Field Service Report on

Installation, Testing and Commissioning of 8 MW Refurbished Generator Stator

Monnet IIspat & Energy Liimiited,, Mandiir Hasuad,, Raiipur Monnet spat & Energy L m ted Mand r Hasuad Ra pur

MIEL Work Order No. WOR11-00047 dated 21.04.2011

Report No. RP.1007.01

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FIELD SERVICE REPORT

Customer Site/Unit Date Assignment Author Contact Person

Monnet Ispat & Energy Limited, Mandir Hasuad, Raipur (CG) 60 MW Power Plant/TG1 26 November 2011
Installation, testing and Commissioning of 8 MW Generator Refurbished Stator

Anil K Panjani (+91 97699 71631) Conrad Pinto (+91 98200 49919)

Date: 28 November 2011 Place: MIEL, Mandir Hasuad

Anil K Panjani for EMRS, Navi Mumbai

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1. Preamble
Monnet Ispat & Energy Limited, Raipur (MIEL) has placed a Work Order No. WOR11-00047 dated 21st April 2011 on The Electrical Rotating Machine Service Company, Navi Mumbai (ERMS) for installation, testing and commissioning of 8 MW refurbished generator stator. The scope of work is as given as an attachment in Annex 1.

2. Executive Summary
ERMS Team mobilized at MIEL Power Plant on the morning of 17th November 2011 to carry out the work of Installation, Testing and Commissioning of 8 MW Refurbished Generator Stator as per the scope of work. The work was completed on 25th November 2011 and the delay was due to additional work for replacement of generator bearings. The unit was synchronized at 18:52 hours on 26th November 2011 and performance was observed to be satisfactory. Following were observed during dismantling and re-assembly of generator: Heavy oil leakage observed on the Turbine End and also on Exciter end Seal oil clearances found in the order of 0.25 0.35 mm which are abnormally higher than acceptable values Exciter air-gap variation found to be 45% from average value against accepted value of 10%. The bore of exciter has become oval and may affect the performance Inner oil seal on Turbine End has damaged badly and need immediate replacement

Exciter end bearing was replaced with new spare available with MIEL. While replacing the Turbine End bearing it was observed that the outer diameter of the bearing shell is less than the bore of the bearing housing and hence rejected. The rejected bearing is not useable. Seal oils were assembled with proper clearances except inner oil seal on Turbine End (bottom clearance is now 0.33 mm). The clearance during dismantling was found to be 0.25 0.35 mm. EMRS Team demobilized from site on 28th November 2011 after completion of the assigned work. Recommendation is to replace the bearing oil seals and exciter at the earliest to get optimum performance from the generator.

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3. Generator Details
Unit ID Serial No. Application: Make: Frame: Rating: Rating: Power Factor: Voltage: Frequency: Pole: Speed: Current: Insulation: Connection: Duty: Type of cooling: Degree of protection D-bearing: N-bearing: Oil viscosity: Generator air-gap: TG1 49057A261-11-01 Triveni Bangalore Steam Turbine thru gear box BHEL, Bhopal G85952 10,000 KVA 8,000 kW 0.80 11,000 V 50 Hz 4 1500 rpm 525 A Class F Star S1 CACW IP 54 D280xL220 (forced oil lubricated, located and insulated) D280xL220 (forced oil lubricated, non-located and insulated) ISO VG 68 25 mm

4. Brushless Exciter Details

Unit ID Serial No. Make: Type: Rating: Voltage: Current Excitation voltage Excitation current Frequency: Pole: Speed: TG1 49057A261-11-01 BHEL, Bhopal Brushless 65 kW 151 V 430 A 165 V 4.8 A 150 Hz 12 1500 rpm

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5. Purpose and Duration of Assignment

Purpose of Assignment Arrival Departure
28-11-2011

Installation, Testing and Commissioning of 8 MW generator 17-11-2011 refurbished stator

6. Manpower Deployment

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7. Site Activity on Thursday, 17 November 2011 (Manpower 2 + 3) 1. Site mobilization started 2. Marking on generator components for dismantling process completed 3. Disconnection of C&I and electrical connections (by MIEL)

