Turbogenerator Stator Windings Support System. Experience-Cigre

A1
Rotating
Rotating electrical
machines
electrical
Turbogenerator stator windings

windings
supportt system
suppor system experience
Re󰁦erence:
Re󰁦erence: 772
77 2
July 2019

TB 77
772 Turbogenerator stator winding s supp ort system experience
2 - Turbogenerator

Turbogenerator stator
windings support system
experience
WG A1.37
Members
A. VILLARRUBIA, Convenor SP S. RODRIGUEZ, Secretary SP

M. GENNARI BR G. STONE CA
A.
J. TLETAL
TRAULT
TRAULT CA R. TRE
TREMB
MBLAY
LAY
J. WEIDNER CA
DE
B. O’SULLIVAN EI R. MANNINEN FI
A. OLDRATI IT M. KRIEG-WEZELENBURG NL
Y. YAMAMOTO JP Y. KIKUICHI JP
T. MUTOH JP H. NAKAMURA JP
B. ADAMS UK O. MARTINEZ SP
W. MOORE US J. STEIN US
J. EDMONDS US K. STEIGLEDER CH
N.W. SMIT ZA
Copyright © 2019
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accuracy or exhaustiveness
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law”.
ISBN : 978-2-85873-474-0

Turbogenerator
TB 772 - T experience
urbogenerator stator wi ndings support system experience
ISBN : 978-2-85873-474-0
4

Turbogenerator
Executi
Executi ve sum
summary
mary
Loss of mechanical integrity of stator windings resulting in amplified vibration, both in the endwinding as
well as in the slot area, has been a major concern on large turbine-generator deterioration in the past
two decades. The capability of these support systems has changed significantly with time and each
manufacturer has adopted different
diff erent design options. However, today this is not a solved issue and there
still remain signs of loss of mechanical integrity which can lead to a failure of machines in service.
This Technical Brochure summarizes the results and conclusions extracted from a survey focusing on
air, hydrogen and water cooled turbo-generators, with the goal to investigate experiences of turbo-
generator stator windings support systems both in the endwinding and slot area including:
Design
▪
▪ Winding support integrity evaluation techniques during commissioning, operation and

maintenance
▪ On-line Monitoring
▪ Detected problems during normal operation or during abnormal conditions
▪ Root Cause Analysis (later RCA)
▪ Repairs
▪ Upgrades or Design modifications
The expected reliability and integrity of generators in service rely on the design and performance of the
support systems to ensure mechanical integrity of the stator winding, both in the endwinding and slot
area. These systems are some of the most critical components causing generator unavailability and
increased forced outage rates because the mechanical insulation wear (abrasion) and the “time to
failure” of this degradation mechanism are generally qui
quicker
cker than uniquely electrically related ones. In
addition, endwinding vibration can sometimes lead to fatigue cracking of the copper conductors.
Normal winding vibration due to electromagnetic forces can cause severe damage due to insulation
wear if support systems have been improperly designed, installed or maintained, even more so if natural
frequencies of the windings are near multiples of the grid frequency
fr equency resulting in amplified vibration levels,
a condition known as resonance.
In addition, to ensure the mechanical integrity of the winding, these support systems
s ystems should be designed
with a commitment to allow normal expansion and compression of the winding due to temperature
change during the operation and start/stop periods,
p eriods, as well as mitigate the overstress due to short circuit
circu it
currents, etc.
These two conditions lead to different technical solutions for implementing these systems and, together
with quality of manufacturing, lead to different problems after some time in operation. Eventually these
systems may require repairs and the implementation of technical improvements or modifications of the
original design.
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Contents
Executive summary ............................................................................................................................... 5
1. Technic al backgr oun d: Stator w ind ing m echanic al stres s in s ervic e ...
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1.1 Introduction .............................................................................................................................................. 11
1.2 Mechani cal str ess in the slo t sect ion .......
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2. Surv ey - Met ho do lo

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2.1 Methodology ............................................................................................................................................ 13
2.2 Anall ysi s an d d is sc
Ana scus
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2.3 Stru ctu re of the ques tio nnai res............
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2.4 Respon ses to the ques ti onn aire .......
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3. Af fec ted gen erat or s .................................................................................................................. 15

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3.1 Introduction .............................................................................................................................................. 15
3.2 Questionnaire –
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3.3 Summar y of qu esti onn aire answ ers ......
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3.3.1 .......................................................... .............................................. 17
Summary of affected generators ........................................................................................................
3.3.2 Cooling system summary ...................................................................................................................
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3.3.3 Answer summary of direct water cooled generators .......................................................................... 19
3.3.4 Answer summary of H2 direct cooled generators .............................................................................. 19
3.3.5 H2 indirect cooled generators ............................................................................................................ 20
3.3.6 Indirect Air Cooled Generators .......................................................................................................... 20
3.4 General Conclusions ............................................................................................................................... 20
4. Endw in
indi
di ng su
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pp or
ortt sys tem
temss .....
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4.1 Questionn aire section descrip tio n for endwin ding suppo rt systems ......
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4.1.1 Endwinding design survey ................................................................................................................. 23
4.1.2 Failure location and oil influence survey: ........................................................................................... 31
4.1.3 Detection and testing techniques: ...................................................................................................... 32
4.1.4 Root cause analyses ................................................................................................................... ....... 37
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4.1.5 Survey on actions taken to repair degraded end windings .......................................................... ....... 38
windi ngs.................................................................
4.1.6 Endwinding monitoring systems ........................................................................................................ 42
4.2 Summar y o f endw ind in g secti on answ ers ............

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4.3 Endw ind in g sup por t syst ems con clu sio ns ....
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4.3.1 Introduction ........................................................................................................................................ 46
4.3.2 Design.......................................................................................................... ...................................... 46
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4.3.3 Location and oil influence .................................................................................................................. 47
4.3.4 Detection and testing techniques ....................................................................................................... 47
4.3.5 Root Cause Analysis ................................................................................................................... ....... 47
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4.3.6 Action Taken ...................................................................................................................................... 47
4.3.7 Endwinding Vibration monitoring systems ......................................................................................... 47
5. Slot area su pp

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5.1.1 Design.......................................................................................................... ...................................... 49
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5.1.2 ........................................................ ................................... 54
Location of degradation and oil influence ...........................................................................................
5.1.4 Root cause analysis ........................................................................................................................... 60
5.1.5
5.1.6 Action
Bar taken .......................................................................................................................................
Vibration monitoring systems ...................................................................................................... 62 64
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5.2 Summar y of slo t area sect ion answ ers .......

