Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Generator Maintenance Technicians
• Power Plant Engineers
• Electrical Supervisors
• Rotating Equipment Specialists
• Reliability and Asset Managers

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Develop comprehensive maintenance and testing programs for large generators.
• Diagnose and correct common mechanical and electrical faults in generator rotors and stators.
• Master inspection and testing procedures for insulation and winding health using advanced tools.
• Apply best practices for cooling system maintenance, including hydrogen, water, and air systems.
• Execute safe and efficient procedures for generator outage planning, disassembly, and reassembly.
• Analyze excitation system performance and troubleshoot common control issues.

DAY 1

Principles, Safety, and Stator Winding Maintenance

• Welcome and Introduction
• Pre-test
• Generator Operating Principles and Types
• Generator Safety and LOTO for Maintenance
• Stator Core Inspections and Common Damage
• Stator Winding Failure Mechanisms and Repair
• Introduction to Insulation Testing Techniques

DAY 2

Insulation Diagnostics and Advanced Stator Testing

• Insulation Degradation Modes and Life Assessment
• Off-Line Diagnostic Testing (DC Hi-Pot, PI, DAR)Advanced Stator Winding Testing: Partial Discharge
• Interpreting Partial Discharge and Tan Delta Results
• Bar and Coil Replacements and Rewinding Procedures
• End Winding Support System Inspections and Repairs

DAY 3

Rotor Systems and Excitation Maintenance

• Rotor Construction, Maintenance, and Common Faults
• Field Winding Insulation Testing and Pole Removal
• Retaining Ring Inspections (NDT) and Maintenance
• Rotor Balancing, Vibration Monitoring, and Diagnostics
• Excitation System Principles and Components
• Troubleshooting Brushless and Static Excitation Systems

DAY 4

Cooling, Bearings, and Alignment

• Generator Cooling Systems (Air, Hydrogen, Water)Hydrogen Cooling Maintenance and Leak Detection
• Water Cooling System Best Practices and Water Quality
• Generator Bearing Types, Lubrication, and Maintenance
• Detailed Inspection of Seals and Housing
• Generator Alignment Checks and Adjustments

DAY 5

Outage Planning, Commissioning, and Action Plan

• Outage Planning, Scheduling, and Critical Path
• Disassembly and Reassembly Procedures Review
• Post-Maintenance Testing and Commissioning
• Maintenance Documentation and Record Keeping
• Reliability Improvement and Failure Prevention Strategies
• Post-test
• Certificate ceremony