8. Site Activity on Friday, 18 November 2011 (Manpower 3 + 8) 1. Site mobilization with tools and tackles completed 2. Generator dismantling started 3. Removal of water pipelines 4. Generator coolers removed 5. Generator covers removed 6. Balance C&I and electrical disconnections by MIEL 7. Removal of bearing oil pipelines 8. De-coupling after taking the existing alignment readings
Radial Alignment Readings +0.00 -0.25 -0.27 -0.02 Axial Alignment Readings +0.00 +0.05 +0.05 +0.02

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9. Checked exciter air-gaps and removed exciter stator

Pole No. Air-gap Deviation Rotor Pos Pole No. Air-gap Deviation Rotor Pos

1 2 3 4 5 6

1.35 1.38 1.20 1.18 0.98 1.34

-10.7% -08.8% -20.7% -22.0% -35.2% -11.4%

8 9 10 11 12 1

7 8 9 10 11 12

1.55 2.03 1.80 1.92 1.71 1.71

+02.5% +34.2% +19.0% +26.9% +13.1% +13.1%

2 3 4 5 6 7

Exciter air-gap variation is abnormally high than the acceptable limits of 5% (or maximum 10%) and need immediate attention to rectify the same.

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10.

Bearings protocol completed Bearing Housing/Bearing Shell Clearance (all values in mm) Turbine End Exciter End Avg. Side Avg. Pos Top Avg. Side Avg. 0.15 1-LF 0.30 0.15 0.17 2-LR 0.31 0.13 0.3125 0.2050 0.3075 0.1500 0.24 3-RF 0.31 0.12 0.26 4-RR 0.31 0.20 Clearance +0.1075 Clearance +0.1575 Less shim thickness -0.0500 Less shim thickness -0.0500 Final clearance +0.0575 Final clearance +0.1075

Pos 1-LF 2-LR 3-RF 4-RR

Top 0.31 0.32 0.30 0.32

Pos 1 2 3 4

Top Oil Clearance (all values in mm) Turbine End Exciter End Top Avg. Pos Top Avg. 0.56 T-end 1 0.62 T-end 0.55 2 0.64 0.5625 0.6325 0.57 3 0.63 0.57 E-end 4 0.64 E-end Top Oil Clearance 0.5625 Top Oil Clearance Side Oil Clearance @ 25 mm depth (all values in mm) Turbine End Exciter End Top Avg. Pos Top Avg. LF 1 LF LR 2 LR 2.49 2.49 RF 3 RF RR 4 RR Side Oil Clearance 2.49 Side Oil Clearance Turbine End Oil Seal Clearance Outer Oil Seal Inner Oil Seal Found up to 0.25 0.35 mm Exciter End Oil Seal Clearance Outer Oil Seal Inner Oil Seal Found up to 0.25 0.35 mm

0.6325

Pos 1 2 3 4

2.49

Found up to 0.25 0.35 mm

Found up to 0.25 0.35 mm

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11.

Measurement of generator air-gaps Turbine Side Readings 25.0 24.5 25.0 26.0 Exciter Side Readings 25.0 27.0 25.0 24.0

Air gap deviation from average value is 3.50% on T-end and 6.90% on E-end.

12.

Inner oil seal of turbine end bearing found badly damaged and need replacement

13. Heavy oil leakage observed on the turbine end side of the generator and also on exciter
side. Turbine side oil leakage is abnormally high and calls for immediate attention.

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9. Site Activity on Saturday, 19 November 2011 (Manpower 2 + 8) 1. Inspection and testing of refurbished stator
Insulation Resistance Test @ 5000 V DC
Phase W-phase U-phase V-phase WUV-ph Criteria Analysis U V 5000 5000 5000 5000 I30 nA IR30 M 8,000 6,000 5,000 4,000
o

I60 nA

IR60 M 10,000 9,000 8,000 6,000

IR60 M 4,061 3,655 3,482 2,612 40oC

Cap nF 64.4 63.8 63.8

Temp. o C 27.0 27.0 28.0 28.0

Humidity %

IR1 min > 100 M at 40 C as per IEEE 43-2000 Insulation resistance of stator winding is well above the minimum value and this means dry condition and absence of any significant contamination

