Turbo Generators

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Turbogenerator S Line Installation, Operation and Maintenance Manual

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Installation, Operation and Maintenance Manual Document No.: 9300.0050 Model: Line S Turbogenerator Material: 10174576 Language: English Revision 0 July 2008 Line S Turbogenerator

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February 2008

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Dear Customer

Thank you for purchasing a WEG generator. It is a product developed with high levels of quality and efficiency to ensure excellent performance. Electric energy plays an outstanding role in the comfort and well-being of humankind. Being responsible for the production of this energy, the electric generator needs to be identified and treated as a machine whose characteristics demand special care, particularly with regard to storage, installation and maintenance procedures. All efforts have been made to ensure that the information contained in this manual can be reliably used for setting up and running the WEG generator. So please read this manual carefully before the installation, operation or maintenance of your generator for a continuous and safe operation and to ensure that all measures have been taken for your safety and the safety of your facilities. If any doubts persist, please contact WEG. Keep this manual always close to the generator for prompt reference when required. ATTENTION 1. It is absolutely necessary to follow the procedures contained in this manual for the warranty to be valid. 2. The generator installation, operation and maintenance must be executed by qualified personnel.

NOTES 1. The total or partial reproduction of the information supplied in this manual is authorized, provided that reference is made to its source; 2. If this manual is lost, an electronic PDF file is available from our website www.weg.net or another printed copy can be requested.

WEG EQUIPAMENTOS ELÉTRICOS S.A.

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CONTENTS 1

INTRODUCTION.........................................................................................................................................9

2

GENERAL INSTRUCTIONS.....................................................................................................................10 2.1 QUALIFIED PERSONNEL ....................................................................................................................................... 10 2.2 SAFETY INSTRUCTIONS........................................................................................................................................10

3

OPERATING CONDITIONS AND STANDARDS.....................................................................................11 3.1 STANDARDS............................................................................................................................................................ 11 3.2 ENVIRONMENT CHARACTERISTICS................................................................................................................... 11 3.3 OPERATING CONDITIONS .................................................................................................................................... 11

4

RECEIVING AND STORAGE...................................................................................................................12 4.1 RECEIVING............................................................................................................................................................... 12 4.2 STORAGE................................................................................................................................................................. 12 4.2.1 4.2.2

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Indoor storage ....................................................................................................................................12 Outside storage ..................................................................................................................................12

LONG STORAGE PERIODS....................................................................................................................13 5.1 INTRODUCTION ...................................................................................................................................................... 13 5.2 GENERAL................................................................................................................................................................. 13 5.3 STORAGE LOCATION ............................................................................................................................................ 13 5.3.1 5.3.2

5.4 5.5 5.6 5.7 5.8

SEPARATE PARTS.................................................................................................................................................. 14 SPACE HEATER...................................................................................................................................................... 14 INSULATION RESISTANCE.................................................................................................................................... 14 EXPOSED MACHINED SURFACES ......................................................................................................................14 ROLLING BEARINGS.............................................................................................................................................. 14 5.8.1 5.8.2 5.8.3

5.9 5.10

Grease-lubricated bearing...................................................................................................................14 Oil-lubricated bearing..........................................................................................................................14 Sleeve Bearing....................................................................................................................................14

TERMINAL BOX....................................................................................................................................................... 15 PREPARATION FOR OPERATION AFTER LONG STORAGE ............................................................................ 15 5.10.1 5.10.2 5.10.3 5.10.4

5.11 5.12

Indoor storage ....................................................................................................................................13 Outdoor storage .................................................................................................................................13

Cleaning .............................................................................................................................................15 Bearing lubrication ..............................................................................................................................15 Checking the insulation resistance ......................................................................................................15 Others ................................................................................................................................................15

INSPECTIONS AND RECORDS DURING THE STORAGE .................................................................................15 MAINTENANCE PLAN TO BE FOLLOWED DURING THE STORAGE ..............................................................16

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HANDLING ...............................................................................................................................................17

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INSULATION RESISTANCE ....................................................................................................................18 7.1 SAFETY INSTRUCTIONS........................................................................................................................................18 7.2 GENERAL REMARKS ............................................................................................................................................. 18 7.3 STATOR WINDING MEASUREMENT.................................................................................................................... 18 7.4 MEASUREMENT OF THE ROTOR WINDING RESISTANCE, EXCITER WINDING RESISTANCE AND ACCESSORIES..................................................................................................................................................................... 18 7.5 CONVERSION OF THE MEASURED VALUES.....................................................................................................19 7.6 MINIMUM INSULATION RESISTANCE..................................................................................................................19 7.7 POLARIZATION INDEX............................................................................................................................................ 19

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CONSTRUCTION CHARACTERISTICS..................................................................................................20 8.1 STATOR.................................................................................................................................................................... 20 8.2 ROTOR ..................................................................................................................................................................... 20 8.3 EXCITER ................................................................................................................................................................... 20 Line S Turbogenerator

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8.4 8.5 8.6 8.7 9

PERMANENT MAGNET GENERATOR (PMG)......................................................................................................20 DUMPING WINDING ...............................................................................................................................................20 BEARINGS................................................................................................................................................................20 HEAT EXCHANGER ................................................................................................................................................20

OPERATION PRINCIPLE ........................................................................................................................ 21 9.1 EXCITATION .............................................................................................................................................................21 9.2 DEEXCITATION........................................................................................................................................................21 9.3 VOLTAGE REGULATOR.........................................................................................................................................22 9.4 UNDERFREQUENCY (U/F) PROTECTION............................................................................................................22

10 INSTALLATION ....................................................................................................................................... 23 10.1 INSTALLATION SITE................................................................................................................................................23 10.2 PROTECTIONS........................................................................................................................................................23 10.3 DIRECTION OF ROTATION ...................................................................................................................................23 10.4 FOUNDATIONS........................................................................................................................................................23 10.5 ANCHOR PLATE SET .............................................................................................................................................24 10.6 ALIGNMENT / LEVELING........................................................................................................................................25 10.7 COUPLING ...............................................................................................................................................................25 10.8 ELECTRICAL AND GROUNDING CONNECTIONS .............................................................................................27 10.8.1 Main stator connections (power cables).............................................................................................. 27 10.8.2 Grounding.......................................................................................................................................... 27 10.8.3 Accessories ....................................................................................................................................... 27

10.9

THERMAL PROTECTIONS.....................................................................................................................................27 10.9.1 10.9.2 10.9.3 10.9.4 10.9.5 10.9.6 10.9.7

Protection location ............................................................................................................................. 27 Temperature sensors ......................................................................................................................... 27 Temperature limits for the windings .................................................................................................... 27 Thermal bearing protections............................................................................................................... 28 Alarm and disconnection temperatures .............................................................................................. 28 Ratio between temperature and the ohmic resistance of Pt 100 temperature sensors......................... 28 Space heater ..................................................................................................................................... 29

10.10 PANEL PROTECTIONS...........................................................................................................................................29 10.11 GENERATOR COOLING.........................................................................................................................................29 10.12 WATER RADIATORS...............................................................................................................................................30 11 ELECTRICAL CONNECTIONS AND ACCESSORIES ........................................................................... 31 11.1 TERMINAL MARKINGS...........................................................................................................................................31 11.2 WIRING DIAGRAMS................................................................................................................................................31 11.2.1 11.2.2 11.2.3 11.2.4

11.3 11.4

Thermal protection on main stator winding ......................................................................................... 32 Generator cooling system .................................................................................................................. 33 Bearings ............................................................................................................................................ 34 Space heater and exciter ................................................................................................................... 35

DESCRIPTION OF THE ACCESSORY FUNCTION..............................................................................................35 ACCESSORIES AND PROTECTIONS...................................................................................................................36

12 START-UP................................................................................................................................................ 37 12.1 BEFORE FIRST START-UP.....................................................................................................................................37 12.2 INITIAL MECHANICAL TURN .................................................................................................................................37 12.3 POWERING-UP .......................................................................................................................................................37 12.4 SYNCHRONIZATION AND LOAD..........................................................................................................................37 13 GENERATOR OPERATION .................................................................................................................... 38 13.1 SHAFT LIFTING SYSTEM (JACKING) ....................................................................................................................38 13.2 WATER RADIATORS...............................................................................................................................................38 13.3 BEARINGS................................................................................................................................................................38 13.4 VIBRATION LIMITS ..................................................................................................................................................38 13.5 SHAFT VIBRATION LIMITS .....................................................................................................................................38 13.6 STOP 39 14 MAINTENANCE ....................................................................................................................................... 40 14.1 GENERAL.................................................................................................................................................................40 14.2 GENERATOR CLEANING.......................................................................................................................................40 6

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14.3 14.4 14.5 14.6

STATOR, ROTOR AND EXCITER WINDING INSPECTIONS............................................................................... 40 WINDINGS CLEANING ........................................................................................................................................... 40 INSPECTION AND CLEANING OF RADIATORS.................................................................................................41 GENERATOR OUT OF SERVICE ...........................................................................................................................41

15 BEARINGS ...............................................................................................................................................42 15.1 SLEEVE BEARINGS ................................................................................................................................................ 42 15.1.1 15.1.2 15.1.3 15.1.4 15.1.5 15.1.6 15.1.7 15.1.8

15.2

Bearing connections ...........................................................................................................................42 Bearings data .....................................................................................................................................42 Bearings installation and operation......................................................................................................42 Hydrostatic jacking system .................................................................................................................42 Setting of the bearing protections .......................................................................................................42 Lubrication..........................................................................................................................................42 Sealing ...............................................................................................................................................43 Bearing maintenance ..........................................................................................................................43

OIL BEARINGS......................................................................................................................................................... 43 15.2.1 Lubrication guidelines .........................................................................................................................43 15.2.2 Bearing operations..............................................................................................................................43 15.2.3 Protection device settings ...................................................................................................................43

15.3

GREASE BEARINGS...............................................................................................................................................44 15.3.1 15.3.2 15.3.3 15.3.4 15.3.5

Lubrication guidelines .........................................................................................................................44 Steps for bearing re-lubrication ...........................................................................................................44 Spring device for grease removal ........................................................................................................44 Protection settings ..............................................................................................................................44 Bearing replacement...........................................................................................................................45

16 EXCITER...................................................................................................................................................46 16.1 EXCITER ................................................................................................................................................................... 46 16.2 DIODES TEST .......................................................................................................................................................... 46 16.3 DIODES REPLACEMENT ....................................................................................................................................... 47 16.4 VARISTORS TEST ................................................................................................................................................... 47 16.5 VARISTORS REPLACEMENT ................................................................................................................................ 47 17 GENERATOR PARTS ..............................................................................................................................48 18 MAINTENANCE SCHEDULE...................................................................................................................49 19 TROUBLESHOOTING..............................................................................................................................50 20 ACCESSORIES AND SPARE PARTS.....................................................................................................52 21 DOCUMENTS ...........................................................................................................................................53 22 WARRANTY CONDITIONS OF ENGINEERED PRODUCTS .................................................................54 23 REPAIR SHOPS .......................................................................................................................................55

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INTRODUCTION

THE TURBOGENERATOR The turbogenerator is a machine that operates as an electric power generator when its shaft is driven by a turbine. THE THERMAL ELECTRIC POWER GENERATION PROCESS The fuel is burned in a boiler. The boiler heats a water volume, which changes into steam. The steam drives the turbine rotor that turns the generator shaft. The electromagnetic action inside the generator generates electric power that is supplied to the consumer network. TERMINOLOGY

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S GENERATOR LINE S Line

EXCITATION TYPE P - Brushless with auxiliary exciter S - Brushless without auxiliary exciter

COOLING SYSTEM W - Air-water heat exchanger A – Open, self-ventilated D - Self-ventilated by ducts, air inlet and outlet T - Forced ventilation, air inlet and outlet by ducts V - Forced ventilation, ventilation on the generator F - Self-ventilated with air-to-air heat exchanger on top of generator I - Forced ventilation in the internal and external air circuit, air-to-air heat exchanger L - Air-to-water heat exchanger, forced ventilation in the internal air circuit

IEC FRAME SIZE Shaft-end height in mm (450 to 5000)

SAFETY WARNINGS IN THE MANUAL Following safety warnings are used in this manual:

DANGER The noncompliance with the procedures recommended in this warning may result in death, serious injuries and considerable material damages.

ATTENTION The noncompliance with the procedures recommended in this warning may result in material damages.

NOTE The purpose of this text is to supply important information for the correct and good performance of this product.

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GENERAL INSTRUCTIONS 2.2

SAFETY INSTRUCTIONS

ATTENTION All the procedures and rules contained in this manual must be followed accordingly to ensure the good operation of the equipment and safety of the personnel involved in its operation. The compliance with these procedures is equally important to ensure the application of the warranty terms on the back cover of this manual. We strongly recommend a detailed reading of this manual before the generator installation and operation. However, in case any doubt persists, please contact your nearest WEG representative.

For practical reasons, it is impossible to supply in this manual all the details regarding possible construction alternatives. In addition, it is impossible to consider all the imaginable cases of operation or maintenance. For this reason, this manual contains only the required information so that qualified and trained personnel may perform the required services.

2.1

QUALIFIED PERSONNEL

People who, because of their education, experience, instruction and knowledge of applicable standards and safety procedures about the corresponding service conditions, are duly authorized to operate and monitor the generator. They must also be knowledgeable about first-aid procedures and be capable of providing these services if required. It is assumed, that all commissioning, maintenance and repair works will only be performed by qualified personnel.

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DANGER During operation of this equipment, there will be exposed energized or rotating parts with high voltage or high temperatures. Thus, its operation with open terminal boxes, unprotected couplings or erroneous handling, without considering the operation standards, may cause serious personal injury and property damage.

The people responsible for the installation safety must assure that: Only qualified personnel will perform the installation and operation of the equipment; These people will have in hand this manual and other documents supplied with the generator and will also perform the works, strictly complying with the service instructions, standards and the product specific documentation; People not qualified will be forbidden to carry out works on the electric equipment. The noncompliance with the installation and safety rules may void the product warranty. Firefighting equipment and first aid warnings will be located in the work site in visible and accessible places. The following should also be observed: All technical data regarding the allowed applications (operating conditions, connections and installation environment) contained in the catalog, purchase order, operating instructions, manuals and other documents; The specific determinations and conditions for the local installation; The use of proper tools and equipment for handling and transport; That the protection devices of the components are removed little before the installation; The individual parts must be stored in vibration-free rooms, preventing falls and assuring that they are protected against rodents and/or may pose risks to people safety.

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3 3.1

OPERATING CONDITIONS AND STANDARDS STANDARDS

WEG turbogenerators are specified, designed, manufactured and tested according to the following standards: Specification

IEC-60034.1 VDE-0530

NBR 5117

Tests

IEC-60034.2

NBR 5052

Degree of protection

IEC-60034.5

NBR 6146

Cooling

IEC-60034.6

NBR 5110

Mountings

IEC-60034.7

NBR 5031

Noise

IEC-60034.9

NBR 7565

Mechanical vibration

IEC-60034.14

NBR 7094

Mechanical tolerances

ISO 286

NBR 6158

Balancing

ISO 1940

NBR 8008

Table 3.1: Standards

3.2

ENVIRONMENT CHARACTERISTICS

Turbogenerators are designed to be operated in following ambient conditions: Ambient temperature: – 15ºC to + 40ºC; Altitudes: up to 1,000 m; Environments without the presence of aggressive agents, such as: sea air, chemicals, etc.; Environments according to the degree of protection of the generator.

ATTENTION For turbogenerators fitted with air-to-water heat exchanger, ambient temperature should not be lower than +5ºC and the cooling water temperature should be from +5ºC to +25ºC.

Special operation conditions can be met upon request and are indicated on the nameplate and data sheet specific for each machine.

3.3

OPERATING CONDITIONS

The operating conditions of the generator must comply with the nameplate data, applicable standards and codes, as well as with this manual in order to assure warranty coverage.

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RECEIVING AND STORAGE

4.1

RECEIVING

All generators are factory tested and supplied in perfect operating conditions. The machined surfaces are corrosion protected. The box or container must be inspected right after receipt and checked for any damages that may be caused during the transport.

