Diesel to gas engine conversion Recommendations for continuous generator availability The paper describes the recommended inspections, maintenance and upgrades when converting a combustion engine’s generator from diesel to gas. — 01 High voltage generator for diesel and gas engines Securing generator availability When converting a combustion engine’s generator from diesel to gas, the following inspections, maintenance and upgrades are recommended to secure the generator’s continuous uptime and availability: • L3 or L4 maintenance • Hydrostatic jacking • ABB Ability™ Condition Monitoring for HV motors • Air gap inspection (not required if an L4 is executed) • ABB Ability™ LEAP During L3 or L4, several critical inspections are performed and parts are replaced. Due to the vibration levels to which combustion engine driven generators are subjected, it is important to thoroughly inspect the generator for cracks and lose cable connections. L3 or L4 maintenance prior to engine conversion L3 or L4 maintenance provides a snapshot of the generator’s condition before combustion engine conversion. The snapshot provides a comparison of the generator’s vibration and/or load cycle status, to gauge their impact before and after conversion. For best results, it is recommended that ABB service specialists execute the maintenance. The recommended maintenance program for ABB’s synchronous generators consists of four levels, L1 - L4. L3 maintenance should be scheduled at least every 40,000 equivalent hours of operation, or maximum six years. L4 maintenance should be scheduled at least every 80,000 equivalent hours of operation, or maximum 12 years. An L3 maintenance takes, on average, five days, while L4 maintenance is typically 10 days. Both L3 and L4 have a specific kit of recommended parts that should be at site when the maintenance starts. Hydrostatic jacking As a gas-driven generator turns more frequently at very low speeds than its diesel counterpart, it is recommended that hydrostatic jacking is fitted to the generator. When the shaft rotates slower than designed, the oil film within the generator’s sleeve bearings – which prevents contact between the shaft and bearing shells – does not work efficiently, cau

— 01 High voltage generator for diesel and gas engines with hydrostatic jack-up unit To avoid this wear, jack-up units ensure sufficient oil film is always present. A jack-up unit supplies oil at high pressure, lifting the shaft off the bearings and creating an oil film between the shaft and bearing. — 02 Hydrostatic jack-up unit — 03 ABB AbilityTM MACHsense-R data acquisition unit ABB supplies all the materials and documentation for retrofitting the hydrostatic jacking to ABB generators. To ensure the best results, ABB service engineers can provide on-site installation assistance. To find out...

— 04 ABB Air Gap Inspector — 05 Stator insulation condition information provided by ABB AbilityTM LEAP The crawler attaches itself to the stator using magnets fitted under the belts. The spacing of the track modules is configurable to allow the crawler to fit in a wide variety of generator designs. This is accomplished with configurable linkages between the tracks and crawler body, and at the hinge between the track halves. Tests include: • PDCA – Polarization-Depolarization Current Analysis • TDCA – Tan Delta & Capacitance Analysis • NLIBA – Non-Linear Insulation Behavior Analysis • PDA – Partial...

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