COR JN40000578 - TN1532 SDES-KLKOM GPB80D v1

PREPARED BY REVIEWED BY APPROVED BY
NAME: NAME: NAME:

KHOLIS JAIMON MOHD HUSNIZAR B ADNAN CHIN KEAN KHOON
DESIGNATION: DESIGNATION: DESIGNATION:
PROJECT ENGINEER PROJECT MANAGER DIRECTOR
DATE: DATE DATE:
27TH OCTOBER 2021 27TH OCTOBER 2021 27TH OCTOBER 2021
GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

No 12 Jalan Sungai Batu 11/KU6, Kawasan Perindustrian Sungai Puloh, Klang 42100, Selangor Darul Ehsan. Malaysia.
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CLOSEOUT REPORT
CLIENT : SIME DARBY ENERGY SOLUTIONS

JOB START : 01ST OCTOBER 2021
JOB FINISHED : 24TH OCTOBER 2021
CUSTOMER REF : KLKOM GPB80D
JOB NUMBER : JN40000578/ TN1532
GENERATOR SPECIFICATIONS:
VOLTS : 11 kV THERMAL CLASSIFICATION
AMP. S : 476 A ARM : 155(F)
OUTPUT : 9063kVA FIELD : 155(F)
RPM : 1500 RPM
FREQUENCY : 50Hz BRUSHLESS EXCITER
EXCITATION VOLTS : 115 VOLTS : 75 V
FIELD AMP.S : 399 A AMP.S : 362 A
ARM. CONNECTION : STAR (Y) OUTPUT : 47 kVA
EXCITATION VOLTS : 110V TYPE : NTAKL
FIELD AMP.S : 8.8A SERIAL NO : 905566A50A

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RE: OVERHAUL OF KLKOM GPB80D 9063kVA NISHISHIBA GENERATOR
SIME DARBY ENERGY SOLUTIONS had engaged Genturbo Industrial Sdn Bhd to perform generator overhaul work
for KLKOM GPB80D generator. Overhaul work was started on 1 st of October 2021 by removing the generator from
the GTG. After 5 days of removal work at site, generator was finally delivered to GTISB workshop.
For overhaul work, there are certain standard that was followed to ensure that the result is still within the range
of the standard. All standard use during overhaul work was list down in each result table. Apart from international
standard, a well calibrated measurement tools also plays a crucial role in each overhaul process as uncalibrated
measurements tool might give an inaccurate result which might lead to unnecessary rework.
Preliminary finding founds out the external of the generator was heavily contaminated with dust. Insulation
resistance and winding resistance were performed prior to generator disassembly work. Result was low even though
it is still within the acceptable range as per IEEE standard. Upon dismantling, it was found out that the internal part of
the generator was heavily contaminated with dust. Detailed work scope was listed down in Chapter 1.0.
1.0 SCOPE OF WORK CARRIED OUT
Below is the scope of work carried out on the generator at Genturbo Industrial Sdn Bhd workshop.
1. GENERAL WORK
a. Generator exterior had been visually inspected for any mechanical damage prior to disassembling
and delivery.
b. Generator parts had been cleaned with high pressure hot water jet.
c. Generator had been repainted prior to delivery.
d. New rubber gasket had been replaced.
2. MAIN STATOR
a. Insulation resistance and winding resistance test had been performed on the winding in room
temperature.
b. Winding had been inspected for any deformation and discoloration.
c. Stator core had been visually inspected.
d. Contamination on winding had been cleaned with degreaser and high-pressure hot water.
e. Oven baked at 130C for 16 hours.
f. Winding had undergone two times varnishing processed. It was oven baked to cure the varnish.
g. Partial discharge (PD) and Tan Delta (TD) test on stator winding was performed before and after
varnish (PERFORMED BY 3RD PARTY)
h. Electrical check on space heaters, sensors and current transformer (CT).
i. Borescope inspection on main stator winding.
3. EXCITER STATOR
temperature.
f. Revarnished with air-dry varnish.

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4. PERMANENT MAGNET(PMG) STATOR
temperature.
f. Revarnished with air-dry varnish.
5. ROTOR
a. Visual inspection on rotor condition was performed.
b. Insulation resistance and winding resistance test was performed on main rotor and exciter rotor
winding.
c. Diode was removed. Polarity check and voltage drop test was performed on the diode.
d. Voltage drop test on main rotor winding was performed.
e. Cleaning of rotor using degreaser and high-pressure hot water.
f. Oven baked of rotor at 130C for 12 hours.
g. Rotor was varnished and cured inside oven.
h. Rotor was coated with red varnish after varnish had been cured.
i. Surface contact check, bearing clearance measurement, shaft run-out check, Non-Destructive Test
(NDT) and electrical continuity check between endshield and rotor was performed on rotor shaft.
6. BEARINGS
a. Visual inspection on the bearing was performed.
b. Bearing clearance check, Non-Destructive Test and plastic gauge check had been performed.
c. Mild polishing of bearing.
d. Electrical inspection on bearing sensors (RTD).
7. ASSEMBLY
a. Air gap between stator and rotor core on main stator, exciter stator and PMG stator was performed.
b. Bearing and seal clearance had been measured.
c. Insulation resistance and winding resistance test was performed on main stator after generator had
been fully assembled.
d. Generator was painted after assembly.
e. Shaft lock prior to delivery.
8. MISC. WORK
a. Refer to daily report for site activities.
b. Alignment between generator and gear box was performed.
c. Vibration check was performed during generator load test. Load test was performed from 0% and
increased with an interval of 25%. Vibration check was performed with each load increment.
d. All result was documented and compiled within this report.

