A GENERATOR OUR EXPERIENCE

Chilamkurti Siva Sankara Rao.

Power Plant Consultancy, Hyderabad
Abstract:
This submission is about our experience with a 60Hz Generator erection and commissioning. It is
learnt that this turbo generator was lying idle in U.S for more than ten years and was purchased by
our client for connecting to our Indian 50Hz system. We are thankful to our client for giving us
opportunity to work in this project. After inspection of the unit depending on physical condition of
the stator winding it was decided to go for full rewinding. During that process we noticed stator
core also require repairs. Repairs to the core and coils rewinding was carried out by professionals
in respective fields. Rotor cleaning and heating was done before insertion into stator. A.V.R was
also brought along with it. Though it can be brought to operation level with some efforts, because
of spare parts problem our client decided to go for retrofitting it by a local make. Finally the unit
was synchronized to the South Indian Karnataka State Grid on 14th August 2008. The unit is now in
service.

HISTORY:
It was learnt that this generator was manufactured by G.E for COOL WATER COALGASIFICATION
PROGRAM and commissioned in 1983 and was in service only for less than two years. Afterwards it
was lying idle. In the year 2004 M/s GE Energy Services studied this unit for reapplication on Indian
50Hz system. Recommendation accepted was to operate the turbine at its original speed of
3600rpm and include reduction gear 3600/3000rpm in between turbine and generator to operate
generator at 3000rpm.

DETAILS OF GENERATOR:
GENERATOR DATA
S. no.
A
B
01
02
03
04
05
C
01
02
03
04
05
06

Data Description
Generator number
Name plate Data
No. of poles
No. of phases
Type of stator winding connection
Frequency
Total temperature at rating guaranteed not to exceed:
Rating:
MVA
Armature Amps
Armature Volts
Field Amps
Excitation Volts
Power Factor

Data
316X423
2
3
wye
60HZ
at 60HZ
67
2803
13.8kv
485 A
250V
0.9

at 50HZ
54.00
2711
11.5
473
0.9

Site Inspection Details:

Inspection Report:

SITE INSPECTION REPORT ENCLOSED SEPERATELY.

Stator inspection findings are given here:
As per these findings and keeping reliability of operation it was decided to go for complete
rewinding. After dismantling of winding coils, before insertion of new winding coils EL CID test was
carried out on the core. At nine locations either end (turbine end and slip ring end) leakage current
was more than allowable threshold value of 100ma. Centre portion of the core is not having any
defect. Defectives laminations were either end only.

ELCID test leakage currents measured were as follows:

EL CID TEST FAULT CURRENT
EXCEEDING ALLOWABLE
THRESHOLD 100ma LEAKAGE
CURRENT
SLIP RING
TURBINE
END
END
ma
ma
4th
xx
110
slot
5th
xx
200
slot
15th
230
220
slot
16th
xx
480
slot
28th
290
xx
slot
29th
280
xx
slot
36th
260
xx
slot
38th
210
xx
slot
41st
240
xx
slot
As no core burning spots were noticed it was first decided to try repair by etching process. One of
well experienced firm carried out the repair but not successful. Then it is decided to go for
restacking of defective areas core at site. Laminations of 11 packets on exciter end and 8 pockets
on turbine end were removed, cleaned, re-varnished and re-stacked.
After re-stacking EL CID test results came down to satisfactory level. Then insertion of new coils
and further process of rewinding was done.

For commissioning the unit on 50Hz system 13.8KV generator has to operate at 11.5kv. For that
matching transformers were used in P.T circuit and excitation power transformer circuit to get
specified voltages for control and protection circuits.
No changes made in C.T circuits.
Original electromagnetic relays were retrofitted with two numbers numerical relays to have 100%
hot standby.
Generator control and metering panels were also retrofitted with new panels.
Because of spares and other problems original A.V.R was replaced with new A.V.R of local make.
Initial wedge tightness report not enclosed as rewinding of complete stator winding was done.
Finally on 14th August 2008 unit was synchronized with Indian Karnataka State grid.
New A.V.R started giving problem with frequent thyristor fuse failure. Hence it was also replaced
by M/s A.B.B make.
In the year 2010 unit experienced vibrations problem and found they were because of shorts in
rotor winding. The rotor was wound with new winding.
Now the unit is in service. Maximum generation went up to 50 MW.

