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Generators 911
August 11, 2010 Kathie Zipp : 1 Comment
Heres what happens, or should, when a generator must visit a service center.
areas identi ed during inspection. Machining the shaft, or bearing housings, or both are completed to the
manufacturers or customers speci cations. The windings are coated with an appropriate resin to protect against View All Events
moisture and environmental contaminants. Finally, collector rings and grounding rings, when applicable, are either
replaced or refurbished to assure good performance and provide the expected brush life. The rotor is then
dynamically balanced incrementally with all shaft mounted components. This balancing process minimizes the e ect Wind Talk Podcasts
of subsequent up-tower maintenance procedures. The rotor is then disassembled and readied for the generators nal
assembly.
Core losses are checked again after the stator or rotor is cleaned to assure that nothing has changed during the
process. The rotor or stator or both are then rewound with new insulated coils using an appropriate insulation design
for the application. Because performance requirements for the rotor and stator di er regarding mechanical and
electrical stresses, it is common to use di erent insulation. It is critical to properly inspect and test to assure the
quality and accuracy of the winding process and the coils connection scheme. Rotor leads are replaced and properly
supported, when applicable.
Rewound components are then vacuum-pressure impregnated with a resin appropriate for their respective insulations
and cured according to the resin manufacturers suggested temperature for, at a minimum, the recommend time for
the mass of the component. Photographing the entire process is crucial to understanding and managing it. Machining,
balancing, and component assembly follows the same path as reconditioned machines.
A few lessons
Obviously, there are many steps and inspection points to prepare a generator for its return to service. Thorough
documentation of the repair and proper reporting of the test results are critical to having con dence for the future.
Reliability of the generator and additional costs of proper reconditioning or remanufacturing will more than be paid
for in the extended life of the machine. It is important to use processes to assure the quality of work is superior to an
individual technicians experience. Although directing and recording these processes through a strong QMS is the
responsibility of the repair companys management, the system should be understood, supported and encouraged by
the customer. ISO 9001, KPI, CTQ checks, ow charts, and failure management systems are all critical to assure that
the work is done as designed and that the performance of the complete machine will meet or exceed expectations.
Overall the goal is this: if a generator has to be brought down-tower, it should only happen once. Do the job right and
do it right the rst time. WPE
Comments
Repair and maintenance regularly by professionals is the best option for good performance of
generators.
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