Excellence in Product Support
Caterpillar Confidential: Yellow
2011 TC ConferenceLafayette, IN
Generator Maintenance
Speaker:Aaron Kempf
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2011 TC ConferenceLafayette, INElectric
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Overview Shipping Maintenance Startup Maintenance Regular, Periodic and Annual Maintenance Monitoring Recommendations Insulation Test Recommendations Bearing Temperature Guidelines Bearing Replacement Stator Temperature Guidelines Vibration Measuring Guidelines Important Updates Maintenance Literature
Agenda
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Overview Scheduled Maintenance
Who: Customers and Dealers! CAT Warranty Statement states that the User is responsible for
performance of the required maintenance. What: Applications
All Applications (Standby, Prime, Continuous, etc.) Where:
Onsite, before/during/after Storage, before/after Shipping When: Product Life
Shipping, Storage, Start-up, Regularly, Periodically, Annually How: Procedures
Cleaning, Drying, Storage, Insulation Resistance, Alignment, Vibration, Bearing Greasing, Bearing Temperature Monitoring, Stator Temperature Monitoring, Controls and Protection Settings
Why: Publications (OMMs and SOTAs for SR4,SR4B, and SR5) SENR5359, SEBU6918, SEBU7270, SENR7968, KENR5284
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What happens when shipping maintenance is not effective?
Generator Maintenance - Shipping
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Packaging Proper generator set cover protection needs to be in place for the
environment generator set is being shipped in. Handling
Proper lifting of generator sets using lifting eyes and fixtures. Refer to respective OMM for more information.
Shipping damages cant be claimed as warranty. These damages should be claimed through the shipping/freight company.
Example of generator foot damage from shipping
Example of grease deterioration after improper shipping and storage
Generator Maintenance - Shipping
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REFERENCE:SEHS9031 Storage
Procedure for Caterpillar
Products
Generator Maintenance - StorageBelow are some photos of adequate and inadequate storage practices.In these examples, the generators/sets should be properly covered from the elements when stored.
BAD
BADBETTER
BEST
Tight wrapping is good for shipping and short storage times. If longer storage is required, make sure to cover the package loosely.
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Dry Location Cover for protection Loose to allow generator to breathe
Turn rotor ten (10) revolutions every sixty (60) days Maintain winding temperature
At least 5 C higher than the ambient temperature Space heater
Insulation test (reference SEHS9124) Insulation test must be done when generator is
received Insulation test must be repeated prior to start-up.
Generator Maintenance - StorageMake sure to complete when package is not installed and
there is no intention of installing in the near future.
Make every effort to complete when package is in storage
and make sure to complete when package is being installed or is installed and not running (i.e.,
standby).
Example taken from SEBD0660 showing condensation inside
the generator.Example of hot spot created on bearing race
after long storage period without rotor turning.
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Generator Maintenance - Start-up Before applying battery and shore power voltage to the Generator Set
Inspect generator for debris, foreign objects, leaks and loose
connections, broken fittings, rubbing or damaged wiring, guards and
components. Repair as necessary.
i.e., Lead chaffing from generator stator to bus.
Check for proper grounding.
(Reference REHS4634)
Check space heaters for proper operation.
Example of loose PMG bolts, not noted before startup
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Generator Maintenance - Start-up System check prior to Generator Set operation
Must DOCUMENT data on each for future reference Alignment (LEBW4975, SEHS7654, SEHS7259, SEHS7073, REHS0177). Air gap (main generator, exciter, & PMG) even around circumference Insulation test (Reference SEHS9124) Measure Generator winding resistances
(SENR5359 for SR4B, KENR5284 for SR5) Main Stator/Rotor, Exciter Stator/Rotor, PM Stator/Rotor Compensate readings for temperature and use micro-ohmmeter Record for trend plotting!
Coordination of settings Generator control and protective settings Factory default settings 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.
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Generator Maintenance - Start-up System check when Generator Set is running
Must DOCUMENT data on each for future reference Record the following at No Load and Full Load
Bearing temperature (per respective OMM) Stator temperature (per respective OMM) Air inlet temperature (and at areas where air recirculation could exist)
Confirm no air recirculation is occurring Refer to TMI generator information and generator nameplate
Vibration levels (Reference A&I Guide LEBW4972) Voltage regulator & excitation system
Sensing voltage Excitation voltage and current (refer to TMI generator information)
Determined by Load and Power Factor
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Generator Maintenance - Start-up After stopping the Generator Set
Inspect the generator and report malfunctions.
Inspect for loose, broken, rubbing or damaged wiring or
components.
Make repairs or adjustments to the generator set as necessary.
Check that generator air inlet filter is clean, if applicable.
Verify generator space heater is operating.
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Generator Maintenance - Regular
During Generator Set operation
Must 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 (when applicable)
Monitor for Alarm and Shutdown Indicators
Check that generator air inlet filter is clean, if applicable.
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Generator Maintenance - Periodic After stopping the Generator Set for periodic maintenance
Periodic Maintenance time interval is based on Application
Reference respective OMMs
Must DOCUMENT and TREND data on each for future reference
Inspect generator for debris, foreign objects, leaks and loose connections, broken fittings, rubbing or damaged wiring, guards and components. Repair as necessary.
Inspect Main Stator & Rotor, Exciter, and PMG Clean as needed (Moisture, Salt, Dirt, Grease, Oil)
Reference SEHS9124 for Generator Cleaning and Drying
Check space heaters for proper operation.
Check Air Gap (main generator, exciter, & PMG)
Insulation Test (SEHS9124)
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Generator Maintenance - Annual After Stopping The Generator Set
Must DOCUMENT and TREND data on each for future reference Complete Periodic Maintenance Procedures Alignment (LEBW4975, SEHS7654, SEHS7259, SEHS7073, REHS0177). Measure Generator Winding resistances (SENR5359 for SR4B, KENR5284 for
SR5) Main Stator/Rotor, Exciter Stator/Rotor, PM Stator/Rotor
Vibration Levels (LEBW4972) Generator Bearings and Wear Sleeves
Grease Bearing(s) as required Refer to REHS4892 for greasing requirements Avoid over-greasing/mixing greases and use correct grease
Check for good integrity of lip seal Inspect and clean all main current carrying mechanical contacts such as
circuit breakers and transfer switches
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Generator Maintenance - Monitoring Recommendations
Trending
Understand the monitored process
Normalized readings For all resistance readings, correct for temperature
Refer to SEHS9124
Record on chart
Focus on changes occurring over time
Scheduled repairs instead of unplanned downtime
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Generator Maintenance - Monitoring Recommendations
Source: Graph taken and formatted from Stitch in Time (Megger, 2006)
Shown above is an example of regular insulation trending and the result of not acting ahead of time.
Time to schedule downtime and repair of the generator.
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Generator Maintenance - Insulation Test Recommendations(References: OMM & SEHS9124)
When to Test Safety Testing Process Prepare for the Test Insulation Resistance Test
Perform the standard 30/60sec test at a minimum Polarization Index Test
Perform when unit is in storage and/or moist environment.
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Generator Maintenance - Bearing Temperature Guidelines
Bearing Temperature Set-points All Applications Alarm 85 C Shutdown 95 C
Exceptions exist in specific SR5 product using synthetic grease. For 1800/3000 frame, set-points are:
Alarm 95 C Shutdown 105 C
Temperature is affected by ambient but max settings are not! Generators shipped with Platinum 100 ohm RTDs
Packages can be ordered with bearing RTDs RTDs are 2-wire
Track and investigate any change from historical trend
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Generator Maintenance - Bearing Replacement Removing Hub and Bearings
When applicable, heat front drive hub evenly with two (2) rosebud torches with propylene gas and puller or use destructive method (ie. cutting tool, etc.) to remove hub with care not to damage rotor shaft.
Heat should be applied to the hub for approximately 5-6 minutes.Do not attempt to heat hub with one (1) torch, and forcibly pull off shaft. Puller and ram drive should be capable of supplying at least 35 tons of force.
Refer to respective SOTA manual for further bearing removal instructions using specified tools.
Installing Hub and Bearings Use an induction heater, etc. to heat the ball bearings to recommended temperature and mount to the shaft. When applicable, evenly heat the drive hub to specified temperature and mount the hub to the shaft.
Reference respective generator SOTA manual for more bearing installation and removal information.
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Generator Maintenance - Stator Temperature Guidelines Stator Temperature Set-Points
Alarm 180 C, Shutdown 190 C (Standby) Alarm 155 C, Shutdown 165 C (Prime/Continuous)
Exceptions exist for SR5 product Alarm 200 C, Shutdown 215 C, (Standby) Alarm 175 C, Shutdown 200 C, (Prime/Continuous)
Based on NEMA standards, it is recommended to stay below the alarm set-points to prevent winding deterioration.
Generators with Form Wound Stators shipped with Platinum 100 ohm RTDs Random Wound Packages can be ordered with stator RTDs RTDs are 3-wire for compensation accuracy
Track and Investigate any Change from historical trend Output Limited by Rotor or Stator Temp. Temp. Rise Function of Generator Output Measurement Method
Embedded Detector Rise by Resistance The standard, must add hot spot allowance
Refer to IEEE 112-1996 (Section 8.3.3)
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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
To accurately compare to factory guidelines per LEBW4972, vibration tool used must be factory approved.
Alternate tools can be used for site-specific trending purposes, but comparison to factory guidelines cannot be relied upon.
New factory tool is currently being validated to replace the previously available CSI Vibration Analyzer Tool.
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SEHS9124 Generator Cleaning and Drying
Existing document updated to improve wording and emphasize Polarization Index (PI) test for testing generators in storage and/or moist environments.
REHS4892 Generator Bearing Service
Special Instruction published in early 2010 to update the latest bearing maintenance recommendations.
Single and Double-shielded bearings are recommended for greasing at prescribed intervals. Research has shown grease does penetrate the shield when the bearing bracket cavity is 50% full.
Bearing Change for 1800/3000 SR5 Generators In late 2011, these generators will be packaged with greaseable (2S-3230
grease) single-shielded bearings in place of non-greaseable synthetic grease double-shielded bearings.
This allows the end-user to add new grease as the grease breaks down over time.
Generator Maintenance Important Updates
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Generator Maintenance - Literature
SEBD9205 Proper Storage of Generators SEHS9031 Storage Procedures for Caterpillar Products SEHS9124 Cleaning and Drying of Generators LEXE0095 Electric Power Start-up Checklist LEBW4975 Alignment A&I Guide SEHS7654 Alignment - General Instructions SEHS7259 Alignment of Single Bearing Generators SEHS7073 Alignment of Two Bearing Generators REHS0177 Alignment of Two Bearing Close-Coupled Generators LEBW4972 Linear Vibration A&I Guide SEBU7270 SR4/SR4B High Voltage OMM SEBU6042 Maintenance for Standby Gensets
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Generator Maintenance Literature, cont.
SEBU6918 SR4B Generator OMM SENR7968 SR4 Generator SOTA Manual KENR5284 SR5 Generator SOTA Manual SENR5359 SR4B Generator Service Manual SENR5833 Digital Voltage Regulator Service Manual RENR2480 VR6 Service Manual RENR7941 CDVR Service Manual REHS4892 Generator Bearing Service REHS4634 Grounding Design Guide for EPG Products