Condition Assessment of Unit # 1

Generator 210 MW NLC

Preliminary Report
On
Residual Life Assessment
Of
Unit # 1, 210 MW Generators
Neyveli Lignite Co-operation

6TH DEC to 16TH DEC 2006

SUBMITTED BY

ALSTOM Projects India Ltd.

Power Services - EM Technology

Alstom Projects India Ltd, Vadodara

-1-

Condition Assessment of Unit # 1

Generator 210 MW NLC

TABLE OF CONTENTS
Electrical Tests:
Stator:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Insulation Resistance and Polarization Index measurement

Winding Resistance measurement
ELCID Test
Capacitance and Tan Delta measurement
Partial Discharge measurement
Core bolt insulation resistance measurement
Wedge tightness test
RTDs Resistance and Insulation resistance measurement
Natural frequency measurement of end-winding

Rotor:
1.
2.
3.
4.

Insulation resistance measurement

Recurrent Surge Oscillograph
Winding Resistance measurement
Winding Impedance measurement

NDT test
Operation history data

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Condition Assessment of Unit # 1

Generator 210 MW NLC

1. Insulation resistance and Polarization Index measurement @ 5KV DC

Temp.: 280C
Time
15 sec
30 sec
45 sec
1 min.
2 min.
3 min.
4 min.
5 min.
6 min.
7 min.
8 min.
9 min.
10 min.
Polarization Index

R Earth (G)
2.71
4.46
6.82
8.52
13.2
17.6
20.3
23.8
30.8
31.2
31.8
37.6
38.6
4.53

Y-Earth (G)
2.18
4.36
6.44
8.13
13.0
17.2
20.3
24.1
33.6
35.7
38.3
40.6
43.6
5.35

B-Earth (G)
2.26
3.90
5.38
6.68
11.4
15.8
17.8
23.3
37.3
40.3
43.6
45.7
49.6
7.43

Insulation resistance measurement between the phases @ 5 KV DC.

Time

R Y (G)

Y-B (G)

B-R (G)

15 sec
30 sec
45 sec
1 min.
2 min.
3 min.
4 min.
5 min.
6 min.
7 min.
8 min.
9 min.
10 min.
Polarization Index

6,54
11,8
17,6
22,8
40,1
55,1
72,1
81,1
90,1
98,2
101,1
107
113
4,95

5,47
9,54
12,8
17,9
36,5
50,1
68,0
83,2
88,8
94,5
99,8
101,2
99,7
5,55

5,54
10,4
13,2
17,3
29,1
39,5
55,8
75,3
88,1
96,5
98,2
101,3
104,2
6,023

2. Stator Winding Resistance measurement @ 280C

Phase
R-R
Y-Y
B-B

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Winding resistance
(m)
1.361
1.352
1.365

Alstom Projects India Ltd, Vadodara

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Condition Assessment of Unit # 1

Generator 210 MW NLC
3. Core bolt Insulation Resistance measurement @ 1 KV DC ( 15 Sec)
Core
Bolt
no,
1,
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Insulation Resistance
Core
Bolt
no,
(G)
0,917
1,02
1,16
1,80
2,05
1,66
1,73
1,68
2,02
1,90
1,85
1,90
1,34
4,50
1,5

16,
17,
18,
19,
20,
21,
22,
23,
24,
25,
26,
27,
28,
29,
30,

Insulation
Resistance
(G)
2,03
1,88
1,97
1,89
2,04
3,02
2,6
8,66
2,33
4,05
3,56
4,05
5,23
5,05
5,38

EE

4. Capacitance and Tan delta measurement on stator winding @ 320C

Phase
Current Watts
% PF Tip(mA)
Loss
% PF
up
CAP (nF)
Test (KV) ENG
GND
2,0
4,0
6,0
8,0
9,0
2,0
4,0
6,0
8,0
9,0

