GEN-SET

Excellence in Product Support Sup port

Gen er at o r Mai n t en an c e

Speaker: Aar A aro o n K emp em p f 2011 TC Conference Lafayett e, IN IN Caterpillar Caterpillar Confidential: Yellow

Excellence in Product Support

Ag A g end en d a

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Overview

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Shipping Ma Maintenance

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Startup Maintenance

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Regu Regula lar, r, Peri Period odic ic and and Ann Annua uall Mai Maint nten enan ance ce

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Monitoring Re Recommendations

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Insu Insula lati tion on Test est Rec Recom omm menda endati tion ons s

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Beari earing ng Tempe empera ratu ture re Guid Guidel elin ines es

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Bearing Replacement

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Stato tatorr Tempe empera ratu ture re Guid Guidel elin ine es

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Vibr Vibrat atio ion n Measu easuri ring ng Gui Guideli deline nes s

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Important Updates

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Maintenance Lit Literature

Caterpillar Caterpillar Confidential: Yellow


Overview •

Scheduled ch eduled Main Maintenance tenance – Who: • Customers and Dea Dealers! • CAT Warranty State Statement ment states states that the User User is responsib respon sible le for performance perfor mance of the requir ed maintena maint enance. nce. – What: Ap plications • Al A l l A p p l i c ati at i o n s (Stan (St and d b y , Pri Pr i m e, Con Co n t i n u o u s , etc et c .) – Where: • Onsite, nsi te, before/dur before/during ing/a /after fter Storage tor age,, before/after before/after Shippin g Produc t L ife – When: Produc hip ping, g, Storage, Start-up, Start-up, Regularly Regularly,, Perio Periodically, dically, Annually Ann ually • Shippin roc edures dur es – How: Proce Cleaning, Dryin g, Storage, Insu Insulation lation Resist Resistance ance,, Alignm Ali gnme ent, • Cleaning, Vibra ibr ation, tio n, Bearin Bearing g Greasing reasing,, Bearin Bearing g Temperature Temperature Monito ring, rin g, Stator Temperature Temperature Moni Monitor toring ing,, Contro ls and Prot Protection ection Setti Setti ngs – Why: Publ ication ic ation s (OMM (OMMs s and SOTAs SOTAs for fo r SR4,S SR4,SR4 R4B, B, and SR5) SR5) • SENR5359, SEBU6918, SEBU7270, SENR7968, KENR5284

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Genera nerato torr Ma Mainte in tena nanc nce e - Shipp hi ppin ing g • What happens happens whe wh en shipp sh ipping ing maintenance maintenance is not no t effectiv e?…

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Genera nerator tor Mainte int enance nance - Shippin hip ping g • Packaging – Proper Proper generator generator set cover pro tection n eeds eeds to be in pl ace for t he environment generator generator set is being ship ped in. • Handling – Proper Proper lift ing of generator generator sets usi ng lif ting eyes and and fix tures. – Refer Refer to respectiv respectiv e OMM OMM for mor e inform ation . • Shippi ng damages can’t can’t b e claimed claim ed as as warranty . – These These damage damages s sh ould be claimed claimed th rough the shippi ng/freight com pany.

Example of generator foot damage damage from ship ping

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Example Example of g rease deterioratio n after improper shipp ing and storage



Genera nerato torr Main Mainte tena nanc nce e - Stora to rage ge Below are some pho tos of adequate and and inadequate inadequate stor age practic es. In th ese examples, the generators/sets generators/sets shou ld b e properly covered fro m the eleme elements nts when stored. st ored. REFERENCE: SEHS9031 “ Storage Procedure for Caterpillar Caterpillar Products”

BAD BETTER

BAD

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BEST

Tight w rapping rapping is good for shipping and short stor age tim es. If longer stor age is requir ed, make sur e to cov er the package loosely.



Genera nerato torr Main Mainte tena nanc nce e - Stora to rage ge •

Dry Location – Cover Cover fo r pr otection – Loo se to allow allow g enerator enerator to br eathe eathe

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Turn ro tor ten (10) (10) revolut ions every every s ixty (60) (60) days

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Maintain Maintain win din g temperature – At A t l east eas t 5 °C h ig h er th an th t h e ambi am bi ent en t t emp erat er atur ur e – Space heater

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Insulation test – (reference (reference SEHS SEHS91 9124 24)) – Insulation test mus t be done when generator generator is

Make Make sure to c ompl ete when package is no t in stalled and and there is no in tention of installing i n the near near futu re.

