TDPS WELCOMES

YOU FOR
CUSTOMER TRAINING

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 CONTENTS

1. General
Safety precautions.

2. Packing and Transport.

3. Principle of Operation

4. Constructional Details
1. Stator of main machine.
2. Rotor of Main machine.
3. Stator of Exciter.
4. Rotor of Exciter
5. Construction of Bearing
6. Rotating Rectifier assembly.
7. Discharge of Resistor.
8. Anti Condensation Heaters.
9. CT and PT Mounting.

5. Installation and Dismantling

1. Lifting
2. Engine to Generator coupling assembly.
3. Earthing
4. Direction of Rotation
5. AVR drawings
6. Commissioning

6. Running
1. Inspection prior to test running.
2. Inspection prior to Load running.
3. Inspection table at running condition

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
7. Accessories

8. Winding and insulation resistance

1. Insulation Resistance
2. Measurement of Insulation resistance
3. Insulation Resistance (IR) Values required for running
4. Prevention of IR drop
5. Cleaning method of Winding
6. Wiping with cloth.
7. Winding Condition.
8. Winding Condition assessment.

9. Inspection and Maintenance

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
1. GENERAL
Safety precautions
Safe and efficient operation can only be achieved if the equipment is
correctly operated and maintained. Before operating the generating set, read
the generating set operation manual and become familiar with it and the
equipment.
Note:

Ensure installation meets all applicable safety and local electrical
codes. Have all installations performed by a qualified electrician.

Do not operate the generator with protective covers, access covers or
terminal box covers removed.

Disable engine-starting circuits before carrying out maintenance.

Disable closing circuits and/or place warning notices on any circuit
breakers normally used for connection to the mains or other generators, to
avoid accidental closure.

2. PACKING AND TRANSPORT

The generators are packed in wooden box and dispatched. The generator is
dispatched in fully assembled condition and caution required to be exercised
so that intensive shock is not imparted to the generator during transport.
Even though the generator is packed, the packed generator should not be
left outdoors and should be protected from moisture, alkali, oil, gas, dust,
dirt and other injurious substances and must be stored in an enclosed
building.
In the case of lifting, slowly lift the generator using lifting lugs. While placing
the generator temporarily for a while, lumbers should be placed and the
generator should be lowered on them in a horizontal position.

Acceptance and Protection:
Our generator is dispatched after conducting strict inspection and test.
At the time of accepting the generator, please confirm the following
points:
 Is there any missing item? (Especially accessory and spare parts if any)
 Is there any damage during transport?
 If any damage is found, the carrier and the relevant TDPS
Office/insurance Company must be notified without delay.
In order to prevent intrusion of foreign matters such as dust, concrete etc.,
in the interior of the generator which was unpacked during the period of
erection work to avoid the drop of insulation resistance due to absorption of
moisture in the coils by rain and water drips, the complete protective
measures such as to cover the generator with canvas sheet etc, is required to
be taken.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
3. Principle of operation
Generator is a machine, which converts Mechanical energy into Electrical
energy.

BASIC WORKING PRINCIPLE:

Generator works on Faraday’s law of Electro magnetic induction. Whenever a

conductor cuts the magnetic flux, EMF will be induced in that conductor.

DC supply will be fed to Exciter Field through AVR (Automatic Voltage

Controller which is the controlling device, & governing level of excitation
provides to the exciter field) exciter field produce magnetic flux & EMF will
be induced in exciter rotor i.e. AC supply. The induced AC supply converts
as DC supply through RRA (Rotating Rectifier Assembly) & the DC supply
will be fed to main rotor in which again producing magnetic field & EMF will
be induced in main stator winding & required balanced voltage will be taken
out though main leads.

PARTS OF GENERATOR:
1. Main Stator (Main Armature)
2. Main Rotor (Main Field)
3. Exciter Stator (Exciter Field)
4. Exciter Rotor (Exciter Armature)
5. Bearings (Anti-Friction)
6. RRA (Rotating Rectifier Assembly)
7. Discharge Resister
8. Space Heaters
9. CT / PT Mounting

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
4. CONSTRUCTIONAL DETAILS

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
1 Stator of the main machine
Outer frame is of steel plate welded construction of high quality & is offered
for rigid design. At the inner side of outer frame, stator core is fitted at ample
pressure through the media of stator core clamps. Two rectangular steel
plates welded to the frame, forms the Generator feet.

