Check list

Maintenance Work Commissioning Overhaul Major Repair

AvK Checklist to Order No.

Page 2

Customer:

.............................................................

Order No.:

.............................................................

Generator Type:

.............................................................

Operation Hours:

.............................................................

Bearing design:

Roller bearing

Sleeve bearing

Replacement of oil:

YES

NO

Bearing inspection performed:

YES

NO

I.

Electrical Inspection
Pos. 1.1 - 1.19

II.

Mechanical Inspection
Pos. 2.1 - 2.20

III.

Test Run
Pos. 3.1 - 3.14

IV.

Maintenance Result

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AVK report checklist-2012

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AvK Checklist to Order No.

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Environmental Conditions (please take pictures):

a) Location:

building

marine

b) Atmosperic conditions:

dry
dust

high humidity
salt

c) Ventilation:

unrestricted
restricted

adequate
inadequate

Air intake needs to prevent dust and moisture is transported into the generator by external ventilation. In
case of doubt please contact the customer support.

Operating Conditions:
Please add the operation charts and diagrams showing electrical parameters and temperatures including
alarm.
a) Site duty:

single

b) Duty cycle:

24 hours

daily

c) Load condition:

inductive

non linear

d) Operation:

manned

unmanned

a) Dirt content:

slight dust
thick dust

b) Corrosion:

none, very little

copper

parallel

idle

occasionally

standby

Generator Conditions:

c) Engine:

Type:
Serial No.:
Fuel:

Cummins Generator Technologies Germany GmbH

AVK report checklist-2012

light layer dirt

thick compact dirt

steel/iron
severe

(....................)

....................
....................
....................

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AvK Checklist to Order No.

3.15

Page 4

Inbuilt type of Automatic Voltage Regulator (AVR)

The regulating system has to be adjusted to the driving conditions and load at site for avoiding a swinging up
and assure an optimal regulation behaviour.

AVR serial number

_______________

Cosimat
Type of Cosimat:

_______________

Additional module:

DECS 100

DECS 200

Unitrol

Other:

_______________

No-load voltage [V]:

_______________

Droop [%]:

_______________

Underfrequency protection [Hz]:

_______________

_______________

Additional module

XE2

SB2

EDM

Manual controller

AVR system mounting plates with extra functions

Standby AVR switchover system

Other:

_______________

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AVK report checklist-2012

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AvK Checklist to Order No.

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Safety instructions:
Safety Regulations:
1.
2.
3.
4.
5.

Disconnect mains!
Prevent reconnection!
Test for absence of harmful voltages!
Ground and short circuit!
Cover or close off nearby live parts!

To energize, apply in reverse order!

Only specially trained and experienced personell is allowed to perform work at the alternator.
Even small failures during work may result in damage of health or major machine failure.
Local safety rules have to be observed.
Caution!
The motor start function has to be blocked twice (Emergency stop & Power Supply Starter).
Before terminal box is opened, HV alternator has to be grounded in the switchboard.
This has to observed by the technician.
Alternator cables need to be proved to be without voltage.
After the terminal box is opened, the cables have to be proved to be without voltage again.
Never operate any alternator with open main terminal box!

General work Instructions:

All bolts and mechanical fixation should be checked visually and in case of any signs of looseness
or movement of fixed parts, the bolts need to be tightened.
Electric contacts, terminals, bolts and cable luggs have to be checked carefully for loseness,
discoloration and other signs of contact problem.
Check for cable chafing and fretting dust as a sign of material deterioration.
Windings need to be checked visually in addition to the measurements shown in the list below.
Any movement of windings, seen by cracks in the protection color layer and discolorations of
windings need to be dokumented with digital pictures.
Digital pictures should show the installation, building, alternator name plate, internal parts and all
alternator parts which are found not to be in good functional order.

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AVK report checklist-2012

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AvK Checklist to Order No.

I.

Page 6

Electrical Inspection

performed

Complaints
see page 18

1.1

Examination of cable entry and cable shoes

to main terminal box

1.2

Examination of strain relief of connecting power cables

1.3

Check of fixation of transformers installed

1.4

Examination of cable entry and cable shoes

to auxiliary terminal box

1.5

Check of strain relief of connection cables

Incoming cables should be supported from either below or above the box level at a sufficient distance
from the centre line of the generating set so as to avoid a tight radius at the point of entry into the
terminal box panel, and allow movement of the generator set on its anti-vibration mountings without
excessive stress on the cable. The generator should be free to move at least 25 mm as per Figure 1.
In addition refer to the operating instructions under point Electrical connections.
Please see also the AvK documentation about commissioning instructions.

