GE Energy

2008 4 10 GE Energy Korea This document and its contents are the property of General Electric. This copy is provided for GE Generator Technical Seminar attendees company internal use only, not to be copied or transmitted in any form to third parties.

Generator Fleet Experience

Generator field Generator stator Generator auxiliaries Generator maintenance

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Generator Rotor Rewinds

Aging fleet- field rewinds are to be expected to maintain reliability
In most cases rewinds can be done with existing copper and high speed balancing is not necessary New copper may be necessary if deformation or compression yielding Peaking units-more frequent rewinds than base load units ~ 2 to 1 Insulation and winding components may be upgraded Design modifications may be possible to uprate unit Rewinds performed with rotor TILs >provide extended rotor life Fast rewinds have been developed to support shorter outages Partial field rewinds require special care Replacement rotors can be made to facilitate fleet rotor maintenance
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Generator Shorts and Grounds

Shorted turns
Difficult to find at standstill Flux probe provides best diagnosis On-line at load Stator short-circuit, no load Allows for planned maintenance Permanent and temporary flux probes available

Rotor Grounds
Field ground circuitry includes field, exciter, rectifier and ground detector Testing Split voltage test Current through forging test Most grounds found in end winding, bore copper or collector areas

Shorts and grounds should be diagnosed prior to disassembly On-line shorted turn detector is available for continuous monitoring RSO (Recurrent Surge Oscillography) can detect shorted turns and possibly speed sensitive and intermittent grounds
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Generator Retaining Rings

18 Mn-18 Cr retaining rings No formal inspection recommendation to date Some 18Mn-18Cr retaining rings found with corrosion pits/cracks Exposed to halides-iodine, bromine, chlorine, etc. Retaining ring insulation used fire retardant New TIL is in the works Inspect 18Mn-18Cr retaining rings Florescent penetrant Eddy Current Retaining ring insulation should not contain fire retardant or other potentially corrosive material In situ retaining inspection now available Primarily aimed at remaining 18 Mn-5 Cr fleet Uses eddy current and UT
In Situ RR Inspection

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Generator Rotor Vibration

Correct problem diagnosis
30.0 PSIG H2 15.0 PSIG H2
8

Field or stator
Lag

40 30 20 10 0

Alignment/mechanical/operation What changed (maintenance, incident, operation, etc.) Resolution-GE expertise

0.5 PSIG H2

7 9 6

Megavars

0.85 PF
1 2 3

10

10

20

30
0.95 PF

40

11 4 12

50

60

70

Lead

Thermal Sensitivity
Testing outlined in GER 3809

10 20 30

No low speed balance

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GE Company Proprietary

GER3809-4
6

Full train turbine-generator review

NO. TEST POINT

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TIL 1292 Inspecting All Large Steam Turbine Generators for Cracks
Mild to severe rotor tooth cracks have been observed on some long service generator rotors Cracks can lead to extended outages & ultimately to rotor failure TIL1292 applies to:
LSTG direct cooled fields Large Schenectady-built conventionally cooled fields Model 324 fields Large Crack Indication
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TIL 1292 Machining

Disassembly: Baseline inspection Remove retaining rings, wedges Measure #1 coil wedge top fits Prepare for TIL 1292 Machining Mfg New Aluminum Wedges Clean/mask field Perform TIL 1292 EC inspection Evaluate EC data Machining Axial Radial & 45/30 Degree Re-assembly Install wedges, retaining rings Perform final inspection
Axial Cutter

Mask Field

Radial & 45 Degree Cutter

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Generator Stator Experience

TIL 1447-Water Cooled Stator Winding Update
Crevice corrosion still possible on phosphorus brazed bars despite stator bar improvements Leaks may be found in other areas of the SWCS (connection rings, lower leads/HVB, rectifier circuit, etc.) On line monitoring and periodic leak testing are most effective method to mitigate the occurrence of a wet bar Epoxy resin coating is an extremely effective method of halting the corrosion process GE water cooled fleet continues to be the most reliable in the industry a controlled and scheduled monitoring and test plan will maintain this On line monitoring with SLMS-HP and liquid leak detector should be implemented New stator bars have phosphorus free Brazes and not subject to Crevice corrosion
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Crevice Corrosion Process

Water Box Copper Strand H2O Voids in Spongy Area of Braze

Selective Attack of Cu3P

Copper Brazing Metal Strand 1) Solution at braze surface = inlet water 2) Water works its way into voids in braze and stagnates 3) Crevice corrosion of braze (primarily Cu3P) 4) Critical solution or surface area conditions met, and Cu corrodes 5) Solution/surface area conditions change favoring braze corrosion 6) Solution/surface area conditions change favoring Cu corrosion 7) Leak drives down the bar to outer surface Phosphorus Is Main Driver for Crevice Corrosion-Eliminate or Isolate