PHASE TO GROUND INSULATION

128,8
1,512
260,8
6,208
R
YB
391,8
15,33
526,4
39,55
590,4
61,88

2,0
4,0
6,0
8,0
9,0

9,0
9,0
9,0
9,0
9,0
9,0

R-B
R-Y
Y-B
Y-B
B-Y
B-R

BR

130,0
260,8
391,2
522,4
589,5

1,472
6,144
15,69
42,62
68,52

(GST MODE)
0,586
0,595
0,652
0,932
1,16
0,574

213,1
213,1
213,3
214
214,4

0,566
0,589
0,688
1,021
1,291

0,725

212,5
212,6
212,9
213,7
214,6

0,744

0,624
0,647
0,718
1,107
1,368

130,6
1,63
0,624
260,8
6,75
0,647
RY
392,4
16,92
0,718
524,0
46,20
1,102
593,1
73,20
1,368
INER PHASE INSULATION (UST MODE)
Y
1,926
0,132
0,76
B
2,043
0,132
0,72
B
2,043
0,116
0,63
R
2,043
0,115
0,62
R
2,061
0,179
0,96
Y
1,935
0,124
0,71

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0,711
0,752
0,752
0,751
0,752
0,711

Alstom Projects India Ltd, Vadodara

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Condition Assessment of Unit # 1

Generator 210 MW NLC

5. Partial Discharge measurement by TVA probe @ 9 KV AC

Slot
no,
1
2
3
4
5
13
14
15
16
17
18
19
20
28
29
30

R- Phase
Bar mA
E,E
T & B 0,4
T & B 0,4
T
0,4
T
0,6
T
0,4
B
0,8
B
0,8
B
1,0
T & B 1,2
T & B 1,2
T
0,8
T
0,8
T
1,2
B
0,4
B
0,4
B
0,4

mA
T,E
1
1,4
1,6
1,8
2,0
1,2
1,4
1,6
1,6
1,8
1,8
1,6
1,4
0,6
0,6
0,8

Slot
no,
8
9
10
11
12
13
14
15
23
24
25
26
27
28
29
30

Y-Phase
Bar mA
E,E
B
1,0
B
0,4
B
1,0
T & B 1,0
T & B 0,8
T
0,8
T
0,8
T
0,8
B
0,4
B
0,4
B
0,4
T & B 0,4
T & B 0,6
T
0,6
T
0,6
T
0,8

mA
T,E
0,4
0,4
0,6
0,6
1,0
0,8
0,6
0,6
0,4
0,4
0,4
0,4
0,4
0,6
1,0
0,6

Slot
no,
3
4
5
6
7
8
9
10
18
19
20
21
22
23
24
25

B- Phase
Bar mA
E,E
B
0,4
B
0,8
B
1,0
T & B 1,2
T & B 1,2
T
1,4
T
1,2
T
1,0
B
1,4
B
1,0
B
1,4
T & B 1,0
T & B 1,0
T
0,8
T
0,6
T
0,4

mA
T,E
0,4
0,4
0,6
0,6
1,0
1,0
1,2
1,2
0,4
0,6
0,6
0,8
1,2
1,0
1,0
0,4

Insulation Resistance after HV test @ 5 KV

Time
15 sec,
30 sec,
45 sec,
1 min,

R-E (G)
3,30
7,03
9,91
14,1

Y-E (G)
3,38
7,80
12,4
17,3

B-E (G)
3,2
7,08
11,8
14,6

6. ELCID TEST :
The digital ELCID test was carried out on Stator core after removal of Rotor. The
condition of interlamination insulation found to be in healthy condition, the leakage
current found with in limit of threshold value. Graphs are attached for ready reference.

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Condition Assessment of Unit # 1

Generator 210 MW NLC

7. RTDs Resistance and IR measurement @ 250V DC

Resitance

RTD No.