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5.3 Slot area sup por t syst ems con clu sio ns ..........
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5.3.1 Introduction ........................................................................................................................................ 68
5.3.2 Design.......................................................................................................... ...................................... 69
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5.3.3 Location and oil influence .................................................................................................................. 69
5.3.5 Root cause analysis ........................................................................................................................... 69
5.3.6 Action taken ....................................................................................................................................... 69
5.3.7 Bar Vibration monitoring systems ...................................................................................................... 69

6. Final conclusions ..................................................................................................................... 71
71
APPENDIX
APP ENDIX A. Def in it io ns , abr evi ati on s & sy mb ol s ......................................................................... 73
A.1. Gener
General
al t erms ............................................................................................................... ............................ 73
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A.2. Specific terms .......................................................................................................................................... 73
73
APPENDIX
APP ENDIX B. L in ks & Ref eren ces .....................................................................................................
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APPENDIX
APP ENDIX C.TB Spec if ic Ap pen di x .................................................................................................. 77
C.1. Affec
Af fec ted gen erat or s an sw ers c har t .............................................................................................. 77
swers
C.2. Enwinding answers chart ....................................................................................................................... 85
85
C.3. Slot area answers chart ........................................................................................................................ 105
Figures and Illustrations

Figure 4-1 Endwinding Support Components (Extracted from from EPRI 1021774 Stator Endwinding Vibration Guide)
(Courtesy of EPRI) ................................................................................................................................................ 24
Figure 4-2 Siemens Rigi-FlexTM Stator Stator Endwinding Design for Indirect Cooled Cooled Generators (Courtesy of
SIEMENS) ............................................................................................................................................................. 25
Figure 4-3 Endwinding Design of a Direct Water Cooled Stator Winding for 4-pole Generator of 1640 MVA, MVA, 27 kV
(Courtesy of SIEMENS) ............................................................................................................. ............................ 26
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Figure 4-4 Stator Endwinding Design at Connection End of an Indirect Air-cooled Air-cooled Generator in Global Vacuum
....................................................... ................................... 26
Pressure Impregnation (GVPI) Technology (Siemens) ..........................................................................................
Figure 4-5 Overview of AlstomAlstom’s ’s winding head designs (Courtesy of ALSTOM) ALSTOM) .................................................. 27
Figure 4-6 Turbo Generator Endwinding Support Systems (Courtesy of Ansaldo (Italy)) ..................................... 27
Figure 4-7 Endwinding support system for air cooled and hydrogen cooled turbogenerator turbogenerator from 320 to 650 MVA

(Courtesy
Figure 4-8ofWater
Ansaldo))Cooled ...............................................................................................................
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Turbo Generator Support System .....................................................................................
description. (Courtesy of National............................
Electric
Electric Coil (USA)) 28
.............................................................................................................................................................................. 28
Figure 4-9 (a to h) - 359MVA Generator 17kV H2 C ooled Stator winding (Courtesy of ESB (Ireland)) ........ 29
H 2 / H20 Cooled
Figure 4-10 Fig. 9 - 320 MVA, 20kV, H2/H20 Cooling (courtesy of ESB ESB (Ireland)) ............................................... 30
Figure 4-11 Hydrogen Cooled Turbo Generator EW Support System (Courtesy of Iberdrola (Spain)) ................. 30
Figure 4-12 Connection Rings Blocks and Ties Ties (Courtesy or Iberdrola (Spain)) .................................................. 30
........................................................ ......................... 33
Figure 4-13 Bump Test (Courtesy of National Electric Coil) .................................................................................
Figure 4-14 Phase Lead Fatigue and Failure. (Courtesy of National Electric Coil (USA) ..................................... 34
Figure 4-15 Phase lug and strand package cracked. (Courtesy of National Electric Coil (USA) (USA) .......................... 34
Figure 4-16 Water Cooled Turbo Generator Broken Series loop for fatigue (Courtesy Of Iberdrola (Spain)) ....... 34
Figure 4-17 Endwinding Dusting. (Courtesy (Courtesy of National Electric Coil (USA)......................................................... 35
Figure 4-18 Hydrogen Cooled Connection Rings Dusting. (Courtesy of Iberdrola (Spain) ................................... 35
Figure 4-19 170MVA, 11kV, Air Air cooled. Fretting dust on ties and support structure (Courtesy of ESB (Ireland). (Ireland). 35
Figure 4-20 170MVA, 11kV, Air cooled. Loose bolt at support support bracket, metallic dust in endwinding (Courtesy of
ESB (Ireland) ......................................................................................................................................................... 36
Figure 4-21 Endwinding Greasing. (Courtesy of National Electric Coil (USA) ...................................................... 36
Figure 4-22 Hydrogen Cooled. Endwinding Greasing Greasing at bars exits to connection rings. rings. (Courtesy of Iberdrola

(Spain)) ..................................................................................................................................................................
Figure 4-23 Brackets and support rings for small machines (Courtesy of National Electric Coil). ........................ 36 39
Figure 4-24 Coils Bracing (Courtesy (Courtesy of National Electric Coil).............................................................................. 39
Electric Coil)..............................................................................
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Turbogenerator
Figure 4-25 New and repositioned blocks and ties in Connection rings (Courtesy of Iberdrola (Spain)) ............... 40
Figure 4-26 Binding Bands Impregnation with Epoxy Resin (Courtesy of Iberdrola (Spain)) ................................. 40
Figure 4-27 Ties over original tying at connection rings (Courtesy of Iberdrola Iberdrola (Spain)) ...................................... 40
Figure 4-28 Loose Ties and dusting at connection rings (Courtesy of Iberdrola (Spain)) (Spain)) ..................................... 40
Figure 4-29 Insulation wear for improper tying system (dry ties). Loose blocks / broken broken ties. (Courtesy of
Iberdrola (Spain))................................................................................................................ ................................... 41
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Figure 4-30 Complete new blocks and ties system (wet ties) at connection rings. Block located in different
positions (Courtesy of Iberdrola (Spain)) ............................................................................................................... 41
Figure 4-31 Endwinding Vibration Coupler at Hydrogen Cooled Generator (Courtesy of Iberdrola (Spain)) (Spain)) ........ 43
Figure 5-1 Slot cross section for indirectly cooled turbogenerators (air or hydrogen cooled) from 100 to 650 MVA
(Courtesy of Ansaldo) ............................................................................................................................................ 51
Figure 5-2 Typical Slot Contents (Extracted from EPRI 1021774 1021774 Stator Endwinding Vibration Guide) (Courtesy of
EPRI) ..................................................................................................................................................................... 51
Figure 5-3 Fillers at the bottom of the slot ..................................................... ....... 52
s lot (Courtesy of Iberdrola (Spain)) ............................................................
Figure 5-4 Bottom bars and side ripple springs (Courtesy of Iberdrola Iberdrola (Spain)) ................................................... 52
Figure 5-5 Bottom bars and between bars filler (Courtesy of Iberdrola Iberdrola (Spain)) ................................................... 52
Figure 5-6 Between bars filler and fillers between top bar and wedges wedges (Courtesy of Iberdrola (Spain)) .............. 53
Figure 5-7 Top and side ripple springs (Courtesy of Iberdrola (Spain)) ......................................................... ....... 53
(Spain)) ................................................................
Figure 5-8 Turbogenerator wedge installation (Courtesy of Iberdrola (Spain)) ..................................................... 53
Figure 5-9 Red Dust/Greasing in the Slot for Wedge Vibration Vibration (Courtesy of Iberdrola (Spain) ........................... 55
Figure 5-10 Greasing at Slot exit. (Courtesy of Iberdrola (Spain)) ...................................................... .................. 55
(Spain)) ........................................................................
Figure 5-11 Greasing at slot bottom. (Courtesy of Iberdrola (Spain)) ................................................. .................. 56
(Spain)) ...................................................................
Figure 5-12 Bar abrasion against Side Ripple Spring (SRS). (Courtesy of Iberdrola (Spain) ............................... 56
Figure 5-13 Bar abrasion against core. (Courtesy of Iberdrola ........................................................ ....... 57
Iberdrola (Spain)) ...............................................................
Figure 5-14 Bottom Bar abrasion at the slot bottom (Courtesy of Iberdrola (Spain). ..................................... 57
Figure 5-15 Wedge Tightness Test using a Durometer Durometer (Courtesy of Iberdrola (Spain))...................................... 59
Figure 5-16 Rewedging (Courtesy of Iberdrola (Spain)). ....................................................................................... 63
Figure 5-17 Rewedging (Courtesy of Iberdrola (Spain)). ....................................................................................... 63
Figure 5-18 Stronger wedges at the core ends (Courtesy of Iberdrola (Spain)). .................................................. 63
Figure 5-19 Thicker and taller top ripple spring (Courtesy of Iberdrola Iberdrola (Spain)). .................................................. 63
Figure 5-20 SRS Installation (Courtesy of Iberdrola (Spain).................................................................................
........................................................ ......................... 64
Figure 5-21 SRS Design modification (Courtesy .......................................................... ....... 64
(Courtesy of Iberdrola (Spain)) .................................................................
Tables
Table 2-1 Answers Distribution......................................................................................................................
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....... 14
Table 3-1 Affected Generators
Generators Answers Summary .............................................................................................. 17 17
Table 3-2 Cooling Systems Answers Summary................................................................................................... 19
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Table 3-3 Direct Water Cooling Systems Answers Summary............................................................................... 19
................................................... ............................ 19
Table 3-4 H2 Direct Cooling Systems Answers Summary.................................................................................... 19
........................................................... ......................... 19
Table 3-5 H2 Indirect Cooling Systems Answers Summary Summary ................................................................................. 20 20
Table 3-6 Indirect Air Cooling
Cooling Systems Answers Summary..................................................................................
Summary......................................................... ......................... 20 20
Table 3-7 General Conclusions Summary
Summary ............................................................................................................ 20
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Table 4-1 Endwinding Answers Summary ............................................................................................................ 44
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Table 4-2 Cooling Systems Answers Summary.................................................................................................... 46
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Table 4-3 End Winding Support Systems
Systems Answers Summary .............................................................................. 46
.................................................. ............................ 46
Table 5-1 Slot Area Answers Summary ................................................................................................................ 66
........................................................ ........................................................ 66
Table 5-2 Cooling Systems Answers Summary Summary....................................................................................................
...................................................... .............................................. 68
Table 5-3 Slot Area Conclusions Summary .......................................................................................................... 68
.................................................. ........................................................ 68
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Turbogenerator
1. Technical backgro und : Sta

