Implementing an effective turbo-generator maintenance

program ensures highest performance

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Posted: Tuesday, February 26, 2008 12:00 am
Regular and systematic maintenance of a plant's electric generator helps
maximize energy output and ensures reliability and longevity of generator's
performance
Technological advances in turbo-generator designs, and their high cost of
ownership, have generated considerable interest in advanced maintenance
techniques for achieving higher performance from electric power
generators.
Implementing an effective generator maintenanceprogram will help ensure
that the generator operates as required at all times. And, one of the most
valuable processes for the success of a generator maintenance program is
a visual inspection of the system.
Evaluating the condition of a generator, however, is a challenging task and should be performed only by an experienced engineer.
Conventional maintenance programs
Routine maintenance activities, conducted while equipment and systems
are in service, are predictable and can be scheduled, staffed, and
budgeted. Generally these activities are scheduled on a time-based, runtime-meter-base, or a number-of-operations schedule. Some examples
include visual inspections, infrared scans, cleaning, functional tests,
measurement of operating quantities, lubrication, oil tests, governor, and
excitation system alignment.
Traditionally generator maintenance has been implemented as:
Preventive maintenance - predetermined maintenance schedules - based
on experience acquired during many years of operation on equipment
reliability, as well as such factors as load demands, weather, personnel
availability, coordination with other plants of the same utility, etc. Provides
systematic inspection, detection, and condition of equipment either before
failure occurs of before they develop into major defects.

Predictive maintenance - programmed maintenance scheduling - based

primarily on statistical calculations, take into account parameters such as
mean time to failure of critical components, age of the insulation
components, type of insulation (insulation systems), load cycles, and
abnormal operation events (such as short circuits, close to the machine,
motoring due to loss of turbine power, and asynchronous operation due to
loss of excitation) helps determine the condition of in-service equipment to
predict when maintenance should be performed.
Predictive maintenance together with planned maintenance, however,
cannot determine in most cases the optimal time to inspect, maintain, and
refurbish a specific piece of equipment, in particular something as complex
as a large turbo-generator.
Condition-based maintenance program
Although planned or predictive maintenance (or both) has proved to be
adequate over many years of operation, recent trends of deregulating the
electric power industry have pushed utilities and independent power
producers to do more with less. The typical maintenance program often has
been forced into longer periods between turbine and generator inspections,
lending itself to possible lower reliability of operation, and more
catastrophic and expensive outages. As a result, the electric power sector
has generally accepted a condition-based approach that guides power
station personnel in determining when to inspect, maintain, and refurbish
the generator (and other plant equipment).
Unlike preventive and predictive maintenance, condition-based
maintenance tracks the concrete need by a component or apparatus to be
refurbished, continuously monitoring various parameters including: current,
voltage, vibration, partial discharges, stator winding vibration, air-gas gap
flux density, gas humidity, decomposition elements of insulation in the
cooling gas, water purity, temperature of core/windings/gas, etc. In addition,
periodic off-line electric tests of insulation components, visual inspection of
commutators, and dc field collectors, etc., are input to the conditionmonitoring program.
Condition-based maintenance, however, can only be applied when
equipment is monitored by a number of on-line, real-time sensors, as well
as off-line periodic testing routines. Although this type of maintenance
activity requires an initial higher capital investment in instrumentation, in the
long run it provides a more reliable and less expensive operation.
Visual inspection
Regardless of the methodology used, a visual inspection is one of the most
valuable processes in carrying out generator maintenance procedures. It

should be performed, however, only by an experienced engineer. A

qualified generator engineer-by combining a good testing program and
thorough inspection-can give a good assessment of almost all common
forms of generator deterioration.
The designated individual, however, must perform both test and inspection
on generators that are important to system reliability. And, it is imperative
that neither the testing nor the inspection is either neglected or superficially
conducted.
Inspection is done by performing a minor outage confined to the
endwinding areas. Removing the rotor and exposing the slot wedges and
core teeth will allow for a more extensive visual inspection; and the wedge
tightness can also be checked. Visual inspection, however, has its
limitations, including:
Necessity to disassemble a number of components.
Inability to see many areas, even with the best tools (including
robots).
Results are qualitative-highly dependent on operator's knowledge
and experience.
Operation is time-consuming.
In addition, each of the many required tests has one or more of several
limitations, including:
Risk - unable to find local discrete weak areas, without risking
insulation breakdown.
Results - produces only averaging results.
Sensitivity - insensitive to vital deterioration mechanisms.
Specialization - requires specialized equipment.
Hazardous - poses personnel hazard.
General inspection guidelines
Many problems will be immediately obvious to the initial glance, and can be
seen without entering the generator (such as stator winding double failure
to ground). Some locations, however, are not easily accessed (such as
under retaining rings); some forms of deterioration are very difficult to
locate (such as stator winding single failure to ground; and some problems
are difficult to assess (such as stator bar vibration).
Therefore, it is vital that the inspection be thorough, that proper tools are
used, and that conclusions as to winding conditions not be lightly or quickly
reached.
Common evidence of deterioration

