Ejpgt Job Plan For Servicing of Gas Turbines

EJPGT - JOB PLAN FOR SERVICING OF GAS TURBINES
Job Specific PPEs

 Safety Shoes  Safety  Safety  Insulated  Rubber  Chemical  Arc Protective
Helmet Goggles Gloves Gloves Gloves Suit
• The requirements of Full Face Mask are subject to or work at heights or as per area condition assessed by Operations group while
issuing work permit.
• Use of Safety Harness is subjected to work at heights and work on Yellow-Tagged scaffolding.
• Dusk mask shall be used wherever de-dusting activity is involved.
• Additionally, other PPEs mentioned in work permit by Operations Group according to Area conditions
OHIH Guidelines
HAZARD:Noise: Noise Level Greater than 105 dB(A) HAZARD: Temperature: High temperate and humidity
CONTROL MEASURES: Level of noise in dB (A) vs. Max. CONTROL MEASURE: Temperature vs. Acclimatized
Daily Exposure Work/Rest
105 [85 dB(A) with ear plug] 8 Hours 29°C or less Continuous
116 [96 dB(A) with ear plug] 3 Hours 30 Minutes 30 – 39°C 50/10 Minutes
122 [102 dB(A) with ear plug] 1 Hours 30 Minutes 40 – 45°C 45/15 Minutes
128 [108 dB(A) with ear plug] 42 Minutes 46 – 54°C 30/30 Minutes
54°C or Above 20/40 Minutes
HAZARD: Radiation: Is radioactive source present nearby Chemicals / Agents / Asbestos: Review job for presence of
CONTROL MEASURE: Consult precautions as per Work Permit hazardous chemicals / agents
and Reduce impact by shielding, increasing distance, and limiting Follow instructions as per MSDS
time.
HAZARD: Illumination: Adequate for work Breathing Air Quality: Poor Ventilation
Make necessary arrangement Ensure proper Air Ventilation in Area
HAZARD: Ergonomic Hazards

CONTROL MEASURE: Review job with potential hazards
including body position, monotony, boredom, repetitive motion,
worry, work pressure, and fatigue.
Avoid potential threat before executing job
Job Plan
The following Job plan is generic and can be followed for all GTs.
(GT specific job plan for Major Inspection is available ahead and should be used where required)
1. Isolate and Interlock Generator, Excitation panel, Incomer and other Electrical auxiliaries (Battery charger, Motors,
Heaters, Protection panel etc.) as per EFERT’s procedure. OPS and Electrical both will be responsible for this activity.
2. Perform/Ensure LOTO.
3. Obtain separate work permit for maintenance activities mentioned below.
4. Carry out Servicing of Incomer. Refer to MV feeder servicing job plan.
Name: __________________ Time: __________________

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Date: __________________ Signature: __________________
5. Carry out Servicing of Excitation & Protection Panel by referring following guidelines;
a) Locate/Check presence of voltage in Excitation panel

b) Make sure to take appropriate safety measures against voltage present.
c) Clean and inspect Excitation Panel thoroughly
d) Check thoroughly to locate any hot spot, if present
e) Check all control & power terminals for tightness
f) Inspect and clean all power components.(thyristers ,capacitors, inductors etc.)
g) Inspect and clean all control components
Note: Use grounding wrist pad when working on control cards
h) Use vacuum and low air pressure blower
i) Inspect and clean all ventilation fans, filters &heat sink
j) Observe leakage/wear tear in electrolyte capacitor
k) Check physical condition relays, contactors, switches, PLC, etc.
l) Thoroughly inspect and clean all connection/ insulators/terminal block
m) Carry out servicing of all magnetic contactors
n) Inspect panel/cable gland sealing
6. Carry out Servicing of GEC/Carbon brush assembly/Ignition Circuit
a) Ensure de-energizing and discharging of all power terminals

b) Clean and inspect all components thoroughly
c) Inspect and replace carbon brushes, grounding brushes, Rotor earth fault detector brush.
d) Check thoroughly to locate any hot spot, if present
e) Check all terminals for tightness
f) Carry out PM of heat detector (for GT-603 only)
g) Check fuse and fuse base
h) Check cabinet for entry points of rodents/reptiles. Thoroughly inspect for presence.
i) Thoroughly inspect & clean all insulators, capacitors, arrestors, resistance, ventilation fans etc.
j) Measure Resistance of Neutral terminal.
k) Resistance (NGR) ____________________
l) Measure Resistance of Field Winding and Insulation Resistance
m) Resistance ____________________
n) Insulation Resistance ____________________
o) Measure Insulation Resistance of Generator from terminals connected to NGR
p) Insulation Resistance (Phase to Ground) ____________________
q) Polarization Index (Phase to Ground) ____________________
Note: Use appropriate voltage as per rated Voltage
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Record any abnormality
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
7. Carry out Servicing of Control (MCC) and Auxiliary Compartment
a) Carry out servicing of feeders and switchgear panels. Refer to relevant job plans
b) Carry out servicing of battery charger. Refer to UPS/DCP/batteries job plan.
c) Carry out servicing of all auxiliary motors. Refer to relevant job plans.
d) Clean and inspect all components including buck boast transformer.
e) Check all power connections/terminals for tightness
f) Check cabinet for entry points of rodents/reptiles. Thoroughly inspect for their presence.
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
8. Carry out Servicing of Generator Power, Control and Excitation Terminal Box at Generator
a) Ensure de-energizing and discharging of Terminals

b) Clean and inspect all JB/ Terminal boxes thoroughly and painting if required.
c) Check thoroughly to locate any hot spot, if present
d) Check all terminals for tightness
e) Thoroughly inspect and clean all insulators
f) Inspect JB & cable gland sealing
g) Ensure calibration of ILMS transducers installed in incomer panels by injection from FREJA.
h) Ensure calibration of GT transducers installed in GCP by injection from FREJA.
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
9. Make sure NGR is connected to Neutral Terminal

