SOP: GENERATOR INTEGRITY | FRANCIS UNIT 1
SOP-ELEC-004 REV 3.1

GENERATOR INTEGRITY

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THE SILENT KILLER: CARBON DUST

CRITICAL RISK

Carbon brushes wear down, creating conductive dust. In high humidity, this dust creates "tracking paths" for electricity to jump to the stator frame (Flash-over / Ground Fault).

CLEANLINESS IS NOT AESTHETICS; IT IS INSULATION INTEGRITY.

BRUSH PROTOCOL

REPLACEMENT LIMIT 25-30%

Never wait for the wire shunt to touch the slip ring. Monitor groove wear monthly.

SPRING PRESSURE 1.5 - 2.0 N/cm²

Too soft = Sparking/Burn Marks. Too hard = Rapid premature groove wear.

HEATER LOGIC

AUTO-ACTIVE ON STOP

Whenever the unit is SHUT DOWN, anti-condensation heaters MUST be ACTIVE. This prevents windings from absorbing tropical moisture.

Heater Status
READY

INSULATION INTEGRITY TESTS

IR (MEGGER)
ANNUAL

Insulation Resistance

500V/1000V DC on Stator/Rotor. Correct all readings to 40°C baseline for trend analysis.

TERM (BOX)
MONTHLY

Terminal Box Audit

Inspect for discolored lugs or melted tape (High Resistance). Torque verification required.