Stator
tor windi ng mechanical
mechanical
stress in service
1.1 Introduction
Electrical rotating machine stator windings are subjected to strong electromagnetic forces resulting in
vibration. These magnetic forces are the result of the magnetic fields from current flowing in the stator
bars. This magnetic field interaction makes coils and bars vibrate radially at twice power frequency.
There is also a twice power frequency force in the tangential direction caused by the rotor’s magnetic
field which interacts with current in the stator bars.
Forces are proportional to the square of the current. Higher currents or stronger fields yield higher forces.
Recent improvements in the cooling systems permit increased power output of the generators and
therefore an increase in the electromagnetic forces on the stator windings. Support systems should be
designed to control these forces and limit winding vibration both in the end windings and slots.
This vibration will gradually increase as the stator windings support system becomes loose or in
r esonant
esonant conditions (stator winding “tuned” close to turning speed or twice power frequencies). Also, an
abnormal current rise caused by events such as short circuits, can dramatically loosen the support
system increasing the vibration levels.
Also, stator windings are subjected to mechanical duty due to the unequal thermal expansion between
copper, insulation, support materials and iron.
In this section, basic information about the mechanical stress in both the end windings and slot section
will be introduced. More detailed information about different support system designs, the degradation
mechanism and root causes, detection techniques and possible solutions will be discussed in the
following sections.
1.2
1.2 Me
Mechanical
chanical stress in the slot section
Stator bars in the slot are subjected to large electromagnetic forces during normal operation, which are
proportional to the current resulting from the interaction of the stator current and rotating magnetic field.
These forces are at twice power frequency
frequenc y and mainly in the radial direction. Also, endwinding
end winding vibration
can be transmitted to the bars at the slot ends.
Therefore, the radial support system in the slot section depends on the current flowing in the bars and
therefore the expected forces in the slot, both in normal
nor mal operation conditions and in the case of a sudden
short circuit or fault condition, where the force depend on the load condition prior to the fault, the fault
type (3 phase, ground, etc.), the sub-transient reactance values and the saturation effects on the
adjacent core tooth.
The force in the top bar is three times that of the bottom bar in slots with bars of the same phase. If the
twothe
on bars in a slot
bottom barbelong to theofsame
is the sum phase,
the top the force
and bottom barisforces,
towardi.e.
the4bottom of the
times the slot so the total
electromagnetic forceIf
force.
the two bars belong to different phases, the force has an upward component towards the slot wedge.
Also, there are thermal duties which can lead to a degradation mechanism related to the bar axial
thermal expansion and the different thermal coefficients of the materials involved. The support system
should be designed to permit it to thermal cycle and avoid damaging the bar surface coating and
eventually the ground insulation.
1.3
1.3 Me
Mechanical
chanical stress in the endwindi ng
The endwinding configuration is a condition of the machine rated voltage and is made in such a way to
allow the connections between the bars to have sufficient dielectric integrity, both to ground and between
bet ween
phases. Therefore, higher voltage machines will need longer end windings and larger distances.
The support system should be designed to support not only the end windings weight, but also the
electromagnetic forces due to the interaction of the individual bar current
curren t with the electromagnetic fields
resulting from the current in other bars as well as the currents in the rotor windings. These forces are
mainly at twice power frequency in the radial and tangential directions. During normal operation,
11