Laminated silicon steel sheets of high quality & little iron loss forms stator
core. Radial ventilation ducts are provided for each proper length in axial
direction for effective cooling of the interior portion.

Stator coils are insulated with mica tapes & winding is VPI (Vacuum
Pressure Impregnation), which possesses heat resistance, humidity
resistance & oil resistance along with sufficient insulating intensity. End
bent part (over hang portion) is rigidly supported by glass cord to protect the
coil against mechanical force due to vibration & over current.

2 Rotor of the main machine

Shaft is made of forged steel. Rotor is manufactured & inspected with due
attention given to machining of parts assembly & balancing.

Laminated steel sheets forms field core. At every suitable length in its axial
direction, duct pieces are provided forming ventilation ducts for effective
cooling of rotor. Also the outer surface of field core is provided with damper
winding that helps to operate with unbalanced loads.

3 Stator of Exciter
Laminating silicon steel sheets of high quality and of little iron loss forms
exciter stator core. Axial Ventilation ducts are provided for the purpose of
effectively cooling the interior. The wound exciter stator is pressed into the
main machine frame.

4 Rotor of Exciter
Located on the same shaft are the laminated rotor core of the exciter with
the three-phase winding, the radial ventilator fan, the rectifier assembly and
the discharge resistors. Axial Ventilation ducts are provided for the purpose
of effectively cooling the interior.

5 Construction Around Bearing

Machine is with Antifriction bearings on both sides.
Bearing fit to housing is transition fit. On delivery, the bearings are
lubricated with high grade, lithium-saponified grease of grade 3
consistencies. The factory uses Shell Alvania NO.2 for this purpose.
The grease channels and the channel between the nipple and bearings are
filled with anti-friction bearing grease before leaving the factory.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
The following alternative types of lithium saponified anti-friction bearing
grease may be used:

Shell Alvania R3

Castrol spherol AP3
Or any other lithium-saponified, brand-name grease of equivalent
specification, heat resistant up to at least 130°C and complying with
Industrial Standard.

Recommendation:

Always lubricate the bearing with same selected brand of grease.
Dismantling the bearings
During shaft production, the bearing seat and the bearing stop shoulder on
the shaft are subjected to high degree of quality control. This is essential to
maintain the accuracy needed to keep the bearings fully operational. When
dismantling the bearings, it is therefore important to handle the bearings
and bearing rings with particular care, otherwise the bearing seats on the
shaft and bearing plate could become damaged. To simplify dismantling, the
parts can be heated uniformly all round to a temperature of apprx. 80°C. Do
not install bearings previously removed, but renew them.
Assembling the bearings:

Bearings must only be renewed by qualified personnel possessing
the necessary knowledge and experience and should be worked in
a dust free environment, on a clean surface and using suitable
tools including metric wrenches.

The grease and bearings must be kept free of impurities; otherwise
they will wear out faster and possibly even fail. The correct
arrangement of the bearing components must be retained: this
applies particularly in the event of repair work.

When renewing bearings, install original type approved bearings
only, and maintain the correct amount of bearing play. The grease-

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 regulating disc should be rigidly attached to the shaft. Do not
remove new bearings from their packs until just before they are
installed. Do not wash the bearings out, as the anti-corrosion
agent applied to them is compatible with most customary anti-
friction bearing greases.

Clean the part of the bearing that is to be re-installed. Before
fitting the bearing, check for dimensional accuracy and lack of
distortion at the bearing seats on the shaft and in the housing.

When single-piece bearings (e.g. deep-groove ball bearing) are
installed, the force exerted to fit them must always be applied to
the firmly located race which has to be mounted first. Forces
applied to the free-moving race have to be transmitted through the
balls or rollers, which can damage them and their tracks.

Installation of separable bearings (e.g. roller bearings) is more
straightforward. The two races can be installed separately. A
screwing movement when assembling them helps to avoid rubs
marks.

