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Customer Field Service Report oY xN without enclosures enclosures

(CFSR)

Report No. CFRG027767 13 30


Location Department Author Date Page No.
AU Thermal Duncan Michael 25.02.2015 0
Services
Site Information
Customer File Name
RIO TINTO ALUMINIUM LIMITED CFRG027767_Diagnostics_150225_Michael.pdf
Site Country Name PDM Event No.
RIOTINTO PARABURDOO AUSTRALIA
Plant Plant Type Outage code
RIOTINTO PARABURDOO GT 3 ID
Unit Service Ref No. Order No.
RIOTINTO PARABURDOO GT 3 n.a. n.a.
System / Machine System / Machine Type System / Machine Serial No.
Generator T214-234 500834
Task Information
Business Case
Others
Task
Diagnostics
Task description

DIRIS Inspection / Diagnosis

Author handed over Draft CFSR to customer o Yes x No


Distribution of CFSR
Authors Distribution List Official Distribution List
Loc. Dept. Name Notes Loc. Dept. Name Notes
MY TSAS Chin-Kit Lai AU Thermal Lloyd PRICE PM
CH TSE Mark BAUMANN
AU TSAS Michael MORLEY

AU Thermal Reviewed by Date


Services Lloyd PRICE 03.03.2015
MY Thermal Approved by Date
Services Mark Savenkov 03.03.2015
CH Thermal Archived by Date
Services Marietta SUETTERLIN 04.03.2015
Task DIRIS Inspection / Diagnosis

Unit RIOTINTO PARABURDOO GT 3


System Generator
Date 25.02.2015

Report No. CFRG027767

Author Duncan Michael


Reviewed by Lloyd PRICE
Approved by Mark Savenkov

CFSR received by Customer

Name Department Date Signature

© ALSTOM 2015. All rights reserved. No part of this report contains any warranty or creates any other legal obligation or
liability. ALSTOM shall not be liable for subsequent functioning of the plant, for any errors or delays in the information, advice
or recommendations provided, or for any actions taken in reliance thereon. ALSTOM reserves the right to revise or change this
data at any time without further notice. Reproduction, use or disclosure to third parties without ALSTOM’s express written
authority is strictly prohibited.
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

TABLE OF CONTENTS

1. Purpose and duration of assignment 3


2. Summary 3
3. Work carried out 3
3.1. RFM (Rotor Flux Monitoring) Installation 3
3.2. Inspection after shutdown - Stator 3
3.3. Inspection after shutdown - Rotor 5
3.4. Inspection after shutdown - Auxiliary components 5
4. Milestones 6
5. Personnel involved 6
6. Operation data 6
7. Technical information 7
8. Appendix 8
9. Enclosure 12

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
2 / 13
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CFRG027767 25.02.2015

1. Purpose and duration of assignment

Purpose of assignment Arrival Date Departure


Date
A generator inspection was performed, in order to establish the current 29.01.2015 02.02.2015
condition of the generator. A Rotor Flux Monitoring probe installation & test
was performed in conjunction with the inspection.

2. Summary
The generator was opened for a DIRIS inspection, inclusive of robotic works. The rotor remained in place during
the inspection. The robotic inspection was performed using the DIRIS air gap robot; access to the air gap was
made with covers partially removed.

The results of the electrical tests have not revealed any critical or accelerated aginging conditions. The
measurements and visual inspections have uncovered the following information which should be noted for the
purposes of long term asset management:

· Minor fretting observed on the NDE end-winding support rings;


· Oil leakage was identified in the NDE bearing pedestal;
· DE bearing compartment missing main coupling guard;
· The filters were found clogged, necessitating a review of the filter maintenance regime and filter grades;
· Rotor earth fault detection device was found to be disconnected at the shaft spool;
· The earthing brush on the DE was found to be heavily contaminated;

The filter maintenance regime must be interrogated at the earliest opportunity.

The drive end coupling guard must be replaced as soon as practicable. Based on the shaft earthing brush
findings, it would be prudent to open the main rotor bearings and check for electro-erosion of the journals and
bearings at the next opportunity. Consideration should be given to a strategic stock of spare bearings.

During the next major outage cable penetration gaskets should also be replaced.

3. Work carried out


3.1. RFM (Rotor Flux Monitoring) Installation
A flux probe has been installed to allow on-line monitoring of the rotor flux. The flux coil has been installed 70%
into the stator winding air gap and has a terminal box installed at the North side of the frame enclosure to allow
access to perform on-line monitoring.

The flux probe bracket has been fixed to the stator core by drilling and tapping into a stator core bar. All clean
condition procedures were followed during this process and all FME's were removed after the drilling process
was completed.

Before installation the flux coil had the resistance of its leads tested and then tested again after termination. The
values remained the same before and after installation.

The leads outside the frame have been run through conduit for protection and the terminations have been
soldered into the terminal box, with heat shrink applied for protection.

The RFM probe was tested once the unit was returned to service, finding the probe to be functional.

3.2. Inspection after shutdown - Stator


3.2.1. Visual Inspection
3.2.1.1. Terminals & MV Frame
The MV frame was found to be in a good clean condition with no signs of water ingress.

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
3 / 13
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CFRG027767 25.02.2015

The main flexible leads were found to be in good condition.

3.2.1.2. End windings


The stator endwindings were found to be in a good clean condition.

Few signs of fretting or excessive vibration were found in either the DE or NDE overhangs. One area of
looseness and minor fretting was notices on a NDE bracket to circumferential ring interface. There were no signs
of partial discharge.

The Phase rings were found to be in good condition, with no signs of fretting or corona discharge.

3.2.1.3. Stator frame


In general, both DE & NDE bearing compartments were found to be clean.

The NDE bearing pedestal was found to have an existing oil leak from the lube oil drain pipework, where it exits
the pedestal. The resultant oil leak has entered the generator frame between the outer and inner covers. On
removal of the NDE outer covers, the extent of the oil contamination mixed with local dust could be seen, with the
inner covers/fan guides heavily contaminated with a mixture of oil and dust.

The covers and internals of the NDE frame were cleaned during the inspection.

Internal package filters were found to be heavily contaminated with local dust and appear to have not been
changed in some time. The filters were removed, washed & replaced during the inspection.

The DE bearing compartment was found to be missing the main coupling guard, leading to heavy contamination
of the shaft earthing device. It is recommended that a new coupling guard be manufactured and installed at the
next opportunity.

Hardened 1/8"rubber gasket pieces were found throughout the frame. The rubber has come from the cable
penetrations between warm and cold zones of the stator frame. It is recommended that the penetration rubber be
replaced with a more suitable material during the next major outage.

3.2.1.4. Stator core rear


The rear of the stator core was found to be in normal condition, with no signs of looseness, lamination damage or
overheating.

3.2.1.5. Standstill heaters


All standstill heaters were found to be in good working order.

3.2.2. Visual inspection with DIRIS video robot


The visual inspection of the stator bore and the surface of the rotor was performed with a self driven probe, which
includes a camera, a mirror and a digital recording system.

The stator core was found to be in normal condition, with no defects observed. Stator vents were found to be free
from blockages.

Slot wedges and end wedges are found to be secure.

3.2.3. Stator slot wedge assessment with DIRIS system


The wedge tightness measurement was performed on the stator radial wedging system using the automated
DIRIS probe.

The measurement data suggests 4.7% of the slot wedging system is loose, which is within an expected range.

Based on the measurement data, it is recommended to perform future monitoring of the stator slot wedge
condition in line with the normal inspection periods.

3.2.4. Low flux iron core test with DIRIS system


The low flux measurement was performed on the iron core using the automated DIRIS probe.

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
4 / 13
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CFRG027767 25.02.2015

Neither critical interlamination short circuits nor abnormal irregularities in the magnetic field were detected in the
measurement data. Under ordinary running conditions, an operational period without any interuptions, regarding
the lamination insulation can be expected.

3.2.5. Charging current measurement


The charging current was measured as a function of time with a constant DC voltage of 2500VDC on each
phase. The test results showed that the insulation surface is faultless and in a dry condition. The measured
values are acceptable and lead to the statement, that the stator winding insulation is reliable.

3.2.6. Insulation resistance measurement


The insulation resistance was measure with 2500VDC for 1 minute, on each phase seperately. The
measurement shows that the stator winding insulation is in normal condition.