Cooling Water (pH:7, low conductivity)

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GE Water Cooled Stator Winding Test and Monitoring Recommendations

Clip-Strand Braze: Phos Containing H2 Leak Orig SLMS, Bagged Monitoring Method Vent, or No Monitoring Test Vacuum Decay Pressure Decay Helium Tracer Gas Capacitance Mapping WID - Wet Insulation Detector Winding Electrical Testing X SLMS-HP Installed Global Epoxy or Clip-Strand Braze: Phos-Free Orig SLMS, Bagged Vent, or No Monitoring SLMS-HP Installed Minor Major Minor Major Minor Major Minor Major 30 Months 60 Months 30 Months 60 Months 30 Months 60 Months 30 Months 60 Months X X X X X X X X X X X X X X X X X X X X X X X X

Notes: 1. If SLMS, SLMS-HP, or pressure or vacuum decay tests indicate a leak, then the helium tracer gas test, WID and capacitance mapping should be done. 2. Refer to GEK 103566 for other testing and inspections not covered here.

Hydrogen Leakage -Cu. Ft. per Day 1 to 5 5 to 50 50 to 200 >200

Recommended Action Monitor weekly and trend (should be < 2 cu. Ft. per day) Monitor daily and trend (leaks exists) Monitor daily+ and trend (leak growing-plan to fix) Take unit off line and fix immediately (large leak)

SLMS (Stator Leak Monitoring System)

Water Leaks
Online monitoring at any time

Maintains SWCS oxygen level >2ppm Minimizes risk of in-service stator failure
SLMS has diagnosed > 15 major in-service leaks

Periodic maintenance required Super sensitive SLMS-HP is available

Significantly reduces SWCS maintenance SLMS-HP Unit
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Generator Stator Experience

Testing for wet stator bars Capacitance mapping/WID
Test top and bottom bars independently Test turbine and collector ends separately If 3 standard deviations are in double figures, repeat test

Full set of recommended HIT skid tests

Vacuum and pressure decay, capacitance & WID, and helium leak test

Wedging
Tight end wedges are most important Upgrading to top ripple spring system provides robust design

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Generator Stator Loose Wedges and End Winding

Inspections -Wedge tightness -Blocking -Dusting and greasing Oil ingress -No damage to insulation -Could accelerate bar and end winding wear Maintenance -First year, then every 5 years -Inspection with MAGIC or field out Consequences -Bar abrasion -Broken hardware/plumbing -Stator ground/other electrical failure -Rapid degradation once started -Loose ties -End winding hardware -Series loop damage-TIL 1045

Key to maintaining stator integrity

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Generator Stator End Winding Experience

Phase connections More complex than series loops Connection rings Water cooled HVB/neutral leads Impact testing recommended Rewind Partial Rewind Evidence of end winding motion Impact testing recommendations being reviewed

Stator End Winding Components

Teflon hoses Header nipples Broken plumbing

Typical Liquid Cooled Stator Phase Connection

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Generator Stator Water Cooling System Experience

Maintenance
Replace filters and resin Inspect & replace strainers TIL 1226 Consider system acid flushing

Hardware
Strainers-appropriate mesh size Duplex strainer system Filters-cotton filters better Resin-GE recommended Install SLMS-HP Maintain proper O2 level>2 ppm On-line leak detection Minimize SWCS maintenance

Spare parts
Filters, strainers, resin, etc.

Typical SWCS

TIL 1312-SWCS operation and maintenance

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Stator Water Cooling System Monitoring

Cold and hot gas RTDs Stator Bar RTDs and TCs Oxygen level >2 ppm Conductivity YTV vent hydrogen SLMS-HP SWCS differential pressure and flow Strainers and filters Monitoring/archiving/trending data is invaluable in diagnosing in-service stator issues
VENT GAS

PLANT COMPUTER
6 CFD

WATER RETURN

YTV SCWS ALARM SAMPLE OUT SAMPLE IN POWER IN (110VAC) Plant Air Supply 6.5 CFM @ 100 psi
6 CFD

WATER COOLED STATOR

WATER STORAGE TANK

SLMS System
AIR INJECTION

DRAIN

PUMP

COOLING WATER

If not maintained and monitored > stator bar plugging

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Generator Stator Core Experience