When fitting the bearing on the shaft, heat it to about 80°C in an
oil bath, oven or by a suitable inductive heating method. Make
absolutely sure that it is located centrally and in positive contact
with the shaft shoulder.

Once they have cooled down, pack the bearing fully with grease.
The inner and outer bearing covers must each be filled with grease
to approx. 50% of their full capacity (Apprx. 500gms/brg).
Monitoring the bearings:
The first indication of the damaged bearings is usually a noticeable change
in temperature or running behavior, or noise and vibration if bearing
damage has reached an advanced stage.
Recommendation:
Monitor the bearings by measuring transmitted noise, temperature and
vibration at regular intervals, and compare the readings with those taken on
previous occasions.
Temperature detectors for bearings:
RTD type bearing temperature detectors are given. Maximum allowable
temperature for grease-lubricated bearings is 90°C. Refer section 7.1 for
further details.
Temperature rise of ball bearing:
Carefully check that temperature rise of the ball bearing doesn’t exceed 50°C
above the ambient temperature. Should it be otherwise, it is necessary to
stop the machine and to proceed to a general inspection.
Abnormal noises:
The production of abnormal noises and vibrations may result from the wear
and tear of the ball bearing: it is better to proceed to their renewal, so as to

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 avoid any risk of seizure that could seriously damage the alternator.
However, before proceeding to this replacement, make sure that the
alignment of the engine alternator set is correct as also the tightening of
bearing caps and of the ventilating fan.

6. Rotating Rectifier Assembly

Construction
Fig 4.61 shows the arrangement and connection diagram of rotating
rectifier assembly. The rectifier assembly is split into two groups, the
positive and negative, and the main rotor is connected across these groups.
This group is formed through the connection bar shorting between two
diodes as shown in fig 4.61. Each group carries 3 diodes, the negative
group carrying negative biased diodes and the positive group carrying
positive biased diodes. Care must be taken to ensure that the correct
polarity.
Diodes are fitted to each respective group. When fitting the diodes to the
connecting bar they must be tight enough to ensure a good mechanical
and electrical contact, but should not be over tightened. The recommended
tightening torque is 4.06 -4.74Nm (36-42lb in).
Silicon diode specification shall be as below:
Model: SKN(R) 240/16
Rated amps: 240 A (Avg.)
Reverse voltage: 1600 V

Inspection and Cleaning
Investigate whether the bolts and nuts around the rotating rectifiers are
loose or not. The life of silicon diodes used is semi-permanent under
condition of normal use. Therefore, unless otherwise there is a problem,
inspection of individual diodes is not required. In case, the voltage is not
built-up or generated voltage is low, failure of diode/s is to be considered
as one of the probable causes. Therefore, remove the lead wires and check
the continuity using a tester/multi-meter.
Refer fig 4.62 for inspection of silicone diode.
In case any diode is found to be damage, replace that with an identical
one.

Fig-4.61

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 Note:
Please note the following points while replacing the diodes.
(A) Since 2 types of diodes (forward polarity and reverse polarity
are used, confirm the polarity of the diode to be replaced).
(B) Clean the tightening thread part of diode and coat electrically
and thermally conducting grease (CHEM MOSIL) to prevent
electrical corrosion of this part.
(C) Tighten the diode using torque wrench. Tightening torque
should be as per the specified value.

7. Discharge Resistor
The discharge resistor is a permanently connected resistor connected across
the two rectifier plates to prevent high transient reverse voltages in the field
winding from damaging the diodes. This device rating is as below. Two
devices shall be connected in parallel. Replace if faulty.
Technical specifications:
Resistance value – 10 Ohms/circuit at 25ºC
Capacity – 500W/circuit
Voltage: 70 V (D.C)
IR: Min 1MΩ
Material: Nichrome

8. Anti Condensation Heaters (Space Heaters)

Anti-condensation heaters are fitted in the machine to avoid condensation in
the event of long storage. Care should be taken to switch on these heaters at
site when the machine is not in operation and should be switched off before
the machine is started.

