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THIS PAPER IS BASICALLY USED ENGINEER AS GUIDANCE FOR GENERATOR IT'S COMPILED BY SISWANTO BASED ON MANY SITE WORKS PROJECTS EXPERIENCES FOR SERVICES AND INSPECTIONS OF TURBINE GENERATORS. THIS IS AN EFFORT TO PROVIDE AS MUCH INFORMATION TO OUR CUSTOMERS AS POSSIBLE IN ORDER TO SELECT THE BEST SERVICES FOR THE OPTIMAL PERFORMANCE OF THE GENERATOR.
ROTOR DETAIL INSPECTION WITH ROTOR REMOVAL ON GE GENERATOR 125 MW, DUE TO HIGH REVERSE POWER ATTACK
3. Mechanical inspection incl, electrical round-out, NDT for journals and retainingrings 4. Visual inspection for the stator, incl. ELCID on the stator core
Generator storage
Rotor
app 40 M with generator
removal
location.
Generator was placed at open area and close to overhead transmission line 150 kV, in No dismantling facility are available at site, such as heavy crane, support, etc Following are site activities mobilization and preparation for rotor removal. 1. 3. 4. 5. 6. 7. Rotor removal Direction kits Site Generator special Roofing Scaffolding tools site office area and electricity facility 2. Lifting facility incl. Raughterr crane 20T, Forklift 5T, Wire sling 40 T, Hyjack 60 T, etc arrangement leveling arrangement erection erection
Cover removal
Top covers including top bearings TE & EE are the main priority to be removed prior other activities will be done, all of parts removed to be marked based on its position and storage at safe area.
Air gap
Copper melted was found entire air gap, to remove the copper melting need more free space in the air gap, rotor was hanged on the frame by using wire sling 40T, its purpose to get max air gap at bottom rotor areas, see illustration as below: Top Air Gap Viewed from Exciter End
Metal
melt
was
collecting
in
approximately
100
kgs,
see
photos
Rotor removal special tools and rotor bed support Rotor removal special tools was arranged based on the generator storage area conditions, prior removal and any mechanical dismantling generator parts, leveling on the generator is required and was done using jacking systems and supported by
wooden .
block
3. INSPECTION ROTOR
VISUAL
INSPECTIONS
Rotor shaft was planned to be inspected by using ERO (Electrical Run-Out), to identify rotor shaft deflections, this planning has defined when the generator still in complete assembly to purpose repair criteria with assuming when rotor forging is not damaged. After rotor was completely remove, visual inspection can assessing to whole of rotor conditions, totally damaged was found on the retaining rings (both exciter end and
turbine end), damaged also found on the rotor forging and steel wedge at exciter end and turbine end close to the retaining rings area, see photos below.
Slot wedges taken from Exciter End Side Typical damaged of Retaining ring Turbine end and Exciter End)
Steel wedge (typical damaged for Turbine side and Exciter side)
PREPARATION INSPECTIONS
Transportation to Workshop
ROTOR
TO
WORKSHOP
FOR
Electrical
Round
out
data
Max = = = = 0.0382 mm
deviation
out
turbine
NDT INSPECTIONS
4. SUMMAY
Rotor to be inspected when rotor was successfully removed from the stator bore, 1. Rotor Forging, retaining rings, found totally damaged on the rotor forging including body flex slot, slot dovetail, both retaining rings, retaining rings locking ,steel wedge at end portions close to retaining rings, see previous pages
NDT and round-out also has been inspected, found minor scratching due to electrical discharge and minor deflection on the journal at exciter end side but still in tolerance. 2. Rotor winding, Rotor winding is not possible to be measured by electrical measurements, due to the winding was totally damaged. 3. Rotor Shaft dimensional , Rotor shaft has been inspected using mechanical run-out and ERO, rotor shaft dimensional have a minor deflection Exciter side journal shaft. Diameter = 355.55 355.57 mm, max TIR = 0.05 mm Turbine end journal shaft Diameter = 355.56 355.58 mm. max TIR = 0.02 mm
5. CONCLUSION
1. Rotor forging, total damaged 2. Both retaining rings, heavy crack 3. Steel wedges, some of them was melted and almost of them was overheated 4. Copper bars winding rotor, melting 5. Journal shaft, minor scratch 6. Shaft, minor deflection Total damaged on the rotor forging and retaining rings, repair is not possible, new unit must be planned to replace it.