REPORT ON UNIT-3

DHAULIGANGA POWER STATION

NHPC LTD., DHARCHULA.

Prepared & submitted by:

Power House Electrical Maintenance

Page 1 of 55
 INDEX

Sl.No. Description Page No.

01 Chapter-1- History 3-4

02 Chapter-2 – Incident 5-7

03 Chapter-3 – Concoction 8-10

04 Chapter-4 – Fault localization 11-13

05 Chapter-5 – Faulty Induction Brazing Machine 14-17

06 Chapter-6 - Testing of New Stator Bar 18-22

07 Chapter-7 – Stator Round Packing Device 23

08 Chapter-8 – De-Brazing & Dismantling of Stator Bar 24-26

09 Chapter-9 – New Stator Bar Fixing 27-28

10 Chapter-10 – Impediment to Work 29-30

11 Chapter-11 – Conclusion 31

12 Chapter-12 - Test Results 32-49

13 Chapter-13 - Copy of MOM 50-54

14 Chapter-14 - The Team 55

Page 2 of 55
 CHAPTER-1

History: The Dhauliganga Power Station is constructed on river

Dhauliganga in Pithoragarh District, Uttrakhand. It is an Underground
Power Station with four generating units of 70 MW capacities each.The
Power Station was submerged in the flash flood of 16/17.06.2013. The
units and its auxiliaries were doused in water for more than three
months. The units were restored in year 2014. since restoration the
units are running on full swing.

After completion of more than five years of restoration the power

station decided to conduct condition monitoring tests on its Generator
and Step up Transformer. A Work order no. NH/DG/PCS/1549/2018/350 dt.
14.12.2018 was issued to M/s. CPRI, Bengaluru for conducting condition
monitoring test/Diagnostic test on Generator (04 nos) & Generator
Transformers (12 nos.)of Dhauliganga Power Station. The scope of work
includes following condition monitoring tests:

A. Generator Transformer
a. Insulation Resistance and Polarization Index measurement
b. Tan Delta and capacitance Measurement.
c. Moisture content in insulation by Recovery Voltage
measurement analysis.
d. Short circuit Impedance.
e. Winding Resistance Measurement
f. Magnetizing current measurement
g. Sweep frequency response analysis
h. Transformer Turn Ratio

B. Generator
a. Stator
i. Insulation Resistance and Polarization Index
Measurement
ii. Tan delta and Capacitance measurement

Page 3 of 55
 iii. Winding Resistance Measurement
iv. Partial Discharge Measurement
v. DC Leakage current measurement
vi. Surge Comparison Test
b. Rotor
i. Insulation Resistance and Polarization Index
Measurement
ii. Field impedance Measurement
iii. Pole Voltage Drop Measurement
iv. Recurrent Surge oscilograph (RSO)
v. Conductor Resistance Measurement.

Annual maintenance of unit-3 has been started on 25.02.2019. The

dismantling works was started after taking Permit to work and
isolation of unit. Pre-maintenance testing for electrical equipment
has been done and below are the testing results of Generator stator
winding IR and PI:

IR AND PI VALUE
Unit-3 IR VALUE (Mega Ohm) TEMP- 38 Deg. Cel.
Configuration (Applied 15 sec. 60 sec. 600 sec. P.I. (600 SEC./60 SEC)
voltage 2500 V)
Generator Over all 10.63 11.40 11.74 1.03
(Capacitance in Circuit)
R+Y+B-E 105 272 984 3.61
R-Y+B+E 237 676 2220 3.28
Y-R+B+E 242 699 2240 3.20
B-R+Y+E 295 908 2480 2.73
R-Y (B+E) 545 1680 5350 3.18
Y-B (R+E) 451 1236 4860 3.93
B-R (Y+E) 450 1180 4710 3.99
ROTOR (250 v) 101.3 101.4

Cleaning of stator winding and Rotor pole was started on 02.03.2019

and completed on 08.03.2019.

Representative of M/s. CPRI has been arrived at site on 07.03.2019.