4.2

Any damage to the painting or to the rust protections on the machined surfaces must be retouched.

ATTENTION The space heaters must be switched ON always the generator is not operating.

ATTENTION Any damage must be reported immediately to the carrier, the insurance company and WEG. If such a condition is not reported, the warranty will be void.

ATTENTION Parts supplied in additional packages or volumes must be checked when received according the complete packing list. When the package (or container) is lifted, following items must be checked: hoist components, the weight indicated on the packaging or on the nameplate, hoist capacity and operation. Generators packed in wooden crates must be lifted always by their own eyebolts or by suitable forklift and never lifted by its wooden packing box. Neither the generator nor its packaging should be dropped or submitted to any impact. Place it on the ground carefully (without impacts) to prevent bearing damages. Do not remove the protecting grease from the shaft end nor the rubber seals or the plugs from the terminals boxes. These protections items must be kept in place until the final installation has been concluded. After unpacking, make a complete visual inspection of the generator. Remove the shaft-lock device and kept it safe for future transport of the generator.

ATTENTION If any damage is detected, it must be photographed, documented and reported immediately to the carrier company and to your nearest WEG representative.

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STORAGE

4.2.1

Indoor storage

When the generator is not unpacked immediately, the box should be stored in a place protected against moisture, vapors, sudden change of temperature, rodents and insects. The site must be free of vibrations to prevent bearing damage.

4.2.2

Outside storage

If possible, choose a dry site, free of floods and vibrations. Repair all damages to the packages before storing the equipment. This is required to ensure the appropriate storage conditions. Store the machines, devices and crates on pallets, wood beams or foundations that provide protection against ground moisture. Prevent the equipment from sinking into the soil. Assure free airflow under the equipment. The covering or tarpaulin used to protect the equipment against the weather should not be in contact with the equipment surfaces. Assure appropriate air circulation by placing wooden spacer blocks between the equipment and the respective covering.

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5 5.1

LONG STORAGE PERIODS INTRODUCTION

The instructions for long storage periods described below are valid for generators that are stored during long time before their commissioning and/or are not operated during long periods.

5.2

GENERAL

The existing tendency, especially during the plant construction, of storing generators for long periods before their commissioning or when only some units are installed immediately, results in the fact that the generator is exposed to influences that may not be assessed in advance for that period. It is difficult to evaluate the atmospheric, chemical, thermal and mechanical stresses imposed on the generator that may occur during the storage, handling, assembly, initial tests and waiting time until its definitive commissioning. Another essential factor is its transport. For example, the general contractor may transport the generator or a unit complete with the generator as a joint transport to the installation site. The hollow spaces inside the generator, bearings and terminal box are exposed to the atmospheric air and temperature fluctuations. Due to air moisture, condensation of water may occur and, depending on the type and degree of contamination in the air, aggressive substances can penetrate the hollow spaces. As a result, after long storage periods, internal components such as the bearings, may rust, the insulation resistance may decrease to values below those regarded as accepted and the characteristics of the bearing lubricants are affected adversely. This influence increases the damage risk before the plant commissioning.

ATTENTION To keep the manufacturer's warranty valid, you must assure that the preventive measures described in this manual, such as: construction aspects, preservation, packaging, storage and inspections are followed and recorded.

5.3

STORAGE LOCATION

In order to provide the best storage conditions to the generator during long storage periods, the storage site should comply strictly with the items below.

5.3.1

Indoor storage

Enclosed storage room with roof; The storage location must be protected against moisture, vapors, aggressive fume discharge, rodents and insects. Room must be free of corrosive gases, such as: chlorine, sulfur dioxide or acids; Location must be free of severe continuous or intermittent vibrations. Storage room must be provided with ventilation system and filter; Room temperature (5°C, > t < 60°C), with no sudden changes in temperature; Relative air humidity <50%; Prevention against dirt and dust deposits; Provided with a fire detection system. Electric power supply for space heater and illumination must be provided. If some of these requirements cannot be provided in the storage room, WEG suggests that additional protection measures should be incorporated into the generator packaging during the storage period as follows: Storage the generator into a closed wooden box or similar with electrical installation that allow the connection of space heaters; If there is any risk of fungus infestation and formation, the packaging must be protected in the storage location by spraying or painting it with appropriate chemical agents. The packaging must be prepared carefully by an experienced person. The company hired for this purpose shall be responsible for the machine packaging.

5.3.2

Outdoor storage

The outdoor storage of the generator is not recommended. If the outdoor storage is unavoidable, pack the generator into a specific packaging for this condition, as described below: For outdoor storage, besides the packaging recommended for indoor storage, cover the packaging completely with some protection against dust, moisture and other foreign matters by using a resistant canvas or tarpaulin. Store the packaging on pallets, wood beams or foundations that provide protection against the ground moisture. Prevent the packing from sinking into the soil. After covering the machine, a shelter must be built to protect it from direct rain, snow and excessive sun heat.

ATTENTION It is recommended to check the storage place and the generator conditions according to the maintenance plan for long-term storage as described in this manual.

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5.4

SEPARATE PARTS

If parts have been supplied separately (terminal boxes, heat exchanger, endshields, etc.), these parts must be packed as described above. The air relative humidity inside the packaging should not exceed 50% until the machine is unpacked.

5.5

SPACE HEATER

The space heaters installed in the generator must be energized during the storage period to prevent the moisture condensation inside the generator, thus maintaining the winding insulation resistance at acceptable levels.

ATTENTION The generator space heater must be mandatorily energized when the generator is stored in a place with ambient temperature < 5°C and relative air humidity > 50%.

5.6

INSULATION RESISTANCE

During the storage period and before installation, the insulation resistance of the generator winding should be measured very 3 months and recorded according to item 2.3.5 of this manual Eventual decrease of insulation resistance must be investigated.

5.7

EXPOSED MACHINED SURFACES

All the exposed machined surfaces (for example, the shaft end and flanges) are protected at the factory by temporary protection film (rust inhibitor). This protective coating must be reapplied at least every 6 months. When this coating is removed and/or damaged, it must be applied again. Recommended products: Name: Dasco Guard 400 TX AZ, Manufacturer: D.A. Stuart Ltda Name: TARP, Manufacturer: Castrol

5.8

ROLLING BEARINGS

5.8.1

Grease-lubricated bearing

The bearings are factory lubricated for the performance of the generator tests. During the storage period, at every two months, the shaft-locking device must be removed and the shaft turned manually to keep the bearing in good lubrication conditions. After 6 months of storage and before starting the operation, the bearings should be relubricated. If the generator is stored for more than 2 years, the bearings must be washed, inspected and lubricated again.

5.8.2

Oil-lubricated bearing

Depending on its mounting position, the generator can be transported with or without oil in the bearings. The generator must be stored in its mounting position with oil in the bearings; The oil level must be respected, remaining in the sight glass half. During the storage period, at every two months, the shaft-locking device must be removed and the shaft turned manually to keep the bearing in good lubrication condition. After 6 months of storage and before starting the operation, the bearings should be relubricated. If the generator is stored for more than 2 years, the bearings must be washed, inspected and relubricated.

5.8.3

Sleeve Bearing

Depending on the mounting position, the generator can be transported with our without oil in the bearings and must be stored in its mounting with oil in the bearings; The oil level must be respected, remaining in the sight glass half. During the storage period, at every two months, the shaft-locking device must be removed and the shaft rotated at 30 rpm to circulate the oil and keep the sleeve bearing in good lubrication condition.

NOTE If it is not possible to rotate the generator shaft, the following procedure should be adopted to protect the sleeve bearing internally and the contact surfaces against corrosion. Drain all the bearing oil; Disassemble the bearing following the procedure described in this manual. Clean the bearing; Apply the anticorrosive protection (for example, TECTIL 511, Valvoline or Dasco Guard 400TXAZ) on top and bottom bearing shell and on the generator shaft contact surface; Assemble the sleeve bearing following the procedure described in this manual; Close all threaded holes with plugs; Seal the gaps between the shaft and the bearing seal by applying a waterproof adhesive tape; All the flanges (for example, oil inlet and outlet) must be protected with blind caps; Remove the bearing top sight glass and spray anticorrosive protection inside the bearing; Put some desiccant (silica gel) bags inside the bearing. The desiccant absorbs moisture and prevents water condensation inside the bearing; Close the bearing with the top sight glass. If the storage period is longer than 6 months: Repeat the above described procedure; Place new desiccant (silica gel) bags inside the bearing If the storage period is longer than 2 years: Disassemble the bearing; Preserve and store the bearing parts.

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5.9

TERMINAL BOX

5.10.3 Checking the insulation resistance

When the generator winding insulation resistance is checked, the main terminal box and additional terminal boxes must also be checked, particularly with regard to the following aspects: The terminal box inside must be dry and free of any dust deposit. The contacts must be free of corrosion. The seals must be in good condition. The cable entries must be sealed correctly. If any of these items is not correct, the parts must be cleaned or replaced.

Before starting the operation, the insulation resistance must be checked following the procedure described in this manual.

5.10

5.11

PREPARATION FOR OPERATION AFTER LONG STORAGE

5.10.1 Cleaning The machine inside and outside must be free of oil, water, dust and dirt. The generator inside must be cleaned with compressed air at reduced pressure. Remove the rust inhibitor from the exposed surfaces using a cloth soaked in a petroleum-based solvent. Remove the existing protection between the grounding brush and the generator shaft. Make sure that the bearings and cavities used for lubrication are free of dirt and that the cavity plugs are correctly sealed and tightened. Oxidations and marks on the bearing seats and shaft must be carefully removed.

5.10.2 Bearing lubrication Use the grease or oil specified for bearing lubrication. This information is indicated on the bearing nameplate. The bearings must be lubricated as described in the "Maintenance" section of this manual according to the bearing type.

5.10.4 Others NOTE Follow other procedures supplied in the "Commissioning" section in this manual before starting the machine operation.

INSPECTIONS AND RECORDS DURING THE STORAGE

The stored generator must be inspected from time to time and the inspection records must be filed. Check following aspects: 1. 2. 3. 4. 5. 6. 7.

Physical damages. Cleaning. Signs of water condensation. Protective coating conditions. Painting conditions. Signs of worms or insect action. Satisfactory operation of the space heaters. It is recommended to install a signaling or alarm system in the storage location to detect any power failure affecting the space heaters. 8. Record room temperature and the relative air humidity around the machine, the winding temperature (using RTDs), the insulation resistance and the polarization index. 9. Inspect also the storage place that must comply with the requirements described in the chapter “LONG STORAGE" .

NOTES Sleeve bearings, where the anticorrosive protection and desiccant were applied, must be disassembled according to the procedure described in this manual. The anticorrosive protection and the desiccant must be washed out and removed. Assemble the bearings as described in this manual and lubricate them again.

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5.12

MAINTENANCE PLAN TO BE FOLLOWED DURING THE STORAGE

During the storage period, the generator maintenance must be performed and recorded according to the plan described in the table 5.1: Monthly

Every 2 months

Every 6 months

Every 2 years

Before operation

Note

Storage Location Inspect the cleaning conditions

X

Inspect moisture conditions and the temperature

X

Check for insect infestation signs Measure the vibration level

X

X X

Packaging Inspect for physical damages

X

Inspect the inner relative humidity

X

Change the desiccant in the packaging (if any)

X

When required

Space heater Check the operating conditions

X

Complete Generator Clean generator outside

X

Check painting conditions

X

Check the oxidation inhibitor on the exposed parts

X

Replace the oxidation inhibitor

X

X

Windings Measure insulation resistance

X

X

Measure polarization index

X

X

Terminal box and grounding terminals Clean box inside

X

X

Inspect the seals and gaskets Roller bearings, grease or oil lubricated Rotate the shaft

X

Relubricate the bearing

X

Disassemble and clean the bearing

X X

Sleeve bearing Rotate the shaft Apply rust inhibitor and desiccant

X X

Clean and relubricate the bearings Disassemble and store the parts Table 5.1: Storage plan

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6

HANDLING

Figure 6.1: Lifting the generator by its eyebolts

Figure 6.2: Lifting the generator by the base eyebolts

To lift the generator, use only the eyebolts on the top or at base of the generator provided for this purpose, as shown in the figure 6.1 and 6.2. Consider the generator weight. Lift the generator smoothly and do not place it abruptly on the base to prevent bearing damages. The eyebolts on the heat exchanger, covers, bearings, radiator, terminal boxes, exciter, etc., were designed only to lift these components. Never use the shaft to lift the generator by means of cables, etc. To move the generator, its shaft must be locked using the locking device supplied with the generator

ATTENTION Ropes, rings and lifting equipment must be capable to support the generator weight.

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INSULATION RESISTANCE

7.1

SAFETY INSTRUCTIONS DANGER Before insulation resistance is measured, machine must be switched off and stopped. The winding under test must be connected to the housing and the ground for a period until all residual electrostatic charge has been removed. Ground the capacitors (if supplied) before disconnecting the lead terminals. The noncompliance with these procedures may result in personal injuries.

7.2

GENERAL REMARKS

When the generator is commissioned immediately after receipt, it should be protected against moisture, high temperature and dirt, thus preventing damages on the insulation resistance. The winding insulation resistance must be measured before the generator operation. If the ambient is very wet, the winding resistance must be measured from time to time during the storage period. It is difficult to prescribe fixed rules for the machine insulation resistance values, since they change according to the environment conditions (temperature, moisture), machine cleaning conditions (dust, oil, grease, and dirt), quality and conditions of the used insulating material. A considerable dose of common sense, resulted from experience, must be applied to conclude when a machine is or is not suitable for service. Periodic records are useful for this conclusion.

NOTE The insulation resistance must be measured using a MEGOHMMETER.

The stator winding insulation resistance must be measured in the main terminal box The megohmmeter must be connected between the generator frame and the winding. The frame must be grounded.

Figure 7.1: Megohmmeter connection

If the winding total measurement shows a value below the recommended one, the neutral connections must be open and the insulation resistance of each phase must be measured separately.

7.4

MEASUREMENT OF THE ROTOR WINDING RESISTANCE, EXCITER WINDING RESISTANCE AND ACCESSORIES

Measurement of the rotor winding resistance: Disconnect the rotor cables from the diode set; Record the winding temperature supplied by the PT 100; Connect the megohmmeter between the rotor winding and the generator shaft. The measured current cannot flow through the bearings. Measurement of the stator winding resistance of the exciter: Disconnect the exciter power supply cables; Connect the megohmmeter between the exciter stator winding (I and K terminals) and the generator frame. Measurement of the rotor winding resistance of the exciter:

7.3

STATOR WINDING MEASUREMENT

The stator winding test voltage must comply with the table 7.1 according to IEEE43 standard. Rated winding voltage (V) < 1000 1000 - 2500 2501 - 5000 5001 - 12000 > 12000

Insulation resistance test (Continuous voltage) (V) 500 500 -1000 1000 - 2500 2500 - 5000 5000 - 10000

Disconnect the exciter rotor cables from the diode set; Connect the megohmmeter between the rotor winding and the generator shaft. The measured current can not flow through the bearings Measurement of the stator winding resistance of the PMG - SP model generators --_: Disconnect the cables that connect the PMG to the voltage regulator Connect the megohmmeter between PMG stator winding (terminals 13, 14 and 15) and the generator frame.

Table 7.1: Insulation resistance test voltage.

Before measuring the stator winding, check following: If the CT secondary connections are not open; If all the power cables are disconnected; If the generator frame and the not measured windings are grounded; If the winding temperature has been measured; If all the temperature sensors are grounded;

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ATTENTION After insulation resistance has been measured, ground the tested winding to discharge it. The test voltage for the rotor, exciter, PMG and space heater must be 500 Vdc. The test voltage for the accessories is 100 Vdc. It is not recommended to measure the insulation resistance of thermal protectors.

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7.5

CONVERSION OF THE MEASURED VALUES

If the test is conducted at a different temperature, the read values must be corrected to 40°C by using an insulation resistance variation curve according to the temperature measured on the machine under test. If this curve is not available, you can an approximate correction, as indicated by the curve in Figure 7.2 as per NBR 5383 / IEEE43.

