OPERATION & MAINTENANCE

OF

GENERATOR AND EXCITER
OPERATION OF GENERATOR
OPERATING AND SETTING VALUES
OPERATING AND SETTING VALUES FOR THE FOLLOWING PARAMETERS
SHOULD BE STRICTLY OBSERVED :
PARAMETER OPERATING VALUE SETTING VALUE
STATOR TOOTH TEMP. 50 - 100 C 120 C
STATOR CORE TEMP. 50 - 100 C 120 C
STATOR WINDING TEMP. 50 - 100 C 120 C
HOT AIR TEMP. 40 - 70 C 75 C
BEARING TEMP. < 75 C 90 C ALARM
120 C m TRIP
SHAFT VIBRATIONS < 85 m 160 m ALARM
240 m TRIP
BEARING TEMP < 75 C 90 C ALARM
120 C m TRIP
ROTOR GROUND FAULT 80 KOHM (ALARM) 5 KOHM (TRIP)
CAPABILITY CURVE
INSPECTION AND MAINTENANCE
IMPORTANCE OF INSPECTION AND MAINTENANCE

- DETECT AND CORRECT ANY DEFECT AT AN EARLY STAGE
BEFORE IT RESULTS A SERIOUS DAMAGE
- AVOID EXPENSIVE OUTAGES
- INCREASE RELIABILITY AND AVAILABILITY OF THE
MACHINE


PERIODICITY OF MAINTENANCE
FOR MACHINES WITH VPI INSULATION -

ROUTINE MAINTENANCE (NO REMOVAL OF ROTOR)
EVERY 8000 HOURS OR ONE YEAR OF OPERATION
MAJOR OVERHAULING(REMOVAL OF ROTOR)
FIRST MAINTENANCE : AFTER 24000 HOURS OR 3 YEARS OF
OPERATION
SUBSEQUENT MAINTENANCE : AFTER 32000 TO 48000 HOURS OF
OPERATION
PERIODICITY OF MAINTENANCE
FOR MACHINES WITH NON-VPI INSULATION -

FIRST MAJOR OVERHAUL (REMOVAL OF ROTOR)
AFTER 8000 HOURS OR ONE YEAR OF OPERATION

ROUTINE MAINTENANCE (NO REMOVAL OF ROTOR)
EVERY 8000 HOURS OR ONE YEAR OF OPERATION


PERIODICITY OF MAINTENANCE
FOR MACHINES WITH NON-VPI INSULATION-

MAJOR OVERHAUL (REMOVAL OF ROTOR)
AFTER EVERY 24000 TO 32000 HOURS OF OPERATION


EVERY START AND STOP MAY BE CONSIDERED AS 10
HOURS OF OPEARTION

INSPECTION DURING MAINTENANCE
ROUTINE
MAINTENANCE -

REMOVAL OF END COVERS
ON TS AND ES AND TOP
COVER
PHYSICAL INSPECTION OF
STATOR OVERHANG
WINDING AND BACK OF
CORE, ROTOR OVERHANGS

INSPECTION DURING MAINTENANCE
THOROUGH CLEANINIG OF
STATOR AND ROTOR
OVERHANGS
MEASUREMENT OF STATOR
IR AND PI VALUES
MEASUREMENT OF ROTOR
IR VALUE ALONG WITH
EXCITER ARMATURE
MEASUREMENT OF
INSULATION RESISTANCE
OF BEARINGS

INSPECTION DURING MAINTENANCE
MAJOR OVERHAULING :
DECOUPLING OF PMG, REMOVAL OF EXCITER YOKE, REMOVAL OF
GENERATOR END COVERS, REMOVAL OF ROTOR
ALL RUNOUTS, ALIGNMENT READINGS, BEARING CLEARANCES
MAY BE NOTED BEFORE REMOVAL OF COMPONENTS
PROPER IDENTIFICATION OF ALL COMPONENTS BEFORE
REMOVAL
THOROUGH CLEANING OF STATOR OVERHANGS, BORE, ROTOR,
EXCITER COMPONENTS ETC.
PHYSICAL INSPECTION OF VARIOUS COMPONENTS

