Refurbishing of stator core and complete re-insulation of stator coils with Class F insulation, re-insulation of defective rotor pole coils with Class H insulation and commissioning of unit 1 at Kadamparai PH

Charges towards removal of 8 Nos. rotor poles from rotor spider

Charges towards dismantling the Generator by decoupling the turbine and threading out the rotor

Charges towards de- brazing and removal of 18 Nos. bus bars on both phase and neutral sides and 72 Nos. of Jumpers with suitable thermal protection and removing 4 Nos. surge ring.

Charges towards dismantling the entire core, chemical washing, drying in the conveyor oven at 180°C mounted at site, varnishing the core with F class insulation in rubberized roller to maintain the uniform thickness, drying out the core at 200°C, Checking the lamination thickness, re-varnishing once again if the coating thickness is not sufficient and drying, checking the IR value of the core, assembling the core, re-staggering and restacking, maintain the core pack thickness, locking the core by core bolts. The following tests are to be carried out in the re-varnished core before staggering. a) Xylol Test, b) Mandrel Test, c)7H Pencil Hardness Test, d)Insulation Resistance Test by applying 110 V AC between 10 Nos. stampings clamped together with a lamp series. The lamp should not glow. (As per IEC /IEEE standard)

Charges towards conducting the ELCID and Flux loop test to ascertain the integrity of insulation of stator core and find out the hot spot and the same to rectify.

Charges towards cleaning and polishing the stator core pack slot for ready to install new stator coils.

Charges towards removing the existing class B insulation, re-insulating the coils to Class “F” insulation, consolidating and applying corona and stress grading coatings and insulating the overhang portion of coils to Class ”F” insulation at required level on both sides.(Totally 359 Numbers ). (The relevant test as per item No. 8 to be carried out)

Tests on stator coils as per relevant IS standard: 1. Dimensional check 2. Coil Resistance Measurement 3. Inter strand IR value test at 110 V AC for 3 sec 4. IR value at 5 KV before and after HVAC test for 1 minute 5. HVAC test at 23 KV for 1 minute 6. Tan delta test at 2.2 KV, 6.6 KV, and 11 KV

Charges towards procurement of the required quantity of glass epoxy class “F” liners, wedges and binding card, mouth block, end cap, coil overhang support epoxy spacer, tape and resin etc.,

Charges towards re-insulating both top and bottom side overhang surge ring -4 nos., 18 Nos. Bus bars, 72 Nos. jumpers in the stator assembly with class ‘F’ insulation.

Charges towards replacement of 27 Nos. RTD for measuring winding, tooth & core temperature, with temperature scanner. (including wiring)

Supply of new stator top Coil with Class F insulation as per sample. (The relevant test as per item No. 8 to be carried out)

Supply of new stator bottom Coil with Class F insulation as per sample (The relevant test as per item No. 8 to be carried out)

Charges for installing the tested new/re-insulated bottom & top coils with using fresh liners, wedges, end banding the overhang portion with fiber tapes and cards using the binding cement of epoxy resin, soldering the non-connection and connection side end ferrules, bus bars and jumpers and insulating the jumper joints & providing end caps.( Totally 396 Numbers)

Charges towards transporting of 3 Nos. rotor poles for re-insulating from KPH to vendor works and back.

Charges towards re-insulating of 3 Nos. rotor pole coils with Class H insulation and testing. Tests on rotor pole coils: 1. Coil resistance measurements 2. IR value at 500V before and after HVAC test 3. HVAC test at 2.5 KV for minute 4. AC pole drop test 5. AC impedance test 6. Surge comparison test at 3 KV 7. Polarity test

Charges towards assembly of all 12 nos. rotor poles, coupling of rotor and turbine, assembling with the Generator.

Charges towards drying out, final testing. The following tests after completion of stator winding. i) IR value at 5 KV before and after HVAC test. ii) AC High voltage test at 23 KV, 50Hz for 1 minute. iii) PI value iv) Winding resistance v) Tan delta test at 11 KV in steps of 0.2, 0.4, 0.6VL Rotor: 1. DC resistance measurement 2. IR value at 500V 3. AC pole drop test

Charges for relocation of HPLOP system (Pump and motor- 2sets with connected pipelines) from the existing position with all accessories and extend its pipeline to the safe position to avoid oil spillage into the Generator.

Charges for replacement of pipe and pipe fitting accessories for LPLOP system in Unit-I of Kadamparai Power House. (As per Annexure –A under Section-VI Technical)

Charges for rehabilitation of CGLS (centralised Grease Lubrication System) for the use of mechanical rotating parts such as Guide vane Top and Bottom points- 24 Nos., MIV system, etc. including the replacement of damaged PVC hoses and servicing of distribution system)

Charges for complete Re-alignment of the whole unit (Comprising of Generator, Rotor, Turbine, Turbine shaft, Intermediate shaft and all the Rotating parts with the Existing static components and fixed References of the unit-1.) by removing all allied accessories and placing shims (if required).After re-alignment, all allied parts to be reassembled. The values achieved in leveling, Rotor centering, Run-out readings, throw, Labyrinth and bearing clearances by the Re-alignment have to be as per BHEL recommended standards. i.e UGB, LGB, TGB radial clearance is within 0.22mm; Turbine Labyrinth clearance within 1.0mm; lower wearing ring axial clearance to be within 10mm + 1mm; TGB radial throw within 0.15mm; LGB radial throw within0.1mm. ( As per Annexure-B under Section-VI Technical)

Charges for dynamic balancing of the whole Rotor assembly of the Unit to achieve the accepted vibration Levels, as per I.S. (Vibration in Top Bracket and in all the three GTGB, GBGB and TGB Bearings have to be proved to be within the Limits as furnished in Special condition Point– a) and Successful Commissioning of the Unit-1 of Kadamparai power house, for a continuous running of 72 Hours with full load. (within prescribed Parameters as furnished in Special condition Point – b).

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