Make Make every every effor t to co mplete when package is i n st orage and make sure to complete when package is being in stalled or is installed and not running (i.e., standby).

received – Insulation test mus t be repea repeated ted prior to start-up.

Example Example taken fro m SEBD0660 showing condensation inside the generator. Example Example of hot spot created created on bearing bearing race after after long s torage period without r otor turning.

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Genera nerato torr Maintena in tenanc nce e - Start tart--up •

Before apply apply ing b attery and shore power vol tage to the Genera Generator tor Set – Inspect Inspect g enerator nerator for debris, foreign objects, leaks leaks and loose connectio ns, broken fitting s, rubbing or d amaged maged wiri ng, guards guards and com ponents. pon ents. Repa Repair ir as necessary. • i.e., i.e., Lead Lead ch affin g fr om generator generator st ator to bus. – Check Check for p roper ground ing. • (Reference REHS4634) – Check Check space s pace heaters heaters for fo r pro per operation .

Example Example of lo ose PMG PMG bolts, not n oted before startup

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Genera nerato torr Maintena in tenanc nce e - Start tart--up • System System c heck pri or to Generator Generator Set Set o peration peration – –

Must DOCU DOCUME MENT NT data data on each each for future fut ure r eference eference

– Al A l i g n m ent en t (LEB (L EBW4975, W4975, SEHS7654, SEHS7654, SEHS7259, SEHS7073, SEHS7073, REHS0177). REHS0177). – Ai A i r g ap (m ( m ain ai n g ener en erat ato o r , exc ex c i t er, er , & PMG) even ev en ar o u n d c i r c u m f erenc er enc e – Insulati on test – (Refe (Reference rence SEHS SEHS91 9124 24)) – Measure Generator winding resistances (SENR5359 for SR4B, KENR5284 for SR5) • Main Main Stator Stator /Roto /Roto r, Excit er Stator Stator /Roto /Roto r, PM Stator Stator /Roto /Rotor r • Compensate readings for temperature and use micro-ohmmeter • Record Record for tr end plot ting! – Coordination of s ettings – Generator nerator control and prot ective settings settings • Factor Factor y default settings not appli cable to every every application • Dea Dealer and/or and/or thir d party cons ultant is r esponsibl e for Coordi nation Study at each each sit e – Circuit breaker – ECM, ECM, EMCP, EMCP, and and CDVR, CDVR, Droop Droo p (KW (K W and K VAR) – Differenti al Prot Prot ection, ectio n, Reve Reverse rse KVAR Prot Prot ection , etc. etc.

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Genera nerato torr Maintena in tenanc nce e - Start tart--up • System System c heck when Genera Generator tor Set is runni ng – Must DOCU DOCUME MENT NT data data on each each for fut ure refe r eference rence – Record the following at No Load and and Full Load • Beari Bearing ng temperature (per r espective espectiv e OMM) OMM) • Stator Stator temperature (per respect ive OMM) OMM) • Ai A i r i n l et t emp em p erat er atu u r e (and (an d at areas ar eas w h ere er e air r eci ec i r c u l ati at i o n c o u l d exi ex i s t ) – Confirm no air recirculation recirculation is oc curring – Refer Refer to TMI generator generator inf orm ation and g enerator enerator n ameplate ameplate • Vibration levels (Reference A&I Guide LEBW4972) Voltage regulator regulator & excit ation sy stem • Voltage – Sensing voltage – Excitation v oltage and and c urrent (refer (refer t o TMI generator generator i nfor mation) » Determi Determined ned by Load and Power Facto Facto r

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Genera nerato torr Maintena in tenanc nce e - Start tart--up • Af A f t er s t o p p i n g t h e Gener Gen erat ato o r Set – Inspect the generator generator and report malfu nction nct ions. s. • Inspect for loose, broken, rubbing or d amaged maged wir ing or components. • Make repairs or adjustments adjustm ents to the generator generator set as necessary. necessary. – Check Check that t hat generator generator air i nlet fil ter is clea c lean, n, if applic able. able. generator space heater heater is operating. – Verify generator