1A
2A
3A
4A
5A
6A
7A
8A
9A
10A
11A
12A
13A
14A
15A
16A
17A
18A
19A
20A
21A
22A
23A
24A
25A
26A
27A
28A
29A
30A
31A
32A

V G
()
111.7
112.0
112.2
112.0
112.1
112.1
111.7
111.7
111.8
112.0
111.9
111.8
111.4
111.3
111.5
111.7
111.5
111.3
111.6
111.8
111.2
112.3
112.1
111.9
112.5
111.4
111.8
111.5
112.1
111.4
112.2
111.5

R-G ()

R - Y ()

Insulation
Resistance
(M)

0.5
0.6
0.8
0.5
0.7
0.8
0.5
0.5
0.5
0.5
0.6
0.5
0.2
0.2
0.2
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.5
0.5
0.3
0.3
0.3
0.3
0.3
0.3

111.7
112.0
112.2
112.0
112.1
112.1
111.7
111.7
111.8
112.0
112.0
111.7
111.4
111.4
111.5
111.7
111.5
111.3
111.6
111.8
112.0
112.3
111.1
111.9
112.5
111.4
111.8
111.5
112.1
111.4
112.2
111.5

175
357
7130
184
184
289
1600
200
3980
101
1150
142
311
7880
117
135
137
143
253
298
198
354
693
453
1020
1130
677
818
1310
611
666
846

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RTD No.

1B
2B
3B
4B
5B
6B
7B
8B
9B
10B
11B
12B
13B
14B
15B
16B
17B
18B
19B
20B
21B
22B
23B
24B
25B
26B
27B
28B
29B
30B
31B
32B

Resitance
V G
()
112.0
112.2
112.5
112.3
112.4
112.3
112.0
112.0
112.0
112.3
112.1
111.7
111.6
111.8
111.9
111.8
111.6
111.6
111.8
112.0
112.4
112.1
111.9
111.9
111.5
111.8
111.4
111.4
112.1
111.3
112.0
111.5

R-G ()

R - Y ()

0.6
0.8
1.0
0.6
0.8
0.9
0.7
0.7
0.8
0.8
0.8
0.8
0.5
0.5
0.6
0.5
0.5
0.5
0.3
0.3
0.3
0.3
0.3
0.3
0.4
0.4
0.3
0.3
0.3
0.3
0.3
0.3

112.0
112.2
112.5
112.3
112.4
112.3
112.0
112.0
112.0
112.3
112.3
111.1
111.7
111.6
111.8
111.8
111.6
111.6
111.8
112.0
112.4
112.1
111.9
111.9
111.5
111.8
111.4
111.4
112.1
111.3
112.0
111.5

Insulation
Resistance
(M)
114
172
184
231
246
105
1270
3730
105
65.2
1090
49.9
230
856
94.9
58.5
1950
94.6
416
1670
605
405
1420
450
2190
756
2850
8120
3280
1140
2980
2350

Alstom Projects India Ltd, Vadodara

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Condition Assessment of Unit # 1

Generator 210 MW NLC

8. Dynamic Natural Frequency test on Stator End winding

B

Hammer Striking Position

Exciter End
Top Bar
Slot no.
A (Hz)
1
57.5
2
132.5
3
131.4
4
132.5
5
145
6
45
7
133
8
141
9
151
10
152
11
64
12
142.5
13
142.5
14
131.5
15
120.5
16
55.5
17
140
18
145
19
145
20
126
21
68
22
123.7
23
130
24
137.5
25
137.5
26
48.7
27
140
28
140
29
146
30
146

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B(Hz)
57.5
132.5
131.4
132.5
145
45
133
141
151
152
64
142.5
143
131.5
120.5
55.5
140
145
145
126
68
123.7
130
137.5
137.5
48.7
140
140
146
146

