AC GENERATOR WORKSHOP EXPERTISE - GEN
Transkript
AC GENERATOR WORKSHOP EXPERTISE - GEN
24.03.2016 AC GENERATOR WORKSHOP EXPERTISE REPORT Report Code: XXXXX.XX.XX.XX GENERAL INFO Company Name: Company Address: Equipment Location: Equipment Name: XXXXXXX XXXXXXX XXXXXXX ME Shaft Generator ALTERNATOR INFO Brand: Type: S/N: Power: Voltage: Current: Speed: Frequency: Cos φ: Rot. Direction: Insulation Class: Protection Class: Mechanic Conn: AvK DSG 74 l2-4 67 27219 A101 1750 kVA 450 V 2245 A 1800 rpm 60 Hz 0,80 CCW (W-V-U) H IP23 Coupling Excit. Stator Volt: Excit. Stator Curr: Excit. Rotor Volt: Excit. Rotor Freq: 23,7 V 3,2 A 85,3 V 60 Hz Coolant Temp: Weight: Manufactured: Grease: 45°C 4,16 t 2005 Unirex N3 Heater Power: Heater Voltage: Heater Current: 350 W 230 V 1,52 A TEST OPERATOR Onur SOLMAZ (+90 532 783 83 38) - GEN-MOT / PSS CONTENT Electrical Expertise Mechanic Expertise Appendix – Thermal Imaging Report GEN-MOT / PSS Tüm hakları saklıdır. 1/10 24.03.2016 ELECTRICAL EXPERTISE MAIN STATOR INSPECTION Insulation Measurement of Stator Windings 4,10 4,00 3,90 3,80 3,70 MΩ 3,60 3,50 3,40 3,30 3,20 19.03.2016 19:39:29.000 9:59,000 (min:s) 1 min/Div 19.03.2016 19:49:28.000 Tests Results (Ru-v-w to Ground) Function Date Voltage R(t°amb) Resistance (t°amb) R(t°ref) Resistance (t°ref) Fixed Voltage 19.03.2016 473,8 V 15°C 3,758 MΩ 40°C 2,621 MΩ PI PI1 PI2 1,003 3,745 MΩ 3,758 MΩ DD Capacitance DD Current 2,203 64,24 nF -67,06 nA DC Resistences of Stator Windings Y-connected U–V 1,873 mΩ U–W 1,887 mΩ V–W 1,883 mΩ Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 14,40°C 1,873 mΩ 20,00°C 1,912 mΩ Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 14,50°C 1,887 mΩ 20,00°C 1,926 mΩ Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 14,60°C 1,883 mΩ 20,00°C 1,921 mΩ Maximum rate of resistence unbalance: %0,7 GEN-MOT / PSS Tüm hakları saklıdır. 2/10 24.03.2016 Stator Visual Check Stator windings and iron core are dirty and all surfaces covered by oil-grease mixture. Some of energy output cables have insulation wears. Bares of phases in terminal box are so dirty and need to be cleaned and painted. After taking the rotor out of the stator, it has been seen that the rotor had rubbed to the stator during operation. Stator has some deep scratches and short-circuits between some group of laminations. This parts of the iron core has been specified by painting it with white colour. The rotor iron core has also scratches on the pole surfaces. However, rotor poles are in better condition than the stator iron core. Loop Test for Stator Core Iron core has been tested as described below: (8 turn) x (60 A) = (480 A*turn) which means that iron core saturated approximately up to %20 of full magnetic field. Test has been applied for 30 mins. GEN-MOT / PSS Tüm hakları saklıdır. 