3X8MW DHUKWAN SMALL HYDRO ELECTRIC

PROJECT
VERTICAL SYNCHRONOUS GENERATOR O & M
MANUAL

DHUKWAN SMALL HYDRO ELECTRIC PROJECT

(3*8MW)

OPERATION MAINTENANCE MANUAL

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INDEX

1. General description ............................................................................................................. 6

2. Design parameters of generator ......................................................................................... 7

3. Brief construction and features ........................................................................................ 14

3.1 Stator Frame ............................................................................................................ 14

3.2 Stator Core ............................................................................................................... 14

3.3 Stator Winding ......................................................................................................... 16

3.4 Rotor…. .................................................................................................................... 17

3.4.1 Main Generator shaft & Thrust-Cum-Guide Bearing Collar ................. 177

3.4.2 Spider...….. ............................................................................................ 188

3.4.3 Rotor Rim ................................................................................................ 18

3.4.4 Poles with Field Windings ....................................................................... 19

3.5 Slip Rings & Brush Gear......................................................................................... 20

3.6 Bearings .................................................................................................................... 20

3.6.1 Thrust Bearing ......................................................................................... 21

3.6.2 Guide Bearings ........................................................................................ 21

3.6.3 Bearing Insulation.................................................................................... 22

3.6.4 Hydro Pressure Lubrication System ........................................................ 22

3.7 Plug in Oil Coolers ................................................................................................... 23

3.8 Ventilation Air Coolers ............................................................................................ 25

3.9 Brake Dust collecting system .................................................................................. 26

3.10 Cooling Water System ........................................................................................... 26

3.11 CO2 Fire Protection System .................................................................................. 26

3.12 Upper Bracket ........................................................................................................ 27

3.13 Lower Bracket ........................................................................................................ 27

3.14 Braking and Jacking System ......................................................................................... 288

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3.15 Lighting System...................................................................................................... 29

3.16Instrumentation & devices……………………………………………………………..29

3.17 Automatic control system ...................................................................................... 32

3.17.1 Generator Automatic control system ..................................................... 33

3.17.2 Startup and commissioning of unit ........................................................ 34

4 Operation and Maintenance Procedures .......................................................................... 38

4.1 Safety Precautions Specific to the Plant ................................................................. 38

4.1.1 General warning ...................................................................................... 39

4.1.2 Pictograms ............................................................................................... 40

4.1.3 Safety devices .......................................................................................... 42

4.1.4 Basic safety instructions .......................................................................... 43

4.1.5 Safety instructions for generator .............................................................. 53

4.2 Operation .................................................................................................................. 56

4.2.1 Safety instructions ................................................................................... 56

4.2.2 General..................................................................................................... 57

4.2.3 Operating conditions................................................................................ 58

4.2.4 Start –up and shut down ........................................................................ 588

4.2.5 Longer shutdown periods ........................................................................ 59

4.3 Maintenance ............................................................................................................. 59

4.3.1 General..................................................................................................... 59

4.3.2 Influences for maintenance .................................................................... 655

4.3.3 Maintenance and inspection plan............................................................. 71

4.4 Maintenance and inspection plan ........................................................................... 77

4.4.1 Stator........................................................................................................ 78

4.4.2 Stator core ................................................................................................ 80

4.4.3 Stator Windings ....................................................................................... 83

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4.4.4 Rotor ........................................................................................................ 85

4.4.5 Bearing..................................................................................................... 86

4.4.6 Excitation equipment ............................................................................... 88

4.4.7 Covers ...................................................................................................... 94

4.4.8 Oil system ................................................................................................ 94

4.4.9 Brake-lifting system ................................................................................ 95

4.4.10 Cooling system ...................................................................................... 97

4.4.11 Heating system ...................................................................................... 98

4.5 Overhaul ................................................................................................................... 98

4.6 Revision ..................................................................................................................... 99

4.7 Repair of operational malfunction ....................................................................... 100

4.7.1 Generator ............................................................................................... 100

4.7.2 Bearing................................................................................................... 101

4.7.3 Excitation equipment ............................................................................. 101

4.7.4 Oil system .............................................................................................. 102

4.7.5 Braking system ...................................................................................... 102

4.7.6 Cooling system ...................................................................................... 103

4.8 Generator Monitoring Guidelines of Generator ................................................. 103

4.8.1 Temperature monitoring ........................................................................ 104

4.8.2 Bearing oil level monitoring .................................................................. 104

4.8.3 Vibration and noise monitoring ............................................................. 104

4.8.4 Insulation monitoring ............................................................................ 105

4.8.5 Current outgoing device monitoring ...................................................... 105

4.8.6 Cooler monitoring.................................................................................. 105

4.8.7 Brake system monitoring ....................................................................... 105

4.9 Operation and maintenance of precautions of generator ................................... 105

4.9.1 Regular maintenance ............................................................................. 106

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4.9.2 Major components maintenance ............................................................ 108

4.9.3 Common Faults and Solutions during Operation of Generator ............. 112

5. De-commissioning ........................................................................................................... 1188

5.1 Information for disassembly ................................................................................ 1188

5.2 Disposal .................................................................................................................. 1199

6. Description of installed equipment ................................................................................ 120

7. Operation & Maintenance Records .............................................................................. 1211

8. Reference Documents for Operation & Maintenance ..................................................... 129

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1. General Description

The Synchronous generator is of vertical shaft, semi-umbrella type having salient poles
with closed air circuit ventilation and suitable for direct coupling to vertical Kaplan
turbine. Static excitation system is provided for energizing the field winding of rotor.
This supply is fed through slip rings located above the generator rotor. Mechanical over
speed device signaling generator (SSG) for turbine is also mounted on the turbine shaft.

The combined thrust bearing and lower guide bearing are positioned below the rotor
in lower bracket and an upper guide bearing above the rotor in upper bracket. The
bearing are of self-lubricating type and immersed in oil bath in which plug-in type of oil
coolers are provided to remove the bearing losses. In order to detect the contamination
of oil, one number moisture detector has also been provided in each TB/GB oil bath.
Thrust bearing is provided with high- pressure oil injection (HS lubrication) system to
avoid any damage to bearing pads during slow speed operation and start/stop of the
unit.

Pneumatic operated brakes are mounted on lower bracket arms. These are also used
for lifting the rotor for maintenance purposes. For trapping & subsequent evacuation
of the bracket dust generated during braking operation, brake dust collection
equipment has also been provided.

Air coolers are directly mounted on the outer steel casing of stator frame. Co2 type
firefighting system is also located inside the generator. In order to prevent the leakage
of cold air in to turbine, a sealing cover has been mounted below the generator on the
lower bracket. Thrust bearing, guide bearing, brakes etc. Located on lower bracket.

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2. DESIGN PARAMETERS OF GENERATOR

RATED PARAMETER

RATED PARAMETERS: VAULE/DETAIL

Type of Generator Semi umbrella

Rated Capacity 8.889MVA/8MW

Maximum Continuous Output (KW) 9.778MVA/8.8MW

Rated terminal voltage 11000 V±10%

Rated Stator Current 466.5 A

Rated Power factor 0.9 lag

Rated Excitation Current 470A

Rated Excitation Voltage 168V

Rated Speed / No. of Rotor Poles 214.3 RPM / 28

Rated Frequency 50 Hz ± 3%

SCR 1.15pu

Negative sequence current capability I22T 40sEC

Direction of Rotation when viewed from top i.e. Slip-ring side. CLOCKWISE

Type of Winding Lap winding

No. of Terminals Brought Out on Phase & Neutral Side Six Each

Class of Insulation for Stator and Rotor `F' '

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ELECTRICAL DATA

PARAMETER VALUE

Resistance of stator winding per phase at 75°C 0.1191Ohms

Resistance of rotor winding at 75°C 0.3022 Ohms

Capacitance per phase to ground of stator winding 0.108μF

Rated KVAR, Zero leading p.f. during line charging with 5% full load
6230KVAR
positive excitation

Direct Axis Synchronous Reactance saturated / unsaturated 0.868/0.984 P.U.

Direct Axis Transient Reactance saturated / unsaturated 0.216/0.245 P.U.

Direct Axis Sub-transient Reactance saturated / unsaturated 0.167/0.189 P.U.

Rise in Temperature Over Cooling Air at Rate Output / Max. Output By

RTD. Rated Max

a) Stator Winding by Embedded RTDs 70°C 70°C

b) Rotor Winding by resistance measurement 80°C 80°C

MECHANICAL DATA

PARAMETER VALUE/DETAIL

Flywheel Moment of the Rotor 491 Tm2

Rated Speed 214.3 RPM

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Maximum Runaway Speed 524.3 RPM

Weight of Wound Stator (without Foundation Plates) 27000 Kg

Weight of Rotor 50000 Kg

Height of Stator Frame 1190 mm

Outer dimension of Stator – Across Flat 5950 mm

Height of Generator Shaft 5154mm

Overall Diameter of the Rotor 4482 mm

Outer Diameter of Generator Barrel 9000 mm

Stator Core Inside Diameter 4504 mm

No. of Slots 240

Heaviest Assembly to be Lifted by EOT Crane Rotor Assembly

Weight (with lifting device) 52 Tons.

Largest Assembly to be Lifted by EOT Crane Stator Assembly

Dimensions( Ø X H – without Foundation plates) 5950mm X 1190mm

Weight (with lifting device) 30 Tons.

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OPERATIONAL DATA

PARAMETERS VALUE/DETAIL

Maximum cold air temperature ( AMBIENT) 45°C

Cooling water requirement of unit at rated output

a) Pressure 1.5 to 3.0Kg/cm²

b) Quantity (Air Coolers) 112 cum/hr.

c) Quantity (TB & LGB) 140 cum/hr.

d) Quantity (UGB) 2.5 cum/h.

e) Quantity (TGB) 19.1 cum/h

Maximum safe working pressure of water for Air & Oil coolers 2.0 Kg/cm²

Test pressure for Air coolers & water boxes of Oil coolers 6 Kg/cm²

Grade & Quality of Oil for Bearings ISO VG- 46

Estimated Quantity of Oil for Thrust bearing & L.G.B. Oil Bath 2600 Lt.

Estimated Quantity of Oil for U.G.B. Oil Bath 400 Lt.

Normal working temperature of oil in the bearings 55 °C

Normal working temperature for thrust and guide bearings 65 °C

Maximum working temperature for thrust and guide bearings 70 °C

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Operating capability of thrust bearing for the following conditions:

a. At any speed under maximum runaway speed with Cooling Water

15 Minutes
ON.

b. At maximum load & rated speed with Cooling Water OFF. 30 Minutes

Air pressure for braking. 5.0 – 7.0 Kg/cm²

At which speed HS Lub. Shall `ON' 0% rpm

At which speed HS Lub. Shall `OFF' 90%

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3. BRIEF CONSTRUCTION AND FEATURES

Generator includes: Stator, Rotor, Upper Bracket, Lower Bracket, Generator Shaft,
Cooler, Bearings, Braking System and Automation system etc.

1.GENERATOR FOUNDATION 10.STATOR OUTGOING LEAD 19.OIL COOLER

(DIAMETRICALLY OPPOSITE)

2.LOWER COVER PLATE 11.UPPER BAFFFLE 20.UNIT LIGHT

3.LOWER BRACKER ASSEMBLY 12.TOP COVER PLATE 21.OIL COOLER

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4.BRAKE AND JACK ASSEMBLY 13.TOP COVER PLATE 22.SEGMENTAL FAN TOP AND
BOTTOM

5.LOWER BAFFLE 14.UPPER BRACKET ASSEMBLY 23.HUGH PRESSURE OIL JACH

SYSTEM

6.STATRO ASSEMBLY 15.SLIP RING COVER 24.BRAKE DUST COLLECTOR

7.ROTOR ASSEMBLY 16.COLLECTOR RING AND 25.VIBRATION DETECTION

BRUSH ASSEMBLY SYSTEM

8.ELECTRIC HEATER 17.SHAFT CURRENT 26.LADDER

MEASUTING CT

9.AIR COOLER ASSEMBLY 18.GROUNDING CARBIN BRUSH 27.SS POST WITH SS HANGING
CHAIN

28.SPEED SENSOR

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GENERATOR MAIN ASSEMBLY

3.1 Stator Frame

The stator frame is built up of weldable steel plates and has adequate depth to prevent
distortion during transport or under any operation condition. The joints between the
segments (3nos) of the frame are heavily flanged internally and coupled by a number
of studs. The stator frame is bolted to its foundation plates, which in turn shall be
grouted to concrete.

Stator frame is designed to carry the weight of upper bracket, brush gear assembly,
stationary parts and flooring for the generator.

3.2 Stator core

The stator core is built up of stampings of high grade, non-aging cold rolled silicon alloy
steel with vanish insulation on both sides to minimize eddy current losses. The
stampings are secured to the frame by dovetail notched engaging with corresponding
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dovetail key bars welded to stator frame. Stator core is pressed between steel end
plates through non-magnetic radial fingers welded to them. Jacking screws are provided
at the outer edge of end plates to adjust the distribution of pressure on stator teeth.

Ventilation ducts are provided at intervals along the stator core, these being formed by
non-magnetic steel spacers welded to adjacent stampings.

The core is securely clamped by number of long studs along the outer periphery of core,
extending over its full height. In order to ensure tightness of the core during service,
high initial clamping pressure is used during building of the core. Intermediate pressings
are adopted for better core consolidation.

Stator core stacking was performed in a factory to ensure circularity. Core loss test was
carried out after stacking.

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3.3 Stator Winding

The stator winding is lap winding. The winding are made of large number of glass
covered polyesterimide varnish bonded rectangular copper conductors of small section.
The insulation is of class 'F' type. Brazing joints the winding ends. The winding are
insulated with continuous type of insulation system. The main insulation consists of half
lap layers of fine mica paper glass tape applied by hand/ machine to formed winding.
The insulation is appropriately impregnated with high-grade epoxy class 'F' insulating
varnish and consolidated over the entire length so that the insulation becomes a dense
homogeneous mass. This ensures complete elimination of voids and gives a high factor
of safety against break down.

In order to prevent partial discharges in the slot, an anti-corona shield consisting of

coating semi-conducting graphite paint is applied to the straight portion of each
winding. It is further wrapped with a polyester-conducting fleece in the slot portion. For
minimizing slot end discharges, the overhang portion has graded stress-relieving paint
up to some length from the bend. The reminder of the winding has been coated with
suitable anti track varnish.

The stator winding is star connected having two parallel paths per phase. Three main
and three neutral terminals have been brought outside the stator frame.

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3.4 Rotor

The rotor has been designed to safely withstand all mechanical stresses imposed by the
maximum runaway speed. The dynamic balancing of the rotor shall be carried out as a
part of pre-commissioning tests at site to keep values of rotor vibrations within
allowable limits.

3.4.1 Main Generator shaft & Thrust-Cum-Guide Bearing Collar

The main shaft having integral thrust-cum-guide bearing collar is forged from high
quality alloy steel. It has been accurately machined and has a hole bored through the
center for inspection and other purposes. An integrally forged half coupling has been
provided at the bottom of the shaft for connecting to the turbine flange. The bottom
surface of the collar is coupled with mirror plate; mirror plate is having high polish for
lubrication surface.