Alternator movement during operation due to changing torque forces

Cummins Generator Technologies Germany GmbH

AVK report checklist-2012

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AvK Checklist to Order No.

Insulation measurement

Page 7

- Caution! -

The AVR plus any voltage transformers should be disconnected, and any temperature detector leads
(RTDs / Thermistors) grounded during the test. Refer to the generator wiring diagram for details.
After measurement discharge all windings and reconnect all cables.
performed

Complaints
see page 18

1.6

Insulation test of stator windings (star point must be opened and T24, T25, T26
disconnected)

a)

Stator winding phase U against ground

Resistance ............. M
Voltage ............. V

b)

Stator winding phase V against ground

Resistance ............. M
Voltage ............. V

c)

Stator winding phase W against ground

Resistance ............. M
Voltage ............. V

1.7

Insulation test of stator windings (star point must be opened)

a)

Stator winding phase U against phase V

Resistance ............. M
Voltage ............. V

b)

Stator winding phase U against phase W

Resistance ............. M
Voltage ............. V

c)

Stator winding phase W against phase V

Resistance ............. M
Voltage ............. V

Insulation test instructions

LV generators
A 1000V megger or similar instrument should be used. Disconnect any earthing conductor connected
between neutral and earth and megger an output lead terminal U, V or W to earth. The 1 minute
insulation resistance reading for the total winding should be in excess of 10 M to earth. Should the
insulation resistance be less than 10 M the winding must be dried out as detailed in the Service and
Maintenance section of this work instruction.

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AVK report checklist-2012

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AvK Checklist to Order No.

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MV & HV generators
A 2500V (MV) / 5000V (HV) motorised megger or similar instrument should be used. Separate the three
natural leads, ground V and W leads and megger U to ground. Repeat for V phase with U and W grounded
and W phase with U and V grounded. The 1 minute insulation resistance for each phase should not be less
than 100 M (MV) / 300 M (HV) and the polarisation index should be in the order of 2 or greater and
20 C. (PI = IR10min / IR1min)
If the IR is lower than described above, check for the reason of low IR values ( i.e. humidity, dirt, wrong
connection).
It should be noted that as winding temperature increases values of insulation resistance will significantly
reduce. Therefore true values of insulation resistance should be established with windings at ambient
temperatures.

performed

Complaints
see page 18

1.8

Resistance measurement of stator

Caution!
Before static winding resistances are measured, the generator set should be shut
down, isolated and proved dead.

1.9

Check and re-tightening of all screws and nuts

in main terminal box by dynamometric key

1.10

Cleaning and examination of insulators for cracks

Terminal box should be cleaned by vacuum cleaner

Insulators to be cleaned with dry cloth or electrical cleaner and cloth

1.11

Re-tightening of contact screws and nuts on

auxiliary terminal strip

1.12

Resistance measurement of all auxiliary windings / PMG

Measurement at UH 1-2 / WH 1-2 / UH 3-4 / WH 3-4

Cummins Generator Technologies Germany GmbH

AVK report checklist-2012

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AvK Checklist to Order No.

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performed

Complaints
see page 18

1.13

Resistance measurement of exciter stator

1.14

Insulation test of auxiliary windings

1.15

Examination of anti-condensation heater

............. V

............. A

The ambient conditions in which a generator is operated or stored should be fully understood, to ensure
the generator is maintained in a fully serviceable condition. Areas for consideration include
temperature, humidity and vibration levels. In stand-still the anti-condensation heaters should be activated.
Within the generators storage or installed area, thermostatic control of space heaters will be of
considerable assistance.
Observe CGT storage instructions in case of longer ( > 6 months) standstill time of the alternator.

1.16

Insulation resistance measurement of rotor winding

a)

Insulation measurement main rotor

Resistance ............. M
Voltage ............. V

b)

Insulation measurement exciter rotor

Resistance ............. M
Voltage ............. V

1.17

Resistance measurement of rotor

A 500V megger or similar instrument should be used. Minimum acceptable values after 1 minute are:
New machine
Exciter stator
Combined rotor

10 M
200 M

In-service machine
5 M
100 M

If the IR is lower than described above, check for the reason of low IR values ( i.e. humidity, dirt, wrong
connection).

