Rapport - Report R YYYY 2012-XXX

Renewable
Hydro Generators

Författare - Author - From

Från Datum - Date Reg. Sida - Page
xxxxxxxxx HSNC 2012-XX-XX 1
Godkännare - Approved by Utredning, teoretisk undersökning Ordernr - Ref.No
B Kjall Analysis, theoretical investigation 72Pxxx-yyyy
Uppdragsgivare - Requested by Provning, experimentell undersökning
yyyyyyyyy Test, experimental investigation
Granskare - Examined by Delrapport Antal sidor - No. of pagest
xxxxxxxxx Partial report 19
Slutrapport
Final report
Titel
Inspection of Generator unit 2 at Kotmale Hydro Power Station

Inspection of Kotmale Unit 2, performed during the period

2003-mm-dd - 2003-mm-dd.

Meet with the following persons:

NN Ceylon Electricity Board

Sammanfattning - Summary

Distribution

This document must not be copied without our written permission, and the contents therefore not be imparted to a third party nor
be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 2
Inspection of Kotmale unit 2.

LIST OF CONTENT
1 POWER STATION AND GENERATOR DATA .................................................................... 3
1.1 Power plant .................................................................................................................... 3
1.2 Generator ...................................................................................................................... 3
1.3 Operation data ................................................................................................................ 3
1.4 Turbine ......................................................................................................................... 3
1.5 Lifting capacity .............................................................................................................. 3
2 MEASUREMENTS AND OBSERVATIONS DURING OPERATION ..................................... 4
2.1 Comments / History ........................................................................................................ 4
2.2 Actual load data ............................................................................................................. 4
2.3 Temperature................................................................................................................... 4
2.4 Other important parameters ............................................................................................. 5
2.5 Other observations .......................................................................................................... 5
3 INSPECTION OF GENERATOR COMPONENTS AT STANDSTILL..................................... 6
3.1 Accessibility at inspection ............................................................................................... 6
3.2 Inspected generator components....................................................................................... 6
3.3 Stator, winding with supporting details ............................................................................. 7
3.4 Stator, terminals with supports ......................................................................................... 7
3.5 Stator, pressure plates and pressure fingers ........................................................................ 8
3.6 Stator, core .................................................................................................................... 8
3.7 Stator, frame with foundation connections......................................................................... 8
3.8 Stator, winding cover and air screen ................................................................................. 9
3.9 Air cooler with piping ..................................................................................................... 9
3.10 Rotor, pole ................................................................................................................... 10
3.11 Rotor, ring, spider, hub, torque transfer, cover plates ........................................................ 10
3.12 Rotor terminal .............................................................................................................. 11
3.13 Excitation terminal ....................................................................................................... 11
3.14 Sliprings ...................................................................................................................... 11
3.15 Brush gear ................................................................................................................... 12
3.16 Exciter, brushless (AC) ................................................................................................. 12
3.17 Exciter, DC .................................................................................................................. 12
3.18 Control / protection wiring and equipment ...................................................................... 13
3.19 Generator top ............................................................................................................... 13
3.20 Upper bracket .............................................................................................................. 13
3.21 Lower bracket .............................................................................................................. 14
3.22 Braking equipment ....................................................................................................... 14
3.23 Thrust bearing combined with guide bearing ................................................................... 15
3.24 High pressure oil lubrication .......................................................................................... 16
3.25 Guide bearing, separate ................................................................................................. 16
3.26 Oil cooler with piping, thrust bearing.............................................................................. 17
3.27 Oil cooler with piping, guide bearing .............................................................................. 17
3.28 Tooth wheel ................................................................................................................. 17
3.29 Shaft current transformer ............................................................................................... 18
4 MEASUREMENTS AT STANDSTILL ............................................................................... 19
4.1 Insulation resistance to earth (IR) ................................................................................... 19
4.2 Polarization-Index (PI) .................................................................................................. 19

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 3
Inspection of Kotmale unit 2.

1 POWER STATION AND GENERATOR DATA

1.1 Power plant

Name
River

1.2 Generator
Type designation
Unit-number
Serial-number
Manufacturer
Year of commissioning
Cross section drawing
Rating data
Power MVA * Φ
Voltage kV
Current A
Speed rpm
Excitation A V
Type of excitation

1.3 Operation data

Previous inspection performed:

Total operation hours:

Operation hours for the period

(yyyy-mm-dd - yyyy-mm-dd)

Total number of starts och stops:

Number of starts och stops for the

period (yyyy-mm-dd - yyyy-mm-dd)

Operation environment/surrounding:

Type of operation:

1.4 Turbine
Manufacturer
Type
Power MW
Head m
3
Flow m /s
Speed rpm

1.5 Lifting capacity

Number of overhead cranes
Crane capacity ton

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 4
Inspection of Kotmale unit 2.