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3.4.2 Spider

The rotor spider is a fabricated structure having lower disc, center hub and rib plates.
The lower disc of the spider is fitted on to the shaft with bolts and dowels. The brake
track, consisting of high tensile steel segments is also mounted on the spider.

3.4.3 Rotor Rim

The rotor rim, assembled around rotor spider at workshop, is built up from sheet steel
laminations each covering four pole pitches and successive layers of laminations
overlapped to give adequate strength to the rim. The laminations are pressed between
steel end plates’ during assembly and clamped by means of tight fitted studs to form a
monolithic laminated body. 'T' shaped slots in the outer periphery of the rim receive
similar shaped projections on the poles. The rim is secured tangentially to the
rectangular bars of the spider. The rim of rotor shall be constructed out of 2mm or 3mm
thickness.

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3.4.4 Poles with Field Windings

The poles are of laminated construction consisting of sheet steel pole punching’s,
clamped between heavy steel end plates by means of studs. The pole core has one
number of’ T shaped tails to engage with corresponding 'T' shaped slots in rotor rim.
The pole face profile is circular and; so chosen as to ensure a suitable grading of air gap.
The damper winding bars are of circular copper section and are: embedded in pole
faces. The ends of damper bars are short-circuited together by copper segments. Pole-
to-pole connections for these damper segments have also been provided.

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The field coils are made of special profile copper strip wound on edge. The insulation
between turns is of epoxy treated Nomex paper and insulation to ground is of epoxy
based glass laminates. The coils are electrically heated and pressurized to cure the turn
insulation and thus consolidate the coil. All connections between adjacent field coils
and between field coils and slip rings are of mechanically strong construction and firmly
secured to the rotor. Class of insulation of poles shall be Class F. The field poles are
provided with adequate continuous type Amortisseur winding of the low resistance
type to improve stability under single phase fault conditions.

3.5 Slip Rings & Brush Gear

The slip rings are of mild steel and shall be mounted on the generator shaft during
erection. The brush-gear collector shall be mounted on insulated studs supported on
slip ring cover and is conveniently accessible for maintenance and inspection.

The insulation for slip rings and their connection is non-hygroscopic and oil resistant.
Current carrying bus bars/Leads from the collector to the generator field poles have
been taken along the shaft.

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3.6 Bearings

The generator shall have a combined thrust and guide bearings located below the rotor
and guide bearing above the rotor. The generator bearings have following features:

 Segmented Pad type (Thrust bearing pads) and segmented pad type (Guide bearing
pads), oil self-lubricated type. The oil lubrication system for the bearings shall be fail
safe and shall work even in the event of power failure.

 For ease of maintenance, lower bracket arms can be dismantled and center can be
taken out from stator bore.

 The thrust bearing shall be suitable to take axial thrusts in top and bottom directions.

 The thrust bearing will be made of stress released mild steel with white metal lining.

 The bearings shall be adequately insulated to prevent any harmful circulating

currents.

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 The guide bearing will be of the segmental pad type consisting of a number of white
metal pads.

 The bearing shall be designed to withstand operation at runaway speed for a period
of 10 minutes. Thermometers, pressure gauges, flow relays, etc. as required shall
be provided.

 The thrust and guide bearing will be cooled by a number of oil coolers. Each cooler
will consist of a block of “U” shaped cupronickel tubes.

3.6.1 Thrust Bearing

Thrust bearing is positioned below the rotor in lower bracket. It has been designed for
the axial load that is summation of the weights of all rotating parts of generator and
turbine and maximum hydraulic axial thrust. Thrust bearing is of pivoted segmental pad
type in which the stationary parts consist of a set of 14 nos. babbitted segmental pads
supported on circular pad. Supports made of alloy steel forging which works like a spring
plate and provides cushioning effect to the whole assembly.

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3.6.2 Guide Bearings

Two Nos. segmental pad type of guide bearings are provided for generator; one
positioned below the rotor along with thrust bearing housed in lower bracket having
12nos. pads and second above the rotor housed in upper bracket having 8 Nos. Pads.

The guide bearings are of pivoted pad type consisting of a row of white metal pads
arranged in a support ring to bear on a journal surface machined or, the periphery of
the T.B. Collar. A pivot bar is bolted to the back of each guide pad to enable the pad to
rock slightly within the pad stoppers provided on both sides of the pad and take the
position required for formation of the oil film during operation. Bearing pads are
immersed in oil. Plug in type oil coolers are 'inserted in the oil bath to remove the
bearing losses. These oil coolers are provided with plugs for draining the water.
Resistance &dial thermometers are provided in pads and oil bath for temperature
measurement &protection against overheating.

The bearing housings are designed to give adequate accessibility to guide bearing pads.

3.6.3 Bearing Insulation

The bearing above the rotor will be adequately insulated to prevent circulating shaft
current from passing through the bearing surface. The insulation will be arranged to
break the possible paths of such currents.

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3.6.4 High Pressure Lubrication System

A high pressure oil system is provided for the thrust bearing in order to create_ a
positive oil film over the pads at low speeds during starting and stopping of the
generator. The components consist of a positive displacement pump with its motor,
filters, valves etc. mounted on a steel base. A pressure switch with electrical contacts
for starting interlock of the generator is also provided. In addition to this, a pump-motor
set with necessary controls has also been provided as stand-by. Working pressure of HP
pump is 80kg/cm2.

3.7 Plug in Oil Coolers

The oil of the lower bearing housings will be cooled by 8 nos. number of plug-in-type
oil coolers. Each cooler will consist of a bank of 'U' shaped cupro-nickel tubes with
aluminum fins carried.

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3.8 Ventilation Air Coolers

The machine will have a closed circuit ventilation system. Suitable number of air cooler
unit are fixed to the outer periphery of the stator frame and the cooled air will be
discharged into the annular space surrounding the stator.

Generator has total 6 nos. of air coolers. Air coolers will consist of a block of cupro-
nickel tubes having aluminum fins. If any one. Of air cooler is out of service, still with 5
nos. of air coolers can operate generator at rated output.

The Generator shall be natural air/water cooled self-ventilated type provided with
cooling system based on closed circuit air circulation principle. The air passages in the
stator, rotor, fans and coolers shall be designed to give a smooth and quite flow of air.
The water for cooling system will be available at a temperature of 28 Deg. C. The cooling
system for the generator shall be complete with the temperature and flow indicators,
thermostat relays, alarm and annunciation devices, etc.

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The Generator would have continuous overload rating 110% of the rated capacity to
match the turbine output at high heads. The stator and rotor windings would beef class
F type epoxy insulation. Closed circuit air cooling by generator rotor action with re-
cooling over air/ water heat exchangers installed around the outer periphery of the
stator frame could maintain the temperature of the generator parts within the specified
limits.

3.9 Brake Dust collecting system

The brake dust collection equipment consists of an extraction unit and control box,
hoppers around brake assembly for collecting the brake dust are provided for each unit.
Provision has been made in the control schematic of the unit for its ON/OFF operation
in auto mode.

3.10 Cooling Water System

Cooling water pipe lines along with pressure gauges and flow monitoring instruments
are provided to supply cooling water to air coolers and oil coolers. Manual isolation
valves are provided in the pipe-lines for isolating a part of the system without affecting
the flow of water in other sections of pipe-lines.

3.11 CO2 Fire Protection System

The CO2 fire extinguishing system is provided and consists of sufficient amount of CO2

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to maintain an inert atmosphere during the deceleration of the machine. There are two
rates of discharge of CO2, one group of cylinders, providing the initial discharge, to
ensure a rapid build-up of CO2 concentration, to put out fire and other group of
cylinders, providing the delayed discharge to ensure concentration of CO2 maintained
for an extended period. Capacity of the bank is sized based on the Volume of Generator.

The Fire in the Generator will be detected by suitable smoke detectors and the system
will operate on Generator Differential Protection also.

3.12 Upper Bracket

The upper bracket consists of a fabricated steel structure having a central part and 6nos.
radial arms. In order to facilitate its transportation, two arms have been detached and
are to be bolted to the central part at site. It supports the weights of the stationary
parts of brush gear, upper air baffles, generator covers, etc. It is placed on stator frame
with shims for level adjustment.

3.13 Lower Bracket

The lower bracket consists of fabricated steel structure having central part and 4 nos.
radial arms. In order to facilitate its transportation, 4 nos. arms have been detached and
are bolted to the central part at site. The lower guide bearing and thrust bearing is
housed in it along with oil coolers. The bracket is designed to carry the weights of the
rotating parts of turbine and generator as well as hydraulic thrust. It is designed in such
a way that it is possible to lift it through the stator bore. Brake-cum-jack units are also
mounted on the bracket for rotor braking and lifting. The bracket is secured to the
foundations by means of foundation plates and bolts. A light fabricated cover has been
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provided at the bottom of the lower bracket arms to prevent the circulating air from
going out of the machine.

3.14 Braking and Jacking System

The generator brakes consist of 4 numbers of fibers based rigid molded friction material
replaceable shoes, mounted on a vertical piston moving in a cylinder and operates
against a polished circular steel brake track located on underside of the rotor spider. To
apply the brakes, air at 0.5MPa shall be fed into the cylinder from--the station com-
pressed air system. Brake will be automatically applied when the speed of the rotor
reduces to a preset value, and will remain applied continuously so that the unit stops
completely.

The brakes also serve as a convenient means for jacking the rotor for maintenance
purposes. For this purpose, a complete hydraulic rotor jacking unit has been provided.
Oil is used as a working fluid for the jacking. A locking nut is provided on each brake
cylinder to hold the rotor in raised position during maintenance.

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3.15 Lighting System

The lighting system is provided for lighting the space between the stator frame and the
housing. Also the lighting arrangement is provided for lower bracket pit.

3.16 INSTRUMENTATION & DEVICES

MECHANICAL OVER SPEED DEVICE

A mechanical over speed device is mounted on turbine shaft over the turbine guide

bearing. It consists of a spring operated latched switch mounted on a bracket. The

switch is tripped by a spring loaded plunger carried on the turbine shaft, when the

plunger hits the cam of the switch box. The device can be reset by hand and has

suitable range of adjustment. The over speed tripping is given at 311rpm. The setting

of the mechanical over speed device is done based on following parameters:

Diameter : 500mm (at the point of installation of device)

Spacing : 2.7mm (Gap between plunger and switch box)

Speed : 311 RPM (Tripping speed)

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ON LINE CONDITION MONITORING SYSTEM FOR VIBRATION

For monitoring vibrations on the bearings of the machine, an On-line (continuous)

monitoring system has been provided. Vibration monitoring system provides display of

relative rotating shaft vibrations at identified locations while the machine is operating.

The monitor shall also have contacts to provide alarm / trip signals with adjustable

setting for them.

VIBRATION MONITORING

The PES eddy current proximity probe (PCS 304) is designed for non-contact

measurements of relative vibration, displacement and axial positioning. The probe is

equipped with built-in conditioning circuitry and protected to be fully operational in oil.

Since it requires no field probe drivers, it can be directly connected to processing

instrumentation. Vibration probes in pairs have been installed at UGB, LGB and TGB at

suitable locations in +Y (Upstream) direction & -X (U#3) directions.

PCS 304(eddy current probe)

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General Specifications

Operation

Measurement Type : Non-Contact Proximity, Capacitive Technology

Measuring Range : 0.5 to 4.5 mm [19.7 to 177 mils]

 Output : 4 to 20 mA

 Sensitivity : 4 mA/mm [0.1 mA/mil]

 Accuracy : ± 2.5% F.S.R.

 Repeatability : ± 0.5% F.S.R.

 Bandwidth : 0 to 1000 Hz (-3dB)

 Load at Current Output :500 Ω max.

 Temperature Drift : < 500 ppm/°C (at mid-range)

Power Requirements

 Voltage : 24 Vdc ± 15%

 Consumption : 60 mA max.

 Voltage Reversal Protection : Built-In

 Warm-Up Time : 5 Minutes

Connection

 Connector Type 4 : Position M12 Male

 Max. Cable Length : 300 m [984 ft]

Environment

 Temperature Range
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Operating : 0 to 60°C [32 to 140°F]

Storage : 25 to 70°C [-13 to 158°F]

 Humidity : Up to 95%, Non-Condensing

Physical Characteristics

 Sensor Body : Chrome-Plated Brass

 Sensing Face : Glass-Reinforced Epoxy,FR-4

SHAFT CURRENT MONITORING SYSTEM

During the operation of generator, undesirable voltage s are developed at shaft ends

due to magnetic asymmetries and result in circulating current through critical parts like

bearing, coupling etc. Even though the bearings are insulated, however, in the event of

insulation failure reduced capacitance of oil film leads to considerable amount of oil flow

thereby damaging the bearings. Shaft current monitoring device monitors the shaft

leakage current in real time. Whenever the magnitude of current exceeds the preset

value of the fundamental components, alarm is initiated.

3.17 Automatic control system

In the auto control system, it is equipped with HP lubrication oil system, temperature,
flow, pressure, shaft current sensing. HP system is to be used for startup and stop of the
unit. Besides, automatic elements for purpose of control, monitor and protection
functions also are provided for speed, temperature, liquid level, and oil & water & air
pipelines for monitoring and alarm and trip.

Unit adopts the method of frequency measurement by residual pressure. The machine
speed signal is collected from PT at the side of machine. Static excitation system with
several limiters and excitation transformer protection system is provided for safe
operation of unit.

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3.17.1 Generator Automatic control system

Startup

After receiving startup signals from control room, the machine shall start automatically
by following operation procedure, and system shall put into work. According to machine
loads based on excitation system current, so that machine could work steadily at the
required load.

Shutdown

After receiving shutdown signals from control room, the machine shall stop
automatically by following normal operation procedure, including unload, oil switch trip,
brake and main cooling water supply shall be cut off.

4.2.3 Emergency shutdown automatically

Generator shall have emergency shutdown automatically if following occasions

happens:

A. If bearing temperature is too high (more than 65℃ for radial pad, more than 55℃
for thrust pad)

B. If speed is up to 140% of rated speed.

C. If pressure of pressurized tank of OPU system is lower than the setting value.

D. If system electrical protection acts.

E. If temperature of cold/ hot wind from air cooler is too high (more than 50℃ for cold
wind, and more than 70℃ for hot wind.

Emergency shutdown

Unit over speed protection device shall act for closing guide vane through servomotor
if governor get failure during shutdown period of machine.

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Protection signals

Signals shall be sent automatically under following conditions:

A. Speed signal device shall act if machine speed rise is more than that of rated speed.

B. Pressure annunciator shall send signal if oil pressure of pressurized tank has down to
the lowest limit allowable.

C. Temperature annunciator shall send signal if guide bearing temperature has up to

upper limit allowable.

