Frame 6 Users Group Meeting

June 14, 2006

Phoenix, Arizona

Recommended
Generator System
Testing and Why!
 Routine Maintenance Program
for the Generator System

Reliability of the Generating System

Dodgethe costs associated with a

Major Breakdown or Failure!

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Routine Maintenance Program
for the Generator System

MUST BE COST
$$$
EFFECTIVE

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Routine Maintenance Program
for the Generator System

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Routine Maintenance Program
for the Generator System

1. How Often?

2. What to Test?

3. Visual Exam / Inspection!

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Routine Maintenance Program
for the Generator System

During regularly scheduled

Minor Maintenance Outages

(18 24 Month Cycle)

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Routine Maintenance Program
for the Generator System

Develop Records as a
Reference File.

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Routine Maintenance Program
for the Generator System

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 Routine Maintenance Program
for the Generator System

40 Relay Trips
Record all Short Circuit Faults
incidents of Lightning Strikes
mis-operation Full-Load Rejection
Regulator Problems
along with Unexplained Alarms
your Overload / Amps
Maintenance Overvoltage
Major VAR Swings
Records

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 Routine Maintenance Program
for the Generator System
What to include?
64F GAC NGT
ROTATING DIODE BRIDGE
HV MAIN BUS
STATOR FIELD
LA / SURGE CAPS 52G
HV NEUTRAL BUS 10
 Routine Maintenance Program
for the Generator System
What to include? (cont.)
RTDS TRANSDUCERS
PT ALARMS PPT
SYNCHRONIZING SYSTEM
TRIP TESTS
CONTROL LOGIC METERS
PROTECTIVE RELAYS 11
Routine Maintenance Program
for the Generator System
What to include? (cont.)

EXCITATION SYSTEM
FUSE SIZING
NERC COMPLIANCE
SHAFT GROUNDING
VOLTAGE REGULATOR 12
 Routine Maintenance Program
for the Generator System
TESTING EQUIPMENT
CLAMP-ON
(calibrated)
AMMETERS
OSCILLOSCOPE
mA / mV TTR
MEGGER SOURCE

RELAY
TEST SET CAMERA DVMs
TORQUE
WRENCH
VACUUM

DC POWER CLEANING
OSCILLOGRAPH
SUPPLY SUPPLIES
DUCTOR

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 Routine Maintenance Program
for the Generator System
VISUAL INSPECTION / ODORS?
(eyes, nose, cameras, boroscopes, mirrors, etc.)
LOOSE WIRES RUST
LOOSE
COVERS

WATER
LEAKS

OIL LEAKS

RACCOONS
EXCESS
BRUSH HEATING
CHATTER SNAKES
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 Generator Field
I. INSULATION TESTING (500 Volt Megger)
To determine the integrity
(moisture, contamination,
etc.) of the Generator Field
Windings.
Two factors:
1. Resistance level per
megger reading.
2. P.I. Value
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 Generator Field
I. INSULATION TESTING (500 Volt Megger) cont.
P.I. = Polarization Index
10 min Reading
= P.I.
1 min Reading
P.I.for Field should be
1.25 or higher

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Generator Field

II. FIELD WINDING COPPER

RESISTANCE CHECK

DLRO - Digital Low Resistance Ohmeter

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 Generator Field
III. BRUSH RIGGING & COLLECTOR RINGS
a) Clean
b) Surface Inspection
c) Check for Brush Wear & Spring Force
d) Check Clearances
e) Check Tightness
f) Check for brush bounce and sparking
during operation
g) Brush Rigging Insulation check

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Generator Field
IV. SHORTED TURNS

High Field Amps to attain rated K.V.

Overexcitation Limiter pickups at low VAR
levels.

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Generator Field
IV. SHORTED TURNS cont.

Impedance Testing
Installed Flux Probe

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64F Field Ground Detector

Field is Ungrounded!

Field Ground can be

detected from rotating
field back through the
excitation system.

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64F Field Ground Detector

A second ground on
the Generator Field is
not a good thing.

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64F Field Ground Detector
Maintenance
1. Operational Test
solid ground at
Collector Rings.
2. Verify minimum
resistance-to-ground
pickup.
3. Verify Output: Alarm
& Trip.
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Generator Stator

Power Factor
Doble
AC s c
Di
Pa arg
T

rti e
h
O

al
P
HI
AC
DC HIPOT
IR /
PI T
estin
g
d
Ci
Re s
Win nce
EL
ista
din
g

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Generator Stator
I. INSULTATION TESTING (5000 Volt Megger)

Two Factors:
1. Resistance Level
2. P.I. Value (2.5 or higher)

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Generator Stator
II. STATOR WINDING COPPER
RESISTANCE CHECK

Use DLRO
Record Stator Temperature at
various RTD locations.