3.3. Inspection after shutdown - Rotor


3.3.1. Visual inspection & DIRIS video robot
The visual inspection of the stator bore and the surface of the rotor was performed with a self driven probe, which
includes a camera, a mirror and a digital video recording system. Nothing inadmissible was found on the rotor
surface or retaining rings.

All rotor balance weights were visually found to be secure. Inspection of rotor cooling vents found no blockages.

The rotor winding heads were also visually and boroscope inspected. Rotor endwinding's are contaminated with
dust. No damage was noted on the coils or pole to pole connections, or main field lead connections.

3.3.2. Check of shaft insulation quality


The shaft insulation was found to be in an acceptable condition.

3.3.3. Rotor winding charging current measurement


The charging current of the rotor field winding was measured with 250VDC for 10 minutes. The measurements
show that the rotor winding insulation is in a normal condition.

3.3.4. Rotating rectifier component check


Rotating rectifier components were found to be clean. The rotating rectifier diode, forward and reverse voltage
could not be checked due to limited access with the exciter stator installed.

All diodes were checked with one end connected to the exciter armature, all found to be free from short circuits.

The exciter armature winding and field winding were subjected to an insulation resistance measurement, using a
250VDC supply. The measured insulation resistance values were in a normal range, 2.18GOhm and 89.4Gohm
respectively.

3.3.5. RSO (Repetitive Surge Oscilloscope)


A repetitive surge oscilloscope (RSO) measurement was performed using a succession of steep fronted low
voltage DC pulses simultaneously injected into opposite into opposite ends of the rotor field winding
(measurement slip rings). The obtained curves give no indication of inter turn short circuits, earth faults or breaks
in the rotor windings. There is a possibility that the rotor winding condition may change between stand still and
running speed can be different. Stand still condition is confirmed by RSO and the running condition can now be
monitored by the RFM probe.

3.4. Inspection after shutdown - Auxiliary components


3.4.1. Rotor earth fault detection device
On removal of the exciter end cover, it was noticed that the rotor earth fault detector (solenoid device) was not
connected. The earth fault carbon brush was not in contact with the shaft spool. During rebuild of the unit, the
solenoid device was reconnected.

3.4.2. Inspection of shaft grounding components


The shaft grounding brush and associated components on the DE were removed for inspection. All components
were found to be heavily contaminated with oil and dust, preventing the brush pressure spring to operate

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
5 / 13
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CFRG027767 25.02.2015

smoothly. The earthing brush was found to be of an acceptable length, but it is likely that insufficient/constant
pressure from the spring has reduced wear on the brush.

It is believed that the majority of the contamination is due to the missing coupling guard, in the direct area of the
earthing brush.

During the inspection, the brush, brush holder & spring were cleaned until all moving parts were free.

The function of the shaft earthing brush is to prevent a build up of voltage in the rotor shaft. The uncontrolled
presence of high shaft voltages leads to discharging from the rotor journal though the lubricating oil to the bearing
surface causing electro-erosion.

It is recommended that the bearings and rotor shaft journals be checked for electro-erosion and pitting at the next
opportunity. It would be prudent to stock spare bearings as a precaution.

3.4.3. Measurement of temperature detectors


All RTD's were tested for ohmic resistance & Insulation Resistance. All were found to be in good condition and
comparable with control room read outs.

4. Milestones

Unit RIOTINTO PARABURDOO GT 3


No. Milestone Planned Date Actual Date
1 Disassembly covers NDE 29.01.2015 29.01.2015
2 DiRIS low flux test 30.01.2015 30.01.2015
3 DiRIS slot wedge test, stator winding charge & discharge current test 31.01.2015 31.01.2015
4 Stator end winding inspection, RSO test, Exciter test 01.02.2015 01.02.2015
5 Final assembly, temperature sensor check 01.02.2015 01.02.2015

5. Personnel involved

Unit RIOTINTO PARABURDOO GT 3


No. Name Department Code Function Position Arrival Date Departure
Date
1 Duncan TSOC-AU EGE Erection Generators Manager 29.01.2015 02.02.2015
Michael
2 Somkuan TSOC-AU CGD Commissioning Specialist 29.01.2015 02.02.2015
Aroonpitoon Generator Diagnostics
3 Brock Bolch TSOC-AU TFA Technical Field Lead 29.01.2015 02.02.2015
Advisor
4 Stephen TSOC-AU TFA Technical Field Lead 29.01.2015 02.02.2015
Johnston Advisor

6. Operation data

Type of data Operation Data Generator


No. Description Unit Reading / Value Remarks
1 Date 29.01.2015 Date of reading
2 OH H 42546 Operating Hour
3 TS - 377 Total starts
4 Trip - Unscheduled Trips
5 Produced Active Energy MWh 1123301

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
6 / 13
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

7. Technical information

Unit RIOTINTO PARABURDOO GT 3


Type of data Technical Information Generator
No. Description Unit Reading / Value Remarks
1 Type - T214-234
2 Generator / Stator Serial No. - 500834
3 Manufacturer (OEM) / Supplier - Alstom
4 Rotor Serial No. - 500835
5 Rated Speed rpm 3000
6 Rated Frequency Hz 50
7 Rated Apparent Power kVA 59000
8 Rated Power Factor - 0.80
9 Rated Stator Voltage kV 11.00
10 Rated Stator Current A 3097
11 Rated Field Voltage kVDC 0.129
12 Rated Field Current ADC 1486
13 Insulation system (stator wind.) F
14 Insulation class (stator wind.) F
15 Cooling System (medium) (rotor/stator) AIR
16 Excitation System - Excitation w. rotating
diodes
17 Exciter Type - TKJ71-13
18 Exciter Fabrication No. - 500835

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
7 / 13
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

8. Appendix

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 1
Description

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 2
Description

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
8 / 13
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 3
Description NDE bearing pedestal lube oil leak

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 4
Description Flexible connections & MV frame

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
9 / 13
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 5
Description Disconnected shaft earth fault detection device

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 6
Description Fretting at NDE endwinding support bracket

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
10 / 13
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 7
Description Rotor pole to pole connection

Unit / RIOTINTO PARABURDOO GT 3 / Generator


Component
Appendix No. 8
Description Missing coupling guard & subsequent contamination

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
11 / 13
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

9. Enclosure

No. E1
Description DIRIS slot wedge assessmant
Reference Number
Pages 3

No. E2
Description DIRIS low flux assessment
Reference Number
Pages 1

No. E3
Description Stator winding charging current measurement
Reference Number
Pages 4

No. E4
Description Stator winding resistance
Reference Number
Pages 1

No. E5
Description Check of shaft insulation quality
Reference Number
Pages 2

No. E6
Description Rotor winding charging current measurement
Reference Number
Pages 2

No. E7
Description Check of temperature sensors
Reference Number
Pages 1

No. E8
Description RSO, rotor interturn insulation quality
Reference Number
Pages 3

No. E9
Description Radial clearances - Dismantle
Reference Number
Pages 2
© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
12 / 13
abcd RIOTINTO PARABURDOO GT 3
CFRG027767 25.02.2015

No. E10
Description Radial clearances - Rebuild
Reference Number
Pages 2

No. E11
Description Mechanical ITP
Reference Number
Pages 6

No. E12
Description DIRIS ITP
Reference Number
Pages 3

© ALSTOM 2015. All rights reserved. No part of this document contains any warranty or creates any other legal obligation or liability. Reproduction, use or disclosure to third parties
without ALSTOM’s express written authority is strictly forbidden.
13 / 13
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DIRIS Slot Wedge Assessment, Wedge Map
date plant & unit page

2015-01-23 Paraburdoo GTG3 1/2


Threshold: 170.0 digit Loose wedges > 1/3 medium wedge length End wedges >= 1/3 loose
MinimumLength: 74.6 mm Loose wedges > 2/3 medium wedge length Loose end wedges - Auto test
Loose wedges > 3/3 medium wedge length

Slot NDE MIDDLE DE ALL NDE MID DE >500 End

0 mm 2250 mm % % % % - -

1 0.0 0.0 0.0 0.0 0 0


2 0.0 0.0 0.0 0.0 0 0
3 16.1 20.5 27.8 0.0 0 0
4 9.5 26.3 2.0 0.0 0 0
5 16.1 7.8 40.5 0.0 0 0
6 0.0 0.0 0.0 0.0 0 0
7 16.5 28.1 21.5 0.0 0 0
8 11.2 19.2 14.4 0.0 0 0
9 7.8 11.5 11.9 0.0 0 0
10 4.0 11.9 0.0 0.0 0 0
11 0.0 0.0 0.0 0.0 0 0
12 0.0 0.0 0.0 0.0 0 0
13 15.7 0.0 0.0 47.1 0 0
14 0.0 0.0 0.0 0.0 0 0
15 0.0 0.0 0.0 0.0 0 0
16 11.2 11.0 0.0 22.6 0 0
17 15.8 14.4 21.9 10.9 0 0
18 3.7 0.0 0.0 11.2 0 0
19 0.0 0.0 0.0 0.0 0 0
20 7.3 10.5 11.3 0.0 0 0
21 7.2 10.0 11.4 0.0 0 0
22 4.3 0.0 13.0 0.0 0 0
23 0.0 0.0 0.0 0.0 0 0
24 15.1 10.3 25.4 9.6 0 0
25 0.0 0.0 0.0 0.0 0 0
26 0.0 0.0 0.0 0.0 0 0
27 0.0 0.0 0.0 0.0 0 0
28 0.0 0.0 0.0 0.0 0 0
29 0.0 0.0 0.0 0.0 0 0
30 5.4 0.0 1.0 15.1 0 0
31 9.4 0.0 28.2 0.0 0 0
32 0.0 0.0 0.0 0.0 0 0
33 7.5 12.0 10.5 0.0 0 0
34 0.0 0.0 0.0 0.0 0 0
35 5.4 0.0 16.1 0.0 0 0
36 0.0 0.0 0.0 0.0 0 0
37 4.0 0.0 8.9 3.1 0 0
38 8.0 0.0 1.8 22.4 0 0
39 17.7 0.0 30.2 22.8 0 0
40 0.0 0.0 0.0 0.0 0 0
DIRIS Slot Wedge Assessment, Wedge Map
date plant & unit page

2015-01-23 Paraburdoo GTG3 2/2


Threshold: 170.0 digit Loose wedges > 1/3 medium wedge length End wedges >= 1/3 loose
MinimumLength: 74.6 mm Loose wedges > 2/3 medium wedge length Loose end wedges - Auto test
Loose wedges > 3/3 medium wedge length

Slot NDE MIDDLE DE ALL NDE MID DE >500 End

0 mm 2250 mm % % % % - -

41 0.0 0.0 0.0 0.0 0 0


42 0.0 0.0 0.0 0.0 0 0
43 0.0 0.0 0.0 0.0 0 0
44 8.0 0.0 24.0 0.0 0 0
45 0.0 0.0 0.0 0.0 0 0
46 0.0 0.0 0.0 0.0 0 0
47 0.0 0.0 0.0 0.0 0 0
48 0.0 0.0 0.0 0.0 0 0
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Title: Reference: Enclosure:
Stator winding; Charging & discharging
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without

Test Certificate current measurement G025896 E3

Measurement conditions:

Phase U V W U-V-W
Charging voltage [V] : 2500 2500 2500 N/A
Charging time [Min.] : 10 10 10
Ambient temperature [°C] : 28.7 28.7 28.7
Winding temperature [°C] : 36.2 36.2 36.2
Relative humidity [%] : 59 59 59

Charging and discharging current diagram stator winding:


express authority is strictly forbidden. © ALSTOM (Switzerland) Ltd. 2004

Charging and Discharging Current = f(t)


I [μA] 10

0.1

0.01
10 100 1000
t [s]
U Phase Charging (20 °C) V Phase Charging (20 °C) W Phase Charging (20 °C)

Characteristic values converted to a reference temperature of 20 °C:

Phase U V W U-V-W
1 min Insulation resistance R 1 min [MΩ] : 5463.1 5361.5 5285.2 N/A
10 min Insulation resistance R 10 min [MΩ] : 22868.8 22309.7 21649.1
Insulation time constant 1 min [sec] : 1169 1174 1168
Insulation time constant 10 min [sec] : 4894 4886 474
Charge factor N (Polarisation index) : 4.22 4.16 4.15
Discharge factor E : UNK UNK UNK
.
Specific discharge current K [mA/(V F)] : 0.743 0.74 0.748

Test Decision: Accepted * [X] Rejected* [] Plant / unit::


(as required/acc.to specification) NC-Report* [] Rework* [] Paraburdoo GTG3
Shop* [] before overhaul* [] NCR No.:* Product designation: Quantity:
Site* [X] after overhaul* [] T214-234 1
Checked by:** Ident No.: Rev.: Power station designation:
D.A.Michael TSOC-AU 01.02.2015 500834 MKA
Approved by:** I & T plan No.: Rev.: Test step: Mat. test. No.:
S.Aroonpitoon TSOC-AU 01.02.2015 EE0-002253-ITP-004 1.20
Auth. / customer:** Order No.: Test Instruction.: Rev.:
EE0-002253 HTAE660447
Resp. dept.: Prepared:** Checked:** Released:** Doc.-type: Language:
TSDXH Bi/ICC /2005-03-24 HS/ICC /2005-03-24 CES/ICC /2005-03-24 PP en
Document- Rev.: Sheet No.: No of sh.:
 ALSTOM Power No.:
HTAE 667004 B 1 4
Template\ICC Diagnostic\ Test Certificate.dot * Mark/Fill in if applicable ** Name / dept. / date / initials
Title: Reference: Enclosure:
Stator winding; Charging & discharging
Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfältigung, Bekanntgabe an

Test Certificate current measurement G025896 E3


Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrückliche Zustimmung verboten. © ALSTOM (Schweiz) AG 2004

Measurement conditions on Phase U:

Rated voltage UN: 11 kV Insulation System: Class F


1)
Charging voltage U: 2500 V Test instrument: MIT520-2 S/N 1000-377/090909/1062
Ambient temperature.: 28.7°C Winding temp.: 36.2°C Rel. hum.: 59%
Charging time (10min/60min): 10 min
1)
measured after 10/60min

Charging- and discharging current readings:

Time Charging current IL [µA] at Time Discharging current IE [µA]


at

Winding. T = 20°C Winding. T = 20°C


Temperature Temperature
15‘‘ 2.955 1.163 10‘‘
30‘‘ 1.805 0.710 20‘‘
45‘‘ 1.433 0.564 30‘‘
I 1L 60‘‘ 1.163 0.458 40‘‘
75‘‘ 1.012 0.398 50‘‘
90‘‘ 0.903 0.355 I 1E 60‘‘ 1.01 0.397
2‘ 0.758 0.298 90‘‘
3‘ 0.598 0.235 2‘
4‘ 0.507 0.200 3‘ 10‘‘
5‘ 0.439 0.173 5‘
8' 0.328 0.129 8'
I 10L 10‘ 0.278 0.109 I 10E 10‘
15‘
30‘
50‘
60‘
I 1L I 1E
N = 3.27 E = UNK
I 10L I 10E

Evaluation / Characteristics:

1 min Insulation resistance R 1 min = U/I1L: 2150 MΩ with ref. to 20°C 5463.1 MΩ
10 min Insulation resistance R 10 min = U/I10L: 9000 MΩ with ref. to 20°C 22868.8 MΩ
Insulation time constant 1 min = R1 min.CX: 460s with ref. to 20°C 1169 s
Insulation time constant 10 min = R10 min.CX: 1926 s with ref. to 20°C 4894 s
. . .
Specific discharge current K = I1E/(U CX): 1.8879 mA/(V F) with ref. to 20°C 0.743 mA/(V F)
2) 2)
CX : 0.214 µF from tan-measurement at 0,1 resp. 0,2 UN or separate capacitance measurement

Remarks:

Discharge after 25 minutes of charging.

Plant / unit: Power station designation: Doc.-type: Language: Rev.: No. of sh.:

Paraburdoo GTG3 T214-234 PP en B 4


Document- Sheet No.:
 ALSTOM Power No.:
HTAE 667004 2
Template\ICC Diagnostic\ Test Certificate.dot
Title: Reference: Enclosure:
Stator winding; Charging & discharging
Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfältigung, Bekanntgabe an

Test Certificate current measurement G025896 E3


Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrückliche Zustimmung verboten. © ALSTOM (Schweiz) AG 2004

Measurement conditions on Phase V:

Rated voltage UN: 11 kV Insulation System: Class F


1)
Charging voltage U: 2500 V Test instrument: MIT520-2 S/N 1000-377/090909/1062
Ambient temperature.: 28.7 °C Winding temp.: 36.2 °C Rel. hum.: 59 %
Charging time (10min/60min): 10 min
1)
measured after 10/60min

Charging- and discharging current readings:

Time Charging current IL [µA] at Time Discharging current IE [µA]


at

Winding. T = 20°C Winding. T = 20°C


Temperature Temperature
15‘‘ 3.209 1.263 10‘‘
30‘‘ 1.855 0.730 20‘‘
45‘‘ 1.438 0.566 30‘‘
I 1L 60‘‘ 1.185 0.466 40‘‘
75‘‘ 1.037 0.408 50‘‘
90‘‘ 0.929 0.366 I 1E 60‘‘ 1.03 0.405
2‘ 0.776 0.306 90‘‘
3‘ 0.614 0.242 2‘
4‘ 0.518 0.204 3‘ 10‘‘
5‘ 0.459 0.181 5‘
8' 0.335 0.132 8'
I 10L 10‘ 0.285 0.112 I 10E 10‘
15‘
30‘
50‘
60‘
I 1L I 1E
N = 3.29 E = UNK
I 10L I 10E

Evaluation / Characteristics:

1 min Insulation resistance R 1 min = U/I1L: 2110 MΩ with ref. to 20°C 5361.5 MΩ
10 min Insulation resistance R 10 min = U/I10L: 8780 MΩ with ref. to 20°C 22309.7 MΩ
Insulation time constant 1 min = R1 min.CX: 462 s with ref. to 20°C 1174 s
Insulation time constant 10 min = R10 min.CX: 1923 s with ref. to 20°C 4886 s
. . .
Specific discharge current K = I1E/(U CX): 1.8813 mA/(V F) with ref. to 20°C 0.74 mA/(V F)
2) 2)
CX : 0.219 µF from tan-measurement at 0,1 resp. 0,2 UN or separate capacitance measurement

Remarks:

Discharge after 25 minutes of charging.

Plant / unit: Power station designation: Doc.-type: Language: Rev.: No. of sh.:

Paraburdoo GTG3 T214-234 PP en B 4


Document- Sheet No.:
 ALSTOM Power No.:
HTAE 667004 3
Template\ICC Diagnostic\ Test Certificate.dot
Title: Reference: Enclosure:
Stator winding; Charging & discharging
Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfältigung, Bekanntgabe an

Test Certificate current measurement G025896 E3


Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrückliche Zustimmung verboten. © ALSTOM (Schweiz) AG 2004

Measurement conditions on Phase W:

Rated voltage UN: 11 kV Insulation System: Class F


1)
Charging voltage U: 2500 V Test instrument: MIT520-2 S/N 1000-377/090909/1062
Ambient temperature.: 28.7 °C Winding temp.: 36.2 °C Rel. hum.: 59 %
Charging time (10min/60min): 10 min
1)
measured after 10/60min

Charging- and discharging current readings:

Time Charging current IL [µA] at Time Discharging current IE [µA]


at

Winding. T = 20°C Winding. T = 20°C


Temperature Temperature
15‘‘ 2.948 1.160 10‘‘
30‘‘ 1.893 0.745 20‘‘
45‘‘ 1.443 0.568 30‘‘
I 1L 60‘‘ 1.202 0.473 40‘‘
75‘‘ 1.050 0.413 50‘‘
90‘‘ 0.940 0.370 I 1E 60‘‘ 1.05 0.413
2‘ 0.794 0.312 90‘‘
3‘ 0.636 0.250 2‘
4‘ 0.529 0.208 3‘ 10‘‘
5‘ 0.464 0.183 5‘
8' 0.342 0.135 8'
I 10L 10‘ 0.293 0.115 I 10E 10‘
15‘
30‘
50‘
60‘
I 1L I 1E
N = 3.28 E = UNK
I 10L I 10E

Evaluation / Characteristics:

1 min Insulation resistance R 1 min = U/I1L: 2080 MΩ with ref. to 20°C 5285.2 MΩ
10 min Insulation resistance R 10 min = U/I10L: 8520 MΩ with ref. to 20°C 21649.4 MΩ
Insulation time constant 1 min = R1 min.CX: 460 s with ref. to 20°C 1168 s
Insulation time constant 10 min = R10 min.CX: 1883 s with ref. to 20°C 4784 s
. . .
Specific discharge current K = I1E/(U CX): 1.901 mA/(V F) with ref. to 20°C 0.748 mA/(V F)
2) 2)
CX : 0.221 µF from tan-measurement at 0,1 resp. 0,2 UN or separate capacitance measurement

Remarks:

Discharge after 25 minutes of charging.

Plant / unit: Power station designation: Doc.-type: Language: Rev.: No. of sh.:

Paraburdoo GTG3 T214-234 PP en B 4


Document- Sheet No.:
 ALSTOM Power No.:
HTAE 667004 4
Template\ICC Diagnostic\ Test Certificate.dot
Reference: Enclosure:
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
Title:
Stator winding G025896 E4
Test Certificate Winding Resistance and Capacitance measurement

Winding resistance measurement on the stator winding


(Design-Value: m per phase at 95 °C)
R [m] R [m]
at winding temperature calculated to 95 °C

2.674 3.254
Phase U measured between terminals U1 and U2 2.673 3.253
express authority is strictly forbidden. © ALSTOM (Switzerland) Ltd. 2015

2.673 3.253

2.646 3.220
Phase V measured between terminals V1 and V2 2.647 3.221
2.647 3.221

2.665 3.243
Phase W measured between terminals W1 and W2 2.664 3.242
2.664 3.242

Measurement conditions
Milliohm-Meter: AEMC 6250, S/N 114935KKDV
Ambient temp. [°C/°F]: 37.5°C Winding temp. [°C/°F]: 35.4°C Rel. hum [%]: 35%

Remarks:

Test Decision: Accepted * [X] Rejected* [] Plant / unit::


(as required/acc.to specification) NC-Report* [] Rework* [] Paraburdoo GTG3
Shop* [] before overhaul* [] NCR No.:* Product designation: Quantity:
Site* [X] after overhaul* [] T214-234 1
Checked by:** Ident No.: Rev.: Power station designation:
TSOC-AU / D.A.Michael 01-02-2015 500834
Approved by:** I & T plan No.: Rev.: Test step: Mat. test. No.:
TSOC-AU / S.Aroonpitoon 01-02-2015 EE0-002253-ITP-004 1.24
Auth. / customer:** Order No.: Test Instruction.: Rev.:
EE0-002253
Resp. dept.: Prepared:** Checked:** Released:** Doc.-type: Language:
TTTTE Ha/TTTE/2008-05-29 Hu/TTTE/2008-06 TH/TTTE/2008-06 PP en
Document- Rev.: Sheet No.: No of sh.:
 ALSTOM Power No.:
HTAE 667055 - 1 1
Template\ICC Diagnostic\ Test Certificate.dot * Mark/Fill in if applicable ** Name / dept. / date / initials
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to Title: Reference: Enclosure:
Test Certificate Lagerisolationsprüfung/ G025896 E5

Bearings insulation test


third parties without express authority is strictly forbidden. © ALSTOM (Switzerland) Ltd. 2000

QS-Nachweis / Quality management certificate


Rogowskispule: DIRIS STD SUPPLY Voltmeter:
Rogowskicoil: Voltmeter:
Variac: VAKO 1063/006 Voltmeter:
Variac: Voltmeter:
Stromzange: A100 Multimeter:
Current clamp: Multimeter:
Measuring point 1

Measuring point 3
Measuring point 2

Measuring point 4

Measuring point 5
Messstelle 1

Messstelle 3
Messstelle 2

Messstelle 4

Messstelle 5
Feeding point: A
Grounding point: B

Measuring points: cross and number

1 2 3 4 5
AS x x x x x
NS
DE NDE
Schleifringe
Sliprings

B A

Erregung / Excitation
Erregerstrom Ierr [A]: 94.7 Erregerspannung Uerr [V]: 15.1
Excitation current Ierr [A]: Excitation voltage Uerr [V]:

Messung / Measurement
Strom an Position 1: [A]: 0 Strom an Position 4: [A]: 94
Current at position 1: [A]: Current at position 4: [A]:
Strom an Position 2: [A]: 0 Strom an Position 5: [A]: 0
Current at position 2: [A]: Current at position 5: [A]:
Strom an Position 3: [A]: 94.4 Strom an Position 6: [A]: N/A
Current at position 3: [A]: Current at position 6: [A]:

Prüfergebnis / Test result


Ja / Nein / nicht geprüft/ Ja / Nein / nicht geprüft/
Yes No not checked Yes No not checked
Lagerisolation NS in Ordnung/ Lagerisolation AS in Ordnung/
Bearings insulation NDE OK
   Bearings insulation DE OK
  
Plant / unit:
Test Decision: Accepted*  Rejected* 
(as required/acc.to specification) NC-Report*  Rework*  Paraburdoo GTG3
Shop*  before overhaul*  NCR No.:* Product designation: Quantity:

Site*  after overhaul*  T214-234 1


Checked by:** Ident No.: Rev.: Power station designation:
D.A.MICHAEL TSOC-AU 30.01.2015 500834
Approved by:** I & T plan No.: Rev.: Test step: Mat. test. No.:

S.AROONPITOON TSOC-AU 30.01.2015


EE0-002253-ITP-004 4.11
Auth. / customer:** Order No.: Test Instruction: Rev.:

EE0-002253
Resp. dept.: Prepared:** Checked:** Released:** Doc.-type: Language:
CSXC4 G. Rudolph/ CSXC4/ 04-06-18 P. Grab/ CSXC4/ 04-06-18 P. Broch/ CSXC4/ 04-06-18 TC d/e
Document Rev.: Sheet No.: No.of sh.:

 ALSTOM Power No.:


1AHX 446434 B 1 2
1AHX612545, A, CSXQ, Test Certificate English.dot, 1AHX446434B - bearing insulation test (old version) .doc * Mark/Fill in if applicable ** Name / dept. / date / initials
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to Title: Reference: Enclosure:
third parties without express authority is strictly forbidden. © ALSTOM (Switzerland) Ltd. 2000
Test Certificate E

Plant / unit: Power station designation: Doc. type: Language: Rev.: No. of sh.:

TC en 2
Document Sheet No.:

 ALSTOM Power No.:


HTAE 667… 2
1AHX612545, A, CSXQ, Test Certificate English.dot, 1AHX446434B - bearing insulation test (old version) .doc
Title: Reference: Enclosure:
Rotor winding
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without

Test Certificate G025896 E6


Charging current measurement
Measurement conditions:

Charging voltage [V] : 500


Charging time [Min.] : 10
Ambient temperature [°C] : 27.2
Winding temperature [°C] : 39
Relative humiditiy [%] : 67

Charging current diagram rotor winding:


express authority is strictly forbidden. © ALSTOM (Switzerland) Ltd. 2004

Charging Current = f(t)


I [μA] 1

0.1

0.01
10 100 1000
t [s]

Charging Current Charging Current (20 °C)

Characteristic values converted to a reference temperature of 20 °C:

1 min Insulation resistance R 1 min [MΩ] : 3700 MΩ


10 min Insulation resistance R 10 min [MΩ] : 4950MΩ
Insulation time constant 1 min [sec] : s
Insulation time constant 10 min [sec] : s
Charge factor N (Polarisation index) : 1.34

Test Decision: Accepted * [x] Rejected* [] Plant / unit::


(as required/acc.to specification) NC-Report* [] Rework* [] Paraburdoo GTG3
Shop* [] before overhaul* [] NCR No.:* Product designation: Quantity:
Site* [x] after overhaul* [] T214-234 1
Checked by:** Ident No.: Rev.: Power station designation:
TSOC-AU / S. AROONPITOON 2015-01-31 500834
Approved by:** I & T plan No.: Rev.: Test step: Mat. test. No.:
TSOC-AU / D.A.MICHAEL 2015-01-31 EE0-002253-ITP-004 2.10
Auth. / customer:** Order No.: Test Instruction.: Rev.:
EE0-002253 HTAE 660448
Resp. dept.: Prepared:** Checked:** Released:** Doc.-type: Language:
TSDXH Bi/ICC /2005-03-24 HS/ICC /2005-03-24 CES/ICC /2005-03-24 PP en
Document- Rev.: Sheet No.: No of sh.:
 ALSTOM Power No.:
HTAE 667005 B 1 2
Template\ICC Diagnostic\ Test Certificate.dot * Mark/Fill in if applicable ** Name / dept. / date / initials
Title: Reference: Enclosure:
Rotor winding
Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfältigung, Bekanntgabe an

Test Certificate G025896 E6


Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrückliche Zustimmung verboten. © ALSTOM (Schweiz) AG 2004

Charging current measurement


Measurement conditions:

Rated excitation voltage UN: 129 VDC


1)
Charging voltage U: 500 VDC Test instrument: MIT520-2 S/N 1000-377/090909/1062
Ambient temperature.: 27.2 °C Winding temp.: 39 °C Rel. hum.: 67 %
1)
measured after 10 min

Charging current readings:

Time Charging current IL [µA] at Time Discharging current IE [µA]


at

Winding. T = 20°C Winding. T = 20°C


Temperature Temperature
15‘‘ 0.338 0.113 10‘‘
30‘‘ 0.170 0.057 20‘‘
45‘‘ 0.138 0.046 30‘‘
I 1L 60‘‘ 0.135 0.045 40‘‘
75‘‘ 0.132 0.044 50‘‘
90‘‘ 0.130 0.044 I 1E 60‘‘
2‘ 0.128 0.043 90‘‘
3‘ 0.121 0.041 2‘
4‘ 0.118 0.040 3‘ 10‘‘
5‘ 0.115 0.039 5‘
8' 0.108 0.036 8'
I 10L 10‘ 0.101 0.034 I 10E 10‘
15‘
30‘
50‘
60‘
I 1L I 1E
N = 2.84 E = UNK
I 10L I 10E

Evaluation/Characteristics:

1 min Insulation resistance R 1 min = U/I1L: 3760 MΩ with ref. to 20°C 11045.9 MΩ
10 min Insulation resistance R 10 min = U/I10L: 4950 MΩ with ref. to 20°C 14777.6 MΩ
Insulation time constant 1 min = R1 min.CX: s with ref. to 20°C s
Insulation time constant 10 min = R10 min.CX: s with ref. to 20°C s
Specific discharge current K = I1E/(U.CX): mA/(V.F) with ref. to 20°C mA/(V.F)
2)
CX : UNK µF

Rotorzustand zum Zeitpunkt der Ladestrommessung:*


[ ] with sliprings [ X ] not cleaned,
[ X ] without sliprings [ ] after cleaning of sliprings / leads,
[ ] [ ] after cleaning of winding,
[ ] after complete cleaning

Remarks:

Plant / unit: Power station designation: Doc.-type: Language: Rev.: No. of sh.:

Paraburdoo GTG3 PP en B 2
Document- Sheet No.:
 ALSTOM Power No.:
HTAE 667005 2
Template\ICC Diagnostic\ Test Certificate.dot
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  !"# 3) '$F997,*6  ' '
  A:44@ 
 A 4     2!8/B     223/ / / 
Condition during test: 04 Remarks: Rotor stationary with NDE covers removed
Insert condition code
& exciter disconnected.

Condition Codes:
Speed during test and detailed state of disassembly
01 = Generator at nominal speed, 02 = Generator at other speeds (see remarks), 03 = Generator at
standstill but housing is closed, 04 = Generator at standstill and housing is opened, 05 = Rotor is removed
but still complete, 06 = Rotor is partially or complete disassembled (details see Remarks)

Pole A Pole B

Ch1 Ch2

Remarks:
Special slip ring arrangements and connections on disassembled rotor

Picture 1 RSO results, Channel 1 and Channel 2, traces superimposed, time base 5s

Picture 2 RSO results, Channel 1 and Channel 2, traces subtracted, time base 5s

Picture 3 RSO results, Channel 1 and Channel 2, traces separated, time base 5s

Picture 4 RSO results, Channel 1 and Channel 2, pulse propagation time 5s

Interturn short circuit is present: N Yes = Y; No = N

Remarks:
Insert shorted coils if known or other comments regarding the taken decision

Vibration behaviour: 1 1 = normal; 2= suspicious; 3 = > alarm level; 4 = > trip level

Remarks:
Insert vibration levels, dependencey on excitation current or reference to other measurements

Equipment used: Oscilloscope: Handyscope HS3 S/N 22666


Type/number/valid until

Pulse generator: ALSTOM RSO 1.0 Matching resistance: RV1 440 , RV2
S/N 0507-017 526
Type/number/valid until Setting (Ohm)

Performed by: B.Bolch Date / time: 2015.01.31


First name, surname YYYY-MM-DD-hh:mm

Decision: X Pass To be confirmed Failed

Remarks:

Site / plant / unit Report Enclosure Sheet Of

Paraburdoo GTG3 G027767 E8 1 3


Picture 1 RSO results, Channel 1 and Channel 2, traces superimposed, time base 5s.

Picture 2 RSO results, Channel 1 and Channel 2, traces subtracted, time base 5s.

Condition during test: 04 Remarks: Non conclusive evidence of shorts at


Insert condition code
standstill. Rotor to be tested at speed with
new RFM probe to confirm results.
For condition codes see user instructions.
Speed during test and detailed state of disassembly

Site / plant / unit Report Enclosure Sheet Of

Paraburdoo GTG3 G027767 E8 2 3


Picture 3 RSO results, Channel 1 and Channel 2, traces separated, time base 5s.

Picture 4 RSO results, Channel 1 and Channel 2, pulse propagation time, time base 5s

Condition during test: 04 Remarks:


Insert condition code

For condition codes see user instructions.


Speed during test and detailed state of disassembly

Site / plant / unit Report Enclosure Sheet Of

Paraburdoo GTG3 G027767 E8 3 3


Prüfprotokoll Titel / Title : Radialspiele des Rotors Einordnungsnr. / File No. :
therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden. © ALSTOM Power (Switzerland) Ltd 2000
We reserve all rights in this document and in the information contained

Test Certificate Radial Clearances of Rotor HTCM Q42-07


Geltungsbereich: Drehrichtung von AS Rechts / right
Scope of Test : Direction of rotation from DE X Links / left
12
11 1
10 2
9 3
8 4
7 5
6
Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte
vor. Vervielfältigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne
unsere ausdrückliche Zustimmung verboten. © ALSTOM Power (Schweiz) AG 2000

Bemerkung : Alle Spiele und Dimensionen sind in mm und von AS aus gesehen.
Note : All clearances and dimensions are given in mm and are seen from DE .

Anlage, Einheit / Plant, Unit :


Entscheid/Test Decision : Verw./Accepted * X Aussch./Rejec. *

(entspr.Vorgabe / acc. to spec. ) Fehler/NC-Report * Nacharb./Rework * Paraburdoo GTG3


NCR No.:* Produktbenennung / Product designation : Anzahl / Quantity :
Werk / Shop * vor Revision / before overhaul * X
Baustelle / Site * nach Revision / after overhaul * T214-234
Geprüft von / Checked by :** Ident-Nr. / Ident No. : Rev.: KKS Nr. / Power station designation :

B.Bolch TSOC-AU 29.01.2015 500834 MKA


Freigegeben / Approved by :** Prüfplan-Nr. / I & T plan No. : Rev.: Prüfschritt / Test step :

D.A.Michael TSOC-AU 29.01.2015 002253-003 4


Behörde, Kunde / Authority, Customer :** Order-Nr. / Order No. : WBZ: MP-Nr. / Material test No. :

Zust. Stelle / Resp. dept .: Erstellt / Prepared **: 91-02-13 Geprüft / Checked **: 91-02-15 Freigegeben / Released **: 91-02-15 Dok.Art/Doc.-T. : Sprache/Lang .:
SGDH Prinzbach Boha Zimmermann FA 83
Dokument-Nr. / Document No .: Rev.: 01-04-11 Bl.-Nr./ Sh. No .: Anz./ No.of sh .:
abcd ALSTOM Power (Switzerland) Ltd HTCM 635 070 H 1 2
*ankreuzen, eintragen wenn zutreffend / Mark , Fill in if applicable **Name, Abt., Datum, Visum / Name, dept., date, initials
therein. Reproduction, use or disclosure to third parties without express Prüfprotokoll Titel / Title : Radialspiele des Rotors Einordnungsnr. / File No. :
authority is strictly forbidden. © ALSTOM Power (Switzerland) Ltd 2000
We reserve all rights in this document and in the information contained

Test Certificate Radial Clearances of Rotor HTCM Q42-07


Messebene Mass Messstelle Sollspiel Gemessenes Spiel
Plane reference Meas. Meas. point Specified clearance Measured clear.
100 103 N/A
Wellendichtsp. AS 106 N/A
s
Shaft seal clear.DE 109 N/A
Fig. 1 112 N/A
200 203 N/A
Ventilatorspiel AS 206 N/A
d
Fan clearance DE 209 N/A
Fig. 2 212 N/A
300 303 N/A
Luftspalt AS 306 N/A
b
Air gap DE 309 N/A
Fig. 3 312 N/A
400 403 N/A
Luftspalt NS 406 N/A
b
Air gap NDE 409 N/A
Fig. 3 412 N/A
500 503 3.4
Ventilatorspiel NS 506 1.9
d
Fan clear. NDE 509 3.0
Fig. 2 512 2.3
600 603 0.25
Wellendichtsp. NS 606 0.75
s
Shaft seal clear.NDE 609 0.70
Fig. 1 612 0.50

Bohrungs Ø / Bore Ø : mm
Rotor Ø / Rotor Ø: mm

* Luftspalt / Air gap : b = ( Bohrungs Ø / Bore Ø - Rotor / Rotor Ø ) / 2 = mm

± 1 % für Neumontage / for Installation : ± mm


Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte

± 2 % für Revision / for Overhaul : ± mm


vor. Vervielfältigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne
unsere ausdrückliche Zustimmung verboten. © ALSTOM Power (Schweiz) AG 2000

Ventilatorspiel AS / Fan clearance DE Ventilatorspiel NS / Fan clearance NDE


Mittelwert / Mean value x : #DIV/0! 2.65

Bemerkung : Alle Spiele und Dimensionen sind in mm und von AS aus gesehen.
Note : All clearances and dimensions are given in mm and are seen from DE .

Anlage, Einheit / Plant, Unit : Order-Nr. / Order No. : Dok.Art/Doc.-T. : Sprache/Lang .:


Paraburdoo GTG3 FA 83
Dokument-Nr. / Document No .: Rev.: 01-04-11 Bl.-Nr./ Sh. No .: Anz./ No.of sh .:
abcd ALSTOM Power (Switzerland) Ltd HTCM 635 070 H 2 2
Prüfprotokoll Titel / Title : Radialspiele des Rotors Einordnungsnr. / File No. :
therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden. © ALSTOM Power (Switzerland) Ltd 2000
We reserve all rights in this document and in the information contained

Test Certificate Radial Clearances of Rotor HTCM Q42-07


Geltungsbereich: Drehrichtung von AS Rechts / right
Scope of Test : Direction of rotation from DE X Links / left
12
11 1
10
9
8
7 5
6
Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte
vor. Vervielfältigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne
unsere ausdrückliche Zustimmung verboten. © ALSTOM Power (Schweiz) AG 2000

Bemerkung : Alle Spiele und Dimensionen sind in mm und von AS aus gesehen.
Note : All clearances and dimensions are given in mm and are seen from DE .