Turbogenerator
endwinding forces are lower than in the slot (approximately one third to one half). However, during
abnormal conditions such as short circuit faults, the forces are proportional to the square of the current
which can become dangerous and lead to a fault if the windings are not properly supported.
On the other hand, since support systems for end windings are principally weaker than the support of a
bar in a slot, end windings the are more prone to vibration problems.
In the same way than in the slot section, the endwinding support system must fulfil thermal axial
expansion and contraction forces of the stator bars during load changes. Phase and serial connections
as well as connection rings, are also subjected to thermal expansion.
Other issues of concern regarding endwinding support systems are resonance at critical frequencies
(rotor turning speed or twice power frequency) and high voltage can be present.
The endwinding support system design should be able to withstand cyclic electromagnetic forces at
normal conditions, manage possible short circuit currents and, at the same
sam e time, flexible enough to allow
thermal expansion of the different components.
End winding vibrations can result in fatigue cracking of the insulation, strand copper conductors or serial
connections. Relative movement between bars, connection rings, ties or blocks can lead to abrasion of
the components increasing the problem.
Another difference with slot support systems is that endwinding vibration can be acceptable if small and
controlled, while small relative movement between slot components can lead to a dielectric failure in a
shorter period of time.
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Turbogenerator
2. Survey - Methodol
Methodol ogy and descriptio
descri ptio n
2.1 Methodology
In 2012 CIGRE´s Technical Committee approved the Terms of Reference (TOR)
(T OR) for the Working Group
W inding Supports Systems Experiences”.
A1.37 “Turbo Generators Stator Winding
The goal of the working group was to develop a questionnaire to investigate the experiences with turbo-
turbo -
generator stator winding support systems, both in the endwinding and slot area. An appendix was also
included with a picture collection from members about failures, repairs and tests to better illustrate the
questionnaire. Two drawings were from the EPRI Generator Stator Endwinding
En dwinding Vibration Guide: Tutorial
(1021774 Final Report, August 2011).
This Technical Brochure contains the results of this questionnaire. It is not the intent of the present TB
to describe in depth technically the phenomena or the root causes of this degradation mechanism. The
aim of this TB is to summarize and extract conclusions from the survey that WG A1.37 has carried out
in the Electricity Generation Industry
Industry over the past years.
2.
2.2
2 Analysis and diss cuss ion
Final revision of the WG A1.37 Questionnaire was sent to all WG members in October 2014 for final
comments. It was sent to all SCA1 members
m embers and experts and the distribution for survey answers was in
January 2015. Additional answers were required.
Responses received before the SCA1 Meeting in Paris 2016 were evaluated and conclusions presented
by the WG Convener during this meeting. After this meeting, it was considered that, as in any survey,
the conclusions were influenced by several factors including the number of answers, number of
generators covered, not all the OEMs expressed their point of view, etc., however, the general opinion
of this WG and SCA1 is that the presented conclusions generalize industry reality and therefore, this
Technical Brochure should be developed.
2.3
2.3 Structur e of the questionn aires
The questionnaire was divided into three sections:
 Affected Generator
 Endwinding
 Slot Section
The first section, Affected Generator, intended to identify the main generator characteristics as well as
characterize the detected problems: e.g. a fleet problem was detected in other generators of the same
OEM and design. Locations of issues detected: endwinding / slot or both and if they could be related.
Also, machine operational conditions were surveyed: where these problems were detected for the first
time and what
root cause was the
analysis wasimpact in the availability of the machine. At the end of this section, a possible
requested.
After this general description and characterization of the detected problems, the questionnaire was
divided into sections which were filled out depending on the location of the problems: endwinding or slot
section.
These two sections have the same structure. First, the main design characteristics were identified as
well as the affected areas involved in the loss of mechanical integrity. Then, further Visual Inspection
and other techniques used to detect or confirm that mechanical integrity was lost. Finally, the
questionnaire asked for the possible influence of oil presence as well as if the machine had failed due
to these issues, whether in service or during a voltage withstand (Hi Pot) test. At the
t he end of both sections,
information related corrective actions such as repairs, design modification, or monitoring systems
installation were also requested.
The analysis of the Survey in this technical brochure is structured in a similar way.
13

Turbogenerator
2.4
2.4 Re
Respon
spon ses to the questionn aire
A questionnaire was prepared and distributed to the international experts through Working Group
members and SCA1 experts, regular and observer members. The following responses were received:
 30 Answers received (11 Countries)
o 26 of Utilities
o 4 of manufacturers).

Information received concerns generator types manufactured by 10 OEM’s.
Answer Distribution for Countries and activity:
Table
Table 2-1
2-1 Answers distribution
Country An sw ers Ac ti vi ty
S ain 3 U
Uttilit
South Africa 3 Utility
Germany 1 Manufacturer
Italy 1 Manufacturer
Brazil 1 Utility
Egypt 1 Utility
Netherlands 13 Utility/Rep
Romania 1 Manufacturer
Croatia 1 Manufacturer
Thailand 2 Utility
Ireland 3 Utility
After analysing the 30 answers received, 18 generator groups were defined in order to evaluate the
results. These 18 Generator groups are defined with the following conditions:
▪ Same OEM
▪ Same Cooling System
▪ Same model or similar technical data: Operational voltage, power range, manufacturing years
These three characteristics will define the generator group in the following tables. Further, similar
generator groups of different manufacturers have been analysed for general conclusions of generator
type. A generator type is intended to be a combination of generator groups with the following similar
characteristics:
▪ Same Cooling System
▪ Same or similar technical data: Operational voltage, power range, manufacturing year
▪ Similar basic support systems characteristics
14

Turbogenerator
3. Affected generators
3.1 Introduction
Symptoms of loss of mechanical integrity in the stator winding support systems have been detected in
different characteristics of generators and were not exclusive to one manufacturer, technology or size
of generator. Therefore, this survey was focused in the range of turbo-generators actually operating in
power stations.
Main technical aspects such as manufacturer, year, power
po wer output or cooling system as well as operating
hours and conditions were taken into account to define which machines were more prone to particular
degradation mechanisms. The first section of the questionnaire defines the area of mechanical integrity
loss, endwinding or slot section for further analysis, if both areas were affected, and any relationship
between these issues.
Conversely, the other aim of this questionnaire in this area was to define the possible characteristic of
the problem and try to identify if the detected problems in an individual machine were common in other
machines of a specific design fleet.
Last, the operational conditions and impact of this loss of mechanical integrity was evaluated.
3.2 Questionnaire –
Questionnaire – Affected
Affected generator
generator section
Af fec ted Gener ato r
Generator Data:
Manufacturer
Power output (MVA)
Rated Voltage (kV)
Rated Current (A)
Power Factor
Speed (rpm)
Nº of Poles:
Frequency (Hz):
Manufacturing Year:
Operating Time (hours):
Global VPI:
Indirect air cooled
Stator Indirect H2 cooled
windings Direct H2 cooled
cooling type:
Direct water
cooled
1.1 Is it a fleet problem? Same or similar type/model of generators shows similar problems.
- Yes - No
15

Turbogenerator
1.2 How many similar generators show these symptoms?

Nº of affected units:
1.3 Where have you detected loss of mechanical integrity of the stator winding support
systems?
- Endwinding (Section 2) - Slot section (Section 3).
If both areas are involved, is there any connection between both problems?
- No - Yes.
Description:__________________________________________________________
1.4 When have you detected the symptoms?:
- After __________years and __________hours of operation.
- After event.
Description:________________________________________________________________.
- After Repair. __________years and __________hours of operation after repair.
- After Rewind. _________ years and __________hours of operation after Rewind.
- Others. Description:____________________________________________
1.5 Operation conditions:
- Base operation.
- Load Cycling. Nº Starts / week: _____________.
1.6 Operation impact of mechanical integrity loss of the stator winding support system.
- No impact.
- Restricted output. Description:____________________________________________
- Forced outage. Duration _______________days/weeks.
- Scheduled Outage extension. ___________days/weeks more.
- Other. Description:____________________________________________
1.7 Character of the problem: Do you consider this symptom
As an expected normal wear and tear of the generator operation
As an excessive problem due to some factor (like design, abnormal operation, unexpected
event, or other)
As unexpected in this generator type and design
16

Turbogenerator
3.3
3.3 Summary of question naire answers
3.3.1
3.3.1 Summary of affect
affected
ed generator s
Table 3-1 Affected generators answers summary (next page)
17

Turbogenerator
Nº
OEM Mod. Cooling Fl e e t ? Pro
rob
bl em
em? Re
Rell ate
ated
d? Chara
ract
cter
er When
en?
? Oper
era
ati
tio
on Imp
Impact
Afected
45-
EW Problem due to
198MW Indirect After Forced
NO 4 YES/NO design, abnormal Base Load
Air event Outage
1982- operation, event,.
EW-Slot
2001
MNF A
300/700
Direct No No No
MW 7 - No Problems Base Load -
water Problems Problems problems
1978-95
530MW H2 No No No
2 - No Problems - -
2008 Indirect Problems Problems problems
300-375 Problem due to 1-2 years

