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EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007 Generator Maintenance The CAT Warranty Statement states that the User is responsible for Performance of the required Maintenance. Here is a Factory Review of the required Maintenance for Generators
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Page 1: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Generator MaintenanceThe CAT Warranty Statement states that the User

is responsible for Performance of the required Maintenance.

Here is a Factory Review of the required Maintenance for Generators

Page 2: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20072

GENERATOR MAINTENANCE AGENDA• Scheduled Maintenance

– What: Applications• Standby, Prime, or Continuous Applications

– When: Product Life• Shipping, Storage, Start-up, Regularly, Periodically,

Annually– How: Procedures

• Cleaning, Drying, Insulation Resistance, Alignment, Vibration, Bearing Greasing, Bearing Temperature Monitoring, Stator Temperature Monitoring, Controls and Protection Settings

– Why: Publications• SENR 5359, SEBD 9208, SEBU6918, SEBU7270

Page 3: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20073

Generator Shipping Maintenance

• What happens when Shipping maintenance is not effective…

Page 4: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20074

Generator Shipping Maintenance

• Packaging– Proper generator set cover protection needs to be in place for

environment generator set is being shipped in• Handling

– Proper Lifting of generator sets using lifting eyes and fixtures• Shipping damages can’t be claimed as a warranty.

Example of shipping damage Example of grease

deterioration after improper shipping and storage

Page 5: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20075

Generator Storage Maintenance

Examples of inadequate storage practice…no cover from elements and no evidence of space heater connection

REFERENCE SEHS9031-4Proper Generator Set Storage Procedures

Page 6: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20076

Generator Storage Maintenance

• Maintain Winding Temperature – At least 5 °C Higher Than the Ambient Temperature– Space Heater

• Insulation Test – (LEBQ 4823)– Insulation test must be done when generator is received – Insulation test must be repeated prior to start-up.

• Dry Location– Cover for Protection– Loose to Allow Generator to Breathe

• Turn Rotor 10 Revolutions Every 60 Days

Example of hot spot created on bearing race after long storage

period

Page 7: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20077

Generator Start-up Maintenance

• Before Applying Battery and Shore Power Voltage to the Generator Set– Inspect generator for debris, foreign objects, leaks and loose

connections, broken fittings, guards and components. Repair asnecessary.

– Check battery charger for proper operation.– Check and clean the battery. Maintain electrolyte level, check for loose

connections.– Visual inspection, check for loose, broken, rubbing or damaged wiring

or components.– Check for Proper Grounding– Check space heaters for proper operation.

Example of loose PMG bolts, not noted before cranking

Page 8: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20078

Generator Start-up Maintenance

• System Check Prior to Generator Set Operation –Must DOCUMENT data on each for future reference

– Alignment (SEHS 7654, SEHS 7259, SEHS 7073).

– Air Gap (main generator, exciter, & PMG) approx 10 mils even around circumference

– Insulation Test – (LEBQ 4823)– Measure Generator Winding resistances (SENR5359)

• Main Stator/Rotor, Exciter Stator/Rotor, PM Stator/Rotor• Compensate readings for temperature• Record for trend plotting!

– Coordination of Settings – Generator Control and Protective Settings• Factory default settings is not applicable to every application• Dealer and/or third party consultant is responsible for Coordination study at

each site› Circuit Breaker› ECM, EMCP, and CDVR, Droop (KW and KVAR)› Differential Protection, Reverse KVAR Protection, etc.

Page 9: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 20079

Generator Start-up Maintenance

• System Check when Generator Set is RunningMust DOCUMENT data on each for future reference– Record the Following (SEBD 9207) @ No Load and Full Load

• Bearing Temperature • Stator Temperature • Air Inlet Temperature (and at areas where air recirculation could exist)

› Confirm no air recirculation is occurring• Vibration Levels (LEKQ 4023)• Voltage Regulator & Excitation System

› Sensing voltage› Excitation voltage and current

» Determined by Load and Power Factor

Page 10: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200710

Generator Start-up Maintenance

• After Stopping The Generator Set– Inspect the generator and report malfunctions. Make repairs or

adjustments to the generator set as necessary.– Check that all switches are in proper position to execute AUTO start.– Record battery charging amperage reading.– Check that generator air inlet filter is clean.– Verify Generator Space Heater is operating – Visual inspection, check for loose, broken, rubbing or damaged wiring or

components.

Page 11: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200711

Generator Regular Maintenance

• During Generator Set OperationMust DOCUMENT and TREND data on each for future reference– Monitor Phase Current, Neutral Current, Voltage, Frequency, Power

Factor, Harmonic Content, and Load variation– Monitor Room Temperatures– Monitor Bearing and Stator temperatures – Monitor for Alarm and Shutdown Indicators– Check that generator air inlet filter is clean.

Page 12: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200712

Generator Periodic Maintenance

• After Stopping The Generator Set for periodic maintenance– Periodic Maintenance time interval is based on Application

SEBD9207, SEBU6042Must DOCUMENT and TREND data on each for future reference– Inspect generator for debris, foreign objects, leaks and loose connections,

broken fittings, guards and components. Repair as necessary.• Inspect Main Stator & Rotor, Exciter, and PMG

› Clean as needed (Moisture, Salt, Dirt, Grease, Oil)– Check battery charger for proper operation.– Check and clean the battery. Maintain electrolyte level, check for loose

connections.– Visual inspection, check for loose, broken, rubbing or damaged wiring or

components.– Check space heaters for proper operation.

– Check Air Gap (main generator, exciter, & PMG) approx 10 mils – Insulation Test - LEBQ 4823)

Page 13: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200713

Generator Annual Maintenance

• After Stopping The Generator SetMust DOCUMENT and TREND data on each for future reference– Complete Periodic Maintenance Procedures

– Alignment (SEHS 7650, SEHS 7259, SEHS 7073)– Measure Generator Winding resistances (SENR5359)

• Main Stator/Rotor, Exciter Stator/Rotor, PM Stator/Rotor

– Vibration Levels (LEKQ 4023)– Check Generator Bearings and Wear Sleeves

• Greasing per Bearing Maintenance Plate on Generator› Avoid Over-greasing and Use Correct Grease

• Double-Shielded Ball Bearing – 2000 hrs, 2S-3230 Grease• Single-Shielded Ball Bearing – 2000 hrs, 2S-3230 Grease• Roller Bearings – 1000 hrs, 108-8611 Grease• Cylindrical Bearings – 2000 hrs, 100-2704 Grease

– Inspect and Clean all main current carrying mechanical contacts such as Circuit Breakers and Transfer Switches

Page 14: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200714

Generator Maintenance Monitoring Recommendations

• Trending– Understand the Monitored Process– Normalized Readings– Record on Chart– Focus on Changes Occurring Over Time– Scheduled Repairs Instead of Unplanned Downtime

Page 15: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200715

Generator Maintenance Insulation Test Recommendations

• When to Test• Safety• Testing Process• Prepare for the Test• Insulation Resistance Test• Polarization Index Test• Step Voltage Test• Dielectric Discharge Test

Page 16: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200716

Generator Maintenance Bearing Temperature Guidelines

• Bearing Temperature Set-points – Standby and Continuous Applications– Alarm 85 °C– Shutdown 95 °C

• Temperature is affected by ambient but max settings are not!• Set-points at lower values if possible…+15°C over highest operating temperature• Generators shipped with Platinum 100 ohm RTDs

– Packages with EMCP3 have embedded monitoring of RTDs– Packages with EMCP2 have RTDs wired to terminal block– RTDs are 3-wire for compensation accuracy

• Track and Investigate any Change from historical trend

Page 17: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200717

Generator Maintenance Bearing Replacement

• Removing Bearings– Heat Hub and Bearings evenly with three rosebud torches or use saw to cut hub and bearings with care not to damage rotor shaft.

Do not attempt to heat hub and bearings with one torch, and forcibly pull off shaft…damage to the shaft will result.

• Installing Bearings– Use an induction heater to heat the ball bearings to 107 °C for ten minutes and mount to the shaft. – Heat the hub to 400 °C for three hours and mount the to the shaft.

Page 18: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200718

Generator Maintenance Stator Temperature Guidelines

• Stator Temperature Set-Points – Standby– Alarm 180 °C, Shutdown 190 °C

• Stator Temperature Set-Points – Continuous– Alarm 155 °C, Shutdown 180 °C

• Class H Stator Insulation rated 150 °C + 40 °C Ambient Rise• Set-points at lower values if possible…+10°C over highest operating temperature• Generators with Form Wound Stators shipped with Platinum 100 ohm RTDs

– Packages with EMCP3 have embedded monitoring of RTDs– Packages with EMCP2 have RTDs wired to terminal block– RTDs are 3-wire for compensation accuracy

• Track and Investigate any Change from historical trend (Delta Pub)• Output Limited by Rotor or Stator Temp.• Temp. Rise Function of Generator Output• Measurement Method

– Rise by Resistance ���� The standard, must add hot spot allowance– Embedded Detector

Page 19: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200719

Generator Maintenance Vibration Measuring Guidelines

• Measure on Package at Normal Operating Temperature• Use Monthly Readings to Establish Baseline• Vibration Levels Are Load Dependent• Investigate Significant Changes

– New Frequencies Showing up– Increasing Amplitudes of Original Frequencies

Page 20: Generator Maintenance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 200720

Generator Maintenance Literature

• LEBQ 4823 Electrical Insulation Testing• SEBD 9205 Proper Storage of Generators• SEHS 9124 Cleaning and Drying of Generators• REHS 0064 Generator Set Start-up Checklist• SEHS 7654 Alignment - General Instructions• SEHS 7259 Alignment of Single Bearing Generators• SEHS 7073 Alignment of Two Bearing Generators• LEKQ 4023 Linear Vibration• SEBU 7270 SR4/SR4B High Voltage OMM• SEBU 6042 Maintenance for Standby Generator Sets• SEBD 9207 Generator Maintenance Schedule Additions

• SENR 5359 SR4B Generator Service Manual• SENR 5833 Digital Voltage Regulator Service Manual

• RENR 7941 CDVR Manual• SENR 8319 SR4B Generator Rewind Data,