AnsaldoEnergia DA MI Hydro power plant Generator Unit 1 ATBW-22-103000-273-13800 Dossier Restoration activity made during 2004 yy s0.r200 1| DOSSIER OF RESTORING ACTIVITY UN. 1 GENERATOR (CHAPTER 1: STATOR WINDING HV SIDE MODIFICATION D_ [Dossier unit 1 After Restoration Activity In 2008 Doc. 612974 Rev. 0 Star Ba ang - = Dig: TEKTOS=REV State Arongoment eeaon ng 197K1o4 REV onnectone Dg 197x195 REV. Stato Waning Wen New Special Phase-esk Bars Dwg. 1970572 RE | B | SeicoonaPriecionopatng On the Removed Bars Dwg. O12 REV. O| Sete weeding bar reatnon Win Sansconascve Varah Dwg. 612W47S~ REV. 8 | Stor Bers Sees Camactans Brana Dp 812 W559 REV 0 Sino ar Series sureion inslaion Dag. 8120525 REV. End Gaps ntrel Aros AccoplancsCrteia__Du. 612548” REV.A | inpecton And Test Plan Doe. 62590 Row. A Ay Fis Real Fa Sir Or Sie Doc STAWODE= Rav 8 {Corona Deacon Tes Ding Volags Test On SatrCois__Doe 6424760 — Rav. 0 ‘Soret Gn Bec Tot On Sse Wing Ate Renoaion Obs TaN Ra 3 ‘enton Revove Top And tom baa ane asso Boe anon Clow nrg Soe Gr Asetind sons Bale Sergh Boe Aron Sao ore Tome Vrtcaon oe atric “ep aodSaom Sun bros Retna Se Aree Datanes Messen Botwoon Bato Bars Stator Upper Sd Doe ATS Datanes Measurement Between Top Gus Sir Upp So Doe ATIO7 Datance Messurement Belweor Top Bas Stat Loner Silo Dos AT/108 Stator Vining Bolom & Top Bar AasombiogIslston 8 DMC Doe grin Skengt Test Dos ATH108 Coat att Presse Test oe arrt10 Renata Corel System: Sang etaca Tost Boe art Stor Weeding Comp AasombnsAerplace Test Dae ATS Stance Meanwenar Gatien Caps An Phas Sei: Vpe Se Doe ATA ‘On Generar Curate Doe. Ar Restoration Of Additonal Caps insulation Between Phase & [fees Doe, 612862 Rev. 0 Ha oe Tawa =e Inaructon Fer A Passepes Moateaten Dos. 612385 — Rew. frame Wrapper Oring Dig 1BeNs79 Rev. B Z| Glenn tteaton Bip 4esnzes Rev A ‘Ar Passages Meitetion Dig 197ME27— Rev. C Ccoier Dug. 175178 Rev. ¢ odes Cooler station Dan tS0KG51— Rev. F Medfleaion Of Stator Wiring Venton up 1924001 Rev. A GB _|New Coolers Thermal Performance Doe. 62515 Rew 0 ~ | Procedure For Fike And Thermal Teale AU Generalor 5 Say raw a | 9 poe Doe. 612711 Rew A CHAPTER 8: FINAL TEST [eae ‘See next sheet10 Eleatical and Mechanical test form Test report including Ineulain resistance of stator windings THI. teste on te stator winaings Ohmic resistance measurament of ter ining -Inculation resstanoe measuroment of ft winding “impadancemansuromert of ter winding eplacement ofthe shat somal speed - Mibraton dtecion onthe hor pl oF bearing at rad speed Shall ral tst “Fuld test Fu tests sey results “Thermal tstin sh rout 6 105% of ated slab carent ‘Annex 1 Fu test results | modfeaton [Analysis of test on Unit 1 after vention —crcult Dos. 61280. Dos ATS Doe. 234604 Rev. AAnsaldoEnergia Dossier Unt aeresiraton att 2004 owes | o Lilo [WataneW Rosanne 2 WWTE-o4018 wt c | ser Enolan : = = ae Toraeat Dat Power lant EVN Eleately of Vitam © |FirtissueAnsaldoEnergia Dossier "As Bull” Unit + after restoration actity 2004 | 6 t2we74 Da Mi Generator UNIT Nr 1 Restoring activity from February to August 2004 ‘The dossier contains the yeference documentaton used during the actly at site on Unit Nr. 1 and the dranings of stator bars Stator connections stator frame platos and wrapper holes dimensions ‘coolers arangements ‘ir bates revised accorting tothe “as