Insulation resistance

Insulation evaluation

2MΩ or less < 50MΩ 50...100MΩ 100...500MΩ 500...1000MΩ > 1000MΩ

Bad Dangerous Regular Good Very Good Optimum

Table 7.2: Orientative limits for the insulation resistance of electrical machines.

7.6

MINIMUM INSULATION RESISTANCE

If the measured insulation resistance is lower than 100 MΩ at 40ºC, the windings must be dried according to the procedure below before the machine starts operating: Disassemble the generator by removing the rotor and the bearings; Take the housing with the stator winding to an oven and heat it up to a temperature of 130°C, leaving it at this temperature for at least 8 hours. For large machines (above IEC 630 frame size or 104XX NEMA series, a dry time on oven of at least 12 hours may be required). Check if the measured insulation resistance is within the acceptable values as shown in table 7.2. Otherwise, please contact WEG.

7.7

POLARIZATION INDEX

The polarization index is traditionally defined as the ratio between the insulation resistance measured in 10 minutes and the insulation resistance measured in 1 minute at a relatively constant temperature. Through the polarization index, it is possible to assess the generator insulation conditions as per the table 7.3: Polarization index

Insulation evaluation

1 or less < 1.5 1.5 to 2.0 2.0 to 3.0 3.0 to 4.0 > 4.0

Bad Dangerous Regular Good Very Good Optimum

Table 7.3: Polarization index (ratio between 10 and 1 minute).

DANGER Right after measuring the insulation resistance, ground the winding to prevent accidents. Figure 7.2: Coefficient of insulation resistance variation with temperature.

With old machines, during longer time in service, the read values for the winding resistance will be usually higher. The comparison with values measured in previous tests on the same machine with similar load, temperature and moisture conditions is regarded as a better indication of the insulation conditions than the value obtained in a single test. Any great or sudden reduction is regarded as suspect.

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8

CONSTRUCTION CHARACTERISTICS

8.1

STATOR

The stator lamination package, formed by silicon steel laminations with insulation on both faces and low electric losses, is pressed and fixed by metal beam or spar system. The windings of the high-voltage generators are constructed with prefabricated rectangular wire coils with class-F insulation resin and coated with mica tape insulation that, after heat treatment process, provides high mechanical resistance to the winding. The coils are inserted into the stator slots and fixed by fiberglass or magnetic wedges. The fixation of these wedges is assured by the dovetail in slot and by using expandable fiberglass lamination. Highly absorbing materials are used for binding the coil heads, thus ensuring the mechanical stiffness required to withstand to the most severe operating conditions. The high-voltage stators are then impregnated by the epoxy VPI-impregnation system.

8.2

ROTOR

The rotor accommodates the field winding whose poles are made of steel laminations. A squirrel cage winding for absorbing purposes compensates for parallel services and abnormal load operation. The rotor is dynamically balanced and designed to withstand to the electrical and mechanical effects of overspeed as required by the applicable standard and of the triggering according to the design. Manufactured with non-salient poles, the rotor has a constant air gap along the whole iron core periphery. The rotor has a cylindrical shape in whose periphery slots is inserted the excitation winding. The field coils are made of bars, wires or copper laminations insulated with a class-H insulating material. The non-salient pole rotor of the turbogenerator is practically a monobloc with no overhangs or recesses. As a result, it becomes sturdier and more resistant to overspeed and coil triggering.

8.3

EXCITER

Installed at the non-drive end side of the generator, the exciter is formed by fixed poles that accommodate the excitation field coils, the armature and the rotating rectifier bridge. Its purpose is to supply direct voltage to exciter rotor. It supplies direct current controlled by the voltage regulator according to the load requirements, thus maintaining constant voltage for the main generator. Exciter Stator The poles accommodate the field coils which are series connected, their ends being connected to the terminal block (I(+) and K(-)). Its purpose is to supply the flux to the exciter rotor. It is supplied with a direct current controlled by the voltage regulator according to the load requirements, thus keeping the main generator voltage constant. Exciter Rotor The exciter rotor is mounted on the main shaft of the machine. The rotor is formed by laminations with slots that accommodate a star-connected three-phase winding. The phases are connected to the rotating rectifying diode set. 20

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The rotor is induced by the flux from the exciter stator using a three-phase AC voltage that is rectified in full wave by the rotating rectifier. Two wires come from the rectifier to feed the main machine rotor (field).

NOTE The rectifier is made up of six diodes and a set of varistors for protection against reverse overvoltage in the diodes.

8.4

PERMANENT MAGNET GENERATOR (PMG)

(Only for the SP_ model generator) Installed at the non-drive end side of the generator, the PMG generates alternate voltage for supplying the voltage regulator power circuit. The rotor is formed by permanent magnet poles inserted into the lamination package mounted on the main generator shaft. The stator is formed by a lamination package and a threephase winding that generates the voltage to supply the power circuit of the electronic voltage regulator.

8.5

DUMPING WINDING

The dumping winding is constructed along the whole rotor periphery, which is of fundamental importance for handling sudden loads, such as motor starts, OFF/ON procedures of heavy loads. The dumping winding has following functions: 1. Dumping of load input and output at generator terminals. 2. In case of an infinite busbar, the machine becomes more stability against abrupt voltage variations. 3. Absorption of zero sequence and negative sequence currents caused by load unbalance. 4. Loads with harmonic distortion of currents will also be absorbed by dumping bars according to standard. 5. They increase the abrupt short-circuit at the machine terminals.

8.6

BEARINGS

The bearings are mounted at the frame ends and their purpose is to support the rotor mass and allow it to turn. Sleeve bearings are lubricated with oil and the rolling bearings can be lubricated with grease or oil. Correct storage, operation and maintenance procedures are determinant for their performance and useful life.

8.7

HEAT EXCHANGER

SPW and SSW turbo-generators are provided with an airto-water exchanger installed at the bottom or top section of the generator. The SPF and SSF models are provided with air-to-air heat exchanger, normally installed on top side of the generator (see in this Manual the item "Cooling" ).

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9

OPERATION PRINCIPLE

AVR: Automatic Voltage Regulator EPT: Main three-phase exciter PMG: Exciter with permanent magnets

Figure 9.1: Internal electrical circuits of the SP_ model generator

9.1

EXCITATION

After the primary machine is driven and reaches is rated speed, starts the excitation process in the generator and the voltage generated by PMG supplies the voltage regulator power circuit. When the voltage regulator is enabled, it rectifies this voltage and supplies direct current to the stator of the generator exciter. The alternate current generated by the exciter rotor is rectified by the rotating diodes and supplied to the main rotor poles. The generator voltage increases as ramp automatically from its residual value up to the pre-established rated voltage that is regulated by monitoring the reference voltage in the electronic voltage regulator. The reference voltage for the voltage regulator must be obtained through reference TPs connected to the main terminals of the generator. The SS_ model turbogenerators (Shunt) are not provided with PMG and the voltage regulator power circuit is supplied by the generator output voltage using power TPs.

ATTENTION To start the shunt generator excitation process, it may be necessary to use an external pre-priming circuit (DC power supply), since the residual generator magnetism may not be sufficient for the priming. Check the procedures in the voltage regulator manual for enabling this function during the excitation process.

DANGER When operated at no load with nominal speed and without excitation voltage there is a residual voltage present in the synchronous generator terminals due to residual magnetism in the exciter magnetic core. These voltage levels can cause serious accidents with risk of death. It is unwise to manipulate the machine while the rotor is turning. Generators with rated voltage of 440V, usually present 180V of residual voltage; Generators with rated voltage of 13800V easily present 1000V of residual voltage.

9.2

DEEXCITATION

The generator full deexcitation is performed by the generator stoppage or voltage regulator shutdown. When the voltage regulator is shut down, the generator deexcitation is performed by a free-wheel circuit installed in the voltage regulator panel. The excitation current flows through a discharge resistance that promotes a faster deexcitation of the main machine. During the maintenance services, the machines must be stopped, since the deexcitation alone is not enough.

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9.3

VOLTAGE REGULATOR ATTENTION

The purpose of the electronic voltage regulator is to keep the generator voltage constant, regardless of the load. The generator excitation process starts from the moment the voltage regulator is activated. This must always be done when the generator reaches at least 90% of its rated speed, thus preventing overcurrent in the generator excitation windings.

Check for the correct wiring diagram in the regulator manual. An erroneous connection may burn the regulator and / or the generator windings.

9.4

UNDERFREQUENCY (U/F) PROTECTION

Automatic operation mode The voltage regulator is intended to keep the generator output voltage equal to the previously programmed reference value. To perform this function, the regulator must be operated in automatic mode, where the generator output voltage is used as feedback. During the automatic operation mode, the reference voltage can be used by other controls, such as: acceleration Ramp, F/U Operation, PF/Q Correction and others. Manual operation mode In this operation mode, the generator excitation is conducted through the excitation voltage variation. This operation mode is selected through a selector switch (automatic/manual = open) and is used during the generator commissioning tests. For technical details, operation, functions, connections, adjustments, abnormalities, etc., see the voltage regulator manual. The regulators are generally microprocessed and allow parallel operation between two machines and with the network. In this case, with power factor correction.

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When the generator frequency drops below the programmed value for U/F in the voltage regulator, the generator output voltage will decrease as programmed by the Volt/Hz ratio.

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10 INSTALLATION 10.1

INSTALLATION SITE

Electric machines must be installed in locations of ease access, allowing periodic inspections, local maintenance services and, if required, the removal of equipment for external maintenance services. The following environmental characteristics must be ensured: Clean and well-ventilated place; The installation of other equipment or walls should not obstruct generator cooling; The space around and above the generator must be sufficient for its maintenance and handling; The environment must comply with the generator protection class.

10.2

PROTECTIONS

The generator is supplied with a shaft-locking device to prevent damages to the bearings during the transport. This locking device must be removed before the generator installation.

ATTENTION The shaft locking device must be used whenever the generator is removed from its base (decoupling from the drive machine) and so prevent bearing damages during the transport. The shaft end is protected by a protective grease coat. During the generator installation, remove this shaft protection from the race where the shaft grounding brush contacts it.

10.3

DIRECTION OF ROTATION

The generators are normally designed to operate in a single direction of rotation as indicated by the arrow on the frame at the drive end side.

When generator rotation direction is changed, the phase sequence will be changed too and the reversal of the two phases will be required. Check the direction of rotation and the phase sequence before operating the generator.

ATTENTION Generators supplied with single direction of rotation can only be operated in the specified direction of rotation. If inversion of the direction of rotation is desired, you must contact the factory through your nearest WEG representative.

10.4

FOUNDATIONS

The foundation or structure where the generator is to be installed must be must be stiff enough, flat, free of external vibrations and able to withstand to the mechanical efforts to which it will be submitted during the start-up or in case of generator short-circuits. The type of foundation chosen depends on soil condition or on the floor resistance. If the foundation dimensions are not executed accurately, serious vibration problems may occur with the generator and drive machine as a whole. The dimensioning of the foundation structure must be executed by considering the dimensional drawing and the information about the mechanical efforts on the foundation, the anchoring procedures and the heat exchanger details (if any).

ATTENTION Provision must be made for a minimum clearance of 2 mm between the anchor plate and the generator feet for inserting the compensation plates (wedges) used for the alignment adjustment.

NOTE The user is responsible for the foundation dimensioning and construction.

DIRECTION OF ROTATION

Figure 10.1: Direction of Rotation

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10.5

ANCHOR PLATE SET

The anchor plate set comprises anchor plate, leveling bolts, leveling wedges, alignment bolts and anchor bolts. Procedure for the assembly, leveling and grouting of the anchor plates

Step 1 Construct the foundation (1) using anchor bars (2) as per the dimensional drawing, considering the efforts to which this base will be submitted as shown in the drawing.

Step 2 Position the anchor bolts (3) in the anchor bars and the leveling bolts on the primary concrete surface.

Step 3 Place the anchor plates (5) on the leveling bolts.

Step 4 Level the anchor plates by using the required instruments. Please consider a 2 mm clearance between the anchor plates and the generator base for inserting the leveling wedges required for the generator alignment.

Step 5 After the anchor plates have been leveled, they must be grouted (6) together with the anchor bolts for their definitive fixation.

Step 6 After the grout cure, place the generator on the anchor plates, align it by using the horizontal alignment bolts (7 and 8) and fix it in place through it base holes and anchor bolts.

Figure 10.2: Anchor Plate

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Leveling and grouting with the anchor plates fixed the generator

The half of the maximum difference of the dial indicator measurement in a full revolution represents the maximum eccentricity. The maximum allowed eccentricity for rigid or semi-rigid coupling is 0.03 mm. When flexible couplings are used, values higher than those above are acceptable, however the value defined by the coupling manufacturer should not be exceeded. We recommend keeping a safety margin for these values. Angular Alignment

Figure 10.3: The anchor plate and the generator

The anchor plates can be leveled and grouted after they have been fastened to the generator base with the 2 mm wedges between the generator base and the anchor plates. For this purpose, place the generator with the anchor plates on the leveling cap bolts, level off the base using these leveling cap bolts and pre-align the generator using the alignment bolts (7 and 8). Secure the generator in place using the anchor bolts and grout the anchor plate and anchor bolts for its definitive fixation.

10.6

ALIGNMENT / LEVELING

The generator must be aligned correctly with the driving machine, particularly in case of direct coupling. An incorrect alignment may cause bearing damages, vibrations and even the shaft rupture. The alignment must be made according to the recommendations of the coupling manufacturer. It is necessary to make the machine parallel and angular alignment as follows: Parallel Alignment

Radial measurement Figure 10.4: Parallel misalignment

Figure 10.4 shows the parallel misalignment of the two shaft ends and a practical way for making the measurements is by using proper dial indicators. The measurement is made at 4 points at 90° with two half-couplings rotating together in order to eliminate the effects caused by contact irregularities of the dial indicators. Choosing the vertical top point 0°, half of the measuring difference of the dial indicator at the positions of 0° and 180° represents the vertical coaxial error. This error must be corrected properly by adding or removing the assembly wedges. Half of the difference of the dial indicator measurement at the positions of 90° and 270° represents the horizontal coaxial error. This provides an indication when leveling (raising or lowering) or moving to the right or to the left at the drive end side is required to eliminate the coaxial error.

Axial measurement Figure 10.5: Angular misalignment

Figure 10.5 shows the angular misalignment and a practical way for making the respective measurement. The measurement is made at 4 different points displaced by 90° each other with two half-couplings rotating together in order to eliminate the effects caused by the irregularities of the dial indicators on the contact surface. Choosing the vertical top point 0°, half of the measuring difference of the dial indicator at the positions of 0° and 180° represents the vertical misalignment. This error must be corrected properly by adding or removing the assembly wedges. Half of the difference of the dial indicator measurement at the positions of 90° and 270° represents the horizontal misalignment. This must be properly corrected by side/angular moving of the generator. Half of the maximum difference in the comparison clock measurement in a full rotation represents the maximum angular misalignment. Half of the difference of the dial indicator measurement during a complete revolution represents the maximum angular misalignment. The maximum allowed misalignment for the rigid or semiflexible coupling is 0.03 mm When flexible couplings are used, values higher than those above are acceptable, however the value defined by the coupling manufacturer should not be exceeded. We recommend keeping a safety margin for these values. During the alignment/leveling procedures, consider the temperature effects of the generator and the driving machine. Different expansion levels of the coupled machines can change the alignment/leveling during the operation

10.7

COUPLING

Use only suitable couplings able to transmit pure torques without generating transverse forces. The generator shaft and the driving machine centers must be in a single line, both for the elastic and rigid couplings. The elastic coupling are intended for mitigating the residual misalignment effects and preventing the vibration transfer between the coupled machines, which is not the case when rigid couplings are used. The coupling must be assembled or removed only with the use o appropriate devices and never by means of rustic devices (hammer, mallet, etc.). Line S Turbogenerator

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Generators fitted with sleeve bearings

Figure 10.8: Coupling axial play.

