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GENERATOR ROTOR REMOVAL PLATFORM

GENERATOR ROTOR REMOVAL PLATFORM

GENERATOR ROTOR REMOVAL PLATFORM

(OP)
HI ANY GOOD IDEA WERE TO FIND GOOD INFORMATION ABOUT PLATFORMS TO ROTOR REMOVAL ON GENERTAOR ? ILL APPRECIATE ANY GOOD TIPS .

REGARDS

AMPER

RE: GENERATOR ROTOR REMOVAL PLATFORM

I haved used 8x8 oak cribbing to build a temporary platform. It depends on your rotor removal kit, generator and of course generator mounting.  

RE: GENERATOR ROTOR REMOVAL PLATFORM

Here you can see the rotor being pulled out of a 2500hp 1800 rpm horizontal motor.  The platform is built from normal scaffold poles and wood.  Some wood cribbing used to keep the rotor from rolling.  

I'm sure your needs are affected by the size of the machine and what you're going to do with that rotor (do you need rollers).  For larger motors (3500 hp 324 rpm) our more consciencious shop builds a contoured wooden cradle to distribute the rotor weight rather than concentrating it on one line along the bottom.

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RE: GENERATOR ROTOR REMOVAL PLATFORM

Salient pole rotor would be more fragile (than squirrel cage motor rotor) - I imagine that would need to be supported from the shaft ends

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Eng-tips forums: The best place on the web for engineering discussions.

RE: GENERATOR ROTOR REMOVAL PLATFORM

By the way, can you describe the machine you're talking about and what are you going to do with rotor once it's removed?

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Eng-tips forums: The best place on the web for engineering discussions.

RE: GENERATOR ROTOR REMOVAL PLATFORM

(OP)
the machine is a brush generator bdax more than 27 tons . space is reduce around we can not used a  crane some some people used it  rail boogie removal system . if you have seen any like that or have pics ill  appreciate if you can send me some copies . thanks to all of you .

regards

amper  

RE: GENERATOR ROTOR REMOVAL PLATFORM

If you're planning to remove such a heavy rotor by yourself based on the tips posted here, forget it. You need to bring in outside professionals.

Muthu
www.edison.co.in

RE: GENERATOR ROTOR REMOVAL PLATFORM

(OP)
edison we dont pretend to don all the job our self but we like reducer budget find out good price on  crane as you may know prices on cranes on this sector are very expensive sometime more than the  spare to overhauling the generator . we really to do business with company from india is far risky anybody this day create profile on internet reclaiming lot of experience but what you have on the end is cowboys and lot of problems .as well some prices from copany abroas are more expensive than in us  

RE: GENERATOR ROTOR REMOVAL PLATFORM

Depends on where you are, country wise that is.  In some parts of the world there are contractors who specialize in this type of work, (and especially Brush) and have standard rail designs for rotor removal.

Brush has some technical information showing different types of rotor removal (crane and rail) which might be helpful.  It is available to the public and is called a TDI, if my memory serves.  Contact your local Brush contact.

I think you will find some views on this link.

http://natlmech.com/pages/1/index.htm

rmw

RE: GENERATOR ROTOR REMOVAL PLATFORM

Siemens Westinghouse have done many rotor removals on BDAX-9 machines in the UK. You could try calling Orlando, but you might have more joy contacting the old Parsons works at Heaton, Newcastle or or the service group at Beeston, Nottinghamshire. SW are not cheap by any means, although possibly less expensive than Brush. If it's a smaller BDAX - which it sounds like it is from the rotor mass - then the chances are someone like Wood Group supporting the offshore industries will have dealt with them.
  

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If we learn from our mistakes I'm getting a great education!
 

RE: GENERATOR ROTOR REMOVAL PLATFORM

Heck Scotty, back at your previous employment, your exciter rotor weighed that much didn't it?  (Grin)

rmw

RE: GENERATOR ROTOR REMOVAL PLATFORM

amper - your rant aside, there are methods of rotor removal that doesn't need a crane. That's why you need professionals. :)

Muthu
www.edison.co.in

RE: GENERATOR ROTOR REMOVAL PLATFORM

I've just re-read the earlier post. I thought 27 tons was the rotor but it might be whole machine. I don't think the exciter rotor was quite that heavy but the main rotor was certainly a big lump of steel - impressive to see it suspended from a mobile crane. Might have a photo somewhere.
  

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If we learn from our mistakes I'm getting a great education!
 

RE: GENERATOR ROTOR REMOVAL PLATFORM

Got a couple of shots of the steam set. Same principles, just bigger machine.