but” situation Chapters . Stator winding H.V. side phase break special bars and connection rings modification 2. Ventilation circuit modification 3. Final TestsAnsaldoEnengia sme ser ee | Dossier “As Bult” Unit t after restoration actity 2004 | rawa7e | 0 | a | 6 DaMi Generator UNIT'N + Restoring activity from February to August 2004 4. Stator winding H.V. side phase break special bars and connection rings modification 1.4 During the activi top and bottom bars ofthe entre stator winding were removed and ‘8 deep cleaning of the core has been done. Drawings ofthe components and specication used forthe actvty are fisted below and attached in the folowing Bescripton Number —[ Rev. Stator brs drawings v7sK188_|__B. ‘Siator winding arrangement modifeation s97K194_| 6. (Connections 197K195_| 9. ator winding wi new special phase break bare sewera |B Sot corona protection repairing on the renioved bars raws62 [0 Stator wining bar treatment wih semiconductive vars erawa7s | A, Stator bars series connections brazing erzwes8_|—0. Stator bars seres junction insulation e12ws25 | A, [End caps internal air voids acceptance crleria ‘eraws4s [A Inspection and Test Plan [_e12wss8 | A, Rus removal fom stator core las ‘erzwe0s_| 0. Stator core re-ightening erawe1t_|—o. [Corona detection test dung velage Teal en lator cols 12w760_| 0.AnsaldoEnergia er |e Doss: ‘As Bul" Unt ste retoratonscivi 2004 | otzwre | 0 | 4 | 6 1.2 Reports ofthe test dung restoration act according o TP. 61258 Desc Nabe] Re Comment on Sesical est on dal winding Unt taer | Grav] 0 esoraton Tet On Revd Tab AS UO Ws Ha DSSS Benes | aa Win BtoB Sas aa & RRS T_| SEATIOA—|—p Sarco Tony Wena Bears —9 epi Sion Bo rc ass ese tro|—p Sac Wesson Boro Soi 6a Gs Wary Upp wae AOS | —G stores Wes set Stes Bat Sas Vina masa: Ts san inary Boao Yo OU5~ tins Vinny proto —t—E ses Messe Boon ep Snag Loree — [Oe AT |B ES Wea Soe Tey br onBos Ts € Oars HT] SSS aE Ra Tot a Renae cone ier So ai Ta teem |p or Winary Conpay sae aps Ta Bee —|—p ta rt Seon ap A Par Waa WORSE | oe ATTA | 6 Src sn Stan ap fd Pras Use 6 WLevs Sar |e TTS] 0 Testor cana pony het se Teg 2:1 Additional maintenance instructions Resioraion of additonal caps insulaion between phase breaks | 6t2W862_[_—0—] Da Mi Generator UNIT NF Restoring activity from February to August 2004 2. Ventilation modification 21 Thelmprovement adopted inthe ventlation arrangement included = modification of air passages inthe stator frame between end region and the back ofthe core ant io the coolers ducts = adoption of new coolers with ineweased surface and performance = adoption of air ducts from the frame tothe coolers conveying athe outlet sir ‘through the coolers = Induction of air baffles toward to the end capeAnsaldoEnergia Dossier “As Bult” Unit tater restoration activity 2004 er2wors ~ Introduction of air bales onthe back ofthe connection rings. Drawings ofthe components and specification used forthe activity are sted below and attached in the folowing (Bossip, Number —[ Raw. Analysis ofthe tosis executed on Da MUA. (en Feb 2008) | 612507 | A linstrucion for ar passages modification er2ws85_| —C [Frame wrapper dria 10K379 | 6. Air closing medication nesn2as_| A, Air passages modifeaton x97Na27 | —C. (Cooter a7sv761_|—C Modified cooler metalation 199K381_ | —F. Modification of stator winding ventilation 798K401_| A, [New coolers performance erawe1s_| 9. 