3/10 24.03.2016 Thermal Imaging For thermal images, please refer to Appendix-Thermal Report at the end of this report. Assessment: • • • • According to standard IEEE43-2000; the insulation resistence of the stator windings is too low. According to standard IEEE43-2000; the polarisation index is too low. As a result of loop test, stator core has many hot spots which can be seen on the thermal report. So, stator windings should be removed from the stator. After that, stator core needs to be repaired, then cleaned and painted. After stator core work, stator needs to be rewinded. MAIN ROTOR INSPECTION Insulation Measurement of Rotor Windings 3,50G 3,00G 2,50G Ω 2,00G 1,50G 1000M 500M 0,00 19.03.2016 19:52:57.000 9:59,000 (min:s) 1 min/Div 19.03.2016 20:02:56.000 Tests Results (R2-3 to Ground) Function Date Voltage R(t°amb) Resistance (t°amb) R(t°ref) Resistance (t°ref) Fixed Voltage 19.03.2016 500,0 V 15°C 3,305 GΩ 40°C 2,811 GΩ GEN-MOT / PSS Tüm hakları saklıdır. PI PI1 PI2 1,985 1,665 GΩ 3,305 GΩ DD Capacitance DD Current 12,30 19,25 nF -118,4 nA 4/10 24.03.2016 DC Resistence of Rotor Winding 4 poles serial connected 2–3 0,540 Ohm Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 14,60°C 0,540 mΩ 20,00°C 0,550 mΩ Rotor Visual Check Rotor windings and iron core are dirty and all surfaces covered by oil-grease mixture. The rotor iron core has also scratches on the pole surfaces due to the rubbing. However, rotor poles are in better condition than the stator iron core. Rotor pole cable leads are in good condition. Assessment: • • • According to standard IEEE43-2000; the insulation resistence of the rotor winding is sufficient. According to standard IEEE43-2000; the polarisation index is at good value. Rotor pole windings need to be cleaned, varnished and painted for protection. GEN-MOT / PSS Tüm hakları saklıdır. 5/10 24.03.2016 EXCITER ROTOR INSPECTION Insulation Measurement of Exciter Rotor Windings 4,50G 4,00G 3,50G 3,00G Ω 2,50G 2,00G 1,50G 1000M 500M 0,00 19.03.2016 20:05:35.000 10:00,000 (min:s) 2 min/Div 19.03.2016 20:15:35.000 Tests Results (RU-V-W to Ground) Function Date Voltage R(t°amb) Resistance (t°amb) R(t°ref) Resistance (t°ref) Fixed Voltage 19.03.2016 500,4 V 15°C 4,320 GΩ 40°C 3,748 GΩ PI PI1 PI2 2,166 1,994 GΩ 4,320 GΩ DD Capacitance DD Current 36,33 4,961 nF -90,20 nA DC Resistences of Exciter Rotor Windings Y-connected U–V 45,65 mΩ U–W 46,03 mΩ V–W 45,67 mΩ Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 14,60°C 45,65 mΩ 20,00°C 46,57 mΩ Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 14,70°C 46,03 mΩ 20,00°C 46,94 mΩ Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 14,60°C 45,67 mΩ 20,00°C 46,57 mΩ Maximum rate of resistence unbalance: %0,8 Exciter Rotor Visual Check Exciter rotor windings and iron core are dirty and all surfaces covered by oil-grease mixture. GEN-MOT / PSS Tüm hakları saklıdır. 