M/s. CPRI has conducted its condition monitoring test on 03 Nos. Gen.
Transformers of Unit-3 in 02 days i.e. from 07.03.2019 to 08.03.2019.

Page 4 of 55
 CHAPTER-2

Incident: Representative of M/s. CPRI started tests on Generator on

09.03.2019. The tests on stator and rotor were conducted as per the
scope of work. The test results for rotor tests are as tabled below

IR AND PI VALUE
Unit-3 IR VALUE (Mega Ohm) Testing equip.
Make Megger, Model S1 5010
Configuration (Applied 15 sec. 60 sec. 600 sec. P.I. (600 SEC./60 SEC)
voltage 500 V)
ROTOR (500 v) 224 229 241 1.06

FIELD IMPEDANCE TEST

Sl. NO. MEASURED MEASURED IMPEDANCE Remarks
VOLT. (V) CURRENT (A) (Ohm)
01 10.52 0.17 61.88
02 20.97 0.35 59.91
03 30.64 0.52 58.92
04 40.1 0.68 58.97
05 50.7 0.87 58.27
06 60.2 1.03 58.44
07 70.0 1.19 58.82
08 80.2 1.36 58.97
09 90.2 1.53 58.95
10 100.0 1.69 59.17
11 110.2 1.86 59.24
12 120.8 2.04 59.21
13 130.2 2.20 59.18
14 140.0 2.35 59.57
POLE DROP TEST
Pole. No. MEASURED VOLT. (V) Remarks
01 10.13
02 10.11
03 9.73
04 10.35
05 10.14
06 10.24
07 9.92
08 10.24
09 9.89
10 10.18
11 9.85
12 9.93
13 9.65
14 10.00
Page 5 of 55
 WINDING RESISTANCE MEASUREMENT
APPLIED CURRENT MEASURED CURRENT Testing equip.
20 AMP 62.430 m Ohm Make- Raytech,
Model – WR50-2

Recurrent Surge was also measured and graph plot in oscilograph was
satisfactory.

After completion of Rotor test Stator test was started. Insulation

resistance of the stator was measured and result is as tabled below:

IR AND PI VALUE
Unit-3 IR VALUE (Mega Ohm) Testing equip.
Make Megger, Model S1 5010
Configuration (Applied 15 sec. 60 sec. 600 sec. P.I. (600 SEC./60 SEC)
voltage 2500 V)
R-Y+B+E 274 745 2430 3.26
Y-R+B+E 316 935 2350 2.51
B-R+Y+E 531 1140 2500 2.20

Winding resistance of stator winding was measured and the results are
as tabled below:

WINDING RESISTANCE MEASUREMENT (Testing equip. Make- Raytech, Model – WR50-2)

R1 R2 Y1 Y2 Y1 Y2
(UPPER PATH) (LOWER PATH) (UPPER PATH) (LOWER PATH) (UPPER PATH) (LOWER PATH)
5.5865 m Ω 5.61155 m Ω 5.5865 m Ω 5.5960 m Ω 5.6130 m Ω 5.6035 m Ω

DC leakage current of stator winding test was started. In DC Leakage

test, stepped dc voltage was applied in between copper conductor
and the ground wall insulation of the generator stator
winding. Then current through the insulation vs. applied voltage is
recorded. In this test, a dc voltage in step of 1000 volt each for 1
min was applied and The leakage current variation with respect to
the applied voltage is measured. The measured value is as tabled
below:

DC LEAKAGE CURRENT MEASUREMENT

VOLTAGE( V) R- PHASE Y- PHASE B- PHASE REMARKS
1000 1.20 µ A 1.00 µ A 0.90 µ A Testing equip.
2000 1.90 µ A 1.80 µ A 1.70 µ A Make Baker,
3000 2.70 µ A 2.70 µ A 2.50 µ A Model AWA-IV
4000 3.30 µ A 3.40 µ A 10.40 µ A
5000 4.40 µ A 4.60 µ A 102 µ A Testing Unit tripped
after 9 Sec.
Page 6 of 55
During the DC Leakage current measurement on stator winding there was
slight variation in results of B-Phase winding in comparison with
other two windings i.e. R- Phase and Y- Phase. The testing equipment
was tripped with the rise of current upto the 102 micro amps.