22 Ventiaton and thermal ests ‘Atthe completion of the actvty vention and thermal tests hes been executed according to the agreement taken during the meeting in July 2003, (Descipion, Niamber [Raw [Procedure for idle and thermal teal at gonoralorestaring | e12w71t [AAnsaldoEnergia Dossier "As Bul” Unit 1 ster restoration activity 2004 | 6t2ws74 o | 6 js Da Mi Generator UNIT Ne 1 Restoring activity from February to August 2008 3. Final tests Tests according tothe Tests and Inspection Plan 612W538 Rev.A have been performed and the results are reported in the folowing documents, Insulation resistance of stator windings -HLV. tess onthe stator windings |- Ohmic resistance measurement of rotor winding -Insulaton resistance measurement of rotor winding - Impedance measurement of roto winding Displacement of the shaft at nominal speed = Vibration detection onthe hor. pl of bearing at rated speed Shaft run-out test Fide test ~Fhidic tests sunmary rosuts + Thermal testin sh, circuit at 105% of rated stator current = Thermal esta rated load (Besarpon: Nomber_[ Re. Electrical and Mechanical fest form “Tahest | Arie —| oaroa/ea Test report (Gonlaining) | Bsawesd_| 03109104 ‘Annex 1 Uni Fluid test resus (91 pages) PaO [Analysis of test on Uni 4 after ventilation eroul medication sraweoa [AAnsaldoEnergia a Drawings of be components and specication sed fr he svt ar tod below and atsched inthe folowing: Bescon ‘Nomber Rev Stator bars aa arekta [8 Sinlocwindng arangorent moacaion serktoa [6 ‘Gannectons iencts [0 Slat: wincing wifi naw spedal phase break bars sewers | 8 Slt corona protection reparng on te removed bar Biwso2 | —0 Stator wing bar Westman wih seriosoducive varia ‘erawa75_[ A Stal bars see connections brazing. ‘erawsee | 0. Sislor bars series uncon meulton e1awso5 | —A. [End caps ntl ar volds scceptance cara eiawsis | A. Inspecton and Test Pian e1aWwsse | A. ust roval fram sar core Si ‘ei2we05| 0 [Corona detcton rest during volaga es on Stor eas ‘i2wreo 10Lato crmesto comesstOM ato eowessiou | or SEE SABO nora ee mh , i : Uni2 = 68 KV (agreed in the {10 488417 meeting held in EVN Hochioh ty), In an internal meting , made in uy 23° 2003 ater the meting wih the customer, we defined havi to accompish tus fequrement ‘The theoretical boundaries ofthe intervention a [Frese breakN—[Botem bari —[Watage drop [Top barn. [Vatage irop | (between (eotween top boom bar N ere NNT) Nea 2 08, 7035; 7 es = Ea 70S. 3s ear Derived from the votage crops foal the 66 phase-beaks, given below inthe table TERRSG SEE [tage aap bme] Vans vp ween Increasing Number | “tothe Top barn | Yotege cron bat ates (relevent to the p.b.) — ; — = a i = 7a 1 : = ta iia 3 a a 1 - a a at = = a ta : = a a £ # at BeAnsaldoEnergia DA a STATORWINOING WITH NEW SPECIAL PHASE: | BREAK BARS sorwore e | 3 ® HAMTUAN DAM! PP. aM ‘numbering 92097319 | Vstage drop between | Volage crop between tracing Number] “tee Taper m2 | REE ln be ce sop z = ae as cn a ‘aa 0 2 a a i tt ea Sa ip a 0 68 i oa er see i 3 50 ae r 108 as as if i 57 sae a si ae ree a “a B35 368 zr “8 tose ‘057 Z wi 038 tse a cr sat 3200 a a7 aso wast ze 8 i oa ze 13 a ae a was Tosa “oat a a oa a a 75s “aa i “aro “ae ists a 135 “bar 2000 7 a "2000 Fetter ete 3 ast “et par Bore Br ator ose ais Haar a8 ze sara ara a Tae ee ar