Insulation Diagnostic Test @ 5000 V DC

Phase W-phase U-phase V-phase WUV-ph Criteria I30 nA IR30 M 8,000 6,000 5,000 4,000
DAR

I60 nA -

IR60 M 10,000 9,000 8,000 6,000

PI

I600 nA

IR600 M 60,000 50,000 30,000 20,000

DAR 1.25 1.50 1.60 1.50

PI 6.00 5.56 3.75 3.33

< 1.0 1.0 - 1.25 1.25 - 1.60 > 1.6 Analysis W-phase U-phase V-phase WUV-ph
DAR

< 1.0 < 2.0 2.0 - 4.0 > 4.0

PI

Alarm Caution Good Very Good

Very Good Very Good Very Good Very Good

Very Good Very Good Very Good Very Good

Measurement of Stator Winding Resistance

W-U m 61.700 72.471 -0.325% U-V m 61.800 72.589 -0.488% V-W m 61.000 71.649 0.813% Average per Phase m m 61.500 30.750 72.236 36.118 from average value Temp. oC 29 75 RH %

measured corrected deviation Criteria Analysis

Deviation (%) should be within 3% from the average value Deviation (%) of stator winding resistance is within the acceptable limits and hence it can be safely assumed that stator windings are healthy

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2. Rotor thread-out

3. Old stator removal from bed plate

4. Removal of bearings and components 5. Generator dismantling completed. 6. Cleaning of components started.

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10. Site Activity on Sunday, 20 November 2011 (Manpower 2 + 8) 1. Rotor and exciter cleaning 2. Testing of exciter
Exciter Stator Insulation resistance measured 100 M with 250 V dc insulation testers at 28oC i.e. 31 M at 40oC Winding resistance measured is 300 m at 28oC i.e. 353.714 at 75oC Exciter Rotor Insulation resistance measured 10 M with 100 V dc insulation testers at 28oC i.e. 3 M at 40oC Winding resistance measured is 24.60 m at 28oC i.e. 29.005 at 75oC

3. Placement of refurbished stator on the bed plate 4. Rotor thread-in 5. Assembly of pedestal bearings

6. Spare bearings shifted from store to TG1

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11. Site Activity on Monday, 21 November 2011 (Manpower 2 + 8) 1. Generator alignment started 2. Initial alignment completed and the readings are as follow:

Radial Alignment Readings +0.00 -0.23 -0.25 0.00

Axial Alignment Readings +0.00 +0.02 -0.04 +0.07

3. MIEL conveyed the decision to replace both the bearings with new bearings available as
spares as the top oil clearances are likely to be on higher side

4. Spare bearings were replaced and top oil clearances measured are as follow:

Pos 1 2 3 4

Top Oil Clearance (all values in mm) Turbine End Bearing Exciter End Bearing Avg. Pos Avg. 0.42 T-end 1 0.42 T-end 0.45 2 0.40 0.505 0.457 0.62 3 0.52 0.53 E-end 4 0.49 E-end Top Oil Clearance 0.505 Top Oil Clearance

0.457

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12. Site Activity on Tuesday, 22 November 2011 (Manpower 2 + 8) 1. MIEL conveyed the decision at 10:00 hours to assemble the generator with old bearings. 2. Removal of new bearings installed earlier and assembly of generator with old bearings. 3. Decision taken to assemble the generator with new spare bearings from reliability point
of view and EMRS agreed to arrange for a specialist to carry out the necessary work on new bearings.

4. New spare bearings installed earlier were removed.

5. Bearing specialist of ERMS arrived at site in the evening for installation of new bearings. 6. New bearings preliminary work started for Exciter End.

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13. Site Activity on Wednesday, 23 November 2011 (Manpower 3 + 8) 1. Work on new spare bearings installation started.

2. Exciter end bearing installation completed after blue matching and protocol. 3. Turbine end bearing found loose in the bearing housing by 0.15 mm and got rejected.
MIEL informed to use the old bearing at Turbine End.

