HAP - Condition Assessment Manualhydropower.ornl.gov/docs/HAP/ChecklistGenerator.pdf · General...

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Condition Assessment Manual Generator Inspection Form and Checklist Revision 1.1, 12/15/2011

Transcript of HAP - Condition Assessment Manualhydropower.ornl.gov/docs/HAP/ChecklistGenerator.pdf · General...

Page 1: HAP - Condition Assessment Manualhydropower.ornl.gov/docs/HAP/ChecklistGenerator.pdf · General Information: ... Instrumentation/Monitoring: ... HAP – Condition Assessment Manual

Condition Assessment Manual

Generator Inspection Form and Checklist

Revision 1.1, 12/15/2011

Page 2: HAP - Condition Assessment Manualhydropower.ornl.gov/docs/HAP/ChecklistGenerator.pdf · General Information: ... Instrumentation/Monitoring: ... HAP – Condition Assessment Manual

HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 2

Prepared by

OAK RIDGE NATIONAL LABORATORY

Oak Ridge, Tennessee 37831-6283

managed by

UT-BATTELLE, LLC

for the

U.S. DEPARTMENT OF ENERGY

under contract DE-AC05-00OR22725

and

MESA ASSOCIATES, INC.

Chattanooga, TN 37402

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 3

Generator – Inspection Form

General Information:

Date of Site Visit: ______________________________________________________ Unit No.________

Plant name: __________________________________________________________________________

Source/s of data:______________________________________________________________________

Manufacturer: _______________________________________________________Age:_____________

Turbine Rated Output (MW):________Max. Turbine Output (MW):_______Rated Speed (rpm):________

General Generator

Description:__________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

Summary Failure History/Maintenance History / Major Repairs Description:

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

Typical Operating Mode:________________________________________________________________

Stator

Rating:__________________@________pf

Voltage: _________________________ Current Insulation Class:___________________________

Winding Age:_____________________ Last Rewedge:__________________________________

Winding Description (pitch, span, circuits, turns/coil, etc.): _________________________________

_______________________________________________________________________________

Installed

Instrumentation/Monitoring:______________________________________________________________

____________________________________________________________________________________

Rotor

Insulation Class:______ No. Poles:________

Type Construction:_____________________________________________________________________

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 4

Excitation Requirements:________________________________________________________________

Installed

Instrumentation/Monitoring:______________________________________________________________

Addition specification data:

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

Cooling System:

General Description of Stator /Rotor Cooling System:

____________________________________________________________________________________

____________________________________________________________________________________

Modifications:_________________________________________________________________________

No. of Air Housing Coolers:___________

Cooler Tube Material:_______________ Cooler Design Data (flow rate, water temp, temp rise):

____________________________________________________________________________________

Temperature Control Method:____________________________________________________________

Addition specification data:

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

Neutral Grounding:

Neutral Ground Method (i.e., high impedance, low impedance, resistance, etc.):

____________________________________________________________________________________

____________________________________________________________________________________

Neutral Beaker:___________ Neutral Disconnect:______________

Ratings:_________________________________________________

Oil Filled Components:_____________________________________

Addition specification data:

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 5

Thrust Bearings:

Type/LocationMaterial: ________________________________________________________________

Installed Instrumentation/Monitoring:______________________________________________________

Cooling Description:___________________________________________________________________

Addition specification data:

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

Guide Bearing(s):

Type/LocationMaterial: ________________________________________________________________

Installed Instrumentation/Monitoring:______________________________________________________

Cooling Description:___________________________________________________________________

Addition specification data:

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

Generator Shaft:

Fabrication Description/ Material: _________________________________________________________

Vibration Monitoring System

Description:____________________________________________________

Vibration Alarm Point(s):______________________________Trip Point:__________________________

Addition specification data:

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 6

Generator Check List

Topic Yes No N/A Comments/Details

Maintenance & Major Repair History

Stator Coil Replacement/Repair Coils Jumpered/Cut out Stator Rewedge - Complete

Stator Rewedge - Partial

Loose winding blocking/bracing/lashings/spacer repairs.

Core Replacement

Core Repairs Core Tightening

Have all plant records regarding stator maintenance, repairs, operating conditions and performance data been

requested/gathered?

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 7

Generator Check List - Continued

Topic Yes No N/A Comments/Details

Maintenance & Major Repair History - Continued

Have there been hi-pot test failures?

Have there been any out-of phase synchronizing events?

Has there been any inadvertent energization at standstill?

Rotor Rewinds?

Shorted Turn Repairs, pole or lead connection issues?

Amortisseur winding issues/repairs?

Rotor or Stator Roundness Issues?

Field Grounds?

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 8

Generator Check List - Continued

Topic Yes No N/A Comments/Details

Maintenance & Major Repair History - Continued

Other Stator / Rotor Failures/Repairs Not Included Above

Neutral Transformer/Reactor/Resistor Issues or Replacements

Neutral Breaker/Disconnect Issues or Replacements

Air Housing Cooler Tube Leak Repairs/Plugged Tubes

Air Housing Cooler Replacements

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 9

Topic Yes No N/A Comments/Details

Equipment Condition Assessment

Do current electrical visual inspection results show evidence of winding looseness, hot spots, corona, wedge or filler migration, vent duct or finger plate, foreign object or mechanical damage, oil and or dirt contamination?

Do electrical rotor and stator test result trends indicate marginal insulation integrity?

Do stator or rotor bridge measurements show deterioration?

Does on-line temperature information indicate any stator or rotor overheating?

Cooler Tubes Air Side Fouled / Water Side Plugged/Mechanical Damage or Fin/Baffle Separation

Cooler RCW System Temperature Controller Fully Functional

Generator Check List - Continued

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 10

Topic Yes No N/A Comments/Details

Maintenance & Major Repair History - Continued

Thrust Bearing Failures/Replacements

Guide Bearing Failures/Replacements

Bearing Oil Cooler Failures/Replacements

Generator Shaft Repairs or Modifications

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 11

Generator Check List - Continued

Topic Yes No N/A Comments/Details

Equipment Condition Assessment – Continued

Rated capacity from RCW supply pumps

Availability of spare cooling system long lead components

Operational bearing/oil overtemperature

Thrust Bearing Babbitt issues (babbitt)bond, electrolysis, scoring

Bearing oil cooler periodically inpected and tested

Neutral Grounding visual assessment

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

12/15/2011 12

Topic Data Input

Generator Data Collection Sheet

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HAP – Condition Assessment Manual – Generator Inspection Form and Checklist

Rev. 1.0, 12/15/2011 13

For overall questions

please contact:

Brennan T. Smith, Ph.D., P.E.

Water Power Program Manager

Oak Ridge National Laboratory

865-241-5160

[email protected]

or

Qin Fen (Katherine) Zhang, Ph. D., P.E.

Hydropower Engineer

Oak Ridge National Laboratory

865-576-2921

[email protected]


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