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2.0 PHOTO REFERENCE
Below is the photo taken during overhaul for your reference.
OVERHAUL PROCESS
2.1 DE view of the generator prior to disassembling. 2.2 DE view of generator prior to delivery.
2.3 NDE view of generator prior to disassembling. 2.4 NDE view of generator as delivered.

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2.5 DE sleeve bearing as found 2.6 DE sleeve bearing as installed.
2.7 NDE sleeve bearing as found. 2.8 NDE sleeve bearing as installed.
2.9 DE winding overhang was contaminated with 2.10 DE winding overhang was varnished and coated
unknown particle. with red varnish. Aluminium tape was used to
detect any crack in the winding.

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2.11 NDE winding was contaminated with unknown 2.12 NDE winding overhang was cleaned, varnished
particle and coated with red varnish.
2.13 PMG stator as found. 2.14 PMG stator after cleaning.
2.15 Exciter stator as found. 2.16 Cleaned exciter stator as installed.

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2.17 Plastic gauge check was performed on DE 2.18 Plastic gauge check was performed prior to
bearing and bearing journal prior to generator installation of top half of the DE bearing during
disassembly. generator assembly.
2.19 Plastic gauge check was performed on NDE 2.20 Plastic gauge check was performed prior to
bearing and bearing journal prior to generator installation of top half of the NDE bearing during
disassembly. generator assembly.

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2.21 Rotor condition after withdrawn from stator. 2.22 Rotor was cleaned, varnish and coated with red
Heavily contaminated with unknown particles. varnish prior to installation.
2.23 Exciter winding as found. 2.24 Exciter rotor was cleaned, varnish and coated
with red varnish prior to installation.
2.25 Diode as found (Positive ring) 2.26 Diode as installed.

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2.27 Diode as found (Negative Ring) 2.28 Diode as installed.
2.29 Tubular heater as found. 2.30 Tubular heaters had been glass beads blasting
prior to installation.
2.31 NDT on DE bearing journal. 2.32 No surface crack was found on DE bearing
journal.

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2.33 NDT on NDE bearing journal. 2.34 No surface crack was found on DE bearing
journal.
2.35 NDT on DE sleeve bearing (Bottom) 2.36 No surface crack was found on DE bottom halve
sleeve bearing. (Bottom)
2.37 NDT on DE sleeve bearing. (Top) 2.38 No crack was found on DE top halve sleeve
bearing

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2.39 NDT on NDE sleeve bearing (Bot) 2.40 No crack was found on NDE bottom halve
sleeve bearing.
2.41 NDT test on NDE sleeve bearing (Top) 2.42 No crack was found on NDE top halve sleeve
bearing (Top)
2.43 Voltage drop test on main rotor winding. 2.44 Insulation of >50MΩ/250V between NDE rotor
shaft and generator body

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2.45 Condition of DE bearing prior installation 2.46 Condition of DE bearing prior installation
(Bottom) (Top)
2.47 Condition of DE bearing prior installation 2.48 Condition of DE bearing prior installation
(Bottom) (Top)
2.49 Tangent Delta is being carried out on generator 2.50 Partial Discharge test is being carried out on
winding. generator winding.

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2.51 NDE insulated labyrinth seal has been checked 2.52 DE insulated labyrinth seal has been checked and
and inspected prior installation. inspected prior installation

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BORESCOPE PHOTO
BEFORE
2.53 Inner view of winding (DE) 2.54 Inner view of winding (DE)
2.57 Inner view of winding (DE) 2.58 Inner view of winding (NDE)
2.59 Inner view of winding (NDE) 2.60 Inner view of winding (NDE)

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AFTER
2.67 Inner view of winding (DE) 2.68 Inner view of winding (NDE)

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3.0 MECHANICAL REPORT
BEARING CLEARANCE
SLEEVE BEARING
(TOP HALF)
SLEEVE BEARING
(BOTTOM HALF)
DRIVE-END BEARING CLEARANCE
BEARING-OUTER (COUPLING SIDE) BEARING-INNER (ROTOR CORE SIDE)
B D
E
C
A
POINT MEASUREMENT (mm) POINT MEASUREMENT (mm)

A 220.29 D 220.35
B 220.30 E 220.35
C 220.29 F 220.35
I
G H
POINT MEASUREMENT (mm)

G 220.02
H 220.02
I 220.02
DE BEARING CLEARANCE
Maximum: 0.33mm
Minimum: 0.27mm

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NON-DRIVE END BEARING CLEARANCE
BEARING-OUTER (EXCITER SIDE) BEARING-INNE R (ROTOR CORE SIDE)
B D E
C
A
POINT MEASUREMENT (mm) POINT MEASUREMENT (mm)

A 220.30 D 220.30
B 220.31 E 220.31
C 220.29 F 220.30
I
G H
POINT MEASUREMENT (mm)

G 220.02
H 220.02
I 220.02
NDE BEARING CLEARANCE:

Maximum:0.29mm
Minimum: 0.27mm
For the clearance of the sleeve bearing, there are no certain guidelines as of the period of generator overhaul. As a
guide, the following clearance was used.

