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PARSONS BRINCKERHOFF

QUALITY SERVICES

AMBER COURT . WILLIAM ARMSTRONG DRIVE . NEWCASTLE BUSINESS PARK . NEWCASTLE UPON TYNE . NE4 7YQ . ENGLAND

PBQS DIRECT TEL No : +44 (0) 191 226 2222


PBQS DIRECT FAX No : +44 (0) 191 226 2200
E-MAIL: pbqs@pbworld.com

QUALITY REPORT Attachments: Yes

Client: Duke Energy Report No: 09SS003 Page 1 of 8

Project: Buck CTCC Project

Project/Task No: FSQ 95063B-002

Distribution: B.Pendrich; PBQS File

Contract/Order No: QS HUB 2009/097 Revision 2 Quality Plan Ref: P24C-AL-6502/E (APRIL 2006)

Material/Equipment Inspected: 275MVA TURBO-GENERATOR ROTOR. 60Hz. 3600RPM

Manufacturer, Location, Ref and Serial No : Doosan Heavy Industries & construction, Busan, Korea - 7C074

serial no. 338x394

Prepared By: Suwarawan Songsak Date of Visit: 18 September 2009 Date of Report: 21 September 2009

1.0 SUMMARY

This report covers our checking the results of the Winding resistance check, the Impedance
check, the Polarization index test, the Insulation resistance check and witness the high voltage
test of the subject generator rotor (Ref 7C074), which is one of the rotors being manufactured
and tested at Doosans Busan generator manufacturing facility for the Duke Energy Buck CTCC
Project.

This testing follows on from the recently performed balance & overspeed tests of the rotor on
September16,2009, which were witnessed separately by PB (Suwarawan Songsak) our report
09SS002 refers.

The outcome of these final electrical tests was satisfactory.

The rotor will now be prepared for despatch and is due for our witness of the preservation &
packing measures around middle of October, 2009.

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ

4NReportNEW
QUALITY REPORT Report No: 09SS003 Page No 2

2.0 REQUIRED FOLLOW-UP

Doosan to notify readiness of rotor for inspection of the packing & preservation of the rotor
prior to despatch

3.0 DETAILS

3.1Personnel

The following were present during this visit:

Jong Hun Lim Quality Control Assistance Manager, Doosan


Woo Jong Yoo Turbine/Generator Testing manager, Doosan
Sung Won Jang Testing operator, Doosan
Suwarawan Songsak PB Quality Services

3.2 Reference Documentation

The following reference documentation is applicable and was utilised during the witness
activities as appropriate:
1) GE process specification document no. P24A-AL-5072Q, Procedure for Hi-Potential testing
of Generator fields.
2) GE process specification document no. P24A-AL-5080, Generator field impedance test
3) Institutes of Electrical and Electronics Engineers, IEEE43 Recommended practice for testing
insulation resistance of Rotating Machinery.
4) American National Standards institute C50.10
5) ANSI/IEEE 115, IEEE guide : Test Procedure for synchronous machines.
6) ANSI. IEEE C 50.13

3.3 Inspection and Test Plan


Prior to our arrival, the following test items were performed and completed at Doosan Factory.
Only the High voltage test and the Insulation Resistance test after hi-pot were witnessed by our
engineer. However, the test results were reviewed and found to be satisfactory.
All test items and details procedures were agreed prior to our engineers visit. The details of
test procedures are given in GE process specification document no. P24A-AL-5072Q,
Procedure for Hi-Potential testing of Generator fields and GE process specification document
no. P24A-AL-5080, Generator field impedance test

1) Rotor Winding Resistance test


2) AC Impedance test
3) Insulation Resistance test and Polarization index test
4) High Voltage test
5) Insulation Resistance test after Hi-pot

Please note that the visual inspection and dimension check were not witness points and not in
inspection and test plan of Doosan, however, a visual check was performed by our engineer,
before performing the High voltage testing.

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ
QUALITY REPORT Report No: 09SS003 Page No 3

4.0 Test Results


During the factory witness test, It was confirmed that all measuring and test equipments listed
in above mentioned procedure and to be used, were within the identified calibration validity
period, normally no later than one (1) year since last calibration. All test equipments were
calibrated by Korean research centre for measuring instrument co. Ltd.

Before performing the tests, visual inspections were made of the rotor body and slip rings unit.
General appearance
Rotor windings were placed in the slots of the rotor body and insulated. The rotor looked well
with no sign of any damage or distress arising from the balance & overspeed runs. Balance
weights were fitted and had been correctly locked in place. The Slip ring units were in good
condition. The visual inspection did not reveal any significant defects. See the attached picture

The following series of tests were performed in the chronological order.

