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History Perawatan Generator

Unit #1dan Unit #2

Prepared by
Marsito B PSitompul
Planner Teknik

Reviewed and Approved by

Supono
Manager Teknik

Date Completed
3 August 2017

PT CahayaFajarKaltim
PLTU-Embalut 2x25MW
DesaTanjungBatu
TenggarongSeberang
KutaiKartanegara
2017

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REPORT INDEX

1. GENERATOR SPECIFICATION

2. GENERATOR FIRST YEARS INSPECTION 2009

3. GENERATOR MAJOR INSPECTION2013

4. GENERATOR MAJOR INSPECTION 2017

5. ANALISYS and RECOMMENDATION

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GENERATOR SPECIFICATION

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Generator Specification
Manufacture : Wuhan Steam Turbine & Generator Plant Wuhan, P.R China
Model : N-25-3.43
Daya : 25 MW
Steam Pressure : 3.43 Mpa
Steam Temperature : 435 ˚C
Speed : 3000 rpm

Unit Generatore : Wuhan

Model : QF-25-2
Daya : 25 MW
Cooler : Air cooler
Voltage : 6.3kV
Cos Φ : 0.8
Speed : 3000 rpm

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GENERATOR FIRST YEAR INSPECTION 2009

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JurnalGenerator First Year Inspection

No NamaPeralatan Kondisi (Hasiltemuan) Standard Tindakan yang dilakukan

1 Rotor dan stator Banyak debu yang Tidak ada debu Dibersihkandengan metode
generator menempel electric cleaner
Isolasiada yang mengelupas Tidak ada isolasi Revarnish insulating
terkelupas
2 Belitan stator Berdebu Tidak ada debu Dibersihkandengan metode
electric cleaner
Revarnish

Tidak ada record khusus mengenai stator wedges dan rotor winding, .

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GENERATOR MAJOR INSPECTION 2013

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Job Summary

Stator winding #1
 The actual condition of stator winding not so dirty.
 The stator cleaning was carried out, wedges stator was checked for any loosen of wedges, the results is
wedges are still tight, only 3 % for loose.
 Electric testing were carried on stator winding such as insulation and resistance test of winding, the result
are still in specification.
 Red varnish was put on stator winding.

Rotor winding #1
 The actual condition of field winding not so dirty,
 Thecleaning of field winding was carried.
 The electrical testing were done during this outage such as insulation and resistance test and the result still
good condition, no repair required
 The fluorescent penetrant was carried on generator retaining ring for checking any crack indication, the
result of fluorescent penetrant of generator retaining ring, no indication crack were found.
 Re varnish was applied on field winding, after all arecompleted.

Tidak ada record khusus untuk inspeksi wedges

Stator winding #2
 The actual condition of stator winding not so dirty.
 The stator cleaning was carried out,
 wedges stator was checked for any loosen of wedges, and based on mapping result, the stator wedges
need to replaced after found 2 slots with results morethan 30% tightness percentage per slot and have 5
suspected slots that have indication to be loosen.
 Electric testing were carried on stator winding such as insulation and resistance test of winding, the result
are still in specification.
 Red varnish was put on stator winding

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Rotor winding #2
 The actual condition of field winding not so dirty,
 the cleaning of field winding was carried.
 The electrical testing were done during this outage such as insulation and resistance test and the result still
good condition, no repair required.
 During the inspection it was found the 1 winding block on both turbine end and exciter end were moved from
it’s position.
 Due to no time for repair, it was decided by Customer ( PT. CahayaFajarKaltim) that no action to be taken
for repair it. However, 1 winding block at exciter end put back to the position without any treatment and 1
winding block at turbine end was removed.
 The fluorescent penetrant was carried on generator retaining ring for checking any crack indication, the
result of fluorescent penetrant of generator retaining ring, no indication crack were found.
 Re varnish was applied on field winding, afterall are completed

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.Wedges analisys #2

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TEST RESULT

The stator has 60 slots with 17 wedges each slots. The testing location start from the exciter end with 6
a’clock position as the first slot. From the test result obtained from the mapping found 8 wedges on the end
of slots are in looses condition and slot number 27, 28, 29, 30, 31, 32, 33 (7 slots ) need to be re-wedges
because of slots number 28 and 30 have more than 30% tightness percentage and the rest are already
have a suspected slot and wedges looses.

CONCLUSION

Stator wedges total amount are 1020 wedges devided by 17 wedges per slot. Base on mapping result, the
stator wedges need to be replace after found 2 slots with results more than 30%tigtness percentage per
slots and have 5 suspended slots that have indication to be loosen.

RECOMMENDATION

 Replace wedges on the slot numbers 27, 28, 29, 30, 31, 32, 33 on next major overhaul,
 Re-pack and tighten all slot, end wedges on next major overhaul.

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GENERATOR MAJOR INSPECTION 2017

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Job Summary
Current condition assessment :
 Stator wedges have experienced wide spreading loose at endwedge and moderate loose at
middle wedge…………………( TAKA, technical report summary, generator #1& #2 page 2
of 48).
 Endoscopic inspection through retaining rings ventilating holes and fan, is clearly shown
that rotor winding insulation is begin to degradation……………………………………( TAKA,
technical report summary, generator #1& #2 page 2 of 48).