Initial symptom-noise change from long term steady-state Belly bands-provide contact between core and frame Round and square keybars-different parts and techniques Check torque on keybar nuts Loose inner core can be tightened with shims Check for keybar to frame weld cracks Inspect at major outages or if significant change in noise or vibration is noted 7A6-A units (early units) TIL 1552-inspection, test and repair of 7A6 frame/core Isomode pad replacement at frame to base interface Core Issues Are Uncommon in GEs Generators
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Core Iron Inspection and Repair

Inspection and testing
-Before disassembly -After disassembly prior to rewind - After rewind/repair

Testing techniques
-ELCID/RACER-for routine inspections -Core ring test-for burning and severe damage

Core iron repair-special techniques needed

-Grinding - Acid cleaning -Significant damage could occur if repaired improperly

RACER Trolley

Vulnerability increases due to lack of scheduled maintenance

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Generator Auxiliary Experience

Collectors and Brushes Maintenance, Maintenance Maintenance! National Carbon 634 brushes Used on most units Carbone LFC554 330H 450H High Voltage Bushings Proper assembly required Proper gaskets and torquing Soft gasket-lower torque Hard gasket-higher torque Modified Magic Dust repair has provided extended operation for leaking HVB Spare HVBs

Dont mix brushes!!!!!!!!!!!!!!!!!

Use brush originally supplied with the generator Spare brushes and collector rings

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Collector Maintenance is Vital

Daily Inspection by Operators Through Window Check for sparking, chatter, burned pigtails, oil, wear, changes from previous conditions (noise, vibration, etc.) Weekly Inspection and Maintenance by Electricians Check for overheating, spot check vibration and record, examine springs and brushes, check for brush hang up, inspect air filters Monthly Inspection and Maintenance Observe rings with strobe light, plot and examine trends in vibration, use of Infrared Thermography may be beneficial Shutdown Inspection and Maintenance Take runouts in each brush track, examine worn parts and replace, check for tightness, clean off dirt and oil, inspect air passages
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Improved Magic Dust Repair

Will repair all possible flange area leaks The level of the magic dust and sealing components raised approx. 2 Grind out solder and re-establishing seal with epoxy Patented solution Implemented successfully on several units Developed as a short term repair, but some units have operated for long periods of time Improved Magic Dust Repair
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Viscasil Silicone grease Magic Dust

Generator End Shield Sealing

This modification must be planned for prior to outage

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Generator Hydrogen Seals

Maintain H2 pressure and minimize consumption CE insulation must be maintained Clean and dry oil Housing and bearing insulation Cracked insulation Megger insulation periodically

Seal installation Different designs (bronze and steel babbitted) Clearances vary Lapping seals Oil feed must be maintained Proper parts and assembly necessary

Typical Seal Assembly

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GE Company Proprietary

Hydrogen Leaks Require Immediate Attention

Hydrogen leaks through the seal oil system Typically 300 to 1000 Cu. Ft. per day Higher values indicate a system breakdown Monitoring/corrective action is necessary Hydrogen leaks up the YTV vent Monitor-SLMS or the old fashioned way <5 Cu. Ft. per day for tight winding >200 Cu. Ft. per day-Immediate shut down to prevent catastrophic failure Other generator hydrogen leaks Snoop generator for leak location SF6 has been used effectively, but long term generator effect unknown Leak area should be well ventilated

All hydrogen leaks should be addressed immediately

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Generator Shaft Currents

Shaft grounding brushes must be operational Carbon or copper braid Regularly scheduled maintenance is necessary Bearing and Seal housing insulation Testing Cleanliness Poor maintenance results in frosting and electrolysis on the journals Can result in degraded bearing and seal performance Journals, bearings and seals may require rework Exciter Coupling Insulation maintained Turbine / excitation induced currents Shaft magnetism could induce shaft currents Check station grounding TIL 1344-Generator Shaft Grounding Brush Maintenance
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Generator Maintenance-TIL 1154

GER 103566-presently being revised Generator testing Generator inspections Overall generator fleet maintenance plan and recommendations are under constant review Condition based maintenance plan may be possible for selected units-requires GE study Generator TILs should be incorporated into maintenance plans to assure long term reliability