NOTE If the shaft cannot be turned, consider the shaft position, the shaft forward displacement (according to the shaft markings) and the axial play recommended for the coupling.

Figure 10.6: Sleeve Bearing

The generators fitted with sleeve bearings must be coupled direct to the driving machine or by means of reducer. The coupling by belts and pulleys is not allowed. The shaft end has three markings, the central mark (red painted) is an indication of the magnetic center and the two external markings indicate the limits of the rotor axial movement.

Before starting the operation, check if generator shaft allows the free axial movement in the above play conditions. During the operation, the arrow must be positioned on the central mark (red) that indicates that the rotor is at the magnetic center. At the start-up or even during the operation, the generator will be allowed to move freely between the two markings. Under no circumstance, the generator will be allowed to operate constantly with axial effort on the bearing. The used sleeve bearings are not designed to withstand constant axial efforts. After the machine set has been aligned and checked ( in cold and hot operating conditions) the generator must be secured in place on the anchor plate as shown in the figure below:

Welding at four points

Figure 10.9: Pin fastening of the generator to the anchor plate

ATTENTION Figure 10.7: Magnetic center marking

For the correct coupling of the generator, the following factors should be considered: Bearing axial play; The axial displacement of the machine coupled to the generator (turbine); The maximum axial play of the opening allowed for the coupling.

ATTENTION Displace the shaft fully to the front side to make correct measurement of the axial play; Align the shaft ends carefully by using a flexible coupling whenever possible, allowing a minimum axial play of 3 to 4 mm between the couplings.

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The pins, nuts, washers and leveling wedges may be delivered with the generator upon the customer request.

NOTES The user is responsible for the generator installation. WEG shall not be responsible for damages to the generator, associated equipment and installation occurred as a result of: Excessive transmitted vibrations; Precarious installations; Alignment failures; Improper storage conditions; Noncompliance with the pre-operation instructions; Incorrect electrical connections.

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10.8

ELECTRICAL AND GROUNDING CONNECTIONS ATTENTION Make a careful analysis of the electric wiring diagram delivered with the generator before connecting the power and ground cables as well as the accessories. For the electrical connection of the auxiliary equipment (voltage regulator, hydraulic unit, etc.), please refer to the specific manuals of these items.

10.8.1 Main stator connections (power cables) The power cables are connected to insulator terminals in the terminal box or to copper terminals, depending on the generator design. The location of the power and neutral terminals is identified in the specific dimensional drawings of each generator. The stator terminal connections must comply with the stator wiring diagram specific for that generator. Make sure that the connection cable cross-section and connection cable insulation class are appropriate to the generator current and voltage. The stator terminal markings and their connections are shown in the specific wiring diagram of each generator, in compliance with IEC60034-9 or NEMA MG1 standards. The phase sequence can be changed by inverting any two connections, however the generator must turn in the direction of rotation specified in the wiring diagram and by the indication arrow as viewed onto the shaft end to be coupled. Generators with a single direction of rotation must turn only in the indicated direction since fans and other devices allow only single direction of rotation. If the generator should be operated in opposite direction of rotation to the shown one, contact the factory through your nearest WEG representative. Before making the electrical connections between the generator and the user power supply, check the winding insulation resistance and the phase sequence carefully.

10.8.2 Grounding The generator grounding terminal is located on the generator frame or on its base and inside the main terminal box or on the terminal strip. These terminals should be used for connecting the grounding cables and the shield as required by local standards.

10.8.3 Accessories The main accessories supplied with turbogenerators are: Stator winding temperature sensors; Bearing temperature sensors; Space heater; Water leak detector; Water flow sensors; Oil flow sensors; Other accessories (if requested) are listed in the specific WIRING DIAGRAM of the involved generator. The accessories are connected to the connection strips located inside the terminal box for accessories according

to the cable markings as shown in the generator-wiring diagram.

10.9

THERMAL PROTECTIONS

10.9.1 Protection location The turbogenerators are fitted with overtemperature protection devices installed in the main stator, on the bearings and other components that require temperature monitoring and thermal protection. These devices must be connected to an external temperature monitoring and protection system.

10.9.2 Temperature sensors The Resistance Temperature Detector (RTD) is a calibrated resistance element. Its operation is based on the principle that the electrical resistance of a metal conductor varies linearly with the temperature. The detector terminals must be connected to a control panel, which includes a temperature meter.

NOTE The Resistance Temperature Detector (RTD) can be monitored according to the absolute temperature supplied by its instantaneous resistance value. Based on this information, the relay can read the temperature and define the alarm and disconnection parameters based on predefined temperatures.

10.9.3 Temperature limits for the windings The temperature of the winding hottest-spot must be kept below the thermal class limit. The total temperature is equal to the sum of the room temperature with the temperature rise (T) plus the difference that exists between the winding average temperature and the hottest spot. According to the applicable standard, the maximum room temperature is 40°C. Above that temperature, operating conditions are regarded as special. Table 10.1 shows the numeric values and the admissible temperature composition for the hottest spot: Insulation class Ambient temperature T = temperature rise (resistance method) Difference between the hottest spot and the average temperature Total: hottest spot temperature

F

H

°C °C

40 40 100 125

°C

15

°C

155 180

15

Table 10.1: Insulation Class

ATTENTION If the generator operates with winding temperatures above thermal class limits, the insulation and, consequently, the generator useful life will be reduced significantly. This may even result in the generator burnout.

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10.9.4 Thermal bearing protections

BEARINGS Maximum temperatures for protection adjustments (°C) Alarm Trip 110 120

The temperature sensors installed on the bearings are used to protect them against damages caused by an overtemperature operation.

Table 10.3: Maximum bearing temperature

10.9.5 Alarm and disconnection temperatures ATTENTION The temperature level for the alarm and trip functions should be set as low a possible. This level can be determined by using the test results as reference or the generator operating temperature. The alarm temperature can be set to 10°C above the machine operation temperature at full load considering the highest ambient temperature. The temperature set for the trip function should not exceed the maximum allowed temperatures for the stator winding (according to the insulation class) and for the bearings (according to the used lubrication system).

The alarm and trip values can be defined through experience, but they should never exceed the above ones. The generator protection devices are listed in WEG Wiring Diagram, specific for each generator. The nonuse of these devices is the user's responsibility, and in case of damages, may void the warranty.

10.9.6 Ratio between temperature and the ohmic resistance of Pt 100 temperature sensors

STATOR WINDING Maximum temperatures for protection adjustments (°C) Alarm Trip 140 155 155 180

Temperature Class F H

The table 10.4 shows the temperature values as function of the ohmic resistance measured for Pt 100 temperature sensors.

Table 10.2: Maximum stator temperature

Formula: Ω -

ºC

0

1

2

3

4

5

6

7

8

9

0

100.00

100.39

100.78

101.17

101.56

101.95

102.34

102.73

103.12

103.51

10

103.90

104.29

104.68

105.07

105.46

105.95

106.24

106.63

107.02

107.40

20

107.79

108.18

108.57

108.96

109.35

109.73

110.12

110.51

110.90

111.28

30

111.67

112.06

112.45

112.83

113.22

113.61

113.99

114.38

114.77

115.15

40

115.54

115.93

116.31

116.70

117.08

117.47

117.85

118.24

118.62

119.01

50

119.40

119.78

120.16

120.55

120.93

121.32

121.70

122.09

122.47

122.86

60

123.24

123.62

124.01

124.39

124.77

125.16

125.54

125.92

126.31

126.69

70

127.07

127.45

127.84

128.22

128.60

128.98

129.37

129.75

130.13

130.51

80

130.89

131.27

131.66

132.04

132.42

132.80

133.18

133.56

133.94

134.32

90

134.70

135.08

135.46

135.84

136.22

136.60

136.98

137.36

137.74

138.12

100

138.50

138.88

139.26

139.64

140.02

140.39

140.77

141.15

141.53

141.91

110

142.29

142.66

143.04

143.42

143.80

144.17

144.55

144.93

145.31

145.68

120

146.06

146.44

146.81

147.19

147.57

147.94

148.32

148.70

149.07

149.45

130

149.82

150.20

150.57

150.95

151.33

151.70

152.08

152.45

152.83

153.20

140

153.58

153.95

154.32

154.70

155.07

155.45

155.82

156.19

156.57

156.94

150

157.31

157.69

158.06

158.43

158.81

159.18

159.55

159.93

160.30

160.67

Table 10.4: Temperature X resistance (PT100)

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10.9.7 Space heater The space heaters in the generators are intended for preventing water condensation when generators are not operated for long periods. These resistances must always be energized during the generator storage period and when the generator remains at standstill and switched off before the generator operation is started again. The specific WEG Wiring Diagram and the nameplate on the generator frame show the supply voltage and the rated power of the installed resistances, as well as show the terminal markings.

10.10

The cooling air is provided by the internal (front and rear) fans, crosses the internal windings and exits through the lower section of the generator where the radiator or the water radiators is(are) located. The hot air passes through these radiators, is cooled and returns to the inside of the generator.

Air Outlet

PANEL PROTECTIONS

In addition to the protection devices listed here, other protection devices should installed in panel. The panel protections are defined by the customer according to his requirements. The table 10.5 lists the usual protections devices for the control panels: POWER Up to 3000 kVA – Medium Voltage 3000 to 7500kVA – Medium Voltage Over 7500kVA – Medium Voltage

PROTECTIONS

Cold Air

Warm Air Outlet

CP-PR-27-32-49-50G-51V52-59 CP-PR-32-40-46-49-50G51V-52-59-87 CP-PR-27-32-40-46-49-50G51V-52-59-78-81-87

Cold Air I l t

Table 10.5: Panel protections.

Symbols:

Radiators

CP - Capacitor PR - Lightning arrester 27 - Undervoltage 32 - Inverse power 40 - Field loss 46 - Current unbalance 49 - Overload 50G - Ground overcurrent 50 - Instantaneous Overcurrent 51 - Timed overcurrent 51V - Overcurrent with voltage locking 52 - Circuit Breaker 59 - Overvoltage 64 - Field ground 87 - Differential 78 - Phase Angle 81 - Frequency 86 - Blocking Relay

Figure 10.10: Cooling by bottom heat exchanger (D5 and D6).

D5 and D6 Constructive Form: Top heat exchanger The generator cooling consists of two internal fans and one or two water radiators installed in the air-to-water heat exchanger on top of the generator. The cooling air is provided by the internal (front and rear) fans, crosses the internal windings and exits through the top section of the generator where the radiator or the water radiators is(are) located. The hot air passes through these radiators, is cooled and returns to the inside of the generator.

ATTENTION Protection 59 (Overvoltage) is mandatory to prevent damages to the generator and the supplied load.

10.11

GENERATOR COOLING

D5 and D6 Constructive Form Bottom heat exchanger Two internal fans and one or two water radiators that are supplied with the generator and must be installed according to its specific dimensional drawing provide the generator cooling.

Figure 10.11: Cooling by top heat exchanger (D5 and D6).

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Constructive Form B3: The generator cooling is provided by internal axial fans and the air-to-water heat exchanger located on top of the generator. The ventilation provided by the internal fans, crosses the windings and exits through the generator upper section where the heat exchanger radiators are located. The hot air passes through the radiators, is cooled, and returns to the inside of the generator.

ATTENTION To prevent premature corrosion in case of cooling with seawater, the materials that get in contact with water (pipes and tube sheets) must be corrosion-resistant. In addition, the radiators must be fitted with sacrificial anodes (for example, Zinc or Magnesium), which are corroded during the exchanger operation and so protect the heads. As a result, these anodes must be replaced from time to time according to the corrosion degree shown, thus keeping the head integrity. The cooling system protection devices must be monitored from time to time. The air-to-water inlets and outlets should not be obstructed. Otherwise, they can cause overheating and even the generator burnout.

Figure 10.12: Cooling with the top heat exchanger (B3).

NOTE The usual types of turbogenerator cooling are shown above. Other cooling types may be used according to the user's requirements.

10.12

WATER RADIATORS

The radiator is a surface heat transmitter, designed to dissipate heat from electrical or other components indirectly, that is, the air in a closed circuit is cooled by the radiator after the heat removal from the equipment that must be cooled. Clean water with the following characteristics must be used as a cooling fluid: pH : from 6 to 9 Chlorides: maximum 25.0 mg/l Sulfates: maximum 3.0 mg/l Manganese: maximum 0.5 mg/l Solids in suspension: maximum 30.0 mg/l Ammonia: with no traces The heat transmission is from the equipment to the air and from the air to the water.

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ATTENTION The data of the radiators that form the air-towater heat exchanger are indicated on the radiator nameplate and in the generator dimensional drawing. The data should be followed for correct operation of the generator ventilation system and to prevent overheating.

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11 ELECTRICAL CONNECTIONS AND ACCESSORIES 11.1

TERMINAL MARKINGS

U1, V1 and W1 – Phases of main stator U2, V2 and W2 – Neutral cables of main stator UR, VR, WR and N – Reference voltage and power supply of voltage regulator. 13, 14 and 15 – Phases of the PMG or auxiliary coil. I and K – Stator of main exciter I(+) and K(-) 16 to 19– Space heater 20 a 25 – Temperature sensor (Pt 100) on stator winding. 26 - 27 – Moisture sensor 68 to 69 – Temperature sensor (Pt 100) on DE bearing.* 70 to 71 – Temperature sensor (Pt 100) on NDE bearing.* 60 a 63 – Thermometer for water 64 to 65 – Diodes fault detector. 66 to 77 – Current transformer. 88D to 91D – Thermometer on DE bearing 88T to 91T – Thermometer on NDE bearing 525 a 527 – Water flow sensor 500 - 501 – Water leak detector 579 to 586 – Thermometer at water inlet and water outlet 636 to 643 – Thermometer at air inlet and air outlet ADDITIONAL ACCESSORIES – In generators fitted with more than 1 Pt 100 on each bearing, the additional temperature sensors are identified by the number 1 that corresponds to the first Pt 100 (1 for the first additional Pt 100) or 2 (for the second additional Pt 100) and so on. Example: NDE bearing fitted with 2 three-wires Pt 100 – the first Pt 100 is identified by the numbers 70 - 70 - 71 and the second one with the numbers 170 - 170 - 171. Note: The terminal markings may differ from previous ones upon customer request or for special designs. In addition to this manual, we recommend to refer also to the wiring diagrams supplied with generator.

11.2

1. 2. 3.

WIRING DIAGRAMS Following wiring diagram should be used or the electrical connections of the turbogenerator. Terminal numbering refers to specific accessories. The installed accessories as well as the number of accessories depend on the generator size and its application.

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11.2.1 Thermal protection on main stator winding

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11.2.2

Generator cooling system

WATER LEAK DETECTION RELAY TO BE INSTALLED IN PANEL

THERMOMETERS (WATER)

WATER FLOW SWITCH

HUMIDITY DETECTOR

THERMOMETERS (AIR)

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11.2.3 Bearings THERMAL PROTECTIONS

THERMOMETERS (OIL)

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11.2.4

11.3

Space heater and exciter

DESCRIPTION OF THE ACCESSORY FUNCTION

In order to get right understand of this description you should check the wiring diagrams found in the previous chapter. 1. PT 100 Temperature sensor with terminal numbers 2020-21, 22-22-23 and 24-24-25 are the main sensors for measuring temperature and protecting the generator stator winding and they should present the following actuation point: Alarm: 130°C Shutdown: 155°C Pt 100 temperature sensors with terminal numbers 20R-20R-21R, 22R-22R-23R and 24R-24R-25R are reserve sensors and they will be activated in case of failure of the main sensors. 2. Pt 100 temperature sensors with terminal number 68-68-69 and 168-168-169 are sensors for measuring the temperature and protecting the DE bearing, and the sensor with the numbers 70-70-71 and 170-170-171 are for measuring the temperature and protecting the NDE bearing and should be activated with following temperatures: Alarm: 110°C Shutdown: 120°C 3. The terminal with numbers 500-501 are connected to the electrode of the water leak detectors and to the bottom plate of water trough of the radiator support. These terminals should be connected to the terminals that have the same numbering of the water leak detector in the generator protection panel. The generator shutdown sequence should be executed immediately after a leakage in the heat exchanger is detected. 4. The terminal with numbers 525-526-527 are related to water flow sensor of radiators. This sensor monitors the water flow and deactivates the generator drive as soon as the lack of water flow

is detected. If water shortage is detected in system during the generator operation, the generator shutdown sequence should be started immediately. 5.