D. Level annunciator shall send signal if the oil level of leakage tank has up to upper limit
allowable.

E. Shear pin annunciator and signal device shall send signal if pin cuts due to block of
distributor GV.

F. Shaft current level is very high.

G. Protection signals from Excitation system

3.17.2 Startup and commissioning of unit

After erection works get finished, the generator should have a comprehensive startup
commissioning before put into official operation. But before this, special team shall be
arranged to make an overall inspection and assessment for erection quality. Test plan
also shall be made in details, and series adjustment test shall be carried out by following
plan.

Preparation for initial startup works.

1.1 After erection or overhaul, the initial startup preparation works of unit should be
done with MIV & Intake gate closed.

1.2 Clean everywhere, and check if anything left inside.

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1.3 All instruments and pipelines shall be cleaned well, check valves under instruments
are opened or not.

1.4 All auxiliary pipelines of shall have hydraulic or air tests based on different working
pressure, and qualified. Pipelines shall be cleaned well, include acid clean and drying.
All connections shall be correct and smooth.

1.5 Sealing test shall be done for turbine runner, and no leakage is allowed. The leakage
quantity of sealing oil within 8 hours shall be not more than erection specification.

1.6 Check cooling water of bearing and air cooler if it flows smoothly, together with
conditions of relating flow switches.

1.7 Check all automatic elements and instruments are mounted well.

1.8 Check bolts and nuts of important components if any loose, specially pay attention
to the coupling bolts between main shaft and runner if welded well.

1.9 Check GV servomotor acts, and whether distributor could works normally by
operating of GV servomotor.

1.10 Check if any block between guide vane and stay ring, top cover and bottom ring
under max opening and close status.

1.11 Check the gaps between inside and outside surfaces, and vertical gaps while guide
vane is closed, they should meet design requirements.

1.12 Check and test the feedback conditions of return mechanism.

1.13 Check and test the actions of all mechanical measuring devices of turbine.

1.14 Close drain valve before filling water into flow passage.

1.15 The manhole of draft tube cone & spiral case shall be closed well.

1.16 Items to be checked after filling into water:

A. Check any leakage of all joint faces.

B. Check any leakage of distributor sleeve, guide vane shaft.

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C. Check leakage condition of shaft seal.

D. Check all gauges and meters are working properly.

1.17 Check Rotor and Stator Air gaps

1.18 Check

Requirements before startup unit.

1.1 Inspection contents mentioned in item 1.1 Preparation for initial startup works have
been checked well.

1.2 MIV is “to be closed” status.

Zero load running test

1.1 The first zero load running test is done by manual operation.

1.2 During zero load condition, speed shall have 5 situations: 50%, 75%, 100%, 115%,
140% of rated speed. Manual startup the machine, and make speed rise up to 50% of
rated speed within 3-5 minutes, then keep it for 2-3 minutes. Make speed rise up if
normal, or find solution or shut down machine immediately if any abnormal.

1.3 Check vibration condition under various speed, and whether there is any friction or
crash between fixed parts and movable parts.

1.4 Check the working conditions of shaft sealing.

1.5 Check other seals, combined faces if any water leakage.

1.6 The machine can be stopped while it is down to rated speed and bearing
temperature is stable.

Initial running test with load

1.1 This test shall include auto-startup, with grid, with load and machine shutdown tests.

1.2 Check excitation system and governor working condition, and the situation of
machine startup- zero load - with grid.

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1.3 Further check bearing about temperature rise condition.

1.4 Check working condition of relating automatic system.

1.5 Check GV opening and blade angle, and their combination relationship.

1.6 Make records of all values shown in gauges and meters.

1.7 Check machine conditions, such as vibration, oil/water leakage.

Load rejection test

The test shall be done from 25%, 50%, 75%, 100% of rated capacity one by one, based
on the actual water head.

1.1 Watching on stability condition of machine.

1.2 Check and measure the speed rise ratio, which should not more than design value
specified.

1.3 Check and measure the pressure rise value before guide vane and vacuum degree
of draft tube behind guide vane.

1.4 Combination relationship shall meet technical requirements.

1.5 Check and measure the closing condition of governor, and make suitable adjustment
for closing time based on actual situation.

1.6 Check the vibration condition of machine.

1.7 Watching on the closing situation of guide vane while control ring is working with
overspeed limit.

Commissioning for 72 hours

The machine shall have commissioning with 50% of rated load for the first 8 hours, then
after running with 100% of rated load. Watching on machine conditions overall.

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4 Operation and Maintenance Procedures

Service inspections and maintenance operations carefully done according to the

following instructions are of vital importance for keeping the plant and all its
components in a reliable operating condition. Service inspections are intended to
detect incipient defects and malfunctions early enough to ensure that by taking
immediate remedial action such as repair and replacement of defective components,
etc. consequential damage and hence extended periods of downtime of the machine
unit will be avoided. Maintenance operations contribute towards keeping the plant
components in a reliable operating condition for an extended period of time. It is
recommended to contact HUNAN ALLONWARD in good time whenever major repairs
or replacements of components will be necessary.

4.1 Safety Precautions Specific to the Plant

The chapter Safety contains general safety instructions, which have to be considered
when working on the machine/plant.
Supplementary additional safety instructions to the individual activities are provided in
the chapters of the manual. These are set apart from the text by special warning
notices.
Safety instructions for components, which were not made by Hunan Allonward, are
included in the descriptions of the component suppliers and have to be considered too.
Non-adherence to the safety instructions can lead to personal injuries, environmental
damages and/or material damages.
Hunan Allonward assumes that the operator guarantees the following:
 The operator prepared a comprehensive general safety program.

 Each person, working on or in the surrounding of the machine /plant was

sufficiently trained (regarding operation of machine/plant and its running
procedures).

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4.1.1 General warning

The following are recommended safety precautions to take when handling, lifting,
installing, operating, and maintaining the equipment. They should be used as minimum
requirements only and additional or other requirements may be necessary depending
on the equipment and/or particular circumstances. Failure to follow these and other
necessary safety precautions could result in injury or death to persons or damage to
property or both. You are responsible for ensuring that appropriate safety precautions
are observed and any operation and/or maintenance is performed by properly trained
personnel. Hunan Allonward shall not be responsible for misuse of the instructions, set
out herein, or the failure to observe proper safety precautions.

All data mentioned in the chapter Safety are important and safety-relevant. Therefore
the information in this chapter is not marked with special danger symbols.

DANGER

This marking advises against direct danger for personal life and health.

Non-adherence can lead to death or serious injuries and to extensive

material damages.

WARNING

This marking advises against an imminent danger for personal life and
health.

Non-adherence can lead to death or serious injuries and to extensive

material damages.

CAUTION

This marking advises against an imminent danger for personal Health.

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Non-adherence can lead to medium or slight injuries and to

environmental and material damages.

NOTICE

This marking advises against a dangerous situation.

Non-adherence can lead to material damages.

INFORMATION

This marking contains useful information.

Considering this information facilitates or supports a correct

performance of the activity described.

4.1.2 Pictograms

All prohibition- warning- and action signs, which can be mounted on the machine/plant
and/or are used in this manual, are stated in the following:

Prohibition signs:

No unauthorized entry No Fire, No Smoking No Trespassing

Do not water fire fighting Do not touch

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Electric Danger

Warning signs:

Generic Warning Warning Hot Surface Dangerous Voltage

Risk of Falling Risk of Crushing Warning Magnetic Field

Risk of Slipping Floating Loads

Risk of Tripping

Dangerous gases
Remotely started Environmental Pollution

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Mandatory signs:

Hearing Protection Protective Eye Wear Wear Safety Shoes

Wear Gloves Wear Helmet Dust Protection Mask

General protective equipment:

Use and take along personal protective equipment in accordance with local instructions
or instructions of plant operator. The wear of protective footwear in all the factory
premises is mandatory.

4.1.3 Safety devices

The access to all safety devices must be ensured at any time.

The machine/plant can be put from operation to a safe operating condition at any time
by pressing the EMERGENCY STOP BUTTON(possible designs see illustrations below).

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The operating and maintaining personnel of the operator must be informed about the
location and function of the EMERGENCY STOP BUTTONS.

The location and number of EMERGENCY STOP BUTTONS is shown on the wiring
diagrams.

Voltages and hydraulic pressures can still be present after pressing the EMERGENCY
STOP BUTTON.

4.1.4 Basic safety instructions

4.1.4.1 Duties of operator

Intended use The operator of the machine/plant is responsible for the intended use
of the machine/plant.

Work instructions In addition to the manual observe and use the relevant national
legislation and other regulations regarding health & safety and
environmental protection.

 Operation, set-up and maintenance of machine/plant by qualified,

Qualification of
reliable and authorized personnel only.
assigned personnel
 Qualified personnel are persons, who were authorized by the
responsible safety person due to their education, experience as well
as knowledge of relevant standards and regulations, rules for the
prevention of accidents and operating conditions to perform the
necessary works and to recognize and avoid possible dangers.
 Ensure that only authorized personnel works on the machine.

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 Personnel in education may only work on the machine/plant after

theoretical training and only under supervision of a qualified
person.
 Take the legal age into account.
 Only an electricity specialist or person instructed by him is entitled
to work on electrical systems of the machine/plant under his
direction or supervision.
 Only competent personnel are entitled to work on gas equipment
(gas consumption equipment).
 Only personnel with special knowledge and experience are entitled
to work on hydraulic equipment.
 The operating and maintaining personnel of the operator must be
Instruction
introduced by qualified persons after completing the installation
work.
 The operator is obliged to introduce new operating and maintaining
personnel in the same extent and with the same care under
consideration of all safety instructions.
 Persons, who are involved with the transport, assembly,
commissioning, operation and maintenance of the machine/plant
must have read and understood this manual as well as the
descriptions of the component suppliers before commencing work.
 Safety instructions for components, which were not made by Hunan
Allonward, are included in the descriptions of the component
suppliers and have to be considered, too.

Definition of area of The operator is responsible for:

responsibility
 The definition of the machine operator responsibility and the
directive authority,

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 The definition of the content (record of the function and

malfunction of monitoring equipment) and the responsibility for
maintaining the shift handover log,
 The duties of the operating and maintaining personnel.

Inspections & tests The operator is obliged to:

 Check regularly whether the safety instructions are kept in

accordance with the manual when working on the machine,
 Train the operating and maintaining personnel regularly and to
confirm their knowledge.

Attachment of safety The operator ensures that an safety-relevant instructions are kept
devices all and symbols and notices are attached in the production area in
accordance with the local instructions.

Beyond that Hunan Allonward recommends attaching of the

following devices, symbols and notices as far as these are not already
contained in the local instructions:

 Emergency lighting
 Information sign - fire prevention equipment
 Information sign - emergency call
 Direction sign - exits
 Direction sign - escape routes
 Information sign - first aid
 Observe the national fire protection regulations

All safety and warning notices on the machine/plant shall be

complete and readable.

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Fire extinguisher The operating and maintaining personnel must be informed about
the location and handling of fire extinguishers.

4.1.4.2 General duties of personnel

ln order to avoid personnel injuries and material damages the following safety
instructions apply to all persons, working on the machine/plant:

 Observe the safety instructions mentioned in the manual and attached on the
machine.
 In case of safety-relevant malfunctions stop or secure the concerned part of the
machine immediately. Announce and repair the malfunctions immediately.
 Any safety-precarious mode of operation is not allowed.
 Use only the provided entries, routes and aisles.
 Keep the machine/plant and work place clean and tidy. Do not put down tools and
other items on the machine.
 Do not near cloths or pieces of jewelries, which enable getting caught by mobile
machine parts. Ties, neckerchiefs, rings and chains belong thereto.
 Do not wear long hair loose.
 Inform the personnel about the function and malfunction of monitoring
instruments before commencing work.
 If necessary, place temporary barriers and limit the entrance when working on the
machine/plant.
 Entering of danger zones is only allowed after the power supply is safely
disconnected and the mechanical safety devices are mounted. Protective
equipment must not be blocked or bridged.
 Avoid contact with switched on circuits or rotating parts.
 Use or take along his personal protective equipment in accordance with the
national instructions of the operator when working on the machine.

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 The wear of protective footwear in all the factory premises is mandatory.

 Re-establish the original condition after maintaining.
 If the operating person cannot survey the entire zone of danger, nevertheless make
precautions to ensure that no persons are in the zone of danger when issuing
control commands.

Set the operating mode to AUTO before leaving the power house in order to ensure
that the machine/plant can be stopped in case of danger.

4.1.4.3 Work on/in electrical systems

High voltage can lead to heavy or fatal injuries. Therefore it is essential to observe
the following:

 Work on/in electrical systems must not be carried out unless a permit has been
issued by the senior authorised person.
 Operation and maintenance of the machine/plant only by qualified personnel.
 A second person must be present when working on live parts. in case of emergency
this person can press the EMERGENCY STOP BUTTON or the main switch with shunt
trip. Demarcate the working area with a red.white safety chain and a warming sign.
 Use proper insulated tools, protection devices and personal protective equipment
and check them before each use.
 It is recommended to make oneself familiar with the safety standards, guidelines
and electrical regulations as well as the usual national and proven operating modes
for plants (e.g. EN 50110, VDE0104 or IEG standards). The following steps have to
be met as minimum requirement before commencing work on electrical
machine/plants:

 Disconnect completely
 Secure against re-connecting

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 Verify that the installation is dead (de-energized).

 Carry out earthing and shot-circuiting
 Provide protection against adjacent live parts

After finishing the work. Carry out the above steps in reverse order.

 Regular inspection of electrical equipment of machine/plant. Lacks such as loose

connections or scorched cables have to be repaired immediately.
 Use only original locking devices with stipulated amperage.
 In addition to the general safety instructions observe and comply with the local
safety instructions and specifications.

Remove covers and safety devices only after the appropriate ranges are de-energized
and secured. Before energizing mount the corers and safety devices again.

4.1.4.4 Hydraulic, pneumatic

 Only personnel with special knowledge and experience are entitled to work on
hydraulic equipment.
 Regular inspection of pipes, hoses and bolted connections for leakage and
externally visible damages (leaking-out oil can bad to injuries and fire). Damages
have to be repaired immediately.
 System sections and pressure pipes (hydraulic, compressed air) have to be
depressurized before commencing repair work in accordance with the module
descriptions.
 Hydraulic and compressed-air pipes have to be laid professionally (connections
must not be mistaken).
 Armatures, length and quality of hose lines must correspond to the requirements.

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The operating space of the actuators must not be blocked and the access to this space
must be property secured- This applies in particular to closing weights, servo motors
and the guide apparatus.

4.1.4.5 Lifting and transport of components

The notices, stated in the following, have to be kept when lifting and harp porting
components in order to avoid injuries and material damages.

 Do not stay or work below floating loads. Further it is not allowed to ride on floating
loads.
 Adhere to the general and also local safety instructions as well as specification or
manuals of the lifting tool or load lifting attachment manufacturer.
 The used lifting tool or transport vehicle must be suitable for the loads to be
transported. if a mobile crane is used, take additionally into account that this crane
is mounted in accordance with the manufacture’s instructions.
 Usage permission for the crane must be available. Operating of remote controlled
cranes only by personnel with proper written driving license
 The results of the regular lifting tool inspection (inspection log book)
 All used slinging means (ropes,chains, shackles, eyebolts, lifting eye nuts, S-hooks)
must be used only in accordance with the manufacture’s data.
 Secure the loading properly before lifting and transport operations.
 Determine the required space in the power plant or on other provided (temporary)
storage areas before commencing with lifting and transport operations. Further
make sure that the floor loading is adequate by granting access to the as-built
drawings.
 During lifting observe the signs and other written instructions attached on the
packing or components; special customer requirements are to be considered, too.

