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Generator Maintenance

The CAT Warranty Statement states that the User is responsible for Performance of the required Maintenance. Here is a Factory Review of the required Maintenance for Generators

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

GENERATOR MAINTENANCE AGENDA

Scheduled Maintenance What: Applications Standby, Prime, or Continuous Applications When: Product Life Shipping, Storage, Start-up, Regularly, Periodically, Annually How: Procedures Cleaning, Drying, Insulation Resistance, Alignment, Vibration, Bearing Greasing, Bearing Temperature Monitoring, Stator Temperature Monitoring, Controls and Protection Settings Why: Publications SENR 5359, SEBD 9208, SEBU6918, SEBU7270

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Shipping Maintenance


What happens when Shipping maintenance is not effective

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Shipping Maintenance


Packaging Proper generator set cover protection needs to be in place for environment generator set is being shipped in Handling Proper Lifting of generator sets using lifting eyes and fixtures Shipping damages cant be claimed as a warranty.

Example of shipping damage

Example of grease deterioration after improper shipping and storage

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Storage Maintenance

Examples of inadequate storage practiceno cover from elements and no evidence of space heater connection REFERENCE SEHS9031-4 Proper Generator Set Storage Procedures

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Storage Maintenance


Maintain Winding Temperature At least 5 C Higher Than the Ambient Temperature Space Heater Insulation Test (LEBQ 4823)
Insulation test must be done when generator is received Insulation test must be repeated prior to start-up.

Dry Location Cover for Protection Loose to Allow Generator to Breathe Turn Rotor 10 Revolutions Every 60 Days

Example of hot spot created on bearing race after long storage period

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Start-up Maintenance


Before Applying Battery and Shore Power Voltage to the Generator Set
Inspect generator for debris, foreign objects, leaks and loose connections, broken fittings, guards and components. Repair as necessary. Check battery charger for proper operation. Check and clean the battery. Maintain electrolyte level, check for loose connections. Visual inspection, check for loose, broken, rubbing or damaged wiring or components. Check for Proper Grounding Check space heaters for proper operation.
Example of loose PMG bolts, not noted before cranking

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Start-up Maintenance


System Check Prior to Generator Set Operation Must DOCUMENT data on each for future reference
Alignment (SEHS 7654, SEHS 7259, SEHS 7073). Air Gap (main generator, exciter, & PMG) approx 10 mils even around

circumference

Insulation Test (LEBQ 4823) Measure Generator Winding resistances (SENR5359) Main Stator/Rotor, Exciter Stator/Rotor, PM Stator/Rotor Compensate readings for temperature Record for trend plotting! Coordination of Settings Generator Control and Protective Settings Factory default settings is not applicable to every application Dealer and/or third party consultant is responsible for Coordination study at each site Circuit Breaker ECM, EMCP, and CDVR, Droop (KW and KVAR) Differential Protection, Reverse KVAR Protection, etc.
EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007
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Generator Start-up Maintenance


System Check when Generator Set is Running Must DOCUMENT data on each for future reference Record the Following (SEBD 9207) @ No Load and Full Load Bearing Temperature Stator Temperature Air Inlet Temperature (and at areas where air recirculation could exist) Confirm no air recirculation is occurring Vibration Levels (LEKQ 4023) Voltage Regulator & Excitation System Sensing voltage Excitation voltage and current Determined by Load and Power Factor

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Start-up Maintenance


After Stopping The Generator Set Inspect the generator and report malfunctions. Make repairs or adjustments to the generator set as necessary. Check that all switches are in proper position to execute AUTO start. Record battery charging amperage reading. Check that generator air inlet filter is clean. Verify Generator Space Heater is operating
Visual inspection, check for loose, broken, rubbing or damaged wiring or components.

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Regular Maintenance


During Generator Set Operation Must DOCUMENT and TREND data on each for future reference Monitor Phase Current, Neutral Current, Voltage, Frequency, Power Factor, Harmonic Content, and Load variation Monitor Room Temperatures Monitor Bearing and Stator temperatures Monitor for Alarm and Shutdown Indicators Check that generator air inlet filter is clean.

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Periodic Maintenance


After Stopping The Generator Set for periodic maintenance Periodic Maintenance time interval is based on Application SEBD9207, SEBU6042 Must DOCUMENT and TREND data on each for future reference
Inspect generator for debris, foreign objects, leaks and loose connections, broken fittings, guards and components. Repair as necessary. Inspect Main Stator & Rotor, Exciter, and PMG Clean as needed (Moisture, Salt, Dirt, Grease, Oil) Check battery charger for proper operation. Check and clean the battery. Maintain electrolyte level, check for loose connections. Visual inspection, check for loose, broken, rubbing or damaged wiring or components. Check space heaters for proper operation.

