PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy

Monthly PM and testing for CAT generators
Date
Position
Team members
Estimated time for PM
Substation
Alternator type
Alternator
Consumed AMP.
Description of the generator
to
Serial Number
be tested:
Last PM (hours)
Check all exposed electrical
connections for tightness.

Not OK

Check all lead wires and electrical

connections for proper clearance.

Not OK

Electrical Connections - Check

Transformers

Check the following devices for

Voltage regulator
loose mounting or for physical
Load sharing modules
damage
A vacuum cleaner should be used to
pick up the following items: dry
Applied
dirt, dust, and carbon.

Not-Applied

A small brush may be attached to

Cleaning
the vacuum hose in order to loosen
Applied
dirt that is more firmly attached
to
(Assembled Generators)"Note(2)"
the surface
Compressed air maximum of (30
psi) may be used to remove the
Applied
remaining dust and dirt.

Not-Applied

Not-Applied

Main stator temperature

Main rotor temperature
Exciter stator temperature
Exciter rotor temperature
Front bearing temperature
Thermograph "Note(3)" & "Note(4)"
Rear bearing temperature
(on Running genset)
Area of concern (hot spots)

Corrective actions

Battery terminals and cables

Applied
cleaning "Note(5)"

Not-Applied

Recommended action.

1 | Page

PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy
6-Month PM and testing for CAT generators
Date
Position
Team members

Estimated time for PM

Substation
Alternator type
Alternator Consumed AMP.

Description of the generator

Serial Number
to be tested:

Last PM (hours)
Ambient temperature
Check all exposed electrical
connections for tightness.

Electrical Connections -

Generator Inspect

Not OK

Check all lead wires and electrical

Not
connections for proper clearance.
Check
Transformers
Check the following devices for
Voltage regulator
loose mounting or for physical
Load sharing modules
damage

OK

Insulation material should be

"Note(1)"examined for cracks, carbon, salt

Not OK

and dirt and dust that is saturated

with moisture

L1 to
Main stator insulation
resistance
Main rotor insulation
resistance

ground

L2 to ground

1st wire to ground

wire to ground

Insulation resistance

"Note(6)", "Note(7)","Note(8)","Note(9)"&
Exciter rotor insulation
"Note(10)"
resistance
wire

Exciter stator insulation

resistance

to ground

L3 to ground

wire to ground

wire to ground

wire to ground

wire to ground

wire to ground

F1to ground

F2 to ground

Recommended action

Main stator temperature

Main rotor temperature
Exciter stator temperature
Exciter rotor temperature
Thermograph "Note(3)" & "Note(4)"
Front bearing temperature
(on Running genset)
Rear bearing temperature
Area of concern (hot spots)
Corrective actions

Battery terminals and cables

Applied

Not-Applied

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PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy
cleaning

"Note(5)"

Recommended action.

1- Switchgear inspection

On de-energized equipment

Turn power off and perform zero energy check.

Ensure good grounding value (less than 5ohms)
Ground all buses, verify that all components are de-energized. Bus maintenance
typically requires a bus outage for work on or in the neighborhood of energized
equipment. Work is performed only after equipment is verified de-energized and
alternate feeds are isolated. Ensure all energy sources are tagged out to
preclude inadvertent energizing. Remove any stored electrical energy by
grounding. Mechanical stored energy should be removed by discharging spring
mechanisms prior to work.

Procedure

Result

Look for physical damagecracks, breaks, delamination, warping,

blisters, flaking, or crazing of insulated parts.

Not OK

Check for foreign objects and loose tools or fallen parts, warped or
distorted insulated bus, and rusty or bent structural framework.

Not OK

Inspect low points in bus for signs of moisture debris accumulation.

Not OK
Inspect the (internal) bus supports for structural integrity and signs
of cracks.

Not OK

Inspect insulation materials for discoloration and cracking.

Not OK
2- Contact resistance testing of Bus bars
Pole resistance Micro ohms readings
Pole#1
Pole#2
Pole#3
As found (Micro-Ohms)
As left (Micro-Ohms)
As found (Micro-Ohms)
As left (Micro-Ohms)
As found (Micro-Ohms)
As left

(Micro-Ohms)

3- Insulation resistance testing of Bus bars

Time resistance test (M)
Second

Phase to ground
Phase (A)

(A) to (B)

Phase to Phase

Phase (B)

(B) to (C)

Phase (C)

(C) to (A)

30
60
DAR

DAR =

Resistance reading at 60 s
Resistance reading at 30 s
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PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy

Corrective action
1. Clean insulation, insulators, bus hardware, and joint covers with a cleaner that is
suitable for the material and application.
2. All dust and dirt should be vacuumed from the switchgear enclosure and
components. Wiping with a dry, clean cloth buses, insulators, cables, and the
like.
3. The surface of all insulating members should be inspected before any cleaning
or dusting, as well as after cleaning for signs of electrical distress, tracking,
corona, and thermal heating.
4. Clean ventilating openings and filters, Make sure that fans are functioning
properly
5. Lubricate hinges, locks, latches, and so on.
6. Compare equipment nameplate information with latest one-line diagram and
report discrepancies.
7. A torque procedure includes initially tightening the bolts finger tight followed
by the use of a torque wrench to half of the recommended torque value. The
torque sequence should ensure a uniform pressure applied to the mating
connection surfaces. The appropriate symmetrical torque sequence can
ensure full clamping force and contact area.
8. Cleaning of C.B should be carried out using a cloth or brush that is perfectly clean
and dry, without using any solvents, avoiding greased parts except for grease on
electrical contacts. Application of products under pressure or containing solvents
(trichloroethane, trichloroethylene, WD40) is strictly forbidden.
9. Greasing: Grease must not be over applied because the excess, if mixed with
dust, may result in mechanism malfunctions. Generally speaking, under normal
operating conditions, the pole-operating mechanism does not require any
regreasing as it is greased for the life of the product.
Lubrication of the Mechanism
The clusters and disconnecting-contacts must be greased according to
the defined intervals using the greases indicated by manufacture.
The main contacts must not be greased.
Thermography or low resistant measurement is an alternate method to determine the
suitability of a connection. Perform a comparison of measured values.