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Generator Stator
III. END WINDING INSPECTION

Cleanliness
Overheating
Damage, etc.

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Generator Stator
IV. OPERATION CHECK OF THE
GENERATOR HEATERS

a) Sequence check by
operating 52G Aux.
Relay
b) Record Amps /
Phase

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HV Neutral Bus

Inspect

Clean

Check Compartment
Strip Heaters

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Neutral Grounding
Inspect
Clean
IR Checks with
Megger; (1000 Volts)
H winding GRD
L winding GRD
H winding L winding

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Neutral Grounding
Transformer Turns Ratio Check
Check Secondary Resistor
Verify Proper Circuit Connections

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HV Main Bus

Inspect

Clean

Verify operation of all

compartment strip
heaters

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Lightning Arrestors / Surge
Capacitors
Inspection
Areground
connections tight?
Clean
Megger Checks
(with Stator Windings)

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Generator Auxiliary Compartment
Inspect
Check for water
tightness of side walls,
doors & roof joints.
Clean
Verify all strip heaters
are operating.
AC Lights and
Receptacles & DC
Emergency Lights
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 52G Generator Breaker
Mechanical Inspection of Breaker &
Racking Mechanism
Binding?
Grease as required

Hipot of the Vacuum

Bottle**
Electrical Operational
Checks
Close & trip
Spring charging
52GX Aux. Relays 36
52G Generator Breaker
Inspection of the 52G
Compartment
Evidence of water
Tightness of
connections
Clean
Record Breaker
Counter

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Potential Transformers (PT)

Clean & Inspect the Drawers

HV & LV Fuse Check
Megger Checks
TTR

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Power Potential Transformer (PPT)
(Excitation Power Source)

Clean and inspect

Megger Checks
HV Winding Grd
LV Winding Grd
HV LV Winding

TTR

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Protective Relays
Inspect
Clean
Operational Tests
Settings/Calibration
Tests

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Protective Relays

Record of all Relay

Trips
Actions Taken
following Trip
Causes Found

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Protective Relays
Settings Review
System Changes to be
accounted for
NERC, following
August 03 blackout,
recommends review of
settings as they relate
to performance during
System Disturbances
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Protective Relays
On Digital Relays, check the set-up of the
Oscillography & Events Recorder
Be prepared
Great troubleshooting
tool for causes of
trips.

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Generator RTDs
Check calibration of all RTDs at Incoming
TB (Generator Control Panel).
Verify operation/calibration of the
Generator Temperature Meter.
Verify pickup and operation of the 49G
Generator Temperature Relay.

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Meters
Calibration Check:
WM
VARM
AM
VM
FM
FAM
FVM
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Transducers

Transducer
Outputs to:
Turbine Control
SCADA System
Meters

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Transducers
Calibration Check:
Zero & Range
4-20mA Output
(or 0-1mA)
Verify Scaling
Inputs utilizing the
4-20mA Transducer
Outputs. 47
Synchronizing
Meter Calibration Check
IncomingVM
Running VM

Monitor Synchroscope at
Closing
Does it close at 12 oclock?

Monitor VAR Flow at

Closing

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Alarms / Annunciators
Fault Transfer
Gen Field Exciter Rectifier
to Manual
Ground Overvoltage Temperature
Regulator
Alarm Alarm HI Alarm
Alarm

Generator
Minimum Bus
Volts Per Over-
Excitation Undervoltage
Hertz Alarm temperature
Limit Alarm Alarm
Alarm

Sequence / Verify all Alarms

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Alarms / Annunciators cont.

Generator Generator Loss of Over-

Loss of PT
Ground Lockout Excitation frequency
Alarm
Alarm Trip Alarm Trip Alarm Alarm

Take Time to Re-familiarize Yourself

What does this mean?
Critical or Non-critical?
Action required?
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Control Sequencing
Proof Test of all Control Circuitry to
verify even seldom utilized circuits.
Examples:
AVR Setpoint R/L & Runback
MVR Setpoint R/L & Runback
Rectifier B-U Cooling Fan
59E Overvoltage Relay
All System TD Relays 51
Control Sequencing cont.
Proof Test of all Control Circuitry to
verify even seldom utilized circuits.
Examples: cont.
Regulator Transfer Logic
Field Flashing / Startup
Power Supply Source Power Transfer
52G Breaker Close / Trip

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Trip Tests 64B
40
24
64G
50/51 64F
87T
87G
86G
59E
86T

TRIP
52G
T 52G TRIP
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EXC.
50
86RE 51V 46

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Fuse Sizing

Are they all in the correct location?