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By using the following tolerance extracted out from Alstom (Manufacturers), bearing tolerance were as follow
Minimum: +0.360mm
Maximum: +0.435mm
By taking the value calculated above, bearing clearance on DE and NDE are still within the acceptable range.

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AXIAL ENDPLAY
X1 X2
OUTER INNER
(TOWARDS COUPLING FOR DE, (TOWARDS ROTOR CORE
TOWARDS PMG FOR NDE)
Y1 Y2
DE NDE
BEFORE (mm) AFTER (mm) BEFORE (mm) AFTER (mm)
X1 5.6 X1 6.8 X1 7.0 X1 6.3
X2 5.4 X2 4.2 X2 7.0 X2 7.7
Y1 5.6 Y1 6.8 Y1 7.0 Y1 6.3
Y2 5.4 Y2 4.2 Y2 7.0 Y2 7.2
SIDE CLEARANCE
U1 U2
OUTER
(TOWARDS COUPLING FOR DE, INNER
TOWARDS PMG FOR NDE) (TOWARDS ROTOR CORE
V1 V2
DE NDE
BEFORE AFTER (mm) BEFORE (mm) AFTER (mm)
U1 0.10 (9mm) U1 0.10 (23mm) U1 0.09 (12mm) U1 0.10 (30mm)
U2 0.10 (9mm) U2 0.10 (22mm) U2 0.10 (12mm) U2 0.10 (20mm)
V1 0.10 (12mm) V1 0.10 (23mm) V1 0.10 (12mm) V1 0.10 (23mm)
V2 1.10 (12mm) V2 0.10 (23mm) V2 0.10 (12mm V2 0.10 (22mm)

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LABYRINTH SEAL CLEARANCE
INNER
(TOWARDS ROTOR CORE
2 3
1
OUTER
(TOWARDS COUPLING FOR DE,
TOWARDS PMG FOR NDE)
DE
SHAFT DIAMETER 260.02mm
FRONT VIEW LABYRINTH SEAL 1 (mm) LABYRINTH SEAL 2 (mm) LABYRINTH SEAL 3 (mm)
260.80 260.90 260.93
260.85 260.83 260.97
A C 260.86 260.91 260.93

B
MAX. CLEARANCEC 0.48mm MIN. CLEARANCE 0.39mm
NDE
SHAFT DIAMETER 260.02mm
FRONT VIEW LABYRINTH SEAL 1 (mm) LABYRINTH SEAL 2 (mm) LABYRINTH SEAL 3 (mm)
260.84 260.84 260.80
260.89 260.90 260.80
A C 260.86 260.87 260.92

B
MAX. CLEARANCEC 0.45 MIN. CLEARANCE 0.39mm

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For the labyrinth seal clearance, there were no specific guidelines available except from manufacturers. By referring
to the guidelines mentioned in EASA Technical Manual, it is better to determine the labyrinth seal clearance from the
bearing clearance compared with shaft diameter. It mentioned that the labyrinth seal clearance should be 0.05mm to
0.10mm more than the bearing clearance.
By using the rules of thumb, the maximum and minimum clearance of the bearing should be as follow:
Maximum DE bearing clearance: 0.33mm

Tolerance for DE labyrinth seal: 0.38mm to 0.43mm
Maximum NDE bearing clearance: 0.29mm

Tolerance for NDE bearing labyrinth seal: 0.34 to 0.39
Labyrinth seal (bronze/brass) clearance guidelines (Extracted from EASA Technical Manual)
By comparing the maximum clearance of the labyrinth seal, it was out from the tolerance calculated. But, by referring
to the table above that was extracted from the EASA Technical Manual; for a shaft with a diameter of 191mm the
radial clearance is 0.31mm but for material other that brass/bronze may require more clearance. Hence, it can be
justified that the labyrinth seal clearance is still within the acceptable value.

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SHAFT RADIAL RUN OUT CHECK
NDE BEARING JOURNAL

Ø 220mm
TIR: 0.00mm
DE BEARING JOURNAL
Ø 220mm
TIR: 0.00mm
COUPLING JOURNAL
Ø 180mm
TIR: 0.02mm
NDE
DE
REMARKS
1. The above T.I.R reading is acceptable as per ISO, DIN 42 955 Shaft Radial Run Out, Flange Coaxial Run and Plan
Parallelism Tolerances for rotating electrical machinery (Electric Motor)

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AIR GAP CLEARANCE
MAIN ROTOR &

MAIN STATOR
EXCITER ROTOR &

EXCITER STATOR
PMG &
PMG STATOR
AIR GAP AIR GAP AIR GAP

PART POINT
PMG EXCITER MAIN STATOR
12
12 1.10mm 1.45mm DE: 14.00mm NDE:11.40mm
3 1.00mm 1.50mm DE: 14.20mm NDE:11.60mm

