Maintenance of electric generators

Summary:
In this report we are going to analyze the different faults that electrical generators have, in order
to give a possible diagnosis for subsequent maintenance, since the repair of a generator is very
expensive, here we are going to see the basic types of preventive, predictive and reagent
Aim:

 Know the types of maintenance that is done on an electric generator

Theoretical foundation:

Reactive maintenance:
It is maintenance in which no type of planning or programming is carried out. It thus
corresponds to the unforeseen repair of failures and is practiced in companies, in those low-cost
components. Where the equipment is of an auxiliary nature that is not directly related to
production, maintenance costs would be extremely high.

Preventive Maintenance:
It is the process of routine periodic services to the equipment. This can be anything from a
lubrication routine to adaptation after a certain time, parts or components. The interval between
services can be in hours of operation, number of operation changes, in time (hours, days, weeks,
months, etc.). Once the program has been established, checks should be carried out to verify if
the set interval is correct.
The task of preventive maintenance can be grouped as follows:

 Routine
 Global
 Overhaul

Routine tasks
Routine PM tasks can be defined as the systematic activities to perform

 Cleaning
 Lubrication
 Inspection
 Proof
 Adjustment
 Service
 Minor repairs

All with the purpose of maintaining the equipment in perfect operating conditions. Each task
typically takes a few minutes and the travel time of maintenance personnel usually exceeds the
actual time working on the equipment. The emphasis here is on the systematic, which means
that there are numbers of daily, weekly or monthly tasks performed in the same way repeated
several times.
Global maintenance tasks
  They are those activities that usually involve:
 Partial dismantling of equipment
 Use of various tools
 Replacement of numerous parts or components
 High skill level of MP staff
 Much longer than routine tasks
Equipment overhaul
Typically involves:

 Removal of equipment from the production line

 Total dismantling of the equipment
 Replacement or reconstruction of many parts, components or systems
 Equipment repainting
 Greater time for execution

Predictive Maintenance
Predictive maintenance is normally performed separately from PM, especially if performed by
the engineering department, however, it serves the same purpose as PM: preventing equipment
failure by predicting when a certain component, for example, a bearing, will fail. , a gearbox, or
a motor. Predictive maintenance includes a series of tests and analyzes such as:

 Vibration analysis
 Insulation tests
 Oil graphic spectrum analysis
 Thermography
 Infrared inspection
 Non destructive essays
 Acoustic analysis
This type of maintenance uses sophisticated testing apparatus to help predict when an
equipment component will fail. These test devices may even be interacting with a
microprocessor to graph equipment wear trends and improve estimates of equipment condition.
Method and scheme
An electric generator powered by an internal combustion engine will be taken as an example.
How to do preventive maintenance on an electric generator?
It is very common for maintenance to be carried out using a checklist. This will allow you to
inspect each and every one of the parts that you must review, without leaving anything aside.
Likewise, it will allow you to carry out maintenance in an orderly and timely manner, since
each piece or component of the equipment requires constant review, and has different check
periods.

We will show an example of what could be a checklist for the maintenance of the electric
generator:

Checked Item to check Frequency Date

Before and after using

External cleaning of the equipment
the equipment

Check ventilation and heating Diary

Observe abnormal noises, vibrations, friction,

Diary
etc.
 Observe condition of bearings and lubrication
Monthly
level

Check load with measuring devices Monthly

Check general condition of the machine Quarterly

Observe aspects of the collector, as well as

Monthly
brushes

Interior cleaning Annual

Look closely at the brushes (replace if

Annual
necessary)

Look closely at the brushes (replace if

Annual
necessary)

Check collector surface and connections Annual

Check air gaps and windings Annual

Test insulation and grounding resistance Annual

Check correct starting maneuver (internal

Quarterly
combustion engine)

Check lubrication, change and clean

Annual
ventilation ducts

Check rotor balance Annual

Other items that can be included in the checklist are the following:
  Daily execution tasks: check the coolant fluid level (if applicable), check the oil and its
level in the tank, and check the air filter.
 Weekly execution tasks: strain the water from the tank and its filters, and check the
battery charger.
 Monthly execution tasks: verify the concentration of the cooler, and check the outlet
water trap.
 Semi-annual execution tasks: validate the radiator hoses, change the fuel, oil and air
filters, clean the respirator air duct.
 Annual execution tasks: debug the cooling system.
For each item on the list, the condition and proper functioning of each part of the electric
generator must be thoroughly inspected.

