REVELSTOKE - 1 YEAR DOWN. Applied to Equipment Instruction Number R Class-Group Generate Date: 11 March 2004

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1 Page 1 of 7 Planned Maint. Type Turbo file - Job Group 1Y-DOWN Lead Trade Applied to Equipment Instruction Number R Class-Group Generate Date: 11 March 2004 Isolation Zone Supersedes References J:\PS\mep\Maintenance Program\Reliability Centered Maintenance\Revelstoke\Turbo Files\Turbo Today\REV RCMT V9.mdb Technical File # Prepared by: Revision History: Reviewed by: Accepted by: EOR: Work Performed by: Date: W.O. # Brush Shunts Complete Shunt connection at the brush or at the brush gear ring termination fails. Effects are the transfer of current to another brush or the shunt coming in contact with the opposite polarity brushgear ring resulting in a slip ring fault. Likely due to vibration/age. - Check for a loose connection of the shunt on the brush and at the brushgear ring. SAI: Loose connection on the brush or at the brushgear ring Brushgear - Visual Excessive dust on the brushgear could cause binding of the brush in the holder; Excessive noise coming from the brushgear could be indicating a possible failure. Also, broken welds and fasteners will cause vibration and possible noise. Likely due to wear. - Vacuum and wipe excess carbon dust in the brushgear pit. Use vacuum cleaner and water only. - Check for ease of movement of brushes (prior to cleaning and after cleaning and brushes have been measured, replaced prior to completion of work in the brushgear pit. - Check welds and for loose fasteners in the brushgear pit. SAI: N/A Complete Complete Complete

2 Page 2 of 7 Exciter Brush Length Complete Inlet and Outlet Filters Brush length becomes too short and insulation on shunts catches on holder. The effect is transfer of current from the brush to another because of poor brush contact (hung up by shunt on holder) resulting in overheating of brushes and breakdown of patina. Likely due to Wear. The inlet filters can get plugged with dusty powerhouse air during the winter and springtime months when vehicles are moved in and out of the powerhouse. The effect is reduced air circulation in the brushgear pit and eventual brushgear failure. The outlet filter becomes plugged with brush dust resulting in the same as for the inlet filters. Likely due to Dust. - Inspect brush wear (72 brushes). - Check for signs of heating. - Measure length. Minimum length for changeout is 40 mm. - Refer to table. SAI: Length does not meet spec. Clean the 2 inlet filters and the single outlet filter. SAI: plugged filters Complete Complete Complete Slip Ring Polarity Brushes and ring will wear at a - Change the position of the bus greater rate on the positive slip connections behind the wire ring than on the negative slip ring. mesh cage. Periodically changing the polarity - Check for overheating. of the slip ring will even out the wear of the brushes and ring. Likely due to Current Polarity. SAI: Input Required Complete Complete

3 Page 3 of 7 Slip Rings - Visual Complete Complete Brush friction and arcing will damage the patina and metal surface of the slip ring. The effects will be increased heat and breakdown of the brushes and eventual failure. Likely due to Heat/Arcing/Chemical. - Inspect slip ring for signs of wear and pitting. - Check for heating (discolouration). - Check for film condition on the ring (bright, dark, normal, mottled, streaky, light). - Check for ring condition (good, grooving, frosty, smearing, inconsistent). Complete Complete BRAKE SYSTEM Brake Pads (16 per unit) LIFT PUMP SYSTEM Coupling - Motor to Pump TH GD BEARING Oil Seals / Gaskets Pads break apart or wear excessively leading to metal to metal contact causing rotor track damage and increasing stopping times. Likely due to Wear & Tear. Loss of high pressure oil to thrust bearing even though pump is running. Likely due to Wear & Tear. Bearing fails to contain oil leading to low oil alarm, contamination of generator winding and resulting overheating. Likely due to Age/Wear. SAI: Input Required - Visual inspection of pad thickness and condition. Record findings. - Pad thickness below 13 mm requires replacement. SAI: Pad thickness below limits (13 mm) - Visually inspect coupling for wear debris below coupling, cracks, looseness, etc. SAI: damaged or loose coupling - Thorough climb-around visual inspection for oil leaks or pooled oil. SAI: Oil leaks / oil vapor deposits found Attached Record Complete Complete Complete