In view of some eventualities an Insulation resistance measurement of

B- Phase was conducted which resulted 0 with respect to earth.

Accordingly, matter was discussed telephonically with generator expert

of OEM and concluded that bar would be replaced for rectification of
fault.

Page 7 of 55
 CHAPTER-3

Concoction: The OEM I.e. M/s. GE Power India Limited (GEPIL) was
recommended for localization of fault and replacement of faulty stator
bar. The preparation for the same in line with the recommendation of
OEM was started and in the first step 02 nos. Work order no.
NH/DG/E&M/WO/2019/300 and 301 dt. 15.03.2019 were issued to M/s.
Purvanchal for providing service support for replacement of faulty
stator bars and to M/s.GEPIL for deputation of Generator expert
respectively. A list of insulating items and other required tools and
tackles were provided by the OEM for replacement of stator bar.

MATERIAL REQUIRED FOR REPLACING ONE TOP BAR

SL. NO. DESCRIPTION QUANTITY REQUIRED

1 DE AND NDE CAPS 6 NOS

2 GLASS TAPE 25 FOR LASHING BLOCK 2 ROLLS

3 INSULATIING BLOCKS 30 NOS

4 RD CORD 5 MM FOR LOCKING TOP BAR ( DE & NDE ) 5 MTS

5 ROUND PACKING TAPE / SEMICONDUCTING TAPE 2 ROLLS

6 FILLERS 20 NOS

7 SLIDING SHIMS 20 NOS

8 PROTECTION SHIM 20 NOS

9 RIPPLE SPRING 20 NOS

10 WEDGE 20 NOS

11 BRAZING FOIL 20 NOS / 100 GRAMS

12 BRAZING ROD 20NOS / 100 GRAMS

13 FELT 20 PIECE

Page 8 of 55
 15 WHITE SPRIT FOR CLEANING 5 LTS

CONSUMABLE

1 RESIN S52 + HARDNER 3 KG

2 EP03 + HARDNER 30NBT + ACETONE 3 KG

3 LL16 + HARDNER 103 + THINNER 3 KG

4 EP03 + HARDNER 30NBT + ACETONE + FILLER 69 3 KG

5 CEMENT J 11 COMP A + COMP B / 15230 A +15230 B + AEROSYL 3 KG

LOAD 18466

6 PAINT GK 128 2KG

7 PAINT DK 222 2 KG

All consumables, particularly resins & hardeners which were not

available with Power station were arranged by M/s. GEPIL on loan basis
from Bijoli Holi Hydro Power Pvt. Ltd. in Himachal Pradesh near
Chamera-III Power Station. Whereas stator bars alongwith accessories
I.e. wedges, spacers etc. Were available at Dhauliganga Power Station.

The Induction Brazing Machine which was required for Brazing and De-
Brazing of bar connections available with Chamera-III Power Station
was collected and transported to Dhauliganga Power Station for the
rectification work.

The Induction Brazing Machine and Insulating materials were arrived at

Dhauliganga Power Station on 27.03.2019. On arrival of Induction
Brazing Machine the machine was made ready I.e. electrical and water
connection between chiller plant and control panel.

The service support team from M/s. Purvanchal were reached at site on
20.03.2019 to 23.03.2019. The team started the work for removal of
Rotor pole to make access to Stator slots. The rotor pole no. 9 & 10
were removed and cleaning of stator was started. After completion of
stator cleaning a visual inspection was made for any mark of damage,
which was not observed at any portion of stator.