9. CT and PT Mounting
CT and PT Assembly is mounted on the A.C Generator as shown in the
drawing.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 TD Power Systems Pvt. Ltd.,
# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
5. INSTALLATION AND DISMANTLING
1. Lifting
Minimum Lifting Capacity Required Is 6.5 Tonnes
Lifting points are designed to position the crane-age point as close to the
center of gravity of the generator as close as possible, but due to design
restrictions it is not possible to guarantee that the generator frame will
remain horizontal while lifting. Care is therefore needed to avoid personal
injury or equipment damage.
2. Engine to Generator Coupling Assembly
During the assembly of the Generator to the Engine it will be necessary to
first carefully align, then rotate, the combined Generator rotor - Engine
crankshaft assembly, as part of the construction process, to allow location,
insertion and tightening of the coupling bolts.
While fitting and tightening the coupling bolts it will be necessary to rotate
the Engine crankshaft - Generator rotor assembly. Care should be taken to
ensure that rotation is carried out in an approved manner that ensures safe
working practice when reaching inside the machine to insert or tighten
coupling bolts, and that no component of the assembly is damaged by non-
approved methods of assembly rotation.
Engine Manufacturers have available a proprietary tool designed to enable
manual rotation of the crankshaft assembly. This tool must always be used,
having been engineered as an approved method of assembly rotation, by
engaging the manually driven pinion with the engine flywheel starter ring-
gear.
A flexible coupling should be fitted and aligned in accordance with the
coupling manufacturer's instruction. If a close coupling adaptor is used the
alignment of machined faces must be checked by offering the generator up to
the engine. Shim the generator feet if necessary. Ensure adaptor guards are
fitted after generator/engine assembly is complete. Open coupled sets
require a suitable guard, to be provided by the set builder. Axial loading of
the generator bearings should be avoided. Should it be unavoidable contact
the factory for advice.
Note:
Incorrect guarding and/or generator alignment can result in personal injury
and/or equipment damage.
3. Earthing
The generator frame should be solidly bonded to the generating set bedplate.
It should be earthed through suitably rated earth conductor (normally one
half of the cross sectional area of the main line cables).
Note:
Refer to local regulations to ensure that the correct earthing procedure has
been followed.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
4. Direction of Rotation

Fan Types
This machine is designed with an improved cooling system fitted
with a radial bladed uni-directional fan. These machines are
suitable only for clockwise rotation, as viewed from the drive end.

Phase Sequence
Phase sequence of this machine is UVW corresponding to direction
of rotation clockwise from DE.
5. AVR Drawings
Refer the attachments.
6. Commissioning
Main lead cables are 35mm² silicone rubber insulated flexible cables. Ensure
that all external cabling is correct and that all the generating set
manufacturer's pre-running checks have been carried out before starting the
set. The generator AVR controls/setting is in set builders will have been
adjusted by set builder.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
6. RUNNING
1. Inspection Prior to Test Running
Conduct the inspection as per the following table prior to test running.

INSPECTION ITEM CONTENT OF INSPECTION

• Is the foundation fully cured and
solidified?
• Isn’t there clearance between the base and
foundation?
Condition of erection
• Are the tightening bolts of respective parts
fully tightened?
• Are there pieces of paper and cloth lying
on the surroundings?
• Is the whole of lead wire secured?
• Are the bolts and nuts tightened?
Terminations
• Is the treatment of terminal (lug or socket)
secured?
• Is the insulation resistance sufficient?
(High voltage circuit is desired to be over
10mega ohms and low Voltage to be over
Insulation resistance 1mega ohms).
NOTE: Terminals of diodes to be shorted for
measurement of insulation resistance of
field winding.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
2. Inspection Prior to Load Running
In the case of running, after test running or stopover for a long period of
time, no load running should be done for about 30 minutes. Then conduct
the inspection in accordance with the following table and confirm the
absence of abnormality. Thereafter commence load running.

INSPECTION ITEM CONTENT OF INSPECTION

• Is the grease o.k?
• Is there any abnormal noise and vibration?
Bearing parts • Is the temperature abnormally high?
• Is the current flowing from bearing housing
to earth?
• Is there any abnormal odor and smoke
coming out?
• Is there any abnormal vibration?
Generator and Exciter (Caution is required because the vibration from
prime mover is high).
• Are there any parts where temperature is
abnormally high?
• Are the voltages of three phases balanced?
• Do the meters indicate the approximate
values?
Control panel
• Is the circuit breaker set at the running
position?

