Generator Testing Manual for Rotor & Exciter

Solicitation No. R13PS17115 Statement of Work for Unit G-2 Motor Driven Exciter Repairs

Table of Contents 1.0 Summary .............................................................................................................................. 2 2.0 Past Overhaul History of Exciter ......................................................................................... 2 3.0 Submittals ............................................................................................................................ 3 4.0 Scope of Work ..................................................................................................................... 3

4.1 Synchronous Drive Motor ................................................................................................ 3 4.2 Main Exciter ..................................................................................................................... 3 4.3 Pilot Exciter ...................................................................................................................... 5

5.0 Shipping/Transportation ...................................................................................................... 6 6.0 Insulating material ............................................................................................................... 6 7.0 Inspection ............................................................................................................................. 6 8.0 Completion Date .................................................................................................................. 7 Appendix A Test Forms .................................................................................................................. 8 Form 430-78 Exciter Motor Winding Test Data ............................................................................. 8 Form 430-79 Main Exciter Winding Data ...................................................................................... 9 Form 430-80 Pilot Exciter Winding Data ..................................................................................... 10 Form MMB-128 Main Exciter Rotor Runouts ............................................................................. 11

List of Figures Figure 1 Typical Main Exciter Nameplate ................................................................................... 12 Figure 2 Typical Pilot Exciter Nameplate ................................................................................... 12 Figure 3 Typical Synchronous Motor Nameplate ........................................................................ 13 Figure 4 Threading and Contamination on Main Exciter Commutator ....................................... 13 Figure 5 Side View of Exciter Set ............................................................................................... 14 Figure 6 Side View of Exciter Set ............................................................................................... 14 Figure 7 Pilot Exciter End ............................................................................................................ 15 Figure 8 Main Exciter End ........................................................................................................... 15 Figure 9 Main Exciter Direction of Rotation ............................................................................... 16 Figure 10 Synchronous Motor with Ten-foot Long Leads .......................................................... 16 Figure 11 Thomas and Betts Co. Deadbreak Plug End Connector on End of Ten-foot Long Motor Lead.................................................................................................................................... 17 Figure 12 Thomas and Betts Co. Deadbreak Plug End Connector on End of Ten-foot Long Motor Lead.................................................................................................................................... 17 Figure 13 Pilot Exciter shaft on End of Synchronous Motor Shaft ............................................. 19 Figure 14 Pilot Exciter Armature Mounted on Synchronous Motor Shaft .................................. 19 Figure 15 Wiring Diagram for Main Exciter ............................................................................... 20


1.0 Summary The contractor shall furnish all labor, equipment and materials to refurbish exciter unit for G-2 generator as outlined in this statement of work. Work includes preparing the exciter components for shipping at Grand Coulee Dam and at the contractor’s facility and shipping to and from contractor’s facility. The Government will disassemble and reassemble the exciter. Main exciter commutator shows signs of contamination of foreign residue and threading of commutator surface. Work includes machining/polishing of main exciter commutator; machining/polishing of pilot exciter commutator; complete clean, dip, bake and painting (insulating type) of exciter unit. Initial and final testing results are to be included with unit repairs along with contractor assessment/recommendations of initial and final results. G-2 exciter unit nameplate information:

Westinghouse Main Exciter- S/N 1S110P583 Pilot Exciter- S/N 2S8P356 Synchronous Drive Motor- S/N 1S8P357 400 kW 250 VDC 1600 Amps 900 RPM

10 kW 250 VDC 40 Amps 900 RPM

600 h.p. 6600 V 42 Amps 100% P.F. 60 cycles 900 RPM Exc. Amps. 17.2 Exc. Volts 250 VDC

Rotational Direction: Clockwise at the pilot exciter end when facing the exciter set 2.0 Past Overhaul History of Exciter In 2005, the following work was performed on the exciter:

• Pilot Exciter o Rewound shunt, series fields, and interpoles

• Synchronous Motor

o Straightened cooling fins o Polished journals o Turned and polished slip rings o Rewound with form wound coils

• Main Exciter

o Polished rotor journals o Banded over existing band and cured on armature o Reinsulated interpoles o Reinsulated pole face windings


3.0 Submittals 1. Short description of cleaning process, baking, and dip

process. Submit with proposal

2. Product data sheet for insulating varnish used for impregnation (dip) and insulating paint if any.

Submit with proposal

3. Brief outline schedule for work Provide estimated testing dates and shipping dates in outline schedule.

Submit with proposal

4.0 Scope of Work The following narrative provides work scope details to be completed for each component of the G-2 exciter assembly. 4.1 Synchronous Drive Motor

- Perform incoming visual inspection (armature, and field and frame).