a seat i rasa ae a a8 teat aie a0 at st aaa a Br a0 oa 02 736 aAnsaldoEnergia =, scuaee = fe] es STATORWINONG WITH NEW SPECIAL PHAGE-| 1S7WOT2 ols |o BREAK OARS emake |= HAMTUAN DAMM PP. AM pce tno] oan | Vaage on tabeen] Voge Gop between cgitaTooget | tenon ters tepbure Ea 3 eT sz sts Tos a HA esas 3 am are 8 cc ce a ae a5 sr eT 3101 3 = a5 a =r 5 a 3a Ea 2 3 20a 3 sat 008 ie =r a 5 = 8 a 2 = “Table 1)-——~ valtage crop foreach phase-bronkin the machine = ‘As a consequence of this phase-bredkvoage check we would have: 7 “eta phase-break to restore 33 % ‘pbersto ciomante a 182 gett bare to sismantie 33 2 MATERIALS AND INTERVENTION ‘The material tobe prepared forthe storing activites are. calculated. sccorcing to the following real sntansion of work { conservative hypotesis}AnsaldoEnergia DA mi | STATOR WINDING WITH NEW SPECIAL PHASE: sorwora slo BREAK BARS iSaaea tense | 2 HAMTUAN DA MI PP. se aie om Phase break —[BotiombarN.” —Vallage os | TopbarN. [Voltage Gop nN (eotwoon | between top Botte bar N= bars N-We) : Net} 6 a 2530, — 88 3 EET —e— Sar a “The flowing table gives the extension of work according to this conservative cheiceAnsaldoEnergia Bo as7w972 8 6 o StaTOR WINDING WITH NEW SPECIAL PHASE: : fo fet BREAK BARS eats HAM TUAN DANI PR hear a as otthe to tho Top bar N. ewe toritbure.0| (elovant to the pb) ‘orware ae a7 az ae ze 3s es zr ele }elel sll els) lx fe sfs Br zis ele} 2 3AnsaldoEnergia E, ez er [oe] 8 Statbeymoncwnnewsrcc. ase:| wore | 8 | 7 | 8 Break ann a]? Frrrt—~—™—rCSEF HAUTUAN OAM PP. ae a a hypothesis forthe ntenention reakto restore 30 % tepartodsmante 228, % vottom bar 10 demante 39 (eventually olher $9 adjacent bars to make easier the disassemby Statorbars ‘otordingy we decided to manufgcure these stator brs per machine 2°59 special boom bars | 39 special top bars % standard bottom bars ¥ 30 standard top bars i ‘That means all the standard bars gifnentied shal be re-used (afer recondtoning ad testing). End-cans Te wil use the resin 11 to fle end-caps. The numberof end caps to be dismantled and recovered are ‘op size = 220-30 =190 Turina sie = 229, Total = 418 ‘tei for wecing Nooded for 228 sots 3. CHECK OF BAR DISTANCES ‘Toavold corona ls necassary to respect these values: (isianae among overhangs 7 oa same layer ‘istanoe between end cape z oi stances are most imgortant betwoen diferent phase bars oc ands, REMARK Irom cate a esse distance can Be cepted, but not ower than 9 mm (according to 64830 fig. 4 eorona inception votage uth mm fi-gap wil start at 25 KV gfeater than Umaknnemen =13.2 wy sears i for same layer bars ha ferent phase bars are densfed inthis manner, as example:AnsaldoEnergia | BA mi ‘STATOR WINDING WITH NEW SPECIAL PHASE BREAK BARS HAM TUAN DA MI PP. a een an [Phase beakn. 8OT—TeTE) ar ae BB bars of dferont phos. ic hs [Tot iferent paso Thos: F108. For al the oer phase-breaks the same situation, thus we ha the dstane atte phase break the rules, batlom bars to check BB n—B8 (0-1) Top bar to chock T8n—TB (ot) a2 TES FRadiles at the phase braaks are resisive paths between bars and reduce the algap, Thus we fecommend 10 spread th fe motorial In order to redaoe ils thickness and then make use of Somicondvctve varnish afer completion of work 4 CHECK OF END CAP ASSEMBLY Make a check of the distance of 12 mm ( 9 mm is the minimum acceptable, paragraph 