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Generato neratorr Ma Maintena in tenanc nce e - Regular gu lar • Durin ur ing g Generator Generator Set Set opera op erati tion on – Must DOCU DOCUME MENT NT and TREND TREND data on each each for fo r fut f utur ure e reference – Monitor Monit or Phase curr ent, Neutral Neutral cu rrent, rr ent, Vol Voltage, tage, Frequ Frequency, ency, Power Facto Factor, r, Ha Harmonic rmo nic content, con tent, and and Load va v ariation – Monitor Room Temperatures – Monitor oni tor Bearin Bearing g and Stator temperatures temperatures (when (when applicable) ppl icable) – Monitor for Alarm Alarm and Shutdow n Indicators Indicators – Check th at ge g enerator nerator air inle inl et filter f ilter is clean, clean, if appli cable. cable.

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Genera nerato torr Ma Maintena in tenanc nce e - Period ri odic ic • Af A f t er s t o p p i n g t h e Gener ato at o r Set f o r p eri er i o d i c m ain ai n t enanc en anc e – Periodic Maintena Maintenance nce tim e interval is based based on Appli cation • Referenc Reference e respectiv respect ive e OMM OMMs s – Must DOCU DOCUME MENT NT and TREND TREND data on each f or futu fu ture re referenc e – Inspect g enerator nerator for debris, foreign objects, leaks leaks and l oose conn ectio ns, broken fitt ings, rubbi ng or d amaged amaged wiring , guards and compon ents. Re Repair as necessary.

– Inspect Main Stator & Rot or, or , Exciter, Excit er, and PMG PMG – Clean Clean as nee n eeded ded (Mois ture, tu re, Salt, Salt, Dirt, Dir t, Grease, Grease, Oil) – Referenc Reference e SEH SEHS9 S912 124 4 for Generato Generatorr Cleanin g and Dryi Dr ying ng – Check space heaters for proper operation. Check Air Gap Gap (main generator generator , exc exciter, iter, & PMG) PMG) – Check – Insulati on Test Test – (SEH (SEHS9 S912 124) 4)

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Genera nerato torr Ma Maintena in tenanc nce e - Annua Ann uall • Af A f t er Sto St o p p i n g The Th e Gener ato at o r Set – Must DOCU DOCUME MENT NT and TREND TREND data on each f or futu fu ture re referenc e – Complete Compl ete Peri Periodi odi c Maintenance Proc Proc edures – Al A l i g n m ent en t (LEB (L EBW4975, W4975, SEHS7654, SEHS7654, SEHS7259, SEHS7073, SEHS7073, REHS0177). REHS0177). – Measur Measure e Generator Generator Windin Wind ing g r esistanc esis tances es (SEN (SENR5 R535 359 9 for SR4B, SR4B, KENR5 KENR528 284 4 for SR5) • Main Main Stator Stator /Roto /Roto r, Excit er Stator Stator /Roto /Roto r, PM Stator Stator /Roto /Rotor r – Vibration Levels (LEBW4972) – Generato Generatorr Bea B eari ring ngs s and Wear Wear Sleeves • Grease Grease Bearin Bearin g(s) as r equired – Refer Refer t o REHS4 REHS489 892 2 for greasing requir ements ements – A – Av v o i d o v er-g er -grr easi n g /mi /m i x i n g g r eases eas es and u s e co c o r r ect ec t g r ease eas e • Check Check for good in tegrity of lip seal seal – Inspect Inspect and clean clean all main curr ent carry ing m echanical echanical cont acts such as circ uit b reakers reakers and and tr ansfer swit ches

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Genera nerator tor Mainte int enance nance - Monitor oni toring ing Recomme com mendation ndations s • Trending – Understand the monit mon itored ored proce proc ess

or malized d readi reading ngs s – Normalize •

For all resistance rea readings, din gs, correct cor rect for temperature temperature

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Refer to SEHS9124

– Record cor d on chart – Focus on changes changes occurri occ urring ng ove ov er time ti me – Scheduled cheduled repa repairs irs inste in stea ad of unplanned unplanned downtime downt ime

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Generator nerator Ma Mainte int enance nance - Monitor oni toring ing Recomme com mendations ndations Time to schedule downti me and and repair repair of o f the th e generator.