INSPECTION DURING MAINTENANCE
MEASUREMENT OF STATOR WINDING IR VALUES, PI VALUES,
RESISTANCE, ROTOR IR VALUE, EXCITER ARMATURE AND FIELD
WINDING IR VALUES ETC.
MEASUREMENT OF ROTOR IMPEDENCE VALUE
CHECKING OF ALL RTDS FOR PROPER FUNCTIONING
PHYSICAL INSPECTION OF BEARING BABBIT SURFACES,
JOURNALS
CHECKING OF LUBE OIL SYSTEM OF BEARINGS
REVARNISHING OF WINDING OVERHANGS, IF REQUIRED
MEASUREMENT OF IR VALUE OF BEARING AFTER ASSEMBLY

INSPECTION DURING MAINTENANCE
FOR MACHINES WITH NON-VPI INSULATION -
DURING THE FIRST OVERHAUL AND SUBSEQUENT MAJOR
OVERHAULS, IN ADDITION TO THE ABOVE POINTS ALSO CHECK THE
FOLLOWING :
WEDGE LOOSENESS CHECK - BY KNOCK TEST OR
BY WEDGE DEFLECTION MEASUREMENT
LOOSENESS OF OVERHANG TYINGS IN THE STATOR
LOOSENESS OF OVERHANG BRACERS IN THE ROTOR
BLOCKAGE OF VENTILATION PATH IN THE ROTOR

CARE TO BE TAKEN DURING INSPECTION
NO LOOSE COMPONENTS OR TOOLS SHOULD BE TAKEN INSIDE
THE STATOR BORE OR OVERHANG WINDING
NO LIQUID CLEANING AGENT TO BE USED INSIDE THE STATOR
BORE
MAINTAIN ALL ALIGNMENT, RUNOUTS AND CLEARANCES AS PER
RECOMMENDED VALUES
PROTECT ALL BRIGHT METAL SURFACES WITH ANTI CORROSION
PASTE
CLEAN THE ANTI CORROSION PASTE THOROUGHLY BEFORE FINAL
ASSEMBLY
DURING SHORT SHUT DOWNS, SPACE HEATERS MAY BE
SWITHCHED ON
COMMON TOOLS AND INSTRUMENTS

STANDARD SPANERS, HAMMERS, SCREW DRIVERS, MEASURING
INSTRUMENTS LIKE VERNIERS ETC., DIAL GUAGES
250V/500V MEGGER, 2.5/5 KV MOTORISED MEGGER
H.V. TEST KIT OF 0-50KV D.C. / 0-33 KV A.C. 50 HZ
SUITABLE AMMETERS, VOLTMETERS
PAINTING GUNS, BRUSHES ETC.
WEIGHING MACHINE
DIGITAL MULTIMETER FOR MEASURING RESISTANCE
ULTRASONIC TEST KIT
PROPER STORAGE ARRANGEMENTS

RECOMMENDED SPARES

ONE SET OF GENERATOR BEARINGS, EXCITER BEARINGS
1/3RD SET OF STATOR BARS FOR NON-VPI MACHINES
FEW WEDGES, INSULATION BELOW WEDGE ETC. FOR NON-VPI
MACHINES
ONE SET OF INSULATION OF BEARINGS
EARTHING BRUSHES
DIODES AND FUSES FOR EXCITERS
CLEANING AGENTS
WHITE PETROL, ACETONE, BENZENE (NO CTC)

TESTS BEFORE RECOMMISSIONING
DRYING OF WINDING
IF PI VALUE OF STATOR WINDING IS BELOW 1.8, DRYING OF
WINDING MAY BE CARRIED OUT
METHOD 1 : BY SENDING CURRENT FROM EXTERNAL SOURCE
METHOD 2 : BY SHORTING THE THREE PAHSES IN SERIES AND
EXCITING
DRYING MAY BE CARRIED OUT TILL SUFFICIENT PI VALUE IS
OBTAINED
OCC OF GENERATOR MAY BE CARRIED BEFORE
COMMISSIONING