SL PERIOD OF INSPECTION AND

SYMBOL
NO MAINTENANCE
Routine inspection once a day at times of
1 D
running and stop
Weekly inspection and maintenance once a
2 W
week at times of stop
Monthly inspection and maintenance once a
3 M
month at times of stop.
Periodical dismantling, inspection and
4 6M
maintenance once in 6 months at times of stop.
Periodical dismantling, inspection and
5 Y
maintenance once in a year at times of stop.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
3. Inspection Table at Running Condition
Note:
The above symbols are used for inspection periods in the explanations.
P
E INSPECTION
INSPECTION JUDGEMEN MEASURES AT T
RI
ITEMS T CRITERIA METHOD ABNORMALITY
O
D
If vibration
increases
gradually, stop at
Whether the
suitable time and
vibration is
conduct
abnormally
If abnormality is investigation.
high or not
Vibration of compared to felt by hand If abnormal
D
Generator body those touch resort to vibration is
observed so vibration meter. sensed suddenly,
far. stop the
generator
immediately and
conduct
investigation.
Discriminating
There should mechanical noise,
be no ventilation noise
abnormal and magnetic
noise noise should
compared to make judgment.
Abnormal noise
noise at Resort to sense of In the case of
from the body
D normal time hearing and noise abnormal noise
including
(noise at hearing rod like magnetic
bearing
normal time noise
should be well accompanying
listened to vibration, precise
and investigation
confirmed) should be
conducted.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 P
E
INSPECTION R JUDGEMEN INSPECTION MEASURES AT T
ITEMS I T CRITERIA METHOD ABNORMALITY
O
D
If standard limits
Temperature are exceeded the
rise limits Measure by the machine must be
must not be attached stopped
exceeded. In thermometers immediately and
case the and scanners at inspected.
Temperature temperature regular times
of respective D rises daily. Current, If there is a large
parts gradually power factor and variation cause
despite room temp should be
running at should be precisely
constant load, recorded at the investigated and
caution is same time. corrective
required. measures should
be taken.
If abnormal odor
is sensed
machine must be
stopped
immediately.
There should
Investigate
be no
Abnormal mainly around
abnormal odor Resort to sense of
odor from D the winding.
compared to smelling.
body. Megger test for
that at normal
the windings
times.
since abnormal
odor mainly
results from
failure of
insulation.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 P
E
INSPECTION R JUDGEMEN INSPECTION MEASURES AT T
ITEMS I T CRITERIA METHOD ABNORMALITY
O
D
There must be
no deposit of
foreign matter Remove foreign
at ventilation matter if it is
openings. deposited at the
Temperature ventilation
By sensing wind openings.
D difference
Condition of pressure by
between If air quantity
ventilation temperature
suction air sensed is lesser
observation.
and discharge stop the machine
air must not by checking
indicate large running condition
difference and investigate.
from that at
normal times.
• Bolts of
respective
parts must
Torque wrench
not have loose
should be used
fit.
After air blow and for tightening the
• There must cleaning using diodes and the
be no color compressed air, tightening must
Surroundings of change by inspection must be conducted at
Y
rectifiers over heat. be conducted by the prescribed
visual torque. For the
• There must
observation or others, take
be no
hand touch. appropriate
deformation measures to the
and extent required.
impairment of
respective
parts.
Increase the
Loose fit of bolts Tighten the bolts tightening. (Do
Check if bolts
that tighten M using spanner or not break the bolt
turn lightly.
respective parts screwdriver. by tightening too
much).

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 P
E
INSPECTION R JUDGEMEN INSPECTION MEASURES AT T
ITEMS I T CRITERIA METHOD ABNORMALITY
O
D
Restore to normal
value by turning
Indicating with screwdriver
Correction of needle must or your finger.
By visual
indicating M be at the Conduct
observation.
meter normal adjustment if
position. frequent
correction needs
arise.
Replace with new
Deterioration grease of
of lubricating specified brand
grease as per the
nameplate data.

Generator
Stator 11kV
winding
greater than
10M ohm
Rotor low By megger
voltage Note: Cleaning and
Insulation
M winding drying should be
resistance Megger should be conducted.
Greater than conducted after
1 M ohm disconnecting
control circuit.

