Reinsulation Rotor Generator

and Repairing of Flexible Lead

GTG 2.1 Tambak Lorok
Combined Cycle
By . Embun K
Rita Triani
Dwi Handoyo
Background
The unit was prepared for charging the bus bar A.
After finishing its, they has loss voltage. That caused
by a capacitive load received by the generator.
1.
Making Electrical and Mechanical test, It founds
that the value of the rotor winding and insulation
resistance is infinite. By using the boroscope it
founds that flexible lead of generator are broken
2.
Drawing of Collector end of Generator Field
Scope of Work
Rotor Winding
assy & Diss asy
a. Disconnect
Interpole
Connection,
Spacer
Block and
Wedges
b. Dismantling
Bar Coil
c. Assembly
Bar Coil
d. Assy Flexible
Lead
Fabrication
a. Flexible
Lead
b. Material
Insulation




Evaluation and
Analysis
Peformance
Test after unit
Syncron

Fabrication Flexible Lead and Material Insulation










Flexible Lead Fabrication

1. Preparing tools for flexible lead
2. Preparing Material flexible lead
3. Manufacturing plate flexible lead
4. Brazing plat flexible lead
5. Repairing isolator flexible lead
6. Ultrasonic Test brazing Flexible Lead
7. Contact Resistance Test brazing of Flexible Lead


Fabrication Flexible Lead and Material Insulation
The weight of the two side flexible leads should be approximately equal in order
to avoid the mass unbalance during operation.
The manufacturing process of flexible lead is performed with quality control as
follows.
a. Quality control of Cu material test of copper plate Cu material
composition (99 % Cu).
b. Quality control of brazing preformed brazing procedure specification
(WPS)
c. Quality control of brazing result nondestructive test (Ultrasonic test ,
megger test and contact resistance)

Manufacture of flexible lead was adjusted with dimensions required by
considering aspects as follows.
a. Electric current-carrying capability, a primary function of flexible leads.
b. The mechanical strength is able to hold centrifugal force when the
generator rotor operates.
From the whole set of material selection, manufacturing and testing, then the
flexible lead is ready to be installed on the generator rotor.

Re-Engineering Flexible Lead
Fabrication Flexible Lead and Material Insulation
Material Insulation Fabrication

1. Preparing tools for insulation profile
2. Preparing Material insulation
3. Manufacturing insulation profile
4. Monitoring and testing insulation profile


Fabrication Flexible Lead and Material Insulation
Evaluation and Analysis
MEASUREMENTS
Standard of Measurement EASA AR 100 2010
(Recommended practice for repair of rotating electrical apparatus)
1. Insulation resistance test ( megger )
2. Winding resistance test (tools micro ohm meter programma )
3. Surge comparison test ( surge test, tools D12R )
4. Voltage drop test ( dc or ac voltage ) coil in series
( ac voltage test )
5. Checking and testing sistem AVR excitation System
6. Recurrent Surge Ocillograph ( RSO )
7. Rotor Temperature Sensitifity ( RTS )
Measurement Results
Measurement Results
Performance Test After Unit Syncron
Performance Test After Unit Syncron
Performance Test After Unit Syncron
Performance Test After Unit Syncron
Performance Test After Unit Syncron
Performance Test After Unit Syncron
CONCLUSION
1. The reinsulation and replacement of flexible lead can be
done through a careful material selection and method
that used in the
Overall. Material insulation is using NOMEX class while for
flexible lead using material Cu 90% .

2. Parameter Quality is based on std EASA AR 100-2012

3. Re insulation and replacement of flexible lead can be
performed by several steps including its quality testing
method. Until now, the generator of Gas Turbine 2.1 can
operate normally.



Recommendation
1. Always monitor the operating parameters of the generator
rotor to avoid the force outage. The parameter as follows :
Vibration, MVAR, temperature, excitation current and etc.

2. Always operate the power plant on its capability curve, to
minimize the risk of rotor generator breakdown.