10. Close all work permits
11. Remove all Isolation and Interlocks of Generator, Excitation panel, Incomer and other Electrical auxiliaries (Battery
charger, Lube oil Motors, Heaters, Protection panel etc.) as per EFERT’s procedure. OPS and Electrical both will be
responsible for this activity
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Acronyms
 OEM Original Equipment Manufacturer
 MI Major Inspection
 DE Drive end of Generator
 NDE Non-drive end of generator
 FM Field Maintenance Department

 OPS Operations Department
 MTS Machinery Technical Service
 MP Motor pool Department

 NGR Neutral Grounding Resistance
 PPT Power Potential Transformer

 CT Current Transformer
 PT Potential Transformer
 JB Junction Box
 IR Insulation Resistance
 PI Polarization Index
 GEC Generator Excitation Cubicle
I&E Reliability Role

Following actions shall be taken by I&E Reliability audit function:
 Validate / Endorse
I&E reliability shall be required to review and sign off the results and hence endorse that results
fall in acceptable limits
 Witness / Verify
I&E reliability shall be required to observe the defined parameters (hold points) and if the
correct methods are being used to collect the readings.
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GT-601
Tag GT-601 Make General Electric
GT-601 is an 18.235 MVA General Electric No of Poles 2 Cooling Mechanism Air Cooled
Gas Turbine Generator. The generator is Rated Power 18.235MVA Rated Stator Current 1595A
a 2-pole machine, having cylindrical
Insulation class F Rated Voltage 6600V
rotor. The excitation system is EX2000
Excitation 250V Rated Frequency 50Hz
from General Electric, implementing
Power Factor 0.85 RPM 300
compound source excitation system.
Field Ampere 189A Rotor Type Cylindrical Pole
Preparations for Servicing
 Polythene rolls to cover the top of generator and wrap the rotor, to avoid
 moisture ingress.
 Tarpaulin sheet for shelter of Generator and Rotor.
 Scaffolding at NDE for ease of winding coolers rigging and JB inspection.
 Scaffolding for rotor shelter and inspection stand for its placement in the field.
 Periscope gauge and filler gauge to measure the end cover air gaps and gaps between stator and rotor.
 Carbon brushes to replace the depleted brushes from collector assembly.
 Dry Ice (CO2)
 Air- Dry varnish (Von-Rol make), purchased through TMS team(External Vendor)
 Portable Receptacles for power supply
 Lighting arrangement to work in evening
 Heat shrink sleeves availability
Work permit / LOTO and Cable Disconnection

1. Carry out LOTO procedure for the main incomer breaker of GT-601 i.e. Panel # 5 in MSGR-I.
2. Perform Tag all the cables i.e. Field, JBs, Breaker side etc.
3. Perform disconnection of cables from both the sides.
4. Remove the incomer PT fuses. Check fuse health.
5. Perform bulk testing/meggering of cables. Values :________________________________
6. Remove the neutral JB cables and wrap properly to ensure no Moisture enters.
Carbon Brush/Collector Assembly
1. Ensure supply is disconnected.

2. Carefully remove the outer covers to expose the assembly.
3. Disconnect all DC field application cables.
4. Mark contact points of all carbon brushes.
5. Check the spring condition and tension.
6. Measure clearance between collector ring and spring assembly.
Values:____________________________
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Generator Disassembly
1. Mark the end cover sides and remove the outer and inner end covers.
2. Measure the Rotor to Stator Air gap. Use a healthy feeler gauge or telescopic
gauge.
Values:________________________________________________________________________
3. Collaborate with FM for generator hood rigging. FM will remove the winding
coolers as well.
Air gap reference values are:
Air Gap between Stator to Rotor
0.379”
0.2657” Inboard 0.359” Inboard
0.305”
Eccentricity – 52.75 Thou
0.3378”
0.3011” 0.3110” Out-board

Out-board
0.3248”
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Air Gap between End Cover and Shaft
OUTER COVER
0.212” 0.291”
0.29” 0.295”
0.1144” 0.0917”
0.13” Out-board
Out-board
0.061” 0.1614”
INNER COVER
0.0866” 0.0826”
0.153” 0.1909”
0.0629” 0.0669”
0.037” 0.98” Out-board

Out-board
0.0276” 0.071”
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Rotor Removal(Where required)
1. Ensure JSA is done and MP and FM teams are on-board with the activity.
2. Rigging of rotor will be carried out. Dead weight of 11000Kg was used last
time.
3. After removal of Rotor is to be wrapped properly to minimize moisture
ingress.
4. Hard Barricade the area around it. Tarpulin covering can be used if weather is
rainy.
Generator Stator Inspection
1. Keep a camera to capture the Before and After cleaning condition

2. The rotor has been removed so the stator is exposed for inspection.
3. Visually Inspect the Stator for any sign of insulation failure, damage,
discoloration, wear and tear.
4. Check the tightness of the wedges by tapping them.
5. Check the end turns/overhand thoroughly for any signs of damaged.
Generator Stator/Rotor Cleaning, Dry-icing and Varnishing
1. If dust/ dirt/ carbon deposits are observed thorough cleaning is required. Use
dry air i.e. Instrument air, to first clean off the excess dirt. Then use dry ice
cleaning to remove carbon deposits and any other unwanted accumulation.
(usually this task is contracted out)
2. Dry ice blasting erodes the insulation at some points. This insulation will be
revived by applying air-dry varnish.
3. Leave the rotor/ stator for curing for at least 24 hours after the dry ice cleaning
to ensure proper drying. Use space heaters for stator and portable heaters in
the portable rotor enclosure.
4. After drying out time, varnish is to be applied. (Von Rol make Class-H type air
dry varnish was used last time)
5. Allow 4 hours drying time after varnish. Testing was started after drying the
varnish.
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Generator Rotor Inspection

1. Thoroughly inspected for any visible heating patterns as well as carbon
deposits. Check the air circulation holes for deposits.
*(GT-601 has cylindrical rotor of 15ft length and 7.5 ton weight)
2. Inspect the winding insulation for any sign of damage/erosion etc.
3. Check wedges for tightness.
Winding Coolers inspection by FM

1. The GT has winding coolers. Ensure FM has hydro tested them.
2. Take test reports from FM and attach.
Inspection of line and neutral side JBs