Keep in mind, when performing a generator inspection, the prevalent

deterioration mechanisms that leave highly visible signs of trouble include:
dust, dirt, grease, fretting, discoloration, displacement, cracks, foreign
objects, deformation, and distortion. Also keep in mind that the evidence
may be subtle and limited, particularly in the early stages. Such evidence
may be extremely important, however, and may easily be overlooked if
proper care is not exercised while performing the inspection.
Because inspection of a generator is inherently difficult and often judgment
must be made as to the significance of evidence, it is essential that the
inspection be performed by a qualified individual with proper training and
adequate experience. For new or more complicated systems, the individual
will also need basic generator design understanding.
While inspection itself is a challenging enough task, correctly diagnosing
the root cause of more subtle failure mechanisms is even more
challenging. The latter may often require the assistance of OEM
engineering personnel or other individuals particularly qualified on
generator design by education and experience.
Equipment and tools
A cursory inspection can be made with little more than a flashlight. When
performing a complete inspection, however, other hand tools are needed,
including: borescope (flexible and rigid), background lights, large and small
flashlights, various shapes of mirrors, magnifying glass, small hammer,
knife, magnet, and still and video cameras, and adapters. Some
inspection/test operations require special equipment to be quantitatively
and expeditiously performed: wedge tapping, top ripple spring checks, and
ElCid test.
Robot equipment is also available for inspection with the field in place.
Generally such inspections will not be as good as direct inspection, but still
can be valuable and are much less costly and time consuming. Also, the
risks of disassembly/reassembly damage are greatly reduced (such as
accidental field contact with the stator during generator assembly).
Time intervals
Accessible components should be inspected at every convenient
opportunity, but particularly during minor and major outages. The frequency
of inspection should also vary based on known problems and on
importance of the machine to the system.
In addition, OEM recommendations should be considered in the planning of
outage schedules-both machine-specific recommendations and general
recommendations. In general, OEMs have recommended major inspection
with field removal every five years. The intervals, however, may logically be

extended for several varied reasons, such as satisfactory inspection

through use of robots, unit base loaded, low operating hours, particularly
reliable performance, cost constraints, and unit not of high priority.
There are several corresponding reasons for shortening the interval,
including: cyclic loading, known weakness in a component, operating
incident, mis-operation, and information of concern from the monitoring
devices. When performing generator maintenance, always follow the
manufacturer's instruction/maintenance manuals for recommendations on
generator maintenance scheduling and procedures, unless local conditions
and operations justify deviations.
And, always schedule generator overhauls based on actual operating
data, not on the manufacturer's recommendations. Take proper
precautions against accidental or unintentional starting when working on a
generator, and make sure that all disconnect switches are properly set.
Recordkeeping system
Key to a program's success is keeping the maintenance recordkeeping
system current so that a complete maintenance history of each piece of
equipment is available at all times. This is not only important for planning
and conducting an ongoing maintenance program, but it also provides
documentation needed for power O&M reviews. Regular maintenance and
emergency maintenance must be well documented as should special work
done during overhauls and replacement.
TROUBLESHOOTING TURBO-GENERATORS
Safety must be the primary concern in troubleshooting generators with
emphasis on providing maintenance personnel with first-aid training in
treating victims of electrical shock and other injuries associated with
servicing generators.
No individual should attempt to troubleshoot the plant's generator unless
they have formal training in generator theory and safety. Lacking such inhouse background, a certified service organization having trained,
experienced technicians should be contracted to perform the
troubleshooting procedures.
Generator specialist engineers have extensive knowledge, familiarity, and
experience in performing the numerous troubleshooting tasks and tests,
including:

Generator stator and field construction and proper winding support

systems

Different types of stator high-voltage insulation

Proper repair procedures for air, hydrogen, and water-cooled stator

bars

Generation field and stator winding insulation testing to determine the

condition of the electrical winding insulation
Understanding the signs of winding and support looseness
Evaluating the winding support system and core wedges for proper
tightness and where repairs are appropriate
Operation and common modes of failure and indications of excessive
electromotive forces applied to the electrical windings
Different types of stator high-voltage insulation
Proper repair procedures for air, hydrogen, and water-cooled stator
bars
Providing generation field and stator winding insulation testing to
determine the condition of the electrical winding insulation
Measuring the low resistance of the field and stator winding
Testing the pole balance of the generator field when accessible
Performing synchronizing and phasing checks to verify proper phase
rotation of the generator loads before the initial closure of the breaker
Generator protection relay and tripping schemes
Providing troubleshooting and programming functions for new multifunction electrical protection relays
Visual plant maintenance inspections
There are, however, some basic visual inspections that plant maintenance
personnel can perform before any electrical tests must be done.
Begin by looking the generator over carefully to identify any environmental
factors that might contribute to potential problems, including:
Rusted or corroded connections. Oxidized connections will prevent
the circuit from being completed. This applies not only to the major cables
externally, but also to the electronic control devices internally.
Carbon flash deposits. Check for carbon flash where the brushes
touch the rotor's slip rings. A broken spring will allow the brush to bounce
and flash.
Signs of overheating. Discoloration of the slip rings and a burnt
smell should be noticeable inside the generator. Look to see if the
windings turned black. The insulative sprays that manufacturers use to
insulate the windings may vary in color from shades of reddish brown to
light brown to dark brown, so try to compare the color to that of a new unit.

Wire insulation that is heat-hardened. Occurs when fabric and

plastic insulation hardens over time due to heat exposure and
overheating. Long-term heating should be more uniform. A short,
excessive heat cycle may have less hardening and burning at the unit's
outer perimeters and excessive heat signs toward the center or heat
source.
Loose bolts, screws, and fasteners. Will either prevent full-time
service or give intermittent service depending on the situation?
Solder joints that have cracked or broken loose. Occurs from
poor-quality workmanship.
Worn insulation allowing wires to short. Insulation deteriorates
from physical contact when wires rub together due to vibrations.
Eventually the internal wires can short to each other or to ground.
Oil or grease on slip rings. Uncommon problem, occurs when
engines start smoking or oil leaks develop.
Crossed wires. Mistakes happen, especially if someone else worked
on the generator before you.
Fuses, circuit breakers, and ground fault interrupts. Can easily
be tested with a volt-ohm-meter.
Brushes making poor contact. Occurs when springs deteriorate or
the slip rings need cleaning, and can easily be checked with an ohm
meter. There should be zero ohms resistance across the brushes. Be sure
to isolate the brushes from the controller before measuring.
Inspection and testing schedules
Because of the complicated nature of inspecting and testing a generator, a
comprehensive checklist is essential to assure important components and
areas are not overlooked. Also, an organized, consistent approach will
make comparison of results of various inspections more meaningful,
particularly if subsequent inspections are not performed by the same
individual.
According to Toshiba engineers, the maintenance schedule as shown in
Table 1 is recommended for large turbo-generators.
CHECKLIST: Visual inspection and testing
Field winding
Overall inspection for field end winding, pole to pole connector,
cooling ventilation holes, main lead, etc.
Measure impedance at decreasing number of rotations or checking of
no-load saturation properties at test-running, these are effective methods.

Retaining ring
Stress corrosion cracking
Rotor shaft and wedge non-destructive examination of rotor &
auxiliaries - every 15 years)
Bearing
Exfoliation, wrinkle or contact of metal caused by repetition of start &
stop
Vibration due to rotation or load fluctuation. Increasing vibration
caused by deterioration of insulation plate.
Clearance adjustment (visual inspection, non-destructive testing)
Seal ring
4-piece type: deterioration of spring strength - Repair and reuse
within tolerance.
2-piece type: impossible to repair after ingress of foreign material Recommendation to prepare spare seal rings.
Packing gland
Hydrogen gas leakage caused by deterioration of packing due to
thermal stress and repetition of start & stop.
Fastening bolts - every 2 years
Replacement of packing - every 15 years
High voltage bushing
Hydrogen gas leakage caused by deterioration of gasket due to
thermal stress and repetition of start & stop.
Replacement of gasket with HVB overall
Generator cooler
Water leakage caused by corrosion or erosion or stress corrosion
cracking
Inspection of tube inside by fiber-scope, inspection of tube by eddy
current examination
AC exciter
Inspections same as generator
Standard inspection,detailed inspection
Stator core
Looseness, Short circuit of lamination caused by over excitation
Tightness check, EL-CID Test
Stator winding
Looseness of stator wedge and end winding tie