Shown above is an an exampl example e of regular r egular insul ation tr ending ndi ng and the result o f not no t acting ahead ahead of tim e.

Source: Source: Graph Graph taken and formatted formatted fro m “ Stitch in Time” (Megge (Megger, r, 2006 2006))

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Generato neratorr Ma Mainte int enance - Insula Insul ation ti on Test Test Recom Recommenda mendati tions ons (References: OMM & SEHS9124) • When to Test • Safety • Testing Process • Prepare for fo r the t he Test Test • Insulation Insul ation Resi Resistanc stance e Test Test – Perf Perfor orm m the th e standard st andard 30/6 30/60se 0sec c test at a mini mi nimu mum m

• Polariza ol arizati tion on Index Test Test – Perform when unit i s in storage and/or and/or moist enviro nment.

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Generator nerator Maintena in tenance nce - Beari Bearing ng Temperature Guid Guide elines li nes • Bearing Bearing Temperature mperature Se Set-points – All Ap plications – Al A l arm ar m 85 °C – Shutd own ow n 95 °C • Exceptions exist in specific SR5 SR5 product using synthetic g rease. rease. – For 1800 1800/3 /300 000 0 frame, fram e, set-poi set-p oint nts s are: • Al A l arm ar m 95 °C • Shutdow Shutd own n 105 105 °C °C • Temperature Temperature is affected affected by ambient mbi ent but m ax setti setti ngs are not! • Generators Generators shipped shi pped with w ith Platin Platinum um 100 ohm RTDs RTDs – Packages Packages can be or dered with wi th b eari earing ng RTDs RTDs – RTDs are 2-wire 2-wire • Track Track and investi gate any change from fro m his torical tor ical trend

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Generato neratorr Main Maintena tenanc nce e - Beari Bearing ng Repla pl acement cement • Removi Removi ng Hub and Bearings – When W hen applicable, heat heat front dr ive hub evenly with two (2) ros ebud torc hes with propylene gas gas and puller or use destructive method method (ie. cutting tool, etc.) etc.) to remove hub with care not to damage rotor sh aft. – Heat H eat should be appli appli ed to the hub fo r approx imately 5-6 5-6 minu tes. – Do not attempt attempt to heat heat hub with one (1) (1) torch, and and forci bly pull off shaft. – Puller P uller and ram drive shou ld be capable of su pply ing at least 35 35 tons of fo rce. – Refer R efer to respective SOT SOTA A manual for fur ther bearin bearin g removal inst ructi ons us ing specified tools. • Installing Hub and Bearing Bearing s – Use – Use an indu ction heater, heater, etc. etc. to heat the ball b earin earin gs to recommended temperature and mount t o the shaft. – Whe – When n applic able, evenly evenly h eat eat the dri ve hub to specified temperature and moun t the hub to the shaft.

Reference Reference respect ive iv e generator SOTA SOTA manual for more bearing bearing installation ins tallation and remov removal al information. Page 280



Generato neratorr Main Maintena tenanc nce e - Stator Temp Tempe erature ratur e Guidelines

• Stator Stator Temperatur Temperatur e Set-Points Set-Points – Al A l arm ar m 180 °C, Shu t d o w n 190 °C (Stan d b y ) – Al A l arm ar m 155 °C, Shu t d o w n 165 °C (Pri (Pr i m e/Con t i n u o u s ) • Exception Exception s exist fo r SR5 SR5 product – Al A l arm ar m 200 °C, Shu t d o w n 215 °C, (Stan d b y ) – Al A l arm ar m 175 °C, Shu t d o w n 200 °C, (Pri (Pr i m e/Con t i n u o u s ) • Based on NEM NEMA A standards , it is i s recomm ended to stay below th e alarm alarm sets etpoint s to prevent prevent wind ing deterior deterior ation. • Genera Generators tors wit h Form Wound Stators Stators ship ped with Platinum 100 100 ohm RTDs RTDs – Rando Rando m Wound Packages Packages can be ordered wit h stator st ator RTDs RTDs – RTDs RTDs are are 3-wir 3-wire e for com pensation accuracy • Track Track and Investig Investig ate any any Change Change from hist oric al trend • Output Lim ited by Rotor o r Stator Stator Temp. • Temp. Temp. Rise Func Func tio n of Generator Generator Out put • Measurement Method – Embedded Detecto Detector r – Rise by Resi Resistance stance The standard, mus t add hot spo t allowance allow ance • Refer to IEEE IEEE 112-19 112-1996 96 (Sect (Sectio io n 8.3.3) 8.3.3)