Exciter
Over 1Mohm
for armature
and field

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
 P
E
INSPECTION R JUDGEMEN INSPECTION MEASURES AT T
ITEMS I T CRITERIA METHOD ABNORMALITY
O
D
• No plugging
of air duct.
• No loose fit
and
deformation of
wedge.
• No color After air blow and
change by cleaning by
over heat. compressed air,
conduct visual Take appropriate
Surroundings
• No inspection. measures as
of field coil
Y deformation required after
(including Observation or
and cleaning by air
exciter) hands touch for
impairment of blow.
respective the range
parts. possible for
inspection.
• There must
be no trace of
contact with
stator.• No
loose bolt of
respective
Parts.
• Antifriction
bearings have
no unilateral
Surrounding contact.
Y Refer section 4.5. Refer section 4.5.
of bearing • Prevention of
shaft current
must be
adequate.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
7. ACCESSORIES
Standard Accessories
Stator winding Resistance temperature detectors

Nine (6 Nos+3 no’s spare) resistance temperature detectors, PT100
type, in the stator winding.
The auxiliary terminal box, which is at right hand side of the
machine looking from NDE, is housing above accessories
terminals. The resistance temperature detectors are in compliance
with IS: 2848:1986.
Bearing temperature detectors

One RTD type temperature detector, PT100 type, in each bearing
The auxiliary terminal box, which is at right hand side of the
machine looking from NDE, is housing above accessories
terminals. The resistance temperature detectors are in compliance
with IS: 2848:1986.
Anti-condensation heaters (Space Heaters)

Two space heaters of capacity 2x250W, 230V, 1Phase, 50Hz is
fitted in the machine as shown in the A. C. Generator outline
drawing. The space heater terminal box is also provided at right
side of the generator looking from NDE.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
8. WINDING AND INSULATION RESISTANCE
1. Insulation Resistance
Note:
Insulation tests should be carried out before running the generating set,
both after assembly and after installation on site. The windings have been
H.V. tested during manufacture and further H.V. testing may degrade the
insulation with consequent reduction in operating life. Should it be
necessary to demonstrate H.V. testing, for customer acceptance, the tests
must be carried out at reduced voltage levels i.e. Test Voltage= 0.8 (2 X
Rated Voltage + 1000)
Insulation resistance is the resistance against leakage current that flows in
the interior and on the surface of insulation when certain value of D.C.
voltage is imposed. In case the generator is installed at a place where high
humidity exists or when the generator is kept idle over a long period of time,
generally the insulation resistance drops due to deposit of moisture on the
insulation surface. Therefore insulation resistance should be measured prior
to running of the generator.
2. Measurement of Insulation Resistance

Measurement of insulation resistance indicates the insulated
condition of the equipment in a very simple way. However, the
value of insulation resistance measured indicates the condition of
insulation deterioration.

Measurement is essential before running the generator. Although
the measured value indicates the absolute value corresponding to
the condition of insulation at the instant of measurement, a
comparative value has more significance. It is essential to measure
periodically and to check in comparison the condition of change
with reference to earlier measured values.

Although the insulation resistance increases with time after the
imposition of D.C.voltage the value that settles down to a constant
should be registered. In case the insulation resistance increases
gradually little by little this insulation resistance value is indicated
by 30 seconds value or 1-minute value.

Since the insulation resistance has a close relationship with the
temperature of insulation, when measuring insulation resistance,
it is always required to measure temperature of insulation at that
time and record this temperature along with the insulation
resistance. It serves convenient for maintenance purposes if the
relationship between the insulation resistance value and winding
temperature at clean and dry condition of winding is available.
Generally, the insulation resistance value drops rapidly together
with the rise of temperature and the relationship between the
logarithm of insulation resistance value and temperature changes
as straight line approximately in the temperature range of usage.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40

Insulation resistance value differs from the process by the
insulation composition of equipment and the temperature rise.
Generally three types as shown in the figure are classified.

Initially the insulation resistance drops at once and then starts
rising as the drying effect progresses. This is most generally seen.

