Generator Overhauling

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    Overhauls

    Presented by

     Abhilash Chandra Aron

    Consultant, Turbogenerators

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    General

     Define scope of mandatory works.

     Define possible areas of additional and unforseen work actiities.

     !ork out list of spares and consumables that shall or may be re"uired. This list to be as e#haustie as possible.

    Consult $%&' ( contractor well before.

     )chedule as many actiities in parallel as possible. )pecial task group may be made to gie emphasis to longest cycle actiity.

     !ithin the organi*ation, create and deelop specialists for main products. They should not only assist in oerhauls or

    operational emergencies,but also work for improements in +  - areas of the product.

    C/T&/A 0+ +1&%A2')  /nitial /nspection3  Dictated by stator end winding and stator slot support systems. )ynthetic and insulating material tend

    to flow4creep5 under pressure and temperature during initial period. Deficiencies of manuf. assembly or design can be corrected.  )tart up stresses3 &ffects of e#pansion, friction on winding and insulation due to thermal  centrifugal force cycles.

    )pecial ibratory forces arising when passing through natural fre"uencies of components.

      -aterial fatigue, especially of rotating parts resulting from centrifugal force cycles.

     6ormal recommendations for inspection interals apply to normal operation without any ma7or disturbances.

    +1&%A2')   1D&! &C+--&6DAT/+6)

     /6/T/A', )%+T, /6T&-&D/AT& A6D -A/6 /6)P&CT/+6)

     TEQIV  8 91 . T1 : 92 . T2 : n . T3  9;, T; 0ACT+(T/-&, T> 0ACT+( T/-& < &'AT/6G T+

    )TAT 2P

    ?@ -1A TG3 9; 8 ;., 9= 8 .B, T> 8 = @ -1A TG3 9; 8 ., 9= 8 .>, T> 8 ;

    =B -1A TG3  9; 8 .E, 9= 8 .;, T> 8 ;  B -1A TG3 9; 8 .F, 9= 8 .;, T> 8 B

    0+''+!/6G '&AD T+ &A' /6)P63  0A2'T )6C%+6/)/6G

     C'+)& /6 ))T&- 0A2'T)

      A)6C%+6+2) +P&AT/+6

     %/G% 26$A'A6C&D '+AD)

      A')+ 0+''+!/6G 0ACT+)3

     !&A(D&T&/+AT/+6 +0 C+-P+6&6T) + 266/6G $&%A1/+2.

     '+AD &J&CT/+6), +T+ 0A2'T)...

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    OVERHAULS - 3

    C%A6G& /6 C++'A6T 0'+! AT&).

    0+2'/6G /6 A/ C++'&D G&6&AT+).

    %D+G&6 + !AT& '&A9).

    )%A0T /6)2'AT/+6 D&T&/+AT/+6.  &C+--&6DAT/+6) 0+ /6)P&CT/+6)

    TEQUIV < /6/T/A'3 ; < = T%+2 %)

    TEQUIV < -A/63 H < @ T%+2 %)  +6& + -+& )%+T  /6T&-&D/AT&

    /6)P&CT/+6 $& D+6& $&T!. = -A/6.

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    OVERHAULS - 4  /6/T/A'  -AJ+ 6&&D +T+ &-+1A'  &GAD'&)) +0 A$+1&, 0+ ?=B -1A3

    -/6+ /6)P&CT/+6 /6 = ).

    -&D/2- /6)P&CT/+6 /6 B ). -AJ+ /6)P&CT/+6 /6 ; ).

     0+  =B -1A /6 >, @, ;= &A)

     C%&C9) 0+ /6/T/A'  +T%& /6)P6. T+ $& AG&&D !/T% -A620ACT2&

     26C%A%A < ;3 H@> T/P) $&T ;E

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     0 10 20 30 40 50 60 70

    ACTUAL OPERATING HRS.: T  (10 ) 3

    90

    80

    70

    60

    50

    40

    30

    20

    10

    FIRST INSPECTION

    3

    FIRST MAOR  INSPECTION

    TIME (!EARS)

    B

    "#$

    2

    4

    6

    8

    2

    4

    6

    8

    10

    12

    10

    8

    6

    4

    2

    100 STARTS%!R  300 ST%!R 

    10ST%!R 

      A. C. ARON

    &UI'.

    OPER.

    RS.

    T*+,

     10 H- 

    A

    10

    12

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    OVERHAULS

     ;st /6)P&CT/+63 ; < = T%+2 %).

     )2$)&I2&6T3 H < @ T%+2 %).

