AC GENERATOR WORKSHOP EXPERTISE - GEN

24.03.2016
AC GENERATOR WORKSHOP EXPERTISE REPORT
Report Code:
XXXXX.XX.XX.XX
GENERAL INFO
Company Name:
Company Address:
Equipment Location:
Equipment Name:
XXXXXXX
XXXXXXX
XXXXXXX
ME Shaft Generator
ALTERNATOR INFO
Brand:
Type:
S/N:
Power:
Voltage:
Current:
Speed:
Frequency:
Cos φ:
Rot. Direction:
Insulation Class:
Protection Class:
Mechanic Conn:
AvK
DSG 74 l2-4
67 27219 A101
1750 kVA
450 V
2245 A
1800 rpm
60 Hz
0,80
CCW (W-V-U)
H
IP23
Coupling
Excit. Stator Volt:
Excit. Stator Curr:
Excit. Rotor Volt:
Excit. Rotor Freq:
23,7 V
3,2 A
85,3 V
60 Hz
Coolant Temp:
Weight:
Manufactured:
Grease:
45°C
4,16 t
2005
Unirex N3
Heater Power:
Heater Voltage:
Heater Current:
350 W
230 V
1,52 A
TEST OPERATOR
Onur SOLMAZ (+90 532 783 83 38) - GEN-MOT / PSS
CONTENT
Electrical Expertise
Mechanic Expertise
Appendix – Thermal Imaging Report
GEN-MOT / PSS Tüm hakları saklıdır.
1/10
24.03.2016
ELECTRICAL EXPERTISE
MAIN STATOR INSPECTION
Insulation Measurement of Stator Windings
4,10
4,00
3,90
3,80
3,70
MΩ
3,60
3,50
3,40
3,30
3,20
19.03.2016
19:39:29.000
9:59,000 (min:s)
1 min/Div
19.03.2016
19:49:28.000
Tests Results (Ru-v-w to Ground)
Function
Date
Voltage
R(t°amb)
Resistance (t°amb)
R(t°ref)
Resistance (t°ref)
Fixed Voltage
19.03.2016
473,8 V
15°C
3,758 MΩ
40°C
2,621 MΩ
PI
PI1
PI2
1,003
3,745 MΩ
3,758 MΩ
DD
Capacitance
DD Current
2,203
64,24 nF
-67,06 nA
DC Resistences of Stator Windings
Y-connected
U–V
1,873 mΩ
U–W
1,887 mΩ
V–W
1,883 mΩ
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
14,40°C
1,873 mΩ
20,00°C
1,912 mΩ
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
14,50°C
1,887 mΩ
20,00°C
1,926 mΩ
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
14,60°C
1,883 mΩ
20,00°C
1,921 mΩ
Maximum rate of resistence unbalance: %0,7
GEN-MOT / PSS Tüm hakları saklıdır.
2/10
24.03.2016
Stator Visual Check
Stator windings and iron core are dirty and all surfaces covered by oil-grease mixture.
Some of energy output cables have insulation wears. Bares of phases in terminal box are so dirty and
need to be cleaned and painted.
After taking the rotor out of the stator, it has been seen that the rotor had rubbed to the stator during
operation. Stator has some deep scratches and short-circuits between some group of laminations. This
parts of the iron core has been specified by painting it with white colour.
The rotor iron core has also scratches on the pole surfaces. However, rotor poles are in better condition
than the stator iron core.
Loop Test for Stator Core
Iron core has been tested as described below:
(8 turn) x (60 A) = (480 A*turn) which means that iron core saturated approximately up to %20 of full
magnetic field. Test has been applied for 30 mins.
GEN-MOT / PSS Tüm hakları saklıdır.
3/10
24.03.2016
Thermal Imaging
For thermal images, please refer to Appendix-Thermal Report at the end of this report.
Assessment:
•
•
•
•
According to standard IEEE43-2000; the insulation resistence of the stator windings is too low.
According to standard IEEE43-2000; the polarisation index is too low.
As a result of loop test, stator core has many hot spots which can be seen on the thermal report.
So, stator windings should be removed from the stator. After that, stator core needs to be
repaired, then cleaned and painted. After stator core work, stator needs to be rewinded.
MAIN ROTOR INSPECTION
Insulation Measurement of Rotor Windings
3,50G
3,00G
2,50G
Ω
2,00G
1,50G
1000M
500M
0,00
19.03.2016
19:52:57.000
9:59,000 (min:s)
1 min/Div
19.03.2016
20:02:56.000
Tests Results (R2-3 to Ground)
Function
Date
Voltage
R(t°amb)
Resistance (t°amb)
R(t°ref)
Resistance (t°ref)
Fixed Voltage
19.03.2016
500,0 V
15°C
3,305 GΩ
40°C
2,811 GΩ
GEN-MOT / PSS Tüm hakları saklıdır.
PI
PI1
PI2
1,985
1,665 GΩ
3,305 GΩ
DD
Capacitance
DD Current
12,30
19,25 nF
-118,4 nA
4/10
24.03.2016
DC Resistence of Rotor Winding
4 poles serial connected
2–3
0,540 Ohm
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
14,60°C
0,540 mΩ
20,00°C
0,550 mΩ
Rotor Visual Check
Rotor windings and iron core are dirty and all surfaces covered by oil-grease mixture.
The rotor iron core has also scratches on the pole surfaces due to the rubbing. However, rotor poles are in
better condition than the stator iron core.
Rotor pole cable leads are in good condition.
Assessment:
•
•
•
According to standard IEEE43-2000; the insulation resistence of the rotor winding is sufficient.
According to standard IEEE43-2000; the polarisation index is at good value.
Rotor pole windings need to be cleaned, varnished and painted for protection.
GEN-MOT / PSS Tüm hakları saklıdır.
5/10
24.03.2016
EXCITER ROTOR INSPECTION
Insulation Measurement of Exciter Rotor Windings
4,50G
4,00G
3,50G
3,00G
Ω
2,50G
2,00G
1,50G
1000M
500M
0,00
19.03.2016
20:05:35.000
10:00,000 (min:s)
2 min/Div
19.03.2016
20:15:35.000
Tests Results (RU-V-W to Ground)
Function
Date
Voltage
R(t°amb)
Resistance (t°amb)
R(t°ref)
Resistance (t°ref)
Fixed Voltage
19.03.2016
500,4 V
15°C
4,320 GΩ
40°C
3,748 GΩ
PI
PI1
PI2
2,166
1,994 GΩ
4,320 GΩ
DD
Capacitance
DD Current
36,33
4,961 nF
-90,20 nA
DC Resistences of Exciter Rotor Windings
Y-connected
U–V
45,65 mΩ
U–W
46,03 mΩ
V–W
45,67 mΩ
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
14,60°C
45,65 mΩ
20,00°C
46,57 mΩ
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
14,70°C
46,03 mΩ
20,00°C
46,94 mΩ
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
14,60°C
45,67 mΩ
20,00°C
46,57 mΩ
Maximum rate of resistence unbalance: %0,8
Exciter Rotor Visual Check
Exciter rotor windings and iron core are dirty and all surfaces covered by oil-grease mixture.
GEN-MOT / PSS Tüm hakları saklıdır.
6/10
24.03.2016
The exciter rotor iron core has some partial scratches on the core surface due to the rubbing to the
exciter stator. However, general condition is good. Exciter rotor leads are in good condition.
Assessment:
•
•
•
According to standard IEEE43-2000; the insulation resistence of the exciter rotor windings are
sufficient.
According to standard IEEE43-2000; the polarisation index is at good value.
Exciter rotor windings need to be cleaned, varnished and painted for protection.
EXCITER STATOR INSPECTION
Insulation Measurement of Exciter Stator Windings
45,0
40,0
35,0
30,0
GΩ
25,0
20,0
15,0
10,0
5,00
0,00
19.03.2016
20:20:09.000
9:59,000 (min:s)
1 min/Div
19.03.2016
20:30:08.000
Tests Results (RU-V-W to Ground)
Function
Date
Voltage
R(t°amb)
Resistance (t°amb)
R(t°ref)
Resistance (t°ref)
Fixed Voltage
19.03.2016
500,4 V
15°C
42,60 GΩ
40°C
35,75 GΩ
GEN-MOT / PSS Tüm hakları saklıdır.
PI
PI1
PI2
1,891
22,53 GΩ
42,60 GΩ
DD
Capacitance
DD Current
10,37
2,485 nF
-12,89 nA
7/10
24.03.2016
DC Resistence of Exciter Stator Winding
12 poles serial connected
I1 – K1
7,660 Ohm
Measurement
Date
Metal
t°amb
R (t°amb)
t°ref
R (t°ref)
Auto
19.03.2016
Copper
13,90°C
7,660 mΩ
20,00°C
7,830 mΩ
Exciter Stator Visual Check
Exciter stator windings and iron core are dirty and all surfaces covered by oil-grease mixture.
The exciter stator iron core has some partial scratches at the bottom side poles due to the rubbing to the
exciter rotor. However, general condition is very good.
Assessment:
•
•
•
According to standard IEEE43-2000; the insulation resistence of the exciter stator windings are
sufficient.
According to standard IEEE43-2000; the polarisation index is at good value.
Exciter stator windings need to be cleaned, varnished and painted for protection.
CONTROL CIRCUITS INSPECTION
PT100 Sensors
Rotating Diodes
AVR
1 pc. at DE Bearing Housing - OK
1 pc. at NDE Bearing Housing - OK
2 pcs. at U Phase Winding - OK
2 pcs. at V Phase Winding - OK
2 pcs. at W Phase Winding - OK
3 pcs. DD89N14K Infineon - OK
Cosimat N+
GEN-MOT / PSS Tüm hakları saklıdır.
Thrystor
1 pc. SKVC20A460C Semikron - OK
8/10
24.03.2016
MECHANIC EXPERTISE
DRIVE-END MEASUREMENTS
DE Shaft Excentricity
N/A – Cannot be measured due to bearing fault
DE Bearing Shaft Diameter
150,03 mm – Needs to be grinded due to fused burres
DE Shield Bearing Housing
270,03 - 270,09 mm – Bearing housing needs to be fixed
DE Outer Grease Flange
Has 3 cracked place – Needs to be renewed
DE Shaft Place of Outer Flange
Scratched – Shaft needs to be spinned
DE Outer Scraper Ring
Fused – Needs to be renewed
DE Shaft Place of Scraper Ring
Scratched – Shaft needs to be spinned
DE Inner Grease Flange
Cracked – Needs to be renewed
DE Shaft Place of Inner Flange
Scratched – Shaft needs to be spinned
DE Bearing
6230 C3
DE Gressor
OK
Cooler Fan
OK
Outer Grease Flange Crack
Dispersed DE Bearing
Fused Outer Scraper Ring
Shaft Place of Outer Ring-Flange
Shaft Place of Inner Flange
Inner Grease Flange Crack
GEN-MOT / PSS Tüm hakları saklıdır.
9/10
24.03.2016
NON-DRIVE-END MEASUREMENTS
NDE Shaft Excentricity
N/A – Cannot be measured due to bearing fault
NDE Bearing Shaft Diameter
150,03 mm – OK
NDE Shield Bearing Housing
270,05 - 270,85 mm – Bearing housing needs to be fixed
NDE Outer Grease Flange
OK
NDE Shaft Place of Outer Flange
OK
NDE Outer Scraper Ring
OK
NDE Shaft Place of Scraper Ring
OK
NDE Inner Grease Flange
Deformed – Needs to be repaired
NDE Shaft Place of Inner Flange
Scratched – Shaft needs to be spinned
NDE Bearing
6230 C3
NDE Gressor
OK
Shaft Place of Outer Ring-Flange
GEN-MOT / PSS Tüm hakları saklıdır.
Shaft Place of Inner Flange
Shaft Place of Inner Flange
10/10
Appendix - Thermal Imaging Report
Ölçümler
Bx1
UNIT_CELSİUS
Max
16,2
Min
15,6
Average
16,0
Max
16,2
Min
14,9
Average
16,0
Sp1
Li1
19.03.2016 18:51:28
UNIT_CELSİUS
18,5
Bx1
15,9
Li1
Sp1
Parametreler
Emisyon
Yans. sıc.
0.95
20 UNIT_CELSİU
FLIR0007.jpg
FLIR E4
10,2
63964217
19.03.2016 18:51:28
FLIR0007.jpg
Initial condition of the stator before test started.
1/5
FLIR E4
63964217
Appendix - Thermal Imaging Report
Ölçümler
Bx1
UNIT_CELSİUS
Max
33,4
Min
14,9
Average
16,9
Sp1
32,3
Sp2
25,9
Sp3
24,1
Sp4
25,9
Li1
Max
33,4
Min
15,8
Average
18,5
19.03.2016 18:52:27
UNIT_CELSİUS
22,2
Bx1
Sp2
Sp1
Sp4
Li1
Sp3
Parametreler
Emisyon
Yans. sıc.
0.95
20 UNIT_CELSİ
FLIR0009.jpg
FLIR E4
13,6
63964217
19.03.2016 18:52:27
FLIR0009.jpg
Some points at the stator get thermally visible by the end of 1 minute.
2/5
FLIR E4
63964217
Appendix - Thermal Imaging Report
Ölçümler
UNIT_CELSİUS
Sp1
57,5
Sp2
44,8
Sp3
44,7
Sp4
51,6
Sp5
49,2
Sp6
43,1
Sp7
46,2
Sp8
45,2
Sp9
Li1
Li2
UNIT_CELSİUS
46,2
Sp5
Sp1 Sp4
Sp8
Sp2 Sp3
Li1
Sp9
42,0
Max
58,9
Min
20,4
Average
30,7
Max
46,0
Min
24,2
Average
30,2
Parametreler
Emisyon
Yans. sıc.
19.03.2016 19:02:28
Sp6
Li2
FLIR0013.jpg
Sp7
FLIR E4
18,6
63964217
0.95
19.03.2016 19:02:28
20 UNIT_CELSİ
FLIR0013.jpg
FLIR E4
63964217
10 minutes later, the difference between the hottest point and the coldest area is more than 25°C which means the iron core
sings a problem.
3/5
Appendix - Thermal Imaging Report
Ölçümler
Bx1
UNIT_CELSİUS
Max
65,1
Min
24,2
Average
33,1
Sp1
65,1
Sp2
50,0
Sp3
51,3
Sp4
57,4
Sp5
Max
64,3
Min
22,2
Average
31,3
Max
49,6
Min
23,2
Average
31,0
Sp1 - Ref. sıc.
65,1
Li2
Parametreler
Emisyon
Yans. sıc.
Bx1
Sp5
Sp1 Sp4
Sp2 Sp3
Li2
FLIR0016.jpg
FLIR E4
21,6
63964217
0.95
20 UNIT_CELSİ 19.03.2016 19:12:18
FLIR0016.jpg
20 minutes later, temperature difference got higher, more than 40°C.
4/5
UNIT_CELSİUS
51,7
Li1
54,8
Li1
Dt1
19.03.2016 19:12:18
FLIR E4
63964217
Appendix - Thermal Imaging Report
Ölçümler
Bx1
UNIT_CELSİUS
Max
71,2
Min
25,8
Average
32,3
Sp1
70,5
Sp2
63,9
Sp3
55,6
Sp4
27,2
Sp5
56,0
Sp6
Li1
Li2
Li3
19.03.2016 19:23:43
Bx1
UNIT_CELSİUS
56,6
Li3
Sp4
Sp5
Sp1Sp2
Li2
55,1
Max
55,9
Min
32,0
Average
39,5
Max
69,1
Min
28,4
Average
38,6
Max
70,9
Min
26,3
Average
36,2
Sp6
Sp3
Li1
FLIR0025.jpg
FLIR E4
23,5
63964217
19.03.2016 19:23:43
Parametreler
Emisyon
Yans. sıc.
0.95
20 UNIT_CELSİ
FLIR0025.jpg
FLIR E4
30 minutes later, at the end of the test the temperature difference reached to 45°C.
This iron core needs to be repaired.
5/5
63964217