9 3
6 1.10mm 1.50mm DE: 14.15mm NDE:11.50mm

6
9 1.05mm 1.45mm DE: 14.00mm NDE:11.50mm
ROTOR & STATOR
UNBALANCED 5.88% 1.69% 0.80% 0.87%
REMARKS
As mentioned in chapter 2.12 Air Gap of Machines in EASA AR100 “The air gap of the machine should not vary from
the average by 5% for two-pole machines or 10% for other machines”. Hence it can be justified that the air gap is
within the acceptable range as per EASA AR100.
Measurements for mechanical work is as below:

Equipment Used Serial Number Calibration Due
Outside Micrometre S/N: 4946368215099 23RD AUG 2024
Inside Micrometre S/N: 4946368215099 23RD AUG 2024
Dial Gauge S/N: ATDZ35 23RD AUG 2024

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4.0 ELECTRICAL REPORT
WINDING RESISTANCE TEST
MAIN STATOR
INSULATION RESISTANCE (BEFORE) VOLTAGE INJECTED:5kV TEMPERATURE:33.0C RELATIVE HUMIDITY: 64.1%
PHASE TO EARTH PHASE TO PHASE

PHASE 1 MIN 10 MIN PI PHASE 1 MIN 10 MIN PI
U-E (VW-G) 1.05 GΩ 1.94 GΩ 1.85 U-V (W-G) 7.50 GΩ 9.83 GΩ 1.31
V-E (UW-G) 1.13 GΩ 3.38 GΩ 2.99 U-W (V-G) 4.30 GΩ 8.17 GΩ 1.90
W-E (UV-G) 1.61 GΩ 9.25 GΩ 5.75 V-W (U-G) 6.80 GΩ 14.28 GΩ 2.10
INSULATION RESISTANCE (AFTER) VOLTAGE INJECTED:5kV TEMPERATURE: 30.4C RELATIVE HUMIDITY:65.8%
PHASE TO EARTH PHASE TO PHASE

PHASE 1 MIN 10 MIN PI PHASE 1 MIN 10 MIN PI
U-E (VW-G) 19.38 GΩ 38.95 GΩ 2.01 U-V (W-G) 31.22 90.85 2.91
V-E (UW-G) 21.35 GΩ 45.05 GΩ 2.11 U-W (V-G) 30.14 76.56 2.54
W-E (UV-G) 24.02 GΩ 53.08 GΩ 2.21 V-W (U-G) 36.79 90.87 2.47
WINDING RESISTANCE (BEFORE) WINDING RESISTANCE (AFTER)

TEMPERATURE 33.1C TEMPERATURE 30.4
PHASE RESISTANCE UNBALANCE PHASE RESISTANCE UNBALANCE
U-V 134.09 mΩ U-V 134.12 mΩ
U-W 134.12 mΩ 0.33% U-W 134.06 mΩ 0.05%
V-W 134.77 mΩ V-W 134.19 mΩ
REMARKS:
1. Due to the limitation of measuring equipment, winding resistance test was performed while the generator is
connected in Y (STAR).
2. From early result, it was suspected that the low reading is due to the present of conductive contaminant or
moisture penetration in the winding.
3. For insulation resistance the acceptable criteria as per IEEE Std 43-2013 is resistance should be >100MΩ and
the Polarization index should ≥2.
4. For winding resistance, the acceptable criteria as per IEEE Std 118-1978, resistance unbalance should be <2%.
5. From point 3 and 4, it can be justified that the result after overhauled work is within the acceptable limit.

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MAIN ROTOR
INSULATION RESISTANCE (BEFORE) VOLTAGE INJECTED:250V TEMPERATURE:33.7C RELATIVE HUMIDITY:71.3%
PHASE TO EARTH
PHASE 1 MIN 10 MIN PI
+VE-E 0.01 MΩ 0.01 MΩ 1
INSULATION RESISTANCE (AFTER) VOLTAGE INJECTED:250V TEMPERATURE:31.2C RELATIVE HUMIDITY: 66.3%
PHASE TO EARTH
+VE-E 6.18 GΩ 8.42 GΩ 1.36
VOLTAGE DROP TEST

TOTAL VOLTAGE INJECTED 60.3 V
WINDING 1 15.2V
1
WINDING 2 14.9V
4 2
WINDING 3 15.3V
3
WINDING 4 15.1V
REMARKS:
the Polarization index should ≥2. Based on this, it can be justified that the result after overhauled work is within
the acceptable criteria.
EXCITER STATOR
INSULATION RESISTANCE (BEFORE) VOLTAGE INJECTED: 500V TEMPERATURE :34.1C RELATIVE HUMIDITY:75.3%
PHASE TO EARTH
F1-E 6.39 GΩ 7.35 GΩ 1.15
INSULATION RESISTANCE (AFTER) VOLTAGE INJECTED:500V TEMPERATURE: 30.8C RELATIVE HUMIDITY:66.1%
PHASE TO EARTH
F1-E 29.2 GΩ 68.91 GΩ 2.36
REMARKS:
the Polarization index should ≥2. Based on this, it can be justified that the result after overhauled work is within
the acceptable criteria.