2 MEASUREMENTS AND OBSERVATIONS DURING OPERATION

2.1 Comments / History

2.2 Actual load data

Power MW
Reactive Power Mvar
Voltage V
Current A
Excitation voltage V
Excitation current A

2.3 Temperature

Stator core °C
Stator winding, phase R °C
Stator winding, phase S °C
Stator winding, phase T °C

Cooling air, warm °C

Cooling air, cold °C
Cooling water, cold °C

Thrust bearing segment °C

Guide bearing segment (comb thrust °C
and guide bearing)
Guide bearing segment (separate guide °C
bearing)

Oil, warm °C
Oil, cold °C

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 5
Inspection of Kotmale unit 2.

2.4 Other important parameters

Water flow, air coolers l/min

Water flow, oil coolers thrust bearing l/min
Water flow, oil coolers separate guide l/min
bearing

Oil pressure, thrust bearing bar

Oil flow, thrust bearing l/min

Oil flow, separate guide bearing l/min

Oil level, thrust bearing mm

Oil level, separate guide bearing mm

Brake pressure bar

Braking time sek
Temperature of brake track (at °C
stoppage)

Shaft voltage at no load and excited V

Ozone content, generator chamber ppm

Type of equipment
Ozone content, surrounding areas ppm
Type of equipment

Shaft throw:
Axial location No exc Exc
mm mm
mm mm
mm mm
mm mm

Measuring equipment:

Vibration in stationary part:

Component No exc Exc
mm/s mm/s
mm/s mm/s
mm/s mm/s
mm/s mm/s

Measuring equipment:

2.5 Other observations

Sparking on commutator

Sparking on sliprings

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 6
Inspection of Kotmale unit 2.

3 INSPECTION OF GENERATOR COMPONENTS AT STANDSTILL

3.1 Accessibility at inspection

3.2 Inspected generator components

Component Inspected
Yes No
Stator, winding with supporting details

Stator, terminals with supports

Stator, pressure plates and pressure fingers

Stator, core

Stator, frame with foundation connections

Stator, winding cover and air screen

Air cooler with piping

Rotor, pole

Rotor, ring, spider, hub, torque transfer, cover plates

Rotor terminal

Excitation terminal

Sliprings

Brush gear

Exciter, brushless (AC)

Exciter, DC

Control / protection wiring and equipment

Generator top

Upper bracket

Lower bracket

Braking equipment

Thrust bearing combined with guide bearing

High pressure oil lubrication

Guide bearing, separate

Oil cooler with piping, thrust bearing

Oil cooler with piping, guide bearing

Tooth wheel

Shaft current transformer

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 7
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.3 Stator, winding with supporting details

Inspection item Check of A B C

1 Winding General impression

2 Coil ends, normal side Cleanliness, cracks, disharge prod

3 Coil ends, connection side Cleanliness, cracks, disharge prod

4 Coil- and interconnections Cleanliness, cracks, movements

5 Coil- and interconn. bracing Tightness, disharge & wear

products

6 Coil end supports, normal Cracks, disharge & wear products

side tightness

7 Coil end supports, Cracks, disharge & wear products

connection side tightness

8 Coil section in slot Cleanliness, movements, disharge

& wear products

9 Coil sliding Supporting

10 Slot wedges Tightness, movement

Comment to inspection item:

3.4 Stator, terminals with supports

Inspection item Check of A B C

1 Terminal bars Damaged insulation, movement

2 Insulators Cleanliness, cracks

3 Terminal bar joints Discoloration, tightness

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 8
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.5 Stator, pressure plates and pressure fingers

Inspection item Check of A B C

1 Pressure fingers Contact to core, rust, movement

2 Pressure plates Tightness

3 Clamping bolts Tightness, locking

Comment to inspection item:

3.6 Stator, core

Inspection item Check of A B C

1 Lamination, at the air gap Cleanliness, rust, hot spots,

pressure

2 Lamination, at the back Cleanliness, rust, buckling,

side pressure

3 Lamination, under pr finger Rust, vibrations

4 Air duct Cleanliness, deformation, tilting air

duct spacers

5 Stator joint Rust, vibrations, buckling, presspan

Comment to inspection item:

3.7 Stator, frame with foundation connections

Inspection item Check of A B C

1 Frame Cleanliness, rust, vibrations, cracks

2 Stator joint bolts Tightness, wear products

3 Stator feet Rust, movement, wear products

4 Foundation plate / Supporting, cavity, cracks

Concrete

Commen for inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 9
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.8 Stator, winding cover and air screen

Inspection item Check of A B C

1 Covers Cleanliness, cracks

2 Joints Movements, cracks

3 Bolt joints Discoloration, tightness, locking

4 Air screens Cleanliness, movement, supporting

5 Brush sealing Supporting, wear

Comment to inspection item:

3.9 Air cooler with piping

Inspection item Check of A B C

1 Assembly on the stator Rust, movement, sealing

2 Valves Leakage, corrosion, function

3 Piping Leakage, corrosion, supporting

4 Air cooler Leakage, cleanliness, fins

5 Tubes, end plates Supporting, leakage, corrosion

6 Flow meter Function, leakage

7 Ventilation system Cleanliness, function

8 Air filter Cleanliness

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 10
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.10 Rotor, pole

Inspection item Check of A B C

1 Coils, insulation Cleanliness, cracks, clearances,

movements

2 Coil to coil connection Discoloration, cracks, movements,

locking

3 Coil supports Cleanliness, movements, cracks

4 Coil support straps Discoloration, movements,

(binding) tightness

5 Pole wedges Rust, movements, locking

6 Short circuit ring Cracks, movements, locking, guide

pin

7 Damper winding Discoloration, deformation,

movement, locking

Comment to inspection item:

3.11 Rotor, ring, spider, hub, torque transfer, cover plates

Inspection item Check of A B C

1 Rotor ring Cleanliness, rust, movement

2 Rotor ring bolts Tightness, locking

3 Support plates Contact/verticality, rust, movement

4 Rotor spider Cleanliness, cracks

5 Wedges (keys) ring/spider Rust, wear, movement

6 Wedges (keys) spider/shaft Rust, wear, movement

7 Cover plates, screw joints Rust, movement, tightness, locking

8 Brake track Discoloration, scratches, cracks,

deformation, cleanliness

9 Brake track, bolts Tightness, locking

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 11
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.12 Rotor terminal

Inspection item Check of A B C

1 Insulation and support Cleanliness, movements, cracks

2 Bar Cleanliness, movements, insulation

3 Joints Tightness, locking

Comment to inspection item:

3.13 Excitation terminal

Inspection item Check of A B C

1 Insulation and support Cleanliness, movements, cracks

2 Bar Cleanliness, movements, insulation

3 Joints Tightness, locking

Polarity switch Cleanliness

Comment to inspection item:

3.14 Sliprings
Inspection item Check of A B C

1 Sliprings Cleanliness, surface finish, polarity

wearing

2 Insulation Cleanliness, damages

3 Hub Rust, movement

4 Earthing screws Exists / Exists not

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 12
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.15 Brush gear

Inspection item Check of A B C

1 Brush gear Cleanliness, mounting, supporting

2 Insulation Cleanliness, damages

3 Brush holder Cleanliness, supporting

Comment to inspection item:

3.16 Exciter, brushless (AC)

Inspection item Check of A B C

1 Stator Cleanliness, insulation damages,

loose connections

2 Rotor Cleanliness, insulation damages

3 Diode bridge Cleanliness, abnormal heating,

wear, supporting

4 Brushes Wear

5 Sliprings Scratches, discoloration

6 Air filter Cleanliness, supporting

Comment to inspection item:

3.17 Exciter, DC
Inspection item Check of A B C

1 Stator Cleanliness, insulation damages

2 Rotor Cleanliness, insulation damages

3 Commutator Cleanliness, wear

4 Brushes Wear

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 13
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.18 Control / protection wiring and equipment

Inspection item Check of A B C

1 Cables Cleanliness, damages

2 Equipment Function

Comment to inspection item:

3.19 Generator top

Inspection item Check of A B C

1 Top Cleanliness, movement, supporting

2 Covers Supporting

3 Filter Supporting, cleanliness

Comment to inspection item:

3.20 Upper bracket

Inspection item Check of A B C

1 Bracket Cleanliness, vibrations, cracks

2 Bracket foot Rust, movement, wear, supporting

3 Welded joints Rust, cracks

4 Screw joints Vibrations, movements, tightness,

locking

5 Radial supports Movement, tightness

6 Cover plates Vibrations, tightness, locking

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 14
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.21 Lower bracket