Page 9 of 55
REMOVAL OF ROTOR POLE

Page 10 of 55
 CHAPTER-4

Fault localization and identification of faulty Stator Bar:

Representative of M/s. GEPIL was reached at Dhauliganga Power Station
on 28.03.2019 for rectification of Generator stator fault. As
suggested by representative of M/s. GEPIL, insulation resistance of
faulty phase I.e. B-Phase was measured on 500 VDC. The voltage was not
rises and shows 0 Volt. Insulation resistance of other two phase I.e.
R- Phase and Y- Phase was found healthy at 500 VDC and thereafter at
2500 VDC.
Representative of M/s. GEPIL suggested to go for DC current injection
for localization of fault using high voltage test kit available with
Power Station. The test was conducted and the injection was increases
slowly between B-phase winding and measured through earth point. An
audible chattering sound was heard as Current injection reached to 5-
10 mA. For localization of chattering in respect to stator slot a
hollow PVC tube was used. The fault was localized to Stator slot no.
151. As no visible sparking was seen it was apprehended that fault may
be in the bottom bar. For confirmation of fault it was decided to de-
braze the top and bottom connection of Top & bottom bar for stator
slot 151.
As the Induction Brazing machine arrived from Chamera –III Power
Station was under fault, top connection of the bar was de-brazed using
gas brazing torch. Insulation Resistance value for the two seperated
path was measured and it was found that the path with top bar was
healthy at first on 500 VDC and then at 2500 V DC and path with bottom
bar shows zero value at 500 V DC.
The preparatory works for removal of faulty bottom bar alongwith
another 11 Top Bar and 03 Top Connection bar was started. Both top and
bottom end caps were removed. The slot wedges,ripple springs and block
spacers from slot no. 151 to 138 were removed.

Page 11 of 55
 TOP BAR of STATOR SLOT 151

TESTING OF BOTTOM BAR

BOTTOM BAR of STATOR SLOT 151

Page 12 of 55
END CAPS REMOVED

REMOVAL OF END CAPS

Page 13 of 55
 CHAPTER-5

Rectification of Induction Brazing Machine: The induction Brazing

Machine which was brought from Chamera-III Power Station to
Dhauliganga for the brazing/De-Brazing of Stator bar connection was
not maintaining requisite heat for De-Brazing. The fault was conveyed
to OEM I.e. M/s. EFD Induction Pvt. Ltd., Bengaluru. The service
engineer of OEM guided online for rectification of brazing machine.
Service engineer suggested some checks for electronic cards and its
connections which was suspected for the faults.

ABNORMAL PARAMETER

FAULTY CONDITION OF INDUCTION BRAZING MACHINE

SUSPECTED ELECTRONIC CARD (VCPM)

Page 14 of 55
SUSPECTED MOTHER BOARD AND ITS OCNNECTIONS

SUSPECTED VCPM CARD CONNECTION

Page 15 of 55
 ELECTRICAL MAINTENANCE PERSONAL CHECKING THE PARAMETERS AS PER
SUGGESTIONS OF SERVICE ENGINEER

All the efforts made by electrical maintenance engineers of

Dhauliganga Power Station with the help of online support of service
engineer of M/s. EFD Induction Pvt. Ltd.,. finally, OEM service
engineer concluded on replacement of Electronic Card (VCPM) and site
visit for the same.

With the approval of competent authority a letter of Intent was issued

to M/s. EFD Induction Pvt. Ltd., for deputation of service engineer
alongwith the suspected faulty electronic card, VCPM on 29.03.2019.

The OEM Service Engineer reached at site on 04.04.2019. the service

engineer replaced the VCPM card and checked for other parameters. A
burn out track was also found in Mother board which was also repaired
on site. The Induction brazing machine was now functional and
maintaining the required heat for brazing/De-Brazing of stator bar
connection.

Page 16 of 55
 AFTER RECTIFICATION
NORMAL PARAMETER

NORMAL PARAMETER ON CONTROL PANEL OF INDUCTION BRAZING MACHINE

The second induction brazing machine which was brought from Chamera-
III Power Station, in view of faulty of first machine, also found
faulty with the fault ‘Tr-1. Over current’ which was also rectified by
service engineer and made ready for operation.