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 A "test brake" of the lifting unit is necessary when lifting heavy loads. Lift the load
approx. 10cm and lower it in small) steps. After each switch-off, the brakes have to
stop the lowering process.
 Use 3D-lifting rings or eyebolts, if provided.

Direction of crane operation by show of hands or wireless only by responsible specialist.

4.1.4.6 Mobile usable machines and components

 Secure the machines/components with appropriate fixings against unintended

positional changes before or immediately after finishing the loading process.
 Attach appropriate warning signs.
 Disconnect the machines/components from any external power supply; also in case
of slight relocations.
 Remove transport and slinging means duty before re-commissioning.
 Mount and fasten the parts, which were removed for transportation purposes,
again before re-commissioning.
 Connect the machines/components again with the system before re-
commissioning.
 Re-commissioning only in accordance with the manual.

4.1.4.7 Gas, dust, steam, smoke

 Welding, burning and grinding operations on the machine/plant are only allowed if
expressly approved.
 Remove dust and inflammable materials from the machine/plant and its
surrounding before welding, burning and grinding operations. Further proper
ventilation is to be ensured (danger of explosion)!

If necessary take available national instructions for work in close rooms into account.

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4.1.4.8 Noise

 Noise protection devices of the machine/plant must be in safe position during

operation.
 When required, use hearing protection.

4.1.4.9 Operating supplies

Before operating supplies can be used, read the safety data sheets of the machine and
the instructions of the manufacturer. Based on these data sheets prepare a proper
protection concept and observe it.

Apart from that take the following measures in order to avoid damages and injuries of
the personnel:
 Wear protective goggles
 Avoid excessive skin contact with the product
 Proper ventilation of surrounding
 Use protective equipment

Ignoring of these precautionary measures can lead to injuries by inhalation of

poisonous steams or lead to suffocation.

Be careful when dealing with hot operating supplies. Danger of bums and scalds!

Swarf of coatings, arising during repair work, must be disposed hazardous waste.

4.1.4.10 Radio equipment

Only EMC-conform radio equipment must be used within the plant.

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4.1.4.11 Gas extinguishing system

The entire operating and maintenance personnel of the operator must be familiar with
the operating mode of the gas extinguishing system, when using such a system. Further
it must also be familiar with the resulting special safety precautions in case of
emergency. Ignoring of these safety precautions can lead to injuries or death of persons
by inhalation or quenching gas.

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4.1.5 Safety instructions for generator

4.1.5.1 Safety markings on generator

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4.1.5.2 Unintended turning of rotor

In case of flooded turbine the rotor may turn due to the leakage water. Therefore the
brakes have to be activated and the guide apparatus has to be closed when working on
or near the rotor. Additionally insert a rotor locking bolt.

4.1.5.3 Electrical system

Too high overload caused by a failure can lead to an overheating of the insulating
materials. Damages on the machine can additionally lead to electric arcs. Noxious
vapours can arise due to overheating and influence of electric arcs. Applicable in this
case:

 Observe the appropriate alarm and shut-down values as precautionary measure.

 The personnel should not approach the generator until the air is free of vapors
(proper ventilation).
 Do not inhale vapours, if generator covers are removed after damage. Inspections
or other activities should not be started before the generator cooled down.

Switched-on electrical equipment should not get in contact with water, since an electric
shock can lead to serious and fatal injuries. In case of fire, interrupt the circuit and fight
flames with a carbon-dioxide fire extinguisher. Before the generator is again put into
operation after a possible damage, check it for damages. If a DC-test is necessary,
additional safety precautions are required due to charging of the insulation. Discharging
of the charged HV-insulation can take very long. After the tests are finished, connect
each strand of the winding with the frame for at least 8 hours, as well as ground them
temporarily in case of physical contact with the winding.

Ignoring of these safety precautions can lead to injuries or death caused by electric
shock or inhaling of noxious vapors.

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4.1.5.4 Residual risk - released substances

Ozone:

In case of an intended use of the generator, ozone is not produced despite

operation with high voltage. However, the release of ozone caused by electrical
discharges with high voltage cannot be completely excluded in the lifetime of the
generator through contamination and aging processes. HUNAN ALLONWORD
recommends periodical monitoring of the ozone value in the generator pit.

Dust /oil mist:

Wear of the carbon brushes and brake linings leads to dust. Wear a dust protection
during maintenance work on the exciter equipment and brake/lifting jacks. Exhaust
existing dust.

Oil mist can escape in the bearing area and can be reduced with an oil mist
exhaust. Basically it is recommended to coat the foundations in those areas with oil-
resistant paint.

Gases:

Particularly during the first commissioning and operating hours strong- smelling
and precarious, but also noxious gases (Formaldehyde) can escape from the insulations
and paints in exceptional cases.

During this period of time the generator interiors must be entered only, after it was
proven that no noxious gases are present.

Proceed as follows:
 Ventilate the generator interior sufficiently.

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 In case of smell pollution, measure the concentration with harmful substances (e.g.
Drager tube for Formaldehyde 0.2-5 ppm).
 If the concentration with harmful substances exceeds the allowed MAK-value (max.
allowable concentration) the interior must be entered with a respiratory mask only.
 Organize a supervisor.

In case of health impairment, initiate immediately first-aid measures.

4.2 Operation

4.2.1 Safety instructions

 Any safety-precarious mode of operation is not allowed.

 Take measures that the machine/plant can be operated in a safe and operational
condition. In addition all protective devices and safety- related equipment as well
as all noise insulations and exhausting equipment have to be available and be in
operational condition.
 In case of malfunctions shut-down and secure the machine/plant immediately.
 Before starting the machine/plant make sure that nobody is endangered by the
starting machine/plant.
 Exhausting and ventilation devices must not be shut-down or removed with
running machine.

General precautions during operation:

The following general precautions shall be made during each generator operation:
 Avoid any contact with electric circuits. Also electric circuits with low voltage can
be dangerous to life. Over voltages may occur in each electric circuit under certain
conditions.

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Generator and control leads, overload protection and earthling must correspond to the
national electro-technical instructions and other applicable standards and are conform
to the locally usual work practices.

4.2.2 General

Commissioning:

Precondition for a reliable operation of the generator is correct.

Commissioning after the final assembly. i.e. before starting the plant, the
commissioning process of the entire plant (generator, control & instrumentation,
auxiliaries, etc.) has to be completed. All alarm and shut down values for temperatures,
pressures, water- and oil flow rates etc.

For longer shutdown periods the heating maintains a higher temperature inside the
generator than outside, and thereby avoids the occurrence of condensed water or
moisture.

The generator stand still heating consists of individual electrical heaters, located below
the stator winding area. A thermostat is provided for switching of these standstill
heaters.

Monitoring instruments were set and checked during commissioning.

Notice

The setting values, specified during commissioning, must not be changed without
agreement of HUNAN ALLONWARD.

Monitoring:

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Notice

The generator should be monitored continuously from start-up to shutdown. All

signals of the monitoring instruments are transferred to the control &
instrumentation. There the signals are evaluated, indicated and stored.

4.2.3 Operating conditions

The following points have to be fulfilled in any case regardless whether the generator is
operated automatically or manually:
 Compressed air is available.
 The power supply for the auxiliaries is ensured.
 The HP- and lubricating oil supply for the bearings is in operation.
 The cooling water system is in operation.
 External fans, if available, are switched-on.
 The excitation system is ready.
 The protective system is activated,
 The synchronization system is activated.

The turbine governor is in operation.

4.2.4 Start –up and shut down

Start-up and shut-down take place step by step and is automatically activated by the
control & instrumentation. Thereby all necessary conditions are automatically fulfilled
and monitored.

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4.2.5 Longer shutdown periods

In order to avoid damages on the generator, the following precautions are to be taken
in case of longer shutdown periods (exceeding 2 weeks):

 Support the rotor on the brake-/lifting jacks.Therefore lift the rotor with the brake-
/lifting device and fasten it in that position using a retaining ring.Insert thin sheets
made of brass between brake ring and braking segments.
 Activate the lubricating- and high-pressure supply (with activated oil mist exhaust)
every 2 weeks as well as the cooling circuit for 2 hours.
 Activate the brakes.
 Lift-off the brushes.
 Activate the standstill heater and air dehumidifier.

4.3 Maintenance

4.3.1 General

This manual was especially prepared for operators and maintenance personnel of a
hydro type generator. The reliability of the generator will be guaranteed by the owner’s
experienced personnel, which follows proven operation- and maintenance procedures.
Before putting the generator into operation we recommend preparing and establishing
a detailed maintenance program.

Responsibility of the operator:

The maintenance of the generator and its auxiliary plants must only be carried out by
highly trained staffs which are familiar with the operation of the generator. It needs to
show expertise in the way the generator, including its components, operate and have
the necessary training regarding the safety aspects of maintenance.

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4.3.1.1 Safety instruction

 The generator and its auxiliary plants are maintained by qualified personnel only.
The personnel must be sufficiently trained and be familiar with the operational
mode of the generator and its components. Further a training regarding safety
aspects of maintenance is necessary.
 Before starting with the maintenance, the operating personnel of the
machine/plant must be informed about these works.
 For particular components (exciter, oil plant, brake-/lifting unit, cooling, heating,
etc.) additional maintenance instructions of the respective manufacturer have to
be observed.
 Undamaged and fully functional parts and original spare parts of the manufacturer
have to be used during maintenance solely.
 While maintaining the generator, working on the manual governor is not allowed.
In order to ensure this, insert the guide apparatus lock and protect it against
unauthorized removal.
 Before starting with maintenance, the following activities are to be performed:

 Disconnect the generator and all auxiliary plants from the system and protect
them against re-start.
 Ensure that the turbine cannot be put into operation.
 Earth and short-circuit the generator.
 Earth the generator in accordance with the local electrical regulations and
corresponding to the usual local work practices.
 Check whether components are de-energized,
 Switch off the C02 fire extinguisher.
 Protect the maintenance areas, as far as required, against entry to unauthorized
personnel.

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 If the machine/plant is completely shut down during maintenance, the following

precautions are to be performed in order to protect them against unexpected re-
start.

 Lock main control panel and remove the key.

 Attach a warning sign on the main switch,
 Lock the machine mechanically,
 Lock the stop valve.
 Use the provided ascent supports and platforms or other ones in accordance with
the safety requirements when performing maintenance work exceeding the body
height. Machine parts must not be used as ascent supports. The use of fall
protections is absolutely necessary for maintenance work in higher altitudes.
 Remove contamination, snow and ice from handles, footstools, railings, platforms
and ladders.
 Re-tighten bolted joints, which loosened during maintenance. The safety-relevant
tightening torques are stated in the appropriate drawings.
 If safety devices have to be removed during repair and maintenance, re-assemble
and check them immediately after finishing repair and maintenance work.
 Provide a safe and environmentally friendly disposal of operating supplies as well
as of replaced parts.
 If a HV-insulation test is necessary, proceed according the procedures and
regulations of NEMA Publication MG-1 and MG-2 or VDE0104.
 The local protection regulative (e.g EN 50110 and EN 50191) are to be observed
when conducting electrical test and working with brushes.

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4.3.1.2 Strategies of maintenance

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4.3.1.3 General precautions

Temperature limit values:

Set values for temperature monitoring according to “Operating and setting values’’.

Overloading of the generator –basis and philosophy:

It is common practice of HUNAN ALLONWARD to provide safety margins in order to

fulfill the contractual requirements and to secure long lifetime and) failure-free
operation.

General precaution:

Operating above this limit can result in damage to the generators' components or in its
complete failure. This is why HUNAN ALLONWARD cannot be held responsible for
malfunctioning due to operating the generator above the calculated limits. This also
leads to loss of warranty.
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4.3.1.4 Feedback

HUNAN ALLONWARD'S main objective is to supply the most advanced generator

technology. To achieve this aim, HUNAN ALLONWARD continuously examines all
generator components for improvements and simplifications, to increase the reliability
of the unit for our clients. This can not only be done by the supplier, instead we also
depend on the feedback from our clients (operators). We welcome positive as well as
negative feedback which constitutes the basis for improvements for the benefit of the
clients of HUNAN ALLONWARD.

In case any failure of the generator is observed, you are kindly requested to submit all
information, documents, records, etc. with respect to the most recent operational
conditions and maintenance of the generator to HUNAN ALLONWARD.

4.3.2 Influences for maintenance

4.3.2.1 Factors influencing the maintenance

4.3.2.1.1 Influences due to normal operational stress

The normal operation includes influences like e.g.

 Period of operation in different operating mode

 Standstill period
 Number and kind of operating mode changes
 Number and type of starts
 Operating mode of generator

Frequent and strong load cycles lead for example to relative movements and thus
stresses and wear between the windings and their fastening elements, but also
between copper conductors and insulation. The resulting effects depend strongly on

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the cooling system, capacity factor and design. Operations, started after stops and
standstills, lead to a specific stress of the machine.

This includes:

 Elongation and frictional influences on winding and insulation caused by

temperature and centrifugal force cycles
 Special vibrational stresses when passing through eigen frequencies of different
machine parts.
 Material fatigue in particular of rotating parts due to centrifugal force cycles.

Influences due to extraordinary stress:

Processes, not included in the normal operation (see list below) shorten the inspection
intervals and increase the maintenance effort.

 Short-circuit near generator

 Out-of-phase synchronization
 Overvoltage
 Unbalanced load
 Loss of synchronization
 Over temperature
 Run-away speed
 Influence of humidity or water
 Strong contamination
 Emergency braking
For evaluating the influences caused by extraordinary stresses make first of all sure that
their occurrence is recognized. For this purpose recording and evaluation provide
valuable reference points for exceeding the limit values. These deviations of the limit
values, which usually lead to an alarm (message) in the control station prior to
protective shut-downs, shall be used at the same time as proposal for special fault

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recording. The analysis of the fault process provides the opportunity to evaluate the
extraordinary stress on the components concerned and to draw conclusions on the
planned inspection and maintenance intervals. For example: An inspection of the end
winding is recommended for a three-phase short circuit near the generator. If an out-
of-phase synchronization is detected, such an inspection is to be performed
immediately. Depending on the severity of the stress, a high-voltage test is
recommended. Extraordinary changes of the steady-state running condition, e.g.
documented by a monitoring system, require a clarification of the causes and perhaps
an inspection of the bearing and rotor. Influences caused by over speed are to be
expected only if the turbine governor or stop valves fails. An emergency braking caused
by high speed will lead to a visual inspection.

4.3.2.1.2 Influences due to generator –specific condition

The inspection and maintenance intervals and maintenance effort are also influenced
by the year of construction, capacity, type of cooling, design and type-specific
experiences. For example: An open cooling circuit will require more cleaning than a
closed one; an older machine can require shorter intervals for visual inspections than a
new one.