1. Open and inspect both the JBs for any signs of discoloration or damage etc.
2. Ensure correct tagging.
3. Ensure tightness of cables.
4. Inspect HV bushings, Surge Arrestors & Capacitors.
Testing of Stator
For any testing, note down ambient temperature and relative humidity. Also note down the equipment used for
testing. Values ________________________________________________________
Following table is to be used as reference for test values. These values were taken in 2018.
Sr. Test Value Range

STATOR
1 DC Resistance Variation ±0.7% ±0.2% between Phases
2 Insulation Resistance Phase-Gnd 6.08GΩ >100MΩ
3 Insulation Resistance Phase-Phase 10.2GΩ >100MΩ
4 Polarization Index >8.72 2<PI<8
5 Power Factor % (GST) 1.245% <1.0%
6 Power Factor % (UST) 0.734% <1.0%
7 Power Factor % (Bulk) 1.260% <1.0%
8 Power Factor % (Tip-up) 0.193% <1.0%
9 Capacitance % (Tip-up) 0.260% <1.0%
ROTOR
1 DC Resistance Variation NA ±0.2% Previous Value
2 Insulation Resistance 14.90GΩ >100MΩ
3 Polarization Index NA 2<PI<8
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1. Insulation Resistance Test
Refer to the following values as reference for IR testing of Stator. Voltage to be kept at 4000VDC
Megger @4000V
Year U V W UVW
2018 6.22 6.1 6.08 2.5
Values: _____________________________________________________________
2. Polarization Index Test
Calculate the PI values using the following formula:
Values: _____________________________________________________________
(Value in 2018 was 8.72)
3. TAN DELTA Test (Power factor Tip-up and Capacitance)
Perform Tan-Delta test to check proper impregnation, insulation health, dielectric losses, moisture and
partial discharge percentage. Capacitance tells about insulation & slot voids, stator slot contamination
and fixing of coil in slots.
Find below reference table:
Year 2018 Year

Value U V W UVW Value U V W UVW
0.2Un 0.837 0.821 0.823 0.873 0.2Un
1.1Un 1.245 1.201 1.224 1.26 1.1Un
Tip-Up 0.408% 0.380% 0.400% 0.387% Tip-Up
Year 2018 Year
Value U V W UVW Value U V W UVW
0.2Un 137.868 138.084 137.870 408.090 0.2Un
1.1Un 138.610 138.806 138.560 410.604 1.1Un
Tip-Up 0.530% 0.522% 0.50% 0.616% Tip-Up
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Values and Observations
` IEEE 60034-27-3 gives reference values for dissipation factor limits. However please note
that these values are on a conservative side and values may come higher than this in
which case take concurrence from I&E reliability and machine OEM.
4. DC Resistance Testing
Perform test for checking loose/ overheat connections, turn-turn short/ inter turn faults (mature faults only),
winding integrity and unbalance phases. Reference values as below:
Year U V W
2018 3.2 3.2 3.2
2009 3.29 3.29 3.29
Testing of Rotor
1. DC Resistance, AC Impedance/ Pole Drop Test
Perform test for for checking loose/ overheated connections, turn-turn short/ inters turn faults (mature faults
only). The tests also tell about integrity of core for each pole which is significantly stressed by centrifugal forces
during operation. Reference values as below:
DC Resistance in Ohms
Test Performed Temperature During Measurement Rotor Resistance
2018 20°C 0.91
2009 35°C 1
Refer to the following values as reference for IR testing of Rotor. Apply respective voltage for 60 secs.
Year Voltage(V) IR(GΩ)

2018 300 14.9
2009 500 17.8
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Servicing of Generator Auxiliaries
All generator auxiliary motors are to be serviced. Use LV motor EJPLVMFS for servicing. 88 HR, 88QA, 88QE,
88HQ, 88GV, 88CA, 88MG, The minimum acceptable IR value declared by IEEE Std. 43 i.e. (0.44+1) MΩ.
Reference Values:
88 GV winding health comparison Year
IR Test @500V for 60 secs 2009 2018

R-Y-B-G 95MΩ 300MΩ
88 QA winding health comparison Year

R-Y-B-G 5.45GΩ 6.82GΩ
88 QE winding health comparison Year

R-Y-B-G 720MΩ 4.62GΩ
88 HR winding health comparison Year

R-Y-B-G 4.16GΩ 205MΩ
Servicing/Testing of GT Magnetics
PPT, surge arrestors and surge capacitors need to be tested for health assessment.
PPT IR
PPT Health Comparison

IR Test @ 60 secs 2009 2018
Pri. to Gnd. @4000V 42.6GΩ 136GΩ
Pri. to Sec @400V >505GΩ 432GΩ
Sec. to Gnd. @250V 57GΩ >274GΩ
Page 12 of 39
Surge Arrestor Health Comparison
Surge Capacitor Health Comparison
IR Test @ 4000V 2009 2018
IR Test @ 4000V 2009 2018
for 60 secs
for 60 secs
T1 to G 1.35GΩ 39.8GΩ
T1 to G 21.8MΩ 26.5MΩ
T2 to G 1.57GΩ 38.2GΩ
T2 to G 21.6MΩ 21.4MΩ
T3 to G 3.72GΩ 26GΩ
T3 to G 26.0MΩ 21.7MΩ
Bus Bar IR with Fluke 1550C
IR test @4000V for 30Secs Values in

2018
R-Y 2.49TΩ
Y-B 4.21TΩ
B-R 4.21TΩ
R-G 42.9GΩ
Y-G 45GΩ
B-G 36.7GΩ
PCT Health Comparison

IR Test @ 60 secs 2003
@500V 625MΩ
*Make sure to disconnect the cables before taking measurement of PCT.
GEC Bus-Bar Servicing and IR

Inspect the Bus bar for insulation integrity and perform IR. Values :_____________________
Servicing of MCC
Perform feeder servicing of the MCC. Use EJPLVFS.
Observations:___________________________________________________________________
Measurement of Earthing Resistance

