2008 Maintenance Manual

Figure 1

1215 KVA Rig Alternator

Electrical Department

Rig - Workshop

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Maintenance Manual for 1215 KVA, 600V Rig Alternator

Drilling Rigs of OIL India Ltd. uses BHEL & KATO make alternators for generation of electrical power. Technical Specification of these alternators is given below. H for Stator MAKE - BHEL F for Rotor FIELD VOLT TYPE OA7001 55 FIELD AMPERES MODEL NOS AZ, 155 A

AY

1215 KVA PHASE 3 FREQUENCY50 HZ RPM1000 VOLTS 600 V AMPERES 1170 A PF0.7 LAG INSULATION CLASS-

ALTERNATOR KVA

EXCITER
EXCITER FIELD AMPS 7.54 A EXCITER FIELD VOLT 63 V

1) MAINTENANCE SCHEDULE: MAKE - KATO TYPE - 22231 MODEL NO A222310000 ALTERNATOR

AMPERES 1169 A PF0.7 LAG INSULATION CLASSF TEMPERATURE RISE 85ROO C DESIGN AMB 45C

KVA 1214.29 EXCITER KVA PHASE 3 FIELD AMPS 5/ FREQUENCY50 HZ 2.5A EX. FIELD VOLT RPM1000 50 / 100 V VOLTS (PH-N/PH-PH)347V/600 V A regular preventive maintenance schedule will ensure peak performance, minimize breakdowns and maximize generator life. The schedule listed below is a guide for operating under standard conditions. Specific operating conditions may require reduced or increased maintenance intervals.

1A) Everyday (at Site)

a) Visually check generator bearing housings for any sign of oil seepage b) Check operating temperatures of the generator stator windings. c) Check the control panel voltmeter for proper stability and voltage output. d) Monitor the power factor and generator loading during normal operation e) Check for abnormal noise and vibrations.

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1B) Every week (at Site)

a) Visually inspect the bearing exterior for dirt, and clean if necessary b) Inspect generator air filters for build up of contaminants and clean or replace as required.

1C) Every months / During Rig Up (at Site)

a) Remove generator outer box cover. Visually inspect the stator output leads and insulation for cracking or damage. Check all electrical connections for tightness. Check all lead wires and electrical connections for proper clearance and spacing b) Clean the inside of the terminal box, air screens, bearing housings with compressed air and electrical solvent. c) Check vibration of the generator d) Regrease the regreaseabletype bearings e) Check insulation resistance to ground on all generator windings, including main rotating assembly, the main stator assembly, the exciter field and armature assemblies. f) Check the space heaters for proper operation g) Check the rotating rectifier connection tightness

1D) Every 4 years / Overhauling (at Rig-Workshop)

Complete Overhauling Steps:
a) Note down all IR Values all windings (armature, field coils) before dismantling. b) Completely disassemble the alternator, including rotor removal. (See disassembly and assembly procedure, point 2B) c) Carry out a complete inspection of all parts of generator for any wear & tear / abnormality. If any defect found plan your job accordingly.

d) Clean the generator winding and coils using Compressed air and Orion 77. Clean rest of generator parts with MTO (Mineral Turpentine Oil). (See cleaning procedure, point 2A) e) Inspect rotor shaft and rotor shaft bearing journals for wear or scoring, send to General Workshop if metal filling etc. is required.

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f) Check Insulation Resistance of main Stator & Rotor coils. (See the insulation resistance testing procedure, point 2F) g) Dry the windings to acceptable resistance level. (See the dry out procedure, point 2G) h) After Drying When Insulation Resistance reaches acceptable value, varnish Stator winding, Main Field, Exciter armature and Exciter Field windings with Epoxy Gel Coat (Red) & Hardener (EH 441) mixed in the ratio 3 : 1. Use thinner (Dr. beck thinner 221) as required. i) Replace the bearings and bearing caps. Grease Bearings with Castrol AP-3 j) Check wipers condition. If required change with new k) Check exciter parts and IR values l) Check all rectifiers with multi-meter. Change defective rectifiers m) Check Wiper. Replace if old one is defective/ got ceased n) Carry out necessary testing, at 35 rpm (by hand drive), minimum output voltage should be 1.0 V AC o) Paint alternator out side with desired color.

2) MAINTENANCE PROCEDURES: 2A) Cleaning

Warning: Take extreme care when using MTO & Orion77. Use only in well ventilated area and away from flame and sparks.
a) Wipe out dirt from the outside surface of alternator with a clean lint-free cloth. b) Remove stubborn accumulation of dirt on alternator metal surface using MTO (Mineral Turpentine Oil). CAUTION: Do not use MTO for cleaning any winding and pole coils. c) Clean all ventilating parts with dry compressed air at a pressure of 1.75 to 2.8 Kg/sq.cm

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d) Clean inside of alternator using dry filtered compressed air at a pressure of 1.75 to 2.80Kg/sq.cm e) Clean stubborn accumulation of dirt and grease from windings and pole coils with Orion-77 f) Open terminal box, clean terminals with xylol. CAUTION: Do not file terminal bus bars.