Engine maintenance
Each electric generator includes maintenance instructions, which we recommend reading
carefully in the instruction manual or user application. However, we will describe the most
relevant aspects for good maintenance of an electric generator motor .

Check the oil level

To perform this action, the appliance motor must be horizontally level. Then, using the dipstick,
we proceed to measure the oil level, which should be between the MIN and MAX marks. It is
recommended to carry out the measurement with the engine cold.

Oil change and oil filters

1. Change the oil and your filters at the same time.

2. Use only the oil indicated by the manufacturer.
3. Rest the electric generator slightly inclined on a prepared surface, and keep the oil drain
screw downwards. Open the screw for oil filling.
4. Open the oil drain screw and drain the engine oil into a container for this purpose.
5. Once all the old oil has drained out, close the drain screw and return the electric
generator to the standard position.
6. Add engine oil, up to the MAX mark on the oil dipstick. Dispose of used oil properly.
7. The engine oil must be changed with the engine warm from operation.

1. Clean the filter fasteners so that no dirt falls inside when installing the new filter.
2. Remove the filter(s).
3. Fill the new filters with engine oil.
4. Secure the filter(s).
5. Start the engine, and check that there are no oil leaks around the filter.
6. Add more oil if necessary.
7. Run the engine at normal temperature.
Inspection and change of the air filter
This filter must be replaced when the filter indicator indicates it. The dirt level of the intake air
filter depends on the size of the filter and the concentration of dust in the air. It is recommended
to change them every six months, but if the concentration of dust and other external agents is
high, they should be inspected and changed more frequently.
 Electric generator maintenance – Air filter change

Verification and adjustment of auxiliary element straps

This check should be performed after the engine has been running, with the belts still hot.
Loosen the screws and then tension the alternator belts. These must give 10 mm. between the
pulleys. Belts that work in pairs must be changed at the same time. For their part, the fan belts
have an automatic tensioner and do not require adjustment, but should still be inspected.

Cooling system inspection

This system must be filled with a coolant that protects the engine against freezing (if applicable)
and against internal corrosion. Because anti-corrosion additives weaken over time, the coolant
must be changed. When replacing coolant, the cooling system must be flushed.

Replacing or cleaning the fuel filter

Check if the electric generator filter requires cleaning or changing. In both cases, you must
loosen the filter fixings to prevent any dirt from entering the injection system.
If you only need to clean the filter, remove it from the equipment and wash it with nonabrasive
detergent and let it dry.

When installing the filter, whether new or clean, lubricate the gasket with a little oil. Screw on
the filter. Bleed the fuel system. Dispose of the old filter properly.

Alternator maintenance
As part of daily maintenance, it is recommended to check the condition of the windings (especially if
the generator has been inactive for a long time), as well as the bearings. If the generator has brushes,
you will have to check their wear and the cleanliness of the slip rings.
Checking the windings
The condition of the windings can be verified by measuring the ground insulation resistance of the
machine casing, with respect to ground. This resistance is disturbed when there is dirt or humidity in
the windings, so the generator insulation measurement will indicate the state of the winding.

The tool to measure insulation is the megohmmeter or Megger. To proceed with the measurement,
the positive pole of the Megger is connected to one of the motor terminals, and the negative pole to
the metal ground, then the insulation resistance is read directly. During the measurement, the
generator must be completely separated from the installation, and disconnected from it. If the
insulation resistance is lower than the resistance of the winding, the latter must be dried
immediately.

Bearing inspection
Oil should be checked for wear or loss, and replaced if necessary. It should also be periodically
validated if the bearings overheat or produce excessive noise during operation. In case of excessive
vibrations, wear or loss of grease, they must be replaced.

For reference, bearings should be changed after 40,000 hours of service, and in the case of pulley-
driven generators, they should be replaced after 25,000 hours of service.

Verification of slip rings and brushes (if applicable)

The brushes must last the entire useful life of the equipment, although in case of intense use of the
equipment, it is possible that they may wear out a quarter of their length, in which case they must be
replaced. The slip rings must be cyclically cleaned thoroughly, especially when the brushes are
changed.