Measure the earth resistance of following:
 East side marshaling plate: ____________________
 East side JB: ____________________
 GEC marshaling plate: ____________________
 GEC body: ____________________
Page 13 of 39
Generator Heaters
There are 02ea space heaters i.e. one for DE and one for NDE side. Each heater consists of 6 strip
elements(500W) and both are connected in parallel.
Verify operation of heaters, Measure current.
Bearing Checkup and Meggering

Bearing meggering is to be carried out if bearing is taken out by FM.
This will verify the insulation strength of the insulated bearing.
Value:_______________________________ (Should be >100MOhms)
Carbon brush assembly checkup

The carbon brushes are checked to verify their health. Measure resistance.
Value:_______________________________
Servicing Excitation Control i.e. EX2000 Servicing

Always wear anti-static wrist band while servicing EX-2000.
Perform the following activity for Periodic Maintenance of EX2000:
 De-energize all incoming sources of power for the cabinet to be inspected and maintained.
 Remove dust and dirt from cabinets and electrical components. Never use compressed air for this
purpose as components may be damaged.
 Clean and replace cabinet air filters, if equipped.
 Check all screw and bolt connections periodically if excessive vibration is present.
 Inspect wiring for wear (fraying, chipping, and nicks) and burns or melted wire insulation.
 Inspect printed wiring board plugs, wiring, and connectors for wear and burns and also to ensure
correct seating.
 Inspect blower motors for correct operation and rotation.
 Inspect contacts on open (as opposed to sealed) contactors and relays.
Discoloration and rough contact surfaces are normal.
If beads form due to severe arcing, dress the contact faces with a fine file. Never use sandpaper or
emery cloth and never oil any part of the power unit.
 Check operating status of space heaters, if supplied.
 Check calibration of discrete protective relays per manufacturer instructions.
 Check field ground detector (see GEI-100026).
 Upon completion of maintenance, apply control power and verify EEPROM checksum values against
values list recorded after initial installation. Use the keypad programmer.
Following it typical SLD of excitor:
Page 14 of 39
Ex-2000 Software
The EX2000 exciter controllers store most configuration data in EEPROM on the SDCC or LDCC. This data I
organized into 16 - bit words, stored, and checksum-ed. The SDCC’s or LDCC’s Main Control Processor (DCP)
controls memory access.
The exciter stores programming data as follows:

• Block library (block definitions) in the drive control processor (DCP) ROM
• Block variables in RAM
• Block configuration parameters in EEPROM
An operator can examine and adjust operating parameters stored in EEPROM in

either of two ways:
• Use the Programmer on the excitation’s SLCC or LDCC

• Use the toolbox on a serially-connected computer
RTDs
Embedded resistance type temperature detectors (RTD’s) measure the temperature of the stator windings.
These are distributed equally throughout the winding between the coil sides.
The RTD is a platinum wire, wound non-inductively to a value of 100 Ohm at 0°C (32°F).
Value:_________________________________________________________________________________
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Relay Testing`
Perform data backup of protection relay.
Perform testing internally or through contracted out vendor i.e. Lineman, Episol etc.
GT Batteries and Battery Charger

Perform servicing of Battery Charger.
Perform Load test of all batteries and note down values.
RTDs
Value:_________________________________________________________________________________
Any Other Observations/ Readings/ Measurements:
Ref for GT-602 Tests(2003):
Page 16 of 39
GT-603 Tag GT-603 Make General Electric

No of Poles 4 Cooling Mechanism Air Cooled
GT-603 is a 20 MVA General Electric Gas
Rated Power 20MVA Rated Stator Current 1750A
Turbine Generator. The generator is a 2-
Insulation class F Rated Voltage 6600V
pole machine. The excitation system is Power Factor 0.85 Rated Frequency 50Hz
DECS400N from Basler Electric. Type ATB-2 RPM 1500
Avg Running Current 1100A Rotor Type Salient Pole
Avg Operating 65°C Year Manufacturing 1997
Preparations for Servicing
Temp.
 Polythene rolls to cover the top of
generator and wrap the rotor, to avoid
 Dry Ice (CO2)
 Air- Dry varnish (Von-Rol make), purchased through TMS team (External Vendor)
1. Carry out LOTO procedure for the main incomer breaker of GT-603 i.e. Panel # 25, Bus 3 in MSGR-I.
3. Perform disconnection of cables from both the sides. ( Field cables are disconnected before disconnecting the
Phase and Neutral JB cables. Power cables were disconnected from Phase JB first and Bulk Testing of the Stator
Winding was done, after which the Neutral JB cables were disconnected.
4. Remove the incomer PT fuses. Check fuse health.(where applicable)
5. Perform bulk testing/meggering of cables. Values: ________________________________
6. Wrap properly to prevent moisture ingress.
Carbon Brush/Collector Assembly
1. Ensure supply is disconnected.

2. Carefully remove the outer covers to expose the assembly.
3. Disconnect all DC field application cables.
4. Mark contact points of all carbon brushes. Check length.
5. Check the spring condition and tension.
6. Check the collector rings surface for any carbon deposits.
7. Measure clearance between collector ring and spring assembly.
Values:____________________________
Page 17 of 39
Generator Disassembly
2. Measure the Rotor to Stator Air gap. Use a healthy feeler gauge or telescopic gauge.
Values:_____________________________________________________________________________
3. Collaborate with FM for generator hood rigging. FM will remove the coolers as well.
0.819”
0.796” Drive-End 0.802” Drive-End
0.778”
0.821”
0.798” Non Drive-End 0.792” Non Drive-End
0.770”
Air Gap between End Cover and Shaft
0.95mm
0.55mm Drive-End 0.55mm Drive-End
0.75mm
Page 18 of 39
1.10mm
0.55mm Non Drive-End 0.55mm Non Drive-End
0.85mm
Rotor Removal (Where required)

1. Ensure JSA is done and MP and FM teams are on-board with the activity.
2. Rigging of rotor will be carried out. Dead weight of 11000Kg was used last
time.
3. After removal of Rotor is to be wrapped properly to minimize moisture
ingress.
4. Hard Barricade the area around it. Tarpulin covering can be used if
weather is rainy.