Overall inspection for stator winding

Stator winding insulation for water cooled machine
Water leakage caused by galvanic corrosion at clip brazed portion
Remarkable deterioration of insulation dielectric strength level
Capacitance mapping test for water cooled stator winding
Stator winding insulation
Deterioration of insulation
Diagnostic test
Reference: EPRI Turbine Generator technology transfer program
(www.epri.com)
(BOX B)
Generator rotor visual inspection & testing
Detailed visual inspections
Signs of physical damage such as dings, dents, or rubs to any part of
rotor slot wedge migration and contact with retaining ring
Unusually large gaps between rotor end turns and retaining rings,
signs of overheating, or arc damage in the retaining rings, nose ring, or
along rotor body
Blocked ventilation ducts
Localized overheating at pole cross slotting
Loose slot wedges or end turn blocking
Migrated turn insulation
Distorted top turns
Shifted or displaced turns
Loose blocking
Torn or detached tabs
Popped out rivets
Torn or displaced slot liner extensions or slot armor
Stress corrosion cracking in the retaining rings, fans, or forging,
including rotor dovetail or tooth-top cracking
Unusual surface condition of rotor journals such as rubs, cracks, or
streaking
Coupling distress shown by wear of coupling bolts in holes, rabbit
wear, and fretting, or other signs such as dings, dents, or rubbing
Testing for Rotors
Lathe run-out tests to gather baseline data

DC field winding resistance measurements and comparisons with

previous test results to assess the mechanical and electrical integrity of
copper conductors and brazed joints
Polarization Index measurements and megger tests, and
comparisons to verify insulation resistance and condition of the windings
Pole balance and stationary impedance across windings and
between axial leads and pole crossovers to identify turn-to-turn shorts
Hardness testing of the retaining rings and fan components
Dye penetrant and magnetic particle tests on forgings, retaining rings,
and fan components
Rotor visual inspections & testing
Loose pole pieces or rim segments
Loose, cracked, or failed connectors
Damage to pole piece laminations
Signs of overheating, arcing, or other localized damage indicating
presence of turn-to-turn shorts
Fatigue cracks in the rotor shaft, spider, or rim
Distortion or warping of the field pole back iron or rotor rim face
Testing for salient pole rotors
Insulation resistance/polarization index
AC pole drop test (comparison test)
Dye penetrant and magnetic particle tests on forgings and castings
Detailed stator visual inspection & testing
Loose or damaged wedges or side fillers
Paint discoloration or cracking
Dusting, greasing, and other signs of movement of coils/bars or bus,
surge, and connection rings or their supports, including the axial support
system
Deterioration or coil/bar corona suppression system
Loose or missing axial support hardware
Broken or missing ties or blocking
Blocked vent duct passages
Damaged laminations
Oil on end turns or other signs of oil leaks
Testing for stators
Winding resistance tests to identify poorly brazed joints, or shorted or
open strands

Polarization Index measurements and megger tests and comparisons

to verify insulation resistance and condition of the stator winding ground
insulation
Tests for RTD continuity and resistance
Wedge tightness survey including wedge tapping for tightness,
compression and movement, deflection measurements of top ripple
springs, and slippage and movement of side fillers
Electromagnetic Core Imperfection Detection (EL CID) test to identify
shorted core iron laminations. In some cases a Core Loop test is used in
addition to verify results of an EL CID.
Core bolt torque check on through-bolts and building bolts
Detailed exciter visual inspection & testing
Detailed visual inspections of exciters - look for:
Bearings requiring re-babbiting or machining
Out-of-tolerance bearing clearances to the journal and shaft seals
Out-of-tolerance conditions for the permanent magnet generator air
gap and fan to shroud clearance
Sites of excessive dirt or contamination at heat sinks, field poles,
fuses, connectors, armature windings, diode wheels, collector rings, PMG,
RTDs, etc.
Deterioration of glass banding shown by fraying or axial cracks
Damaged insulation materials, including those related to the diode
wheel, coils, and heat sinks
Internal wiring that is frayed, cracked, or brittle
Damaged or worn screening
Loose, damaged, or distorted hardware and connectors, including
phase leads, pole to pole connectors, standoff insulators and washers that
have become worn or dished foreign objects that can lead to damage
such as loose shims, unattached hardware, or missing tools
Sites of inadequate electrical connections caused by dirt,
contamination, vibration, or worn hardware
Sites of moisture contamination, such as cooler leaks
Testing for exciters
Measurement of diode forward and reverse bias resistance and
voltage drop
Measurement of resistances of fuses for diodes. Results may indicate
necking down of fuse element.

Verification and comparison of capacitor charging with Fluke meter on

highest resistance scale
Verification of the operability of bearing thermocouples
Electrical tests to check for open capacitor fuses
Electrical tests on the rotating armature:
--insulation resistance/polarization index
--DC winding resistance of individual taps (comparison test)
Electrical tests on the stator field pole coils to verify winding integrity
-- insulation resistance/polarization index
-- AC pole drop test (comparison test)
Dielectric and resistance tests on the PMG