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PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy

Quarterly (3-months) PM and testing of low voltage

switchgear
The following PM is applied on L.V switchgear
1-

Thermographic surveys

Reason of survey:
Description of equipment to be tested:

Equipment name
Ampere rating

Last thermograph survey (Date):

Temperature difference between the area of
concern and the reference area.
Probable cause of temperature difference.
Areas inspected. Identify inaccessible and
unobservable areas and equipment.
Identify load conditions at time of inspection.
Provide photographs and/or thermographs of the
deficient area.
Recommended action.

2Visual inspection
On energized equipment

Procedure

Result

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PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy
Listen for popping, spitting, or cracking sounds produced by
electrical dischargesalso humming noises or vibration produced
by resonance.

Not OK

With lights out, look for blue or purple corona halos. Orange or red
sputter arcs are created by intermittent sparking.

Not OK

Ozone, produced by corona or overheating of organic materials,

can usually be detected by their scents.

Not OK

3-

Data recording

Procedure

Result

Record Voltage THD

Record Neutral current

Gen#1

Gen#3

Gen#2

Gen#4

Gen#1

Gen#3

Gen#2

Gen#4

Note(1)
i.

If there is an insulation resistance value that is below normal, a conductive

path may be present which may produce shorts.
ii. Cleaning is advisable if heavy accumulations of dirt or dust can be seen. If
excess dirt is the cause of a restriction in the ventilation, cleaning is also
advisable. Restricted ventilation will cause excessive heating.
iii. To avoid the possibility of deterioration to the generator windings, do not
clean the generator unless there is visual, electrical, or thermal evidence
that dirt is present.

Note(2)
Cleaning may be required at the point of installation.

i.

In this case, a vacuum cleaner should be used to pick up the following items:
dry dirt, dust, and carbon. This will prevent the spreading of these
contaminants.
ii. A small nonconductive tube may need to be connected to the vacuum
cleaner. This will allow the vacuum cleaner to clean the surfaces that are not
exposed. After most of the dust has been removed, a small brush may be
attached to the vacuum hose in order to loosen dirt that is more firmly
attached to the surface.
iii. After the initial cleaning with a vacuum, compressed air may be used to
remove the remaining dust and dirt. Compressed air that is used for cleaning
should be free of moisture and free of oil. Air pressure should be a maximum
of (30 psi) in order to prevent mechanical damage to the insulation.

Note(3)
Thermograph determines the highest point of temperature (hot spots) in the winding. The hotspot is the location in stator windings with the highest temperature. A hot-spot is located
approximately in the center of each stator slot and approximately in the center of each field
winding.

Note(4)
6 | Page

PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy

SR5 generators are limited to a 20C (257F) temperature rise over the same conditions SR4
generators.

Note(5)
Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.

Note(6)
i.

Insulation must prevent electrical breakdown between components, but it

must also be used as sparingly as possible. Less insulation means more
space available for copper and better heat dissipation. More copper and
better heat dissipation improves maximum output from the generator.
ii. Before the generator is stored, does an insulation resistance check and
record the readings to get a data base. Always do insulation resistance check
before starting up any generator that has been in storage.

Note(7)

Note(8)
Recommended Procedure for the Insulation Test

i. Take the generator out of service.

ii. Visually inspect the generator for moisture. If moisture exists, do not
perform this insulation test. dry and clean the unit first.
iii. Inspect the installation. Determine the equipment that will be tested by
the insulation tester.
iv. Discharge the capacitance of the windings.
v. Disconnect T0 from ground.

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PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy

vi. Disconnect the sensing lead wires for the regulator. This may be
accomplished by unplugging the harness connectors.
vii. Disconnect the PT leads of the load share module.
viii.
Use the 30/60 Time Resistance Method:
ix. Evaluate the readings.

Field-Winding Test

Individual Stator Winding Test

Note(9)
6wire exciter rotor is existed in case of 1400 frame (3500 series generator).

Note(10)
Recommended action may be:
If test readings are accepted Cleaning assembled generator.

If test readings aren't accepted an intensive cleaning [Cleaning

disassembled generator] then repeat insulation test.
o If test readings are accepted OK
o If test readings aren't accepted Re-varnish suspected part of
alternator to increase insulation resistance then repeat insulation
test.

If test readings are accepted OK

If test readings aren't accepted A complete rewound of

suspected part of alternator.

A high pressure wash is normally an effective way to clean windings. This includes windings that
have been exposed to flooding or windings that have been contaminated by salt. A solution of hot
water and detergent is used for this method of cleaning.
A high pressure wash sprays a high velocity fluid stream of this solution over the generator that is
being cleaned. This detergent washing is followed by multiple sprays of clean water. The clean
water is used in order to remove the detergent or the clean water is used in order to dilute the
detergent.

8 | Page

PM Sheet for CAT generator

Prepared by/ Adel Muhamed Fawzy
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It may be necessary to use solvents if the
generator is contaminated with oil or if the generator is contaminated with grease.

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