Generator Test Report

Customer :

Project name : Reparatie ABB AMK500L

Project :

EMRI reference :

Date :

32140133

07-02-2014

Total Wind B.V.

WO1399

Generator Test Report

General informationCustomer: Total Wind B.V. Customer reference: WO1399Project name: Reparatie ABB AMK500L EMRI order number: 32140133

Generator detailsMake: ABB Power: 2020 kWType: AMK 500L4A BATYH Voltage: 690 VSerial no: 4575450 Current: 1522 AInsulation class: F Frequency: 50 HzEnclosure: IP54 Rotation speed: 1680 Rpm

Insulation Resistance testsComponent: Megger voltage Value after 60 sec. Result

Main stator windings 1000 V >2000 MΩ PassedMain rotor windings 1000 V >2000 MΩ Passed

Testdata

No

load

dat

a No

load

data N

o lo

ad d

ata N

o lo

ad d

ata

Condition bearing seating

42140133 - Test Report Versie: 1.0 Testrun generator

Driven End (DE) Non Driven End (NDE)Applicable tolerance class Shaft: m5 Bore: H6 Applicable tolerance class Shaft: m5 Bore: H7Shaft (original) 150,015 mm Shaft (original) 150,022 mmBore (after repair) 320,020 mm Bore (after repair) 320,020 mm

1,0 Passed

Bearing conditions (Shock pulse measurement) Value: Bearing:

Initial value (dBi)

Max. value (dBm)

Carpet value (dBc) Result

Remarks (NDE): NDE bearing renewed on 22-05-2014

Driven End (DE): 23,0 1,0 1,0 PassedNon Driven End (NDE): 23,0 3,0

2: 0,30 mm/sec

Bearing type (DE): 6330 - MC3 Remarks (DE): DE bearing renewed on 22-05-2014Bearing type (NDE): 6330 - MC3

0,20 mm/sec 4: 0,30

Vibration measurement (ISO 2372) - idle / unloadedHorizontal 1: 0,30 mm/sec

mm/secAxial 5: 0,30 mm/sec 6: 0,30 mm/secVertical 3:

Overall rating of vibration level (ISO2372): PassedGauge SPM, type T30, serial number: 9750013

Remarks

- Testrun performed after general overhaul, including renewal of bearings.- Rotor rewound (round wire / random wound / insulation class H)- DE and NDE bearing seating (bore) repaired.- All tests passed succesfully.

Acceptance test approvalRepair Engineer(s): Test Engineer(s): Certificate number: Fill in date:

WBO / JME EME 32140133 22-05-14

5 6

3 4

1 2

42140133 - Test Report Versie: 1.0 Testrun generator

1500 rpm1800 rpm

2,6 x mx m

750 rpm1000 rpm

x m3,0 x m5,0x m

20,018,0 x m

8,0 x m7,0 x m

x m

M3AA100L-2/4 Diameter driven end: 167Diameter non driven end:

33,0 x m16,0 x m12,0

mm

0,42

nci

ng

Type:

Balancing data

Admissible tolerance (DE): 0,42 g4040 g.mm Admissible tolerance (NDE):

3600 rpm

Balancing details

x m9,0 x m6,0 x m

x m12,0

167

10 kg-

32140133

mm

mmObject length:

Reparatie ABB AMK500L

Fan motor II

Dynamic Balancing Report

General information

Object detailsObject:

Project name:Customer: WO1399

RpmBalancing speed:

Total Wind B.V.EMRI order number:Customer reference:

Manufacturer:

Serial number: 34210p0354/035

Object mass:ABB

3000 rpm

Balancing criteria according to ISO1940 (VDI 2060)

Rotating speed (rpm)Acceptable inbalance [U]

G = 1,0 [g.mm]G = 2,5 [g.mm]G = 6,3 [g.mm]

40,0

g.mm

35,0 x m25,0

Rpm

Admissible tolerance (NDE):

1510Key way situation in shaft:Balancing standard: G = 2,5 [g.mm] Operational speed: 2900

gAdmissible tolerance (DE):

85,0 x m63,0 x m

42140133 - Test Report Versie: 1.0 Balancing report

WBO EME 32140133 12-05-14

Balancing results approvalBalancing Engineer(s): Approved by: Certificate number: Fill in date:

Remarks

- Dynamic balancing of rotor performed after rewinding.

Calib

ration

data

Res

ult

s b

efo

re b

alan

Res

ult

s af

ter

bal

anci

ng

42140133 - Test Report Versie: 1.0 Balancing report

Pictures

General informationCustomer: Total Wind B.V. Customer reference:

Picture 1 Picture 2

WO1399Project name: Reparatie ABB AMK500L EMRI order number: 32140133

Defect rotor windings Close-up of burned rotor windings

Picture 3 Picture 4

First layer of new copper coils inserted inside rotor slots Last coils inserted inside rotor slots.Slots closed with glass wedges.

Rotor after pyrolising and removal of windings.Slots and rotor core prepared for new coils

New copper coils prepared and double insulated(coils wrapped with mica glass insulation)

Picture 5 Picture 6

42140133 - Test Report 3-6-2014 Pictures (1)

Welding 2 layers of copper coils together on both side of the rotor (silver welding)

Welding 2 layers of copper coils together on both side of the rotor (silver welding)

Picture 9 Picture 10

Project name: Reparatie ABB AMK500L EMRI order number: 32140133

Picture 7 Picture 8

Pictures

General informationCustomer: Total Wind B.V. Customer reference: WO1399

Assembly of new rotor terminalsRotor prepared for dynamic balancing

Dynamic balancing of rotor(check balancing report for results)

Final stage of rotor rewindingPreparing rotor for Vacuum Pressure Impregnation

(VPI process)

Rotor after VPI process

Picture 11 Picture 12

42140133 - Test Report 3-6-2014 Pictures (2)

Pictures

General informationCustomer: Total Wind B.V. Customer reference: WO1399Project name: Reparatie ABB AMK500L EMRI order number: 32140133

Picture 13 Picture 14

Testing of stator winding - All tests passed successfully(high voltage test / surge test)

Rotor placed inside statorPrepared for bearing renewal and assembly of generator

Picture 15 Picture 16

Picture 18

Cooling unit after overhaul and spray paintingThree ventilation motors completely overhauledDynamic balancing of cooling fans performed

Generator after final test and spray painting

Assembly of generatorRepaired DE and NDE bearing shield placed

Dynamic test-run of generator after repairAll tests passed successfully(check test report for results)

Picture 17

42140133 - Test Report 3-6-2014 Pictures (3)