MG-SET Reliability

Proposal
EFERT Manufacturing Division
I&E Department
Engro Fertilizer, Daharki

Aug 2023

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 MG-SET Reliability Proposal - EFERT Manufacturing Division

MG-SET – Overview
MG-Set is the backbone of the Ammonia-II plant since all power to this unit is being supplied through MG-Set.

The Ammonia-II plant was relocated from USA in 1992 and is rated at 60 Hz. The purpose of the MG-Set is to generate
2.4kV, 60 Hz power to meet the requirements of the Ammonia-II plant.

Parameters MG-2501 (MG-SET)

Make Brush

Model & Serial No. 61646A – 1M/G

Type Motor Generator Set

Supply system 6600V / 3 Phase / 50 Hz

Power rating (Gen Output) 4MW, 5MVA

Full Load Amperes (Gen) 1203A

Insulation Class F (155 Deg C)

Speed 600 RPM

Commissioning Year at EFERT 1992 (31 years -Service)

Approximate Running Hours 2,36,520

Motor Generator Set Specifications Motor Generator Set

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 MG-SET Reliability Proposal - EFERT Manufacturing Division

MG-SET – Interventions Till Date

Motor-Generator set is the most critical machine at Ammonia-II. It is a Single Point of Failure since it is the only source of
supply for all 60Hz Ammonia-II plant loads.

A detailed preventive maintenance regime exists for MG-SET to ensure its reliable operation which is covered through below PMs:

Preventive Maintenance PM Frequency Replacement/Upgradation Year

Motor and Generator Field Servicing 2 Years Excitation & Control System Upgrade 2012
Motor and Generator Feeder Servicing 2 years Protection System Upgrade 2012

Control & Excitation Panel Servicing 2 years
Power Cable Testing 4 years
MG-SET Life Assessment Testing
4 years
Major Inspection
10 years (However, MI done after
30 years in LTR’22)
Major Inspection 2022 – Supported by ENG1
Team*
*OEM- Brush Electric refused to provide engineering services for MG-
SET Major inspection but ENG1 team supported well throughout the
engineering & services process. All future correspondence regarding
spares & engineering services will be done with ENG1 team as they have
all the required dimensions & data for this critical machine
Interventions – Upgradation & Replacement Projects

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 MG-SET Reliability Proposal - EFERT Manufacturing Division

MG-SET Reliability Concerns

Based on the age of the machines, physical condition of its components and suggestions of the vendor, the following area of concerns are highlighted for
long term reliability

Preventive
Maintenance Rotor Poles (Motor & Main Stator Coils
Oil Cooler / Pump
Generator) (Motor & Generator)

Intervention
Required*

PMG (Motor &

Bearings (MTR & Gen) Exciter Rotor
Generator)

*The proposed intervention/concerning

areas are highlighted based on findings
during recent Major Inspection of the
machine during LTR & the Winding Support Slot Wedge Tightness
recommendations shared by ENG1
Heat Exchanger
Structure (Gen Rotor) (Gen Stator)
team.

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 MG-SET Reliability Proposal - EFERT Manufacturing Division

Concerns & Reliability Plan

Concern: MG-SET Reliability based on recent Major Inspection
Approx. Cost
# Proposal Impact
MPKR

Proposal-1
1 Unavailability of spares & rely on existing PM regimes & planned Major inspection. -
Retain current philosophy

- Procurement of 2 spare Stator Coil sets & plan complete replacement of 3 set
of stator coils for both Motor & Generator as recommended by ENG1. (1 Set of
Stator coil is available) – Replacement plan 5 years
Proposal-2
2 Spares Procurement & Vulnerable - Procurement of 2EA Rotor poles for both Motor & Generator as spares.- 50*
parts Replacement Replacement plan in next Health Assessment

- Procurement of Complete exciter set/PMG for both Motor & Generator –

Critical Spare

*Budgetary Quotes are still awaited from ENG1 as they were not providing quotes due to long pending payments issue. (LC issue)
However, we expect to receive the quotes soon as the payments have been released now.

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 Thank You!

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