Ve spc Report of ; Ingenieurburo fur Maschinendiagnose | findings ae Uecer @ Schalke Diagnostic een 03 / 2007 etree enwor 7b Wane ‘Oni Datum Pie, Date Lanen power plant Andisleben, 08 March 2007 Tye “Arlagenibesuch Exarination Pood THRI 92/37 06 March 2007 ‘Besta Ne 7B NE ‘Supplier numbar ~ “Thema TAalaas 7 Sabet Vertassar Tal Tahoe ‘Small generator inspection Mr. Schilke / +49 (0) 3643 496690 ‘7 ZUSAMMENFASSUNG / SUMMARY Text pages: & ‘The following checks and measurements have been performed during a small inspection on the generator: isassembly / assembly of TE/EE top end shields; = Open / close top bearing shells; - Visual inspection of all accessible parts; - Visual bearing inspection; - Measurement of winding insulation and winding resistance values; + Electrical check atthe temperature sensors (The rotor has not been disassembled for performing the small inspection.) Fact-finding has been carried out by visual inspections at the components which were accessible from the ‘outside. In addition, electrical and visual inspections have been performed at the opened generator leads and terminal boxes. ‘The evaluation ofthe fact-finding results shown below allows the conclusion that all generator assemblies accessible from the outside are in a serviceable condition, Please make certain to observe the recommendations described in section 5 Participating personnel: Mr. Schulke ‘SDC Ingeniourbaro far Maschinendiagnose Mr. Lieder, D. SDC Ingenieurbaro far Maschinendiagnose Mr. Schulze ‘SDC Ingenieurbtiro fur Maschinendiagnose Mr. Rauch Lonrmann Montage Ltd. Mr. Kienzle Lonrmann Montage Ltd. Me Lanza Empresa Electrica Guaracachi S.A. ‘Unterschvit Veriassor ‘Sgnature of Autor Veraler - Distue 1 eotrmann Mortage Li |VESDC Ingenieurboo fo Mascrinendtagnes, machine fle spc Blatt /Page tSF soc Report of “@, | Ingenieurboro for Maschinendiagnose | findings Lieder & Schalke 03/2007 1.0 Generator output data: Manufacturer /type Siemens / THR! 92/37 Machine number 12-7021 Voltage 40500 V + 5% Current 6870 Power factor 0.80 Power Si 125,000 kVA Rotational speed 3,000 tpm Frequency 50H Direction of rotation « only vuw Excitation 420V/ 8254 Insulation class F 41.4 General information Operational designation: ‘Type of drive Bearing data: Cooling method: Generator 4 Steam turbine, directly coupled ‘White metal journal bearing, TE and EE insulated Hydrogen cooling, circulation through water cooler, above-fioor 2.0 Visual findings - generator stator Winding condition ‘TE and EE showing slight dry dust contamination; no damage visible outside End.winding 'No signs of local overheating; tight insulation; no damage to cover layers; no connections Visible deformation End-winding Tight, no visible damage. insulation: End.winding spacer No visible friction or chafing. arrangement: Winding overhang No signs of relative motion were detected: in working order. support Connecting lines: EE = SS, not accessible. Output cables! Not accessibie, bushings Slot wedges: Drive strip, no axial displacement as far as visible, Laminated core No visible loosening or fiction dust formation atthe step-shaped laminated core chamfer: ‘edges, as far as could be seen Core end plates: No signs of local heating Lacquer coating Red insulating vamish, closed elastic coat spc Blatt / Page 2Oe" Commissioning Ingenieurboro fur Maschinendiagnose Lieder & Schalke Report of findings 03/2007 2.4 Visual findings ~ rotor No visible damage to the cap surface. (One axialiow fan on every side; no signs of damage or deformation; ring test No visible conductor damage in the accessible sections. Surface of the 2 slip rings (slotted) slightly indented: firm seating on slip ring Retaining Fingsirtaining ring seats: Balancing weights EE 7 pos, tight, secured DE 6 pes, tight, secured Crack inspection: Not performed. Fan blades: ok, ‘Slot wedges! Not accessible. locking: End-windings: End-winding spacer _No visible defects. arrangement: Collector ring status! seat ‘body, corroded surface. Brush rocker: No visible defects, in working order Carbon brushes: Not available. 3.0 Metrological findings Measuring equipment: ‘Thomson bridge PT 100 (embedded thermometer) and PT 100 measuring accessories Metrahit TRMS digital multimeter ‘Metriso 5000 A insulation resistance meter (measuring range: 100 V - 5000 V) CA megohmmeter 8547 (OAR, PI factors) 3.1. Generator stator Winding resistance values, winding temperature 18 °C. ut-u2 vi-v2 wi -w2 25ma 25 ma 21.25ma Insulation resistance values, winding temperature 18 °C U-v =677M0 Measuring voltage 5,000V DC Vv-W =657M0 Measuring voltage 5,000V DC W-U =540M0 ‘Measuring voltage 5,000V DC Winding Winding Re Ras Raz | DARTactor | Pifactor | capacitance Urua=t | sama | soma | aaeMa | 116 125 O3tt oF Viv2>1 | 360Ma_| 401MQ_| 465Ma 112 17 O3Tt uF Wiw2>1 | 238Mo_| 279Mo | 498MO a7 178 Ost oF spc Blatt Page 3spc Report of Ingenieurburo far Maschinendiagnose | findings Lieder & Scholke | 03/2007 ‘Stator core slot resistance temperature detector We 207 202 205 20 205 206. Ring 7220 | 1233 | 1237 | 1228 | 72a. 122.4 Ryo in GO 10 5 5 18 20 18 3.2, Bearing thermometer [TE teh: Resistance: 2x 4.30 TE left: Insulation resistance: 150 M2. (TE right Resistance: 2x 4.46 2 TE right: Insulation resistance: 25 MO EE let Resistance: 2x 4.32.0 EE let Ineulation resistance: 1200 EE fight: Resistance: 2x 4.38.0 EE right: Insulation resistance: _ 80 Ma. 3.3. Gas thermometer TET 211-212 Resistance 110500 213-214:Resistance: 110.300 TE2 217-218 Resistance: 110.18. 