The terminals 26 and 27 are related to moisture sensor. They are installed in some generators as an additional device for detecting water leak in the radiator by means of the presence of moisture.

6.

The terminals 88D-88D-90D-91D are connected to the thermometer that contacts the DE bearing. The terminals 88T-88T-90T-91T are connected to the thermometer that contacts the NDE bearing.

7.

The terminals 636-637-638-639 are connected to the thermometer that contacts the generator air inlet. The terminals 640-641-642-643 are connected to the thermometer that contacts installed the generator air outlet.

8. The terminals 579-580-581-582 are connected to the thermometer that contacts the water inlet of front radiator. The terminals 583-584-585-586 are connected to the thermometer that contacts the water outlet of front radiator. 9. The switches with terminals 534-535 and 536-537 corresponds to the contacts of oil flow sensor at the oil inlet piping that lubricates and cools the DE and NDE bearings, respectively. These sensors detect the presence or the lack of oil flow in these piping. In case of oil shortage in inlet piping for one or both bearings during or after star-up procedure, the equipment shutdown sequence should be executed immediately in order to adopt the required corrective actions. The bearings cannot be without lubrication under any circumstances while the shaft of generating unit is operating, which may result in irreversible damage to these bearings. Line S Turbogenerator

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10. The terminals 16-17 supply the space heaters, ensure moist removal inside the generator and maintains the temperature inside the generator. The space heaters should always be switched On during longer standstills in order to ensure that temperature inside the generator remains always higher than the ambient temperature.

11.4

11. The terminals I - K correspond to the main exciter stator and should always be powered by the electronic voltage regulator. The main exciter generates a three-phase voltage in rotor that is rectified by diodes in the rotating rectifier and supplies the main field of generator (main rotor). 12. The terminals 13-14-15 match PMG stator of the turbogenerator Model SP_ and supply the power circuit of voltage regulator.

ACCESSORIES AND PROTECTIONS

In order to get right understand of this description, check the generator wiring diagram.

Description

Location

Operation point

Measured value

Function

STATOR Thermal resistance Pt -100 (Phase Stator Winding U) Temperature sensor Pt 100 (Phase Stator Winding V) Temperature sensor Pt 100 (Phase Stator Winding W)

Alarm=130°C Shutdown = 311.00°F Alarm=130°C Shutdown = 311.00°F Alarm=130°C Shutdown = 311.00°F

Measures stator temperature (phase U) Measures stator temperature (phase V) Measures stator temperature (phase W)

FRONT AND REAR BEARING Temperature sensor Pt 100

DE bearing

Alarm=110°C Shutdown = 248.00°F

Contact thermometer

Bearing oil reservoir

Alarm=60°C Shutdown = 80°C

Oil flow switch

Oil piping

_

Measures bearing temperature and protects against overtemperature Measures bearing oil temperature and protects against overtemperature Detects oil flow on bearings

COOLING SYSTEM _

Thermometer (water inlet)

Water circuit

Thermometer (water outlet)

Water circuit

Thermometer (air inlet)

Heat exchanger

Thermometer (air outlet)

Heat exchanger

Water leak detector

In each radiator

_

Relay of water leakage detector

In the generator control panel

_

Water flow sensor

Water circuit

_

Moisture Sensor

_ _ _

_

Measures water inlet temperature in radiator Measures water outlet temperature in radiator Measures air inlet temperature in heat exchanger Measures air outlet temperature in heat exchanger Detects water leakage in radiators Detects water leakage in radiators Detects water flow in the cooling system Detects the presence of moisture inside generator

OTHERS ACCESSORIES Space heater

CT for protection CT for measuring Lightning arrester Capacitors

Inside the chamber or generator enclosure Terminal box of neutral conductor or panel (separate supply) Main Terminal box or panel (separate supply) Terminal box of neutral conductor and surge cell Terminal box of neutral conductor and surge cell

Turn on when generator is at standstill

Maintains winding temperatures and prevents water condensation

_ Differential protection _

Measures the current

_

Surge protection

_

Surge protection

Table 11.1: Accessories and shields

The alarm temperature of bearings and stator windings should be set to 10ºC higher than rated operating temperature and should not exceed the values indicated in the table 11.1.

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12 START-UP 12.1

BEFORE FIRST START-UP

Before first start-up of generator or after long standstill periods, check following items: 1. Generator fixing bolts should be tightened. Feet should be anchored and pinned; 2. Measure the winding insulation resistance. Assure that the insulation resistance is according to specified value; 3. Check if generator is clean and if package, measuring instruments and alignment devices have been removed from generator working area; 4. The couplings should be in good conditions, properly tightened and lubricated, if required; 5. The generator should be aligned correctly; 6. Check if bearings are properly lubricated. Lubricant should be as specified on nameplate. Check oil level of the generators fitted with oil lubricated bearings. Bearing with forced lubrication should have oil pressure and flow as indicated on the nameplate; 7. Inspect connections of accessory cables (thermal protectors, space heaters, etc.) and how they act on control panel; 8. Check if all electrical connections meet the generator wiring diagram; 9. Check if connections and parameter settings of the electronic voltage regulator are in accordance with the Installation Manual; 10. The line cables connected to main terminals should be proper tightened in order to prevent short-circuit or loosening; 11. Check cooling system. On machines with water cooling system, check the operation of water supply system in the radiators; 12. Assure that generator air inlet/outlet are not obstructed; 13. Moving parts of generator should be protected in order to avoid accidents; 14. The terminal box covers should be fixed correctly; 15. Test operation of shaft oil pressure operated lifting system (hydrostatic jacking), if any, and assure that it operates correctly.

12.2

INITIAL MECHANICAL TURN

After checking all items mentioned above the following procedures should be carried out to get generator initial turn: 1. Switch Off space heater; 2. Set circuit breaker to test position; 3. Set voltage regulator parameters according to manual; 4. Turn on oil pressure pump for raising hydrostatic jacking (if any) of the bearings; 5. Check oil level of oil lubricated bearings; 6. If bearings are fitted with forced lubrication system, turn oil circulation system on and check the level, oil flow and oil pressure making sure that they meet the nameplate data. 7. If system is fitted with oil flow sensors, wait for flow return signal of the oil circulation system of both bearings that ensure that the oil get into bearings; 8. Turn on industrial cooling water system, check required water flow and water pressure (generators fitted with air-to-water heater exchange); 9. Rotate the generator shaft slowly to make sure that there is no dragging part or abnormal noises; After this procedure has been completed, proceed with the following steps for the generator start-up sequence;

10. Increase speed up to the rated speed so the oil film on bearings is formed readily. 11. The hydraulic jacking system, if any, should be turned off when the acceleration of the generator set reaches 80 rpm. 12. Keep generator operating at rated speed and record the temperatures of the bearings in 1-minute intervals until the temperature becomes constant. Any sudden increase of bearing temperature indicates abnormality for the bearing lubrication or bearing contact surface. 13. Monitor temperature, oil level of bearings and vibration level. If there is a significant change, stop generator start-up in order to evaluate possible causes. 14. When temperatures on bearings become constant you can proceed with the next steps of the generator operation.

12.3

POWERING-UP

With generator at rated speed, assure that all protection devices have been tested and are operating properly, and in case of some fault, they act immediately. Generator is powered-up by setting the voltage regulator to the automatic mode. The voltage regulator maintains the output voltage of generator at reference voltage. In manual operation mode, the generator can be powered up in steps until the rated voltage is reached. This operation mode is usually selected by the automatic/manual selector switch and is used only for generator commissioning tests. Refer to the manual of voltage regulator for correct use of this operation mode as well as to know the protections that are not enabled for this- operation.

NOTE All measuring and control instruments should be watched in all times in order detect any change and adopt the prompt corrective actions.

12.4

SYNCHRONIZATION AND LOAD

To synchronize generator with network bus: 1. Turn on voltage regulator and allow it controls machine voltage, making the required settings. 2. To connect generator to power system, the voltage signal, frequency and phase sequence should be equivalent. 3. Set the circuit breaker to original position and execute the synchronization and the line connection. THE ACTIVE POWER CONTROL (kW) OF GENERATOR IS MADE BY TURBINE POWER VARIATION. GENERATOR REACTIVE POWER CONTROL (kVAR) AND ITS POWER FACTOR ARE CONTROLLED BY VARIATION OF THE EXCITATION CURRENT.

NOTE These functions can be parameterized by the voltage regulator. For the parameter setting, refer to the Voltage Regulator Manual. Line S Turbogenerator

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13 GENERATOR OPERATION The operation procedures vary significantly due machine application and used control equipment. This section describes only the general procedures. For operation procedures of control system and voltage regulator, refer to the specific manuals of each equipment. All measuring and control instruments should be watched in all times in order detect any change and adopt the prompt corrective actions.

13.1

SHAFT LIFTING SYSTEM (JACKING)

Turbogenerator bearings fitted with jacking option during the start-up or stop process by oil pressure, this system is driven by an external oil pump and following procedures should be adopted:

ATTENTION The oil pressure system for jacking should be turned on before start-up (speed = 0 rpm) and turned off only after machine exceeds 80 rpm. This oil pressure system should be turned on during the deceleration process after the machine reaches 80 rpm and turned off after stop (speed = 0 rpm).

13.2

WATER RADIATORS

Control the water temperature at radiator inlet/outlet and correct the water flow, if required. Regulate the water pressure only if necessary to overcome the resistance in radiator pipes. For operation control, provide thermometer at the radiator air/water inlet/outlet and record the temperatures in determined intervals. During the thermometer installation, also signaling or recording instruments (horns, lamps) can be installed at specific locations.

13.3

BEARINGS

13.4

WEG generators are factory balanced and meet the vibration limits specified in the standards IEC60034-14, NEMA MG1 - Part 7 and NBR 11390 (unless different values have been agreed in the Purchase Agreement). The vibration are measured on the DE and NDE, in horizontal and axial directions. When costumer sends half-sleeve coupling to WEG, the generator is balanced with half-sleeve mounted on shaft. Otherwise, according to standards mentioned above, generator is balanced with half shaft key (i. e., key slot is filled out during balancing procedure with a bar of the same width, thickness and high as the key slot). Maximum vibration levels recommended by WEG for generators during operation are indicated in the table 13.1. These values are only general orientative values so specific conditions should be considered for each application: Vibration Levels (mm/s RMS) Rated speed (rpm)

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Frame size

< 355

355 a 630

> 630

Alarm

4,5

4,5

5,5

Shutdown

7,0

7,0

8,0

Alarm

3,5

4,5

5,5

Shutdown

5,5

6,5

7,5

600 ≤ n ≤ 1800

1800 < n ≤ 3600 Table 13.1: Vibration (RMS)

The most common vibration causes in field are: Misalignment between generator and driving machine; Improper fixation of the generator onto the base with “loose wedges” under one or more feet of the generator and loose securing bolts; Improper base with poor stiffness; External vibration transmitted by other equipment.

Watch closely the system start-up as well as its first operating hours. Before start-up, check: If the jacking system (if any) of is turned on. If the external lubrication system (if any) is On. If the used lubricant meets the specification. The lubricant characteristics. The oil level (oil lubricated bearings). The trip and alarm temperature set for the bearings. During first start-up, pay attention to vibrations and noises. If bearings do not run smoothly and uniformly, turn the generator OFF immediately. The generator must operate during several hours until the temperature in bearings stabilizes and remains within the temperature limits mentioned previously. In case of overtemperature, switch the generator OFF immediately and check bearing temperature and temperature sensors. After bearings have reached the operating temperature, check plugs, joints and shaft end for leakage.

VIBRATION LIMITS

ATTENTION Generator operation at higher vibration levels than specified above may impair its useful life and/or performance).

13.5

SHAFT VIBRATION LIMITS

Generators fitted with proximity sensor or with provision for the installation of these devices (normally used in generator with sleeve bearings), the shaft surfaces are machined with special finishing in the areas adjacent to bearings in order to assure correct measurement of shaft vibration. The measured shaft vibration should meet IEC 34-14 or NEMA MG 1 standard. The alarm and shutdown values in table 13.2 specify the maximum allowable vibration levels for electrical machine coupled according to ISO7919-3 standard.

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These values above are only indicative and for each application should be considered the specific site conditions, such as the diametric clearance between shaft and bearing. Rated speed (rpm) 1800

3600

Shaft Vibration (μm - peak-to-peak) 280 e 355 a Frame size > 450 315 450 Alarm

110

130

150

Shutdown

140

160

190

Alarm

85

100

120

Shutdown

100

120

150

Table 13.2: Shaft vibration

Generator operation with shaft vibration in the area of alarm or shutdown levels may cause damage to the bearing shell. Main causes for increase of the shaft vibration are: Unbalance, coupling or other problems that have an indirect influence on the machine vibration; Shaft machining problems during the manufacturing process; Stress or residual magnetism on the shaft surface where measurements are made; Scratches, knockings or variations in shaft finishing at the measuring area.

13.6

STOP

(manual mode – local) To stop the generator: 1. Reduce generator load up to 5 - 10% of rated current; 2. Open armature circuit breaker; 3. Disable voltage regulator; 4. Shutdown the primary machine; 5. Enable the bearing jacking system (if any) when speed reaches 80 rpm; 6. After generator is stopped, shutdown jacking system (if any), close cooling water valve (if any) and turn off bearing oil circulation system. 7. Turn on space heater if generator will be idle by extended time.

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14 MAINTENANCE 14.1

GENERAL

The maintenance of generators applied correctly should consider following procedures: Keep generator and associated devices clean; Check insulation levels periodically; Check overtemperature periodically (windings and bearings); Check wears, lubrication and useful life of bearings; Check ventilation system and ensure correct air flow; Inspect heat exchanger; Check machine vibration levels; Inspect associated equipments (hydraulic unit, oil pressure system – jacking, voltage regulator); Inspect all accessories and generator protection devices ensuring correct operation and connections. Non-observance of one of the item above could result in unexpected stops of the equipment. The required inspection frequency depends on the local condition of the application. If repair, recondition or overhaul of the generator or some part is required, please contact WEG. In addition to its well-trained service centers, WEG supplies all factory and engineering services in order to provide full-service to your company.

14.2

GENERATOR CLEANING

Maintain generator enclosure clean, free of oil and dust and so improve the machine heat exchange to the surrounding medium. Clean inner surfaces of the generator, removing dusts, debris and oils. Use for cleaning always clean cotton cloth. If the dust is not abrasive, industrial vacuum cleaner can be used for the cleaning procedure. Remove all dirt and dust from the fan cover, fan blades and generator housing. Oil impregnated debris and moisture can be removed with cloth soaked in properly solvent. Clean also the terminal boxes. Maintain terminals and connectors clean and free of oxidation and in good conditions. Avoid grease or verdigris on connection components.

NOTE If generators are used for no-breaks supplying, they must be operated from 2 to 3 hours each month, depending on the moisture at the installation site.

14.3

STATOR, ROTOR AND EXCITER WINDING INSPECTIONS

Stator, rotor and exciter winding insulation should be measured in regular intervals, specially in wet weather or after extended generator standstill. Inspect windings visually in regular intervals, record and repair all detected damages. Low measured values or sudden variations of insulation resistance should be investigated carefully. The insulation resistance could be increased to proper values when it is low (due to dust and excessive 40

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moisture) by cleaning and drying it for removing dust and moisture.

14.4

WINDINGS CLEANING

In order to ensure high performance and longer useful life for the machine, maintain windings free of dirt, oil, metal dust, contaminants, etc. Ensure that operation site is clean, make periodical inspections and clean the machine and if required impregnate the winding again (for this procedure contact WEG ). The windings may be cleaned with industrial vacuum cleaner with fine and non-metallic tips or by rubbing with dry cloth. For extreme dust conditions it can be necessary to clean with proper liquid solvent. This cleaning procedure should executed as fast as possible to not expose windings to solvent action for long times. After cleaning with solvent, windings should be dried thoroughly. Measure insulation resistance and polarization index to determine if windings are dried thoroughly. Time required for winding drying process varies to weather conditions such as temperature, moisture, etc.