- Perform Insulation Test -- as-found, after cleaning, and as–left (after sealing windings) and record on test data sheet 430-78:

Field winding Stator

- Clean unit to remove all contaminates. Bake to ensure moisture removal and dip to

renew insulation integrity of windings.

- After cleaning: o Perform Phase Comparison Test on Armature Coils. Attach hard copies of

waveforms to test form 430-78. Provide a tabulation of the results with a brief narrative description of the test results.

o Perform AC voltage drop test on field. Record on test from 430-78.

- If required, install new 10-feet long motor leads on synchronous motor: o Use 1 AWG stranded copper cable (210 strands x 24 AWG) UL Type AWM

Style 3499 rated for 7,500 V, 150 degree C, EDPM insulation o Install Thomas and Betts Corporation, Elastimold 15 kV/25kV 200 Amp

Deadbreak straight plug on end of cable, part number K151SP-W0X (W0X part of part number depends on wire stranding and insulation thickness).

4.2 Main Exciter

a. Main Exciter - Perform incoming visual inspection (armature, and field and frame).

- Perform Insulation Test- as-found, after cleaning, and as–left (after sealing windings)

and record on test data sheet 430-79


Rotor Interpole Coils Brush Rigging Main Shunt Field (F1 and F2) Differential Shunt Field (F3 and F4)

- Check and record journal and commutator runouts before machining commutator. If

journals are worn greater than 0.002 inch, notify the Government.

o After approval to proceed from the Government is obtained, metallic powder spray and machine to correct shaft diameter plus/minus 0.0005 inch.

- Record as-found measurements on test data sheet MMB-128. Make note of as-found

eccentricity on form MMB-128.

- Machine/grind commutator surface to concentricity with shaft bearing seats.

• Machine commutator for a runout of 0.001 inch maximum.

• Check the height of adjacent commutator bars to see if any bar-to-bar height variation exceeds 0.001 inch. If variations exceed 0.001 inch, then commutator grinding is required. Make note of bar-to-bar height variations before and after grinding.

• Undercut mica so that mica depth will be 1/16 inch plus/minus 1/64 inch after

machining.

• After any machining or grinding of commutator surfaces, clean and inspect all commutator slots. Depth gauge slots to assure that mica is undercut 0.0625; (1/16 inch) plus/minus 0.0156 inch (1/64 inch). Take remedial action if mica depth is not within these tolerances.

• Bevel the commutator edges at about 45 degree with a 1/32 inch chamfer for

medium thickness bars. For narrower or wider bars, change the chamfer accordingly.

Measure and record journal and commutator as-left runouts. Record as-left measurements on test data sheet MMB-128. Make note of as-left eccentricity on form MMB-128.


renew insulation integrity of windings. - After cleaning:

o Record ductor readings (bar-to-bar resistance) of the armature coils on a separate sheet and attach to test form.

o Perform Surge Comparison Test on Armature Coils. Attach hard copies of typical waveforms and abnormal waveforms (if found) to test form 430-79.


Provide a tabulation of the results with a brief narrative description of the test results.

o Perform both AC and DC voltage drop test on main shunt field, the differential shunt field and the commutating (interpole) fields. Record on test from 430-79.

- Check balance of rotor (armature). If balancing is required, notify the Government.

- Prior to shipping motor perform the insulation tests:

Rotor Interpole Coils and Pole Face Winding Brush Rigging Main Shunt Field (F1 and F2) Differential Shunt Field (F3 and F4)

4.3 Pilot Exciter

- Perform incoming visual inspection (armature, and field and frame)

- Perform Insulation Test-as-found, after cleaning, and as–left (after sealing windings) and record on Test Data Sheet 430-80:

Rotor Interpole Coils Brush Rigging Main Shunt (F5 and F6) Series Coils (S1 andS2)

- Machine/grind commutator surface to concentricity with shaft bearing seats.