4.3.2.1.3 External influences

External influences are influences, which are not caused by the generator:

 Number of units in power plant

 Standstill of other components of same unit or power plant
 Influences due to load or system
 Economic influences (costs/benefit, water passage ...)
 Organizational influences

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4.3.2.1.4 Other influences

Also the results of consistent operating observations should be included in the

maintenance and inspection plan:

 Results of already performed maintenance and inspection activities

Results of monitoring-, measuring- and diagnostic systems, in particular modem
monitoring systems (partial discharges, cooling gas, air gap, structure-borne sound,
vibrations, cooling circuit symmetry) can contribute substantially to an extension of
inspection internals and accordingly to a reduction of the maintenance work.

4. 3.2.2 cleaning of generators

4. 3.2.2.1 General

The active parts of the generators shall be kept as clean as possible. Especially the
windings of both, the stator and the rotor are very sensitive to surface contamination,
which can cause partial discharges or creeping current across the surface of the
insulation material. This may lead to flashover and may therefore cause severe damage
to the generator.

4.3.2.2.2 Cleaning methods

The best way to clean the active parts of a generator is determined depending on the
kind of contamination. Most common reasons for contamination are

 oil vapour
 carbon dust
 brake dust

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These components can be “glued” together forming a thick hygroscopic layer. Usually,
oil and grease can be removed using solvent or cleaning agents in combination with
suitable mechanical tools.

4.3.2.2.3 Cleaning procedure

 First try cleaning as much as possible without using a cleaning agent but only with
the aid of a powerful vacuum cleaner. Make sure not to use a metallic nozzle.
Instead, use a soft plastic or rubber nozzle to prevent damage to the sensitive
surfaces.
 If the contamination is resistant to the above mentioned method, spray the
cleaning agent onto the layer of dirt until soaked.
Then carefully clean the surface using cleaning rags and/or brushes.

4.3.2.2.4 Tool and material

 Vacuum cleaner with plastic or rubber nozzle Brushes of Various sizes and shapes
(non-metallic!)
 Note: Never use any type of metallic brush or tools containing metal to clean the
stator core and windings.

 Cleaning rags
 Cleaning agents which are not harmful to the environment and tested by HUNAN
ALLONWARD:

LOSOL 920 (CHEMISCHE) or other equivalents.

Note:

Good aeration is vital when using a solvent agent In any case, it has to be proven that
the solvent or cleaning agent used does not affect neither the surface nor the general
condition of the insulation material nor the insulating varnish.

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All cleaning agents used by HUNAN ALLONWARD are tested on the material and
varnishes used in our electrical machines. However, HUNAN ALLONWARD cannot
guarantee for any cleaning products and their effects used by other generator
suppliers.

4.3.2.2.5 Cleaning process

WARNING:

Dust and vapor can lead to health injuries of skin and respiratory system. Wear
protective gloves during cleaning and additionally a dust mask in case of dust formation.
While handling cleaning agents the safety precaution acc. safety data sheets are to be
observed.

NOTICE:

The fire extinguishing system tan be triggered by hot cleaning agents. When cleaning
the machine/plant consider the temperature sensor of the fire detector and
extinguishing system do not in contact with the cleaning agent in order to prevent an
activation of the extinguishing system. When using solvents pay attention to sufficient
ventilation.

NOTICE:

Metal –based brushes or tools can cause damages on the stator core and winding during
cleaning. Use never metal-based brushes or tools when cleaning stator cores and
windings.

1. Remove as mush dirt as possible as possible without cleaning agent, only with a
power vacuum cleaner.
2. Inject the remaining dirt with a cleaning agent till the dirt soaks.
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3. Remove the soaked dirt with a cleaning reg and /or brushes.
4. After cleaning examine all fuel, engine oil and hydraulic oil pipe for leakages,
loosened connections, chafe marks and damages. Detected damages have to be
shown and removed.

4.3.2.3 Drying process

Having finished the cleaning work the generator parts, in particular the windings, must
be dried carefully:

 Drying using several hot-air blowers. Make sure not to overheat insulating parts
locally!
 Drying of windings with current of welding set
 Drying during short circuit run of the generator (turning off the coolers should only
be carried out by specialists).In this case it is vital to check the display of the
temperature sensors in the generator
 Before applying high voltage to the windings or putting the generator into
operation, it is again necessary to check the insulation resistance of the windings

4.3.3 Maintenance and inspection plan

The works stated in this section are to be performed at the latest after the specified
interval is achieved. The intervals have possibly to be shortened depending on the
operational conditions (particularly in case of wear parts). See section 3.1.2.

The intervals stated in the maintenance and inspection plans have to be repeated
periodically. I.e. each small inspection is included in a larger one (e.g. a weekly
inspection is part of the monthly inspection, etc.).

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NOTICE:

The activities stated in the maintenance and inspection plan refer to a standard
generator design. Design deviations have to be considered accordingly during
maintenance and inspection.

INFORMATION:

Basically electrical wiring does not require maintenance. Nevertheless a regular visual
inspection is recommended.

4.3.3.1 Definitions

Visual inspection

Visual inspection of machine with the naked eye in visible range for loose or missing
parts and damages; each instant opportunity for a visual inspection of the machine shall
be used

Extended Visual inspection

A visual inspection extended by simple tests, measurements or checks

Test verification

Examine correct function or proper condition of a component with suitable means.

Measurement

Estimation of a quantitative statement about a physical variable with calibrated and

tested measuring equipment

Check

Comparison with defined parameter and definition and evaluation of deviations

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Cleaning See section 3.2.2.

4.3.3.2 Activities during continuous operation

Interval

Maintenance and inspection work Reference / Note

Bi-annually
Quarterly
No.

Annually
Monthly

Revision
Weekly

2 years
Daily

1 Stator 4.3.4.1

2 Rotor 4.3.4.4

3 Bearing 4.3.4.5

Visual inspection of bearings X 4.3.4.5.1

4 Excitation equipment 4.3.4.6

Visual inspection of brush wear X 4.3.4.6.1

Check suction and blow-out filter X 4.3.4.6.2

Check carbon dust exhaust X 4.3.4.6.3

5 Covers 4.3.4.7

6 Oil system 4.3.4.8

Drain collecting tank of oil mist 4.3.4.8.1

X
exhaust

Check HP-oil plant X 4.3.4.8.2

Check oil filter in bearing cooling 4.3.4.8.3

X
circuit

Check HP-filter X 4.3.4.8.4

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7 Brake-lifting system 4.3.4.9

Visual inspection of brakes/lifting 4.3.4.9.1

X
plant

Check air filter X 4.3.4.9.2

Check oil level in oiler X 4.3.4.9.3

Check oil level in oil tank of lifting 4.3.4.9.4

X
plant

8 Cooling system 4.3.4.10

Check pump units in cooling 4.3.4.10.1

X
system

Check fan X 4.3.4.10.2

Visual inspection of air-water 4.3.4.10.3

X
coolers

9 Heating system 4.3.4.11

4.3.3.3 Activities on shut-down machine

Interval

Maintenance and inspection work

Bi-annually

No. Reference / Note

Quarterly

Annually
Monthly

Revision
Weekly

2 years
Dally

1 Stator 4.4.1

Check fixation of frame X 4.4.1.1

Check stator core pressing X 4.4.1.1

Measure insulation resistance of

X 4.4.1.3
stator core pressing bolts

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Check end windings, supports and

X 4.5.1.4
bandages

Check connection and terminal

X 4.4.1.5
bracings form seat

Check bolting of current lead

extension X 4.4.1.6
board

Measure insulation resistance of

X 4.4.1.7
stator winding

Visual inspection of dovetail bars

X 4.4.1.8
and holding straps

Cleaning of stator winding and

X 4.4.1.9
connection

Check whether joint screws are

X 4.4.1.10
tight

2 Rotor 4.4.4

Visual inspection of pole and

X 4.4.4.1
damper windings

Extended visual inspection on pole

connections, damper connections X 4.4.4.2
and rotor leads

Measure insulation resistance of

X 4.4.4.3
poles and supply lines

Check whether all bolted

X 4.4.4.4
connections are tight

Check pole wedging and pole

X 4.4.4.5
fixations

Cleaning of pole winding X 4.4.4.6

Check of coupling bolts and nuts X 4.4.4.7

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Bearing 4.4.5

Check oil level in standstill X 4.4.5.1

Extended visual inspection of

3 X 4.4.5.2
bearings

Check quality of bearing oil X 4.4.5.3

Extended visual inspection of

4.4.5.5
brackets

3 Excitation equipment

Visual Inspection (X X 4.4.6.1

Check bearing surfaces of slip ring X 4.4.6.2

Reverse polarity of exciter voltage X 4.4.6.3

Cleaning of brushes, brush

holders, brush gear clamping X 4.4.8
pieces and slip rings

Extended visual inspection of

X 4.4.8.1
brush holders

Measurement of insulation
X 4.4.8.2
resistance

Measurement of brush pressure X 4.4.8.3

4 Covers 4.4.7

Visual inspection of all covers 4.4.7.1

Oil system 4.4.8

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Visual inspection on all oil-

X 4.4.8.5
conveying pipes and armatures

5 Check oil mist exhaust X 4.4.8.6

Brake-lifting system 4.4.9

6 Check brake lining for wear X 4.4.9.1

Visual inspection of brake-/lifting

X 4.4.9.2
jacks

Check function of braking plant X 4.4.9.3

7 Cooling system 4.4.10

Heating system 4.4.11

Check function of heating system X 4.4.11.1

4.4 Maintenance and inspection plan

WARNING:
During maintenance and inspection works consider beside the safety instructions
mentioned in this chapter also the instructions mentioned in section 3.1.1 safety
instruction.

CAUTION:
Enter the ring room during operation only, if the generator is in normal operation.

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NOTICE:
Remove all air shields and winding covers from the stator and rotor before
maintenance and inspection works. For individual works remove also the coolers (drain
them appropriately). In addition provide sufficient lighting in these areas.

NOTICE:
After each removal or separation of a component all locking elements (lock washers)
and sealing elements (gaskets, etc.) have to be replaced by new ones.
Check all screws, pins, etc. for functionality. If the functional condition of the fastening
elements is questionable, these have to be replaced also by new ones.

Notices about the operating supplies and lubricants to be used, are stated in the individual modules
of supplier’s documentation.

4.4.1 Stator

Maintenance and inspection works on the rotor are only possible with shutdown machine/plant.

4.4.1.1 Check fixation of frame

Check the fixation of stator frame with sole plates for correct installation position. Ensure proper
securing.

4.4.1.2 Check stator core pressing

Check stator core on face-side for full pressing between pressing finger and dynamo sheet teeth on
the circumference. Recognizable gaps and movement tracks are not allowed and have to be clarified
with HUNAN ALLONWARD.

4.4.1.3 Measure Insulation Resistance of stator core pressing bolts

Only the insulation resistance for inner pressing bolts has to be measured.
1. Connect the measuring instrument with the bolt end or nut and a specified ground.
2. Measure the insulation resistance .conductor to ground". The allowed value for the insulation
resistance of the pressing bolt amounts to 100 MΩ. If this value is under run, the pressing bolt
has to be replaced.

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4.4.1.4 Clean and check end winding, supports and bandages

1. Clean and windings, support and bandages.

2. Check whether end windings, supports and bandages are tight and whether parts are missing
or are damaged (e.g. broken bandages Repair work must be performed only after consulting
HUNAN ALLONWARD.

4.4.1.5 Check connection and terminal bracings for firm seat

Check clamping of insulating parts (isolated Cu-bars and positioned in silicone joints) for firm seat
and if necessary, tighten those according drawing data.

4.4.1.6 Check bolting or current lead extension board

Check bolting of current lead extension board and if necessary, tighten it according drawing data.

4.4.1.7 Measure insulation resistance of stator winding

Measure the insulation resistance. Conductor to ground" for each phase. The allowed value for the
insulation resistance of the stator winding amounts to 200 MΩ. If the value is under run, appropriate
maintenance measures have to be performed in agreement with HUNAN ALLONWARD.

4.4.1.8 Visual inspection of dovetail bars and holding straps

In order to be able to perform a visual inspection via the cooler openings, dismantle the coolers.
Visual inspection of dovetail bars, holding straps and welds for obvious cracks, mechanical damages
or deformation
Repair work on dovetail bars or holding straps (welding, cutting, etc.) is only allowed in agreement
with HUNAN ALLONWARD.

4.4.1.9 Check whether joint are tight.

In order to be able to inspect the joint connections via the cooler openings, dismantle the coolers.
Check whether joint screws are tight acc. drawing data and re-tighten them, if necessary.

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4.4.2 Stator core

In principle, there are two ways of assessing the condition of the core:
 Assessment of condition during operation
 Assessment of condition during standstill

4.4.2.1 Assessment of condition during operation

During operation the condition of the core can be monitored by means of thermometers which allow
for measuring and controlling the temperature of the core. The second possibility is ONLINE
diagnosis (DIATECH) System for HUNAN ALLONWARD).

4.4.2.2 Assessment of condition during stand still

During standstill the following methods of inspection may be applied:

 Bolt expansion
 Insulation control of core tension bolts
 Compression of stator core and pressing fingers
 Visual inspection
- end parcels and tooth support
- back side of stator core, mounting bars, stator bore
- arcing marks, hotspot control
- stator joint (frame, core)

Bolt expansion
Check:
The bolt expansion may be checked in two ways:

 by means of the tightening torque

 by means of dial gauges

The dial gauge method involves the complete loosening of the bolt and measuring of the stretch by
means of dial gauges. Both methods can normally be applied when rotor is already installed.

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The result i.e. the torque or stretch measured by the dial gauge, is checked for concurrence with
manufacturing record the drawings.

Consequences:
Bolt that are insufficiently pre-tightened may lead to a loose stator core. This usually culminates in
vibrations of the core and causes the end plates to hit onto the pressing fingers. This may cause the
end plates to brake or the pressing finger to be damaged.
Apart from this, movements of the core may damage the wiring in the area of the slot.
Excessive noise is usually also a consequence of a loose core. Loosening of the core may also be
caused by a fractured bolt.

Insulation control of core tension bolts

Inspection:
The electrical insulation between the tension bolts and core is measured by means of insulation
tester. Defective insulation between bolt and core leads to an electrically closed login (short
circuit).Short circuits across the iron may also occur at the washer or the tension bolts, respectively
.In this case, the conductive connection is usually by fouling or by thread metal etc.

Consequences :
A short circuit between bolt and core may lead to local overheating in the area of the defective
insulation.

Compression of core and pressing fingers:

Inspection:
The stability of the stator core is checked by means of a steel key which is inserted into the vent slot.
This method requires a high degree of experience
Consequences:
A loose core may lead to vibration, breakage of end sections, deformation of pressing fingers,
damage to the winding, and noise.

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Visual inspection:
Inspection
The visual inspection focuses on the end parcels, the tooth support the rear side of the core, the
mounting bars (dovetail bars) and the stator bore. The end parcel must be checked for broken or
deformed end sections.
The welding seams must be subject to visual inspection for cracks or deformed pressing fingers,
respectively. Each welding seam of the dovetail bars must be visually checked for cracks as long as
this is possible.