DANGER Most cleaning solvents are very toxic and flammable. Solvents should not be used on straight parts of coil since the protection against corona effect may be damaged. Inspections Make following inspections after carefully cleaning of the windings: Check insulations of windings and connections. Check fastening of spacers, winding head lashing, slot wedges, bandages and supports. Assure that there is no cable breakage, poor welding, or short-circuit between turns, against mass or connections. If some is detected, contact WEG Authorized Repair Shops. Assure that cables are connected properly and terminals are well tightened. Retighten, if required Reimpregnation If winding insulation (resin layer) has been damaged during cleaning or inspection process, retouch the damaged parts by using proper insulation resin (contact WEG). Insulation resistance The insulation resistance should be measured after all maintenance procedures are completed.

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ATTENTION Measure the insulation resistance of the stator, rotor and exciter windings when generator was out of operation for longer time and before it is powered-up again. Ensure that measured values met the specified ones.

14.5

INSPECTION AND CLEANING OF RADIATORS

Guidelines for heat exchanger removal and maintenance Proceed as follows for removing the heat exchanger: 1. Close all water inlet and outlet valves after stopping ventilation; 2. Drain water from radiator through the drain plugs; 3. Unscrew the heads retaining cap screws, nuts and washers; 4. Scrub pipe inside surface of the pipes by using nylon brushes for removing all scales. If during the cleaning process damages are detected in the radiator pipes, repair them. Radiator storage after operation When radiator is maintained out of operation during long periods for maintenance procedures, drain out all water and then dry it. Drying may be carried out with preheated compressed air. During the winter, when the water in the radiator pipes can freeze, drain all water out even for short standstill periods, in order to avoid pipe deformation and damages.

NOTE

Radiator operation and performance To control the generator operation we recommend that water and air temperatures at radiator inlet and outlet are measured and recorded periodically. The radiator performance is expressed by the temperature differences between cold water and cold air during regular operation. This difference should be controlled periodically. If this temperature difference increases after a longer period of regular operation, this is a sign that the radiator should be cleaned. Performance decrease or radiator damage may also be caused due to the accumulation of air inside the radiator. In this case, a deaeration of radiator and water piping may correct this problem. The water pressure difference at the water inlet and outlet can be a sign that radiator cleaning is required. Measure and record the water pressure difference at the water inlet and outlet. Compare periodically the measured values with the first measured value. An increase of the pressure difference indicates that radiator cleaning is required.

14.6

GENERATOR OUT OF SERVICE

The following procedures should be adopted when generator remains long periods out of service: Turn the space heater on to ensure a slightly higher temperature inside generator than the ambient temperature, thus preventing water condensation and consequent insulation resistance drop of the windings and oxidation of metal parts. All water pipes should be drained in order to reduce corrosion and deposition of suspended matter of the cooling water. Follow also the procedures mentioned in chapter 5 of this Manual “Extended Storage”

During short stops, when water is not drained from radiator, maintain low water flow circulating through the radiator pipes to ensure that the harmful products such as ammonia and hydrogen sulfates compounds are purged out from the radiator. Radiator maintenance Radiator can be operated during many years without requiring any cleaning when supplied by clean water. When radiator is supplied by dirty water, a complete cleaning is required every 12 months. The increase of the air temperature may be a sign that radiator is dirty. When cold air temperature, at the same operation condition, exceeds the specified value, you can assume that pipes are dirty. If any corrosion is detected, proper corrosion protection (for example, zinc anode, plastic, epoxy covering or covering by similar products) is required, in order to prevent more damages to the affected parts. The external coatings of all radiator parts should be maintained in good conservation conditions.

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15 BEARINGS 15.1

SLEEVE BEARINGS

ATTENTION Following temperatures should be set for the bearing protection system: ALARM 110ºC SHUTDOWN 120ºC The alarm temperature should be set 10 ºC higher than rated operation temperature, however should not exceed the limit of 110ºC.

1 2 3 4

NOTE 5

At no circumstance, water can leak into the oil reservoir, since water results in oil contamination.

Figure 15.1: Sleeve bearing

15.1.1

Bearing connections

1. Oil inlet pipe of the hydrostatic jacking system, if any. 2. Bearing oil inlet pipe. 3. Connection of the temperature sensor on bearing shell. 4. Oil outlet pipe/Sight glass of oil level. 5. Connection of the oil thermometer.

15.1.2

Bearings data

Characteristic data: type, size and oil flow rate are indicated on the DE and NDE bearing nameplate and must be followed strictly in order to prevent bearing overheating and damage. Hydraulic installation and generator bearing oil supply is user’s responsibility.

15.1.3

Bearings installation and operation

For parts list, assembling and disassembling guidelines, maintenance details, refer to bearing Installation, Operation and Maintenance Manual.

15.1.4

Hydrostatic jacking system

Due to application and technical features of some generators, the use of an auxiliary Hydrostatic Jacking is required for providing an oil film during generator start-up and deceleration process, or when generator is running for long periods at low speed. The installation and operation of the hydraulic pump for the shaft jacking system is user’s responsibility.

ATTENTION Ensure correct speed for the jacking pump, if any (see chapter “START-UP”).

15.1.5

Setting of the bearing protections

Each bearing is fitted with temperature sensors. These devices should be connected to a control panel that gives information on the bearing temperature and prevents bearing damage due to overheating.

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15.1.6

Lubrication

Oil should be changed every 20.000 operation hours when bearings are fitted with forced lubrication system and every 8.000 operation hours when bearing are selflubricated, or always when the oil characteristics changed. Check periodically the oil viscosity and pH.

NOTE Check oil level daily and maintain the oil level about center of the of sight glass.

Bearings should be lubricated with the specified oil considering the flow rates indicated on the nameplate. All unused screwed hole should be closed with plugs and no connection may present any leakage. Oil level is reached when lubricant is at the center of the sight glass. The addition of more oil than required does not damage the bearings, but may cause oil leakage through the shaft sealing.

ATTENTION Cares to be taken during the lubrication process will determine the bearing lifetime and generator operation safety. Thus consider following guidelines: The selected elected should have suitable viscosity for bearing operation temperature. This should be checked during oil change or during periodical maintenance procedures. Machine operation with too low oil level means lack of lubricant and could damage bearing sleeves. Minimum required oil level is reached when lubricant reaches the bottom part of sight glass with generator at standstill.

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15.1.7

Sealing

After bearing maintenance, both halves of seal labyrinth should be fixed together by a circlip ring. They must be inserted into the ring seat, so the locking pin is fitted into the undercut of the upper half part of housing. Poor installation damages the sealing. Before seal assembling, clean carefully the contact surfaces of the ring and seating and coat the contact area with soft sealing compound. Drain holes at bottom half of the ring should be cleaned and cleared. When installing this halve of the sealing ring, press it slightly against bottom shaft side.

15.1.8

Oil type: Type and quantity of oil to be used are indicated on the nameplate fixed on generator next to bearing. Oil change: Bearing oil change should be carried out at following intervals considering the bearing operation temperatures, as shown in table below: Below 75ºC = 20.000 hours Between 75 and 80ºC = 16.000 hours Between 80 and 85ºC = 12.000 hours Between 85 and 95ºC = 8.000 hours Between 90 and 95ºC = 6.000 hours Between 95 and 100ºC = 4.000 hours

ATTENTION

Bearing maintenance

Bearing lifetime depend on generator operation conditions, environment conditions and preventive procedures adopted by the maintenance people. The following guidelines should be followed: The selected oil for the application should has proper viscosity for expected bearing operation temperature. The type of oil recommended by WEG already considers these criteria. Insufficient amount of oil may damage bearing. Minimum level of oil is reached when lubricant reaches the bottom part of sight glass with generator at standstill.

Sleeve bearing maintenance: Check periodically lubricant level and conditions; Check noise levels and bearing vibration, Follow up and record operation temperature and retighten all fixing bolts. Clean generator frame. Remove dust and oil from the frame outside to improve the heat exchange with the environment. NDE bearing is electrically isolated. The spherical seat of the bearing shell is covered by an insulation material. The locking pin is insulated and the seals are made of non-conductive material. The temperature control devices that contact the bearing shells are also insulated.

15.2

OIL BEARINGS

ATTENTION 1. Oil inlet pipe

Oil level should be inspected daily and maintained in the middle of oil sight glass.

4 2. Oil sight glass

1 2

3. Oil outlet

15.2.2

4. Temperature sensor.

The system start-up should be watched carefully during the first hours of operation. Before start-up check: If used oil meets the specification on nameplate. The lubricant characteristics. Oil level. The bearing temperatures set for shutdown and alarm. During first start-up check if the are abnormal vibrations and noises. If bearings do not run smoothly and quietly, stop generator immediately. The generator must operate during several hours until the bearing temperature stabilizes within the temperature limits mentioned above. If an overtemperature is detected, stop the generator and check bearings and temperature sensors. After operating temperature has been reached, check plugs, joints and shaft seals for oil leakage.

3 Figure 15.2: Oil bearings

15.2.1

Lubrication guidelines

Oil removal: When oil change is required, remove the plug from the oil outlet pipe (3) and drain all oil. For oil filling proceed as follows: Close oil outlet pipe with plug (3). Remove plug from oil inlet pipe of filter (1) (if any). Add specified oil up to the level indicated in sight glass.

Bearing operations

NOTES 1. All unused screwed holes should be closed with plugs and no connection may leak. 2. Oil level is reached when lubricant is in the middle of sight glass. 3. Addition of more oil than recommended does not damage the bearings, but may result in oil leakage through shaft sealing.

15.2.3

Protection device settings

The temperature sensors installed on bearings should be connected to a control panel to monitor bearing overheating and so protecting the bearings against damage due overtemperature during operation.

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ATTENTION ATTENTION

Following temperatures should be set for the bearing protection system: ALARM 110ºC SHUTDOWN 120ºC The alarm temperature should be set 10ºC higher than normal operation temperature, however should not exceed the limit of 110ºC.

Clean grease nipples before greasing procedure in order to prevent that foreign matter are drawn into the bearings with the grease. For lubricating, use manual grease gun only.

15.3.2 15.3

GREASE BEARINGS Grease nipple

Steps for bearing re-lubrication

1. Remove drain plug. 2. Clean the area around the grease nipple with cotton cloth. 3. With running rotor, add grease with manual grease gun until grease comes out the drain hole or until the total amount of grease as specified in the table has been applied. 4. Run the generator for a longer time in order to drain all grease excess. 5. Check the bearing temperature in order ensure that no significant temperature changes have occurred.

15.3.3

Spring device for grease removal

When operator cannot access grease relief valve, some generators are fitted with an extended spring device for grease removing during bearing relubrication procedures.

Grease drain hole Figure 15.3: Grease-lubricated bearings

15.3.1

Lubrication guidelines

Lubrication system has been so designed that during lubrication procedures the old grease is removed from bearing race and expelled through drain hole that prevents the ingress of dust or other harmful contaminants into bearing. This drain hole prevents bearing damage due to overgreasing. Grease bearings with running generator in order to ensure grease renewal in the bearing housing. If this is not possible due to rotating parts next to the grease nipples (pulleys, etc.) that can injure the maintenance people, proceed as follows: With grease gun, apply about the half of total specified amount of grease and operate the generator around 1 minute at full speed; Stop generator and apply the remaining grease. The injection of total amount of grease at one time with the generator at standstill can cause lubricant penetration into the generator inside through internal bearing seal.

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Steps for lubrication: 1. Clean grease nipple with cotton cloth before starting bearing lubrication procedure; 2. Remove dipstick with spring, clean spring and insert it again; 3. With rotor running, add quantity of grease specified on bearings nameplate using manual grease gun. 4. Grease excess is expelled through bottom drain hole and deposits on spring. 5. Operate generator during certain time so all grease excess is expelled through bottom drain hole and deposits on spring. 6. Remove this grease excess by removing the dipstick with the spring remove the grease from the spring. Repeat this procedure as necessary so often as required till no grease is deposit on the spring. 7. Check bearing temperature to ensure that no significant temperature changes have occurred.

15.3.4

Protection settings ATTENTION Following temperatures should be set at bearing protection system: ALARM 110ºC SHUTDOWN 120ºC The alarm temperature should be set 10ºC higher than rated operation temperature, however should exceed the limit of 110ºC.

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15.3.5

Bearing replacement

In order to avoid damages to steel laminations, insert cardboard shims in the air gap in the same thickness of the air gap after endshield removal. Bearing disassembly is very easy provided suitable tools are used (with 3 grips according to figure15.4).

Figure 15.4: Bearing extractor.

The extractor grips must be applied on sidewall on the inner ring to be stripped, or on an adjacent part. In order to assure good operation and avoid bearing damages, it is essential that assembly of bearing is carried out under complete cleanliness and skilled personnel. New bearings should be removed only from packaging just before the assembly. Before installing the new bearing, remove any burrs and correct any knocks on bearing seat onto the shaft. During bearing assembly procedures do not apply direct blows by hammer. We recommend to heat the bearing by inductive heater in order expand the bearing inner ring and thus facilitate the bearing assembly onto the shaft. The press support should be applied on the inner ring.

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16 EXCITER EXCITER

DIODES SET

Figure 16.1: Exciter of Turbogenerator SP_

1. 2. 3. 4. 5. 6. 7.

16.1

Pilot exciter with permanent magnets (PMG) Fan Stator of auxiliary exciter Rotor of main exciter Stator of main exciter Exciter housing NDE endshield of the exciter

EXCITER

For good performance of its components, the compartment of generator exciter should be cleaned. Perform periodic cleaning according to procedures mentioned on item 14.3 of this manual. Windings Check periodically insulation resistance of main and pilot exciter windings to determine their insulation conditions following procedures in item 7.4 of this manual.

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8. 9. 10. 11. 12. 13. 14.

Diodes set Heat sink Varistor wiring bridge Varistor Diode Heat sink Stranded cable

16.2

DIODES TEST

Rotary rectifier bridge housed on diode wheel is formed by 3 anode diodes and e 3 cathode diodes. These diodes are components that have higher durability and not require frequent tests. If generator shows any fault that indicates diodes damages, for example an increase of field current for same load condition, then these diodes should be tested according to following procedure: 1. Remove rear cover of exciter (7) to access diodes; 2. Loose flex cables of all 6 diodes; 3. With ohmmeter measure each diode resistance in both directions. Diode is in good condition when presents low ohmic resistance (until ± 100Ω) in its direct direction and high resistance (approx. 1 MΩ) in the reverse direction. Faulty diodes will present ohmic resistance of 0Ω or higher than 1 MΩ in both measured directions.

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16.3

DIODES REPLACEMENT

16.4

For replacing any diode WEG recommends you to follow following procedures: 1. Replace damaged diodes by new ones considering the position of each diode anode and diode cathode. 2. Diodes are supplied with stranded insulated connection cable (13) and connection terminal; 3. Clean carefully heat sink (9 and 12) around the mounting holes of diode. 4. Ensure that mounting area is free of burrs than prevent perfect diode insertion into the heat sink. 5. Check diode thread to make sure it is clean and free of burrs. 6. Install diode in its correct position by using torque wrench and tighten it according to the torques recommended in the table 16.1: Diode Base Thread (mm) M12 M16 M24

Torque Meter Wrench (mm) 24 32 41

Tightening Torque (Nm) 10 30 60

Table 16.1: Diodes Tightening Torque.

ATTENTION It is important that specified tightening torques are applied in order to not damage diodes during assemble procedures. 1. After diodes have been fixed, connected stranded cables as shown in figure above.

VARISTORS TEST

Varistors are devices installed between both halves of rectifier bridge disk where are installed diodes and their purpose is to protect diodes against overvoltage. In case of fault of these components, replace them. An ohmmeter can be use to test varistor conditions. The resistance of varistor should be very high (±20.000 ohms). If varistor damage is detected or if its resistance is too low replaced it.

