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Procedure & Methodology: Generators

The document outlines procedures for rewinding generator stators using either round or rectangular magnet wire. For round wire rewinding, the procedures include removing the rotor, inspecting components, stripping the old winding, cleaning the core, rewinding according to the original data, testing the new winding, baking and varnishing it, and reassembling. For rectangular wire, similar steps are followed but with additional taping of the coils for insulation and protection. Final testing is conducted on both types of rewinding before the generator is reassembled and delivered.

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Donnabel Cale
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82 views3 pages

Procedure & Methodology: Generators

The document outlines procedures for rewinding generator stators using either round or rectangular magnet wire. For round wire rewinding, the procedures include removing the rotor, inspecting components, stripping the old winding, cleaning the core, rewinding according to the original data, testing the new winding, baking and varnishing it, and reassembling. For rectangular wire, similar steps are followed but with additional taping of the coils for insulation and protection. Final testing is conducted on both types of rewinding before the generator is reassembled and delivered.

Uploaded by

Donnabel Cale
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOC, PDF, TXT or read online on Scribd
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P1

PROCEDURE & METHODOLOGY


GENERATORS

The following procedures should be implemented in the rewinding of generator stator

1. REWINDING OF STATOR USING ROUND MAGNET WIRE, 600 VOLTS

 Pick the unit at site & bring to DEEC workshop.


 Visual inspection of generators, lists all parts/ components for QA/QC references
slide out rotor from stator.
 Physical marking on generators, remove coupling and covers and carefully slide
out rotor from stator.
 Conduct physical inspection on the following
a. Stator core
b. Bearing housing
c. Rotor shafting
d. Bearing (NDE & DE)
e. Fan assembly
f. Frame/cover
g. Others
 Strip out burned stator winding carefully and note original winding data and
record the following information.
a. Nameplate data
b. Connection
c. Number of turn per coil
d. Wire size
e. Pitch
f. Coil per groups
g. Number of poles
h. Number of groups
i. Number of slots
j. Type of winding
k. Weight of wire
l. Number of leads out
 Clean & file out bare stator core for clinging dirts and tough edges.
P2

 Loop test bare stators are for possible hot spots and shorted lamination. Using
EASA standard.
 Paint stator core w/ GE red aerosol anti-corona paint varnish.
 Cut to size class F insulation & lay-out to stator core to insulate the core using
nomex aramid paper.
 Coil forming and rewinding of stator according to original winding data using
heavy armored round magnet wire.
 Wedges stator with polyester fiberglass board.
 Make necessary connection and weld all connections.
 Conduct initial instrumentation testing on stator winding.
a. Insulation resistance test
b. Winding resistance test
c. Polarity test
d. Surge comparison test
 Preheating/ oven baking of stator to cure moisture.
 Dip stator winding into class H GE insulating varnish.
 Re-bake stator to cure varnish and monitor until high insulation resistance is
attained.
 Conduct final instrumental testing an stator winding
a. Insulation resistance test
b. Surge comparison test
 Scrape excess varnish on stator core surfaces
 Cleaning & painting of motor interior & exterior parts.
 Replacement of bearing.
 Clean & assemble the unit.
 Paint & deliver the unit with delivery receipt, invoice & service report.

2. RE-TAPING/REWINDING OF STATOR USING RECTANGULAR MAGNET


WIRE, 600V-6600V

 Mobilization of manpower and equipment to site.


 Pick-up the unit.
 Dismantle the unit Haul motor to DEEC plant.
 Visual inspection and evaluate the unit.
 Remove stator wedges to give access for coil removal.
 Press out burned stator winding carefully and note original winding data.
 Clean and file out bare stator core for clinging dirts and rough edges.
 Conduct loop test to determine hot spots and shorted lamination.
 Paint stator core with GE red aerosol anti-corona paint varnish.
 Lay-out and cut to size class H insulation using nomex Dupont Aramid paper with
mica insulation.
P3

 Dip cleansed formed coils using boiling soda to remove insulation, clinging dirt
and carbon residue.
 Strengthen coils to original shape and formed.
 Retaping of formed coils with the following layer of insulation.
a. First layer- G.E Scotch no.5 tape with 5.5 max. voltage
dielectric strength.
b. Second layer- G.E IMI Mica-mat-tape for thermal protection
c. Third layer- Glass fiberglass tape for mechanical stress
d. Slot insulation- Nomex paper (10 mils)
e. Wedge- Phenolite board
 Dip formed coil into class H GE insulating varnish.
 Oven bake to cure varnish.
 Surge testing of coils prior to insertion on the stator slots.
 Carefully insert coils into slots and conduct insulation resistance test on every
coils inserted using a 5kva insulating tester.
 Fabricate high frequency end ring and secure both end of coils at end rings to
prevent vibration and mechanical stress.
 Conduct high potential test on stator winding by inducing a dc voltage with an
increment of 500VDC up to 12000 VDC and plot leakage current versus induced
voltage.
 Conduct the following final testing:
a. Winding insulation resistance test
b. Polarization index test
c. Winding resistance test
d. Surge comparison
 Assemble & paint the unit.
 Deliver the unit
 Demobilization
 Demobilization
 Submit test result and acceptance.

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