     -/6+ /6)P&CT/+6) /6 $&T!&&6.

     DATA $&0+& )%2T D+!6.

     CA)& +0 6A+A +T+ < '+! /

    D&T&CT&D A0T& +T+ &/6)&T/+6.

    DATA A0T& &+''/6G.

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    BEFORE OVERHAUL

     $&A/6G 1/$AT/+6) $& &C+D&D.

     C%&C9 $&A/6G  )%A0T )&A' /6)2'N.

     +T+ !DG. /-P&D&6C&  &)/)TA6C&.

     )TAT+  +T+ !/6D/6G / -&A)2&D.

     !/6D/6G T&-P, !AT& 0'+!) &C+D&D.

     GA) '&A9)  )&A'

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    DURING OVERHAUL

      INITIAL AND MAJOR   C+& C+6D/T/+6  &'C/D C+& T&)T.

     /0 0A2'T C2&6TK ? ; mA , A6D /0 A6 C+&

    DA-AG& 1/)2A'' )&&6, A6D ( + &PA/&D

    &TC., P+!& C+& '+)) T&)T T+ $& D+6&.

     )TAT+ &6D !/6D/6G )2PP+T ))T&- A6D

    +1&%A6G C+6D/T/+6.

    )TAT+ !/6D/6G /6)2'AT/+6 C+6D/T/+6.  )TAT+ !/6D/6G /K A6D '&A9AG&).

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    DURING OVERHAUL - 2

      INITIAL AND MAJOR   )TAT+ !&DG& T/G%T6&)).

     '&A9AG& T&)T +0 %D+G&6 ))T&-.

    )'/P /6G)  $2)%G&A.  C%&C9 A'' 2$$& GA)9&T).

     '&A9AG& T&)T) +6 )TAT+ !/6D/6G, !AT&

    ))T&-, 0/'T&) C'&A6/6G.

     $&A/6G '/6&  $+D /6)P&CT/+6.

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    DURING OVERHAUL - 3

      INITIAL AND MAJOR   +T+ &TA/6/6G /6G )20AC&).

     C%&C9 /0 +T+ )%A0T /) -AG6&T/)&D.

     26 +2T C%&C9) +6 +T+.  C%&C9 &-+1&D +T+ 1/)2A''.

     +T+ !/6D/6G /K.

    +T+ $&A/6G  )&A') J+26A').  P2G& T&)T)K +6 +T+.

     C%&C9 +T+ 0A6) 1/)2A''.

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    DURING OVERHAUL - 4   INITIAL AND MAJOR 

     +T+ C.C. $+'T) 0+ '&A9AG&).

      A'' C++'&) T+ $& C'&A6&D C! )/D&.

    C%&C9 $&A/6G A6D )&A') /6)2'AT/+6.  $&A/6G C'&AA6C&), $A$$/T, A'' +/'

    CATC%&), JAC9/6G +/' '/0T, TCs ( TDs.

     )P%&/CA' )20AC&) +0 $&A/6G.

     )'/D/6G C+6TACT 0AC&) +0 )&A' /6G), )&A' $+D, )%A0T )&A' C'&AA6C&).

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    DURING OVERHAUL - 

      INITIAL AND MAJOR  C'&A6'/6&)) !%&6 $+L/6G 2P.

     '&A9AG&) /6 C+-P'&T& %= GA) ))T&-.

    026CT/+6 +0 T+TA' )&A' +/' ))T&-.  )&A' +/' 0'+!) AT 02''  M&+ )P&&D

     C%&C9 $&A/6G 1AP+2 &L%A2)T&).

      A'' T&-P&AT2& GA2G&)  A'A-).

     '/I2/D '&1&' A'A- )!/TC%&) &TC.

     C+6D/T/+6 +0 G+26D/6G $2)%&).

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    !ra"#$"es   RE!LIES TO %UERRIES B& BHEL IN '()

     $ased on = replies to "ueries following

    maintenance planning periods obtained3

     otor, )tator, Au#iliary systems and $earings < for each < ;B days

     %ydrogen shaft seals > days

     )haft insulation and earthing B days  $rush gear and slip rings = days

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    !ra"#$"es - 2

      RE!LIES TO %UERRIES B& BHEL IN '()

     2sual actiities3 )tator wedges tightness

    )tator core tightness, core flu# test

    %ydraulic tests on stator wdg.,coolers

    Purge tests on rotor and gastightness

    / on stator,rotor,bearing insulation Gas tightness test on complete m(c

    +CC  )CC after resynchroni*ation

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