Cummins Generator Technologies Germany GmbH

AVK report checklist-2012

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AvK Checklist to Order No.

performed

Page 10
Complaints
see page 18

1.18

Inspection of rotating rectifiers

The rotating rectifier assembly is mounted on the generator shaft end near the non drive end
bearing. Access can be achieved by removal of the rectifier cover.
The diodes on the main rectifier assembly can be checked with a multimeter. The flexible leads
connected to each diode should be disconnected at the terminal end, and the forward and reverse
resistance checked. A healthy diode will indicate a very high resistance (infinity) in the reverse
direction. A faulty diode will give a full deflection reading in both directions with the test meter on the
10,000 ohms scale, or an infinity reading in both directions.
On an electronic digital meter a healthy diode will give a low reading in one direction and a high reading
in the other.
Compare the readings of the rectifiers in operation with new ones during same temperature condition.
Varistor and diode reverse check with 500V insulation measuring instrument.
Check for discolorations and signs of high temperature.
Check for cable chafing and mechanical stress to the cables and cracks in rectifier blocks.

1.19

Inspection of stator end winding (please take pictures)

1.20

Inspection of rotor winding (please take pictures)

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AVK report checklist-2012

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AvK Checklist to Order No.

II.

Page 11

Mechanical Inspection

performed

Complaints
see page 18

Sleeve Bearing Design

YES

NO

Oil flow DS:

Oil flow NDS:

Hydrostatic function installed:

Hydrostatic function checked:

Oil lubrication system installed:

If YES:

Pressure indication
After pump started:

DS High Value: .................... NDS High Value: ....................

After shaft lifted:

DS Low Value: ..................... NDS Low Value: ....................

Inspection of sleeve bearing

Check type of oil (provided by customer)

Oil viscosity used: ....................

2.1

according to ISO VG ....................

Check of oil level in sleeve bearing (30% to 50% of level gauge)

Oil level

O.K.

not O.K.

2.2

Check for leakage of sleeve bearings

2.3

Check of oil quantity in oil lubrication system

2.4

Check of oil pressure in oil lubrication system:

.................... mbar

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AVK report checklist-2012

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AvK Checklist to Order No.

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performed

Complaints
see page 18

2.5

Check of oil temperature in oil lubrication system

2.6

Check of air pressure inside the bearing housing

.................... mbar (max. 5 mbar)

2.7

Check of lubrication ring

2.8

Check for any corrosion on drive side and non-drive side bearing

Roller/Ball Bearing Design

Roller bearing manufacturer / type (if applicable):

Type of grease:

..............................................................

..............................................................

2.9

Roller/Ball bearing: Check of bearing noise (hand turning)

2.10

Manual check of bearings and vibration

2.11

Relubrication of roller/ball bearing according to operating instructions

(depends on bearing type)

2.12

Scales available

Yes

No

Grease storage clean

Yes

No

Tools clean

Yes

No

Visual check of grease colour in bearing

Bearing grease colour has to be checked between rollers and running surface. Grease has to be soft and not
black.

2.13

Removal of surplus grease

2.14

Removal of old grease from bearing covers

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AVK report checklist-2012

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AvK Checklist to Order No.

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performed

Complaints
see page 18

Additional Mechanical Checks

2.15

Inspection of abrasion at earthing brush and slip rings

2.16

Inspection of base frame for mechanical deviations

Mounting of alternator / Check of feet fixation (take pictures)

2.17

Visual inspection of the drive coupling

2.18

Check of inlet and outlet airducts for dust and dirt

2.19

Check of inlet and outlet airducts for corrosion, dirt or loose particles

2.20

Cooler / leakage monitoring

2.21

Check of drainage stoppers / drainage for condensation

water

2.22

Torque check for electrical assembly (steel property class: 8.8)

Bolted assembly steel brass

Bolted assembly steel copper

Dimension

Torque [Nm]

Dimension

Torque [Nm]

M4

2,5

M4

1,5

M5

4,5

M5

2,5

M6

M6

4,5

M8

20

M8

10

M10

40

M10

20

M12

65

M12

40

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AVK report checklist-2012

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AvK Checklist to Order No.