1. Keep a camera to capture the Before and After cleaning condition
2. The rotor has been removed so the stator is exposed for inspection.
3. Visually Inspect the Stator for any sign of insulation failure, damage,
discoloration, wear and tear.
5. Check the end turns/overhand thoroughly for any signs of damaged.
6. If dust/ dirt/ carbon deposits are observed thorough cleaning is required.

Use dry air i.e. Instrument air, to first clean off the excess dirt. Then use dry
ice cleaning to remove carbon deposits and any other unwanted
accumulation. (usually this task is contracted out)
7. Dry ice blasting erodes the insulation at some points. This insulation will be
revived by applying air-dry varnish.
8. Leave the rotor/ stator for curing for at least 24 hours after the dry ice
cleaning to ensure proper drying. Use space heaters for stator and
portable heaters in the portable rotor enclosure.
9. After drying out time, varnish is to be applied. (Von Rol make Class-H type
air dry varnish was used last time)
10. Allow 4 hours drying time after varnish. Testing was started after drying
the varnish.
Page 19 of 39


1. Open and inspect both the JBs for any signs of discoloration or damage etc.
Testing of Stator
testing. Values ________________________________________________________
Following table is to be used as reference for test values. These values were taken in 2017.

STATOR
1 DC Resistance Variation ±0% ±0.2% between Phases
3 Polarization Index N.A 2<PI<8
4 Tan Delta 1.381% <1.0%
5 Tan delta tip-up 0.228% <1.0%
7 Partial Discharge 1.2nC% <2nC
ROTOR
1 DC Resistance Variation NA ±0.2% Previous Value
3 Polarization Index NA 2<PI<8
4 Pole Drop AC Impedance 0 ±0.2% between Poles
Page 20 of 39

Refer to the following values as reference for IR testing of Stator. Voltage to be kept at 5000VDC
Megger @5000V (corrected to 40°C)

Year U V W U-V V-W W-U
2017 26.75 27.85 26.24 58.06 65.77 69.12

Values: ___________________________________________
(PI is invalid when IR > 5 G Ohms,)

Power Factor Values

Year Value U V W UVW
0.2Un 0.74 0.75 0.88 1
2015
0.6Un 1.24 1.24 1.35 1.3

Tip-Up 0.50% 0.49% 0.47% 0.30%

0.2Un 1.049 1.041 1.156 1.114
2017
0.6Un 1.253 1.269 1.381 1.318

Tip-Up 0.20% 0.23% 0.23% 0.20%

0.2Un
20_ _
0.6Un
Tip-Up
Page 21 of 39
Capacitance Values
0.2Un 130.8 130 129.7 384.9
2015
0.6Un 131.9 131.2 130.9 387.4

Tip-Up 0.84% 0.92% 0.92% 0.65%

0.2Un 134.28 133.89 133.84 396.2
2017
0.6Un 134.81 134.42 134.39 398.1

Tip-Up 0.39% 0.39% 0.41% 0.47%

20_ _
Observations
DC Resistance in Milli Ohm(corrected to 22°C)

Year U V W
2005 7.505 7.505 7.58
2017 5.746 5.746 5.746
20_ _
Testing of Rotor
Perform test for for checking loose/ overheated connections, turn-turn short/ inters turn faults (mature faults
only). The tests also tell about integrity of core for each pole which is significantly stressed by centrifugal forces
during operation. Reference values as below:
2005 22°C 65.9
2017 22°C 56.41
20 _ _
Page 22 of 39
IR Values corrected to 40°C

Year Voltage(V) IR(GΩ) PI
2005 500 7.11 3.1
2017 500 6.52 3.06
20 _ _
All generator auxiliary motors are to be serviced. Use LV motor EJPLVMFS for servicing. 88 HR, 88QA, 88QE,
88HQ, 88GV, 88CA, 88MG, The minimum acceptable IR value declared by IEEE Std. 43 i.e. (0.44+1) MΩ.
Reference Values
88QA Value 88HR Value

Operating Voltage 380VAC Operating Voltage 125VDC
Test Voltage 500VDC Test Voltage 200VDC
Time for IR application 30secs Time for IR application 30secs
Resistance Measured(L-G) 15.7GOhm Resistance Measured(L-G) 2.25MOhm
CAB 01/02 Value

88QE Value Operating Voltage 220VAC
Operating Voltage 125VDC Test Voltage 250VDC
Test Voltage 200VDC Time for IR application 30secs
Time for IR application 30secs Resistance Measured(L-G) 121GOhm
Resistance Measured(L-G) 5.07MOhm CAB 01
Resistance Measured(L-G) 137.3GPhm
CAB 02
Page 23 of 39
Servicing/Testing of GT Magnetics
PPT, surge arrestors and surge capacitors need to be tested for health assessment.
Reference values:
Surge Arrestor Health Comparison IR Test @ 4000V for 60 secs

IR Test @ 4000V for 60 secs T1 to G
T1 to G T2 to G
T2 to G T3 to G
T3 to G
PPT
Primary Side - 6.6KV
Phase to Ground IR 239GOhms
Test @2500V for 1 min
Secondary Side - 110V
Phase to Ground IR 13.95GOhms
Test @250V for 30 sec
GEC Bus-Bar Servicing and IR

Inspect the Bus bar for insulation integrity and perform IR.
Values:______________________________________________________________________
Servicing of MCC/ MV Panel.