ANNEXURE:
Generator Preliminary Visual Inspection Report
Dates of inspection: 29th to 31st May 06
Client: m/s Satavahana Ispat Ltd., Kudathini plant

Power Plant Consultancy

HYDERABAD
GENERATOR INSPECTION REPORT
Plant:
Make
Capacity
p.f
Gen.
Des no:

E225U04

Elect. Design no:

Turbine ser num

frequency

wedges

197867

60hz unit to be operated at 50hz

* derated values for 50hz operation

E213UR01

Item
STATOR
SLOT PORTION

Looseness of all the wedges checked by tapping with

spanner. Number of loose wedges is not high.

Over bottom half of front core, deposits of dust noticed

mostly at both ends. As the deposits are wide spred at the
core end portions, there is possibility for bar vibrations at the
ends. It has to be thoroughly investigated with the help of
generator winding specialists.

Front core

s.no
A

Satavahana Ispat Ltd., KUDATHINI, Karnataka state

Service
General Electric
316X423
No
54MW*
voltage
11.5kv*
current
2711*
field
0.9
field volt
250V
473
amps

At both ends of core at the start of end windings, in many

places, the top layer insulation tape came off and also
noticed brown colour deposits. These deposits indicating
partial discharge activity occurred in presence of bearing oil
vapour. Testing of powder collected is to be arranged.

End windings
Core
Frame

End winding supports are firm and coils ties are tight
at some locations partial discharge activity noticed
between coil sides. End winding insulation has not
shown any softness because of oil leakage. Lot of oil
leaked on turbine end. Slight oil vapour deposit found
slip ring end.

From distance it is appearing as if core got rusted. But

it is due deposits only. The insulation varnish in the
area where deposits are noticed got peeled off and
core got the colour of deposits. Checked the tightness
of core teeth and found o.k. however the core
insulation integrity has to be checked by El-Cid test.
core heating symptoms due to over fluxing and
laminations insulation failure not found. cooling ducts
also found in good condition but dust to be cleaned.
There is no possibility for back core inspection as
there are no man holes provided for that.

Around 50ltrs of bearing oil leaked into frame at

turbine end. The oil taken out and cleaned the surface
for identification of oil leakage to be studied. Coolers
could not be inspected as they cannot be removed at
present site because of lower height of roof. Weld
points in the frame structure inspected and are o.k

Checked the resistance values of r.t.ds.The values are 10 ohms for all and corressponds
to 25 0 c.no physical damage for those visible at present. R.t.ds provided for cooler inlet
temp. will be checked for any physical damages, when coolers are taken out for
inspection.

Phase & Neutral take

off leads
Bearings and
Seals
ROTOR

BRUSH HOLDER RIGGING

Mechanical erection group will be attending to the bearings, and seals. In view of oil
leakage into frame of generator the seals clearances please be checked for their
clearances limits. Insulation material for slip ring end bearing assembly and oil deflector
assemblies to be searched, if not available to be procured and the material fibre glass of
good quality. Pitting not observed on bearings babbit material.

INSTRUMENTATION
Instrumentation

Phase and neutral terminals insulation is o.k. but

noticed partial discharge activity in this area ,in
between crossing leads. Some leads where partial
discharge symptoms observed found to be of max. volt
difference. Stator winding Meggar value with 500v
static device is taken.. to and to earth values
for all phases found infinity.