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Generato neratorr Ma Mainte int enance - Vibration ib ration Mea Measuri su ring ng Guideline Guidelin es • Measur easure e on packa p ackage ge at nor mal ope op erating temperatur temperature e • Use monthl mon thly y readin readings gs to establish b aselin aseline e • Vibra ibr ation tio n levels levels are load dependent dependent • Investi Investigate gate signif sig nificant icant changes frequencies es showin sho wing g up – New frequenci – Increasin Increasing g ampl amplitu itudes des of origi nal frequenci frequencies es • To accu accurate rately ly comp c ompare are to f actory guidelines gui delines per LEBW49 LEBW497 72, vibr ation tool t ool used must be factory factory approved. – Al A l t ern er n ate at e to t o o l s c an b e us u s ed f o r s i t e-sp e-s p eci ec i f i c t r end en d i n g p u r p o s es, es , bu but comparison t o factory guidelines guidelines cannot b e relied relied upon. – New facto factory ry to ol is curr c urr ently ntl y being validated to replace the previou sly available available CSI CSI Vibr Vibration ation Analyzer Analyzer Tool.

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Generato neratorr Maint Mainte enance – Importa Import ant Updates pdates •

SEHS SEHS91 9124 24 – Generator Generator Cleanin Cleanin g and Dry ing – Existing docum ent up dated dated to impr ove wordi ng and emphasize emphasize Polariza Polarization tion Index Index (PI) (PI) test for testing generators generators i n s torage and/or and/or mo ist environm ents.

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REHS REHS48 4892 92 – Generator Generator Bearin Bearin g Servic e – Special Special Instruct ion p ublis hed in early early 2010 2010 to up date the latest latest bearing bearing maintenance recommendations. – Single and and Doubl e-shi e-shi elded bearings bearings are recom mended for gr easin easin g at prescr ibed intervals. in tervals. Resea Researc rch h has sho wn gr ease ease does penetrate penetrate the shield when the bearin bearin g bracket brack et cavity i s 50% 50% ful l.

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Bearing Bearin g Change for f or 1800 1800/3 /300 000 0 SR5 SR5 Generato Generators rs – In late 2011 2011,, these generator generator s w ill be packaged wi th greaseable greaseable (2S(2S-32 3230 30 grease) grease) sing le-shielded le-shielded bearing bearing s i n pl ace of n on-greasea on-greaseable ble synth etic grease grease doubl e-shielded e-shielded bearing bearing s. – This allow s the th e end-user to add new grease as the grease grease breaks breaks down d own o ver time.

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Genera nerator tor Mainte int enance nance - Lite Lit erature • SEBD9205 Proper Storage of Generators • SEHS9031 Storage Procedures for Caterpillar Products • SEHS9124 Cleaning and Drying of Generators • LEXE0095 Electric Power Start-up Checklist • LEBW4975 Alignment LEBW4975 Alignment A&I Guide • SEHS7654 Alignment SEHS7654 Alignment - General Instructions • SEHS7259 Alignment SEHS7259 Alignment of Single Bearing Generators Generators • SEHS7073 Alignment SEHS7073 Alignment of Two Bearing Generators Generators • REHS0177 Alignment REHS0177 Alignment of Two Bearing Close-Coupled Close-Coupled Generators • LEBW4972 Linear Vibration A&I Guide • SEBU7270 SR4/SR4B High Voltage OMM • SEBU6042 Maintenance for Standby Gensets

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Generato neratorr Ma Mainte int enance – Lite Lit erature, cont. con t. • SEBU6918 SR4B Generator OMM • SENR7968 SR4 Generator SOTA Manual • KENR5284 SR5 Generator SOTA Manual • SENR5359 SR4B Generator Service Manual • SENR5833 Digital Voltage Regulator Service Manual • RENR2480 VR6 Service Manual • RENR7941 CDVR Service Manual • REHS4892 Generator Bearing Service • REHS4634 Grounding Design Guide for EPG Products

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