Removal
Heavy Lift
  

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If we learn from our mistakes I'm getting a great education!
 

RE: GENERATOR ROTOR REMOVAL PLATFORM

(OP)
well when i mentioned crane is because take off the rotor with any technics at some stage you need to lift up {crane up} if not how wyou going to kake off 27 tons { weight spec  on the manual}

RE: GENERATOR ROTOR REMOVAL PLATFORM

Can you translate that last post in to English? I have read it five times and it is incomprehensible nonsense.
  

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If we learn from our mistakes I'm getting a great education!
 

RE: GENERATOR ROTOR REMOVAL PLATFORM

The answer to the original question depends a lot on how the rotor is to be removed from the generator's frame/stator. How can the machine be broken down to gain access to lift and move it, how much working room there is around the unit and what sorts of equipment one can bring in to do the work.

Once the rotor is out, what do you want to do with it? If its just going to sit there, building cribbing is relatively simple. But of you need access to the rotor itself (perhaps you need to turn it during some maintenance procedure) that may complicate things.

RE: GENERATOR ROTOR REMOVAL PLATFORM

Scotty,

I was being a little tongue in cheek about the weight of your exciter rotor, but the generator rotor in that BDAX frame 9 beast of yours (formerly) weighted a lot more than 27 tons.  Somehow I remember that being the weight of maybe a BDAX 7 series rotor.

amper,

As PHovanian has mentioned, your methodology depends on what it is that you are tying to accomplish in the end.  You didn't specify that in your original post.

If your crane access to the generator rotor in the package enclosure is limited, you will have to rail via the use of a platform the rotor to a point where you can lift it with a crane.  That would only be necessary if you intended to do some more work on the rotor like remove the end caps, rewind, do bearing journal work, etc.

If your purpose is only to inspect the generator, then you can rail the rotor out on the platform and leave it set there while you accomplish all the tasks.

If you are going to do any detailed work on the rotor then it has to be taken to a clean weather protected place and that will involve the use of a crane at some point.

At this point, it is unclear to us what you are actually trying to accomplish.

rmw

RE: GENERATOR ROTOR REMOVAL PLATFORM

Hi rmw,

About 40 tonnes rings a bell. I recall the one from the steam set in that photo was nearer 60 tonnes.
  

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If we learn from our mistakes I'm getting a great education!
 

RE: GENERATOR ROTOR REMOVAL PLATFORM

(OP)
hi scotty well space around is limited the machine is over 10k working hours  you righ we want to try rail out there  our requesting question is were to find a more fear price on a rail system some company pretend to charge over 120K us dollars is ridiculous prices just only for the removal rail system . which only will be use every 10k hours .  

RE: GENERATOR ROTOR REMOVAL PLATFORM

In the days of steam power ststions (i.e. before the 70's) all large power stations had a station crane. (also known as a travelling crane).  This would be sized to lift any part of the station plant, turbine casings, rotors, generator rotor, stator etc.  This resulted in the crane and its supports being designed to accomodate the forces.

So you had a large, costly "power station" building.

Along come the 70's and gas turbines.  Salesman "You do not need those big power station buildings, we have these simple packaged units, so cheap, lightweight turbines etc etc".  Everyone forgot that the generator parts had the same mass.  No station crane........  Also, some had the bright idea of not using water (via heat exchangers) to cool the generator air.  No water for the gas turbine, so why not save even more money and open ventilate the generator.  Dust in the air?  Filters, they take all the dirt out!

So we went from generators that ran on base load, closed air circuit. To gas turbine driven units, on peaking or cyclic duty, open air circuit.

So we have the guys in the field, like the OP, who have to clean out the generator every 10,000 hours, not every 10 years!

Sorry for the whinge!

We devised a skid method of putting curved plates between the rotor and the stator bore, to minimise the use of a crane when pulling out the rotor.  Find an expert company and talk to them.

Finally, lift the rotor as Scotty shows, by the body NEVER by the end caps (end bells)

RE: GENERATOR ROTOR REMOVAL PLATFORM

Whinge away! You wanna try running an outage in the rainy North-East of England where if the rain stops it gets windy: perfect conditions to pull the rotor out of a hydrogen-cooled machine and lift it down 20m to grade using a mobile crane. Massive bad-weather stand-down costs? Check. Wet generator? Check. Outage programme in tatters? Check. Gotta love power plants designed by accountants.
  

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If we learn from our mistakes I'm getting a great education!
 

RE: GENERATOR ROTOR REMOVAL PLATFORM

(OP)
hoxton pardon each year 8k/hour 12year  ~100khour/working  

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