Power Generators and Transformers: Their Configuration, Installation, Operation, Maintenance and Repair

Limited Course Contents, Concepts and Issues

Module 1: Power Generator Configuration, Installation, Operation, Maintenance and Repair

Module 1: Part 1 - Generator Selection and Installation (1)

• Selecting the Right Generator

• Power Outages;

• What’s available;

• Generator Power Output;

• Generator Power Quality:

  1. Generator Voltage;

  2. Power Frequency;

  3. Power Distortion.

• Engines or Prime Movers;

• Fuel Options;

• Other features worth having:

  1. Instrumentation;

  2. Circuit breakers;

  3. Ground-fault circuit interrupters;

  4. Automatic idle control;

  5. Noise;

  6. Sizing.

Module 1: Part 2 - Generator Selection and Installation (2)

• Powering Up:

  • Location;

  • Hookup:

    1. Power cords;

    2. Power inlet box;

    3. Transfer switches;

    4. Transfer switches and neutral grounds;

  • Electrical Safety:

    1. Grounding rods.

  • Fuels:

    1. Gasoline;

    2. Propane;

    3. Natural gas;

    4. Diesel.

  • Planning Ahead.

Module 1: Part 3 – Generator Functionality and Repair (1)

• Generator Repair:

  • Conventional generators;

    1. Brushed generators;

    2. Brushless generators;

    3. Power quality;

    4. Tools;

    5. Measurements;

    6. Output tests;

    7. Resistance tests;

    8. Ohmmeter tests;

    9. Mega-ohmmeter tests;

    10. Rotor excitation test;

  • Inverter generators:

    1. Operation;

    2. Troubleshooting.

Module 1: Part 4 – Generator Functionality and Repair (2)

• Engine Electrical Functionality:

  • Engine Management Controls;

    1. Power sources;

    2. Fuel cutoff valves;

    3. Idle control;

    4. Automatic choke;

    5. Oil-pressure sensor;

    6. Oil-level sensor;

  • Solid State Ignition;

    1. Ignition myths.

  • Starter Motors.

• Emergency Repairs:

  • Tools and supplies;

  • No power:

    1. No power from any receptacle;

    2. No power from one receptacle.

  • Genset Slows Under Load;

  • Storage Batteries;

  • Gasoline Engine Malfunctions;

    1. Preliminaries;

    2. No start.

  • Loss of Power as Engine Warms;

  • Sudden Shutdowns;

  • Insufficient Power;

  • Weak Compression;

  • Diesel Engine Malfunctions:

    1. No or slow starting;

    2. Runaway.

Module 1: Part 5 – Generator Functionality and Repair (3)

• Generator Fuel Systems:

  • Generator Carburetor Standard and Operation;

  • Generator Fuel System Tools and Supplies:

  • Generator Fuel System Parts and materials.

  • Generator Removal and Installation;

  • Generator Fuel System Cleaning;

  • Generator Float Carburetor Service;

    1. Carburetor Needle and seat;

    2. Carburetor Float adjustments;

    3. Carburetor Jets;

    4. Carburetor Primer;

  • Diaphragm Carburetor Service:

    1. Diaphragm Carburetor Operation;

    2. Diaphragm Carburetor Plumbing;

    3. Diaphragm Carburetor Troubleshooting;

    4. Diaphragm Carburetor Pressure Test;

    5. Diaphragm Carburetor Mixture-adjustment screws;

    6. Diaphragm Carburetor Fuel pumps;

    7. Diaphragm Carburetor Metering;

    8. Diaphragm Carburetor Idle circuits;

    9. Diaphragm Carburetor Check valves;

    10. Diaphragm Carburetor Final pressure check;

    11. Diaphragm Carburetor Mixture adjustments: all carburetors.

  • Fuel Injection;

  • Diesel:

    1. Diesel Wet stacking;

    2. Diesel Safety;

    3. Diesel Tools;

    4. Diesel Fuel system checks;

    5. Diesel Injectors;

    6. Diesel High-pressure pump;

    7. Diesel Timing.

Module 1: Part 6 – Major Generator Engine Repair (1)

• Pertinent Issues in Generator Engine Repair;

• What’s needed for Generator Engine Repair;

• Torque Limits in Generator Engine Repair;

• Evaluation of Generator Engine Repair;

• Excessive Generator Engine Compression During Repair;

• Minimal Compression in Generator Engine Repair;

• Compression Test in Generator Engine Repair;

• Leak-Down Test;

1. Leak Down Test-Four-Cycle Generator Engine;

2. Leak Down Test-Two-Cycle Generator Engine.

• Blowby Gauge;

• Cylinder Head Casting;

• Valves;

• Valve Guides;

• Valve Springs;

• Pushrods;

• Pistons;

• Rings: Installation;

• Piston Installation:

1. Integral Bores;

2. Detachable Cylinders.

Module 1: Part 7 – Major Generator Engine Repair (2)

• Connecting Rods;

1. Construction;

2. Orientation;

3. Bearings;

4. Micrometers;

5. Plastigage;

6. Failure analysis;

7. Rod assembly.

• Cylinders:

1. Cylinder Glaze breaking;

2. Cylinder Inspection;

3. Cylinder Boring;

4. Cylinder Sleeving.

• Flywheel;

• Crankcase;

• Crankshafts;

• Antifriction main bearings;

• Camshafts;

• Balance Shafts;

• Oil Seals;

• Oil Circuits;

• Rewind starters:

1. Starter Troubleshooting;

2. Preload release and restoration;

3. Brake Dogs;

4. Recoil Springs.

Module 1: Part 8 - Generator Design and Construction

• Stator Core;

• Stator Frame;

• Flux and Armature Reaction;

• Electromagnetics;

• End-region Effects and Flux Shielding;

• Stator Core and Frame Forces;

• Stator Windings;

• Stator Winding Wedges;

• End-Winding Support Systems;

• Stator Winding Configurations;

• Stator Terminal Connections;

• Rotor Forging;

• Rotor Winding;

• Rotor Winding Slot Wedges;

• Amortisseur Winding;

• Retaining Rings;

• Bore Copper and Terminal Connectors

• Slip/Collector Rings and Brush Gear;

• Rotor Shrink Coupling;

• Rotor Turning Gear;

• Bearings;

• Air and Hydrogen Cooling;

• Rotor Fans;

• Hydrogen Containment;

• Hydrogen Coolers.