Brush holders to be procured as some parts are

missing. Brushes also to be procured. Existing shaft
earthing device is brush type. It is to be modified for
utilisting flexible copper strip with minor modifications
to the existing fixture.die penetration check for any
cracks to be carried out for gen. stator & rotor cooling
blades and slip ring brushes. fixed guide vanes
availability in total nos. to be ascertained. hard ware
materials for assembly of fan blades, fixed guide
vanes to be collected.

ROTOR WINDING,SLIP
RINGS,JOURNALS,BEARINGSETC.

Rotor winding require thorough cleaning. Wedges condition

is o.k. Outer surface of retainig ring is with any dents or
other damages. Information about retaining ring is that it is
of 18-18 Mn Cr. No physical damage observed on Slip
Rings. Rotor winding require heating for improvement of
insulation value. No hot spots observed either on core or
wedges. As 100V Meggar is not available insulation value is
taken with AVO meter and found to be 50K.ohms. Journals,
seals seating areas are normal. Die penetration test to be
done on all fan blades to find any cracks. Availability of fan
fixing bolts and washers to be checked. Rotor winding
heating equipment to be made available.

INSPECTION FINDINGS:
i
STATOR
The following abnormalities noticed are to be taken up on priority
1) Deposits at both end of core
2) Partial discharge activities in end windings
3) Peeling of top insulation layer of winding bars
1) Deposits at both end of core
Formation of deposits mostly at the core ends pointing towards bar vibrations occuring
only at the ends of the core. It is mostly due to the bars being held off the bottom of
the slot. Wear can occur with very small clearance, perhaps less than 5 mils. Clearance
less than 30mils cannot be seen directly or with a boroscope, nor measured by feeler
gauge and to be verified with the use of standard bar jack and core mounted dial
indicator.
Therefore it requires thorough inspection by generator winding specialist of same voltage
class. It is a must to ensure about bar vibrations. Except these no core heating traces
found.
2) Partial discharge activities in end windings
at different locations of end winding and take off leads of phase and neutral leads
deposits
of partial discharges noticed. Colour of these deposits can be because of the discharges
in presence of oil vapours. These spots to be further examined to ensure that the
discharges have not cut into the insulation. If they have not cut into the insulation,
cleaning is only required.
This can also be discussed with winding specialist.
3) Peeling of top insulation layer of winding bars
at many locations of end windings of both ends peeling of top layer insulation of bars
noticed. This is to be repaired and to be discussed with winding specialist during above
defects inspection.

ii

Rotor
a)Heating of rotor has to be co-ordinated with the insertion of rotor, such that the rotor will
not be outside for long time after heating activity
as informed earlier, rotor heating requires suitable D.C source (D.C welding machine),
copper clamps for connecting the leads to rotor winding slip rings, suitable d.c ammeter,
good quality winding resistance measuring unit, tent arrangement and exhaust fan to take
off moisture released etc. are to be made available.
after completion of winding heating A.C impedance test will be conducted along with other
tests.
b) In brush holder rigging unit some components of brush holders are missing hence new to
be procured. Along with them two sets of carbon brushes to be procured. Recommended
carbon brush grade is " National Carbon 634 "
c) For assembly of slip ring end bearing, oil seals insulation materials to be made ready
if not available to be procured.
d) Fixed guide vanes to be numbered and checked for any damages and their fixing
hardware materials to be kept ready.
e) As lot of leakage observed at turbine end, the seals to be checked for their clearances
limits.

iii

iv

Coolers
Coolers inspection could not be done because of space constraint to take them off.
as there are no manhole covers on generator frame to inspect back core, it will be tried
when coolers are removed.
Shaft earthing device
Shaft earthing device with the use of carbon brushes is not that effective. It may be
modified using copper flexible. For it slight modification of the unit is necessary.

Partial discharges and / or top insulation tape of bars peeling off areas over end windings
Turbine end slot ares
S09
S10
S11
S12

Slip ring end slot areas

S - 33

S - 20

S - 37

S - 23

S - 37

S - 23

S - 38

S - 24

S - 38

S - 25

S - 39

S - 25

S - 39

S - 26

S - 26

S - 40
S - 41