4. Turbine end bearing installation completed after blue matching and protocol. 5. Bearing protocol final readings are as follow.
Top Oil Clearance (all values in mm) Turbine End Exciter End Top Avg. Pos Top Avg. 0.530 T-end 1 0.580 T-end 0.540 2 0.570 0.580 0.600 3 0.620 E-end 4 0.580 E-end Top Oil Clearance 0.570 Top Oil Clearance Side Oil Clearance (all values in mm) Turbine End Exciter End Top Avg. Pos Top Avg. 0.20 1 0.30 0.20 2 0.30 0.20 0.30 0.20 3 0.30 0.20 4 0.30 Side Oil Clearance 0.20 Side Oil Clearance

Pos 1 2 3 4

0.580

Pos 1 2 3 4

0.20

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Pos 1 2 3 4

Top 0.64 0.58 0.59 0.62

Bearing Housing/Bearing Shell Clearance (all values in mm) Turbine End Exciter End Avg. Side Avg. Pos Top Avg. Side 0.47 1 0.57 0.47 0.47 2 0.56 0.47 0.6075 0.47 0.575 0.47 3 0.58 0.47 0.47 4 0.59 0.47 Clearance 0.1375 Clearance Less shim thickness 0.0500 Less shim thickness Final clearance 0.0875 Final clearance

Avg. 0.47 0.105 0.050 0.055

6. Alignment started.

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14. Site Activity on Thursday, 24 November 2011 (Manpower 2 + 8) 1. Generator alignment with gear box continued.

2. Final alignment completed and readings are as follow:

Radial Alignment Readings 0.00 -0.09 -0.16 -0.05 Axial Alignment Readings 0.000 0.005 +0.005 0.000

3. Final generator air-gap readings are as follow:

Turbine Side Readings 24.5 24.5 24.8 26.0 Exciter Side Readings 25.7 25.8 25.0 24.7

Air gap deviation from average value is 4.20% on T-end and -2.40% on E-end.

4. Measurement of bearing insulation after final bearing assembly

Turbine end: Exciter end: 100 M at 28oC with 100 V dc insulation testers. 100 M at 28oC with 100 V dc insulation testers.

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5. Measurement of insulation resistance of stator windings after final assembly

Insulation Resistance Test @ 2500 V DC
Phase W-phase U-phase V-phase WUV-ph Criteria Analysis U V 2500 2500 2500 2500 I30 nA IR30 M 1800 1000 800 I60 nA IR60 M 5000 2600 1800 IR60 M 2176 1132 783 @40 C IR1 min > 100 M at 40oC as per IEEE 43-2000 Insulation resistance of stator winding is well above the minimum value and this means dry condition and absence of any significant contamination. DAR values are in VERY GOOD region.
o

Cap nF 64.4 63.8 63.8

Temp. o C 28 28 28 28

DAR 2.78 2.60 2.25

6. Final seal oil clearance readings are as follow:

Turbine End Oil Seal Clearance Outer Oil Seal 0.06 0.20 0.06 Exciter End Oil Seal Clearance Outer Oil Seal 0.40 0.18 0.03 0.18 0.20 0.03 Inner Oil Seal 0.40 0.20 0.20 0.20 0.33 Inner Oil Seal 0.40 0.20

7. Generator box up started and winding covers installation completed. 8. Bearing assembly completed.

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15. Site Activity on Friday, 25 November 2011 (Manpower 3 + 8) 1. Generator box up completed (covers, coolers, exciter and pipelines). 2. Checked exciter air-gaps and the final readings are as follow:
Pole No. Air-gap Deviation Rotor Pos Pole No. Air-gap Deviation Rotor Pos

