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HANNON ELECTRIC COMPANY<br />
<strong>ESI</strong> <strong>–</strong> <strong>EMD</strong> <strong>Owner’s</strong> <strong>Group</strong><br />
<strong>Summer</strong> <strong>2016</strong> <strong>Meeting</strong> & <strong>Training</strong><br />
<strong>Stephen</strong> R. <strong>Pomesky</strong>
Yesterday’s <strong>EMD</strong> Generator…<br />
Maintenance friendly design<br />
Maintenance Instructions (<strong>EMD</strong> MI 3327<br />
Rev D) Issues<br />
• Use caution and protect the Output<br />
Bus Terminals when floating the rotor<br />
assembly into and out of Stator<br />
• When assembling the bearing housing, coat the<br />
bearing housing with Molycoat and wait before<br />
beginning assembly<br />
<strong>EMD</strong> Design modifications over the years<br />
• Rectangular to Round wire in pole windings<br />
• Stopped using “rubber” coated stator windings
Yesterday’s Generator… What We See Today<br />
Bearing Grease<br />
Stator Windings
Yesterday’s Generator… What We See Today<br />
Core Loss<br />
• Overall stator core loss is<br />
within an acceptable range<br />
• Small sections of the core<br />
have excessive loss
Yesterday’s Generator… What We See Today<br />
Pole Piece<br />
Unwinding Each Pole
Yesterday’s Generator… What We See Today
Yesterday’s Generator… What We See Today<br />
Discovering a shorted pole<br />
Pole piece insulation
Rewinding Today’s Generator for Tomorrow...<br />
Stator and Layout<br />
Installing Stator Windings
Rewinding Today’s Generator for Tomorrow...<br />
VPI Process with Mock Slot Coils<br />
Stator after VPI Process
Rewinding Today’s Generator for Tomorrow...
Rewinding Today’s Generator for Tomorrow...
Rewinding Today’s Generator for Tomorrow...<br />
Stator after Bake-out
Rewinding Today’s Generator for Tomorrow...
Rewinding Today’s Generator for Tomorrow...<br />
Pole Piece and Winding Profile<br />
Isotropic Insulation <strong>–</strong> The Foundation
Rewinding Today’s Generator for Tomorrow...<br />
Pole Windings:<br />
Rectangular wire optimizes thermal transfer<br />
The Hannon Wet Winding Epoxy process<br />
ensures complete encapsulation<br />
Corners are insulated with a layer of DMD<br />
Crossovers are formed with DMD insulation<br />
<strong>–</strong> DMD is then replaced after completely<br />
formed<br />
Connection straps are mechanically<br />
integrated into the pole<br />
Epoxy is applied to the outer pole windings<br />
Poles are allowed to “rest” for 24 hours (coil<br />
weight out) before bake out
Assembling Today’s Generator...<br />
Rotor is balanced<br />
after it is fully<br />
assembled<br />
Balanced to G0.4
Testing Today’s Generator... For Tomorrow…<br />
Stator Testing<br />
• Megger / Hi-Pot with PI (up to 14KV)<br />
• Surge Test<br />
• PdMA Resistance Imbalance<br />
• PdMA Inductance Imbalance<br />
• “Ball Out” Test<br />
Pole / Rotor Testing<br />
• Megger<br />
• PdMA Resistance Imbalance<br />
• AC Volt Drop (typically at 240 VAC)<br />
• DC Volt Drop at rated current<br />
• Megger at Field Lead Connection once Assembled
Testing Today’s Generator... For Tomorrow…<br />
Dynamic Testing at 900 RPM’s<br />
Motive force provided by 400 HP DC Motor<br />
Testing Sequence Derived from IEEE<br />
Standard 115, Method 4, Section 6.2.4<br />
• Full Voltage Output <strong>–</strong> Open Circuit<br />
○ Maintain 4160 Volt output until Temperature<br />
Stabilizes (typically 4 to 5 hours)<br />
○ Chart all Electrical and Mechanical Parameters<br />
• Full Load Current Output <strong>–</strong> Short Circuit<br />
○ Maintain 452 Amps output (<strong>EMD</strong> A20) until<br />
Temperature Stabilizes (typically 5 to 7 hours)<br />
○ Chart all Electrical and Mechanical Parameters
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…
Testing Today’s Generator... For Tomorrow…<br />
Post Dynamic Testing<br />
• Stator Testing<br />
○ PdMA Resistance Imbalance<br />
○ PdMA Inductance Imbalance<br />
○ Megger<br />
• Revolving Field Testing<br />
○ Megger<br />
○ Check brush tension<br />
Megger Bearing Insulation<br />
Check Brushes & Rings
Noteworthy items…<br />
Use caution when floating generator apart and<br />
together<br />
Read ALL assembly instructions before<br />
assembly<br />
Reducing Vibration<br />
• Install Stiffeners in<br />
Supporting I-Beams<br />
• Install support feet<br />
• Eliminate soft foot<br />
• Shim under structural<br />
framing members
Conclusions…<br />
Diesel driven generators can be Rewound /<br />
Rebuilt to match Original Nameplate<br />
Specifications<br />
Generators can be thoroughly tested to<br />
verify the Rebuild<br />
Additional Items: Winding RTD’s, Bearing<br />
RTD’s, Space Heaters, Bearing<br />
Accelerometers, MTAP’s for PdMA Testing<br />
can be added<br />
Rewound / Rebuilt Generators will provide<br />
decades of reliable backup power with<br />
proper maintenance
HANNON ELECTRIC COMPANY<br />
THANK YOU<br />
For Visiting Us Today!
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