4.1) Rotor Winding Resistance


Prior to our arrival, The rotor winding temperature were measured at 5 points on the rotor by
temperature measurement, Testo type 625 , The average rotor temperature was 24.5 C
Using a Digital Low resistance Ohmmeter (Biddle) range 0.1A, 0-600m the cold resistance of
the rotor winding was measured and recorded as 0.1375 at 24.5C and corrected by
calculation to the reference temperature of 25C with a resultant value of 0.13777 recorded.
This is within the tolerance of 2% of the Design Value of 0.1403

4.2) AC Impedance test


Prior to our arrival, The AC impedance measurement of the rotor windings were completed by
applying a steady ac voltage of about 100V from a stabilised power source SD3000, rated
3kVA,60Hz,12A (Daesung) across the slip- rings and the resultant rotor current recorded as
12.2 A.
The voltage across slip-rings were measured by Fluke 189 and rotor current was measured by
Ammeter(Yew) range 0-50A
By calculation,The result of impedance check was 8.20 , This is within the tolerance of 25%
of the Design Value of 8.49

4.3) Measurement of Insulation resistance (Pre-High voltage test )


Prior to our arrival, The measurement of insulation resistance ( Pre-Hi voltage test ) was
completed by using a Insulation resistance tester (Megger) type S1-5010, at 500VDC, the
insulation resistance of the rotor winding was checked with the rotor cold (24.5C) and
stationary and found to be a healthy 1430 M after one minute. This is more than the
acceptance criteria value of 25 M

4.4) Polarization Index test


Prior to our arrival, The polarization index test was completed by using a Insulation resistance
tester (Megger) type S1-5010, at 500VDC, the insulation resistance of the rotor winding was
checked with the rotor cold (24.5C) and stationary. The insulation resistance values at 1
minute , 5 minutes and 10 minutes were recorded.
Polarization index is the ratio of 10 minute insulation resistance to the one (1) minute insulation
resistance. By calculation, The Polarization Index value was 3.54,This is more than the
acceptance criteria value of 1.0

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ
QUALITY REPORT Report No: 09SS003 Page No 4

4.5) High Voltage Test


With the rotor at a standstill, a high voltage test at 3.5 kV 60Hz ac, by AC hi-pot tester (MS
Electric) was carried out via the sliprings and temporary brushgear. The test voltage was
applied and maintained for a period of one minute without and incident or flashover.
The test result was found to be withstand, no breakdown or flashover. The leakage current
reading was 0.73 ampere.

Both prior to and on completion of this test the rotor winding insulation resistance readings were
noted to be acceptably high demonstrating that the winding had not suffered any damage or
distress due to the HV test.

4.6) Measurement of Insulation resistance (Post-High voltage test )


Using an Insulation resistance tester (Megger) type S1-5010, at 500VDC, the insulation
resistance of the rotor winding was checked again with the rotor cold (24.5C) and stationary
and found to be a healthy 659 M after one minute. This is more than the acceptance criteria
value (25 M or greater and at least 60 percent of the one minute pre-high potential
measurement, or 200 M or greater)

5.0 Review of Test Results & Certification


On completion of the test sequence above, the Doosan test certification covering these witness
tests was reviewed and found to be satisfactory

The test certification was suitably endorsed and a copy is attached to this report

6.0 ATTACHMENTS

Doosan Rotor Test Certification ( Final hi-pot test) PCG-RW-005

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ
QUALITY REPORT Report No: 09SS003 Page No 5

Figure 1 Rotor Body is placed on Rotor stand

Figure 2 Slip ring units are in good condition

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ
QUALITY REPORT Report No: 09SS003 Page No 6

Figure 3 Balance weights were fitted and had been correctly locked in place

Figure 4 Preparation for High Voltage test

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ
QUALITY REPORT Report No: 09SS003 Page No 7

Figure 5 HV lead connection to slip ring

Figure 6 High voltage test set

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ
QUALITY REPORT Report No: 09SS003 Page No 8

Figure 7 Insulation resistance measurement after high voltage test

Figure 8 insulation resistance test equipment

Parsons Brinckerhoff Ltd


Registered in England No 2554514
Over a Century of Registered Office : Amber Court, William Armstrong Drive
Engineering Excellence Newcastle upon Tyne NE4 7YQ