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Generator Testing

We understand that your generator is one of the most critical assets in the plant. It’s reliability is the heart of plant operations. Our team is equipped with the skill set and technical expertise to find the right solutions for your generators. Just like MotoCARE®, we offer GenCARE for generators.

GenCARE

Generator Condition and Reliability Evaluation Program

GenCARE is our comprehensive diagnostic procedure merging our experience from testing 1,000+ generators and overhauling 250+ generators (up to 300 MW) with all relevant CIGRE, IEC, IEEE & ISO standards.

Why choose GenCARE?

GenCARE can predict practically any electrical or mechanical fault well in advance. It offers several USPs like
Safe operational period for a generator is specified
Incipient defects are identified, along with an assessment of their severity
Corrective actions are recommended and can be planned in advance
Healthy generators are identified so that unnecessary overhauls are avoided
All tests and results are in accordance with relevant standards
Residual life can be estimated when GenCARE is used in combination with generator history and operational data

GenCARE can detect all
possible failure modes in generators like

Level I GenCARE

Overall insulation aging

Localized insulation faults

Interturn degradation

Loose connections

Moisture ingress

Contamination

Corona

Rotor winding faults

Mechanical defects

Leve II GenCARE

Moisture ingress

Contamination

Overall insulation aging

Localized insulation faults

Interturn degradation

Corona

Loose coils

Stator core degradation

Lack of mechanical bracing in overhang

Internal physical damage

Key technologies used in GenCARE

GenCARE
Assembled Condition

LEVEL I

Partial Discharge Analysis

Tan Delta And Capacitance Analysis

Polarization-Depolarization Current Analysis

Surge Comparison Test

Repetitive Surge Oscillograph Test

Vibration Analysis

Corona

GenCARE
Disassembled Condition

LEVEL II

Visual Inspection

EL-CID

Natural Frequency Test

Wedge Deflection Test

Full Flux Loop Test

Corona Probe Test

Coil Contact Resistance Test

What is the process of deploying GenCARE?

Vibration Analysis is performed during routine operations

GenCARE Level I is performed during a planned outage

GenCARE Level I is repeated based on the safe operational period specified

If generator is in disassembled condition, the following are performed:

Visual Inspection, ELCID, NFT and WDT tests

Flux Loop Test if ELCID results are abnormal

Corona Probe Test if PD and/or PDCA results are poor