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Wedges analisys #1

End wedges looseness inspection accessibility data sheet using EQUOTIP

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Tight = 3.0 pcs = 2.5%

Partial looses = 20.0 pcs = 16.7%
Complete looses = 97 pcs = 80.8%
Total Complete looses + partial looses = 117.0 pcs = 97.5%
Total No. of wedges = 120.0 pcs

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Middle wedges inspection manual tapping

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Tight = 419 pcs = 77.6%

Complete looses = 121 pcs = 22.4%
Total complete looses = 121 pcs = 22.4%
Total Middle wedges = 540 pcs

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Rotor winding Endoscopic inspection#1

Endoscopic inspection through underneath of the retaining ring are shown degradation of rotor winding
insulation,….

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PenyebabutamadiakibatkanpembebananMVAr yang terlampautinggi…..( TAKA, technical report summary,

generator #1 page 2 of 48)

RSO

Rotor winding was inspected using RSO, by injecting 1.0V at pole A and B frequency = 2.1Hz and 2Volt
with frequency = 2.1Hz,
RSO wave pattern was shown minor overlapping wave, it is mean minor insulation degradation was
occurered in the rotor insulation.

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Wedges analisys #2

End wedges looseness inspection accessibility data sheet using EQUOTIP

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Tight = 1.0 pcs = 0.8%

Partial looses = 19.0 pcs = 15.8%
Complete looses = 100 pcs = 83.3%
Total Complete looses + partial looses = 119.0 pcs = 99.2%
Total No. of wedges = 120.0 pcs

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Middle wedges inspection manual tapping

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Tight = 250 pcs = 46.3%

Complete looses = 290 pcs = 53.7%
Total complete looses = 290 pcs = 53.7%
Total Middle wedges = 540 pcs

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Rotor winding Endoscopic inspection#2

Endoscopic inspection through underneath of the retaining ring are shown degradation of rotor winding
insulation,….…..( TAKA, technical report summary, generator #2 page 13 of 50)

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RSO
Rotor winding was inspected using RSO, by injecting 2.0V at pole A and B frequency = 2.4Hz
RSO wave pattern was shown minor mismatch overlapping wave, it is mean minor insulation degradation
was occurered in the rotor insulation.

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ANALISYS
chart comparison base on SULZER recommendation result and TAKA recommendation result, in
endwedges slot 27, 28, 29, 30, 31, 32, 33 stator generator unit #2.

1000

900 880 MI2013W

800

700 680
670 651 652
600 616 MI2013E
568
528 540
500 480
462 479 470 470
400 400 409 420
357 369 380 MI2017W
325 331
300
272
200 220
180 190
100 MI2017E
80 90
0
Slot 27 Slot 28 Slot 29 Slot 30 Slot 31 Slot 32 Slot 33

≥700 Nmm : Tight, 550 ~ <700 Nmm : partial loose, < 500 Nmm : Complete Loose

there are 1 wedge with tight condition, 1 wedges almost loose, and 12 wedges are loose ( from Major
Inspection 2013 )
there are 0 wedge with tight condition, 3 wedges almost loose, and 11 wedges are loose ( from major
Inspection 2017)

from Major Inspection 2013 sample slots and Major Inspection 2017 sample slots we can take a
conclusion, that 14 endwedges from 7 stator slots are definitely loose, and need to be repairing.
others slots neet to be checked on next overhaul.

Blocking coil issue,

from SULZER report arose recommendation to repair rotor generator, since it was found the stator block
was moved from original position, they said if not repaired soon, during operation copper winding will
expand extremely, destructive behavior to others wedges and possible to be failure.
TAKAs inspection report also re-enforce that block of rotor generatore need to be repaired soon, due to
insulation and block are loose.

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RECOMMENDATIONS

1. Based on SULZER Electrical Report page 313 – 315 and TAKA Electrical Report page 43 – 49
(unit #2), page 45 – 48 (Unit #1), highly recommended taking an action sooner, for replace the
stator wedges, ect…due to TAKA Electrical Report page 49, Recommendation.
duration estimating time for repairing, are :
 need 3 ~ 4 weeks for dismantle and reassembly

2. based on SULZER and TAKA report about blocking coil of rotor generator, highly recommended to
repair the rotor blocking coil.
duration estimating time for repairing, are :
 need 3 ~ 4 weeks for dismantle and reassembly
 need 1 week for balancing rotor
 need 1 weeks pull-out, pull-in, reassembling generator
 need 2 weeks for mobilization (if can’t repaired on site)

Turbo generator rotor service

 remove piping, pedestal upper bearing & cover generator .................................................... 1 day
 pull-out rotor generator ........................................................................................................... 1 day
 perform electrical test (stator, rotor) ..................................................................................... 1 day
 Test and Inspections ................................................................................................................ 2 day
 Inspection of endwindings ....................................................................................................... 1 day
 removal of retaining rings ........................................................................................................ 2 day
 radial hydrogen seal replacement ........................................................................................... 1 day
 re-wedging .............................................................................................................................. 15 day
 partial / complete rewinds and balancing ............................................................................. 18 day
 perform RSO test (rotor winding) before after ........................................................................ 1 day
 perform stator wedges MAP and record before after ............................................................. 1 day
 perform re-varnish winding rotor ........................................................................................... 1 day
 pull-in rotor generator ............................................................................................................. 1 day
 install bearing and pedestal ..................................................................................................... 1 day
 Trial ........................................................................................................................................... 1 day
Total days 48 days

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