Revitalization of Generator Rotor Shaft

The Revitalization of Generator Rotor Shaft project was carried out to restore the rotor shaft’s mechanical integrity, dimensional accuracy, and operational performance after indications of wear and surface deterioration in critical areas. Given the rotor shaft’s essential role in maintaining generator reliability and rotational stability, the work required a controlled repair process combining inspection, restoration, machining, testing, balancing, and commissioning.

This project focused not only on repairing damaged areas, but also on ensuring the rotor shaft could return to service with performance parameters aligned to operational requirements.

Scope of Work

The project execution covered the following main activities:

• Preparation and mobilization tools and manpower
• Perform chemical cleaning
• Perform incoming inspection before repairing, including: NDT inspection, Dimensional inspection, Roughness test, Hardness test, Run out test, Residual magnetic inspection
• Perform electrical testing, including: Insulation resistance, Winding resistance, Recurrent surge oscilloscope test, AC impedance test
• Provide summary inspection report
• Generate manufacture drawing, QP, WP, ITP, and WPS
• Perform laser welding on generator shaft area, including: Shaft journal bearing area diameter 450 mm at position #5 and #6, Shaft air seal area diameter 520 mm
• Perform machining as per target dimension
• Final inspection after repairing
• Manufacture balance weight
• Perform in-situ balancing
• Commissioning with good performance parameters

Result

Through this revitalization work, the generator rotor shaft was successfully restored through a complete process of inspection, repair, machining, balancing, and commissioning. The project ensured that the shaft area requiring repair could be recovered properly and returned to operation in line with expected performance requirements.