• Machine commutator for a runout of 0.001 inch maximum.

• Check the height of adjacent commutator bars to see if any bar-to-bar height

variation exceeds 0.001 inch. If variations exceed 0.001 inch, then commutator grinding is required. Make note of bar-to-bar height variations before and after grinding.

• Undercut mica so that mica depth will be 1/16 inch plus/minus 1/64 inch after

machining.

• After any machining or grinding of commutator surfaces, clean and inspect all commutator slots. Depth gauge slots to assure that mica is undercut 0.0625; (1/16 inch) plus/minus 0.0156 inch (1/64 inch). Take remedial action if mica depth is not within these tolerances.

• Bevel the commutator edges at about 45 degree with a 1/32 inch chamfer for

medium thickness bars. For narrower or wider bars, change the chamfer accordingly.


Note: The pilot exciter fits on the end of the synchronous motor shaft. The Government will provide an arbor for the contractor to use to machine commutator surface.


renew insulation integrity of windings.

- After cleaning: o Record ductor readings (bar-to-bar resistance) of the armature coils on a

separate sheet and attach to test form 430-80. o Perform Surge Comparison Test on Armature Coils. Perform Surge

Comparison Test on Armature Coils. Attach hard copies of typical waveforms and abnormal waveforms (if found) to test form 430-80. Provide a tabulation of the results with a brief narrative description of the test results.

o Perform both AC and DC voltage drop test on field and the commutating (interpole) fields. Record on test from 430-80.

- Prior to shipping motor perform the insulation tests:

Rotor Interpole coils Brush rigging Main shunt field (F5 and F6) Series coils (S1 and S2)

5.0 Shipping/Transportation Upon work completion and testing, the contractor shall package components in such a manner as to prevent damage from weather and transportation hazards. Packaging methods must be adequate to ensure integral components susceptible to contaminates and damage are well protected to ensure product integrity upon final return to client location. 6.0 Insulating material The contractor shall submit a list of proposed material to be used for insulating varnish finish or paint at the time of proposal. Information should include product data sheets for materials to be used for various components and will be reviewed and approved by Government prior to start of work. 7.0 Inspection The Government reserves the right to witness testing and inspect the exciter components prior to shipping. The contractor shall provide two business days notice of expected testing times and provided the same for expected date of shipping.


8.0 Completion Date The contractor shall complete all work and deliver G-2 motor driven exciter to client location by December 21, 2012. 9.0 Informational Drawings: The drawing(s) are available by faxing 509-633-9175. Due to new security procedures at this location, you must fax your contact name, company name, physical address, phone and fax numbers, your e-mail address, Dun and Bradstreet (DUNS) number, and Federal Tax ID number (TIN) in order to obtain the drawing(s). 10. Questions: Direct all comments and questions regarding this scope of work to Peter Erie at 509-633-9230 ot fax to 509-633-9175, or by e-mail at [email protected]. all questions shall be submitted in writing and all vendors will receive a copy of all questions and answers. The attached Wage Determination No. 2005-2565, Rev. 12, dated 06/13/2012, Occupation Code 23430, Heavy Equipment Mechanic, shall form a part of any contract resulting from this solicitation.

Statement of Work for Unit G-2 Motor Driven Exciter Repairs Appendix A – Test Data Sheets

Form 430-78 (10/2006) Date Exciter Motor Winding Test Data W.O. P.O. Job#

UNIT G1-G6 EXCITER MOTOR WINDING TEST DATA

UNIT: G-2 Insulation Resistance (meggared). Test Instrument: _______________________ BRUSHES REMOVED As Found After Cleaned As Left ROTOR (field) Test Voltage: Field (disconnected

from rings) to shaft. Megohms Megohms Megohms Stator (armature) Test Votlage: Phase A to frame _______Megohms _______Megohms _______Megohms Phase B to frame _______Megohms _______Megohms _______Megohms Phase C to frame _______Megohms _______Megohms _______Megohms ARMATURE WINDING AFTER CLEANING Phase comparison tests: Attach separate sheet with photos for each phase and a narrative of test results. FIELD AFTER CLEANING Pole Drop Test _________amps @ _________VAC _____ - _____ - _____ - _____- _____ - _____ - _____ Total = ______volts Remarks:


Form 430-79 (3/89) Date Main Exciter Winding Data W.O. P.O. Job#

UNIT G-2 MAIN EXCITER

Insulation Resistance. Test Instrument_______________________ As Found As Left

Test Voltage: Rotor (armature) _______Megohms _______Megohms Stator (fields) Test Voltage Interpole Coils and Pole Face Winding _______Megohms _______Megohms Brush Rigging _______Megohms _______Megohms Main Shunt (F1 and F2) _______Megohms _______Megohms Diff. Shunt (F3 & F4) _______Megohms _______Megohms Armature Coils After Cleaning

Ductor (bar-to-bar resistance): Attach separate sheet with ductor readings.

Surge Comparison Tests: Attach separate sheet with photograph. Field Coils After Cleaning

Volt Drop Tests Interpoles, amps @ VAC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ - ___ -____ Total = ______volts Interpoles, amps @ VDC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ - ___ -____ Total = ______volts

Main Shunt (F1 - F2) amps @ VAC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ - ___ -____ Total = ______volts

Main Shunt (F1 - F2) amps @ VDC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ - ___ -____ Total = ______volts

Diff. Shunt (F3 - F4) amps@ VAC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ - ___ -____ Total = ______volts

Diff. Shunt (F3 - F4) amps@ VDC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ - ___ -____ Total = ______volts


Form 430-80 (3/89) Date Pilot Exciter Winding Data W.O.

P.O. Job#

UNIT G-2 PILOT EXCITER

Insulation Resistance. Test Instrument: _______________________

As Found As Left Test Voltage ROTOR (armature) _______Megohms _______Megohms Stator (fields) Test Voltage Interpole Coils _______Megohms _______Megohms Brush Rigging _______Megohms _______Megohms Main Shunt (F5 and F6) _______Megohms _______Megohms Series Coils(S1 & S2) _______Megohms _______Megohms Armature Coils After Cleaning

Ductor (bar-to-bar resistance): Attach separate sheet with ductor readings.

Surge Comparison Tests: Attach separate sheet with photograph. Field Coils After Cleaning

Volt Drop Tests

Interpoles, amps @ VAC ____ - ____ - ____ - ____ - ____ - ____ - ____ - ____

Total = ______volts

Interpoles, amps @ VDC ____ - ____ - ____ - ____ - ____ - ____ - ____ - ____

Total = ______volts

Main Shunt (F1 - F2) amps @ VAC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ Total = ______volts Main Shunt (F1 - F2) amps @ VDC

____ - ____ - ____ - ____ - ____ - ____ - ____ - ____ Total = ______volts

Remarks:


Stateme

Figure

Figure

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1 Typical

2 Typical

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Figure

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Stateme

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Note: T

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5 Side Vie

6 Side Vie

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Main Exciter

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Figure

Figure

ent of Work

7 Pilot Ex

8 Main Ex

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xciter End

xciter End

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R

G-2 Motor D

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Driven Excit

ter Repairs

Statement of Work for Unit G-2 Motor Driven Exciter Repairs

Figure 9 Main Exciter Direction of Rotation

Figure 10 Synchronous Motor with Ten-foot Long Leads


Figure 11 Thomas and Betts Co. Deadbreak Plug End Connector on End of Ten-foot Long Motor Lead

Figure 12 Thomas and Betts Co. Deadbreak Plug End Connector on End of Ten-foot Long Motor Lead


Stateme

Figure

Figure

ent of Work

13 Pilot E

14 Pilot E

k for Unit G

Exciter shaf

Exciter Arm

G-2 Motor D

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s Motor Shhaft


Figure 15 Wiring Diagram for Main Exciter

Documents

Generator Testing Manual for Rotor & Exciter