Root Cause Analysis of High Vibrations of Rewound Generator Rotor and Error Correction

This paper explores the diagnosis and resolution of high vibrations in a 15 MW, 11 kV industrial generator rotor post-rewinding in a power plant. The rotor, which should have been operational, instead presented abnormal vibrations, suggesting discrepancies in the reverse engineering, remanufacturing or reassembly processes. An OEM veteran’s logical methodology aided to identify the fault source. The investigation revealed a rewinding error, hindering the generator's voltage output. Dissection and innovative procedures isolated the fault, leading to successful rectification and normalized rotor vibrations. The study concludes with preventative rewinding practice recommendations, offering insights for the affiliated group.