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GEK103566 - J Creating An Effective Generator Maintenance Program
GEK103566 - J Creating An Effective Generator Maintenance Program
Rev J
Released 11/14/2014
Page 1 of 12
GEK 103566
Revised, November 2014
Creating an
Effective Generator
Maintenance Program
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in
connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are
not covered sufficiently for the purchasers purposes the matter should be referred to General Electric Company. These instructions contain
proprietary information of General Electric Company, and are furnished to its customer solely to assist that customer in the installation, testing,
operation, and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of General Electric Company.
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
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GEK 103566
Rev J
Released 11/14/2014
Page 2 of 12
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
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Rev J
Released 11/14/2014
Page 3 of 12
GEK 103566
Contents
Part 1 Maintenance Outage Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Background Part 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Maintenance Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Maintenance Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. MAGIC* (Miniature Air Gap Inspection Crawler) Robot Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.
List of Tables
Table 1. Recommended Initial Maintenance Interval in Absence of Operational Experience. . . . . . . . . . . . . . . . . 5
Table 2. Recommended Stator and Core Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Table 3. Recommended Water Cooled Stator Leak Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 4. Recommended Field Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Table 5. Summary of Generator Field Inspection Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
3
without prior permission of the copyright owner.
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Rev J
Released 11/14/2014
Page 4 of 12
GEK 103566
Part 1 Maintenance
Outage Planning
1. Background Part 1
A thorough maintenance program is
recommended to retain generator reliability
and avoid major failure expenses. The three
important elements of a thorough program
are maintenance frequency, testing and
visual inspection. It is the intent of this
document to provide information on
each of these elements, which will aid the
owner/operator to establish a thorough
and cost effective maintenance program.
2. Maintenance Planning
Advanced planning for maintenance is
necessary for generator operators in order
to maintain reliability and availability.
The correct implementation of planned
maintenance and inspection provides direct
benefits in the avoidance of forced outages,
unscheduled repairs, and downtime.
The basic design and recommended
maintenance of GE heavy-duty thermal
generators are oriented toward:
Maximum periods of operation
between inspections
In-place, on-site inspection and
maintenance
Use of local trade skills to disassemble,
inspect, and re-assemble generator
mechanical components
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
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Rev J
Released 11/14/2014
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3. Maintenance Frequency
There are a number of components which
require routine maintenance or inspections
between scheduled outages. The operator
will find these recommendations in various
equipment manuals, and should also
include additional maintenance tasks as
operating experience indicates. Results
of this routine maintenance should be
retained in well-organized files readily
available for reference. These routine
maintenance records coupled with
the information from the monitored
operating data are a good indicator of
pending service or operating problems
that should be addressed at the next
scheduled outage. The monitored
information alone is usually not sufficient
for tracking or highlighting trends.
GEK 103566
Model
1st Major
Minor
Major
7FH2, 7FH2B,
6A2, 6A3, 6A6,
6FA, 7A3, 7A6,
9A3, 9A5
24,000 to 32,000
Factored Turbine
Hours or 900 to 1,250
Factored Turbine Starts
30,000 to 32,000
Turning Gear Hours
48,000 to 64,000
Actual Turbine Hours
or 1,800 to 2,400
Actual Turbine Starts
60,000 to 64,000
Turning Gear Hours
Liquid Cooled
48,000 to 64,000
Actual Turbine Hours
or 1,800 to 2,400
Actual Turbine Starts
All Other
Models
20,000 to 24,000
Factored Turbine Hours
or 750 to 900 Factored
Turbine Starts
40,000 to 48,000
Actual Turbine Hours
or 1,800 to 2,400
Actual Turbine Starts
12,000 to 15,000
Factored Turbine Hours
or 400 to 600
Factored Starts
24,000 to 30,000
Actual Turbine Hours
or 800 to 1,200
Actual Starts
Asphalt Stator
Bar Windings
for Core
Does not apply
Lengths Over
150 Inches
Note:
1
These initial recommendations assume GE approved repairs, field services, and full
compliance to GEs technical recommendations.
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
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without prior permission of the copyright owner.
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Rev J
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GEK 103566
Major
Rotor
Major
In with
LCSW Minor
Rotor
MAGIC*
Out
Robot /
RAC
AIR
HYD
Stator Winding
CE Bearing
Contamination and/or
deterioration of insulation.
Contamination and/or
deterioration of insulation.
Polarization Index
Stator Winding
Contamination and/or
deterioration of insulation.
DC Leakage Current
Stator Winding
Contamination and/or
deterioration of insulation.
Over Potential/Hipot
Stator Winding
Stator Wedges
All Visible
Components
Cleanliness, foreign
material, loose or displaced
parts, damage, wear,
corrosion, deterioration
Core Laminations
Core End
Test
Component
Inspection Objectives
and Assessment
RTD Element
Resistance
Gas and
Winding RTDs
RTD Ground
Insulation
Winding Copper
Resistance
Insulation Resistance
(aka Megger)
Wedge Tightness
Map1
Visual Inspections
Migration, cooling
passage blockage
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GE Proprietary Information - Class II (Internal) US EAR - NLR
Rev J
Released 11/14/2014
Page 7 of 12
GEK 103566
Major
Rotor
Major
In with
LCSW Minor
Rotor
MAGIC*
Out
Robot /
RAC
AIR
HYD
Stator Wedges,
Top and Side
Ripple Springs
Evidence of abrasion
or looseness
Stator Bars
End Winding
Support System
Overheating,
hardware looseness
Frame
Corrosion, cracks,
blocked ventilation
Corrosion, cracks,
worn parts, burning
Coolers
Partial Discharge
Analysis
Stator Winding
Insulation
Localized deterioration
Water Flow
Verification
Water Cooled
Stator Winding
Magnetic Scalar
Potential (EL CID)
Dynamic Frequency
Response
Potentially damaging
resonance.