Page 17 of 55
 CHAPTER-6

Testing of New stator bar: After the fault localization and

identification of faulty bottom bar the required 15 nos. Bars were
marked and identified for De-Brazing and further replacement as per
the stator winding drawing.

R- Phase winding

Y- Phase winding

B- Phase winding

Page 18 of 55
There were 03 types of stator bars, 01 no. Bottom bar marked as R-01,
11 nos. Of Top Bar marked as R-02 and 03 nos. Of Top connection bars
marked as R-04, in total 15 nos. Of stator bar which was required to
be replace.

All above said identified bars were brought out from store. The
cleaning of new stator bar was made for further electrical testing.
There are two electrical tests, insulation resistance test at 2500 VDC
and high voltage test (Hipot test)at 40 kV DC, were performed on each
stator bars,

ELECTRICAL TESTING ON NEW STATOR BAR

Page 19 of 55
 STATOR BAR TESTING VALUES

HIPOT
IR MEASUREMENT (IN OHM) TEST @ 40 IR MEASUREMENT (IN OHM)
BEFORE HIPOT TEST KV DC AFTER HIPOT TEST
APPLIED VOLTGE 2500 VOLT (APPLIED APPLIED VOLTGE 2500 VOLT
FOR 1
MIN) REMARKS
DESCRIPTI MEASURM
ON ENT OF
(IDENTIFIC LEAKAGE
SL. ATION OF 600 CURRENT 15 600
NO. BAR) 15 SEC. 60 SEC SEC PI IN mA SEC. 60 SEC SEC PI

BOTTOM
1 BAR (R1- 11.94 24.00 26.70 1.11 0.080 40.10 70.80 59.80 0.84 STATOR SLOT 151
128)

TOP BAR
2 3.12 4.18 5.80 1.39 0.150 19.70 30.70 31.20 1.02 STATOR SLOT 138
(R2-22)

TOP BAR
3 22.40 46.30 50.50 1.09 0.130 15.03 27.90 29.20 1.05 STATOR SLOT 139
(R2-24)

TOP BAR
4 21.20 28.20 30.10 1.07 0.110 14.40 25.50 26.60 1.04 STATOR SLOT 146
(R2-16)

TOP BAR
5 18.80 40.60 37.40 0.92 0.130 28.20 37.40 34.80 0.93 STATOR SLOT 141
(R2-08)

TOP BAR
6 4.86 6.26 7.79 1.24 0.040 13.84 22.10 22.80 1.03 STATOR SLOT 149
(R2-01)

Page 20 of 55
 TOP BAR
7 3.96 4.49 5.14 1.14 0.040 19.68 35.30 33.20 0.94 STATOR SLOT 147
(R2-07)

IR MEASUREMENT (IN OHM) HIPOT

BEFORE HIPOT TEST TEST @ 40
APPLIED VOLTGE 2500 VOLT KV DC IR MEASUREMENT (IN OHM)
(APPLIED AFTER HIPOT TEST
FOR 1 APPLIED VOLTGE 2500 VOLT
MIN) REMARKS
DESCRIPTI MEASURM
ON ENT OF
(IDENTIFIC LEAKAGE
SL. ATION OF 600 CURRENT 15 600
NO. BAR) 15 SEC. 60 SEC SEC PI IN mA SEC. 60 SEC SEC PI

TOP BAR
8 1.89 2.26 2.87 1.27 0.100 35.60 41.20 35.10 0.85 STATOR SLOT 148
(R2-21)

TOP BAR
9 16.69 29.40 30.50 1.04 0.110 15.96 26.50 27.20 1.03 STATOR SLOT 142
(R2-18)

TOP BAR
10 19.47 34.30 35.30 1.03 0.120 15.90 29.30 30.90 1.05 STATOR SLOT 151
(R2-10)

