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