2019/12/18. Winding Insulation Maintenance and Cleaning and Drying of the Generators {4450} (SEHS9124.07) ‘SMCs - 4450 oso09as4 Engine 35168 (SIN: ZNT1-UP) Generator Set all Introduction Winding insulation breakdown in generators causes current leakage and lower high-voltage fesistance, which allows short circuit condition to occur. Generators stored in or operated in contaminated environments are especially at risk. Environment contaminants include excess dust, water, salt, jgrease, and humidity and should not be allowed to accumulate on the generator windings. This Spécial Instruction provides information for testing and maintenance procedures. Reference: Refer tothe folowing documents for more information: “IEEE STD 43.2000 Recommended Practice fo Instlation Testing of Rotating AC Machinery" + Engine News, SEBD0660, "Operating Environment and Etfects on SR4 Generators! + Application and Installation Guide, LEBW499S, "Generator Systems" + Application and installation Guide, LEBES294, "EP Applications, Engine & Generator Sizing” Important Safety Information Work safely. Most accidents that involve product operation, maintenance, and repaf are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have te necessary training, skilsand tools in order to perform these functions properly. Safely precautions and warnings are provided in this instruction and on the product: I these hazard warnings are pot heeded, bodly injury or death could ‘occur to you orto other persons. Caterpillar cannot anticipate/every possible circumstance that might involve a potential hazard. Therefore, the ‘warnings in this publication and the warnings that are on the product are not ll inclusive. IT tool, procedure, work method, of operating technique not recommended by Caterpila i used: Ensure that such tool, procedure, work method, or operating technique are safe for you and for other people to use, Ensure that the product will not be damaged, or be made unsafe, by the operation, lubrication, maintenance, or repair procedures that ae used, ETN th can result from high voltage. Personal injury or: ‘When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to is ust Make sure the testing equipment is designed for and correctly ‘operated for high voltage and current tests being made. When servicing or repairing electric power generation ‘equipment: + Make sure the unit is off-line (disconnected from utility andlor other generators power service) , and either locked ‘out or tagged D0 NOT OPERATE. + Remove all fuses. ‘+ Make sure the generator engine is stopped. + Make sure all battories are disconnected. ‘+ Mako sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make Sure residual voltage in the rotor, stator and the generator discharged,Personal injury or death can result from a spark. ‘An incompletely discharged capacitor can cause a spark. Do not use the insulation tester in an oxplosive atmosphere. FCO es Personal injury or death can result from electrocution. ‘The megohmmeter is applying a high voltage to the circuit. ‘To avold electrocution, do not touch the instrument leads ‘without first discharging them. Whon finished testing also discharge the gonerator windings. Personal injury or death can result from the engine starting. Rogardloss of the cleaning mothod used: to avoid serious injury fr death, make sure there is no voltage applied to the windings. Make sure the engine can not be started. Personal injury can result from working with cleaning solvent. Bocause of the Volatilo nature of many cleaning solvents, ‘oxtrome caution must be exercised when using them. If unsure about a particular cleaning fluid, rofer to the manufacturer's Instructions and directions. ‘Always wear protective clothing anid eyé protection when ‘working with cleaning solvents. FCO es Personal injury can result from air pressure. Personal injury can result without following proper procedure. ‘When using pressure air, wear a protective face shield and protective clothing. Maximum air prossuro at tho nozzle must be less than 205 kPa (@0 psi) for cloaning purposes. Checking Equipment The generator should be checked periodically for any accumulation of dust, water, salt, grease, or ol fms. If cleaning is necessary, refer to the ‘methods that are covered in *Cleaning’and "Drying" for more information. Note: Windings must be kept clean and dry. Any accumulation of dirt will trap moisture. This moisture will reduce the dielectric strength of the insulation Note: The use of a space heater is recommended whenever the unit s not running. Even generators that cycle on and off within a 24 hour perlad should use space heaters during the off hours The frequency ofthe insulation resistance checks will be determined by the environmental conditions and the operating conditions during operation of the generator. At the minimum, an insulation resistance test must be performed annually.For determining a preventive mal nance schedule, use the following guidelines: + Generators that have a seasonal operation should be tested