2B) Disassembly & Assembly of alternator

a) Remove terminal box cover and disconnect alternator phase terminals and exciter field cables. Tag leads and terminals to make sure that those terminals are correctly connected when unit is reassembled. b) Remove alternator coupling c) Remove bolts securing alternator base pads to foundation. Remove alternator to location affording sufficient room for disassembly. Attach slings to lift from eyebolts to move alternator. d) Remove exciter cover. Disconnect alternator field leads from diode wheel. Remove diode wheel retaining nut and slowly slide out the diode wheel from the shaft. Remove clips securing exciter field leads to exciter frame, alternator frame and end shield. e) Open exciter clamping bolts and remove exciter stator from end shield. f) Free the bearing housing NDE side by removing the bearing wiper and pedestal plate bolts. g) Remove end shield bolts and bearing housing bolts. Remove end shield on DE side. h) Install pipes over alternator shaft on the drive end and exciter end. Attach slings and hoist pipes to remove rotor assembly from stator by moving it axially towards DE side. Make sure that air gap is maintained between rotor and stator during removal of rotor. CAUTION: Ensure that pipes are of sufficient strength to support weight of rotor and that they do not have sharp edges which would damage shaft surface i) Assemble alternator in the reverse order of disassembly procedure. For installation of bearings and exciter follow procedure given in the point 2D & 2E respectively. j) Ensure that Rotor is aligned with the stator. k) Measure air gap. Ensure air gap as follows.

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Air-gap between Main field rotor & stator windings Top - 4.15 mm Side - 4.10 mm Side - 1.85 mm Side - 4.10 mm Air-gap between Exciter Armature & Fields Top - 2.3 mm Side - 1.85 mm 2C) Exciter Armature & Rotating Rectifier assembly Removal
Remove exciter armature and rotating diode wheel as separate units as per instruction given below. a) Remove exciter cover. Disconnect alternator field leads from positive(+) and negative(-) terminals located on the heat sink of the rotating rectifier assembly. Remove diode wheel by unscrewing the nut at the end of shaft. b) The diode wheel and exciter armature are SLIP FIT on alternator shaft. If the individual diode wheel and exciter armature cannot be removed by hand , use extraction holes provided alongwith puller as described below. CAUTION: Do not pull on rotating rectifier assembly. - Bolt to the end of the sleeve a metal plate and hook a bearing puller to the metal plate and pull the rotating rectifier assembly from the shaft. - The exciter armature hub is also provided with two M10 extraction holes. Use long studs and bolt the metal plate. Hook a bearing puller to the metal plate and pull the exciter armature assembly from the shaft same as that for diode wheel.

2D) Bearing Installation:

a) Roller bearing: Inner bearing sleeve, bearing wiper and bearing inner race of roller bearing should be heated to a temperature of about 100OC for about 1 hour and shrunk fitted on the shaft. Assemble the alternator after the bearing has cooled. b) Ball Bearing: Fit the bearing on shaft. Then use a fibre or soft metal tube to tap bearing into place. Make certain that pressure is applied only to the bearing inner ring. Press bearing onto shaft until inner ring is against bearing shoulder on the shaft.

Bottom - 3.95 mm

Bottom - 1.70 mm

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2E) Exciter Armature & Diode wheel Assembly Installation

The exciter armature will be installed first followed by the diode wheel. a) Place the key in position on the alternator shaft and align the exciter armature and fix it in position on shaft b) Place the key in position on the alternator shaft and align the diode wheel and lock in position. If the SLIP FIT exciter armature and diode wheel do not slide easily onto the shaft by hand, install with fixture as shown in figure, page 16 of BHEL maintenance manual. Note: If the exciter armature and diode wheel do not slide smoothly on the shaft, each can be lightly tapped on the sleeve with a soft rubber or fibre mallet. Make sure that mallet hits only the sleeve, not rectifier assembly or armature winding. c) Install diode wheel retaining bolt and washer. Connect alternator field leads to positive(+) and negative(-) terminal located on the heat sink of the rotating rectifier assembly. Also connect leads between exciter armature and diode wheel. Install exciter cover

2F) Insulation Resistance Test at low voltage

Insulation tests are conducted for two reasons: to discern existing weakness or faults or to give some indication of expected service reliability. Insulation resistance tests are based on determining the current through insulation and across the surface when a direct voltage is applied. The current is dependent upon the voltage and time of application, the area and thickness of the insulation, and the temperature and humidity condition during the test. The insulation resistance test is used to determine the insulation condition prior to application of more extensive testing measure. Refer to the following electrical measurement procedures for testing details. Refer IEEE Standard, 432-1992 when more extensive insulation tests are required. A hand cranked megger of not over 500 volts is a convenient and safe means of testing insulation resistance.

a) Exciter field (stator)

1. Disconnect the exciter leads from the terminals in the terminal box. 2. Connect exciter leads to one clamp of 500-volt megger, and connect the other clamp to the generator frame.