In the case of drying on site the equipment that has absorbed
moisture excessively and/or large size machines, this type of
characteristic is frequently experienced. In the case of equipment
that has absorbed moisture excessively, since the amount of
moisture absorbed is large, the insulation characteristic is to be
absorbed before the drying effect appears. In the case of large size
machines a long time is required for the temperature rise of
equipment and the drop portion due to insulation characteristic
offsets the rise portion due to drying effect. In both the above
cases, a fairly low value for the measured insulation resistance by
megger should continue without change. About 3 full days (days
and nights) may be required to reach the rising point.
Note:
At the time of measuring insulation resistance, attention should be paid to
the following points:

If rotating type megger is used, rotating it for one-minute at least
should do measurement.

If battery driven megger is used, error increases as the battery
voltage drops.

Prior to measurement, residual electric charge of winding should
be removed.

To exclude the effect of connected auxiliary devices, other circuits
should be disconnected at an easy convenient part and then
measurement should be done.

After the measurement the residual charges should be discharged.
3. Insulation Resistance (IR) Values Required for Running
The minimum permissible insulation resistance value changes extensively by
the type, rating, dimension and insulation method of generator. A general
value cannot be determined. However, the following guideline can be
approximately used when the windings are at normal temperature, for
permitting normal running.

Greater than 1 Meg-Ohm for low voltage stator winding and the field
winding

Greater than 5 Meg-Ohm for 3.3kV and 6.6kV stator windings

Greater than 10 Meg-Ohm for 11kV stator windings

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
4 Prevention of IR Drop
It is desirable to run the generator with its winding condition always set
clean and dry. Dust deposited on the winding surface prevents heat
dissipation and becomes the cause of deterioration dependent on its kind.
Also, the intrusion of moisture into the interior from the cracks on insulation
leads to the drop of insulation resistance. Therefore, daily attention to
cleaning and prevention against moisture absorption leads to prevention of
IR drop especially for exciter, which is open type. Although generator’s
interior presents dry condition during running, there may be moisture
absorption during stoppage of generator at times of high humidity such as
rainy season. To prevent such situations, it is required to put-on the space
heater immediately after stopping the generator and to raise the temperature
of generator interior higher than the ambient temperature.
5. Cleaning Method of Winding
Dust accumulated on the insulation reduces the ventilation area and the
cooling effect. This may result in over-heating of the generator. Even though
the accumulated dust is not conductive by itself, it absorbs moisture and
becomes conductive thereby causing short circuit of winding and ground
fault. Therefore, it is essential to keep the winding always in a clean
condition.
The particular points that need to be paid consistent attention are to the
following: -

Isn’t there any abnormality of the respective parts of generator
itself?