Perform feeder servicing of the MCC. Use EJPLVFS. For MV panel use, EJPMVFS.
Observations:__________________________________________________________________

 East side marshaling plate: ____________________
 East side JB: ____________________
 GEC marshaling plate: ____________________
 GEC body: ____________________
Generator Heaters
Verify operation of heaters, Measure resistance.
Carry out heater Insulation resistance (Along with cable) measurement using a 500 Vdc Megger. ______________
(Reference Value: Heater insulation resistance: 2000 M Ohms)
Page 24 of 39
Carry out heater element resistance: ________________
Reference Value: 31.06Ohms @ 20°C

Bearing meggering is to be carried out if bearing is taken out by FM. This will verify the insulation strength of
the insulated bearing.
Value:_______________________________ (Should be >100MOhms)
Carbon brush assembly checkup

The carbon brushes are checked to verify their health. Measure resistance.
Value:_______________________________
Measure resistance of NGR (Ohm) _________________
Excitation System Servicing – DECS 400N

DECS-400 preventative maintenance consists of regular checks to ensure that the DECS-400 connections are
clean and tight and periodic replacement of the backup battery.
1. Check cleanliness, tightness and sealing issues in the panel.
2. Make sure the panel auxiliaries are in order i.e. lights and fans is working.
3. An internal battery maintains real-time clock information when DECS-400 operating power is removed
or lost. The 3.6 volt, lithium, backup battery is secured in a holder located behind the front panel. The
backup battery should be replaced every five years.
Procedure:
 Remove the DECS-400 from service by observing all applicable safety and shutdown
procedures.
 Loosen the captive Phillips screw in both latches, release each latch, and withdraw the draw-
out assembly from the case.
 Locate the battery holder and cover on the circuit board attached to the front panel. When
facing the back side of the front panel, the battery holder and cover are located near the
upper, left-hand corner of the circuit board.
 Unclip and remove the cover from the battery holder.
 Remove the battery from the battery holder. Note the orientation (polarity) of the battery.
The new battery must be installed with the same orientation.
 Install the new battery in the holder. Ensure that the polarity of the installed battery is correct
(+ to + and – to –).
 Place the battery cover over the battery holder and snap it into place.
 Insert the draw-out assembly into the case and secure it with the latches.
If the front panel display (LCD) is blank or frozen (does not scroll), remove input power and then reapply input
power after approximately 60 seconds
*It is a good practice to go through all tabs in the excitation system HMI and note down the setpoint and values.
Page 25 of 39
RTDs
Value:_________________________________________________________________________________
Relay Testing`
Perform data backup of protection relay.
GT Batteries and Battery Charger

Perform servicing of Battery Charger.
Perform Load test of All Batteries and note down values.
Page 26 of 39
GT-604
Tag GT-604 Make General Electric
No of Poles 4 Cooling IC8A1W7
Rated Power 26.235MVA Rated Stator 2295A
GT-604 is a 26 MVA Brush Electric Gas
Current
Turbine Generator. The generator is a 4- Insulation class F Rated Voltage 6600V
Power Factor 0.85 Rated Frequency 50Hz
pole machine. The excitation system is
Type DG185ZL-04 RPM 1500
brushless Prismic A10.
Rated Temp 33°C Rotor Type Salient Pole
Preparations for Servicing Temp Rise B Year Manufacturing 2007
 Polythene rolls to cover the top of generator and wrap the rotor, to avoid
 Dry Ice (CO2)
 Air- Dry varnish (Von-Rol make), purchased through TMS team (External Vendor)
1. Carry out LOTO procedure for the main incomer breaker of GT-604 i.e. Panel #15 , in MSGR-2.
3. Perform disconnection of cables from both the sides. (Field cables are disconnected before disconnecting the
Phase and Neutral JB cables. Power cables were disconnected from Phase JB first and Bulk Testing of the Stator
Winding was done, after which the Neutral JB cables were disconnected.
4. Remove the incomer PT fuses. Check fuse health. (where applicable)
5. Perform bulk testing/meggering of cables overall after ensuring disconnection from both sides.
Values: ________________________________
6. Wrap properly to prevent moisture ingress.
Generator Disassembly and PMG Inspection
2. Measure the Rotor to Stator Air gap. Use a healthy feeler gauge or
telescopic gauge.
Values:______________________________________________________________
3. PMG Stator assembly will be disconnected from main body of the
generator.
4. Collaborate with FM for generator hood rigging. FM will remove the winding coolers as well.
Page 27 of 39
18.81mm
19.12mm Drive-End 18.23mm Drive-End
19.04mm
Air Gap between PMG and Stator
2.10mm
1.75mm 1.80mm
1.40mm
Air Gap between Exciter and Field Stator
4.57mm
3.77mm 4.05mm
3.55mm
Page 28 of 39
Air Gap between Fans and Deflector Plates
2.25mm
2.25mm Inboard 2.25mm Inboard
2.0mm
1.5mm
3.01mm 2.84mm Out-board

Out-board
1.3mm
Rotor Removal(Where required) + PMG dismantling

1. Ensure JSA is done and MP and FM teams are on-board with the
activity.
2. Rigging of rotor will be carried out as per Brush Instructions.
3. After removal of Rotor is to be wrapped properly to minimize
moisture ingress.
4. Hard Barricade the area around it. Tarpulin covering can be used.
5. During extraction of rotor, the PMG stator winding, which is
fastened to the generator body, will be disconnected and be
allowed to hang on the rotor shaft.
6. To protect it from damage during rotor extraction, it will be
fastened with the frame around the PMG with the help of binding
belt.
Page 29 of 39
1. Keep a camera to capture the Before and After cleaning
condition
2. The rotor has been removed so the stator is exposed for
inspection.
3. Visually Inspect the Stator for any sign of insulation failure,
damage, discoloration, wear and tear.
5. Check the end turns/overhand thoroughly for any signs of
damaged.

1. If dust/ dirt/ carbon deposits are observed thorough cleaning is
required. Use dry air i.e. Instrument air, to first clean off the
excess dirt. Then use dry ice cleaning to remove carbon deposits
and any other unwanted accumulation. (usually this task is
contracted out)
2. Dry ice blasting erodes the insulation at some points. This
insulation will be revived by applying air-dry varnish.
3. Leave the rotor/ stator for curing for at least 24 hours after the
dry ice cleaning to ensure proper drying. Use space heaters for
stator and portable heaters in the portable rotor enclosure.
4. After drying out time, varnish is to be applied. (Von Rol make Class-H type air dry varnish was used last time)
5. Allow 4 hours drying time after varnish. Testing was started after drying the varnish.