TOP BAR
11 20.99 32.89 34.00 1.03 0.170 15.33 25.00 26.10 1.04 STATOR SLOT 143
(R2-13)

TOP BAR
12 14.17 23.40 24.40 1.04 0.220 12.68 21.90 17.92 0.82 HIGH LEAKAGE CURRENT
(R2-15)

TOP BAR
13 12.36 17.23 18.01 1.05 0.320 11.09 16.49 17.67 1.07 HIGH LEAKAGE CURRENT
(R2-12)

TOP BAR
14 20.00 40.00 42.30 1.06 0.100 20.60 34.70 36.80 1.06 STATOR SLOT 144
(R2-11)

Page 21 of 55
 TOP
CONNECTI
15 12.85 21.20 22.10 1.04 0.160 14.00 24.20 25.00 1.03 STATOR SLOT 150
ON BAR
(R4-01)

IR MEASUREMENT (IN OHM) HIPOT

BEFORE HIPOT TEST TEST @ 40 IR MEASUREMENT (IN OHM)
APPLIED VOLTGE 2500 VOLT KV DC AFTER HIPOT TEST
(APPLIED APPLIED VOLTGE 2500 VOLT
FOR 1
MIN) REMARKS
DESCRIPTI MEASURM
ON ENT OF
(IDENTIFIC LEAKAGE
SL. ATION OF 600 CURRENT 15 600
NO. BAR) 15 SEC. 60 SEC SEC PI IN mA SEC. 60 SEC SEC PI

TOP
CONNECTI
16 7.13 12.37 12.82 1.04 0.200 7.86 12.49 12.97 1.04 HIGH LEAKAGE CURRENT
ON BAR
(R4-02)

TOP
CONNECTI
17 12.17 18.95 20.10 1.06 0.600 10.87 17.75 18.76 1.06 HIGH LEAKAGE CURRENT
ON BAR
(R4-03)

TOP
CONNECTI
18 15.05 27.30 30.40 1.11 0.140 15.66 27.50 29.60 1.08 STATOR SLOT 140
ON BAR
(R4-04)

TOP
CONNECTI
19 12.35 20.50 21.60 1.05 0.180 13.31 22.60 23.07 1.02 STATOR SLOT 145
ON BAR
(R4-05)

On the basis of test results 02 nos stator top bars (R-02) and 02
stator top connection bars (R-04) which had high leakage current were
decided not to use. Other 15 nos. Stator bars were cleaned and heating
was started to avoid moisture absorption.

Page 22 of 55
 CHAPTER-7

Fabrication of stator round packing Device: A semiconducting tape with

a thin layer of Resin (Resin S1 52 + Hardener 105)was used for round
packing of Stator bars. Stator Round Packing device was fabricated in
house as per the suggestion of GE representative. This device applied
a thin layer on semiconducting tape and folded it at half on width for
wrapping on stator bar.

STATOR ROUND PACKING DEVICE

SEMICONDUCTING TAPE

Page 23 of 55
 CHAPTER-8

De-Brazing and dismantling of Stator bars: The De-Brazing of Stator

bars started on 04.04.2019 as soon as the Induction Brazing Machine
was rectified. The De-Brazing of both Upper Connection and Bottom
Connection was completed on same day and Bottom faulty bar was
dismantled.

DE-BRAZING OF STATOR BARS INPROGRESS

FLASH OVER MARK AT

BOTTOM BAR

STATOR BOTTOM BAR OF STATOR SLOT 151

Page 24 of 55
 FLASH OVER MARK AT
TOP BAR

SATOR TOP BAR OF STATOR SLOT 151

BURNT SPACER FROM

STATOR SLOT 151

STATOR SPACER WITH RTD SLOT (SPARE RTD AT STATOR SLOT 151)

Page 25 of 55
Another 13 nos. Stator Bars from stator slot no. 138 to 150 were
dismantled on 05.04.2019. dismantling of these bars was carried out by
great manoeuvre. These bars damaged completely due to lot of rust &
silt, which was due to total submergence of units during flood in June
2013. Cleaning of stator slot was started.