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performed

Complaints
see page 18

2.23

Torque check for mechanical assembly

Bolted assembly steel - steel

Dim.

Porperty class

Torque [Nm]

Abm.

Porperty class

Torque [Nm]

M4

8.8
10.9
12.9

3,0
4,6
5,1

M18

8.8
10.9
12.9

295
421
492

M5

8.8
10.9
12.9

5,9
8,6
10,0

M20

8.8
10.9
12.9

415
592
692

M6

8.8
10.9
12.9

10,1
14,9
17,4

M22

8.8
10.9
12.9

567
807
945

M7

8.8
10.9
12.9

16,8
24,7
28,9

M24

8.8
10.9
12.9

714
1017
1190

M8

8.8
10.9
12.9

24,6
36,1
42,2

M27

8.8
10.9
12.9

1050
1496
1750

8.8
10.9
12.9
8.8
10.9
12.9

48
71
83
84
123
144

8.8
10.9
12.9
8.8
10.9
12.9

1428
2033
2380
1928
2747
3214

M14

8.8
10.9
12.9

133
195
229

M36

8.8
10.9
12.9

2482
3535
4136

M16

8.8
10.9
12.9

206
302
354

M39

8.8
10.9
12.9

3208
4569
5346

M10

M12

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AVK report checklist-2012

M30

M33

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AvK Checklist to Order No.

III.

Page 15

Test Run

Please attach a copy of the protection relay setting and a single line diagram of the power station.

performed

Complaints
see page 18

Precaution!

3.1

Check whether earthing switch is disconnected before start up

3.2

Check of bearing noise (hand turning not possible at sleeve bearings)

3.3

SPM bearing analysis:

DE:

LR ..........

HR ..........

NDE:

LR ..........

HR ..........

3.4

Check of oil amount in sleeve bearings during operation

3.5

Effectivity of lubrication ring

3.6

Test tripping of temperature protection, alarm and shut down levels

3.7

Check signals and contacts between alternator and external control systems

3.8

Vibration test / Vibration values (mm/s)

DE:

.......... Hor. (1)

.......... Ver. (2)

.......... Axi. (3)

NDE:

.......... Hor. (4)

.......... Ver. (5)

.......... Axi. (6)

Frame:

.............

Output:

............. kW

Airduct inlet:

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AVK report checklist-2012

.............

Airduct outlet:

.............

Page 15

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performed

Complaints
see page 18

3.9

Check of regulator functions at no-load operation

a) Exciter current at rated voltage and rated speed:

I1-I1':

............. A

b) Exciter current at rated load:

I1-I1':

............. A

c) Supply voltage:

UH1-UH2:

............. V

UH1-WH2:

............. V

WH1-WH2:

............. V

d) Under speed protection setpoint:

3.10

Check of parallel operation

............. Hz

Check of distribution of load

Voltage droop adjustment

.......... %

3.11

Check of overcurrent and short circuit protection trip

3.12

Check of differential protective trip

3.13

Check of exciter monitoring system

XE2
EDM200
Other modules

3.14

Check of generator voltage in parallel operation

grid voltage min.:
grid voltage max.:

............. kV
............. kV

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AVK report checklist-2012

Page 16

AvK Checklist to Order No.

performed

Page 17
Complaints
see page 18

3.15

Bearing and winding temperature after continuous

operation

__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________

Cummins Generator Technologies Germany GmbH

AVK report checklist-2012

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AvK Checklist to Order No.

IV.

Page 18

Maintenance Result

Complaints:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________

The operation of the alternator can be continued without immediate

elimination of the complaints.

Electrical and mechanical checks were performed without any

complaints.

The alternator must be stopped immediately due to the complaints.

________________
(Date)

________________________
(Signature Customer)

________________________
(AvK-Service-Technician)

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AvK Checklist to Order No.

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Please revert to our work instructions

Cummins Generator Technologies Germany GmbH

Bunsenstrae 17
85053 Ingolstadt, Germany
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250
e-mail: info@cumminsgeneratortechnologies.com
www.cumminsgeneratortechnologies.com

Cummins Generator Technologies Germany GmbH

AVK report checklist-2012

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