Module 1: Part 9 - Generator Auxiliary Systems, Operation, Control and

Diagnostics

Generator Auxiliary Systems

• Lube-Oil System;

• Hydrogen Cooling System;

• Seal-Oil System;

• Stator Cooling Water System;

• Exciter Systems.

  Generator Operation and Control

• Basic Operating Parameters;

• Operating Modes;

• Machine Curves;

• Special Operating Conditions;

• Basic Operation Concepts;

• System Considerations;

• Grid-Induced Torsional Vibrations;

• Excitation and Voltage Regulation;

• Performance Curves;

• Sample of Generator Operating Instructions.

Generator Operational Monitoring and Diagnostics

• Generator Monitoring Philosophies;;

• Simple Monitoring with Static High-Level Alarm Limits

• Dynamic Monitoring with Load-Varying Alarm Limits;

• Artificial Intelligence Diagnostic Systems;

• Monitored Parameters.

Generator Protection

• Basic Protection Philosophy;

• Generator Protective Functions;

• Brief Description of Protective Functions;

• Specialized Protection Schemes;

• Tripping and Alarming Methods.

Module 1: Part 10 – Generator Inspection, Maintenance, and Testing (1)

Generator Inspection Practices and Methodology

• Site Preparation;

• Experience and Training;

• Safety Procedures – Electrical Clearances;

• Inspection Frequency;

• Generator Accessibility;

• Inspection Tools;

• Inspection Forms.

Generator Stator Inspection

• Stator Frame and Casing;

• Stator Core;

• Stator Windings;

• Phase Connectors and Terminals;

• Hydrogen Coolers.

Module 1: Part 11 – Generator Inspection, Maintenance, and Testing (2)

Generator Rotor Inspection

• Rotor Cleanliness;

• Retaining Rings;

• Fretting/Movement at Interference Fit Surfaces of Wedges and Rings;

• Centering (Balance) Rings;

• Fan Rings or Hubs;

• Fan Blades;

• Bearings and Journals;

• Balance Weights and Bolts;

• End Wedges and Damper Windings;

• Other Wedges;

• Windings – General;

• Windings – Slot Region;

• End Windings and Main Lead;

• Collector Rings;

• Collector Ring Insulation;

• Bore Copper and Radial (Vertical) Terminal Stud Connectors;

• Brush-Spring Pressure and General Condition;

• Brush Rigging;

• Shaft Voltage Discharge (Grounding) Brushes;

• Rotor Winding Main Lead Hydrogen Sealing – Inner and Outer;

• Circumferential Pole Slots (Body Flex Slots);

• Blocked Rotor Radial Vent Holes – Shifting of Winding and or/ Insulation;

• Couplings and Coupling Bolts;

• Bearing Insulation;

• Hydrogen Seals;

• Rotor-Body Zone Rings;

• Rotor Removal.

Module 1: Part 12 – Generator Inspection, Maintenance, and Testing (3)

Auxiliaries Inspection

• Lube-Oil System;

• Hydrogen Cooling System;

• Seal-Oil System;

• Stator Cooling Water System;

• Exciters.

Generator Maintenance Testing

• Stator Core Mechanical Tests;

• Stator Core Electrical Tests;

• Stator Winding Mechanical Tests;

• Water-Cooled Stator Winding Tests;

• Stator Winding Electrical Tests;

• Rotor Mechanical Tests;

• Rotor Electrical Testing;

• Hydrogen Seals;

• Bearings;

• Thermal Sensitivity Testing and Analysis;

• Heat Run Testing;

• Hydrogen Leak Detection.

Generator Maintenance

• General Maintenance Philosophies;

• Operational and Maintenance History;

• Maintenance Intervals/Frequency;

• Type of Maintenance;

• Work Site Location;

• Workforce;

• Spare Parts;

• Uprating;

• Long-Term Storage and Mothballing;

• Life Cycle Management (LCM).

Module 2: Electric Transformer Configuration, Installation, Operation, Maintenance and Repair

Module 2: Part 1 - Guidelines for Transformer Application Designs (1)

• Introduction;

• Selection Process;

1. Application of the unit;

2. Choice of insulation (liquid-filled or dry type):

3. Choice of winding material (copper and aluminum);

4. Possible use of low-loss core material;

5. Regulation (voltage stability);

6. Life expectancy;

7. Any overloading requirements;

8. Basic insulation level (BIL);

9. Temperature considerations;

10. Losses (both no-load and operating losses);

11. Any non-linear load demand;

12. Shielding; and

13. Accessories.

Module 2: Part 2 - Guidelines for Transformer Application Designs (2)

• Two Types of Transformers:

1. Liquid filled transformers;

2. Dry type transformers.

• Dry Type Transformers Classification:

1. Ventilated;

2. Non-ventilated;

3. Sealed units.

• Cooling and Insulating System;

• Power Transformers Construction – Core;

• Difference between Power Transformer and Distribution Transformer;

• Network Distribution Transformers – Serving Grid and Spot Networks.