Presentation 22.


Reinsulation Rotor Generator and Repairing of Flexible Lead
GTG 2.1 Tambak Lorok Combined Cycle

Embun Kobul

Rita Triani

Dwi Handoyo

Maintenance Division of PT. Indonesia Power MSBU
Engineering Division of PT. Indonesia Power MSBU
J l. KS Tubun no 8 J akarta Barat, Indonesia
Phone: +62-21-5638666, Fax: +62-21-5638622,


Rotor Generator of Tambak Lorok Gas Turbine 2.1 GE Frame 9, with its voltage 500 V and 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 the retaining ring. The insulation condition of rotor generator inter
turn especially in end winding insulation and turbine end, both has migrate from its place. Also the insulation
between 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 and with respect to design parameters, the work can be completed within a
period of two months, and now the unit can 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
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
 Electric current-carrying capability, a primary
function of flexible leads.
 The mechanical strength is able to hold
centrifugal force when the generator rotor
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

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

Fig 9. RSO Measurement

Insertion of coils in the next slot was conducted if
the three test results meet the standard value.
Quality control of the installation is done from the
installation of first coil slot 1A through slot 7A and
from slot 1B to slot 7B. Failure in one of the slots
will cause failure of insulation. The installation was
conducted with caution to avoid damage insulation
and coil, it means the results meet the standard.

Fig 10. Surge Test Measurement

After the whole installation complete (including the
retaining ring), the rotor generator has to test its
run out (to know the results of the overall
compliance). The result must meet standards of its
run out. If the results is not running well, then it
should be repaired before the generator rotor is
declared ready to insert.
Before the generator is really ready to operate, it
should pass the final test. The final test is rotor
thermals sensitivity (RTS). This test has to be
conducted to ensure the absence of RTS effect at
the generator rotor.

Fig 11. Run Out Rotor Generator

Fig 12. Run out result data

Fig 13. Performance Test Data

Fig 14. Rotor Thermal Sensitivity measurement

4. Conclusion

a. The reinsulation and replacement of flexible
lead can be done through a careful material
selection and method that used in the
b. Overall, reinsulation and replacement of
flexible lead can be performed by several steps
including its quality testing method. Untill now,
the generator of Gas Turbine 2.1 can operate

Recommendation :
a. 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.
b. Always operate the power plant on its
capability curve, to minimize the risk of rotor
generator breakdown.

[1] Technical Report at GTG 2.1 PLTGU Tambak
[2] Greg C Stone, Edward A Boulter, Electrical
insulation for Rotating Machines
[3] Thikhumporn Daorote, EGAT Public
Company Limited, Thailand Generator Rotor
Repair Following Thermal Sensitivity Problem.
[4] Ronald J Zawoskysky, Karl C Tornroos GE
power Systems Schenectady , GE Generator
Rotor, Design, Operational Issuedand
Refurbishment Options
[4] Ronald J Zawoskysky, Karl C Tornroos GE
power Systems Schenectady , GE Generator
Rotor, Design, Operational Issuedand
Refurbishment Options
[5] Ronald J Zawoskysky, , GE Generator Rotor,
Retaining Rings and Fleet Data


Rita Triani (05 J anuary
1978 – now) is at the
generator maintenance
field engineer who worked
at PT. Indonesia Power.
Indonesian power is PLN
subsidiary which has a
generating capacity of
9000 MW in Indonesia.

She initially started his career as a technician
switchgear, and after that to continue as the
generator technician. Actively participate in
seminars and writing several papers to be
presented in a level. He was also active in the
management of a technical magazine in its work
place, and be a contributor, and any writings.

Dwi Handoyo (29
J une 1978 – now) is
at NDT Material field
engineer who worked
at PT. Indonesia
Power. Indonesian
power is PLN
subsidiary which has
a generating capacity
of 9000 MW in

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