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3. Apply 500 volts from the megger, and measure the resistance reading after one 1 minute. The reading must be a minimum of 1.6 mega ohm. If it is not, refer to the dry out procedures. 4. Ground the exciter field leads to the generator frame for several minutes after the megger has been disconnected. This will allow the voltage build up be properly discharged.

b) Exciter armature
1. Disconnect the exciter armature leads from the rotating rectifiers. 2. Connect the leads of exciter armature to one clamp of a 500 volt megger, and connect the other clamp to suitable connection on the shaft. 3. Apply 500 volts from the megger, and measure the resistance reading after 1 minute. The reading must be a minimum of 1.6 mega ohm. If it is not, refer to the dry out procedure. 4. Ground the exciter leads to the shaft after disconnecting the megger. This will allow the voltage build up to be properly discharged.

c) Main rotor
1. Disconnect the generator field leads from the positive and negative terminals of the rotating rectifier. 2. Connect the positive and negative leads to one clamp of the 500-volt megger, and connect the other clamp to the shaft. 3. Apply 500 volts from the megger, and measure the resistance reading after 1 minute. The reading must be a minimum of 1.6 mega ohm. If it is not, refer to the dry out procedures. 4. Ground the field leads to the shaft after disconnecting the megger. This will allow the voltage build up to be properly discharged. 1. Disconnect power connections and all control apparatus from the generator terminals. 2. Measure insulation resistance of each phase separately with the two other phases shorted to the frame. 3. Use a 500-volt megger connected between the lead(s) of the phase to be measured and generator frame. The minimum 1 minute insulation resistance must not be less than that given by following formula:

d) Main stator

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Resistance in megaohms= Rated Generator voltage +1000 1000 If the resistance is less than above, refer to dry out procedures 4. Ground the leads to the frame after the 1 minute megger test. This will allow the voltage build up to be properly discharged.

2G) Dry Out Procedures

If the insulation resistance is below the recommended minimum values dry it in the hot box (by hot air) at 90OC for 8 to 10 hours. Measure Insulation Resistance at 2 hours interval. Typically, the insulation resistance will slowly drop while the temperature is coming up and then gradually increase and level out. CAUTION: Use a forced air circulating oven not a radiant type, because the latter would overheat some parts of the alternator before remote parts reach the required temperature.

3) LIST OF TEST EQUIPMENTS/TOOLS REQUIRED FOR INSTALLATION AND MAINTENANCE

Test Equipment Notes Ammeter Clamp-on 0-500Amp range Multimeter For measurement of Amp, Voltage, Frequency and resistance. Thermometer For temperature measurement Megger To

measure insulation resistance Resistance Bridge To measure resistance of winding Special Tools Notes Bearing Puller For changing bearing Exciter Puller For pulling exciter armature Standard tools Notes Cable tool Crimping Flash light As required Grease Gun For lubricating bearing Hammer Soft-faced Lamp(incandescent) Safety light Screwdrivers Standard size as required Screwdrivers Philips, size as required Wrench Adjustable, 12-inch Wrench Torque 0 to 100ft-lb Wrench set Allen, 1/8 to inch Wrench set Socket, to 1 inch with 3/8 and inch drive

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Wrench set Standard,open-end/box-end combination sized1/4 to 1 inch Vacuum Cleaner Electric with nonmetallic nozzle Materials Air Compressed, dry Corrosion inhibitor Nox-Rust VC # 10 Oil or equivalent Covering materials Waterproof desiccant bags for protection from moisture during long-term equipment storage. Detergent As required for cleaning Gloves Chemical-protective Gloves Electrical protective Heaters Space heater, for eliminating excess moisture in damp areas and dry out of motor or generator windings. Plastic Protection for long-term storage Rags As required for cleaning Water Warm & clean, for cleaning Tags Warning & caution

4) REFERENCES
a) Bearing Lubrication Refer KATO manual page no 34. b) Rectifier Tests:

Refer KATO manual page no 35. c) Disassembly Refer KATO manual page no 37 d) Assembly. Refer KATO manual page no 40 e) Troubleshooting (Corrective maintenance). Refer KATO manual page no 43. f) Maintenance of BHEL alternator BHEL alternator Maintenance Manual