Consequences:
Fractured welding seams in the region of the dovetail bars may result in shifting of the stator core
and thus could cause damage to frame, core and winding.

Arcing marks and hotspots:

Defective insulation of the stator core, i.e. damaged insulation between 2 lamination plates or
burrs between 2 plates, creates a closed conductive loop between adjacent plates that have ) already
been electrically connected at the back of the stator core by the mounting bars (dovetail bars). Due
to the magnetic flux voltage is induced in this loop, and the resulting current can lead to a local
increase in temperature at the points of defective insulation.
Hotspots can usually be detected using the following methods:

 CM2 measurement
 Core induction test
 Thermo vision camera

Inspection of stator joints :

When inspecting the stator joints special attention must be paid to the slightest widening of the gap
between the joints. Changes can be pinpointed by measuring the gap and comparing the results with
the manufacturing records or the drawing, respectively. Furthermore, the sheets in the stator joints
must be checked for possible shortcomings.

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4.4.3 Stator Windings

4.4.3.1 Dielectric measurements

The following major dielectric measurements can be performed to examine and assess the condition
of stator windings.

Insulating resistance measurements

The Insulation resistance test serves as a basis for the detection of errors and helps to decide on the
necessity of cleaning, drying or repairing faulty insulation. This method is also used to determining
whether the winding is fit for further operation or whether a high-voltage test can be performed.
Furthermore, this test is suitable for the detection of insulation defects, e.g. short circuits, dirty or
moist insulating surfaces etc.

Voltage test
(Only on suspicion of damage through abnormal operating values and after reparation of winding.)
The voltage test serves to determine the insulating property of the main insulation and detect
insulation faults.

Tangent delta test

The tanδ test is performed to detect service-induced changes in the main insulation, e g.
Delamination.

Partial discharge Measurement

Partial discharge measurements are taken to detect service- induced changes in the main insulation
of windings, e.g. formation of small cavities, wear and tear due to electricity, delamination etc.

Inspection of slot wedge fit: (not applicable for EWB-installation of stator winding)

Another criterion for assessing the condition of stator windings is the tight fit of the slot wedges. A
small hammer is used to tap the wedges, the resulting sound being recorded by a microphone and

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analysed by means of a computer frequency analysis. This operation can be performed with the rotor
being installed or removed. Further operation of the machine depends on the percentage and the
distribution of the loose wedges.

Visual inspection of stator winding

End winding
During the visual inspection of the end winding and circuitry, special attention should be paid to the
following points:
 Fouling - dust, oil etc.
 Missing or loose supports or spacers
 Loose bandages ;
 Deformation and traces of shifting;
 Tightness of bolted connections
 Insulating caps must be checked for tightness and intact filler material

Special attention should be paid to the slot exits of the winding of the stator core. Check for:

 Damage to end corona protection

 Corona attack at outer corona protection due to creeping discharge resulting from insufficient
contact between outer corona protection and stator core.
 Damage at the transition from outer corona protection to end corona protection, traces of
shifting at the insulation may cause damage to the insulation
 Backing out of insulating strips reduces the tight fit of the winding in the slot.

Wedges
If wedges are missing they need to be completely or partially renewed. The same usually follows
from the results of checking the wedge seat fit.
The visual inspection of the wedges focuses on fractured wedges or the backing out of insulation
strips. In the case of wedges with slot-top ripple springs the necessary residual spring travel must be
checked in order to ensure the tight fit of the winding.

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4.4.4 Rotor

Maintenance and inspection works on the rotor are only possible with shutdown machine/plant.

4.4.4.1 Visual inspection of pole and damper windings

1. Visual inspection of pole windings for obvious migrated turn insulations.
2. Visual inspection of pole winding connections and damper windings for mechanical damages
and discolorations due to local overheating. In case of migrated turn insulations, mechanical
damages and discolorations due to local overheating, proper maintenance measures have to be
performed in agreement with HUNAN ALLONWARD.

4.4.4.2 External visual inspection on pole connections, damper connections and rotor leads

1. Visual inspection of all contact surfaces for discolorations or mechanical damages. Damaged or
discolored contact points have to be repaired.
2. Check whether all bolted connections are tight. Therefore check or re-tighten the tightening
torques of the bolted connections as stated on the drawing. Check the locking elements for
proper function and if necessary, replace them.
3. Visual inspection of damper connections for broken laminations. Damper connections (damper
connection links) with broken laminations have to be replaced.

4.4.4.3 Measure insulation resistance of poles and supply lines

Measure the insulation resistance “Conductor to ground" for each phase. The allowed value for the
insulation resistance of the poles amounts to 200 MQ. If the value is under run, appropriate
maintenance measures have to be performed in agreement with HUNAN ALLONWARD.

4.4.4.4 Check whether all bolted connections are tight

Check whether all bolted connections on the rotor (pole winding connections, damper connections,
fans, rotor spider covers, etc.) are tight and re-tighten them, if necessary according drawing data.

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4.4.4.5 Check pole wedging and pole fixations

Check pole fixing dowels fixation. Ensure proper tightening & locking. Loose pole connections have
to be re-tightened.

Information
In order to specify a technically efficient design, re-tightening of the poles has to be
agreed with HUNAN ALLONWARD.

4.4.4.6 Cleaning of pole windings

Clean the pole windings on face and longitudinal side.

4.4.4.7 Check of couplings bolts and nuts

Check bolting of shaft couplings for correct tightening torque or elongation acc.. drawing data or
erection protocol and if necessary , re-tighten it.

4.4.5 Bearing

Information
For an extended visual inspection of the bearings or brackets with regular shut-down
machine all covers within these ranges have to be dismantled (air shield, bracket
covers, etc.).

Information
Basically oil does not influence the generator negatively. In connection with dust dirt
accumulations occur, which can lead to partial discharges or leakage current, creeping
over the surface of the insulating material.

4.4.5.1 Visual inspection of bearings

Visual inspection of bearings and complete generator for oil leakages or wet positions in ranges,
which can be observed from the generator ring room.

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Information
Oil, leaking out at the bearings, can lead to oiling in the entire generator range as oil
dust via the cooling circuit.
The causes for oiling points in the generator range have to be clarified with HUNAN
ALLONWARD.

4.4.5.2 Check oil level in standstill

Check oil level in standstill acc. marking on sight glass or data stated on the bearing cross section and
if necessary, refill it ± 3mm are recommended as tolerance for allowed deviations.

Notice
A rise of the oil level, exceeding the tolerance value, could be a sign for leakages in the
oil/water heat exchanger and has to be clarified absolutely. Only lubricating oil must
be used for re-filling.

4.4.5.3 Extended visual inspection of bearings

1. Usual inspection of bearing including all bolted connections and pipe connections for oil
leakages or wet oiling points. Wet oiling points have to be clarified with HUNAN ALLONWARD.
2. Check gaps of air seal rings. The distance between shaft and seal points must not exceed the
bearing clearance acc. bearing cross section.
In case of a larger distance, the seal rings have to be re-adjusted.

4.4.5.4 Check quality of bearing oil

The bearing oil has to be checked periodically. Thereby the oil is examined for water content,
viscosity, wear, contamination, etc. Based on the results proper measures can be taken.

Information
The samples shall already be taken in agreement with the appointed laboratory
(sample container, quantity, etc.).

4.4.5.5 Extended visual inspection of brackets

1. Visual inspection of brackets including welds for obvious cracks or mechanical damages; repair
work on brackets (welding, cutting, etc.) is only allowed in agreement with HUNAN ALLONWARD.

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2. Check bolted connections of brackets acc. drawing data for firm seat and if necessary, re-tighten
them.
 Bolted arms
 Fixations to foundation or stator frame

4.4.6 Excitation equipment

Caution
Inhaling of carbon dust can lead to damages to health!
When opening the covers near the exciter equipment wear a dust protection. Then
suck-off the present carbon dust immediately.

Notice
For maintenance of exciter equipment see also product documentations of the
component manufacturer.

Information
During the warranty period the following measurements have to be performed by the
operator after approx. 500 operating hours and then after every 1000 operating hours.
The results have to be documented.
 Brush length - same allocation of numbering as for first measurement
 Number of operating hours
 Mean exciter current in previous period
 Surface quality (formation of patina, grooves ) of slip rings with indication of
polarity

4.4.6.1 Visual inspection of brush wear

Visual inspection of brushes for sufficient brush length; 20 mm are recommended as limit, shorter
brushes have to be replaced. In case of unequal brush wear clarify the cause with HUNAN
ALLONWARD.

Notice
In principle brushes must be replaced as set only.

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Only brushes, specified by HUNAN ALLONWARD for the respective generator have to
be used.
In order to provide good electrical and mechanical contact in axial and tangential
direction between slip ring and carbon brushes, it is necessary to grind-in the bearing
surfaces of the carbon brushes. That means the brush ring contour has to be made on
the brush surface with an emery cloth strip along the slip ring surface in direction of
the rotor rotation.

4.4.6.2 Check suction and blow –out filter

Check suction and blow-out filter (blow-out filter only, if no carbon dust exhaust is available) in the
slip ring cover for contamination, if necessary, replace it.

4.4.6.3 Check carbon dust exhaust

1. Check exhaust motor for bearing damages (noticeable noises and vibrations). Repair bearing
damages based on the instruction of motor supplier.
2. Check filter unit in the range of the exhaust motor and if necessary, replace the fleece mat.

4.4.6.4 Reverse polarity of exciter voltage

Information
In case of new or revised slip rings change the polarity of the slip rings monthly till an
appropriate patina is developed. Then an annual replacement is sufficient.
Reverse of polarity should be recorded in any case.

4.4.6.5 Check bearings surfaces of slip rings

1. Check contact grinding surface of slip rings for roughness.
The maximally allowed average roughness Ra amounts to 0.8 µm. If the average roughness is larger,
re-set or re-grind the slip ring.
2. Measure the roundness.
The eccentricity must not exceed 0.3 mm. Values up to 1 mm are allowed for low-speed machines
(number of poles > 20). If the ,values of the slip rings are unacceptable, re-set or re-grind the slip
ring.

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Information
If the operator overhauls the slip rings, the manufacturing tolerances stated on the
drawing have to be observed.
The grinding operation shall not be performed manually.
Check bearings surfaces for thermal discolorations and damages. Discolorations and
damages are not allowed and have to be clarified with HUNAN ALLONWARD.

4.4.6.6 Environment of the slip ring

Humidity
The slip rings should neither have too much nor too little humidity. An intermediate degree of
humidity is necessary for the optimum formation of the surface film. The appropriate absolute
humidity should be between 8-15 g/m3.
Air humidity must be measured regularly, especially in environments where high air humidity is to
be expected (e.g. in mountains at high altitude or in regions with severe frosts.) If air humidity drops
below 4,5 g/m3, high friction occurs between slip ring and brush. The performance of the generator
must be lowered in order to reduce the heat created through friction.
Such a situation can be improved by adding steam to the cooling air.
Steam raises the air humidity and thus reduces the friction. The addition of steam should be
discontinued as soon as normal air humidity is reached. For locations with permanent low air
humidity and constant friction problems, it is recommended to install automatic monitoring systems
for humidity in the cooling air.

Oil, grease –containing substance and solvents

The heat on the brush surface causes the oil that forms on the slip ring to decompose. This leads to
the formation of an abrasive layer with greater friction increases the wear and tear of the brush. The
transitional resistance between slip ring (PATINA) and the carbon brush surface increases.
If the layer of grease is too thick, brush sparking occurs. In most cases the brush then catches fire.

Dust
Any kind of dust is disadvantageous to the running of the carbon brushes. The dust accumulates
between the sliding surfaces which has a strong roughening effect. This increases the wear and tear
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of the carbon brushes and the sliding surfaces. In addition to this, the free movement of the carbon
brush holder can be inhibited by dust. Carbon dust is a good electrical conductor. Excessive formation
of carbon dust can lead to a short circuit. For this reason it is required that the ring slip be cleaned
regularly. The equipment needed for this purpose consists of a compressor, compressed air and a
vacuum cleaner. However, vacuum cleaning the carbon dust during operation can prevent the
accumulation of carbon dust in the slip ring area in the first place.

Temperature of the brushes

It is necessary to check the temperature of the brushes regularly. Large temperature fluctuations
lead to increased wear and tear of the brushes or even worse to burnt strands of wire. Modern infra-
red thermometers which measure exactly and reliably can be used.

Radial run-out deviation

If chatter marks in form of chafed bare spots on the brushes occur and are not created by sparking,
the ring must be tested for roundness. Should the ring be found to be out-of-balance, it should be
re-machined and reground. If possible it should be avoided to perform the grinding process manually
because the run-out fault may become worse.
Eccentricity of slip ring should not exceed the drawing dimension.

4.4.6.7 Extended visual inspection of brushes

1. Measure the brush dimension and record the wear. If the brushes under run 20 mm. replace
them. See also relevant section
2. Visual inspection of brush sliding surface for mechanical damages, blunt surfaces and leakage
current marks.

Indications Possible causes

Not correct mounting of
brushes or other mechanical
Mechanical damages
influences (vibration and
roundness error)
Sparking ,too low contact
Blunt surfaces pressure or bad contact to slip
rings
Insufficient electrical
Leakage current marks
connection

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Clarify the causes for the indications on the brush sliding surfaces and remove them or replace
the brushes.
3. Visual inspection of strand connections for thermal discolorations. Discolorations are a sign of
overheating and have to be clarified with HUNAN ALLONWARD.

4.4.6.8 Cleaning of brushes, brush holders, brush gear clamping pieces and slip rings

The running behavior of the carbon brushes is negatively influenced by any kind of dust. The dust
settles between the grinding surfaces and thus has a grinding effect The result is an increased wear
of the carbon brushes and grinding body. Further the free movement of the carbon brushes in the
brush holders can be influenced. Since carbon dust is a good conductor, too much dust can lead to
different polarity. Thus regular cleaning of the slip ring room is necessary.
1. Loosen the brush dust with a paint brush and suck the dust off with a vacuum cleaner. Carbon
and metal dust must not get into the "winding
2. Clean and degrease slip rings with solvent and cleaning rag.
Information
Brush holders must not be cleaned through sand blasting or similar procedures. These
methods lead to a rough surface and would in further consequence limit the
movement of the carbon brush in the pocket.

4.4.6.9 Extended visual inspection of brush holder

1. Visual inspection of brush holders for mechanical damages; clarify the causes of mechanical
damages with HUNAN ALLONWARD and specify proper maintenance measures.
2. Measure the distance from brush holder to slip ring. The distance shall be 2-3 mm and has to be
re-adjusted, if necessary.
3. Check free movement of brushes in brush holders manually. In case of tight brushes clean the
brush holders and brushes properly.
4. Check firm seat of brush holder and if necessary, tighten bolted connection as started on the
drawings.