MW H2 Base/load Scheduled
Yes 10 EW-Slot YES design, abnormal and 1000
Indirect cycling Outage
2005- operation, event,. hours
extension.
2007
350-475 Problem due to 1-2 years Scheduled

H2 Base/load
MW Yes 6 EW-Slot NO design, abnormal and 1000 Outage
MNF B Indirect cycling
operation, event,. hours extension.
2002-06
11 years
Problem due to
50MW Indirect and
No 1 EW-Slot NO design, abnormal Base
Base Lo
Load
ad No Im
Impa
pact
ct
Air 72264
operation, event,.
2004 hours
575MW Direct No No No
1 - No Problems Base Load -
1967 water Problems Problems problems
170- 5 years
Scheduled
Indirect and Base/load
YES 50 -1 00 EW - Outage
1995 Air 50000- cycling
extension
100000
5-10
Forced/
MNF C 800MW As unexpected in years and Scheduled
Direct H2 YES 6 EW-Slot YES this generator type 50000- Load cycling
Outage
and design 100000
extension
90’s hours
300-
No No No
800MW Direct H2 3 - No Problems - -
Problems Problems Problems
70’s
445MW Problem due to 5 years
H2 Forced
MNF D No 1 Slot - design, abnormal and 4 Base Load
2007 Indirect Outage
operation, event months
3 years
300MW Problem due to Scheduled
Indirect and
No 1 EW - design, abnormal Load Cycling Outage
Air 23000
MNF E 2006 operation, event extension
hours
375Mw Direct Expected
Expecte d normal
No 1 EW-Slot NO
1975 water wear of the operation

Indirect
MNF F No 1 Slot - design, abnormal and 8303 Load Cyclin
Cycling
g No Impact
Impact
2012 Air
operation, event hours
25 years
388MW Problem due to Scheduled
Direct and
MNF G Yes 7 EW - design, abnormal Base Load Outage
Water 110000
1980 operation, event extension
hours
50-
Indirect No No No
MNF H 150MW 5 - No Problems - -
Air Problems Problems Problems
1986-94
Various
665MW
Direct Expected
Expecte d normal water Forced
MNF I YES 2 EW - Base Load
Water wear of the operation leaks Outage
1974
over years
18-25
770MW Scheduled
Direct Expected normal
Expected years and
MNF J YES 2 EW - Load Cycling Outage
Water wear of the operation 95000-
1976 extension
15000
18

Turbogenerator
3.3.
3.3.2
2 Cooling system summary
Table 3-2 Cooling systems answers summary
OEM Mod. Cooling Location Direct Water Direct H2 Inirect H2 A ir

EW 3 /6 0/ 2 0/4 2/ 6
18 Grups:
Air 6/18
Same Slot 0 /6 0/ 2 1 /4 1/ 6
H2 indirect 4/18
All affected MNF
H2 Direct 2/18 Both 1 /6 1/ 2 2 /4 2/ 6
Same
Directt Water 6/1 8
Direc
model No
2 /6 1/ 2 1 /4 1/ 6
problems
3.3.
3.3.3
3 Answer summary of direct water
water cooled gene
generators
rators
Table 3-3 Direct water cool ing systems answers summary
Nº
rob
ble
lem
m? Re
Rela
late
ted
d? Chara
ract
cter
er When
en?
? Oper
era
ati
tio
on Imp
Impact
Afected
300/700
MW Direct No No No
MNF A 7 - No Problems Base Load -
water Problems Problems problems
1978-95
575MW No
Direct No No problems
MNF B 1 - No Problems Base Load -
1967 water Problems Problems after
340000
375Mw
MNF E No 1 EW-Slot NO
1975 water wear of the operation
25 years
Problem due to Scheduled
Direct and
MNF G 388MW Yes 7 EW - design, abnormal Base Load Outage
Water 110000
operation, event extension
hours
Various
665MW Direct Expected normal water Forced
MNF I YES 2 EW - Base Load
Water wear of the operation leaks Outage
1974 over years
770MW 18-25
years and Scheduled
MNF J YES 2 EW - 95000- Load Cycling Outage
1976 Water wear of the operation
15000 extension
hours
3.3.
3.3.4
4 Answer summary of H2
H2 direct cooled generators
generators
Table 3-4 H2 Direct Cooling Systems Answers Summary
Nº
rob
ble
lem
m? Re
Rela
late
ted
d? Chara
ract
cter
er When
en?
? Oper
era
ati
tio
on Imp
Impact
Afected
5-10
Forced/
As unexpected in years and
800MW Scheduled
Direct H2 YES 6 EW-Slot YES this generator type 50000- Load cycling
90's Outage
and design 100000
extension
MNF C hours
300-800 No No No
Direct H2 3 - No Problems - -
MW Problems Problems Problems
19

Turbogenerator
3.3.5
3.3.5 H2 ind irect coo led generator s
Table 3-5 H2 Indirect cool ing systems answers summary
Nº
OEM Mod. Cooling Fleet?
Fl Pr
Pro
obl
blem
em?
? Re
Rela
late
ted?
d? Cha
Chara
ract
cter
er When
When?
? Opera
Operati
tion
on Impact
Impact
Afected
530MW H2 No No No
MNF A 2 - No Problems - -
2008 Indirect Problems Problems problems
300-375 MW Problem due to 1-2 years Scheduled

H2 Base/load
Yes 10 EW-Slot YES design, abnormal and 1000 Outage
Indirect cycling
2005-2007 operation, event,. hours extension.
MNF B
Problem due to 1-2 years Scheduled
350-475 MW H2 Base/load
Yes 6 EW-Slot NO design, abnormal and 1000 Outage
2002-2006 Indirect cycling
operation, event,. hours extension.

H2 Forced
MNF D No 1 Slot - design, abnormal and 4 Base Load
2007 Indirect Outage
operation, event months
3.3.6
3.3.6 Indir ect Air Cooled Gene
Generato
rato rs
Table 3-6 Indirect air coolin g systems answers
answers summary
Nº
OEM Mod. Cooling Fleet?
Fl Pr
Pro
oble
lem
m? Re
Rela
late
ted
d? Cha
Chara
ract
cter
er When
en?
? Oper
Opera
ati
tio
on Imp
Impact
Afected
45-198MW EW Problem due to
Indirect After Forced
MNF A NO 4 YES/NO design, abnormal Base Load
1982-2001 Air EW-Slot event Outage
operation, event,.
50MW 11 years
Problem due to
Indirect and
MNF B No 1 EW-Slot NO design, abnormal Base Load No Impact
2004 Air 72264
operation, event,.
hours
170-300MW 5 years
and Scheduled
Indirect Base/load
MNF C YES 50-100 EW - 50000- Outage
1995 Air cycling
100000 extension
hours
300MW 3 years
Problem due to Scheduled
Indirect and
MNF E No 1 EW - design, abnormal Load Cycling Outage
2006 Air 23000
operation, event extension
hours
Indirect
MNF F No 1 Slot - design, abnormal and 8303 Load Cyclin
Cyclingg No Impact
Impact
2012 Air
operation, event hours
50-150MW Indirect No No No
MNF H 5 - No Problems - -
1986-94 Air Problems Problems Problems
3.4
3.4 Ge
General
neral Concl
Conclusi
usi ons
Table 3-7 Gene
General
ral conclusi ons summary
OEM Mod. Cooling Fleet? Problem?

