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Figure 1
Electrical Department
Rig - Workshop
P age - 2
AY
1215 KVA PHASE 3 FREQUENCY50 HZ RPM1000 VOLTS 600 V AMPERES 1170 A PF0.7 LAG INSULATION CLASS-
ALTERNATOR KVA
EXCITER
EXCITER FIELD AMPS 7.54 A EXCITER FIELD VOLT 63 V
AMPERES 1169 A PF0.7 LAG INSULATION CLASSF TEMPERATURE RISE 85ROO C DESIGN AMB 45C
KVA 1214.29 EXCITER KVA PHASE 3 FIELD AMPS 5/ FREQUENCY50 HZ 2.5A EX. FIELD VOLT RPM1000 50 / 100 V VOLTS (PH-N/PH-PH)347V/600 V A regular preventive maintenance schedule will ensure peak performance, minimize breakdowns and maximize generator life. The schedule listed below is a guide for operating under standard conditions. Specific operating conditions may require reduced or increased maintenance intervals.
P age - 3
d) Clean the generator winding and coils using Compressed air and Orion 77. Clean rest of generator parts with MTO (Mineral Turpentine Oil). (See cleaning procedure, point 2A) e) Inspect rotor shaft and rotor shaft bearing journals for wear or scoring, send to General Workshop if metal filling etc. is required.
P age - 4
f) Check Insulation Resistance of main Stator & Rotor coils. (See the insulation resistance testing procedure, point 2F) g) Dry the windings to acceptable resistance level. (See the dry out procedure, point 2G) h) After Drying When Insulation Resistance reaches acceptable value, varnish Stator winding, Main Field, Exciter armature and Exciter Field windings with Epoxy Gel Coat (Red) & Hardener (EH 441) mixed in the ratio 3 : 1. Use thinner (Dr. beck thinner 221) as required. i) Replace the bearings and bearing caps. Grease Bearings with Castrol AP-3 j) Check wipers condition. If required change with new k) Check exciter parts and IR values l) Check all rectifiers with multi-meter. Change defective rectifiers m) Check Wiper. Replace if old one is defective/ got ceased n) Carry out necessary testing, at 35 rpm (by hand drive), minimum output voltage should be 1.0 V AC o) Paint alternator out side with desired color.
P age - 5
d) Clean inside of alternator using dry filtered compressed air at a pressure of 1.75 to 2.80Kg/sq.cm e) Clean stubborn accumulation of dirt and grease from windings and pole coils with Orion-77 f) Open terminal box, clean terminals with xylol. CAUTION: Do not file terminal bus bars.
P age - 6
Air-gap between Main field rotor & stator windings Top - 4.15 mm Side - 4.10 mm Side - 1.85 mm Side - 4.10 mm Air-gap between Exciter Armature & Fields Top - 2.3 mm Side - 1.85 mm 2C) Exciter Armature & Rotating Rectifier assembly Removal
Remove exciter armature and rotating diode wheel as separate units as per instruction given below. a) Remove exciter cover. Disconnect alternator field leads from positive(+) and negative(-) terminals located on the heat sink of the rotating rectifier assembly. Remove diode wheel by unscrewing the nut at the end of shaft. b) The diode wheel and exciter armature are SLIP FIT on alternator shaft. If the individual diode wheel and exciter armature cannot be removed by hand , use extraction holes provided alongwith puller as described below. CAUTION: Do not pull on rotating rectifier assembly. - Bolt to the end of the sleeve a metal plate and hook a bearing puller to the metal plate and pull the rotating rectifier assembly from the shaft. - The exciter armature hub is also provided with two M10 extraction holes. Use long studs and bolt the metal plate. Hook a bearing puller to the metal plate and pull the exciter armature assembly from the shaft same as that for diode wheel.
Bottom - 3.95 mm
Bottom - 1.70 mm
P age - 7
P age - 8
3. Apply 500 volts from the megger, and measure the resistance reading after one 1 minute. The reading must be a minimum of 1.6 mega ohm. If it is not, refer to the dry out procedures. 4. Ground the exciter field leads to the generator frame for several minutes after the megger has been disconnected. This will allow the voltage build up be properly discharged.
b) Exciter armature
1. Disconnect the exciter armature leads from the rotating rectifiers. 2. Connect the leads of exciter armature to one clamp of a 500 volt megger, and connect the other clamp to suitable connection on the shaft. 3. Apply 500 volts from the megger, and measure the resistance reading after 1 minute. The reading must be a minimum of 1.6 mega ohm. If it is not, refer to the dry out procedure. 4. Ground the exciter leads to the shaft after disconnecting the megger. This will allow the voltage build up to be properly discharged.
c) Main rotor
1. Disconnect the generator field leads from the positive and negative terminals of the rotating rectifier. 2. Connect the positive and negative leads to one clamp of the 500-volt megger, and connect the other clamp to the shaft. 3. Apply 500 volts from the megger, and measure the resistance reading after 1 minute. The reading must be a minimum of 1.6 mega ohm. If it is not, refer to the dry out procedures. 4. Ground the field leads to the shaft after disconnecting the megger. This will allow the voltage build up to be properly discharged. 1. Disconnect power connections and all control apparatus from the generator terminals. 2. Measure insulation resistance of each phase separately with the two other phases shorted to the frame. 3. Use a 500-volt megger connected between the lead(s) of the phase to be measured and generator frame. The minimum 1 minute insulation resistance must not be less than that given by following formula:
d) Main stator
P age - 9
Resistance in megaohms= Rated Generator voltage +1000 1000 If the resistance is less than above, refer to dry out procedures 4. Ground the leads to the frame after the 1 minute megger test. This will allow the voltage build up to be properly discharged.
measure insulation resistance Resistance Bridge To measure resistance of winding Special Tools Notes Bearing Puller For changing bearing Exciter Puller For pulling exciter armature Standard tools Notes Cable tool Crimping Flash light As required Grease Gun For lubricating bearing Hammer Soft-faced Lamp(incandescent) Safety light Screwdrivers Standard size as required Screwdrivers Philips, size as required Wrench Adjustable, 12-inch Wrench Torque 0 to 100ft-lb Wrench set Allen, 1/8 to inch Wrench set Socket, to 1 inch with 3/8 and inch drive
Page - 10
Wrench set Standard,open-end/box-end combination sized1/4 to 1 inch Vacuum Cleaner Electric with nonmetallic nozzle Materials Air Compressed, dry Corrosion inhibitor Nox-Rust VC # 10 Oil or equivalent Covering materials Waterproof desiccant bags for protection from moisture during long-term equipment storage. Detergent As required for cleaning Gloves Chemical-protective Gloves Electrical protective Heaters Space heater, for eliminating excess moisture in damp areas and dry out of motor or generator windings. Plastic Protection for long-term storage Rags As required for cleaning Water Warm & clean, for cleaning Tags Warning & caution
4) REFERENCES
a) Bearing Lubrication Refer KATO manual page no 34. b) Rectifier Tests:
Refer KATO manual page no 35. c) Disassembly Refer KATO manual page no 37 d) Assembly. Refer KATO manual page no 40 e) Troubleshooting (Corrective maintenance). Refer KATO manual page no 43. f) Maintenance of BHEL alternator BHEL alternator Maintenance Manual