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EXCITER ROTOR
INSULATION RESISTANCE (BEFORE) VOLTAGE INJECTED:250V TEMPERATURE: 33.8C RELATIVE HUMIDITY: 74.8%
PHASE TO EARTH
U-E 3.45 GΩ 10.01 GΩ 2.90
INSULATION RESISTANCE (AFTER) VOLTAGE INJECTED: 250V TEMPERATURE:31.1C RELATIVE HUMIDITY:65.8%
PHASE TO EARTH
U-E 51.5 GΩ 98.37 GΩ 1.91

TEMPERATURE 33.8C TEMPERATURE 30.4C
U-V 5.765 mΩ U-V 5.835 mΩ
U-W 5.838 mΩ 0.77% U-W 5.791 mΩ 0.67%
V-W 5.826 mΩ V-W 5.864 mΩ
REMARKS:
1. Exciter rotor was internally connected in Y (STAR) connection, hence only 1 insulation reading was measured.
PERMANENT MAGNET STATOR

INSULATION RESISTANCE (BEFORE) VOLTAGE INJECTED: 500V TEMPERATURE:33.6C RELATIVE HUMIDITY:76.2%
PHASE TO EARTH
U-E 169 MΩ 239 MΩ 1.41
INSULATION RESISTANCE (AFTER) VOLTAGE INJECTED: 500V TEMPERATURE:30.4C RELATIVE HUMIDITY: 65.4%
PHASE TO EARTH
U-E 2.92 GΩ 14.9 GΩ 5.10

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TEMPERATURE 33.4 C TEMPERATURE 30.3C
U-V 0.4497 mΩ U-V 0.4999 mΩ
U-W 0.5008 mΩ 0.37% U-W 0.5011 mΩ 0.32%
V-W 0.4975 mΩ V-W 0.4981 mΩ
REMARKS:
1. Exciter rotor was internally connected in Y (STAR) connection, hence only 1 insulation reading was measured.
SENSOR ELECTRICAL CHECK
Temperature: 32.1°C
Diodes Voltage Drop Test
Voltage Injected: 1.5 V
Phase
U (Volt) V (Volt) W (Volt)
Direction
0.414 0.429 0.404
0.420 0.419 0.407
Forward
0.428 0.409 0.430
Diodes
0.410 0.425 0.426
0.422 0.409 0.403
0.424 0.419 0.402
0.426 0.406 0.416
Reverse
0.396 0.400 0.421
Diodes
0.409 0.381 0.417
0.421 0.416 0.418
Remarks
1. Each phase consists of 5 diodes for each direction. The 5 diodes were connected in parallel.
2. All diode in good condition

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Sensor Temperature: 32.5°C
Type Resistance (Ω)
H1-H2 (OVERALL HEATERS READING) 66.0 Ω (IR TO GROUND @250v: 60.1 MΩ)
T1-T2 0.1
PT 100 (DE) 112.6
PT 100 (NDE) 112.1
PT100 (A1) 112.1
PT100 (A2) 112.5
PT100 (A3) 112.1
PT100 (A4; SPARE) 112.0
PT100 (A5; SPARE 112.1
PT100 (A6; SPARE 112.3
CURRENT TRANSFORMER (C1) 166.05
HEATER 1 (DE) 266.1
HEATER 2 (DE) 267.5
HEATER 3 (NDE) 265.3
HEATER 4 (NDE) 265.3
REMARKS
1. Measurement tools are as below:
Winding Resistance Meter 190814916 01ST SEPT 2023
Insulation Resistance Meter 201213734 21ST AUG 2023
Multimeter 201052118 22ND AUG 2024
2. PT100 temperature chart were as follows:

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6.2 PARTIAL DISCHARGE AND TAN DELTA TEST
GST = Grounded Specimen Test

• Measures anything connected to ground
• Measures grounded insulation
• Describes the connection of the LV leads either connected to the ground point
(measured) or the guard point (not measured)
UST = Ungrounded Specimen Test

• Does not measure anything connected to the ground (Ground is
guarded)
• Measure ungrounded insulation
• Describes the connection of the LV leads either connected to the meter
(measured) or the ground point (not measured).
Figure 6.1 Schematic drawing of TD test
Test Energize Mode Injection (KV) Measure
1 U, V, W GST Tip-up Coverall
Figure 6.2 Schematic drawing of PD test

To date, there is no governing body or organization that has come up with an international
standard for the acceptance of partial discharge profile technology. As a rule of thumb and
based on manufacture guideline, the following guideline is used for condition acceptance.

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PD Magnitude (QIEC/QWTD) Severity
Within ±25% Change Normal
> 25% Change Further Monitor
>50% Change Further Investigate
Table 3: PD Overall Guideline
Quality PD (Slot Section) nC PD (End winding)

Excellent <2 <2
Good < 4 to 5 < 4 to 5
Average 4 to 10 4 to 10
Acceptable ~ 10 ~ 15 to 20
Inspection Necessary > 15 > 20
Potential Problem > 20 > 50
Table 4: PD Table provided by PD Tech as a reference and should only be used as a
general guideline.
Description Limit
DF at 0.2Uo or 2kV 3.0%
DF per 0.2Uo to 1.0Uo 0.5%
Tipup (1.0Uo – 0.2Uo) 2.0%
Table 5: TD based on IEEE 286-2000 &IEC 60034-27-3
All defects identified in this report should be scheduled for rectification and the repaired areas.
This should be re-inspecting again after the works have been completed. All equipment should
be scheduled for another inspection within 12 months from this inspection or earlier, depending
upon their importance.
6.2.1 INSULATION RESISTANCE CHECK
Pre-Test Pre-Test
Phase
(07/10/2021) (13/10/2021)
R-E 3.52G 19.7G
Y-E 6.21G 18.9G
B-E 3.14G 20.8G
R-Y 312M 41.7G
Y-B 416M 36.5G
B-R 7.43G 37.0G
Post Test Improve: PASS

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6.2.3 TAN DELTA TEST
RED (PRE)
V test I meas. (mA) Frequency Cp (nF) DF (%) % Tip Up
1,270 38.968 97.2348 9.6492
2,540 77.983 97.2666 9.6903
3,810 116.79 *50.00 Hz 97.1114 9.6905 0.05
5,080 155.12 96.7386 9.6804
6,351 192.80 96.1710 9.6981
RED (POST)
1,270 28.192 70.6559 0.4723

2,540 56.415 70.6973 0.5325
3,810 84.682 *50.00 Hz 70.7451 0.6068 0.43
5,080 113.06 70.8250 0.7198
6,351 141.62 70.9693 0.9026
YELLOW (PRE)
1,270 38.910 97.0985 9.7148
2,540 77.871 97.1341 9.7690
3,810 116.58 *50.00 Hz 96.9344 9.7622 -0.03
5,080 154.85 96.5435 9.7157
6,351 192.39 95.9561 9.6886
YELLOW (POST)
1,270 28.094 70.4183 0.4663
2,540 56.229 70.4565 0.5232
3,810 84.395 *50.00 Hz 70.5027 0.5955 0.45
5,080 112.67 70.5874 0.7161
6,351 141.18 70.7493 0.9138
BLUE (PRE)
1,270 38.685 96.5558 9.6652
2,540 77.387 96.5327 9.6757
3,810 115.72 *50.00 Hz 96.2309 9.6174 -0.16
5,080 153.62 95.8183 9.5619
6,351 190.86 95.2125 9.5057
BLUE (POST))
1,270 28.058 70.3193 0.4671
2,540 56.153 70.3569 0.5229
3,810 84.280 *50.00 Hz 70.4005 0.5930 0.44
5,080 112.49 70.4774 0.7067
6,351 140.95 70.6326 0.9035

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6.2.4 PARTIAL DISCHARGE
(Pre-Test)
Divider Q IEC/ Q Avg
F Centre Factor Q WTD (noise) P Dis. Q Peak Q Avg
200 kHz 21.17 5.502 nC 44.17 pC 274.0 mW 15.40 nC 6.474 nC

500 kHz 17.60 5.958 nC 58.45 pC 535.4 mW 11.93 nC 5.137 nC
Red
2 MHz 37.40 3.897 nC 100.4 pC 273.9 mW 7.298 nC 4.231 nC

4 MHz 3.117 2.019 nC 108.6 pC 79.82 mW 2.737 nC 1.959 nC
6 MHz 2.967 1.167 nC 109.8 pC 72.63 mW 1.840 nC 1.181 nC
200 kHz 20.80 24.63 nC 32.37 pC 385.8 mW 54.26 nC 26.04 nC
500 kHz 17.28 24.78 nC 54.33 pC 572.5 mW 51.78 nC 24.84 nC
Yellow
2 MHz 40.56 2.298 nC 105.7 pC 95.61 mW 5.194 nC 2.521 nC

4 MHz 15.21 5.258 nC 104.7 pC 167.2 mW 8.999 nC 4.559 nC
6 MHz 52.85 20.15 nC 211.8 pC 563.7 mW 42.97 nC 20.64 nC
200 kHz 6.445 8.629 nC 36.64 pC 101.4 mW 16.54 nC 8.106 nC
500 kHz 5.251 5.063 nC 68.43 pC 171.7 mW 9.412 nC 4.569 nC
Blue
2 MHz 9.555 1.300 nC 97.36 pC 33.73 mW 2.423 nC 1.500 nC

4 MHz 8.961 1.711 nC 285.3 pC 41.09 mW 4.807 nC 1.778 nC
6 MHz 1.683 74.62 pC 119.8 pC 2.737 mW 171.3 pC 68.96 pC
(Post-Test)
Divider Q IEC/ QAvg
F Centre Factor Q WTD (noise) P Dis. Q Peak Q Avg
200 kHz 7.520 6.738 nC 44.17 pC 63.73 mW 10.11 nC 6.414 nC

500 kHz 4.249 2.362 nC 58.45 pC 95.32 mW 4.765 nC 2.573 nC
Red
2 MHz 0.666 131.7 pC 100.4 pC 40.49 mW 253.9 pC 134.3 pC