Tips and recommendations:

 Check the generator twice a year, even if it is not in use. Look for loose or worn cables,
corroded elements, stuck buttons, etc.
 Minimize dust and dirt on safety devices, ventilation slots and motor housing as much
as possible.
 To clean the device, rub it with a clean cloth or blow it with compressed air using low
pressure. It is recommended to clean the electric generator after each use.
 When cleaning the appliance, do not use solvents or cleaning products as these can
damage the plastic parts of the appliance.
 Prevent water from entering the interior of the device.
 Change the spark plugs annually.
 Start the generator regularly, even if it is not used frequently. It is recommended to turn
it on every three months, to verify its proper functioning.
 Check that the fuel pump, turbocharger, injectors and automatic voltage regulator are
calibrated correctly. Depending on the use of the device, this review should be done
every year or every two years.
 Store the generator in a dry space protected from dust or dirt.

Warnings:

 Always test the generator in a well-ventilated area. This is because the exhaust gases
that accumulate contain carbon monoxide, which can be fatal.
  Do not handle a generator in wet conditions. If necessary, it should be covered with
something that keeps it protected.
 Always consult a professional, especially if you do not know the subject well or do not
have a direct relationship with the machine on a frequent level.

Stator failures:

For short circuits:

Short circuits in the stator windings generate high currents that can cause significant damage at
the location where the fault occurred, such as destruction of part of the stator laminations, if
they are not cleared quickly.

In phase-to-ground short circuits, the stator iron is compromised because, regardless of the
connection of the generator neutral to ground, the casing is connected externally to ground,
allowing fault current to flow. The stator blades are also affected, and the damage they present
will be directly related to the intensity of the short-circuit current and the time in which it
circulates. The value of the short-circuit current in a phase-to-earth fault depends on the type of
generator neutral connection. If the generator is solidly grounded, the current intensity will be
maximum, and it will be minimum if the neutral is grounded through a high impedance. The
generator manufacturers ensure that they can withstand mechanical and thermal stress due to a
phase-to-earth short circuit that occurs at their terminals, as long as the value of the current does
not exceed that of a three-phase short circuit.

Internal structure of the Stator of an electric generator

Mechanical failures:
In the search to minimize operating costs and maximize the performance of generators,
mechanical failures play a very important role, since they have the following consequences:
deterioration of the stator, contamination, misalignment and loosening of the core, reduction in
operating efficiency. , among others leading to the replacement of the generator completely.
Failures due to damage or deterioration of stator insulation:
The impact of insulation degradation of a generator differs depending on the design of the
electrical generator in terms of the type of insulation system used and the type of cooling of
different external contaminants.
In the Figure, it is observed that inside a generator there is an accumulation of contaminating
residues from the environment and the lubricant. The location of this contamination is observed
in the ferromagnetic core, winding, connections, coil heads.

The proximity of chemicals, oils, corrosive vapors and dust affect the insulation performance of
the materials. The appearance of mold and the accumulation of particles in humid and hot
environments also cause the degradation of the insulation characteristics of the installations.
One of the consequences of this deterioration of insulation is electrical failures (short circuits
and partial discharges).

Generator rotor failures:

Synchronous generators are machines that operate in conditions of humidity, high temperatures,
polluting elements, great mechanical stress, among others. Which can generate different types
of failures in different parts of the machine.

For short circuits:

A common fault in the rotor is the ground fault of the field winding, which initially may not be
very serious, because the voltage levels handled by this winding are relatively small compared
to the stator voltages, and it is not connected in no point to ground so there is no return path for
the fault current from ground to the winding. Due to the above, a ground fault in the rotor is not
sufficient cause for immediate disconnection of the unit, but requires taking it out of service for
inspection of the generator as soon as possible, in order to avoid damage that could occur. could
happen if a second ground fault occurs.
Due to disturbances or failures in the power system:

 Excessive current in the stator: Produces serious heating in the stator windings. This
heating can also be caused by damage to the cooling system, or short circuit in stator
laminations.
 Overvoltages: Overvoltage directly affects the insulation. One source of overvoltage is
overspeed. Any overvoltage associated with overspeed can be controlled by the
automatic voltage regulator. In the case that the exciter is coupled directly to the
machine, the voltage tends to grow almost with the square of the speed. Another source
of surges are atmospheric discharges that reach the generator due to failures in the
shielding systems.
 Low frequency: Low frequency can damage turbine blades due to vibration.
  Operation of the generator as a motor, due to the loss of the driving force
generator: This could result in partial or total damage to the mechanical structures of
the turbines, for example, the blades in a low pressure turbine.
 Loss of synchronism: If the unit fails and the system is out of phase.
 Closing of a generator circuit breaker with the generator out of phase with the
system: This causes mechanical damage to the generator windings and the turbine is
also affected.
Failures in the rotor insulation system:
All non-metallic reinforcing and insulating materials deteriorate over time due to the heat of the
windings. The speed at which material components deteriorate is a function of their thermal
properties and the temperatures to which they are subjected. If the thermal ratings of the
material components have been selected correctly, thermal aging and associated deterioration
will occur gradually over an acceptable service life.
Modern salient pole winding designs use Nomex in the ground insulation and in the turns in
strip on edge winding windings, laminated glass washers on the poles. For high temperature
operation they are in turn covered with insulating enamel, and thermosetting bonding resins
provide insulation systems that have a thermal rating of at least class F (155 ºC). If materials are
operated at a class B temperature (130°C), they must have adequate thermal life. The materials
most susceptible to thermal degradation are organic bonding and reinforcing materials, while
inorganic components such as mica, glass, and asbestos are not affected at the normal operating
temperatures of electrical machines. The thermal life of the insulation in the hot spots of the
windings is significantly reduced, since the margin between operating temperature and thermal
power is much smaller. This effect is much more critical in older class B insulation systems and
such hot spots are very difficult to detect.

Failures in the exciter:

The exciter is responsible for supplying the voltage and direct current to power the rotor of a
synchronous generator, and converting it into an electromagnet with the general ability to
regulate the intensity of the magnetic field.
The resistance offered by the rotor winding is fixed, so by varying the direct supply voltage it is
possible to vary the intensity of the current that circulates through the rotor, thus varying the
intensity of the coupling magnetic field.
The great mechanical problem that the exciter has to solve is that of connecting the cables that
feed the rotor coils, in motion, with external elements, which do not rotate. The problem can be
solved mechanically or electrically, giving rise to different types of exciter. All of them should
ideally have the ability to regulate the rotor supply voltage, to vary the coupling magnetic field.
Static exciter, or rotating rings and brushes.
Permanent magnet exciter.
Rotating diode exciter.
Self-excited generator.

Bearing failures:
The most common failures can be caused by:

Electrical erosion:

Electrical erosion, or arcing, can occur when a current passes from one ring to the other through
rolling elements. The degree of damage depends on the amount of energy and its duration. To
prevent damage caused by the passage of electrical current, an electrically insulated bearing is
often used at the non-driven end. Two types of SKF insulated bearings are available:
INSOCOAT bearings and hybrid bearings.

Inadequate lubrication and contamination :

If the layer of lubricant between the rolling elements and raceways is too thin due to inadequate
viscosity or contamination, metal-to-metal contact occurs. In some cases, depending on the
application, it may be necessary to use a lubricant with higher viscosity to increase the thickness
of the oil film.
Damage caused by vibration :

Motors that are transported without properly securing the rotor shaft in place can experience
vibrations in the bearing clearance that can damage the bearings. Similarly, if a motor is stopped
and subjected to external vibrations for a period, the bearings can also be damaged.

Damage caused by improper installation and configuration :

Common installation errors include using a hammer or similar tool to mount a half coupling or
belt pulley on a shaft, misalignment, imbalance, excessive belt tension, and incorrect mounting
resulting in overload. .
Bearing underload :

Bearings must always have a minimum load to function well. Damage will appear in the form
of sticking to the rolling elements and raceways. This is important to remember when using
cylindrical roller bearings as they are typically used to support heavier loads. This is not valid
for preloaded bearings.

Generator Repair:
Testing before installation :

Disarmament:
In this process, with the necessary tools, we prepare to disassemble the generator, seeing each of
the possible faults that the generator may have.

Identification of parts:
Once the generator has been
disassembled piece by piece, we separate the defective parts and see if some can be fixed or not.
Tests on the stator winding:
These tests include voltage measurements, insulation resistance/polarization index, and DC
winding resistance, as well as turn-to-turn fault detection.

Tests on the Rotor winding:

These tests include voltage measurements, insulation resistance/polarization index, and DC
winding resistance, as well as turn-to-turn fault detection.
Repair Procedure:
Once the faults have been found and corrected, we proceed to assemble the generator piece by
piece.