Geothermal Power Plant, Stator

Reconditioning & Rotor Rewind of Generator

Manila, Philippines

Project Summary Project Value: £500,000

Service: Repair and Refurbishment
Duration: 3 Months

Background Quartzelec had the opportunity to work with a Geothermal Power Plant situated
in Leyte in the Philippines. The Power Plant generates and supplies electricity in
Leyte and also exports power to Cebu through the Leyte-Cebu interconnection
project.

Quartzelec were awarded the contract to recondition and rewind the generator
rotor of Unit 3 with the aim to restore the reliability and efficiency of the rotor. The
rotor was inspected in 2010 and a number of problems were identified including
loose and cracked end winding blocking, heavy dusting, contamination, possible
insulation degradation and shorted turns on STIIT tests and drop tests.

The Project The generator is 2 pole, 3PH, 60HZ air cooled with a brushless exciter,
13,800V and 3600RPM. On site, the generator was disassembled and the rotor
was removed. Initial inspections and testing was conducted on the rotor which
included winding and insulation resistance tests and a general overhaul visual
inspection. The rotor was dismantled by removing the diodes and fuses, fans
and retaining rings. Existing rotor coils were removed and the end winding was
inspected. Further tests and inspections took place after the rotor disassembly
including non destructive examination, testing of diodes and fuses, the collector
ring and lead insulation and the rotating excitation system.

The new insulation including rotor coils was designed and manufactured by our
team of experienced and qualified engineers in the Rugby workshop and were
suitably packed and shipped to site.

The rotor was prepared for winding and the new coils were prepared for
installation. Each coil was wound into the slots and the coils were pre-insulated
and epoxy coated Nomex strips were applied during the fitting of turns. The
rotor was reassembled by installing the top wedges using top filters of polyester
glass laminate, installing permanent end turn blocking, applying retaining ring
insulation, the retaining rings, refitting the cooling fans and installing new fuses.
Once assembled, electrical and mechanical tests and visual inspections were
conducted on the rotor and also on the exciter. Tests were also carried out on
the stator including insulation and winding resistance tests, polarization index
measurements, wedge tightness tests and El-CID core tests.

During the stator inspection, evidence of fretting and Partial Discharge was
discovered and repairs were completed during the outage. The work was
successfully completed and a resonance test was conducted so that possible
movement could be trended by repeating the test at a future date.

Finally, a Condition Monitoring System was installed which consisted of a stator

partial discharge monitoring unit and a rotor shaft voltage monitoring unit and
the generator was then reassembled and recommissioned.

To discuss your support requirements, or to find out more about our total capability in Rotating
Machines, please contact: info.uk@quartzelec.com or visit www.quartzelec.com