Pr Related? Character When? Operation Impact
Air 6/18 EW 5/18 Design, operation, event 7/18 5 years or less 7/18
18 Grups: Yes 7/18 YES 2/18 Base load 7/18 Forced Outage 4/18
All H2 indirect 4/18 EW-Slot 5/18 Unexpected in type and design 1/18 About than 10 years 2/18
Same MNF No 6/18 NO 3/18 Base/Load Cycling 3/18 Outage Extensión 7/18
affected H2 Direct 2/18 Slot 2/18 Expected normal wear 3/18 More than 10 years 2/18
Same model No issue 5/18 No Data 12/18 Load Cycling 4/18 No Impact 1/18
Direct Water 6/18 No issue 6/18 No issue 6/18 No issue 6/18
20

Turbogenerator
Almost all main OEMs were represented in the survey and, in some ways, show problems in the
mechanical integrity of the stator windings.
In the documented machines, most of the problems were in the end winding region or in both areas (end
windings and slot section) and were not necessarily related to each other.
Regarding the cooling system, Direct Water cooling generators, which were all in base load operation,
did not show problems or the wear which may have appeared at the end of service life was considered
normal regarding the type of operation.
Smaller generators in this survey (air or indirect H2) were more prone to winding vibration problems.
There is an indication that, the correlation of smaller generators with air or indirect H2 cooling systems
documented in this survey,
thermal conductivity hassystems,
insulation nowadays the exception
allowing of genarators
for the generator powermanufactured
capability to with
be inthe
thenew
samhigh
same
e or
higher range than some water cooled generators included in this survey. These new units include
different support systems than older ones which should be analysed in the future.
Machines built in the late 1990’s and early 2000’s which show that mechanical integrity was lost in the
first years of operation (1 to 5 years), were considered fleet problems common to a specific design. In
most cases this was also related to cycled operation. These generators were mainly H2 indirect cooled
generators installed in Combined Cycle plants, which were designed for and operated at beginning of
their service life in a base condition and, due to the financial crisis and a greater presence of renewable
sources, were moved to a cycling operation mode.
The characteristic of the problem was normally considered as excessive due to some factor, e.g. design,
abnormal operation, unexpected event, or other. In the following
f ollowing specific problem sections, it is analysed
with more detail.
Except in some cases, when the problem didn’t result in a forced outage, these problem
problemss were detected
through visual inspection during scheduled outages and the impact in the operation
oper ation was covered during
that or following the scheduled outage with some extension.
It is also noticeable that, in most
m ost cases and especially in the end windings issues, the loss of mechanical
m echanical
integrity was not solved after the first repair and was instead an issue that needed to be inspected in
following outages resulting in new, and in most of the cases, more extensive repairs.
21

Turbogenerator
22

Turbogenerator
4. Endwin ding su pport systems

4.1
4.1 Que
Question
stion naire section descript ion for endwindi ng suppor t syst ems
After the ‘Affected Generator’ section, the questionnaire was divided in two sections with the same
structure. The first section was related to Endwinding issues.
4.1.
4.1.1
1 Endwinding design
design survey
Endwinding support system design. (Mark all which are present in your generator).
- Rigid structure (with massive rings to support the winding and resist motion)
- Flexible structure(a lighter structure that builds strength into the interconnections between the
stator bars)
- Support structure re-tightable or de-coupled. (Allow to correct the loosening of endwinding or to
be de-coupled by the adoption of insulating bolts, springs, etc).
Support Brackets.
 Attached to: - Core. - Frame.
Interface to allow axial thermal expansion between brackets and the rest of the support system.
- Mechanical Mobile or sliding systems.
- Sliding layer in between.
- Other. Description:________________________________________________.
- Supports Braces.
- Supports Rings.
- Outer Diameter. - Inner Diameter.
- Blocking between top and bottom baskets.
- Rings. - Blocks.
Conforming materials:
- Impregnated Felts. - Flexible Tubes.
- Blocking of phase connections.
- Blocking between adjacent winding bars.
- By pairs. - Whole Basket.
Tying System.
- Wet ties. - Dry ties. - Other. :_______________________________________.
- Connection rings supports.
- Dedicated supports attached to core/frame. - Using or attached to basket supports.
- Endwinding blocks or rings close to the slot exist.
- Blocks or rings at bar ends series connections.
- Bar ends series connections support attached to frame/core.
- Bushing/Phase leads supports.
- Bushing/Phase leads flexibility systems.
- Other.
Description:_____________________________________________________________
23

Turbogenerator
The endwinding support system depends on the OEM design and the vibration response was related to
the current through the bars and associated forces in the slot, both in normal operation and in the case
of a sudden short circuit or fault conditions. During normal operation, endwinding forces vary sinusoidal
at twice power frequency.
The bars and endwinding support system shape and dimensions should meet electrical, mechanical
and dimensional criteria:
▪ Electrical Clearances related to line voltage as well as to pass high voltage withstand tests.
▪ Mechanical clearances: bar to bar distance, series loop distances, support components for
connection rings.
▪ Maintain the endwinding basket’s axial length as short as possible.
Endwinding design has the challenge to withstand cyclic electromagnetic forces during normal
conditions, manage possible short circuit currents and, at the same time, be flexible enough to allow
thermal expansion of the different components. Furthermore, two or four pole turbo-generators, due to
long end windings, are likely to have resonant frequencies
f requencies close to the frequency of the magnetic forces
which must be avoided.
In the questionnaire, the main design characteristics were identified. Two
T wo options about the basic design
fundamentals were indicated:
▪ Rigid structure (with massive rings to support the winding and resist motion).
▪ Flexible structure (a lighter structure that builds strength into the interconnections between the
stator bars).
This section also required users to identify if the support could be re-tightened or de-coupled, allowing
to correct for loosening of the endwinding
etc. en dwinding or to be de-coupled by the adoption of insulating bolts, springs,
Different design options to allow axial thermal expansion of the stator bars between the brackets and
the rest of the support system were included for OEM’s: mechanical mobi le or sliding systems, sliding
layer in between, or others were requested in the questionnaire.
Also, the different components included in the support structure were covered in the questionnaire:
braces, brackets, radial support rings, binding bands, blocking systems between bars or on the phase
connections, blocks or rings at slot exits or in the series connections, etc.
Figure 4-
4-1
1 Endwind ing sup port com ponent s (Extracted
(Extracted from EPRI
EPRI 102
102177
1774
4 Stator Endwindi ng Vibratio n
Guide) (Courtesy o f EPRI)
EPRI)
24