1. Open and inspect both the JBs for any signs of discoloration or
damage etc.
PMG Bolts Inspection and Replacement
1. It is recommended by BRUSH FSR that PMG bolts should be closely inspected for rust of any signs
of damage.
2. If rusting is evident, replacement needs to be carried out.
Page 30 of 39
Testing of Stator
testing. Values ________________________________________________________
Following table is to be used as reference for test values. These values were taken in 2018

STATOR
1 DC Resistance Variation ±0.2% ±0.2% between Phases
2 Insulation Resistance Phase-Gnd 9.31GΩ >100MΩ
3 Insulation Resistance Phase-Phase 17.28GΩ >100MΩ
4 Polarization Index >4.5 2<PI<8
5 Tan Delta % (GST) 0.592% <1.0%
6 Tan Delta % (UST) 0.378% <1.0%
7 Tan Delta % (Bulk) 0.601% <1.0%
8 Tan Delta % (Tip-up) 0.062% <1.0%
Partial Discharge 0.732nC <2nC
ROTOR
1 DC Resistance Variation NA ±2% Previous Value
3 Polarization Index 3.31 2<PI<8
4 Pole Drop/AC Impedance NA ±0.2% between Poles

Refer to the following values as reference for IR testing of Stator. Voltage to be kept at 2500VDC.
IR value in G-Ohm @2500V (corrected to 40°C)
Year U V W U-V V-W W-U UVW
2018 13.59 11.62 12.52 22.55 25.19 24.67 4.39
20_ _

Values: _____________________________________________________________
(PI is invalid when IR > 5 G Ohms,)
Page 31 of 39

Power Factor Values
0.2Un 0.36 0.38 0.4 0.48
1.1Un 0.55 0.55 0.57 0.57
2016
Tip-Up 0.19% 0.17% 0.17% 0.09%

0.2Un 0.521 0.535 0.53 0.567
1.1Un 0.56 0.584 0.592 0.601
2018
Tip-Up 0.04% 0.05% 0.06% 0.03%

20_ _
Capacitance Values
0.2Un 249.52 249.75 250.3 745.3
0.6Un 250.1 250.68 251.18 747.8
2016
Tip-Up 0.23% 0.37% 0.35% 0.33%

0.2Un 249.92 250.59 250.12 743.11
0.6Un 250.24 250.67 250.35 744.48
2018
Tip-Up 0.12% 0.04% 0.09% 0.18%

20_ _
Values and Observations
Page 32 of 39
(During last PM, Shorting links were used between phase to neutral JB to measure phase resistance. With star
point connected, the resistance was 6.0 1milli Ohms for all the phases.)
DC Resistance in Milli Ohm(corrected to 22°C)

Year U V W
2018 3.6 3.59 3.63
20_ _
Testing of Rotor
Perform test for checking loose/ overheated connections, turn-turn short/ inters turn faults (mature faults only).
The tests also tell about integrity of core for each pole which is significantly stressed by centrifugal forces during
operation. Reference values as below:
2018 20°C 64.6
20_ _

IR Values corrected to 40°C

Year Voltage(V) IR(GΩ) PI
2018 500 79.8 3.3
20_ _
All generator/HRSG motors are to be serviced. Use LV motor EJPLVMFS for servicing.
The minimum acceptable IR value declared by IEEE Std. 43 i.e. (0.44+1) MΩ.. Reference Values below:
Page 33 of 39
1. SAF01-A
2. CAB01-A
4. FD01B
5. 88BA-1
6. 88BA-2
7. 88HG-1
8. 88QT-2
9. CAB01-B
10. MP-611A
11. FDF01A
12. SAF01B
13. 88QA-1
14. 88QV-1
15. 88QT-1
16. 88TA1/2
17. 88CR
Year 2009 20_ _ Equipment 88BA-2

Equipment PMG 604 Test Voltage 500V
Test Voltage 250VDC Time 30s
Time 1 min
Year 2009 20_ _
WDG-GND 178MΩ/204MΩ
Megger Results MΩ
PMG Resistance Lead- 0.5Ω/0.1Ω
Lead V-G 174
U-G 170
Year 2009 20_ _
W-G 155
Equipment EXC 604
W-V 265
Test Voltage 250VDC
W-U 305
Time 1 min
V-U 311
WDG-GND 6GΩ
PMG Resistance Lead- 5.2Ω
Lead
Year 2009 20_ _
Equipment 88BA-1 Equipment Gen 604
Test Voltage 500V Test Voltage 5000V
Time 30s Time 1 min
Year 2009 20_ _ Megger GΩ
Results
Megger Results MΩ
V2-G 7.9
V-G 153
U2-G 8.01
U-G 164
W2-G 6.45
W-G 165
U2-V2 14.8
W-V 358
U2-W2 17.8
W-U 305
V2-W2 16.1
V-U 353
Page 34 of 39
Year 2009 20_ _

Cable Tag PC-GT604-88CR-1
Equipment 88-CR-1
Test Voltage 5000V
Time 1min 10min PI 1min 10min PI
Megger GΩ GΩ
Results
R-G 4.53 6.84 1.5
Y-G 4.81 7.01 1.5
B-G 5.63 9.57 1.7
R-Y 16.5 37.7 2.3
R-B 19.2 42.5 2.2
Y-B 18.5 42.6 2.3
Testing Values form Manual
Rotating Diodes
Inspect rotating rectifier bridge
Keep the multimeter in Diode mode/resistance mode and check value across rotating diodes
6 Diodes
Observations:________________________________________________________________________________
Note: The resistance in both directions can be measured, for

example with a multi-meter with resistance range. In the forward
direction the resistance will be between 1 and 100 Ohm, depending
on the type of diode and the used measuring instrument, while in
the reverse direction the resistance will have to be at least a 1000
times higher.
If a diode is defect, the resistance in both directions will be either
almost 0 Ohms or infinity.
Page 35 of 39
Servicing of MCC/ MV Panel

Perform feeder servicing of the MCC. Use EJPLVFS. For MV panel use, EJPMVFS.
1. SAF01-A
2. CAB01-A
3. GT-604 incoming breaker
4. FD01B
5. 88BA-1
6. 88BA-2
7. 88HG-1
8. 88QT-2
9. CAB01-B
10. MP-611A breaker
11. FDF01A
12. SAF01B
13. 88QA-1
14. 88QV-1
15. 88QT-1
16. 88TA1/2
17. 88CR breaker
DCP 604
Perform inspection and Testing of DCP-604 as per PM plan EJPUPSDCP
Observations:_________________________________________________________________________________________
Relay Testing`
Perform data backup of G60.