Anlage, Einheit / Plant, Unit :


Entscheid/Test Decision : Verw./Accepted * X Aussch./Rejec. *

(entspr.Vorgabe / acc. to spec. ) Fehler/NC-Report * Nacharb./Rework * Paraburdoo GTG3


Werk / Shop * vor Revision / before overhaul * NCR No.:* Produktbenennung / Product designation : Anzahl / Quantity :

Baustelle / Site * nach Revision / after overhaul * X T214-234


Geprüft von / Checked by :** Ident-Nr. / Ident No. : Rev.: KKS Nr. / Power station designation :

B.Bolch TSOC-AU 01.02.2015 500834 MKA


Freigegeben / Approved by :** Prüfplan-Nr. / I & T plan No. : Rev.: Prüfschritt / Test step :

D.A.Michael TSOC-AU 01.02.2015 002253-003 4


Behörde, Kunde / Authority, Customer :** Order-Nr. / Order No. : WBZ: MP-Nr. / Material test No. :

Zust. Stelle / Resp. dept .: Erstellt / Prepared **: 91-02-13 Geprüft / Checked **: 91-02-15 Freigegeben / Released **: 91-02-15 Dok.Art/Doc.-T. : Sprache/Lang .:
SGDH Prinzbach Boha Zimmermann FA 83
Dokument-Nr. / Document No .: Rev.: 01-04-11 Bl.-Nr./ Sh. No .: Anz./ No.of sh .:
abcd ALSTOM Power (Switzerland) Ltd HTCM 635 070 H 1 2
*ankreuzen, eintragen wenn zutreffend / Mark , Fill in if applicable **Name, Abt., Datum, Visum / Name, dept., date, initials
therein. Reproduction, use or disclosure to third parties without express Prüfprotokoll Titel / Title : Radialspiele des Rotors Einordnungsnr. / File No. :
authority is strictly forbidden. © ALSTOM Power (Switzerland) Ltd 2000
We reserve all rights in this document and in the information contained

Test Certificate Radial Clearances of Rotor HTCM Q42-07


Messebene Mass Messstelle Sollspiel Gemessenes Spiel
Plane reference Meas. Meas. point Specified clearance Measured clear.
100 103 N/A
Wellendichtsp. AS 106 N/A
s
Shaft seal clear.DE 109 N/A
Fig. 1 112 N/A
200 203 N/A
Ventilatorspiel AS 206 N/A
d
Fan clearance DE 209 N/A
Fig. 2 212 N/A
300 303 N/A
Luftspalt AS 306 N/A
b
Air gap DE 309 N/A
Fig. 3 312 N/A
400 403 N/A
Luftspalt NS 406 N/A
b
Air gap NDE 409 N/A
Fig. 3 412 N/A
500 503 2.8
Ventilatorspiel NS 506 1.5
d
Fan clear. NDE 509 2.9
Fig. 2 512 2.6
600 603 0.10
Wellendichtsp. NS 606 0.10
s
Shaft seal clear.NDE 609 0.30
Fig. 1 612 0.50

Bohrungs Ø / Bore Ø : mm
Rotor Ø / Rotor Ø: mm

* Luftspalt / Air gap : b = ( Bohrungs Ø / Bore Ø - Rotor / Rotor Ø ) / 2 = mm

± 1 % für Neumontage / for Installation : ± mm


Für dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte

± 2 % für Revision / for Overhaul : ± mm


vor. Vervielfältigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne
unsere ausdrückliche Zustimmung verboten. © ALSTOM Power (Schweiz) AG 2000

Ventilatorspiel AS / Fan clearance DE Ventilatorspiel NS / Fan clearance NDE


Mittelwert / Mean value x : #DIV/0! 2.45

Bemerkung : Alle Spiele und Dimensionen sind in mm und von AS aus gesehen.
Note : All clearances and dimensions are given in mm and are seen from DE .

Anlage, Einheit / Plant, Unit : Order-Nr. / Order No. : Dok.Art/Doc.-T. : Sprache/Lang .:


Paraburdoo GTG3 FA 83
Dokument-Nr. / Document No .: Rev.: 01-04-11 Bl.-Nr./ Sh. No .: Anz./ No.of sh .:
abcd ALSTOM Power (Switzerland) Ltd HTCM 635 070 H 2 2
INSPECTION & TEST PLAN Site/Unit: Paraburdoo GTG2

Date: 22-10-14
ITP Description Mechanical works for DIRIS including Flux Contract Name & No: Paraburdoo GTG3 ITP No. 002253-003 Rev.0 Page
Probe Installation
1 of 6

PREPARER SITE REVIEW

OK () N/A () OK () Note: Where ITP requires Client approval, include as activity on the ITP.

1 The ITP covers all items in the work scope, and the work scope items have been cross referenced against ITP.

2 All dimensional checks have a record sheet/s or a ‘report’ called up.

3 The acceptance criteria is defined for all relevant activities. This means a reference to a procedure which states what is acceptable, or a clear statement of the values that are acceptable.

4 HOLD points and the actions required to clear these HOLD points are clearly defined. Client HOLD points must be applied by Client

5 Where ‘Log…’ is called for as record format, the page number must be called for as well.

Where special processes (welding, painting, NDT, etc.) are called for, the following must be stated:
Procedure to be used.
6
Record of operator qualifications called for.
Specific records called for in procedure

7 The final inspection identified at an appropriate point.

8 The last activity of the ITP calls for all NCR’s to be checked and signed completed

After all tasks in this ITP have been signed off, the front page of this ITP is to be signed off by both the Site Manager and Workshop Manager for site activities, or the Project Engineer and Workshop Manager for workshop activities

LEGEND H = Hold W = Witness V = Verification Required S= Surveillance D = Documentation Review S/C = Subcontractor

AL = ALSTOM Limited CL = Client I = Inspect O = Other MDR = Manufacturer’s Data Report (* add “Y” if to be included)

Prepared by: Brock Bolch Date: 22/10/14 Reviewed by: Date: Approved by: Date:

20.01.2014
D.A.Michael
Final Completion Signoff
Site Manager or Project Engineer Date: Project Manager or Workshop Manager Date:

TSOC.QI.F16 Template Rev/Date - 23/07/2013


INSPECTION & TEST PLAN Site/Unit: Paraburdoo GTG2

Date: 22-10-14
ITP Description Mechanical works for DIRIS including Flux Contract Name & No: Paraburdoo GTG3 ITP No. 002253-003 Rev.0 Page
Probe Installation
2 of 6

Act Activity/Process/Hazard Procedure/ Verifying Document Verification & Signoff & Date MDR Remarks
No Check/Control Acceptance Criteria S/C AL CL O (*)
1. Complete JSEA/SWMS Document TSOC1-1.2_F1.1 H

Disassembly
2. Obtain PTW Rio Tinto PTW procedure PTW: H H All isolations to be viewed
by Alstom supervisor prior to
accepting the PTW.

3. Dismantle Outer Covers NDE Visual Log: I Record Air Seal


SWMS: 001955;001 Measurement
Record: HRS_G3_10_16

4. Dismantle Inner covers NDE Visual Lift Study: I Record Fan Blade
SWMS: 001955;001 Clearances
Record: HRS_G3_10_16

5. Open MV Cubicle and Remove Flexible Visual SWMS: 001955;001 I


Connections Log:

6. Remove Exciter Cover and remove Visual SWMS: 001955;001 I Diodes not removed for
diodes Log: testing. Visual inspection
only.

Flux Probe Installation

TSOC.QI.F16 Template Rev/Date - 23/07/2013


INSPECTION & TEST PLAN Site/Unit: Paraburdoo GTG2

Date: 22-10-14
ITP Description Mechanical works for DIRIS including Flux Contract Name & No: Paraburdoo GTG3 ITP No. 002253-003 Rev.0 Page
Probe Installation
3 of 6

Act Activity/Process/Hazard Procedure/ Verifying Document Verification & Signoff & Date MDR Remarks
No Check/Control Acceptance Criteria S/C AL CL O (*)
7. Open Side Frame Door Visual SWMS: 00155;003 I

8. Test resistance of flux probe Visual SWMS:001955;003 I


Tool Log
Log:

9. Trial Fit Flux Probe Visual SWMS:001955;003 I Clean Conditions to be


Tool Log adhered to
Log: Ensure probe protrudes
70%of air gap

10. Final Installation of flux probe to core Visual SWMS:001955;003 I Clean Conditions to be
Tool Log adhered to.
Log: Finished product to be
measured for internal
records
11. Install termination box and terminate Document SWMS:001955;003 I
wires Tool Log
Log

12. Run wires and terminate. Check final Document SWMS:001955;003 I Clean Conditions to be
Resistance. Tool Log adhered to.
Log:

TSOC.QI.F16 Template Rev/Date - 23/07/2013


INSPECTION & TEST PLAN Site/Unit: Paraburdoo GTG2

Date: 22-10-14
ITP Description Mechanical works for DIRIS including Flux Contract Name & No: Paraburdoo GTG3 ITP No. 002253-003 Rev.0 Page
Probe Installation
4 of 6

Act Activity/Process/Hazard Procedure/ Verifying Document Verification & Signoff & Date MDR Remarks
No Check/Control Acceptance Criteria S/C AL CL O (*)
13. Close side door. Document SWMS:001955;003 H W
Tool Log
Log:

Installation
14. Assemble Outer Covers NDE Visual Log: I Record Air Seal
SWMS: 001955;001 Measurement
Record: HRS_G3_10_16

15. Assemble Inner covers NDE Visual Lift Study: I Record Fan Blade
SWMS: 001955;001 Clearances
Record: HRS_G3_10_16

16. Open MV Cubicle and Install Flexible Visual SWMS: 001955;001 I


Connections Log:

17. Install Diodes and close exciter cover Visual SWMS: 001955;001 I
Log: N/A

18. Final Inspection Visual Log: H Ensure work area is clean


and ready for safe operation

TSOC.QI.F16 Template Rev/Date - 23/07/2013


INSPECTION & TEST PLAN Site/Unit: Paraburdoo GTG2

Date: 22-10-14
ITP Description Mechanical works for DIRIS including Flux Contract Name & No: Paraburdoo GTG3 ITP No. 002253-003 Rev.0 Page
Probe Installation
5 of 6

Act Activity/Process/Hazard Procedure/ Verifying Document Verification & Signoff & Date MDR Remarks
No Check/Control Acceptance Criteria S/C AL CL O (*)
19. Return permit /permits to work Rio Tinto PTW procedure PTW No: H 27.01.2015

20. All NCR’s to be checked and signed Document NCR no: H


completed

TSOC.QI.F16 Template Rev/Date - 23/07/2013


INSPECTION & TEST PLAN Site/Unit: Paraburdoo GTG2

Date: 22-10-14
ITP Description Mechanical works for DIRIS including Flux Contract Name & No: Paraburdoo GTG3 ITP No. 002253-003 Rev.0 Page
Probe Installation
6 of 6
cut

No. NAME COMPANY NAME POSITION/ JOB TITLE SIGNATURE SAMPLE INITIAL SAMPLE

1. D.A.Michael Alstom Generator Service Supervisor

2.

3.

4.

5.

6.

7.

8.

9.

10.

*To identify the initials within the ITP refer to the initials and signature samples above and associated personnel name.

TSOC.QI.F16 Template Rev/Date - 23/07/2013


Basis Inspection and Test Plan FOR INFORMATION ONLY Sheet No. : 001 (003).
Name: S. Aroonpitoon
Department: TSAA-AU
==================================================================================================================================================
I&T Plan ID : EE0-002253-ITP-004-DIAGNOSTIC Revision : 0 Prepared : Aroonpitoon 2015-01-16
I&T Plan Name : DIRIS PARABURDOO GTG3 LC State : Released Reviewed : L. Price 2015-01-19
Resp. Dept. : TSAA-AU Derived From : - Approved : L. Price 2015-01-19
Variant : 0
==================================================================================================================================================
No. Description Procedure Test Cert. Kind of QA Remarks Conf.
Q-record 1.) 2.) 3.)

GENERATOR INSPECTION ON ALSTOM T214-234


GENERATOR DIRIS ON ALSTOM T214-234

Preconditions:

- Machine is at standstill
- Starpoint is open
- Inner/outer covers open
- Exciter partially disassembled

1 STATOR

1.10 Visual inspection of stator frame HTCZ656808 HTCZ656980 L Y Q

1.11 Visual inspection of core rear HTCZ656808 HTCZ656980 L Y Q

1.12 Visual inspection of endwinding HTCZ656808 HTCZ656980 L Y Q FROM DISASSEMBLED END

1.13 Visual inspection of terminals and flexibles HTCZ656808 HTCZ656980 L Y Q

1.20 Charging current measurement phase wise HTAE660578 HTAE667004 L Y Q 2500 VDC MAX, 10 MINS

1.22 Low flux measurement of iron core 1AHX613070 HTCZ656981 L Y Q

1.23 Wedge Tightness measurement 1AHX613342 HTCZ656918 L Y Q

1.24 Winding Resistance (optional)

2 ROTOR

==================================================================================================================================================
Symbols, Abbreviations HP = Hold point for execution Q = Quality record which have to be handed over
1) Performed by L = Execution Company R = Quality record for internal purpose
2) Acceptance by KM = Customer witness point S = Hold point for acceptance by an authority
3) Q Record O = Customer acceptance tests recommended by ALSTOM WP = Point witnessed by ALSTOM
NP = ALSTOM notice point Y = ALSTOM internal test
The Inspection and Test Plan does not release the subcontractor / manufacturer from his obligation to take all steps necessary to ensure that the
requirements stipulated in drawings and specifications are fulfilled for the product concerned.
================================================================================================== (C) ALSTOM ====================================
Basis Inspection and Test Plan FOR INFORMATION ONLY Sheet No. : 002 (003).
Name: S. Aroonpitoon
Department: TSAA-AU
==================================================================================================================================================
I&T Plan ID : EE0-002253-ITP-004-DIAGNOSTIC Revision : 0 Prepared : Aroonpitoon 2015-01-16
I&T Plan Name : DIRIS PARABURDOO GTG3 LC State : Released Reviewed : L. Price 2015-01-19
Resp. Dept. : TSAA-AU Derived From : - Approved : L. Price 2015-01-19
Variant : 0
==================================================================================================================================================
2.10 Charging current measurement HTAE660567 HTAE667005 L Y Q 250 VDC MAX, 10 MINS

2.11 Repetitive surge oscilloscope (optional) TSAA-AU STD TSAA-AU STD L Y Q

2.12 Winding resistance (optional)

3 EXCITER

3.10 Visual inspection of rectifier HTCZ656808 HTCZ656980 L Y Q WHERE ACCESSIBLE ONLY

3.11 Test of the diodes HTCZ657150 L Y Q WHERE ACCESSIBLE ONLY


1600 VDC

4 BEARINGS

4.10 Visual inspection of bearings housing HTCZ656808 HTCZ656980 L Y Q

4.11 Bearing insulation check 1AHX613070 1AHX446434 L Y Q

5 COOLING SYSTEM

5.10 Visual check for leakages and contamination HTCZ656808 HTCZ656980 L Y Q


(incl. air leakage filter) (optional)

6 SHAFT GROUNDING

6.10 Check for condition (wear, contamination) HTCZ656808 HTCZ656980 L Y Q


(optional)

7 INSTRUMENTATION

7.10 RTD Calibration - - L Y Q


==================================================================================================================================================
Symbols, Abbreviations HP = Hold point for execution Q = Quality record which have to be handed over
1) Performed by L = Execution Company R = Quality record for internal purpose
2) Acceptance by KM = Customer witness point S = Hold point for acceptance by an authority
3) Q Record O = Customer acceptance tests recommended by ALSTOM WP = Point witnessed by ALSTOM
NP = ALSTOM notice point Y = ALSTOM internal test
The Inspection and Test Plan does not release the subcontractor / manufacturer from his obligation to take all steps necessary to ensure that the
requirements stipulated in drawings and specifications are fulfilled for the product concerned.
================================================================================================== (C) ALSTOM ====================================
Basis Inspection and Test Plan FOR INFORMATION ONLY Sheet No. : 003 (003).
Name: S. Aroonpitoon
Department: TSAA-AU
==================================================================================================================================================
I&T Plan ID : EE0-002253-ITP-004-DIAGNOSTIC Revision : 0 Prepared : Aroonpitoon 2015-01-16
I&T Plan Name : DIRIS PARABURDOO GTG3 LC State : Released Reviewed : L. Price 2015-01-19
Resp. Dept. : TSAA-AU Derived From : - Approved : L. Price 2015-01-19
Variant : 0
==================================================================================================================================================

7.11 Flux probe installation and measurement - - L Y R

7.12 Ductor testing (optional) - - L Y R

==================================================================================================================================================
Symbols, Abbreviations HP = Hold point for execution Q = Quality record which have to be handed over
1) Performed by L = Execution Company R = Quality record for internal purpose
2) Acceptance by KM = Customer witness point S = Hold point for acceptance by an authority
3) Q Record O = Customer acceptance tests recommended by ALSTOM WP = Point witnessed by ALSTOM
NP = ALSTOM notice point Y = ALSTOM internal test
The Inspection and Test Plan does not release the subcontractor / manufacturer from his obligation to take all steps necessary to ensure that the
requirements stipulated in drawings and specifications are fulfilled for the product concerned.
================================================================================================== (C) ALSTOM ====================================