3). Als hs checks most important at tne phase break ication 10 Rematk at 5 SPECIAL BAR / CONNECTION INSULATION In bis now confguration with longer special bars we have the brazing area outside the endcaps mits. Therefore we have more space fo insulate tha brazed jin. The following aspects nave to be respected £11 everapping between the bar Insulation and new insulation slope overlap In order to avoid tverstheknesses) ‘5.2 wel pulled wrappings to have a compactsuation wal 5.3 dstance bemoon insulation and end-caps 12 mm (min. cstance 8mm but on all he length of the endcaps), Having atte piace break both 88 and TS. bars the tao ules of pra, 3 shat be respected ‘ 85 n= 88 (n+) TBn—TB (ort) Consequenty both endcaps. at bath sides of the specil bars ar at ifeent votages and the distance shal be checked.AnsaldoEnergia DA Ml Seni joc |e | . 6 SEQUENCE OF RESTORING AND TESTS ‘The sequence of wor and relevant tests and apeticabe documents are: Sequence: “TRV [surea [aration —[Bacument Disessembly of bare 1 rare . : sorwsr2 (leaning of bare and varnicning B1aWa75 Tost of oa bas se [e ae [Test on remaiing od winding [36 [Oo B08 "Assembly Bottom bars (Check ot distances oTWOTe Test of moved BB a 15e as ‘Assembly of Top bars (Check of cistancos — irae “eat of moved B6+T8 af wa = ‘wedi : (Brazing plates, comnecions Tega Mis, nvlations,ondoaps (Ghat enceap citanoes iarBTe "Aesaplance test, Bia [Re ae rAccording To ec e00s4-1 (2Uns9}0.75, ‘arising 12075- AnsaldoEnergia [SLOT CORONA PROTECTION REPAIRING sr2wse2 o ftts JON REMOVED STATOR BARS AFTER MAINTENANCE WORKS Sea ana worn 3 (RESIN RICH TECHNOLOGY) ar a INTE-04-008 ATA | METEPsEreI English Fots00 ° @ roe HAM THUAN DA Mi HPP ELECTRICITY OF VIETNAM a 8 3 g 5 3 ° ae ee Soe | conse 5 neE AnsaldoEnergia é SLOT CORONA PROTECTION REPAIRING. 62ws62 2 . ON REMOVED STATOR BARS AFTER =a re p MAINTENACE WORKS. vst pase IN TE.04.008 ‘tints ‘This spetiaton descster the reping athiles to be mace on stor ars st corona rotacton afr tee aenssombly anatbelre har sce. The speciation rela oan eh achry. 4. USTOF MATERIALS Epoxy Adaeue Va 6408 Twasisz oro ‘orn vom VB 6480 ‘TWastsa 0100 estone TN 54940 0060 : Glare fap type 6926 0.25% 40 mm W426 0025 Gace ape ype 6227188. 40 mm ‘Wara6s 0008 i ios inp ype 6928 00x40 mm swarasa.cosa é 21 Sony adosive VB 893 Prepare he dese mang the wo componcat jst before the splat SVB OAD IA ‘00 waht pat, YB 6403 27 weit pt ‘cata upto amscimum of 70 weigh rath aie has high viscosity) ary ming for ee (3) miss The cans ef part A and ara the ight proportan, so i easy to mic pat and A oy cing a the quant of pa Bin ta pan Aca. The can so prepared must be slred oso, when 16 not Uso, 9 avi that evens goes tt Roma the ade every 10 minutos curing fs Use ‘he adesve so papared musl be used in hous src ts preparation, 22 Aotlcorona vanish vB csa0 Z Prapace ha antcoora epoxy adhesha bing "YB400/A “Do wightsar Hariner V8 © 6500 2weightpart | pars Sir windy over so Doc. N.ATIHOB- dated 30-0404~ sheets 14 | AnsaloleterEMED-AE-T1031 Date: ‘aor Distance measurement between tp bas — a , | Sar weg upper se Doc. N. ATHO7- dated 0-06.04 sheets 14 | Ansaldo later EMGO-AE-T1031 Dated not Distance measurement between top bars — - io er Eweo. - [Stor wining lore Doc. N ATHOB- dated 26-0504~sheets 14 | AnsaldoleierEMBD-AE-T1031 Dated: 1207104 Tena