6/10 24.03.2016 The exciter rotor iron core has some partial scratches on the core surface due to the rubbing to the exciter stator. However, general condition is good. Exciter rotor leads are in good condition. Assessment: • • • According to standard IEEE43-2000; the insulation resistence of the exciter rotor windings are sufficient. According to standard IEEE43-2000; the polarisation index is at good value. Exciter rotor windings need to be cleaned, varnished and painted for protection. EXCITER STATOR INSPECTION Insulation Measurement of Exciter Stator Windings 45,0 40,0 35,0 30,0 GΩ 25,0 20,0 15,0 10,0 5,00 0,00 19.03.2016 20:20:09.000 9:59,000 (min:s) 1 min/Div 19.03.2016 20:30:08.000 Tests Results (RU-V-W to Ground) Function Date Voltage R(t°amb) Resistance (t°amb) R(t°ref) Resistance (t°ref) Fixed Voltage 19.03.2016 500,4 V 15°C 42,60 GΩ 40°C 35,75 GΩ GEN-MOT / PSS Tüm hakları saklıdır. PI PI1 PI2 1,891 22,53 GΩ 42,60 GΩ DD Capacitance DD Current 10,37 2,485 nF -12,89 nA 7/10 24.03.2016 DC Resistence of Exciter Stator Winding 12 poles serial connected I1 – K1 7,660 Ohm Measurement Date Metal t°amb R (t°amb) t°ref R (t°ref) Auto 19.03.2016 Copper 13,90°C 7,660 mΩ 20,00°C 7,830 mΩ Exciter Stator Visual Check Exciter stator windings and iron core are dirty and all surfaces covered by oil-grease mixture. The exciter stator iron core has some partial scratches at the bottom side poles due to the rubbing to the exciter rotor. However, general condition is very good. Assessment: • • • According to standard IEEE43-2000; the insulation resistence of the exciter stator windings are sufficient. According to standard IEEE43-2000; the polarisation index is at good value. Exciter stator windings need to be cleaned, varnished and painted for protection. CONTROL CIRCUITS INSPECTION PT100 Sensors Rotating Diodes AVR 1 pc. at DE Bearing Housing - OK 1 pc. at NDE Bearing Housing - OK 2 pcs. at U Phase Winding - OK 2 pcs. at V Phase Winding - OK 2 pcs. at W Phase Winding - OK 3 pcs. DD89N14K Infineon - OK Cosimat N+ GEN-MOT / PSS Tüm hakları saklıdır. Thrystor 1 pc. SKVC20A460C Semikron - OK 8/10 24.03.2016 MECHANIC EXPERTISE DRIVE-END MEASUREMENTS DE Shaft Excentricity N/A – Cannot be measured due to bearing fault DE Bearing Shaft Diameter 150,03 mm – Needs to be grinded due to fused burres DE Shield Bearing Housing 270,03 - 270,09 mm – Bearing housing needs to be fixed DE Outer Grease Flange Has 3 cracked place – Needs to be renewed DE Shaft Place of Outer Flange Scratched – Shaft needs to be spinned DE Outer Scraper Ring Fused – Needs to be renewed DE Shaft Place of Scraper Ring Scratched – Shaft needs to be spinned DE Inner Grease Flange Cracked – Needs to be renewed DE Shaft Place of Inner Flange Scratched – Shaft needs to be spinned DE Bearing 6230 C3 DE Gressor OK Cooler Fan OK Outer Grease Flange Crack Dispersed DE Bearing Fused Outer Scraper Ring Shaft Place of Outer Ring-Flange Shaft Place of Inner Flange Inner Grease Flange Crack GEN-MOT / PSS Tüm hakları saklıdır. 