16.5

VARISTORS REPLACEMENT

For replacing any varistor, WEG recommends to follow the guidelines below: 1. Replace damaged varistors by new ones according to generator manufacturer specification. 2. For replacing the varistor loose the bolts that fix it to the heat sink and the bolt that fixes varistor wiring bridge (10) to heat sink. 3. When removing varistor note how components are assembled in order to install the new varistor in the same way. 4. Before mounting new varistor, ensure that all component contact surfaces (heat sink, wedges, insulations and varistor) are leveled and smooth so that allow perfect contact. 5. Secure the new varistor, tighten the bolt hat fixes it to the heat sink by applying only sufficient tightening torque to ensure good electrical connection. Excessive tightening torque may cause varistor cracks and damage. 6. Tighten also the bolt that fixes the varistor wiring bridge to heat sink.

NOTE Diode polarity is indicated by an arrow on its housing. During diode replacement, ensure that they are installed on the heat sink with correct polarity.

Current conduction should occur only in the anodecathode direction, i.e., in direct polarization condition.

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17 GENERATOR PARTS

Figure 17.1: Parts of model SP_ turbogenerator _

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

DE bearing Shaft DE seal Closing of DE endshield/frame Internal DE fan Stator winding DE endshield Stator winding DE fan cover Rotor core Stator core Frame Equalizer winding NDE fan cover NDE endshield

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Internal NDE fan Closing of NDE endshield/frame NDE seal Exciter fan Pilot exciter (PMG) Exciter compartment Main exciter Rotary rectifier set Exciter cover Anchor plate set Accessory terminal box Intermediate base Alignment cap screws Anchor bolts

NOTES Parts identification and location may vary depend on turbogenerator model and mounting; SS_ model Turbogenerators are not fitted with pilot exciter (PMG) Turbogenerators for mounting B3_ have bearings fixed on DE and NDE endshields; Heat exchanger can be installed on top or bottom side of generator as required by the costumer.

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18 MAINTENANCE SCHEDULE The following maintenance schedule is a guideline and intervals between each maintenance procedure may vary according to conditions and location of equipment operation. For associated equipment such as hydraulic unit and voltage regulator we recommend to also refer their specific manuals. EQUIPMENT

Weekly

Monthly

Every 3 month

Every 6 month

Yearly

Every 3 Years

Note

STATOR Visual inspection of stator

x

Cleaning control

x

Inspection of the slot wedges

x

Stator terminal control

x

Measure wing insulation resistance

x

ROTOR x

Cleaning control Check connection of poles and dumping winding Visual inspection and measurement of pole insulation resistance EXCITER

x x

Cleaning control

x

Test diodes and varistors

x

Inspect windings

x

BEARINGS Noise, vibration, oil flow, leakage and temperature control

x

Checking of high pressure system (jacking)

x

Oil quality control

x

Inspection of sleeve shells and shaft race (sleeve bearings)

x As indicated on bearing nameplate

Change lubricant HEAT EXCHANGER Radiator inspection

x

Radiator cleaning

x

Inspection of the radiators sacrificial anodes (if any)

Sacrificial anodes are used in radiators that uses salt water

x

CONTROL AND PROTECTION EQUIPMENTS Performance inspection Value records Disassemble and test the operation performance

x x x

COUPLING Alignment inspection

x

Fixation inspection

x

Check after the first week of operation Check after first week of operation

COMPLETE GENERATOR Noise and vibration control Drain condensed water

x x

Retighten cap screws

x

Clean terminal box Retighten electrical and ground connections

x x

Table 18.1: Maintenance Schedule

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19 TROUBLESHOOTING Please find below a list of some abnormal conditions that can occur during generator as well some procedures for checking and correcting these faults. Generator does not excite or prime ANOMALY Activated protection Excitation switch, if any, is not operating. nterruption in power supply circuit of voltage regulator. Incorrect drive speed.

Interruption of main excitation circuit.

PROCEDURE Check the main panel and regulators modules for signalization of the activated protection. Check excitation switch. Check cable connection of the pilot exciter and voltage regulator to the terminal block. Measure generator speed and if required make new settings. Check if underfrequency protection is not activated. Measure all rotary diodes; replace damaged diodes or replace whole diode set. Check wiring between main rotor and diode disc.

Relay or other regulator component damaged.

Set to manual mode. Replace voltage regulator.

Voltage reference set too low

Reset parameterization.

Varistor of diodes protection is defective.

If defective replace it. If there is no spare part remove it temporally.

Generator do not excite, until to rated voltage ANOMALY

PROCEDURE

Rotating rectifiers defective.

Measure each rotating diode; replace damaged diode; eventually replace the whole set.

Speed below to parameterized setting for U/F function of the voltage regulator.

Check if the U/F function of voltage regulator is enabled. If U/F function is set above rated frequency, reset to –5% lower. Measure and set the speed.

Voltage reference set too low.

Set the voltage reference.

Remote setting of voltage lower than the rated.

Reset the remote pushbutton to correct value.

Generator does not excite up to the rated voltage ANOMALY Power supply voltage of the voltage regulator lower the desired voltage resulting in an output voltage lower than required.

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PROCEDURE Check if wiring is according to Voltage Regulator Manual.

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At no load generator excites up to until rated voltage, but collapses under load ANOMALY

PROCEDURE

Rotating diodes are defective.

Measure each rotating diode; replace damaged diode; eventually replace the whole set.

Protection activation: overcurrent, overexcitation, overvoltage.

Check if parameters are not set wrong and so activate the protection in normal operation condition.

Activation of excitation current limit.

Check the parameter settings.

Strong speed drop with enabling of U/F function or not.

Check turbine speed control. Check U/F function setting.

The generator, at no load, excites by overvoltage ANOMALY

PROCEDURE

For momentary overvoltage with immediate shutdown: opening of signal transformer circuit.

Check fuse and wiring.

In remote mode: parameter setting errors by remote pushbutton, with shutdown after a period of time (also adjusted with parameter setting).

Reset reference voltage.

On manual mode: parameter setting errors of the reference voltage: protection will no be activated.

Reset reference voltage.

In local mode: parameter setting errors of reference voltage, with shutdown after a period (also adjusted with parameter setting).

Reset reference voltage.

Generator voltage oscillations ANOMALY

PROCEDURE

Manual Mode: Poor adjusted stability.

Adjust on parameterization of voltage regulator.

Automatic mode: Poor adjusted stability.

Adjust on parameterization of voltage regulator.

Load variation.

Check causes of variations.

Variations of the turbine speed.

Check turbine speed control.

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20 ACCESSORIES AND SPARE PARTS WEG recommend maintaining following spare in stock:

SPARE PARTS

Quant.

Description

01

Sleeve bearing shell (upper and bottom) for the DE bearing with hydrostatic jacking (if any)

01

Sleeve bearing shell (upper and bottom) for the NDE bearing with hydrostatic jacking (if any)

03

Anode SKR Diode

03

Cathode SKN Diode

02

Space heater

Accessories listed below are standard supply for WEG turbogenerators. Others accessories can be installed upon costumer request. ACCESSORIES Quantities Description

Cooling with 1 radiator

Cooling with 2 radiators

03

03

Air thermometer

02

04

Water thermometer

01

02

Water flow sight glass

02

02

Contactless thermometer for bearing

04

04

Space heater - Pt 100 - 3 wires - for bearing

1, 2 or 3 per phase 01

02

Temperature sensor - Pt 100 - 3 wires - for coils* Level indicator relay for water leak sensor in radiator

01

02

Rod electrode for water leakage sensor in radiator

01

02

Water fluxostat

02

02

Oil fluxostat

01

02

Water pressure relief valve

01

01

Shaft grounding brush

* Winding temperature sensors can not be replaced. This accessory can be replaced only during stator rewinding. HOW TO PURCHASE: For purchasing spare parts and accessories, user must inform to WEG the generator serial number.

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21 DOCUMENTS For correct installation, operation and maintenance of generator, WEG recommends that in addition to recommendations mentioned in this manual, following specific documents must be considered: Generator connection diagram; Generator dimensional drawing; Pump drawing (Jacking pump), if any; Bearings installation and operation manual; Water radiators maintenance manual; Voltage regulator manual; Manual of the hydraulic unit for the bearing lubrication.

ATTENTION All machines included in this manual are updated constantly, so any information given herewith my be changed without prior notice. More information about the parameter setting can be found in the voltage regulator manual.

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22 WARRANTY CONDITIONS OF ENGINEERED PRODUCTS WEG warrants its products against defects in materials and workmanships for twelve (12) months from the from the invoice date issued by the factory. When products are purchased from retailer/distributor/manufacturer, the warranty will be for twelve (12) months from the invoice date issued by retailer/distributor/manufacturer, limited to eighteen (18) months from manufacturing date. The Warranty does not depend on the product installation date and the following requirements should be met: Proper transport, handling and storage; Correct installation based on the specified ambient conditions, and free of aggressive chemical; Operation under generator capacity limits; Performing periodical preventive maintenance; Repairs and/or replacements are executed only by personnel authorized in writing by WEG. The failed equipment be available to the supplier and/or repair shop for the required period to detect causes of the failure and make the corresponding repairs; Immediate notice by purchaser about the occurred failures and that these are accepted by WEG as manufacturing defects. This warranty does not include disassembly services at purchaser facilities, transportation costs with product, tickets, accommodation and meals for technical personnel when requested by costumer. The warranty services will be carried out only in WEG authorized repair shops or at WEG facilities. Components, whose useful life under normal use, is shorter than the warranty period, are not covered by these warranty terms. The repair and/or replacement of parts or components, at WEG discretion during the warranty period, will not give warranty extension. The present warranty is limited to supplied product and WEG will have no obligation or liability whatsoever to people, third parties, other equipment or installation, loss of profit or any other emergent or consequential damages.

WEG Equipamentos Elétricos S.A. Jaraguá do Sul - SC Phone Number (47) 3276-4000 - Fax (47) 3276-4020 São Bernardo do Campo - SP Phone Number (11) 2191-6800 - Fax (11) 2191-6849 [email protected] www.weg.net

1012.05/0708

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23 REPAIR SHOPS

ATTENTION Analyze accreditation level and in case of any doubt, contact WEG Service Department. Phone Number: (47) 3276-432.8

BRAZIL BAHIA BARREIRAS (47800-000) ELÉTRICA RAPOSO LTDA Rua Prof. José Seabra, 22 Phone.: (77) 611 1812 Fax: (77) 611 6149 Level: 3.2 [email protected]

SERRA (29160-440) TEREME TEC.RECUP.MAQS.ELETR. LTDA Rua D, 100 – District Novo Horizonte Phone: (27) 3228 2320 Fax: (27) 3338 1755 Level: 1.2, 2.2, 3.2, 4 and 5.2 [email protected]

DOURADOS (79841-000) ÁVILA DA CRUZ & CIA. LTDA-ME Av. Marcelino Pires, 7120 Phone: (67) 3424 4132 Fax: (67) 3424 2468 Level: 3.4 [email protected]

MINAS GERAIS SIMÕES FILHO (40310-100) STAUMMAQ SERV. TEC. AUT. MOT. E MAQS. LTDA Via Urbana, 01-CIA-SUL-Simoes Filho Phone: (71) 22036301 Fax: (71) 22036310 Level: 1.1, 2.2 and 3.3 [email protected] TEIXEIRA DE FREITAS (45995-000) JOÃO SANDRO MARTINS RODRIGUES Av. Pres.Getúlio Vargas, 324-São José Phone: (73) 32926399 Fax: (73) 32925600 Level: 1.2, 2.2, 3.2, 4 and 5.2 [email protected]

GOIÁS ACREÚNA (75960-000) AILDO BORGES CABRAL Rua Amaury P. Caetano, nº 117-Centro Tel./Fax: (64) 3645 1491 Level: 3.3 [email protected] GOIÂNIA (74435-190) AJEL SERVICE LTDA Rua 12, nº 206 - District Aeroviário Phone: (62) 3295 3188 Fax: (62) 3295 1890 Level: 1.1, 2.1 and 3.3 [email protected]

MARANHÃO CEARÁ FORTALEZA (60325-330) ISELÉTRICA LTDA Av. José Bastos, 933, Otavio Bonfim Phone: (85) 3281 7177 Fax: (85) 3281 5681 Level: 3.4 [email protected] MARACANAÚ (61900-000) P.W.ELETROTÉCNICA COM.E SERV.LTDA Av.Dr.Mendel Steinbruch, 2807, Lojas B/C Phone: (85) 3297 2434 Fax: (85) 3297 2434 Level: 1.2, 2.2, 3.2, 4 and 5.2 [email protected]

ESPÍRITO SANTO ARACRUZ (29190-000) ESTEL – MÁQS.E SERV.INDS. LTDA Rua Luiz Musso, 240 - Centro Phone: (27) 3256 1711 Fax: (27) 3256 3138 Level: 1.1, 2.2 and 3.4 [email protected]

SÃO LUIS (65054-100) ELÉTRICA VISÃO COM. E SERVS. LTDA Rua Projetada 2, Qd L, s/n - Forquilha Phone: (98) 3245 4500 Fax: (98) 3244 1144 Level: 3.4 [email protected]

MATO GROSSO SINOP (78550-000) ELETROTÉCNICA PAGLIARI LTDA Rua Colonizador Enio Pepino, 1505 – Setor Industrial Sul Phone: (66) 3511 9400 Fax: (66) 3511 9404 Level: 1.2 and 3.4 [email protected]

MATO GROSSO DO SUL CAMPO GRANDE (79006-600) BERGO ELETRICIDADE COM. DE SERVS. LTDA R: Brigadeiro Tobias, 415 Tel./Fax: (67) 3331 3362 Level: 3.4 [email protected]

ARCOS (35588-000) ELETROMECANICA GOMIDE LTDA Rua Jacinto da Veiga, 147 - Centro Phone: (37) 3351 1709 Fax: (37) 3351 2507 Level: 1.1, 2.2 and 3.3 [email protected] BELO HORIZONTE (31250-710) LEOPOLDO E SILVA LTDA R: Caldas da Rainha, 1340 – District São Francisco Phone: (31) 3491 1096 Fax: (31) 3492 8944 Level: 1.1, 2.3 and 3.1 [email protected] SARZEDO (30660-220) DATA ENGENHARIA LTDA R: São Judas Tadeu, 280 Phone: (31) 3577 0404 Fax: (31) 3577 6877 Level: 1.4, 2.5 and 3.5 [email protected] SARZEDO (32450-000) MPC COM. SERV. ELETR. LTDA R: São Judas Tadeu, 144 Phone: (31) 3577 7766 Fax: (31) 3577 7002 Level: 1.2, 2.3 and 3.3 [email protected]

PARÁ BELÉM (66113-010) ELETROTÉCNICA WILSON LTDA Travessa Djalma Dutra, 682 Tel./Fax: (91) 3244 5191 Level: 2.1 and 3.4 [email protected]

PARAÍBA JOÃO PESSOA (58011-200) G.M.S. SERVS. E COM. LTDA R: Índio Piragibe, 418 - Varadouro Tel./ Fax: (83) 3241 2620 Level: 3.1 [email protected]

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PARANÁ CURITIBA (81610-020) C.O.MUELLER COM.MOT.BOMBAS R: Anne Frank, 1134 Phone: (41) 3276 9041 Fax: (41) 3276 0269 Level:1.1 and 3.3 [email protected] FRANCISCO BELTRÃO (85601-190) FLESSAK ELETRO IND. LTDA Av. Duque de Caxias, 282 - Alvorada Tel./Fax: (46) 3520 1060 Level: 1.4, 2.4 and 3.5 [email protected] PONTA GROSSA (84001-970) SS MOTORES ELETRICOS LTDA Av. Ernesto Vilela, 537-Fundos Phone: (42) 3222 2166 Fax: (42) 3222 2374 Level: 1.1, 2.2 and 3.3 [email protected]

RIO DE JANEIRO (20911-290) ELÉTRICA TEMPERMAR LTDA Av. Dom Helder Câmara, 186 - Benfica Phone: (21) 3890 4949 Fax: (21) 3890 1500 Level: 1.3, 2.4 and 3.4 [email protected]