Test
Component
Inspection Objectives
and Assessment
Visual Inspections
Optional Tests
Note: For inner gas cooled stator bars use the hydrogen column.
1
This test does not apply to units with asphalt stator windings or units with the camelback wedge system.
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
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without prior permission of the copyright owner.
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Rev J
Released 11/14/2014
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GEK 103566
Stator
Orig SLMS,
Bagged Vent, or
No Monitoring
SLMS HP
Installed
Test
Minor
Major
Vacuum Decay
Pressure Decay
Capacitance Mapping
Electrical Testing
Minor
Minor
Major
Major
SLMS HP
Installed
Minor
Major
These tests are required to detect hydrogen leaks in water cooled stator windings only and should be performed in conjunction with the recommended tests
in Table 1
HYD
Major
Rotor
In with
LCSW Minor
MAGIC*
Robot /
RAC
Major
Rotor
Out
Test
Component
Winding Copper
Resistance
Field Winding
Polarization Index
Field Winding
Contamination and/or
deterioration of insulation.
Field Inter-Turn
Insulation
Turn shorts
Incremental Winding
Copper Resistance
All Visible
Components
Field Surface
Body Weights
Looseness, staking
Visual Inspection
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
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Rev J
Released 11/14/2014
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GEK 103566
Field
AIR
HYD
Major
Rotor
In with
LCSW Minor
MAGIC*
Robot /
RAC
Major
Rotor
Out
Component
Body Wedges
Retaining Rings
Fans
Cracks
Spindles
Cracks
Winding
Collectors
Journals
Over Potential/Hipot
Field Winding
Chevron Seals
Test
Visual Inspection
Optional Tests
The preferred method for shorted turn testing is the flux probe. Another method is AC Impedance testing.
4. Testing
5. Visual Inspection
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without prior permission of the copyright owner.
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Rev J
Released 11/14/2014
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GEK 103566
6. MAGIC* Robot
Inspection
GEs MAGIC* (miniature air gap inspection
crawler) robots provide a thorough visual
inspection of the stator and field using
the robots on-board high-resolution
video cameras. Additionally, it is capable
of providing quantitative wedge tightness
and Electromagnetic Core Imperfection
Detection (ELCID) assessments. Coupled
with the Remote Access Camera (RAC),
the MAGIC* robot inspection can provide
a comprehensive stator and field
inspection. The customer may utilize
the MAGIC* robot to perform the
recommended inspection tasks that
normally require the removal of the rotor.
As a result, the customer may substitute
a MAGIC* robot inspection for a major
inspection providing the major inspection
tasks outlined in Tables 2, 3, and 4, that
dont require the removal of the rotor, are
performed during the outage as well.
In order to use a MAGIC* robot, the
generator must meet the following
minimum radial entrance gap dimensions:
MAGIC* (Senior)
MAGIC* (Junior)
Retaining ring to
core minimum
radial gap 1.13
inches [28.7 mm]
Retaining ring to
core minimum
radial gap 0.5
inches [12.7 mm]
Field to core
minimum radial
gap of 2.0 inches
[50.8 mm]
Field to core
minimum radial
gap 0.75 inches
[19.05 mm]
10
Bored Rotors
Outage
Type
Ultrasonic
Volumetric
Maintenance
Notes 1
and 2
Note 3
Maintenance Note 1
Rewind
Notes 1
and 2
Note 4
Rewind
Note 1
Note 4
Note 3
Note:
[1] Ultrasonic volumetric testing includes boresonic tests (bored rotors only), axial UT
and periphery UT tests. The recommendations for subsequent re-inspections will
be made on the basis of the test results and associated structural integrity, with a
2000 start-stops or 20 year (whichever occurs first) re-inspect interval being the
maximum. If the rotor has not been inspected within the last 20 years or the rotor
has operated higher than the re-inspect interval, then the rotor should be inspected
at the earliest opportunity.
[2] Magnetic particle testing of the rotor bore surface (bored rotor only) should be
performed concurrent with ultrasonic volumetric testing.
[3] The turbine end of the generator field from the coupling face to the fan ring should
also receive a magnetic particle inspection concurrent with ultrasonic volumetric
testing. Extreme caution should be exercised during magnetic particle testing to
prevent foreign particles from entering the field windings.
[4] During full rewinds, perform mag particle testing of all accessible surfaces including
axial and circumferential magnetization.
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GE Proprietary Information - Class II (Internal) US EAR - NLR
Rev J
Released 11/14/2014
Page 11 of 12
GEK 103566
Part 2 Other
Maintenance
Considerations
8. Other Maintenance
Considerations Part 2
Part 1 includes general guidance and
recommendations in connection with
generator maintenance. As technology is
continually evolving, additional methods
that aid the owner/operator in maintaining
generator reliability at lower lifecycle costs
become available. Non-invasive inspection,
monitoring, and diagnostic technologies
are a few recent examples.
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
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without prior permission of the copyright owner.
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Rev J
Released 11/14/2014
Page 12 of 12
Imagination at work
2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GE Proprietary Information - Class II (Internal) US EAR - NLR