 Generator Marshaling plate: ____________________
 Field JB: ____________________
Generator Heaters
Verify operation of heaters, Measure resistance.
Observations:____________________________________________________________________________________________
Heaters are located within the generator to prevent moisture condensing on the windings and metal parts
which could lead to a low insulation resistance or corrosion in the generator, and consequential damage.
Page 36 of 39
Figure 1 Heater Resistor Cubicle
GT Fuel Mixing Skid Heater
Fuel Mixing Skid Heater is installed at MSGR-2 for heating of GT-604 fuel. The heater heats the incoming fuel
from ENCOP-1/2 compressors to 60˚C.
 Open the panel and do general cleaning.
 Check for any sealing issues. Rectify.
 Check tightness of all cables.
 Check control power.
 Service the Mulitdrive-3PH Thyristor Unit
o Clean the Heatsink thoroughly
o Clean the fans
o Check tightness of cables including the ground cable
 Inspect Gefran 1300 Temperature Controller
 The FMS heater heats the fuel through 330KW, 440VAC, 50Hz, 433A Heater with 6 heating coils per
phase. If available, inspected the heater coils and take resistance.
Page 37 of 39
Observations:______________________________________________________________________________________________
The Generator Excitation Panel (GEP)

The Generator Excitation Panel (GEP) is a free standing cabinet
containing one or two (digital) AVR’s and the required devices,
e.g. power supplies, meters, buttons etc, to make it an
independent operating and control system.
The GEP is designed for controlling brushless exciters.
Perform the PM of GEP as per EPPJBDB.
Generator Control and Protection Panel

The GCPP contains, meters, G60 relay and interconnection.
 Open the panel and do general cleaning.

 Check for any sealing issues. Rectify.
 Check tightness of all cables. Individual components.
 Check control power.
 Check G60 relay connections
 Check PTs and their connections.
RTDs
Embedded resistance type temperature detectors (RTD’s)
measure the temperature of the stator windings. These are
distributed equally throughout the winding between the coil
sides.
The RTD is a platinum wire, wound non-inductively to a value of
100 Ohm at 0°C (32°F).
Value:_____________________________

Bearing meggering is to be carried out if bearing is taken out by FM. This will
verify the insulation strength of the insulated bearing.
Value:_____________________________ (Should be >100MOhms)
Measure resistance of NGR (Ohm) _________________

(11GOhm for 1 min @2500V)
Excitation System Servicing – Prismic A10

It is recommended that the A10 is inspected every 12 months to check that
the connections are secure and that there is no excessive dust build-up.
Page 38 of 39
When maintenance is being carried out, suitable WARNING signs should be

prominently displayed and the necessary precautions taken to ensure power is
not inadvertently switched-on to the equipment whilst work is in progress, or is
not yet complete
 Check all wiring associated with the excitation system.

 Check all contactors, switches and other external components
associated with the A10
 unit.
 Check that the correct links are fitted on the A10 as detailed in the
contract QC48
 document.
 Check all fuses and replace any if required.
PRISMIC A10 passwords

Operator Password: 123456
Maintenance Password: 441509611511
*It is a good practice to go through all tabs in the excitation system HMI and note down the setpoint and values.
Page 39 of 39

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EJPGT - JOB PLAN FOR SERVICING OF GAS TURBINES

Job Specific PPEs

HAZARD: Ergonomic Hazards

4. Carry out Servicing of Incomer. Refer to MV feeder servicing job plan.

Name: __________________ Time: __________________

a) Locate/Check presence of voltage in Excitation panel

6. Carry out Servicing of GEC/Carbon brush assembly/Ignition Circuit

a) Ensure de-energizing and discharging of all power terminals

a) Ensure de-energizing and discharging of Terminals

9. Make sure NGR is connected to Neutral Terminal

responsible for this activity

 NDE Non-drive end of generator

 FM Field Maintenance Department

 MTS Machinery Technical Service

 MP Motor pool Department

 PPT Power Potential Transformer

I&E Reliability Role

fall in acceptable limits

Work permit / LOTO and Cable Disconnection

Carbon Brush/Collector Assembly

1. Ensure supply is disconnected.

Air gap reference values are:

Air Gap between Stator to Rotor

0.2657” Inboard 0.359” Inboard

Eccentricity – 52.75 Thou

0.3011” 0.3110” Out-board

Eccentricity – 50.39 Thou

Air Gap between End Cover and Shaft

0.24” Inboard 0.295” Inboard

0.295” Inboard 0.053” Inboard

0.037” 0.98” Out-board

Rotor Removal(Where required)

Generator Stator Inspection

1. Keep a camera to capture the Before and After cleaning condition

Generator Stator/Rotor Cleaning, Dry-icing and Varnishing

Generator Rotor Inspection

Winding Coolers inspection by FM

Inspection of line and neutral side JBs

Sr. Test Value Range

1. Insulation Resistance Test

2. Polarization Index Test

Calculate the PI values using the following formula:

3. TAN DELTA Test (Power factor Tip-up and Capacitance)

Find below reference table:

Year 2018 Year

Year 2018 Year

Value U V W UVW Value U V W UVW

0.2Un 137.868 138.084 137.870 408.090 0.2Un

1.1Un 138.610 138.806 138.560 410.604 1.1Un

Tip-Up 0.530% 0.522% 0.50% 0.616% Tip-Up

Values and Observations

2. Insulation Resistance Test

Year Voltage(V) IR(GΩ)

Servicing of Generator Auxiliaries

88 GV winding health comparison Year

IR Test @500V for 60 secs 2009 2018

88 QA winding health comparison Year

88 QE winding health comparison Year

Name: Time: