Maintenance of Ingersoll Three-phase AC Synchronous Generator Part 1

If the Ingersoll generator is regularly maintained and inspected, it can detect and correct more than common phenomena, which is very important for the safe operation of the generator and the prevention of accidents. All maintenance measures should be carried out regularly, and repairs should be determined based on usage. For example, after 500 hours of operation, insulation resistance should be checked once, powder, oil, and mud should be cleaned, bearing oil should be replaced, and after 1000 hours, spare parts should be checked for any abnormal phenomena, such as normal temperature rise, deformation of fan blades, and loosening of screws and nuts. Regular maintenance plans should be developed based on usage, and carried out on schedule. Regular inspection wells should be recorded.

General maintenance: The generator should not be affected by moisture. During the period of discontinuation, it is advisable to cover with a tarpaulin to prevent moisture from entering.

The generator must avoid the entry of metal dust, water droplets, acidic or alkaline water vapor, or other harmful gases into the interior of the motor during parking, assembly, or operation.

The generator should maintain normal ventilation during operation. The front and rear window covers, as well as the top cover, should be kept in the correct position. Do not cover any objects on the motor to avoid obstructing ventilation and heat dissipation. Do not remove the top cover to avoid affecting the ventilation and cooling of the automatic voltage regulator.

Pay attention to monitoring the load of the generator. The load current should not exceed the rated current of the generator. When the power factor of the load is low, the excitation current of the generator should not exceed the rated value on the nameplate. When the three-phase load is unbalanced, the current of the maximum phase of the load should not exceed the rated current.

Pay attention to the temperature of the generator bearings. Under normal circumstances, the temperature of the bearing should not exceed 55k.

During the operation of the generator, it shall not exceed the rated speed, rated voltage, and rated current of the unit. During operation, if abnormal noise, odor, or vibration is detected, the operation should be stopped immediately. Emergency shutdown is required. When the unit triggers an alarm shutdown or the system trips, the cause should be promptly identified and the fault should be reported before restarting or powering on.

Check the insulation resistance of each winding and measure it with a 500 volt megohmmeter. If the insulation resistance is below 0.4 megohms (hot state) or 5 megohms (cold state), it should be dried thoroughly. If the insulation resistance cannot be improved after drying, it means that the insulation has aged and the coil and insulation should be replaced, and the insulation treatment should be redone.

Check the wear of the bearings, whether there is any looseness or other abnormalities.

There are two types of bearing assemblies for EG generators: (1) sealed deep groove ball bearings and (2) grease filled bearing chamber structure. Sealed deep groove ball bearings are standard for all EG generators. Under ideal operating conditions, the bearing life is approximately 40000 hours. The shaft extension end of EG160~EG355 and other types of motors have ball bearings that can be lubricated with grease. The grease type is Unirex N3 (Ulex 3) from Mobil Lubricants. For bearings that can be lubricated with grease, it is recommended to add grease every 3000 hours, with a recommended amount of grease added each time; GP=0.005 × D × B (g) -- Outer diameter of D bearing (mm); B： Bearing width (mm): If the lubricating grease changes color or has uneven color, replace the grease. When changing the oil, remove all the old oil in the bearing and bearing cover. The operating environment will affect the bearing life. Overheating, vibration, dust pollution in the air, and humidity will all reduce the bearing life.

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