LUZERNA (89609-000) AUTOMATIC IND.COM.EQUIP.ELET. LTDA R: Rui Barbosa, 564 Tel./Fax: (49) 3523 1033 Level: 1.1 and 3.4 [email protected]

SÃO JOÃO DE MERITI (25555-440) ELETRO JULIFER LTDA R: Senador Nereu Ramos, Lt.06 Qd.13 Phone: (21) 2751 6846 Fax: (21) 2751 6996 Level: 1.2, 2.3 and 3.3 [email protected]

SIDERÓPOLIS (88860-000) INO INOCÊNCIO LTDA R: Família Inocêncio, 57 - Centro Phone: (48) 3435 3088 Fax: (48) 3435 3160 Level: 1.2 and 2.4 [email protected]

RIO GRANDE DO NORTE

SÃO PAULO

NATAL (59040-340) ELÉTRO MEC.IND.E COM.LTDA R: Dr.Luiz Dutra, 353 - Alecrim Phone: (84) 3213 1252 Fax: (84) 3213 3785 Level: 1.1, 2.1 and 3.3 [email protected]

ADAMANTINA (17800-000) OLIVEIRA & GOMES ADAMANTINA LTDA Av. Francisco Bellusci, 707 Tel./Fax: (18) 3521 4712 Level: 1.2 and 3.3 [email protected]

RIO GRANDE DO SUL

ARUJÁ (07400-000) PRESTOTEC TECN. EM MANUT. INDUST. LTDA R: Bahia, 414 Cx. Postal 80 Phone: (11) 4655 2899 Fax: (11) 4652 1024 Level: 1.4, 2.3, 3.4 [email protected]

PERNAMBUCO JABOATÃO DOS GUARARAPES (54345-160) ENERGY SERVICE LTDA Rod. Br 101 Km 82,1 - Prazeres Phone: (81) 3476 1633 Fax: (81) 3476 1616 Level: 1.4, 2.5 and 3.5 [email protected] RECIFE (50090-000) J. M. COM. E SERVIÇOS LTDA R: Imperial, 1859 - São José Phone: (81) 3428 1288 Fax: (81) 3428 1669 Level: 1.2, 2.3 and 3.4 [email protected]

PIAUÍ TERESINA (64000-370) ITAMAR FERNANDES R: Coelho de Resende, 480 - Sul Phone: (86) 3222 2250 Fax: (86) 3221 2392 Level: 1.1, 2.1 and 3.2 [email protected]

RIO DE JANEIRO CAMPOS GOYTACAZES (28035-100) ELETRO SOSSAI LTDA Av. 15 de Novembro, 473/477 Phone: (22) 2732 4008 Fax: (22) 2732 2577 Level: 1.3, 2.4 and 3.3 [email protected] MACAÉ (27910-230) ELETRO SOSSAI DE MACAÉ LTDA R: Aluisio da Silva Gomes, 123 Phone: (22) 2762 4124 Fax: (22) 2762 7220 Level: 1.1, 2.2 and 3.3 [email protected]

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PELOTAS (96020-380) CEM CONSTR. ELÉTR E MEC. LTDA R: Santos Dumont, 409 Tel./Fax: (53) 3225 8699 Level: 1.1 and 3.3 [email protected] PORTO ALEGRE (90200-001) JARZYNSKI & CIA LTDA Av. dos Estados, 2215 - Anchieta Phone: (51) 3371 2133 Fax: (51) 3371 1449 Level: 1.1 and 3.3 [email protected] RIO GRANDE (96200-400) CRIZEL ELETROMECÂNICA LTDA R: General Osório, 521 - Centro Phone: (53) 3231 4044 Fax: (53) 3231 4033 Level: 1.1 and 3.3 [email protected] SÃO LEOLPOLDO (93010-260) M.V.M. REBOBINAGEM DE MOTORES LTDA R: São Pedro, 365 Phone: (51) 3592 8213 Fax: (51) 3589 7776 Level: 1.1, 2.2 and 3.4 [email protected]

SANTA CATARINA ITAJAÍ (88303-040) ELETRO MAFRA COM. REPRES. MOT. LTDA R: Almirante Barroso, 257 Tel./Fax: (47) 3348 2915 Level: 1.1 and 3.3 [email protected]

CAPIVARI (13360-000) ELETRO TÉCNICA MS LTDA Al. Faustina F. Annicchino, 960 Phone: (19) 3491 5599 Fax: (19) 3491 5613 Level: 1.2, 2.2 and 3.3 [email protected] CATANDUVA (15805-160) MACIAS ELÉTROTÉCNICA LTDA R: Rosa Cruz, 130 – Jd. Caparroz Tel./Fax: (17) 3522 8421 Nível : 1.1 [email protected] JABOTICABAL (14870-010) ELÉTRICA RE-VOLTIS LTDA Av. Carlos Berchieri, 200 - Centro Tel./ Fax: (16) 3202 3711 Level: 1.2, 2.2, 3.2, 4 and 5.2 [email protected] JANDIRA (06618-010) THEMA IND. COM. ASSES. E MANUT. ELÉTRICA LTDA R: Manoel Alves Garcia, 130 - Vl. Márcia Tel./ Fax: (11) 4789 2999 Level: [email protected] JUNDIAÍ (13211-410) REVIMAQ ASSIST. TEC. DE MÁQ. E COM. LTDA Av. Com. Gumercindo Barranqueiros, 20 Phone: (11) 4582 8080 Fax: (11) 4815 1128 Level: 1.1, 2.1 and 3.3 [email protected]

www.weg.net LIMEIRA (13480-743) GOMES PRODUTOS ELET. LTDA R: Pedro Antonio de Barros, 314 Phone: (19) 3451 0909 Fax: (19) 3442 7403 Level: 1.1, 2.2 and 3.3 [email protected] MATÃO (15990-000) WALDEMAR PRIMO PIN.& CIA. LTDA R: Narciso Baldan, 135 - Centenário Phone: (16) 3382 1142 Fax: (16) 3382 2450 Level: 1.2, 2.4 and 3.4 [email protected] MOGI GUAÇU (13844-282) ELETROSILVA ENROL.MOTOR. LTDA Av. Ulisses Leme, 1426 Phone: (19) 3861 0972 Fax: (19) 3861 2931 Level: 1.2, 2.2, 3.2, 4 and 5.2 [email protected] PIRACICABA (13400-770) ENROLAMENTOS DE MOTORES PIRACICABA LTDA R: do Vergueiro, 183 - Centro Phone: (19) 3417 8080 Fax: (19) 3417 8081 Level: 1.2, 2.2 and 3.3 [email protected] SANTO ANDRÉ (09111-410) MANUTRONIK COM.SERV.MOT.ELETR. LTDA Av. São Paulo, 330-Parque Marajoara Phone: (11) 6875 6280 Fax: (11) 6875 6290 Level: 1.2, 2. 2 and 3.3 [email protected]

SANTOS (11013-152) ELETROTÉCNICA L.S. LTDA Rua Armadro Bueno, 438-Paqueta Phone: (13) 3222 4344 Fax: (13) 3235 8091 Level: 1.2, 2.2, 3.2, 4 e 5.2 [email protected]

SÃO PAULO (03055-000) ELETRO BUSCARIOLI LTDA R: São Leopoldo, 225/301 Phone: (11) 6618 3611 Fax: (11) 6693 3824 Level: 1.3, 2.3 and 3.4 [email protected]

S. BERNARDO CAMPO (09832-270) ERG - ELETROMOTORES LTDA R: Luiza Viezzer Finco, 175 Phone: (11) 4354 9259 Fax: (11) 4354 9886 Level: 2.1 [email protected]

SÃO PAULO (04366-000) ESA-ELETROT. SANTO AMARO LTDA Av. Cupece, 1678 - JD Prudência Phone: (11) 5562 8866 Fax: (11) 5562 6562 Level: 1.2, 2.4 and 3.3 [email protected]

S. BERNARDO CAMPO (09844-150) HRISTOV ELETROMEC. LTDA Estrada Marco Pólo, 601/611 Phone: (11) 4347 0399 Fax: (11) 4347 0251 Level: 1.1 and 2.2 [email protected]

SÃO PAULO (02111-031) YAMADA–ASSIST.TEC.MOT.LTDA R: Itauna, 1111 – Vila Maria Phone: (11) 6955 6849 Fax: (11) 6955 6709 Level: 1.1 [email protected]

S. BERNARDO CAMPO (09735-520) YOSHIKAWA COM. MANUT. MÁQS. EQUIPS. LTDA R: Assahi, 28 - Rudge Ramos Phone: (11) 4368 4955 Fax: (11) 4368 0697 Level: 1.1, 2.2 and 3.2 [email protected]

SUZANO (08674-080) ELETRO MOTORES SUZANO LTDA R: Barão de Jaceguai, 467 Tel./Fax: (11) 4748 3770 Level: 1.1 [email protected]

SÃO JOSÉ DOS CAMPOS (12245-031) J. R. FERNANDES MOT. E MAQS. ELÉTRICAS LTDA Rua Miguel Couto, 32 - Jd. São Dimas Tel./Fax: (12) 3922 4501 Level: 1.1 [email protected]

OTHER COUNTRIES SAUDI ARABIA DAMMAM ISCOSA – INDUSTRIES & MAINTENCE, LTD P.O BOX 1032, 31431 Phone: 966 (03) 842 8380 Fax: 966 (03) 843 4333 [email protected]

ARGENTINA CASEROS – BUENOS AIRES ELECTROMECANICA ANTONIO CATTOZZO e HIJOS S.A.I.C Av. Mitre, 3628 Phone: (01) 750 2873/6987 Fax: (01) 734 2121/6885 Level: 1.2 and 3.3 [email protected] GODOY CRUZ - MENDOZA ELECTROMECANICA SASSO S.A R: Rodriguez Peña y Acceso Sur Tel./Fax: (054) 261 405 5100 Level: 1.3, 2.4 and 3.4 [email protected]

MÓRON – BUENOS AIRES REDINTER S.A Monteagudo, 871, 1708 Phone: (054) 11 4629 4142 Fax: (01) 11 4627 2611 Level: 1.3, 2.4 and 3.4 [email protected]

CHUQUICAMATA CODELCO CHUQUICAMATA District: Tocopilla, s/n Phone: (56) 55 352 185 Fax: (56) 55 325 167 Level: 1.4, 2.5 and 3.5 [email protected]

CHILE

SANTIAGO FERROMAN S.A Av. José Miguel Carrera, 13104 Phone: (56) 252 80851 Fax: (56) 252 84032 Level: 1.4, 2.5 and 3.5 ferroman-jsn@entelchile [email protected]

ANTOFAGASTA P&M MINE PRO Av. Pedro Aguirre Cerda, 6551 Phone: (56) 55 350 200 Fax: (56) 55 350 228 Level: 1.4 caaraya@phmining ANTOFAGASTA SALAR ELECT. ELECTM. INDUST. Av. Argentina, 4274 Phone: (56) 55 260 262 Fax: (56) 55 265 934 Level: 1.4, 2.5 and 3.4 [email protected]

SANTIAGO JORGE E. PINTO CARRASCO (TCHEM) R. José Joaquim Perez, 4385 Phone: (56) 2 773 3815 Fax: (56) 2 775 1868 Level: 1.4, 2.5 and 3.4

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CHINA

UNITED STATES

PARAGUAY

SHANGHAI SHANGHAI DON GHAO ELEC. MACHINERY CO. LTDA 399 Jin Wan Road, Jin Qiao Export Processing Zone, Pudong, Shang Hai, China. Zip: 201206 Phone: 86 21 5834 0165 Fax: 86 21 5834 2775 Level: 1.4, 2.4 and 3.4 [email protected] / [email protected]

CEDAR RAPIDS, IOWA HUPP ELECTRIC 275 33rd Avenue Southwest Phone: 1 319 366 0761 Fax: 1 319 366 4597 [email protected]

SAN LORENZON RECORD SERVICE R. Mcal. Estigarribiá km 10,5 Phone: (59) 521 511 991 Fax: (59) 521 585 096 Level: 1.3, 2.4 and 3.4

LONGVIEW, TEXAS FLANDERS ELECTRIC INC. 901 Harrison Road Phone: (903) 759 9439 Fax: (903) 297 9439 [email protected]

THAILAND

COLOMBIA BARRANQUILLA CENTRAL DE BOBINADOS S.A Carrera 13 Nº 30 - 44 Phone: (5) 363 6634 Fax: (5) 362 7041 [email protected] BUCARAMANGA CENTRAL DE BOBINADOS S.A Calle 17 Nº 17 – 18 Phone: (7) 671 2643 – 671 9394 Fax: (7) 671 3781 [email protected] SANTAFE DE BOGOTÁ L.K.S DEL CARIBE LTDA Carrera, 24 nº 23-89 Phone: (57) 1 596 7493 Fax: (57) 1 268 1957 Level: 1.4, 2.5 and 3.5

CUBA HABANA WALDO DIAS FUENTES Calle Jon de La Concha, 25 Phone: (537) 863 8371 Fax: (537) 863 8285 Level: 1.3, 2.5 and 3.5

INDIA BANGALORE RAJAMANE & HEGDE SERVICES (P) LTD Whitefield Road Mahadevapura Post Bangalore, 5600 48 Phone: 91 80 8524252 / 91 80 8524409 Fax: 91 80 8524950 Level: 2.3, 1.3 and 3.5 [email protected] DIST. PUNE IEC MOTOR SERVICES PVT. LTD Shed Nº 1094, Seurvey Nº 32/1/2/3, Tathwade, Tal. Mulshi, 411033 Phone: 91 20 5886651/ 91 20 5880689 Fax: 91 20 5889206 Level: 1.3, 2.3 and 3.4 [email protected] NAGAR (MAHALI) HSB ELECTRO HI-TECH PVT LTD C 142, Industrial Área, Phase VIII SAS, 160 057 Phone: 91 11 256624 / 91 11 390790 Fax: 91 11 390796 / 91 11 390438 Level: 1.3, 2.3 and 3.4 [email protected]

ACCREDITATION LEVEL 1. 1.1. 1.2. 1.3. 1.4.

INDUCTION MOTORS Up to frame 355 – Low Voltage – squirrel cage Up to frame 355 – Low Voltage – squirrel cage and slip ring Up to frame 500 – High and Low Voltage (up to 6.6 KV) – Cages and Rings Up to frame 500 and above – High and Low Voltage (up to 6.6 KV) – squirrel cage and slip ring

2. 2.1. 2.2. 2.3. 2.4. 2.5.

DC ENGINES Up to frame 132 Up to frame 180 Up to frame 280 Up to frame 355 Up to frame 355 and above

3. 3.1. 3.2. 3.3. 3.4. 3.5.

SYNCHRONOUS GENERATORS Up to frame 160 (Self-adjusted) Up to frame 225 (Low Voltage) Up to frame 250 (Low Voltage) Up to frame 400 (Low Voltage) Up to frame 400 and above – High and Low Voltage (6.6 KV)

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SAMUTSAKOM U-SERVICES CO. LTD 1/116 Moo 6 Industrial Park, Thasai, Muang, 74000 Phone: 66 34 490 584 5 Fax: 66 34 490 586 Level: 1.3, 2.3 and 3.4 [email protected] PATHUMTHANI AMC SERVICE – ASIA MOTOR SERVICE CENTER CO. LTD 13/2 Moo 6 Sanphigthai, Amphur Muang, 12000 Phone: 975 0223 30 Fax: 975 0231 32 Level: 1.3, 2.3 and 3.4

VENEZUELA CIUDAD OJEDA RIMES ELECTRO MEC. C.A Av. Intercomunal Phone: (58) 65 411 763 Fax: (58) 65 413 261 Level: 1.4, 2.5 and 3.5

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WEG Equipamentos Elétricos S.A. Internation Division AV. Prefeito Waldemar Grubba, 3000 89256-900 - Jaraguá do Sul - SC - Brasil Phone: 55 (47) 3276-4002 Fax: 55(47) 3276-4060 www.weg.net