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22_Rita _Maintenance Rot Machines_paper.pdf

22_Rita _Maintenance Rot Machines_paper.pdf

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Published by: bcqbao on May 11, 2014
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Presentation 22.1
Reinsulation Rotor Generator and Repairing of Flexible Lead GTG 2.1 Tambak Lorok Combined Cycle
Embun Kobul
, Rita Triani
, Dwi Handoyo
3 1,2
Maintenance Division of PT. Indonesia Power MSBU
Engineering Division of PT. Indonesia Power MSBU Jl. KS Tubun no 8 Jakarta Barat, Indonesia Phone: +62-21-5638666, Fax: +62-21-5638622, E-mail: embun.kobul@indonesiapower.co.id; rita.triani@indonesiapower.co.id,, dwihandoyo@indonesiapower.co.id 
Rotor Generator of Tambak Lorok Gas Turbine
with its
voltage 500
 rotor current
1.283 A, 2 poles, having troubles with high vibration indication, causing the unit to be shutdown (tripped). After checking either mechanically or electrically, it was found that its Flexible Leads was broken and disconnected. The incidence of flexible leads rupture is a recurring occurrence for the generator rotor type GE Frame 9. Therefore GE through the Technical Information Letter (TIL 1161-3) informs that the generator type 9 H2- made for a power plant in 1992, advised to do replacement of flexible lead include modification / installation pole
Shocking fact founds after dismantling of 
condition of 
generator inter 
 especially in
end, both has migrate from its place
. Also
layers was
broken. To overcome those, Flexible Leads replacement and re-insulation rotor generator were carried out independently by Indonesia Power based on TIL from manufacturer. By adding the support block to protect the Flexible Lead centrifugal force and also hydrogen turbulences into the rotor. Through
those improvements
with respect to
design parameters
the work
can be completed
within a period of 
months, and now the unit
operate normally. Key Words;
Flexible Lead, Re insulation, Retaining Ring, short inter turn, rotor, pole block.
It begins from the Black start capability test, the Gas Turbine GTG 2.1 Tambak Lorok was prepared for charging the busbar A. After finishing line charging test, the unit has loss voltage, that caused by a capacitive load received by the generator. This load contains very high currents, as well as with current excitation which resulted in breakdown in the Generator.  After make an either mechanical or electrical test, it founds that the value of the rotor winding resistance and insulation resistance is infinite. It means that the generator rotor coil having an open circuit. By using the Boroscope, it founds that Flexible Lead of Generator are broken.
2. Re-insulation Rotor Generator and Repairing of Flexible Lead 2.1 Preparing of Materials and Tools
Besides preparing tools and special tools, special and general materials are also necessary to prepare in specific quality and number. For common materials, it can be easily obtained as needed. Nonetheless for special insulating material that include its manufacturing process, it takes time according measures the required for inter-turn, elbow and retaining ring insulation.
2.2 Reinsulation Work a. Disconnect Interpole Connection, Spacer Block and Wedges
It start form dismantling of the retaining ring, then the release of the inter-connection between slot and pole as an interface between the coil on pole A to B. Inter-pole connector is sometimes called center tap because of its middle position between the pole A and pole B. After that we perform the release of the spacer block as a separator between coil slot end winding. While for retaining ring centrifugal force, it is locked by a wedge slot. To remove the coil from the slots, it has to be done after the dismantling of the wedges.
b. Dismantling Coil
Dismantling coil is perform by release it layer by layer and started from coil pole A. After that, the screening stage started to make sure generator rotor pole position B is at the top. The entire coil then placed in the space provided. Dismantling of flexible leads can be performed after the coil slots 1A and 1B finished dismantling. The position of flexible lead is under the end of winding coil 1A and 1B and brazed on bottom of slot 1A and 1B layer
Fig 3. Dismantling Process
c. Assembling Coil
The installation work of re-assembling rotor coil or generator can be performed, if all spare parts have been finished cleaning, inspect and all insulation material are available with good quality. The coil installation then performed by observing and monitoring the quality of the installation, and testing
in accordance with international standard methods (IEC, IEEE, etc).
d. Assembling Flexible Lead
Flexible leads is a part of generator rotor, as a conductor to flow the current in axial bar in coil slot 1A (on the 0
) and slot 1B (on the 180
). Prior to installation, flexible leads assembly are inspected by certain quality test (megger, contact resistance and ultrasonic test). Flexible leads are assembled on two opposite sides. 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.
 Quality control of Cu material
 test of copper plate Cu material composition (99 % Cu).
 Quality control of brazing
 preformed brazing procedure specification (WPS)
 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.
Electric current-carrying capability, a primary function of flexible leads.
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.
Fig 4. Dimension of Flexible Lead Bushing
Fig 5. Lay Out Instalasi Flexible Lead Fig 6. Installation of Flexible Lead
Flexible lead was installed by care and tensioned by using a key moment and then locked using a nut. Flexible leads are positioned such that to make sure that after tightening flexible lead and nut would be appropriate to performed brazing the coil slot 1A or 1B without any troubles happen. To ensure no insulation damage occurred during the process of installation, it should be performed a Megger Test. If the result is eligible, it can be continued by inserting coil no 1A or 1B.
Coil Installation as Slot
Prior to insertion of coils into the slot, it starts by cleaning the slot, then install the filler and insulating bottom armor slots (slot insulation liner). Installation of the coil needs to be done very carefully to avoid mistakes. Installation of coil is carried out by a serial methods, by sequence installation starting from slot: 1A, 2A, 3A, 4A, 5A, 6A and 7A. The same method was performed for the insertion of coils on the pole starting slot B. . .
Fig 7. Assembly Coil Fig 8. Isolasi inter turn , material Nomex wide 30 mm thick 0.25 mm
Installation of coil is carried out layer by layer in series (each layer consist of inter turn insulation). Inter turn insulation using nomex material with a thickness of 0.25 mm. Nomex material, a category of H class insulation, is able to resist temperatures up to 180
C. From the mechanical side point of view, this material is not easily broken when compared with existing materials (using glass fiber).
3. Evaluation and Analysis
 After installation of each slot coil, some testing has been done to ensure its quality, as follows: 1. Megger testing 2. Contact Resistance 3. Surge Test and Recurrent Surge Oscilloscope (RSO)

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