CLEANING OF STATOR SLOT

Page 26 of 55
 CHAPTER-9

Fixing of stator bar and application of insulation: The cleaning of

stator slot was completed on 06.04.2019. Bottom bar (R1)in stator slot
151 was fixed and required insulation spacers were tied. Insulation
resistance of bottom bar fixed in stator slot was measured and DC high
voltage test at 18 KV was performed and 0.010 mA leakage current was
measured.
11 nos. Top bars and 03 nos. Top connection bars were fixed and
required insulation was provided on 08.04.2019. Electrical tests on
new fixed top bars were performed on 18 kV DC and leakage current was
measured on next day I.e. 09.04.2019. The test results were found
satisfactory.Brazing of both top and bottom end connections completed
and insulations viz. Insulating tapes, end caps, spacers were applied
and fixed.

NEW FIXED TOP AND BOTTOM BARS READY FOR BRAZING

Page 27 of 55
 BRAZING OF STATOR BAR CONNECTION

Rotor pole no. 9 & 10 were fixed at their locations. Assembly of unit
I.e. dome cover fixing, assembly of top and bottom Air baffles,
electrical connections of rotor and stator, water pipe connections for
the coolers of Thrust and Generator guide bearings etc completed.

Final Insulation resistance and polarization index of Generator was

measured. The machine spinned on 11.04.2019 for dry run.During dry run
the Phase terminal and Neutral terminal of Stator was shorted. After
achievement of requisite value of insulation resistance and PI for
voltage build-up to generator it was decided to stop the spinning of
machine for terminal connections of stator for voltage buildup and
further synchronization with national grid.

The machine started and voltage was buildup in manual mode and voltage
was increased upto 11 kV. The inspection was made at Transformer and
Generator barrel for any abnormal sound. After assurance for normal
behaviour of unit the synchronization process was started in auto mode
and unit synchronized on 14.04.2019 at 12:22 hrs.

Page 28 of 55
 CHAPTER-10

Impediment to work: The Condition monitoring test on unit was

conducted on 09.03.2019. During DC leakage current measurement the
stator winding of B-Phase got punctured and leakage current rises
abnormally. The Insulation resistance measurement confirmed the fault
in B- Phase of winding. The unit was rectified from fault and
synchronized on 14.04.2019 I.e. the rectification period for the fault
was almost 37 days. The main delay for the rectification was observed
as follows:
1. Non availability of Insulating material at site: The
insulating materials mainly the consumables viz. Resins,
hardeners, chemical compounds etc. for rectification or
replacement of stator bar was not available with power station.
Insulation items required for replacement of 1 no. bar was made
available from Bijoli Holi Hydro Power private ltd., site of OEM
i.e. M/s GEIPL. but it is not sufficient for replacing 15 nos.
stator bars. O&M division vide IOM no. NH/O&M/DGPS/04/670 dated
20/03/2019 has intimated that “Dr. Beck” make insulation was used
for 11 KV voltage level and even higher i.e. 13.8 KV at Uri-I
Power Station, Srinagar. Dhauliganga power station is also of
the opinion that “Dr. Beck” make insulation item may be used.
Accordingly, insulation item of “ELANTAS Beck formerly known as
Dr. Beck” has been arranged by power station from Delhi Market.
The final quantity was arrived at Power Station on 06.04.2019.
2. Deputation of Service Engineer from OEM: As soon as the fault
in Stator winding was confirmed through electrical test, the OEM
was informed telephonically and requested for deputation of
service engineer. The OEM was confirmed the same but the service
engineer reahced at site on 28.03.2019. In the meanwhile the
power station also issued the work order on 15.03.2019 to OEM
I.e. M/s. GEPIL for deputation of Service engineer for
rectification of fault in station winding.