9/10 24.03.2016 NON-DRIVE-END MEASUREMENTS NDE Shaft Excentricity N/A – Cannot be measured due to bearing fault NDE Bearing Shaft Diameter 150,03 mm – OK NDE Shield Bearing Housing 270,05 - 270,85 mm – Bearing housing needs to be fixed NDE Outer Grease Flange OK NDE Shaft Place of Outer Flange OK NDE Outer Scraper Ring OK NDE Shaft Place of Scraper Ring OK NDE Inner Grease Flange Deformed – Needs to be repaired NDE Shaft Place of Inner Flange Scratched – Shaft needs to be spinned NDE Bearing 6230 C3 NDE Gressor OK Shaft Place of Outer Ring-Flange GEN-MOT / PSS Tüm hakları saklıdır. Shaft Place of Inner Flange Shaft Place of Inner Flange 10/10 Appendix - Thermal Imaging Report Ölçümler Bx1 UNIT_CELSİUS Max 16,2 Min 15,6 Average 16,0 Max 16,2 Min 14,9 Average 16,0 Sp1 Li1 19.03.2016 18:51:28 UNIT_CELSİUS 18,5 Bx1 15,9 Li1 Sp1 Parametreler Emisyon Yans. sıc. 0.95 20 UNIT_CELSİU FLIR0007.jpg FLIR E4 10,2 63964217 19.03.2016 18:51:28 FLIR0007.jpg Initial condition of the stator before test started. 1/5 FLIR E4 63964217 Appendix - Thermal Imaging Report Ölçümler Bx1 UNIT_CELSİUS Max 33,4 Min 14,9 Average 16,9 Sp1 32,3 Sp2 25,9 Sp3 24,1 Sp4 25,9 Li1 Max 33,4 Min 15,8 Average 18,5 19.03.2016 18:52:27 UNIT_CELSİUS 22,2 Bx1 Sp2 Sp1 Sp4 Li1 Sp3 Parametreler Emisyon Yans. sıc. 0.95 20 UNIT_CELSİ FLIR0009.jpg FLIR E4 13,6 63964217 19.03.2016 18:52:27 FLIR0009.jpg Some points at the stator get thermally visible by the end of 1 minute. 2/5 FLIR E4 63964217 Appendix - Thermal Imaging Report Ölçümler UNIT_CELSİUS Sp1 57,5 Sp2 44,8 Sp3 44,7 Sp4 51,6 Sp5 49,2 Sp6 43,1 Sp7 46,2 Sp8 45,2 Sp9 Li1 Li2 UNIT_CELSİUS 46,2 Sp5 Sp1 Sp4 Sp8 Sp2 Sp3 Li1 Sp9 42,0 Max 58,9 Min 20,4 Average 30,7 Max 46,0 Min 24,2 Average 30,2 Parametreler Emisyon Yans. sıc. 19.03.2016 19:02:28 Sp6 Li2 FLIR0013.jpg Sp7 FLIR E4 18,6 63964217 0.95 19.03.2016 19:02:28 20 UNIT_CELSİ FLIR0013.jpg FLIR E4 63964217 10 minutes later, the difference between the hottest point and the coldest area is more than 25°C which means the iron core sings a problem. 3/5 Appendix - Thermal Imaging Report Ölçümler Bx1 UNIT_CELSİUS Max 65,1 Min 24,2 Average 33,1 Sp1 65,1 Sp2 50,0 Sp3 51,3 Sp4 57,4 Sp5 Max 64,3 Min 22,2 Average 31,3 Max 49,6 Min 23,2 Average 31,0 Sp1 - Ref. sıc. 65,1 Li2 Parametreler Emisyon Yans. sıc. Bx1 Sp5 Sp1 Sp4 Sp2 Sp3 Li2 FLIR0016.jpg FLIR E4 21,6 63964217 0.95 20 UNIT_CELSİ 19.03.2016 19:12:18 FLIR0016.jpg 20 minutes later, temperature difference got higher, more than 40°C. 4/5 UNIT_CELSİUS 51,7 Li1 54,8 Li1 Dt1 19.03.2016 19:12:18 FLIR E4 63964217 Appendix - Thermal Imaging Report Ölçümler Bx1 UNIT_CELSİUS Max 71,2 Min 25,8 Average 32,3 Sp1 70,5 Sp2 63,9 Sp3 55,6 Sp4 27,2 Sp5 56,0 Sp6 Li1 Li2 Li3 19.03.2016 19:23:43 Bx1 UNIT_CELSİUS 56,6 Li3 Sp4 Sp5 Sp1Sp2 Li2 55,1 Max 55,9 Min 32,0 Average 39,5 Max 69,1 Min 28,4 Average 38,6 Max 70,9 Min 26,3 Average 36,2 Sp6 Sp3 Li1 FLIR0025.jpg FLIR E4 23,5 63964217 19.03.2016 19:23:43 Parametreler Emisyon Yans. sıc. 0.95 20 UNIT_CELSİ FLIR0025.jpg FLIR E4 30 minutes later, at the end of the test the temperature difference reached to 45°C. This iron core needs to be repaired. 5/5 63964217