4 MHz 1.723 814.5 pC 108.6 pC 216.8 mW 1.025 nC 819.7 pC
6 MHz 12.25 532.7 pC 109.8 pC 110.9 mW 746.4 pC 491.6 pC
200 kHz 7.553 7.932 nC 32.37 pC 76.01 mW 14.75 nC 6.722 nC
500 kHz 4.258 6.766 nC 54.33 pC 108.5 mW 12.03 nC 6.160 nC
Yellow
2 MHz 0.691 1.296 nC 105.7 pC 41.29 mW 2.671 nC 1.187 nC

4 MHz 1.377 733.1 pC 104.7 pC 187.1 mW 1.862 nC 885.4 pC
6 MHz 10.75 514.5 pC 211.8 pC 108.0 mW 938.0 pC 500.6 pC
200 kHz 7.626 13.46 nC 36.64 pC 82.25 mW 24.13 nC 13.10 nC
500 kHz 4.504 9.355 nC 68.43 pC 115.0 mW 16.26 nC 8.686 nC
Blue
2 MHz 0.690 1.399 nC 97.36 pC 43.44 mW 2.679 nC 1.492 nC

4 MHz 1.587 938.3 pC 285.3 pC 216.1 mW 1.853 nC 874.1 pC
6 MHz 10.53 691.2 pC 119.8 pC 108.1 mW 1.136 nC 633.4 pC

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PD Result Red Phase
(PRE)
PD Result Red Phase

(POST)
Fcentre = 200kHz, ∆F= 300kHz

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PD Result Red Phase
(PRE)
PD Result Red Phase

(POST)

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PD Result Red Phase
(PRE)
PD Result Red Phase

(POST)
Fcentre = 2MHz, ∆F= 1MHz

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PD Result Red Phase
(PRE)
PD Result Red Phase

(POST)

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PD Result Red Phase
(PRE)
PD Result Red Phase

(POST)

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PD Result Yellow Phase
(PRE)

(POST)

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(PRE)

(POST)

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(PRE)

(POST)

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(PRE)

(POST)

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(PRE)

(POST)

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PD Result Blue Phase
(PRE)

(POST)

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(PRE)

(POST)

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(PRE)

(POST)

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(PRE)

(POST)

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(PRE)

(POST)

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6.2.5 SUMMARY
1. The PRPD pattern of this motor shows that the partial discharge activities occur at the first
and third quadrant of the 50Hz sinusoidal, which indicated the partial discharge may exists
in motor insulation.
2. Tan Delta value (%DF) is still within limit, less than 3 %. The overall capacitance changes
and leakage current for this motor still within limit 5%. Below is the summary chart show the
charge value surveyed at 500kHZ.
3. PD detected is LOW. PD pattern indicate void discharge based on after service.

4. Recommended to monitor within 12-month time to observe the increment on the TD and
PD value.
5. During the pre-survey, there is abnormal detected, an electrical sparking can be seemed at
the winding insulation. The condition of the generator is dirty and contaminate. The
generator undergone overhaul and re-vanishing.
6. After generator compete servicing. Testing shown no abnormal, and no sparking sound
detected. TD and PD value drop. Insulation resistance value increase

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7.0 ALIGNMENT REPORT
7.1 PRE-ALIGNMENT
Before generator mounting bolt was loosened, alignment check was performed between generator and GB. Alignment
reading as follow:
Figure 5.1 Pre-alignment data was collected as a reference
7.2 ALIGNMENT AFTER OVERHAUL

After generator was skid back to its original place, coupling spacer was installed. The distance was set to 554.4mm
by using calibrated inside micrometre. This value is still within the tolerance which is +0.6mm.
Figure 5.2 Setting end-to-end distance between generator and GB

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Prior to alignment work, generator soft foot was measured. Result is as follow:
Figure 5.3 Soft foot check of generator
After generator soft foot had been rectified by adding 0.1mm thickness of shim, alignment work was then
performed between generator and GB. Alignment reading is as follows:

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Figure 5.4 Final alignment result was verified & approved by KGA and KLKOM representative
Tolerance for the generator are as follows
Figure 5.5 Tolerance for generator alignment

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To avoid over tighten of the fastener, all the fasteners supplied by client were properly tightened with a
calibrated torque wrench. The torque value set was 35 Nm and still within the range as per Figure 5.5. New nut was
use on the spacer and was supplied by client as per Figure 5.6.
Figure 5.6 New self lock nut

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6.0 VIBRATION REPORT
Vibration data collection was performed once before GTG shut down and 5 times during testing. 3 point was marked
on the generator for data collection to ensure the data is consistent. Vibration point were as follow
VERTICAL VERTICAL
AXIAL AXIAL
HORIZONTAL HORIZONTAL
DRIVE END NON- DRIVE END
Figure 6.1 Vibration point (DE) Figure 6.2 Vibration point (NDE)
6.1 BEFORE OVERHAUL

Vibration data was acquired before GTG completely shut down. Data were as follows:
Point Drive End (mm/s) Non-Drive End (mm/s)
Horizontal 0.93 1.11

Vertical 1.07 0.81
Axial 1.02 0.96
6.2 AFTER OVERHAUL

Vibration check was performed during generator is connected to loadbank system. Load sequence was performed
from 0% and increased with an interval of 25%. Vibration check was performed with each load increment.
6.2.1 0% LOAD (WITH EXCITATION)
LOAD N/A