Turbogenerator
4.1.
4.1.1.
1.1
1 Ma
Main
in suppo rt struc ture compo nents
Supports braces and brackets: Depending on the design, support brackets can be attached to the
frame or the core. Support braces can be fixed to the support brackets.
Brackets restrict circumferential and radial movement but allow axial movement. Different design options
to allow axial thermal expansion of the stator bars between brackets and the rest of the support system
were implemented by the OEM’s: Mechanical Mobile or sliding sy stems, Sliding layer in between or
others.
Connection rings support system could include dedicated supports attached to the core frame or using
the same supports for the rest of the basket depending on the design.
Radial rings and Binding bands: fiberglass, polyester, or insulated steel hoops which encircle and
support the bar legs prevent radial movement. Radial rings can be located over support braces. Binding
bands fit around the outer surface of the bottom bars. Over the rings and binding bands, resin
impregnated felt fills the gap and bonds the bars to the rings. Bars can be lashed to the rings. The
number and size of these rings depends on the expected short-circuit forces as well as if there are many
starts or stops expected (cycled operation).
Blocks: In the endwinding legs composite (hardwood in the past) blocks space bars from each other
and provide a load path to help control transverse short-circuit forces. Blocks can be located between
bars at each binding band or radial ring location. Also, blocks can be installed between
bet ween connection rings.
Ties: Bar legs or end arms can be tied to binding bands by glass cords (cotton in older ones). Also,
connection rings can be tied to their supports. There were two main tying systems:
▪ Dry Ties: Impregnation resin (normally epoxy) injected after fiber filament or cord lashing.
▪ Wet ties: Fibre glass cords previously impregnated with resin and then tied.
The tying system solution, dry ties or wet ties, was also identified in this section of the questionnaire.
Finally, it was also considered in this section if the phase/bushing leads include supports or some other
system to allow flexibility.
4.1.1.
4.1.1.2
2 Images and diagrams of several OEM’s support systems
Figure 4-2 Siemens Rigi

Rigi -Fle
-FlexTM
xTM Stator Endwind ing Design for Indi rect Cooled Generators
Generators (Courtesy of
SIEMENS)
25

Turbogenerator
Figure 4-3 Endwind ing Design o f a Direct Water

Water Cooled Stator Windin g for 4-pol e Generator
Generator of 1640 MV
MVA,
A,
27 kV (Courtesy of SIEMENS)
Figure 4-4 Stator Endwindi ng Design

Design at Connection End of an Indirect Air -cooled Generator
Generator in Global
Vacuum Pressure Impregnati on (GVPI)
(GVPI) Technolog y (Siemens)
(Siemens)
26

Turbogenerator
Figure 4-5 Overview of Alstom’s winding head designs (Courtesy of ALSTOM)

ALSTOM)
Figure 4-6
4-6 Turbo Generator Endwi
Endwi ndin g Support Systems (Courtesy
(Courtesy of Ansaldo (Italy))
27

Turbogenerator
Figure 4-7
4-7 Endwinding support system for air cooled and hydrogen cooled turbo genera
generator
tor from 320 to
650 MVA
MVA (Court
(Court esy of Ansaldo ))
Figure 4-8 Wate

Waterr Cooled Turbo Generator
Generator Suppor t System descri
descri pti on. (Court
(Court esy of Nation
Nation al Electri
Electri c Coil
(USA))
a) Wa
Water
ter cooled endwinding
endwinding showing suppo rt b) Sta
Stator
tor endwinding wi th water cooling (support
structure with water cooled circular phase structure of surge rings and axial braces)
rings
28

Turbogenerator
c) Tangential packing bl ocks (with hairli ne

Tangential d) Endwinding support structure tightening
cracking) mechanism
e) Endwinding fixed support to the stator f) Inner support rings and bracing.
housing
g) Wa
Water
ter cooled endwinding
endwinding showing suppo rt h) Sta
Stator
tor endwinding wi th water cooling (support
structure with water cooled circular phase structure of surge rings and axial braces)
rings
Figure 4-9 (a to h) - 359MVA
359MVA Generator 17kV H2 / H20
H20 Cooled Stator w indi ng (Courtesy of ESB (Ireland))
(Ireland))
29

Turbogenerator
Water cooled endwinding showing support

Water Inner ring bracing and axial struts
struts
structure
structure
Figu re 4-10 Fig. 9 - 320 MVA, 20kV, H2/H20
H2/H20 Cool in g (cour tesy of ESB (Ireland ))
Figure 4-11
4-11 Hydrogen Cooled Turbo Generator EW Support System (Courtesy of Iberdro la (Spain))
(Spain))
Figure 4-12
4-12 Connectio n Rings Blocks and Ties (Court
(Court esy or Iberdr ola (Spain))
(Spain))
30

Turbogenerator
4.1.
4.1.2
2 Fa
Failur
ilur e location and oil influ ence survey
Indicate areas
areas where you have detected
detected vibration / los s of mechanical int egrity
symptoms/evidence in the endwinding (Mark all in your generator).
- Endwinding legs ties to support rings.
- Dusting. - Greasing. - Broken ties. - Abraded Insulation.
- Support Brackets.
- Supports Braces.
- Connection rings blocks and ties.

- Dusting. - Greasing. - Broken ties. - Abraded Insulation.
- Connection rings supports.
- Series loops (bar to bar) connections.
- Dusting. - Greasing. - Broken copper strands. - Broken connection.
Type of bar-to-bar connection:
Strand-to-strand Solid copper connector
- Blocking of Phase leads to connection rings.
- Dusting. - Greasing.
- Insulation and/or copper strand cracks or damage just at the slots exits.
- Phase drops. Bushing leads to connection rings.
- Loose or lost connection. - Broken copper strands.
- Broken Stand-off insulators.
- Cooling tubes.
- Fatigue of cooling tubes. - Leakages.
- Water nozzles.
- Cracked bar connections. - Water Leaks.
- Other. Description:____________________________________________________________.
Inadequate mechanical integrity of the endwinding support system leads to excessive vibration, mainly
in radial and tangential directions.
Two possible problems can be detected: general vibration or local resonances. General vibrations can
be linked to poor tying system or poor application of tying and the risk of failure is normally low, at least
in the short term. Local resonances are more dangerous and the risk of failure is relatively higher.
The first sign of endwinding vibration issues is the appearance of dusting or greasing (if oil was present
at the end windings surface). This dust can be formed
f ormed by the abrasion of the coils surface and ties/blocks
of the support system, when there is a relative movement between them. Fiber glass cords used for
tying bars is hard enough to easily abrade bar insulation.
When oil is present, this dust can become a paste known as greasing and accumulates in the vibration
areas. If this relative movement is not contained, broken ties and abraded insulation can appear.
Cracks in the bars surface varnish or even ground insulation cracks can be the result of excessive
endwinding vibration. An area of concern is at core ends where the bars are tightly held and pivot.
The connection rings at the collector end is an area where signs of vibration usually
us ually appear, with dusting
/ greasing in the blocks and ties that become
becom e loose allowing for higher vibration amplitudes abrading the
insulation. Fortunately, in this area the insulation is relatively thicker and the possibility of a dielectric
failure is much less than at the bar legs.
31