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Generator TILs
747 &757-Generator Rotor Bore Inspections 854-Generator Temperature Monitoring 965-Copper Dust 1001-18Mn-5Cr Retaining Rings 1002-Generator Main Lead Replacement 1005-Generator Rotor Top Turn Breaks 1027-Rectifier Cooling Tube Concerns 1035 & 1036-Aluminum Field Wedges 1037-Generator Alterrex Flexible Couplings 1045-Generator Stator Series Loop Inspection for Medium Sized Units 1098-Inspection of Generators with Water Cooled Windings 1154-Generator Test and Inspection 1163-Lead Carbonate Contamination in Hydrogen Cooled Generators 1197-Liquid Cooled Stator Bar Abrasion 1226-Generator Y-Strainer Inspection or Replacement 1292-Rotor Dovetail Inspection 1308-End Winding Insulation Migration 1312-SWCS Maintenance, Monitoring and Operational Guidelines 1398-End Winding Support Hardware Issues 1447-Water Cooled Stator Winding Update 1515 & 1516-Nuclear Generator Coupling/shaft Inspection Rec. TIL 1552-Inspection, Test and Repair of 7A6 Frame/Core
GE Company Proprietary

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Diagnosing Generator In-Service Incidents

Evaluating the Incident Severity Immediate action is necessary to address incident Contact local GE Rep ASAP and enter PAC case Obtain vital data immediately Conference with GE experts when necessary Need Vital Unit Operating Data to Diagnose Problem Events or conditions preceding fault Fault location Duration Stator phase currents Field current Which relays operated Generator terminal voltage Speed changes Load changes Vibration changes Main transformer impedance Neutral grounding transformer impedance
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Generator Fleet Experience Summary

Generator RTDs and TCs should be monitored on a scheduled basis The SWCS should not be operated with O2 < 2 ppm Do not operate with YTV H2 leakage > 200 ft3 per day Duplex strainers should be installed on all stator water cooling systems Tight stator wedges and end windings will assure long term reliability H2 leaks should be addressed immediately. This could be a safety issue! Hydrogen seals require the proper parts and assembly techniques Generator rotor copper leaf components should be replaced during rewinds Generators should not be operated with a field ground Rotors should not be pulled prior to troubleshooting shorts and grounds Use collector brushes supplied with unit. Do not mix brushes! A regularly scheduled collector maintenance plan should be set up Grounding brushes should be checked on a routine basis Install flux probes and SLMS-HP on all units Know your local GE Service Manager and Generator Specialists
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2008 Steam Turbine Generator Users Conference

Save the date for GE's annual technical conference for steam turbines and generators. This conference has a long history as THE source of the latest information for steam turbine and generator owners and operators. New this year we are expanding the conference program to include Industrial and Small Steam Turbine Genenerators and Mechanical Drives.

Were going back to New York for the 2008 conference!

Date: July 08-10, 2008 Location: Crown Plaza-City Center, Albany, NY

A new look and feel

Bring your family
Scheduled for the week after the 4th of July holiday, we are inviting you and your families the opportunity to piggy back a family vacation in upstate NY with this years event. There are many things to do in the area for the family, while we have the conference and we have several tours of the GE facilities in the area and a tent event for the family, built into the agenda this year. So bring the family and see what Albany and upstate NY has to offer.

http://mailcenter.newmediagateway.com/accvb/sites/43/aboutalbany.html
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Link to the Albany Visitors Bureau

Agenda change
We have adjusted the agenda in response to your feedback, to give you more time in the breakouts and your peers in similar power plants. Track groups will include users from fossil, nuclear, combined cycle and industrial. In addition we are adding break out sessions in some new categories to address the changing needs of our audience. Break out sessions will be in the categories of: training, operations, component design, and new technology.
7 /7 /2 0 0 8 M o n d a y 7 :0 0 r e g is tr a tio n 7 /8 /2 0 0 8 T u e s d a y 7 /9 /2 0 0 8 W e d n e s d a y 7 /1 0 /2 0 0 8 T h u rs d a y

8 :0 9 :0 1 0 :0 1 1 :0 1 2 :0 1 :0 2 :0 3 :0 4 :0 5 6 7 8 9 :0 :0 :0 :0 :0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

g e n e r a l s e s s io n

t r a c k s e s s io n s

product fair

b re a k o u ts

lu n c h tr a c k s e s s io n s b re a k o u ts product fair r e g is t r a tio n / r e c e p t io n

product fair

tra v e l to c o n fe re n c e

lu n c h t r a c k s e s s io n s to u rs

lu n c h g e n e r a l s e s s io n

r e c e p t io n

te n t e v e n t - S c h d y p la n t

Attendee Profile: GE steam turbine generator owners/users plant operators/managers maintenance managers corporate turbine engineers/technical services Agenda Topics include: Generator Fleet Experience Outage Experience Hot Topics Discussions Steam Path Audit Repairs Multi-OEM Repairs Repair Engineering Boiler Feed Pump Upgrades Startup Optimization Online registration Vibration Analysis Oil System Reliability

will begin in late April 2008

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