using an overhead chain fall, lift the turbine end pedestal and jack it axially toward the turbine until it is off the base platform. Lower the pedestal and secure it in position. With the pedestal in this position, the coupling will slide past without interference. 17. Attach the bearing shoe (7) to the turbine end journal. This will be used to support the turbine end of rotor on the rotor pan just prior to the rotor shoe passing beyond the rotor pan on the exciter end of the unit. 18. Attach axial pulling cable to the pulling device on the exciter end of the shaft. NOTE Insure that the exciter armature is covered and properly protected from damage. No force is to be applied to any portion of the exciter body.

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C. Rotor Removal (Refer to Figures 2 & 3)

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1. Pull the rotor axially until the pulling device on the pedestal is clear of the end of the outer frame. (Opening in roof). The pedestal will be near the end of the support block (6) at this point. Care must be taken that the pedestal slides on the shim (5) and does not hang up on the edge. Also, the rotor shoe should be sliding on the rotor pan and not allowed to hang up on the retaining ring. 2. Attach the vertical cable between the pulling/lifting device (using the swivel hook provided) and the overhead crane. This will support the rotor vertically during the next phase of the rotor pull. 3. Continue to pull the rotor axially until rotor shoe (4) approaches the exciter end of the core and the bearing shoe picks up on the rotor pan. Insure that the edge of the bearing shoe does not hang up on the pan as it approaches the pan. 4. Continue to pull the rotor axially until the edge of the bearing shoe is near the edge of the exciter end of the core. 5. Position a support structure under the pedestal at this point and remove the vertical cable from the pulling device. 6. Using the rotor body sling, make a 11/2 wrap of the rotor body at both ends of the rotor and connect the cable to the overhead hook. 7. Raise the rotor to remove the weight from the exciter end pedestal and the bearing shoe. Check that the rotor is supported in a level position. 8. Continue to move rotor axially until the rotor coupling clears the generator. Care must be taken not to allow any part of the rotor to come in contact with the core or stator end winding. 9. The rotor, complete with exciter end pedestal and bearing shoe, is to be positioned on solid ground. The pedestal and the bearing shoe can then be removed and the rotor lifted and repositioned as required. II. ASSEMBLY Assembly of the rotor is accentually the reverse of disassembly. The rotor with the exciter end pedestal and the bearing shoe is inserted into the stator and supported as shown in Figure 3. The cables around the body are removed and replaced with a cable at the pulling/lifting device (8 & 9). If necessary, eye bolts can be installed in the coupling bolt holes and a come along can be used to pull the rotor into the stator. The rotor shoe should be assembled when the turbine end retaining ring is into the core far enough to permit the shoe to rest well within the core. When the rotor has been inserted to the point shown in Figure 2, threaded rods with washers and nuts can be used to pull the coupling halves together.

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1 7
Turbine End

8
Connection End

2 4 3 5 9 6

NOMENCLATURE LIST 1. Lifting cables 2. Protective shim 3. Rotor pan 4. Rotor shoe 5. U shaped shim 6. Wooden block 7. Bearing shoe 8. Swivel hook 9. Pulling/Lifting device

Figure 2. First Stage of Rotor Removal.


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Turbine End Connection End

2 3 7

5 9 6

Pedestal Support By Customer

NOMENCLATURE LIST 1. Lifting cables 2. Protective shim 3. Rotor pan 5. U shaped shim 6. Wooden block 7. Bearing shoe 8. Swivel hook 9. Pulling/Lifting device

Figure 3. Second Stage of Rotor Removal.

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