Check Air Gap (main generator, exciter, & PMG) approx 10 mils
Insulation Test - LEBQ 4823)

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Annual Maintenance


After Stopping The Generator Set Must DOCUMENT and TREND data on each for future reference
Complete Periodic Maintenance Procedures

Alignment (SEHS 7650, SEHS 7259, SEHS 7073)


Measure Generator Winding resistances (SENR5359) Main Stator/Rotor, Exciter Stator/Rotor, PM Stator/Rotor

Vibration Levels (LEKQ 4023) Check Generator Bearings and Wear Sleeves

Greasing per Bearing Maintenance Plate on Generator Avoid Over-greasing and Use Correct Grease Double-Shielded Ball Bearing 2000 hrs, 2S-3230 Grease Single-Shielded Ball Bearing 2000 hrs, 2S-3230 Grease Roller Bearings 1000 hrs, 108-8611 Grease Cylindrical Bearings 2000 hrs, 100-2704 Grease

Inspect and Clean all main current carrying mechanical contacts such as Circuit Breakers and Transfer Switches
EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007
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Generator Maintenance Monitoring Recommendations


Trending Understand the Monitored Process Normalized Readings Record on Chart Focus on Changes Occurring Over Time Scheduled Repairs Instead of Unplanned Downtime

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Maintenance Insulation Test Recommendations


When to Test Safety Testing Process Prepare for the Test Insulation Resistance Test Polarization Index Test Step Voltage Test Dielectric Discharge Test

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Maintenance Bearing Temperature Guidelines


Bearing Temperature Set-points Standby and Continuous Applications Alarm 85 C Shutdown 95 C Temperature is affected by ambient but max settings are not! Set-points at lower values if possible+15 C over highest operating temperature Generators shipped with Platinum 100 ohm RTDs Packages with EMCP3 have embedded monitoring of RTDs Packages with EMCP2 have RTDs wired to terminal block RTDs are 3-wire for compensation accuracy Track and Investigate any Change from historical trend

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Maintenance Bearing Replacement


Removing Bearings
Heat Hub and Bearings evenly with three rosebud torches or use saw to cut hub and bearings with care not to damage rotor shaft. Do not attempt to heat hub and bearings with one torch, and forcibly pull off shaftdamage to the shaft will result.

Installing Bearings
Use an induction heater to heat the ball bearings to 107 C for ten minutes and mount to the shaft. Heat the hub to 400 C for three hours and mount the to the shaft.

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Maintenance Stator Temperature Guidelines


Stator Temperature Set-Points Standby Alarm 180 C, Shutdown 190 C Stator Temperature Set-Points Continuous Alarm 155 C, Shutdown 180 C Class H Stator Insulation rated 150 C + 40 C Ambient Rise Set-points at lower values if possible+10 C over highest operating temperature Generators with Form Wound Stators shipped with Platinum 100 ohm RTDs Packages with EMCP3 have embedded monitoring of RTDs Packages with EMCP2 have RTDs wired to terminal block RTDs are 3-wire for compensation accuracy Track and Investigate any Change from historical trend (Delta Pub) Output Limited by Rotor or Stator Temp. Temp. Rise Function of Generator Output Measurement Method The standard, must add hot spot allowance Rise by Resistance Embedded Detector
EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007
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Generator Maintenance Vibration Measuring Guidelines


Measure on Package at Normal Operating Temperature Use Monthly Readings to Establish Baseline Vibration Levels Are Load Dependent Investigate Significant Changes New Frequencies Showing up Increasing Amplitudes of Original Frequencies

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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Generator Maintenance Literature


LEBQ 4823 Electrical Insulation Testing SEBD 9205 Proper Storage of Generators SEHS 9124 Cleaning and Drying of Generators REHS 0064 Generator Set Start-up Checklist SEHS 7654 Alignment - General Instructions SEHS 7259 Alignment of Single Bearing Generators SEHS 7073 Alignment of Two Bearing Generators LEKQ 4023 Linear Vibration SEBU 7270 SR4/SR4B High Voltage OMM SEBU 6042 Maintenance for Standby Generator Sets SEBD 9207 Generator Maintenance Schedule Additions SENR 5359 SR4B Generator Service Manual SENR 5833 Digital Voltage Regulator Service Manual RENR 7941 CDVR Manual SENR 8319 SR4B Generator Rewind Data,

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007


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