Vertical 0.66 0.52
Axial 1.09 0.56

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6.2.2 (≈)25% LOAD
LOAD 1700kW

Vertical 0.55 0.47
Axial 0.68 0.58
6.2.3 (≈)50% LOAD
LOAD 3250kW

Vertical 0.68 0.46
Axial 0.73 0.94
6.2.4 (≈)75% LOAD
LOAD 4850kW

Vertical 0.68 0.38
Axial 0.66 0.41
6.2.5 (≈)100% LOAD
LOAD 6500kW

Vertical 0.81 0.33
Axial 0.81 0.51
REMARKS:
1. Overall vibration level is within ISO 10816-3 standard satisfactory limit.
2. Measurement tools are as below:

VIBRATION METER 628683 24TH AUG 2024

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7.0 CONCLUSION
In order to achieve optimum and best work quality, Genturbo has adopted multiple sources of international standard
as a benchmark and guideline of every electrical and mechanical test carried out. Obviously, the generator test result
and performance has drastically improved after serial of quality control in place.
8.0 EXECUTIVE SUMMARY

In today’s modern and forward-thinking world, Facilities Management is a crucial part of the business. As such,
maintenance either planned, preventive or scheduled plays an important role in the facilities management in order to
develop a benchmark and keep track the machine performance as the parts in rotating machine will undergo wear and
tear that may require attention. Hence it is highly recommended Sime Darby Energy Solution and KLK Oleomas fully
utilizes the information and test result in this report for future preventive and predictive scheduled activities.
9.0 WARRANTY
This Nishishiba made generator, Serial Number 905566A50A is covered by our standard warranty as follows
1. 6-months warranty from the date of GTG package is successfully loaded. The warranty
covered against failure due to workmanship or material used and the generator is strictly
to comply with schedule maintenance recommended by OEM
We believe we have informed you sufficiently for the work scope/repair mentioned above. Should you require further
assistance or information on this matter, please do not hesitate to contact us.
By signing off this document, I acknowledge that By signing off this document, I acknowledge that
GENTURBO INDUSTRIAL SDN BHD have delivered GENTURBO INDUSTRIAL SDN BHD have delivered
all the work mentioned in this report. all the work mentioned in this report.
NAME: NAME:
DESIGNATION: DESIGNATION:
COMPANY: SIME DARBY ENERGY SOLUTIONS S/B COMPANY: KL-KEPONG OLEOMAS SDN BHD
DATE: DATE:
*This report is intended solely for the information and use of SIME DARBY ENERGY SOLUTIONS AND KL-KEPONG
OLEOMAS and is not intended to be and should not be used by anyone other than these specified parties.

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*THIS PAGE IS INTENTIONALLY LEFT BLANK

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PREPARED BY REVIEWED BY APPROVED BY

NAME: NAME: NAME:

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

CLIENT : SIME DARBY ENERGY SOLUTIONS

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

1.0 SCOPE OF WORK CARRIED OUT

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

Below is the photo taken during overhaul for your reference.

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

2.13 PMG stator as found. 2.14 PMG stator after cleaning.

2.15 Exciter stator as found. 2.16 Cleaned exciter stator as installed.

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

2.25 Diode as found (Positive ring) 2.26 Diode as installed.

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

DRIVE-END BEARING CLEARANCE

BEARING-OUTER (COUPLING SIDE) BEARING-INNER (ROTOR CORE SIDE)

POINT MEASUREMENT (mm) POINT MEASUREMENT (mm)

POINT MEASUREMENT (mm)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

BEARING-OUTER (EXCITER SIDE) BEARING-INNE R (ROTOR CORE SIDE)

POINT MEASUREMENT (mm) POINT MEASUREMENT (mm)

POINT MEASUREMENT (mm)

NDE BEARING CLEARANCE:

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

260.80 260.90 260.93

260.85 260.83 260.97

A C 260.86 260.91 260.93

260.84 260.84 260.80

260.89 260.90 260.80

A C 260.86 260.87 260.92

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

Maximum DE bearing clearance: 0.33mm

Maximum NDE bearing clearance: 0.29mm

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

NDE BEARING JOURNAL

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

MAIN ROTOR &

EXCITER ROTOR &

AIR GAP AIR GAP AIR GAP

3 1.00mm 1.50mm DE: 14.20mm NDE:11.60mm

6 1.10mm 1.50mm DE: 14.15mm NDE:11.50mm

Measurements for mechanical work is as below:

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

WINDING RESISTANCE TEST

PHASE TO EARTH PHASE TO PHASE

INSULATION RESISTANCE (AFTER) VOLTAGE INJECTED:5kV TEMPERATURE: 30.4C RELATIVE HUMIDITY:65.8%

PHASE TO EARTH PHASE TO PHASE

WINDING RESISTANCE (BEFORE) WINDING RESISTANCE (AFTER)

GENTURBO INDUSTRIAL SDN. BHD. (COMPANY NO: 1223590-X)

INSULATION RESISTANCE (AFTER) VOLTAGE INJECTED:250V TEMPERATURE:31.2C RELATIVE HUMIDITY: 66.3%