and inspected prior to being pu back in servic. + Ifthe generators installed in an enclosed building with low humisty and minimal temperature variations, test the insulation annually. + Ifthe generators notin a controlled environment, the insulation tests should be performed every 3 months. + Ifthe generator isin, or near, a salt laden water environment, or ina high humidity environment (above 75% relative humidity): Test the insulation every 3 months, Required Tooling Caterpilar recommends the use of an industry standard calibrated insulation tester for checking the insulation resistance. Insulation testers apply a ‘nominal voltage to test insulation resistance of the generator windings, Note: Before performing an insulation resistance test, disconnect any ofthe following tems: grounds, loads, meters, and controls. See tool test voltages listed below per generator rated voltages, Note: Certain conditions will give acceptable or even high insulation resistarice values but the unit may stil fal. However, these tests are used to determine when cleaning, drying, and repair ls necessary. Generator Components Insulation Resistance Test Voltage For the main stator, the recommended test voltage will Vary depending on the generator AC output voltage, See Table 1 Winding Rated Voltage (L-L ACV) | Insulation Resistance Test Voltage (DCV) < 1000 500 "1000 - 2500 ‘509 - 4000 2501 - 5000 1600 - 2500 5001 - 12000 2500 - 5000) > 12000 {5000+ 10000 Table 1 “The main rotor and excite components ae low alae conor. The insulation esotancetatage shouldbe ro mere han 500 VOC. Insulation Resistance Tests [A permanent record of the resistance readings ofthe insulation and the values of the temperature readings forthe windings should be kept. All readings must be corrected to winding temperature for ending or comparison purposes. Main Stator Insulation Resistance Recommended Criteria (at 40° ¢ (104° F)) Insulation Resistance: Random-wound (0-20 (megaohms) ‘Clean and ary [20 - 100 (megaohms) | Check Polity index (Pl) (Pl 2 or more: Ok to run. PI <2: Clean and dy.) > 100 (megaohms) Ok to start Insulation Resistance: Form-wound (< 5kV) (0-100 (megaohms) Clean and dry > 100 (megaohms) (Okto start, Insulation Resistance: Form-wound (>5 kV) (0-300 (megaohms) ‘Clean and ary > 300 (megaohms) (Oko start Table 2 The minimum insulation resistance value forthe main rotor and the exciter components is S megaohms, but higher values should be expected. Note: The Polarization Index test (PI test) is an additonal insulation test, described ina later section, thats effective at identifying how moisture is affecting the health of insulation of winding, Since random wound windings tend to be more susceptible to retaining moisture, the Pl test may be @ ‘more effective measure of moisture content in random wound windings than form wound windings. Ifinsulaion is identified to be low withthe Insulation resistance test, performing the Pl test on a random wound, as well asa form wound, winding is stil recommended to determine ifthe presence of moisture is cause for ow insulation value.Ifthe recommended values cannot be obtained after cleaning and drying the ge should be reconditioned by a qualified electrical shop. Conversion factor ‘Temperature Conversion Factor ‘Whang Temppegees Winding Temp | Conversion Factor Degrees 10 0.125 20 025 30 05 40 1 | 50 2 60 4 70 a a0 16 0 32 100 64 110 128 120 256 Table 3 rator windings, the insulation has deteriorated. All such insulation eossketsy For example, 100 megaohms at 50 degree C are converted to 200 (2 x 100) megaohms at 40 degree C. ‘Trending insulation resistance overtime will help prevent sudden failure and therefore unplanned generator down time. Note: Results from the insulation resistance test give a good indication of the time that cleaning and repairing is becoming more eftical. The Insulation resistance wil vary greatly with temperature, The test should be performed as near as possible o the same temperature and humility. Periodic readings ofthe insulation resistance should establish a trend in deterioration of the insulation. Resistance readings with a 50% reduction (or more from the previous reading may indicate an abnormal condition, Polarization Index Polarization Index (PI) test isan indicator of moisture and the cleanliness of all the generator windings. Polarization Index is defined as the ratio of the insulation resistance measured after 10 minutes tothe insulation resistance value measured after 1 minute Polarization Index = Insulation Resistance after 10 minutes / Insulation Resistance after 1 min,Ifthe minimum acceptable Pl values cannot be obtained after cleaning and drying the generator windings, the insulation has deteriorated. ll such insulation should be reconditioned by a qualified electrical shop. Note: Ifthe 1 min insulation resistance is above 5000 megaohms, the calculated PI may not be meaningful n such cases, the PI may be disregarded as a measure of winging condition. Pl criteria Pb=2 + Normal range Plea + significant