4 Page 4 of 7 REV - TRANSFORMERS HV BUSHING Pressure Pressure to high or too low. Likely due to age/fault. - Verify correct oil pressure in bushings 10 to 14.5 psi (0.7 to deg C). Pressure PSI REV - TURBINE SERVOMOTORS Piston Rings REV - TURBINE SERVOMOTORS Servo blocking device REV - TURBINE TURB BRG Oil Seals / Gaskets Oil leaks past worn rings or cylinder wall scoring resulting in reduced operating force from low oil pressure. Likely due to normal wear & tear or dirty oil. Likely due to dirt/debris. Damage to wedge or rod slot from operating wicket gates against the blocking device. Likely due to Normal operation. Bearing fails to contain oil leading to possible environmental issues, increased cleaning costs and possibility of sudden oil loss leading to bearing failure. Likely due to Age/Wear. SAI: pressure is too high or too low Drain oil from valve at the bottom of all four servomotors to clear out accumulated dark deposits or water. Note - Govenor must be isolated. Visual inspection before each use and repair if neccessary. (Safety / Environment Requirement) Visual inspection around and under bearing pot looking for oil leaks, oil pools. SAI: Oil leak found. Complete Complete Evidence of leakage Yes No LIFT PUMP SYSTEM Contactor Arcing, burning, high resistance, mechanical jamming, or burnt coil. Likely due to overload, frequent use. - Remove actuator, clean contact surfaces (moving and stationary parts) with fiber brush. - Check freedom of motion for actuator. - Check wiring and terminals - tightness, damage. SAI: excessively pitted contact surfaces Complete Complete Complete

5 Page 5 of 7 ROTOR Field Ground Insulation Insulator, mylar tape breakdown due to age and O/L. Effects operation of the field ground relay and winding failure should 2nd ground occur. Likely due to age/vibration. - At the END of the outage and Prior to return to service then megger rotor circuit (1000 VDC) from exciter field breaker (includes brushgear, bus work, and field leads & poles (field). 1 Min = 100 M-ohm, 10 min = 100 M-ohms. Record resistance and temperature. SAI: megger < 1 megohm/1000 volts minimum, good is 150 megohm/1000 volts. Normal is between Meg Found Left 1 min deg C_ Mohms 10 min deg C_ Mohms P.I. = SHAFT Shaft Grounding Brush Shaft has potential above ground because of loss of continuity due to worn brush or broken wire. Can lead to pitting and erosion of bearing surfaces. Likely due to Age/Wear. - Visually inspect length of brush, check holding spring tension, and clean brush and holder if required. - Check continuity from station ground to shaft. SAI: brush length reduced so end is close to sitting inside of holder. poor or loss of continuity. Complete Complete

6 Page 6 of 7 WINDING Ground Wall Insulation (2) Protection operation (59N1 relay). Likely due to age/heat/debris. - Complete megger ONLY at the END of the outage and just prior to returning the unit to service. Megger at 2500 vdc - refer to latest maint standard for accepted procedure. This should be completed just prior to return to service of the unit - IR value; 1 minute specified minimum = 25 M-ohms; 10 minute specified at 50 M-ohms; polarization index (specified PI min = 2). SAI: Does not pass megger test. 1 min deg C_ Mohms 10 min deg C_ Mohms Polarization REV - GOVERNOR CONTROLS Gate Limit Motor Timing Failed start due to motor becoming sticky or jammed from bearing, linkage or clutch problem. 48A incomplete start relay. Likely due to malfunction / adjustment. - Jumper motor out at actuator cubicle. - Raise and lower at UCB. - Measure the time it takes to raise or lower. - Specified 40 sec +/- 5 sec. SAI: Does not meet timing specification. Found Left sec_ sec

7 Page 7 of 7 REV - GOVERNOR CONTROLS Gate Pos/Lmt Ind Unit fail to start or misoperation due to gate position switches out of calibration. Gate position indication not same at UCB, CR, or actuator cubicle. Likely due to vibration/calibration. ***Note: Coordination required between Elec, Mech and P&C. - Check that gate position indicator and gate limit indicator at actuator cubicle reads 50% when servo gauge is 50%. Note pilot valve is re-installed by Mech. LVDT = 50%. Complete - P&C check UCB/Control Room display. - Follow procedure (#3) in P&C red binder - Gov Routine Test Procedures. - Refer to gate swings tab in binder. - 25%, 50%, and 75% gate positions. SAI: Act. cub. does not show 50% when servo gauge is 50% +/- 1%- Incorrect reading after primary maint Complete Complete Complete REV - INTAKE GATES FUNCTIONAL TESTS Intake Gate No-Flow Test OMS (Operation, Mtce & Surveillance) guidelines require annual test of open & close function. Likely due to Adjustment/age/malfunction. Function check of the operating gate by lowering and raising. May be part of isolation or functional checks with tradesmen. Complete

Applied to Equipment Instruction Number R Class-Group Generate Date: 11 March 2004

Applied to Equipment Instruction Number R Class-Group Generate Date: 11 March 2004 Page 1 of 7 Planned Maint. Type Turbo file - Job Group ZI Lead Trade Applied to Equipment Instruction Number R Class-Group Generate Date: 11 March 2004 Isolation Zone Supersedes References J:\PS\mep\Maintenance

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