4.4.6.10 Measurement of insulation resistance

Measure the insulation resistance:

 Brush holder to ground
 Slip mgs to ground
 Slip rings to each other

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If the values worsen noticeable (below 5 MΩ), the components have to be cleaned properly. If
cleaning does not lead to the desired improvement, proper maintenance measures have to be
performed in agreement with HUNAN ALLONWARD.

4.4.6.11 Measurement of brush pressure

Measure the brush pressure of all brushes with a suitable measuring instrument and if necessary,
set them considering the recommendations of the carbon brush supplier.
Only even and correct brush pressure ensures safe operation and normal wear of brushes.

Information
The pressure cannot be adjusted for conveyor brush holders. In case of wrong brush
pressure, replace the springs.

Correct and even brush pressure is necessary for a faultless run of the brushes. A too low brush leads
to an increased electrical wear (sparking). A too high brush pressure leads to an increased
mechanical wear (sparking).
Continuous operation of the generator at low load (below 50% nominal load) requires frequent
checks of the brushes. In case of long term operation it is recommended to remove several brushes
at low load.
8 A/cm2 has to be considered as the minimum current density of the brushes. Recommended
maximum value :12 A/cm2
Example:
Brushes 32 mm x25mm=8 cm2
Actual excitation current at load point=640A
N/2: Number of brushes/ring
A/(N/2 x brush cross section) = 640/(8x8)=10 A/cm2 (current density)
Result : 8 brushes per slip ring are necessary.
For particular project used 11 brushes per ring.

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4.4.7 Covers

4.4.7.1 Visual inspection of all covers

Visual inspection of all covers (generator covers, pit covers, generator housing, winding covers, etc.)
for mechanical damages, cracks, displacement and loose or missing parts.
Loose parts have to be fastened and damaged or missing parts have to be replaced.

4.4.8 Oil system

Caution
Risk of injury for eyes and face caused by spouting hydraulic liquids. which are
pressurized.
Take care when checking the oil system for leaky pipes and connections and wear
always safety glasses.

Notice
For maintenance of oil system see also product documentations of the component
manufacturer.

4.4.8.1 Drain collecting tank of oil mist exhaust

1. Please suitable vessel below and oil drain
2. Open three-way ball valve and drain the oil.
Caution
The oil from the collecting tank and cleaning rags, moistened with oil have to be
disposed considering the latest environment conditions.

4.4.8.2 Check HP-oil plant

Check HP-oil plant of thrust bearing:

A pressure reading on the manometer of the HP-oil plant indicates a leaky check valve. The leaky
check value has to be replaced during the next revision.

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4.4.8.3 Check oil filter in bearing cooling circuit

1. Visual inspection of oil filters for leakage or wet oiling points ;a leaky oil filter has to be replaced.
2. Check via indicator on oil filter, whether the filter has to be cleaned in the near future .If
necessary, cleaning shall be provided for the next machine standstill

4.4.8.4 Check HP-filter

1. Visual inspection of HP-filter for leakages or wet oiling points. A leaky HP-filter has to be
replaced.
2. Check via indicator on HP-filter, whether the filter has to be cleaned in the near future. If
necessary, cleaning shall be provided for the next machine standstill.

4.4.8.5 Visual inspection on all oil-conveying pipes and armatures

Visual inspection of all pipes and units (oil filter, oil cooler and pump units if available) of bearing oil
circle, HP-relief and oil mist exhaust for leakages and mechanical damages as well as loose or missing
parts.
Loose parts have to be fastened, damaged or missing parts have to be replaced and leakages have
to be repaired professionally.

4.4.8.6 Check oil mist exhaust

Reference: For maintenance of oil mist separator consider also the instructions of the component
manufacturer.

4.4.9 Brake-lifting system

Caution
Inhaling of brake dust can lead to damages to health!
Wear dust protection when performing maintenance work near the brake-/lifting jacks.

Notice
For maintenance of brake-/lifting systems see also product documentations of the
component manufacturer.

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Information
In order to get access to the brake-lifting jacks, dismantle all cover in that area (air
shields, bracket covers, etc.).

Information
Only lubricating oils must be used for the oiler of the braking unit and the oil plant of
the lifting unit.

4.4.9.1 Visual inspection of brake-/lifting plant

Visual inspection of entire brake-/lifting plant for mechanical damages and loose or missing parts;
loose parts have to be fastened and damaged or missing parts have to be replaced.

4.4.9.2 Check air filter

Check whether the air filter in the pressure air piping is contaminated and if necessary, replace it.

4.4.9.3 Check oil level in oiler

Check oil level of oiler for braking plant and if necessary, replenish oil.

4.4.9.4 Check oil level in oil tank of lifting plant

Check oil level of lifting plant and if necessary, replenish oil.

4.4.9.5 Check brake lining for wear

The wear of the brake lining and thus the maintenance effort depends strongly on the number of
standstills.
The brake linings are riveted on brake lining frames. A replacement of these frames is required.

4.4.9.6 Visual inspection of brake-lifting jacks

Visual inspection of all brake-lifting jacks for leakages, in case of oil leakage maintain or replace the
brake /lifting jack.

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4.4.9.7 Check function of braking plant

The braking plant operates with compressed air. If the compressed air supply fails the machine/plant
must not be started; he ever shut-down without brakes are possible. But the retardation time is
extended and the rotor is not fixed in the following standstill.
Since a not working braking plant will be detected immediately during operation, it is only
meaningful to check the function after a longer standstill of the generator.
1. Loosen the retaining ring. The piston is retracted by spring force.
2. Active the solenoid valve manually and this simulate the backing operation.
3. Trigger limit switch for position indication on each brake/lifting jack manually.

4.4.10 Cooling system

Notice
For maintenance of cooling system see also product documentations of the component
manufacturer.

4.4.10.1 Check pump units in cooling system

Pump units are used for closed cooling systems only. Check them for noticeable noises and
vibrations. Damaged pump units have to be repaired in accordance with the product documentation
of the component manufacturer.

4.4.10.2 Visual inspection of air-water coolers

Visual inspection of air-water coolers for air-side contamination and leakages; contaminated or
damaged air-water-coolers have to be repaired in accordance with the product documentation of
the component manufacturer.

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4.4.11 Heating system

Caution
Risk of burns for hands and bodily parts due to heater!
Wear protective gloves when maintaining the heating system, which is active during
standstill.
In direct proximity of the hot components work carefully and prudently. If necessary,
cover hot components.

Notice
For maintenance of heating system see also product documentations of the
component manufacturer.

4.4.11.1 Check function of heating system

Check function of heaters and thermostat. Damaged components have to be repaired in accordance
with the product documentation of the component manufacturer.

4.5 Overhaul

Notice
Before starting with the generator maintenance contact HUNAN ALLONWARD.
The overhaul includes all measures, which are necessary to return the generator into
its operating condition. More or less complex disassembly, repair and assembly of
components are part of it.

Warning
Arising faults, impairing the safety, must be removed immediately. The generator must
not be put into operation before the fault is removed.

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4.6 Revision

Beside regular maintenance and inspection work periodical revisions are recommended in order to
ensure the operating reliability of the machine/plant.

Information
Revisions shall be planned by the operator in time. Further the revisions shall be
coordinated with HUNAN ALLONWARD regarding extent of revision, tool-, device- and
spare part requirements as well as personnel and process planning.

4.6.1 Revision intervals

Since the operating conditions of machines/plants are very different, only recommendations for
revision intervals can be made.
Basically HUNAN ALLONWARD recommends performing revisions every 50.000 to 70.000 operating
hours or every 5 to 9 years.

Warning
The recommended revision intervals require a trouble-free operation. In case of
failures and exceptional operating conditions (e.g. overload, short- circuit, out-of-phase
synchronization or something similar), which lead to extreme stresses of the machine,
an appropriate revision shall be performed immediately.

The revision intervals have to be adapted depending on the operating mode (river or pump-storage
power plant) and experiences gained at site.
A revision contains the removal of the rotor or stator as standard and includes basically the following
activities:
 Cleaning of complete machine, in particular of following components:
 Rotor/stator winding
 Oil-water cooler
 Air-water cooler
 Inspection of bearings
 Inspection of rotor and stator winding, insulation resistance measurement, aging measurement
(diagnostic extent as far as possible and on customer’s request)
 Inspection of slot wedging, bandages, supports, connections and stator terminals

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 Inspection of stator core for loosening and thermal damages (electrical I and mechanical
diagnostic measurements as far as possible and on customer’s request)
 Inspection of rotor rim and rim bolts
 Inspection of rotor for mechanical and thermal damages, particularly of energised parts
 Inspection of joint pressing and position of joint insulating pieces of ' multi-sectional stator cores
 Inspection of bolted joints;
 Inspection of oil- and water systems
 Inspection of monitoring instruments
Information
Appropriate measurements and tests (diagnostic extent as far as possible and on
customer's request) are performed before and after the revision.

4.7 Repair of operational malfunction

Information
All data, which are necessary for a faultless generator operation, are continuously
checked. If not allowed values are achieved, an alarm is triggered or the generator is
shut-down.

In case of obvious malfunctions, the concerned measuring instruments and appropriate wiring have
to be checked; where possible repair them.

4.7.1 Generator

Repair of
Failure Actions Possible cause of fault
fault

Failure of fan unit

Winding temperature
Alarm and shut down
in store are too high
Failure of generator cooling circuit

Failure of fan unit

Temperature is stator Alarm and
core are too high optionally shut down
Failure of generator cooling circuit

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Too low differential

Alarm Failure of fan
temperature

Alarm Failure of fan unit

Cold and warm
temperature Shut-down
Failure of generator cooling circuit
(optionally)

The insulation value of the oil supply

Shaft current Shut-down
head is too low

4.7.2 Bearing

Failure Action Possible cause of fault Repair of fault

Temperature of Failure of lubricating oil supply

Alarm and shut
bearing pad too
down
high Failure of generator cooling circuit

4.7.3 Excitation equipment

Failure Action Possible cause of fault Repair of fault

Failure of carbon dust exhaust

Temperature in slip Brush sparking

Alarm
ring room too high
Carbon dust filter is blocked
(contaminated)

Too high
Clean or
differential Alarm Filter is blocked (contaminated)
replace filter
pressure

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4.7.4 Oil system

Failure Action Possible cause of fault Repair of fault

Float (gauge) is blocked

Oil level is too low Alarm and shut

Oil system is leaky
or too high down

Water inlet in oil system

Pipes are clogged

Oil flow too low Alarm

Oil temperature during start –up was
too low

Switch to 2nd
Too high differential
Alarm Filter is blocked (contaminated) filter or replace
pressure
filter

Water in oil Alarm Water inlet in oil system

4.7.5 Braking system

Failure Action Possible cause of fault Repair of fault

Too low braking Leaky or interrupted compressed

Alarm
pressure air supply

Worn brake lining Alarm (optional) Wear Replace lining

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4.7.6 Cooling system

Failure Action Possible cause of fault Repair of fault

Too high cooling Alarm Failure of generator cooling circuit

water temperature
Contaminated air-water –cooler
on air-side

Contaminated water-water –
cooler on river water-side

Too high or low Alarm Leakage in cooling water circuit

pressure in closed
cooling water Expansion tank damaged

circuit

Cooling water flow Alarm Pump damaged Switch to

too low 2nd filter or
replace filter

Cooling water circuit clogged

4.8 Generator Monitoring Guidelines of Generator

Periodical round check is to be performed on the hydro-generators in operation

(generally 1 time/hour), to monitor generator operation status, record readings on
various instruments and operation log. Round check shall be done in a concentrated
manner, observe carefully and find problem in time to ensure the safe generation of the
unit.

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4.8.1 Temperature monitoring

Windings, core, bearing of generator shall be monitored for its temperature, the value
shall not exceed specified values. If temperature is changing rapidly or having the
tendency of changes (partially over heating or sudden temperature rise), operation
personnel shall shut down the machine and find reasons.

4.8.2 Bearing oil level monitoring

Bearing oil level shall be checked regularly , if oil level is higher than normal oil level, it
may cause due to oil cooler water leakage; if oil level is lower than normal oil level, it
might due to oil groove oil leakage or pipe valve is not properly closed.

4.8.3 Vibration and noise monitoring

Vibration and noise shall be measured regularly for the generator in operation.
Measured value shall not exceed stipulated value. If vibration and noise is changing
(strong vibration, noise and run-out is increasing apparently), shut down the machine
and check immediately.

4.8.4 Insulation monitoring

Insulation resistance of generator windings shall be checked regularly. If generator

insulation resistance is changing apparently, such as resistance value decrease suddenly,
rotor one point grounding, shut down the machine to check and repair.

4.8.5 Current outgoing device monitoring

Check regularly whether sparks are there, working conditions of brush ( brush and

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collector ring contacting conditions, wearing status, whether brush is moving flexibly in
the brush holder), surface condition of collector ring ( if any burnt, abrasion or scale
depositing), take proper action if any of these conditions are found. Brush shall be
replaced with brand-new same type number and same size if abrasion, change the
polarity of collector ring 1-2 times in a year in order to make the abrasion equal of
collector ring.

4.8.6 Cooler monitoring

Coolers shall be checked regularly, if the cooler discharged is reduced or blocked, air or
temperature after cooling will apparently increase. Take proper measures to handle the
problem. When generator is in operation, thrust bearing oil temperature shall be 20-40
centigrade, guide bearing oil temperature is allowed to be maintained below 45
centigrade. Adjust cooling water flow to keep bearing pads of bearing and oil
temperature at 20 centigrade. When starting up the generator, pay attention that the
oil temperature inside bearing oil groove shall not be lower than 10 centigrade, to avoid
bearing pad thermal deformation. Close water inlet valve of coolers when shut down
the machine, in order to avoid over deformation of bearing pad if oil cooler is adopted.

4.8.7 Brake system monitoring

Check break regularly, especially it shall be checked before starting up. When brake
system is abnormal or in jacking condition, it is not allowed to start the generator.

4.9 Operation and maintenance of precautions of generator

Except monitoring the generator during daily operation and take immediate action to
dispose the defects, overall check and maintenance is also required to perform on
generator. Daily maintenance of generator is generally in two types: common
maintenance and major parts maintenance. Generator maintenance items and quality
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criteria is given in table below.

Generator maintenance items and quality criteria

SN Item Acceptance Criteria

1 Various bearing checks Oil level is ok, oil color is normal. No abnormal
sound in bearings, bearing pad temperature is
within range; No need to reject oil; cooling water
flow is smooth.

2 Appearance check of the unit No abnormal vibration and noise

3 Measure guide bearing run-out In compliance with stipulations, no abnormal

increase

4 Brake appearance check No abnormity, no oil leakage

5 Meters inspection Indication is correct, no leakage

6 Generator cooling water reservation Various valve is in correct position, no water

water resource check leakage.

4.9.1 Regular maintenance

1) Make record is a necessary routine work of the power station. Record is including
the readings of various instruments, such as load, temperature, flow and
replacement of consumption components etc., the measures for disturbance, fault
and repair during operation shall also be recorded.

2) Operation of hydro-generator must in compliance with national standard “ hydro

generator fundamental technical requirements” GB7894-87.

