Repair/Rectification of Generator Stator Winding Fault of Unit 8 at MGHE Power House, Karnataka Power Corporation Ltd, Jog Falls - 577435, Shimoga - dist., Karnataka,

1)Inspection of stator coil for Identification of exact no. of the faulty coil and setting up the arrangements for Rotor Pole coils removing and rotation as per scope of works along with supply of materials and other consumables as per scope of works2)De-brazing the rotor pole terminations and removing the rotor poles (as required). Dismantling of rotor poles using suitable and compatible tools, fixtures, and lifting arrangements. Ensure safe handling and proper marking for reassemble. Rotate and position the rotor appropriately to access the damaged stator coil area.3)Remove insulation from both ends of the affected winding section.4)De-brazing of defective coils. 5)Driving out the slot wedges Carefully remove wedges from stator winding slots without damaging adjacent coils or core.(Entire Stator winding shall be inspected in case of loose wedges, worn out wedges and missing wedges shall be replaced) along with supply of materials and other consumables.6)Insulation Removal- Remove insulation from both ends of the affected winding sections.7)Cutting the coil bindings in both sides. Cut the identified damaged winding portion using appropriate tools. Carefully pull out the damaged coil from the stator slots without affecting surrounding windings.8)Damaged Winding Cutting- Cut the identified damaged winding portion using appropriate tools.9)Winding Extraction- Carefully pull out the damaged coil from the stator slots without affecting surrounding windings. While removing the faulty coils from stator, utmost care should be taken to prevent any damage to stator core.10)Removal of faulty coils from the slot.11)Slot Cleaning and Preparation-Clean stator inner tooth slots thoroughly. Use emery paper to smoothen and maintain uniform slot condition.12)Cleaning of carbon deposits/heavy oil content from complete stator coils through CO2 cleaning process /Dry ice blasting.13)New Coil Installation-Insert new stator coil with proper alignment. Fix securely using new wedges of appropriate grade and size.14)Brazing of the coil ends.15)Re-fixing the rotor poles and connecting them.16)Insulation Application-Apply insulation as per specified class (e.g. Class F/ ClassH). Ensure proper curing and finishing.17)Complete CO2 / dry ice cleaning of stator and rotor.Re insertion of removed rotor poles. 18)Final Checks & Testing- Insulation Resistance (IR) Test, High Voltage (HVDC) Test, Continuity Check, Visual Inspection and any other tests which are required (will be carried out by KPCL).19)Assembling of removed damper doors and stator covers.20)Maintain quality standards throughout the process & use calibrated tools and approved materials.21)Presence of the agency during excitation and synchronization of the unit by KPCL.22)Safety & Quality-Follow all safety procedures and PPE requirements