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Excitation / Voltage Regulators

Pre-Excitation System Checks

(with Unit down)

Off-Line / FSNL System Checks

On-Line System Checks

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 Excitation / Voltage Regulators
Pre-Excitation Checks:
PCB inspection
Flashing circuit check
(resistor & diode)
Field Overvoltage
Protection Calibration
& Function check
Power Supply check
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 Excitation / Voltage Regulators
Pre-Excitation Checks:
Verify all
Potentiometer
Setpoints
Verify Gain Settings
Transducer (DCPT)
Calibration checks
Functional Check of
AVR
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 Excitation / Voltage Regulators
Pre-Excitation Checks:

Functional Check of MVR

Inspection / tests of Power
Rectifier Bridge(s)
Check integrity of the
Shaft Voltage
Suppression Circuit

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Excitation / Voltage Regulators
Off-Line Checks: (FSNL)
Verify Flashing
Timing/Amps
Monitor MVR to AVR
transfer
Verify VFNL Setpoint
of AVR (Runback)

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 Excitation / Voltage Regulators
Off-Line Checks: (FSNL)
Record VFNL data for
future reference:
KV, PT Volts, PPT Volts,
PPT Amps, PCB Test
Points, Field Amps, Field
Volts, etc.
Check Field Voltage Waveshape & record
Verify Firing Circuit Data
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Excitation / Voltage Regulators
Off-Line Checks: (FSNL)
Check/record all
system gain, lead,
lag, loop gain, etc.
Verify operation of all
limiters
(overexcitation, V/Hz,
etc.)
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 Excitation / Voltage Regulators
On-Line Checks:
Monitor MVAR bump
Verify operation and
Proof Test of ALL
limiters (URAL,
overexcitation, etc.)
Record operating data
at varying load points
(for future reference)
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Shaft Grounding Brush

Helps prevent
damage to bearings
via electrical
discharge through
the oil films.

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Shaft Grounding Brush
Provides a low
impedance path to
ground so current
flow due to the
360 Hz ripple
goes to ground,
bypassing the
bearings.

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 Shaft Grounding Brush
Inspection
Clean
Remove surface glaze
on brush
Check spring force &
brush holder gap
Using oscilloscope,
check shaft-to-ground
voltage (6 volts, 0-to-
peak)
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NERC Compliance Testing
NORTH AMERICAN ELECTRIC
RELIABILITY COUNCIL

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NERC Compliance Testing
Actual Reactive Capability Range
Excitation System Models (data validated
by tests)
Generator characteristics (verified by tests)
Governor Droop / Deadband Proof Tests

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NERC Compliance Testing
Model & Proof Test of Excitation Limiters
Generator Protective Relay Testing &
verification that settings are coordinated
with the Excitation Limiters
Operation in AVR only (Performance
Proof Test)
Power System Stabilizer operating and
verify Model (WECC)
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NERC Compliance Testing

An actual power swing test of a Power System Stabilizer. The voltage

setpoint was given a 2% step up then 5 seconds later returned to normal.
The red chart above shows the KW swing with the Power System
Stabilizer turned off and the green chart shows the KW swing with the
Power System Stabilizer enabled. Of note is the much faster damping of
the stabilized wave form.
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Questions?

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Rotating Diode Bridge

Rectifies the AC output of the Rotating

Exciter for direct input to the generator field.
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 Rotating Diode Bridge
Variety of Packages & Configurations:
Stud Mounted
Press Pack (hockey puck)
Single or Dual Diode
Modules

Fig 3: Westinghouse Mark III Exciter Diode Assembly

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Rotating Diode Bridge
Common Reasons for Failures

Transients on the Electrical Power Feed.

Faulty or wrong replacement component
installed.
Surface leakage due to dirt & moisture.

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Rotating Diode Bridge
Common Reasons for Failures (cont.)

dV / dT
Low Resistance Short in Generator Field
windings or leads.
Improper installation.

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Rotating Diode Bridge

One of the most important conditions for

testing the diodes is that the rated voltage

MUST NEVER
be exceeded.

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Rotating Diode Bridge

Meggers & Hi-Pot Test set should not

be used they can easily damage
the components.

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Rotating Diode Bridge

Ohm meters are only reliable to detect

a Short, since they do not have
enough voltage to properly energize
the silicon wafer in a
Power Semiconductor.

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Rotating Diode Bridge

Test Diodes
Clean Components!!
Dirt & moisture can cause surface leakage

Check Connections
Verify Assembly Components (Varisters,
Resistors, Filtering Circuits, etc.)

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