molature in the windings + Recomended to clean and dry immediately Reference Generator Test Report Data Sheet i a exe) Space nenvEns GrtMaTE® Secu WOR TO TEST t 4 Cleaning The generator should be checked periodically for any accumulation of dust, water, salt, grease, or ol fms. These contaminants should not be allowed to accumulate on the windings. Generators that have been submerged, flooded, or filed with dit may need extreme cleaning. Refer to “Extreme Cleaning" for more information. Generators may be routinely cleaned by the following methods:Brushing Brush using only ine soft bristied NON ABRASIVE brushes to loosen and remove debris. Vacuuming Dry contaminants may be removed by vacuuming. A soft bristle NON ABRASIVE brush may be used in order to loosen the dit before vacuuming oF during vacuuming. Also not that "vacuuming" ané using “pressurized ai” can be performed on an assembled unit. Washing and steam cleaning ‘must be performed on a disassembled unt "Note: In order to dry the insulation completely, refer to the procedures in “Drying” for more information. Washing It the equipment for drying is avaliable, washing may be performed ina dealer shop. Refer tothe procedures in “Drying” inorder to determine the equipment that may be needed NOTICE Read and understand the information on the container label ‘before using. A cleaner that is nonflammable and safe forall ferrous and nonferrous parts should be used. The cleaner ‘should be readily removable with water. Failure to do so may ‘cause equipment damage. A liquid cleaner designed to remove grease, ol, dirt, and other contaminants from electric motors, pars, and equipment can be used. Heavy-duty cleaners atthe recommended concentration levels can also be used. Rete tothe fllowing procedure in order to clean the generators: 1. Create the cleaning solution as per the manufacturer recortmendatiohs)If a pressure washer is used do not exceed 205 kPa (30 psi). 2, Clean the insulation and rinse the insulation with fresh watm water. Note: Cleaning should be done as rapidly as possible in order fo avoid long periads of exposure ofthe insulation tothe solvent 3. Wipe off excess moisture wih a clean dry cloth 4. Bake dry in an oven before placing back into service! Refer tothe “Ovens” in “Drying” for more information. Steam Cleaning ‘Steam cleaning should only be performed if there is-a great amount of grease or dif present. Use a qualified electrical rebuld shop to steam clean the generator. NOTICE After steam cleaning, a complete drying is required before the Unit s placed back into service otherwise damage to the ‘equipment may occur. Use a qualified electrical rebuild shop. Pressure Air ‘The generators may be cleaned wih fitered pressurized a. Note: This method isthe least desired method of cleaning the generators, Pressurized ir can relocate the dit instead of removing the dit NOTICE Nover aim the pressured air directly against the insulation’ without first removing all of the moisture and contaminates from the insulation. Contaminates that are blown into the insulation ‘and some areas of the generator may cause damage. Carefully blow the dirt out ofthe windings by using 135 kPa (20 psi) to 205 kPa (30 psi) fltered dry ait. (Once the ditis out of the windings, refer to the procedures in "Drying" for more information in order to dry the unitExtreme Cleaning This method is for electrical equipment that has been submerged completely, flooded, or filed with dit. Note: Even with the best treatment and careful testing, the insulation of a generator that has been submerged may be damaged beyond repair. NOTICE When water pressure is used for cleaning purposes, the pressure of the water must not exceed 205 kPa (30 psi) ‘otherwise damage to the equipment may occur. Flush the unit with fresh warm water in order to remove all traces of salt and sit. Washing should continue until tests of the fresh water show the Insulation tobe free of salt. Note: Complete disassembly of the generator may be necessary in order to accomplish a proper cleaning, ‘Bake and dry the unit completely with externally applied heat before placing back into service. Retr to the procedure in “Drying” for more: Information, Note: Ifthe generator is used in or near salty air and high humidity environments, special electric component cleaners and protectors are needed to prevent corrosion, Drying Drying may be accomplished by external heat, intemal heat, a combination of internal heat and external heat, or circulating current. NOTICE Whon using extemal hoat to dry the generator, do not oxco {85° C (185° F) otherwise damage to the equipment may occur. External heat is the most preferable method. Insulation drying time can vary from a few hours to several days, depending on moisture content and the process used for drying Note: Drying sometimes does not produce the required fesults. The use of qualified rebuild shop for drying nd redipping of the generator may be necessary. 