1 2 3 4 5 6

1.21 1.40 1.65 2.01 2.01 2.35

-18.7% -5.9% 10.9% 35.1% 35.1% 57.9%

1 2 3 4 5 6

7 8 9 10 11 12

2.01 1.61 1.08 0.94 0.72 0.87

35.1% 8.2% -27.4% -36.8% -51.6% -41.5%

7 8 9 10 11 12

3. Generator box up completed.

4. Oil flushing started.

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16. Site Activity on Saturday, 26 November 2011 (Manpower 3 + 8) 1. Oil flushing continued and completed. 2. Turbine put on barring gear. 3. Unit synchronized at 18:52 hours and loaded to 4 MW. 4. Generator parameters recorded after synchronization are as follow: Operating Parameters
Time hours 18:52 19:07 19:22 19:37 19:52 Output MW 0 3.5 4.0 4.0 4.0 Freq. Hz 0 49.88 49.80 49.71 49.87 Volt V KV 0 11.8 11.8 11.4 11.4 R A 0 200 220 220 220 Current Y A 0 B A 0 Ch. A Vibration Levels Ch. B Ch. A Ch. B

m
10 10 10 10 10

m
18 22 22 22 22

m
66 68 66 66 66

m
22 24 24 22 22

Temperature Profile
Time hours 18:52 19:07 19:22 19:37 19:52 R C 33 48 55 58 61
o

Y C 33 47 53 58 61
o

Stator Winding B R o o C C 35 33 49 48 56 54 60 57 63 59

Bearings Y C 33 48 53 57 60
o

B C 33 48 53 58 59
o

T-end

E-end

C 52 52 51 51 51

C 47 51 49 49 49

Cold o C 28 34 37 39 40

Cooling Air Hot Cold o o C C 29 28 35 35 39 42 41 46 43 47

Cold o C 32 39 45 48 50

5.

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17. Site Activity on Sunday, 27 November 2011 (Manpower 2 + 4) 1. Unit running at 4.0 MW and started to increase load to 8 MW at 09:45 hours. 2. Operating parameters and temperature profile recorded during the day is as follow: Operating Parameters
Time hours 09:40 10:43 11:07 14:00 19:00 Output MW 4.0 7.5 8.0 8.0 8.0 Freq. Hz 49.66 49.61 49.72 49.90 49.90 Volt V KV 11.4 11.4 11.4 11.4 11.4 R A 220 378 400 400 400 Current Y A B A Ch. A Vibration Levels Ch. B Ch. A Ch. B

m
10 10 10 10 10

m
22 22 22 22 20

m
66 66 66 66 64

m
22 22 22 24 24

Temperature Profile
Time Hours 09:40 10:43 11:07 14:00 19:00 R o C 72 88 94 104 105 Y o C 71 86 92 102 102 Stator Winding B R Y o o o C C C 73 69 70 88 89 85 95 91 92 104 101 102 102 101 101 Bearings B o C 69 86 90 98 100
T-end E-end

C 55 56 57 52 52

C 53 55 55 52 52

Cold o C 43 46 48 51 52

Cooling Air Hot Cold o o C C 48 55 52 60 53 63 54 59 53 59

Cold o C 57 61 64 70 71

3. Unit is running satiafcatoirly.

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18. Site Activity on Monday, 28 November 2011 (Manpower 1 + 4) 1. Unit is running at full load of 8 MW for more than 24 hours. 2. Operating parameters and temperature profile recorded during the day is as follow: Operating Parameters
Time hours 08:45 Output MW 7.69 Freq. Hz 49.42 Volt V KV 11.4 R A 400 Current Y A B A Ch. A Vibration Levels Ch. B Ch. A Ch. B

m
10

m
20

m
64

m
24

Temperature Profile
Time hours 08:45 R C 104
o

Y C 102
o

Stator Winding B R o o C C 106 102

Bearings Y C 104
o

B C 99
o

T-end

E-end

C 60

C 50

Cold o C 56

Cooling Air Hot Cold o o C C 59 59

Cold o C 70

3. The performance of the generator after 24 hours running at full load has been found satisfactory. 4. ERMS has completed the work as per the scope of Work Order. 5. EMRS Team demobilized from MIEL site on 28th November 2011. 19. Thanks ERMS Team expressed their thanks and gratitude to Mr. GS Bhatia (HOD-Power), Mr. M Subba Rao (GM-Electrical) and their Team Members for the courtesy and co-operation extended during carrying out the work on TG1 and stay in the colony.

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