Isn’t there any harmful matter in the surrounding atmosphere?
When abundant dust is in presence in the wind passage, such dust will stick
to coil and dust and the dust will lead to the cause of short-circuit failure
and grounding failure. When the generator is started after a long time, since
there may be chances of lowering the insulation resistance of coil, perform
the drying thoroughly.
As for drying there are methods like resorting to space heater and the
method of permitting the flow of current directly through the coils.
For either of the above two methods, please avoid over-heating locally as well
as raising the temperature above 80°C. Though inspection in detail of the
respective parts is carried out at the time of trimming the generator, during
daily inspection, please inspect the machine by your sense as whether any
abnormality compared to previous condition has arisen or not.
In other words, please pay due attention by comparing the temperature rise
and vibration through the feeling obtained by touching your hand on the
generator, and by sensing abnormal noise or odor.
As for the confirmation of abnormal odor, please confirm it by opening the
covers once in a while.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
6. Wiping with Cloth
This method is especially effective for cleaning the local parts where the
contamination is severe. Dry and clean cloth from which thread pieces do
not come out should be used. Attention should be paid as not to impair the
insulation by rubbing strongly
As part of routine maintenance procedures, periodic attention to winding
condition (particularly when generators have been idle for a long period) and
bearings is recommended.
7. Winding Condition
Guidance of Typical Insulation Resistance [IR] Values
The following is offered as general information about IR values and is aimed
at providing guidance about the typical IR values for generators from new
through to the point of refurbishment.
New Machines
The generators Insulation Resistance, along with many other critical factors,
are measured during the alternator manufacturing process. The generator
will have been transported with an appropriate packaging suitable for the
method of delivery to the Generating Set assemblers works. Where we expect
it to be stored in a suitable location protected from adverse environmental
conditions. However, absolute assurance that the generator will arrive at the
Gen-set production line with IR values still at the factory test levels of above
100 MΩ cannot be guaranteed.
At Generating Set Manufacturers Works
The generator should have been transported and stored such that it will be
delivered to the assembly area in a clean dry condition. If held in appropriate
storage conditions the generator IR value should typically be 25 MΩ.
If the unused/new generators IR values fall below 10 MΩ then a drying out
procedure should be implemented by one of the processes outlined below
before being dispatched to the end customer’s site. Some investigation
should be undertaken into the storage conditions of the generator while on
site.
8. Winding Condition Assessment
Note:
The AVR should be disconnected and the Resistance Temperature Detector
(R.T.D.) leads grounded during this test.
The condition of the windings can be assessed by measurement of insulation
resistance [IR] between phase to phase, and phase to earth.
Measurement of winding insulation should be carried out: -
1. As part of a periodic maintenance plan.
2. After prolonged periods of shutdown.
3. When low insulation is suspected, e.g. damp or wet windings.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
Care should be taken when dealing with windings that are suspected of
being excessively damp or dirty. The initial measurement of the [IR]
Insulation Resistance should be established using a low voltage (500V)
megger type instrument. If manually powered the handle should initially be
turned slowly so that the full test voltage will not be applied, and only
applied for long enough to very quickly assess the situation if low values are
suspected or immediately indicated. Full megger tests or any other form of
high voltage test should not be applied until the windings have been dried
out and if necessary cleaned.
Procedure for Insulation Testing
Disconnect all electronic components, AVR, electronic protection equipment
etc. Ground the [RTD's] Resistance Temperature Detection devices if fitted.
Short out the diodes on the rotating diode assembly. Be aware of all
components connected to the system under test that could cause false
readings or be damaged by the test voltage. Carry out the insulation test in
accordance with the ‘operating instructions for the test equipment.
The measured value of insulation resistance for all windings to earth and
phase to phase should be compared with the guidance given above for the
various 'life stages' of a generator.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
9. INSPECTION AND MAINTENANCE
To avoid failure in advance, it is indispensable to watch and inspect the
generator at all times.
By preparing checklist, please perform the inspection and trimming
periodically. Hereunder, points that need to be paid attention especially date
of inspection and method of inspection is given.
Respective tightening bolts and connecting location
Inspection and maintenance within the extent considered possible must be
performed once a year without taking out the rotor. In particular, inspection
of stator winding and re tightening of respective bolts and nuts must be
carried out. Tightening of set bolts must be done once after half a month
from the date of commencing running and furthermore inspection and re
tightening of these bolts must be done at the rate over 3 times within one
year thereafter.
Bearing
After the starting if bearing is overheated considerably within a short time or
if abnormality of noise or odor is detected, there is the need of dismantling
and inspection.
The causes of overheating of bearing are given hereunder.

Lubricating grease is not adequate

Use of filthy grease

Deficient erection and coupling

Generation of rust or presence of scar in bearing during the time
generator is laid off.

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
Major requirement of inspection and maintenance at respective time is
tabulated in the following table:

Control of Daily Monthly

I inspection inspection inspection
t place of (during (during Annual inspection
e inspection running) stop)
m
1.Maintenance of
winding.
1.Insulation
1.Noise 2.Maintenance of
Static part Resistance. core Parts.
1 2.Temperature
2.Air gap 3.Inspection of lead
3.Vibration wires.
3.Cleaning
4.Inspection of bolt
and Nuts.
1.Loosening of spigot
fitting part and
balance weight.
2.Contact with static
Rotating 1.Inspection part.
2 1.Noise
part resistance.
3.Inspection of lead
wires.
4.Retightening of
bolts and nuts.

1.Noise 1.Examination of
rolling elements
3 Bearing part 2.Temperature 2.Cleaning
2. Pitting marks to be
3.Vibration checked
1.Odour
4 Others 2.Abnormal
noise

TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40