100 80 60 40 ao 24 40 56 7288104120 36 28 20 12 8 24 40 5672 71Htustraton 3 goreeri3s “ipa carves ofthe resistance in he insti hats drying {3} Cure o the temperate ne windings (a) Heat ened of {5} Dring tne nous (0) Temperature in dogs Cots {7} Cone ofinslabonrestnce dring drying rocess {8} nelson restance mmegachm= Note: When new insulation or damp insulation is being dried, the resistance will probably fall rapidly as the temperature is raised to a value for drying, After reaching a minimum for a given temperature, the resistance will again rise as moisture is driven out ofthe insulation. The actual values will vary with each situation. Refer to Iilustration 3. If the windings or insulation become wet during the resistance measurement: Use a five megaohme resistor for protection, in series with the red positive lead, to limit the voltage across the circuit under test. Use this method untl drying is well in progress, and the resistance has reached an acceptable level During the drying period, check the windings every 4 hours, or every hour, forthe method of circulating current with the insulation resistance tests, Refer to "Insulation Resistance Tests” for more information, Drying is complete when the testing demonstrates that Pl > = 2. Record these readings in the Generator Test Data Sheet and compare to previous readings. Keep these records fr future reference. External Heat Ovens ‘The best oven is a forced air drying oven for drying electrical equipment. Radiant ovens sometimes cause localized overheating NOTICE Do not heat the generator too quickly. Ty to limit the rise in temperature of the insulation and windings to 11° C (19.8" F) per hour. Failure to do so may cause equipment damage. Heat the generator to a maximum temperature of 85 °C (185 °F) fora minimum of 4 hours. Alternate Method ‘A tent formed by a tarp or a canvas with heating lamps or a portable space heater may be used as an alternate method. ‘Anole should be left in the top ofthe tarp for ensuring proper circulation through the generator and fot permitting the moisture to exhaust. Heat the {generator to @ maximum temperature of 86 °C (185 “F) fora minimum of 4 Hours, Internal Heating \¥a generator operates under one of he folowing condltions electric space heats Should be installed as part of he generator: + Generators are in damp environments and go for long periods of tine without operation, + Generators operate regulary in an environment with ioisture laden alt Circulating Current Drying can be accomplished by circulating lowvollage current through the windings. Since the voltage is low, breakdown of the insulation wl not ‘occur. More likely, the breakdown might have occurred with normal operation voltage and wet insulation,10 1" Ly ye YY \ 2 \. 13 istration + 901753867 Schomate forthe exten power souce (9) Baty (12 VOC) (Ho) sare (net {32} Lescol thats being eg) (ia) (18) 0010 Ohm Rowostat Refer to the folowing procedure in order to dry the windings with circulating current: 1. Follow all safety procedures before continuing 2. Disconnect the generator load and open the breaker 3, Disconnect the leads of the excitrfleld from the voltage regulator with the engine stopped. Typically, the leads have the folowing labels: Ft (11) and F2 (13) 4. Connect the output leads for the generator together. Typically, the leads have the folowing labels: 11, T2 and 3. 6. Install an AC current probe (clamp-on probe) to generator output lead Tt 6. Adjust theostat (14) in order to give maximum resistance, 7. Connect the extemal power source to wires F1 (11) and F2 (13). Switch (10) remains open, NOTICE Do not exceed the rated phiase current that is listed on the: {generator nameplate, Exceeding the rated phase current will damage the generator windings. 8, Run the generator set at idle speed. Residual voltage will ause current to circblate within the generator windings, 8. While ine current is being monitored, slowly increase rpm Uni rated line curentis obtained, oF until full generator set speed is obtained. ‘Note: When line currents being measured on multiple lead units, measure the current in each conductor per phase, and add the currents together. 10. Ifthe generator reaches full speed and more line current is Stil néceésary, repeat the folowing procedure until the rated phase current is, obiained. 2. Run the generator at ale speed Close switch (10). ¢. Slowly tur rheostat (14) 16 the rated phase cure “1, Continue running the curent at hes setiigs for *.hour. 2. Stop the drying procedure ». Verity the insulation resistance with the insulation test. f minimum Pl value cannot be obtained, continu to step tte. «. Continue the Circulating Current arying procedure, checking insulation resistance values every hour untl the insulation resistance test is acceptable.4d. After cleaning and drying the generator windings, ifthe minimum acceptable Pl values anol be obtained, the insulation has deteriorated, All such insulation should be reconditioned by a qualified electrical shop. Pip-11146867 202210125 09:47:16+09:00 voss147e4 (© 2022 Caterpillar Inc. Caterpitar: Confidential Green