Page 29 of 55
3. The fault in Induction Brazing Machine: The Induction brazing
machine from Chamera-III Power Station was arrived at Dhauliganga
Power Station on 27.03.2019. The water connection to chiller
plant and electrical connection to both chiller and Control Panel
was made on same day. The service Engineer from OEM I.e. M/s.
GEPIL reached on 28.03.2019 and fault was localized and stator
bottom bar at Stator slot 151 was identified. The De-Brazing of
winding connection was required but the machine failed to
maintain the required heat. The OEM of equipment I.e. M/s. EFD
induction Pvt. Ltd. Was contacted with the problem. The OEM
service engineer suggested some electrical tests on Electronic
cards. Based upon the values and test results OEM concluded for
deputation of engineer for replacement of faulty Electronic card
(VCPM card. The Power Station issued a Letter of Intent for
deputation of service engineer alongwith the faulty electronic
cards. The service Engineer reached at Power Station on
04.04.2019 and rectified the Induction Brazing Machine. The
Stator winding connection were debrazed on 04.04.2019 and again
brazed on 09.04.2019.

Page 30 of 55
 CHAPTER-11

Conclusion: The stator Winding fault of Unit-3 was occurred on

09.03.2019 during condition monitoring tests. The unit was
synchronised after rectification of fault on 14.04.2019 almost after
37 days. The delay in rectification was observed due to three main
component I.e. 1) Non-availability of Insulating items at Dhauliganga
Power Station, 2) Delay in deputation of service engineer by OEM and
3)Faults in Induction brazing Machine.
In view of above, future occurance of this type of winding fault, the
Power Station concluded for preparedness and to take following steps
I. Availability of Insulation consumables at Site: The Power
Station will purchase the minimum required quantity for
replacement of 01 no. Stator bottom bar (I.e. for replacement of
total 15 nos. Of stator bar). The insulating consumables I.e.
Resins, Hardeners and chemical compounds etc have its self life
of 2 to 3 years. The OEM suggested not to use expired chemical
compounds as they may loose their physical and chemical
properties.
II. As Open contract with OEM for Deputation of Service Engineer
for breakdown maintenance of GPM: in view of delay in deputation
of service engineer for rectification of stator winding fault the
power station decided to go for an open contract with OEM I.e.
M/s. GEPIL for deputation of Service Engineer for breakdown
maintenance of GPM.
III. Regular inspection of Brazing Machine: Regular periodical
inspection will be scheduled to make the Brazing machine readily
available for any eventualities.

Moreover, during the replacement of stator bar it was observed that

the old stator bars got damaged in the course of dismantling due to
lot of rust & silt, which was due to total submergence of units during
flood in June 2013. these conditions are well known to OEM and
recommended to overhaul the winding and core of Generator stator.

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CHAPTER-12
TEST RESULTS

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 CHAPTER-13

MINUTES OF MEETINGS WITH M/S. GEPIL

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MINUTES OF MEETINGS WITH M/S. PURVANCHAL

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MINUTES OF MEETINGS WITH M/S. EFD INDUCTION PVT LTD.

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 CHAPTER-14

THE TEAM

The team members who were involved in Rectification/Replacement of

stator winding fault:

NHPC Management:

1. Sh. Bikram Singh, General Manager (I/c)

2. Sh. Anil Kumar, General Manager (E&M)
3. Sh. Rajab Hussain, DGM (Elect.)

NHPC Officers:

Electrical Maintenance:-

1. Sh. Pravin Shekhar, Sr. Manager (Elect.)

2. Sh. Rajiv Singh, Dy. Manager (Elect.)
3. Sh. Bhaskar Rautela , Dy. Manager (Elect.)
4. Sh. Sanjay Singh, Dy. Manager (Elect.)
5. Sh. Randhir Kumar, Asstt. Manager (Elect.)

O&M,CO Representative:-

1. Sh. Abhishek Kumar, DGM(Elect.)

OEM Technical Support (GE Power):

1. Sh. Dharamveer Jamwal, Service Engineer

M/s. Purvanchal engineering projects, Ghaziabad

1. Sh. Parmeshwar Tiwari and his team.

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