219-220:Resistance: 110200 EE 1 239-240: Resistance: 110.000 _241-242:Resistance: 110.04 0. TE insulation resistance - 6 Ga 260) TE 2 ineulation resistance : 30 Ga (250 V) EE insulation resistance: 10 Gr (250 V) 3.4. Generator rotor Inductor insulation resistance, at 18 °C F1-1=1000Ma ‘Measuring voltage 500 V DC Voltage drops at the exciter current conductor connections, measuring current: 98.4 A DC ‘The diagram below shows the position of every contact point, and the table lists the measured voltage drops inmv. 1 2 3 1 4 Slip ring 2 Link 3 Bot Measuring point 42 7, ‘External Ring 084 mv. 704 mv Internal Ring (0.20 mv. 046m SDC Blatt Page 4spc Report of, | Ingenieurbaro far Maschinendiagnose | findings Lieder & Schalke ‘Service Diagnostic ‘Commissioning 03/2007 4.0 Visual bearing component inspection TE bearing “The bearing bottom shell presents grooves, running marks, and slight contamination in the running area of the oi lift parts. ‘The upper shell has grooves and discoloration marks, The white metal presents no cracks and no chipped spots. The lif pressure hoses are al right a8 far as visible, EE bearing ‘The bearing bottom shell presents grooves, running marks, and slight contamination in the running area of the oll it pars. ‘The upper shell has grooves and discoloration marks. ‘The white metal presents no cracks and no chipped spots. ‘The lift pressure hoses are all ight a8 far as visible Labyrinth rings ‘The labyrinth rings present normal discoloration or wearing marks. Shaft ‘The shaft bearing surfaces present visible running marks which can hardly be felt. There are no mechanical ‘damages or heating sympioms, 44 Lateral and diametral bearing clearances ‘Auxiliary materials: Feeler gauge / lead wire / micrometer gauge [Measuring point | Lateral clearance | Measuring point | Lateral clearance | ‘TE bearing [mm] EE bearing [mm Wei O58. WIR 0.80. WK right 0.60, WK right 0.58. Front eft 0.58. Rear left 0.80. Front right, 0.60 Rear right 0.58 Diametral 035 Diametral 040 dlearance clearance, WK end.wvinding end = generator end font = drive end. rear = exciter end left/right as seen from drive end to generator end spc Blatt Page $7, | y Lieder & Schiilke Diagnostic ‘Commissioning 0312007 spc Report of Ingenieurbiro fur Maschinendiagnose | findings 4.3. Bearing block labyrinth rings. Measured values in {mm} measured using a feeler gauge: TE ond winding TE coupling end 2 038 014 —|— 022 0.24} — 026 oo ona EE end winding EE exciter end 30 0.30 016 —| 02 a o 0.10 ‘The bearing inspection did not yield any negative diagnostic findings. There is no objection to the continued Use of the bearings. The bearings should be smoothened or reworked during reassembly. The rubber ‘gaskets or Kautasit gaskets forthe oil scraper rings or bearing applications have to be replaced. ‘The covers and plates have been reinstalled on the generator after completing the inspection. 5.0 Evaluation of inspection {A visual inspection of all assemblies accessible at the generator stator and rotor was carried out, and all ‘ohmic and insulation resistance values were measured during this inspection without rotor removal ‘The effective insulation resistance values ofthe stator windings are good. But the measured polarization index PI indicates humidity forall 3 phase windings. ‘These measurements should be carried cut in every case afler reinstaling the generator in the new power plant ‘The value has been assessed by applying the folowing cxiteria DAR PI__| Insulation condition =1.25 <1 | Insufficient <2__| Action required [ =i8 <4 | Good. 16 34 | Excellent ‘The winding should be dried when the PI factor falls below 2 again. We recommend the use of a Munters dryer for this purpose, Adapter disks are mounted to the generator at present. “The slip rings need to be ground off or skimmed before start-up. spc iat / Page S sDC Blatt / Page &i ‘spc Report of Secs "jg. | Ingenieurburo for Maschinendiagnose _| findings Lieder & Schdike Diagnostic ‘Commissioning ee ‘The exciter end bearing block insulation should be replaced (see figures 1 and 2) Figure 1 Figure 2 ‘The use of NKF 634 (Morgan Carbone) 32x32x64 in combination with plug-in brush holders (write 130 oN thrust piece) made by Shunk should be considered as no carbon brushes and no brush holders are available. No shaft earthing/grounding brush is available either but needs to be installed at the TE housing as a ‘mandatory concition prior to start-up. Preferably, two double brush holders offset at an angle of 80° should be used in combination with 2 two-layer carbon brushes (EGSU/AG20).. Bush holier Grounding brush with siver {Grounding brush with carbon layer Brush spindle, Rotor shaft 20 30 spc Blatt /Page 7|soc Report of “@,|Ingenieurburo fur Maschinendiagnose | fncings Service 4 5 | Lieder & Schilke pean | 03 / 2007 Se | The slot closure wedges should be checked when the inductor is removed. It is expected that wave-spring ‘wedges will be used in this generator again. These wedges are also subject to an aging process. ‘A determined residual spring excursion must be implemented, depending on the strength of the installed resilient comugated packing strip. Otherwise, bar retention inthe slot would not be guaranteed any longer, ‘and damage might be caused to the bar insulation due to relative movements in the long run. SDC lat /Poge 6