Bottom Bar
Slot no.
A(Hz)
B (Hz)
1
57.5
57.5
2
132.5
132.5
3
131.4
131.4
4
132
132
5
147.5
147.5
6
70
71
7
133
133
8
141
141
9
151
151
10
152
152
11
87.5
85
12
142.5
142.5
13
142.5
142.5
14
131
131
15
120
120
16
76
76
17
140
140
18
145
145
19
145
145
20
126
126
21
87.5
87.5
22
123.7
123.7
23
130
130
24
137.5
137.5
25
137.5
137.5
26
140
140
27
140
140
28
88.7
88.7
29
146
146
30
146
146

Alstom Projects India Ltd, Vadodara

-7-

Condition Assessment of Unit # 1

Generator 210 MW NLC

Turbine End
Top Bar
Slot no.
A(Hz)
1
119
2
129.5
3
91.5
4
132.5
5
130.5
6
134
7
133.5
8
109
9
133.5
10
119.5
11
136
12
120
13
92.5
14
135
15
133
16
133
17
126.5
18
119
19
130
20
130
21
119
22
129
23
112.5
24
138
25
136
26
132
27
125.5
28
126.5
29
131
30
119

B(Hz)
119
129.5
91.5
132.5
130.5
134
133.5
109
133.5
119.5
136
120
92.5
135
133
133
126.5
119
130
130
119
129
112.5
138
136
132
125.5
126.5
131
119

Bottom Bar
Slot no.
A(Hz)
1
119
2
129.5
3
91.5
4
132.5
5
130.5
6
134
7
133.5
8
109
9
133.5
10
119.5
11
136
12
120
13
92.5
14
135
15
133
16
133
17
126.5
18
119
19
130
20
130
21
119
22
129
23
112.5
24
138
25
136
26
132
27
125.5
28
126.5
29
131
30
119

B(Hz)
119
129.5
91.5
132.5
130.5
134
133.5
109
133.5
119.5
136
120
92.5
135
133
133
126.5
119
130
130
119
129
112.5
138
136
132
125.5
126.5
131
119

9. Wedge Deflection measurement on Stator wedges.

Test was carried out at 120 Kg/ Cm2 as per attached chart. All result
found with in limit.

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Alstom Projects India Ltd, Vadodara

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Condition Assessment of Unit # 1

Generator 210 MW NLC

Rotor :

1. Insulation Resistance measurement @ 500V DC Temp. : 320C

IR 15 sec
IR 1 min.
1,00 M
1.33 M
2. Winding Resistance measurement @ 28 0C = 101,6 m
3. Winding Impedance measurement
Voltage
(V)
6,74
12,31
19,69
25,12
31,58
38,38
45,51
53,60

Current
(A)
2,22
4,06
6,47
8,09
10,05
12,03
14,01
16,01

Impedance
(Z)
3,03
3,03
3,04
3,10
3,14
3,19
3,24
3,33

4. Digital Recurrent Surge Oscillograph test:

The test was carried out on 08.12.06 after removal of generator rotor. Test was
conducted to detect the inter turn and earth fault inside the rotor winding. Both the
waveform are superimposed perfectly on each other, hence there is no indication
of fault inside the winding. Graphs are recorded further analysis and same will
give in final report.
NDT test:
Following test were carried out, no abnormalities found. Results will be submitted with final
report.
1. Vent holes and cooling path checked for blockage
2. UT examination of retaining ring and Journals
3. DPT on fan rings
4. Magnetic Particle Inspection of Half coupling
5. Metallographic surface examination of rotor / end retainings.

Machine history collected from NLC for Unit # 1

Sr.
No.
1
2
3
4
5
6
7
8

Description
Total working hours
Working Hours since last overhaul
Hour per year at rated power (From
1997-1998)
Hour per year at 75% of rated
power (From 1997-1998)
Hour per year at 50% of rated
power (From 1997-1998)
Starts up (Cold / Hot)
Starts up since last overhaul (Cold /
Hot)
Over loads per year

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Data
132102:50
34942:13
6386:35:00
807:33:00
107:40:00
239
72
1.74%

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-9-