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3) During operation of generator, cover plate shall be kept closed to prevent outside
dust, air leakage entering into inside of generator.

4) When generator is stopped for long time, use electric heater to maintain interior
temperature of generator not less than 5 centigrade.

5) During operation of generator, cooling water shall be clean without any sediment,
weeds or other garbage.

6) Initial oil temperature in the oil slot of bearing shall not be less than 10 centigrade.

7) Bearing lubrication oil parameters shall in conformity with relevant regulations and
requirements.

8) After generator over speed or runaway speed, check the rotation parts of generator
is loose or damaged or not.

9) Maximum travel distance of brake jacking rotor shall not exceed 20mm.

10) When brake is in fault, generator can’t be started.

11) No acid, alkali air is allowed in the power house that may harm generator insulation.

12) Generator shutdown for more than 3-5 days, measure the insulation resistance
before starting, value shall not be less than stipulated value. Otherwise, drying is
required. It can only be put into operation after the insulation resistance value is
meeting requirements.

13) When any of the following conditions happened, stop the running hydro-generator.

① Abnormal sound and serious vibration happen at generator.

② Generator runway and voltage rise rapidly.

③ Smoke or fire comes out from stator, rotor or other electric equipment of
generator.

④ Big sparks come out at brush or collector ring of generator, and no proper
measures to be taken.

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⑤ Thrust bearing or guide bearing pad temperature rises suddenly and pad get
burnt.

After emergency shutdown of the hydro-generator, record and report the emergency
conditions timely, meanwhile eliminate the fault as soon as possible. Start the generator
again after everything gets normal.

(14) Keep power house and generator clean regularly, clean the surface dust of various
components regularly, apply butter on the metal machining surface of generator
exposed outside to prevent from corrosion.

4.9.2 Major components maintenance

4.9.2.1 Stator

1. Stator winding check and maintenance

1) Check the stator winding end is deformed or not, clean the dust and dirt on the
windings.

2) Check the binding of end hoop is loose or not.

3) Check wedge is loose or not.

4) Check the insulation aging of stator winding insulation. Check if the insulation
is damaged. Repair it if there is any damage.

2. Stator core inspection and maintenance

(1) Check if there is dust, dirt inside the stator ventilation ducts. Use dried compressed
air to blow it cleanly.

(2) Check if there is any loose or corrosion between gear sheet, gear plate and core; if
finger plate and pressing plate is spot welded structure, check the welding point is
cracked or not. Press finger plate is inclined or projected or not. Check the color of finger
plate, whether it is in blue color due to too high temperature.

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4.9.2.2 Rotor

1) Check the fixing condition of rotor parts.

① Whether all fixing nuts on the rotor are fastened and locked. If any one is
loose, find out reasons and fasten, lock it.

② Check whether yoke key and pole key is loose or not. Make it tight and
lock by spot welding if it is loose.

③ All welding joints are having no crack on the rotor.

2) Check pole winding

① Check whether the connection between pole connecting wires and rotor
leads between windings are perfect.

② Check inter-turn and to-ground insulation, if the to-ground insulation

resistance of pole winding is lower than 0.5 MΩ. Find out the reasons and
repair.

③ Clean the dust and dirt on the pole windings, keep it clean and dry.

3) Check the frication surface of brake ring is damaged or not.

4) Check the fan is fixed, not loose and no deformation.

5) Check the clearance between rotor and stator core is uniform and in
compliance with stipulated requirements.

4.9.2.3 Thrust bearing

(1) Check thrust bearing pad surface, if obvious abrasion is found on the pad surface,
find out the reason and repair it in time.

(2)Measure bearing insulation resistance, the value shall not be less than 0.2 MΩ (after

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filling oil in the oil slot).

(3) Check the runner plate frication surface, there shall be no scraping marks or other
defects. Check the joint surface quality attaching with thrust collar.

(4) Use retro reflector to check the quality of thrust collar surface.

4.9.2.4 Guide bearing

Check thrust bearing pad surface, if obvious abrasion is found on the pad surface, find
out the reason and repair it in time.

(2)Measure guide bearing insulation resistance, the value shall not be less than 4MΩ.

(3) Measure the clearance between guide bearing pad and guide bearing collar, stud
bolt shall be fastened one time after 3 months of operation since the first time, adjust
the clearance properly.

4.9.2.5 Lubrication oil

Lubrication oil shall be sampled and checked periodically, generally annual check shall
be performed. Lubrication oil quality can be checked by color, smell, clarity, foam and
water content etc.

Oil color may get darker but it shall not have any other change. Oil color shall not get
further darker.

Oil shall not have the smell of putrefaction or burnt.

Clean oil shall be clear and transparent. Roily oil might have mixed particles, sundries
or water. Particles in the oil might cause abrasion, damage or corrosion to the interior
of bearings. Or it may happen due to no proper cleaning for the oil slot before filling oil.
Other sediments may also be found in the oil. Such as varnish, Bakelite and Fibrous. In
the sampling check of oil, metal sediment or metal compound content is beyond 0.05%
of the oil volume, then oil shall be drained from oil slot and filtered, to make the oil in
compliance with requirements or replace with new oil. After draining all dirty oil, clean
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thoroughly in the slot. Metal particle will usually occur during the initial operation, if
metal particle repeatedly occurs or metal particle is always there, then bearing may also
be checked.

Experiment can be performed to check whether there is water in the oil. Put 5ml oil
into test tube and heat it carefully, when oil is heated to certain temperature, buzz
sound will be there if there is water in the oil. If oil has no sound at all, it shall be
considered as qualified.

Lubrication oil will be aged and spoiled gradually after using a period of time. New oil
shall be used to replace old oil generally after 5000 hours.

4.9.2.6 Coolers

(1) All coolers shall be cleaned regularly. Generally, use 1.2 times of rated work water
pressure to flush in reverse direction or use compressed air to blow the sand and other
dirt inside the tube. For straight pipe of air coolers, use cloth to tie on the steel wire
and rub in and out to clean inside wall of tube. Be careful that the cloth shall not be left
inside the tube while rubbing in and out to avoid blockage.

(2) All incrustation inside cooler pipes shall be cleaned timely to avoid impacting on
cooling effect.

4.9.2.7 Collector ring and brush

(1) Collector ring surface shall be kept clean. If collector ring is not circular, eccentric,
rough or burnt, take proper measures to handle; measure the insulation resistance of
collector ring regularly, the value shall not less than 1 MΩ. In order to avoid uneven
abrasion of the collector ring, change over the polarity of collector ring time to time.

(2) Check brush spring pressure regularly, use balance spring to measure. Pressure on
the surface of brush shall be 15-20Kpa. If it is not in line with this value, adjust the
pressure of brush spring.
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(3) Check the distance between bottom line of brush box and collector ring surface,
generally it is 3-4mm; if any inconformity is found, adjust the brush holder.

(4) Brush can be moved flexibly inside brush box. Brush shall be kept clean to avoid
sparkles. Change new brush with the same grade and size,put fine crocus cloth between
brush and collector ring to rub the surface of brush, so that the brush become arc shape
and the bottom side of brush can be in good contact with collector ring.

4.9.2.8 Brake and pipeline

(1) Check brake and all pipes are having oil leakage and air leakage or not.

(2) Check the brake piston can move flexibly inside the air cylinder or not. If clogging is
found, take proper measures.

(3) Lock after jacking rotor by brake, to prevent guide vane water leakage cause any
damage by rotating generator.

4.9.2.9 Upper cover plate and upper air baffle

Check all bolts and nuts are loose or not on the upper cover plate and upper air baffle.
Re-fasten and lock the bolts and nuts if they are loose, to prevent accident from falling.

Check distance between baffle ring and fan, the value shall be bigger than the height of
jacked rotor.

4.9.3 Common Faults and Solutions during Operation of Generator

Fault
SN Reasons Solutions
description

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De-excitation Use “positive” and “negative”

pole of 12 V battery to face
with the “+” “-“wire of field
winding of generator (static
excitation) or AC exciter
（ brushless excitation ） to
charge.

There is fault in field flashing Eliminate the fault as per

device of thyristor manual of “Static excitation
excitation. panel”.

Brush and collector ring is Running-in the brush again

not in good contact. Spring and replace brush holder
pressure is too small. spring.
1 No output
Collector ring or magnetic Check the short circuit point or
field winding short circuit or earthing point, re do the
earthed insulation.

Generator field winding is Find out the location of wire

damaged, inter-poles breaking or improper welding
connections or lead welding and repair it.
is not good.

Speed is too low. Increase water inlet volume of

prime motor, make the speed
of generator at rated value.

Three phase load is Adjust three phase load and

seriously unbalanced. make it equal.

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Air duct is blocked and air Clean the dust and dirt from air
ventilation is blocked. There duct.
is too much dust
accumulated between
windings.

There is no sufficient cooling Make the flow of air cooler in

water in air cooler. compliance with requirement
after finding out reasons.

Generator magnetic field Check out the coils short

windings are partially short circuited or earthed, re do the
Voltage is too circuited or grounded. insulation.
2
low
Speed is too low. Keep generator running at
rated speed.

Unbalanced 3 Three phase load is Adjust three phase load and

3
phase voltage unbalanced. make it closer.

Unit centerline is not on the Re-align or adjust the

same level. concentricity.

Anchor bolts are loose, or Tighten the anchor bolts and

Generator uneven sedimentation enhance the foundation.
4 vibration is too occurs.
much
Main shaft is bend and Use dial indicator to check the
deformed main shaft is bend or not.

Main shaft run out is Turning to adjust run-out.

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beyond the allowable value.

Rotor winding inter-turns Check short circuit or earthing

are short circuited or two position and re do the
points are earthed. insulation.

Generator Over load operation, stator Reduce load during operation.

5 temperature is rotor current is exceeding
too high. rated value, and

Improper erection and Re-install the bearing or

bearing is damaged. replace bearing.

Lubrication oil (grease) Clean bearing and replace the

grade is not in compliance lubrication oil (grease) with
with requirement, filling new one in compliance with
amount is not as per requirements.
requirement, lubrication oil
Bearing is too (grease) is spoiled or
6
hot. impurity.

Bearing insulation is For the bearings with

damaged and shaft current insulation structure, clean the
occurs. dirt around insulation time to
time, measure the insulation
resistance regularly. Insulation
value shall be in compliance
with table 4.

Sparkles come Brush or brush box is not Clean the carbon dust, dirt
7
out from tidy. around the brush box.

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brushes.

Collector ring surface is Use 00# fine sand paper to

having dirt, rust or rough. grind the surface of collector
ring to make it smooth and
clean, if not, then polishing is
required.

Contacting area of brush Scrape the brush, keep 80% of

and collector ring is too the brush area in good contact
small. with collector ring surface.

Brush is over abrasive or Replace the new brush with

damaged, spring pressure is same brand and size. Replace
too less. the brush spring.

During synchronization not After disconnecting, operate

at the same time, large as per synchronization
impact current is produced. conditions.
Generator is having howling
sound.
Generator has
abnormal Exterior wire is short Eliminate the fault and recover
8
sound during circuited or struck by normal operation.
operation thundering, abnormal
sound occurs instantly.

Exterior wire is in fault, Eliminate the fault and keep

three phase current is not three phase load balance.
balanced.

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Exterior wires are short Find out short circuit point or

Generator no
circuited or earthed. earthing point, re do the
load operation
insulation.
is normal, but
9 it is beyond Excitation system wiring Adjust wire, check wiring and
limit after adjustment loops are re-connect wires as per
connecting wrongly connected. drawing requirements.
exterior circuit

Generator is running on Reduce load. Generator

over load for too long time. overload operation time shall
not exceed the allowable limit.

Insulation is break down Install lightning protective

due to thundering or over device, check out the location
voltage, or other of damage and repair it.
mechanical reasons has
Generator
caused the damage of
10 smoke or on
insulation.
fire

Stator winding inter- phase Check out the short circuited

or inter- turns short winding and repair it.
circuited.

Stator and rotor scratched Check out the fault position

with each other or and repair.
scratched by other objects.

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Mis-operation while After eliminating the faults,

synchronizing. operate correctly in
conformity with the
synchronization conditions of
generator.

5. De-commissioning

If the machine/plant is no longer operational and shall be scrapped, it must be put out of
operation and disassembled.

5.1 Information for disassembly

Before dismantling evaluate the condition of the machine/plant through an expert. Expert
means a person who has gained experience in power plants.

This evaluation shall contain the design conditions, static conditions, type and condition of
components as well as type and position of pipes and other installations. On the basis of
the determined findings an expert has to provide a written disassembly plan. This plan shall
include the following:

 Extent, sequence and type of disassembly work.

 Required tools and safety precautions.
 Dangers to health by impact of possible hazardous ingredients

Usually the disassembly takes place in reverse order than the assembly. Therefore loosen
or separate the connections of the individual parts thermally.

Remove all liquids from the plant before dismantling or scrapping.

Fix the parts to be dismantled in a way or with lifting tools on the slinging means that they

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cannot fall down or die after loosening or separating the connections.

Work on parts, which may fall down, is only allowed, if a safe stay in the working area is
possible by suitable attachments.

Supporting and stiffening components must be removed only, if measures for stability were
met.

Take the danger of fire and release of hazardous vapors and combustion products into
account during thermal separation.

5.2 Disposal

All national, regional and local legal requirements and regulations have to be kept during
the disposal or recycling of parts and components of the machine/plant as well as for
materials being necessary for the operation.

High-Quality recyclable materials like steel or copper are integrated in the machine, which
can be recovered via a scrapping process with a high recycling ratio.

Caution

Substance, being hazardous for water and soil, like parts contaminated
with oil, have to be stored in separated areas or collecting trays. If
necessary remove oil, grease and other contamination from the parts.

Separate the different materials (steel, copper, aluminum, casting, plastic,

cables, etc.) as good as possible.

Remove electrical and electronic components from the machine and

collect them separately.

A disposal via the normal domestic waste is not allowed.

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6. Description of installed equipment

Caution

The maintenance and safety instructions of sub-suppliers

have to be observed in any case.

Reference:

For the documentation (instructions, data sheets, etc.) of sub-suppliers for

auxiliary plants and installed instruments consider the appropriate folders of the
project documentation.

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7. Operation & Maintenance Records

Below some of the format for keeping Operation & Maintenance Records are provided.
Based on specific requirements client is advised to improve on these formats. These are
only basic guidelines.

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MANUAL

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3X8MW DHUKWAN SMALL HYDRO ELECTRIC
PROJECT
VERTICAL SYNCHRONOUS GENERATOR O & M
MANUAL

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 3X8MW DHUKWAN SMALL HYDRO ELECTRIC
PROJECT
VERTICAL SYNCHRONOUS GENERATOR O & M
MANUAL

8. Reference Documents for Operation & Maintenance

Below listed documents are mandatorily to be referred while carrying our operation
and maintenance of unit. As a good practice copy of 1 set of documents shall be placed
always next to the equipment for ready reference. Following documents should be
referred –

1. This O&M manual.

2. As built drawings of Generator and all its auxiliary equipment.
3. Generator erection manual.
4. All automation components manuals.
5. All erection and commissioning records.

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