Inspection item Check of A B C

1 Bracket Cleanliness, vibrations, cracks

2 Welded joints Rust, cracks

3 Screw joints Vibrations, movements, tightness,

locking

4 Radial supports Movement, tightness

5 Bracket foot Rust, movement, wear, supporting

6 Foundation plate / Supporting, cavity, cracks

Concrete

5 Cover plates Vibrations, tightness, locking

Comment to inspection item:

3.22 Braking equipment

Inspection item Check of A B C

1 Braking equipment Function

2 Brake jacks Function, leakage

3 Brake plate lining Wear, damages

4 Piping Leakage

5 Oil pump (for lifting) Function, leakage

6 Brake panel Function, leakage

7 Compressor Function, leakage

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 15
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.23 Thrust bearing combined with guide bearing

Inspection item Check of A B C

1 Bearing complete (frame) Leakage

2 Sealing cover/shaft Leakage, wear

3 Oil cup Leakage

4 Thrust block, guide bearing Wear, scratches, discoloration

surface

5 Guide bearing segment Wear, scratches, discoloration,

binding

6 Thrust block, thrust bearing Wear, scratches, discoloration

surface

7 Thrust bearing segment Wear, scratches, discoloration,

binding

8 Sealing, pressure chamber Wear, delamination

9 Sealing, oil seal sleeve Wear, delamination

10 Radial- and tangential Movement, rust, tightness

support

11 Bearing insulation Cleanliness, cracks, megging

12 De-ventilation Function, leakage

13 Barring ventilation Exists / Exists not

14 Oil level indicator Function, leakage

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 16
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.24 High pressure oil lubrication

Inspection item Check of A B C

1 Tryckoljeutrustning Function, leakage

2 Pumpaggregat Leakage, supporting

3 Valve block Leakage, supporting

4 Suction filter Leakage, pressure drop

(cleanliness)

5 Pressure filter Leakage, pressure drop

(cleanliness)

6 Piping Leakage, supporting

7 Turning by manpower Number of persons

Comment to inspection item:

3.25 Guide bearing, separate

Inspection item Check of A B C

1 Bearing complete (frame) Leakage

2 Sealing cover/shaft Leakage, wear

3 Oil cup Leakage

4 Guide bearing sleeve Wear, scratches, discoloration

5 Guide bearing segment Wear, scratches, discoloration,

binding

6 Centrum connection to Movement, rust, tightness

bracket

7 Radial- and tangential Movement, rust, tightness

support

8 Bearing insulation Cleanliness, cracks, megging

9 De-ventilation Function, leakage

10 Barring ventilation Exists / Exists not

11 Oil level indicator Function, leakage

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 17
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

Comment to inspection item:

3.26 Oil cooler with piping, thrust bearing

Inspection item Check of A B C

1 Oil cooler Leakage, corrosion, supporting

2 Piping Leakage

3 Flow meter Function, leakage

Comment to inspection item:

3.27 Oil cooler with piping, guide bearing

Inspection item Check of A B C

1 Oil cooler Leakage, corrosion, supporting

2 Piping Leakage

3 Flow meter Function, leakage

Comment to inspection item:

3.28 Tooth wheel

Inspection item Check of A B C

1 Tooth wheel Exists / Exists not

2 Tooth wheel Supporting

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 18
Inspection of Kotmale unit 2.

A = Take measures
B = Remark, but measures not required
C = Whithout remark

3.29 Shaft current transformer

Inspection item Check of A B C

1 Shaft current transformer Exists / Exists not

2 Shaft current transformer Supporting

Comment to inspection item:

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB
 R YYYY 2012-XXX Page 19
Inspection of Kotmale unit 2.

4 MEASUREMENTS AT STANDSTILL

4.1 Insulation resistance to earth (IR)

Measurement to check the condition of the insulation material.

Generator, stator winding MΩ

Generator, rotor winding MΩ
Air temperature °C
Relative humidity %
Measuring equipment

Exciter, stator winding MΩ

Exciter, rotor winding MΩ
Air temperature °C
Relative humidity %
Measuring equipment

Bearing insulation MΩ
Measuring equipment

4.2 Polarization-Index (PI)

Measurement to check the condition of the insulation material.

Generator, stator winding PI = R10 min/R1 min

Measuring equipment

This document must not be copied without our written permission, and the contents therefore not be imparted to a thired party
nor be used for any unauthorized purpose. Contravention will be prosecuted. ALSTOM Power Sweden AB