Turbogenerator
Series or phase connections fatigue cracks or broken copper strands can also appear as a result of
endwinding vibrations.
In water cooled machines, this vibration can fatigue crack brazed bar to bar connections or water
nozzles, allowing for water leaks.
The signs of this vibration behaviour are manifested in visual inspections. The main areas of the
endwinding support systems were listed in the questionnaire, in order for OEMs / users to identify where
vibration / loss of mechanical integrity symptoms / evidence have been detected. Also, details of the
nature of the evidence or systems detected were marked: dusting, greasing, broken ties, abraded
insulation, broken copper strands or connections, etc.
The unusual presence

and criticality. of oil at the
This is because the winding
presencesurface
of oil isand
notitsnecessarily
level was requested to evaluate
the root causee valuate
of thesethe influence
issues, but
could have a “catalyst effect”.
Have you detected unusual oil presence over the winding surface?
- No
- Yes.
Level: - Low. - Medium. - High.
4.1.
4.1.3
3 De
Detection
tection and testing techniques
This sectionintegrity
mechanical surveyedis further
lost. Visual Inspection and other techniques used to detect or confirm if the
Further Visual Inspection, Have
Have you detected or confirm ed endwi
endwi nding m echanical
integrity lost by other technique?
- Endwinding vibration monitoring system.
Maximum Displacement or acceleration (peak to peak):________________m/s 2 or g.
Direction: - Radial. - Tangential. - Axial.
- Bump Test.
- Power Natural Frequency (50/60Hz). - Twice Power Natural Frequency (100/120 Hz).
- Established margin to take into account test limitations (temperature, response non-
linearity, etc.).
Description:___________________________.
Water Cooled: - Filled with water. - Empty
- Base line test after manufacturing. Any differences?
Description:______________________________.
Does this experience of yours reinforce the necessity of base line test after manufacturing for
fingerprint?
Yes No
- Partial Discharges Tests.
- Other.
Description:________________________________________________________________.
If an endwinding vibration monitoring system was installed, the maximum displacement (peak to peak)
or acceleration (peak) and the direction (Radial, Tangential or Axial) measured during machine
operation
peak is valuable
to peak information
(2 or 3 mils and acould
peak to peak) way be
to characterize these defects.
considered acceptable. Magnitudes
However, of 50 todepend
these criteria 70 µm
32

Turbogenerator
strongly on the design, so the analysis of the results should be based on trend analysis rather than a
direct application of pass / fail criteria.
As was introduced in preceding sections, the main concern with endwinding support systems was
avoiding resonances with turning speed or twice power frequencies. In order to ensure that natural
frequencies of the endwinding were far enough away from these critical bands, bump testing was
normally carried out after a machine rewind or a significant support system modification. During this test,
different locations (serial connections, phase exits, connection rings) were excited with the impact of a
calibrated hammer and the resulting natural frequencies were recorded.
Bump Test results were also reported in the questionnaire, indicating if the detected natural frequencies
were near turning speed frequency or twice power frequency as well as if the temperature effect of doing
a bump test at room temperature was taken into account.
The modal stiffness may change depending on the temperature of the stator end-winding
endwinding structure (IEC
TS 60034-32:2016). Also, if the stator end-winding support structure is is not design to allow for thermal
flexibility, such thermal stress might lead to an initial loosening that can develop furtherbe with age (IEC
TS 600034-32:2016). Natural frequencies reduce as temperature increases and become lower with age.
A normal exclusion band could be 10 to 20 Hz over twice power frequency.
Differences with a base line test after manufacturing

manuf acturing (if available) and the convenience of this test during
commissioning was also surveyed.
In water cooled machines, hydrogen content in cooling water could also be a symptom of broken
br oken strands
due to advanced vibrations.
Other electrical test results such as partial discharges or the ability of the winding to withstand a Hi- Pot
test could be affected by an stator winding with ground insulation abrasion. Partial Discharge may be
effective when
severe, just thetoconsequences
prior failure. of endwinding vibration (abraded insulation or cracked strands) are
Has
Has generator experienced a fault in service or HI Pot
Pot failure for thi s endwind ing pro blem?
- No
- Yes.
- In Service. - Hi Pot.
4-13
Figure 4-13 Bump Test (Courtesy
(Courtesy of National Electric Coil)
33

Turbogenerator
Following images show several endwinding support system faults and visual evidence:
Figure 4-14 Phase Lead

Lead Fatigue and Failur
Failur e. (Courtesy
(Courtesy of Nation al Electric Coil (USA)
Figure 4-15 Phase lug and str and package cracked. (Courtesy of National Electric Coil (USA)
Figure 4-16
4-16 Wate
Waterr Cooled Turbo Generator Broken Series loop for f atigue (Courtesy Of Iberdro
Iberdro la (Spain))
(Spain))
34

Turbogenerator
Figure 4-17
4-17 Endwind ing Dustin g. (Courtesy
(Courtesy of Nation
Nation al Electri
Electri c Coil
Coil (USA)
(USA)
Figure 4-18
4-18 Hydrogen Cooled Conn
Conn ection Rings Dusting . (Courtesy of Iberdro
Iberdro la (Spain)
(Spain)
Figure 4-19
4-19 170
170MVA,
MVA, 11kV, Air coo led. Fretti
Fretti ng dust on ti es and
and suppo rt stru cture (C
(Court
ourt esy of ESB
ESB
(Ireland)
35

Turbogenerator
Figure 4-20
4-20 170
170MVA,
MVA, 11kV, Air cool ed. Loose bolt at support br acket, metallic
metallic du st in endwin ding
(Courtesy of ESB (Ireland)
Figure 4-21
4-21 Endwind ing Greasing. (Court
(Court esy of Nation
Nation al Electri
Electri c Coil (USA)
(USA)
Figure 4-22
4-22 Hy
Hydrogen
drogen Cooled. Endwinding
Endwinding Gre
Greasing
asing at bars exits to con nection rings.
(Courtesy of Iberdrola (Spain))
36

Turbogenerator
4.1.4
4.1.4 Root cause analyses
Cause. (Mark all hypotheses for your generator).
Possible Root Cause.
- Design.
- Assembly / workmanship.
- Improper Application.
- Unusual operation conditions.
- Poor maintenance.
- Normal winding ageing / tying relaxation regarding age/running hours.
- Other.
Description:________________________________________________________________.
Detailed description of the possible root cause:
Has
Has thi s RCA bee
been
n agreed with t he generator
generator m anufacturer?
- No
- Yes.
Various options for possible Root Causes were listed in the questionnaire. A detailed description of the
possible root cause could be included as well as information if this RCA has been agreed with the
manufacturer. Manufacturer participation in this analysis is very valuable due to the knowledge of the
design parameters related to electromagnetic stresses in each area of the basket and support system.
Design
Regarding design, the root cause is normally related to the magnetic forces calculation and the proper
design of the support systems not taking into account all possible factors that could lead to bar vibration
and consequences, such as bar insulation abrasion or fatigue cracking of strands or connections.
An important design factor that can lead to vibration
vibrat ion issues is the natural frequencies influencing rotating
speed or twice power frequencies resulting in a resonance
reso nance condition. Grid frequency must be taken into
account during design, for example resonance can be an issue on machines designed for 50 Hz and
not properly modified for 60 Hz operation.
Sometimes repetitive axial thermal expansion due to cycled operation was not considered in the
machine design.
Other design points of concern were the number of blocking rows at connection rings as well as the
tying system or blocking solution which can be a root cause for relative movement between these
components.
As sembl
sem bl y / w or km ans hi p i ss ues
Assembly or workmanship issues identified were a non-uniform distribution of the blocking system in
the basket and improper resin injection in dry ties solutions.
Other possible root cause were:
▪ Not considering the different thermal coefficients of the endwinding components during curing
process. This could lead to cracks in the bonding between ties and bars and further vibration
issues.
▪ Ties or blocks not properly tightened, improper bar dimensional control or axial positioning
could leave different gaps between bars and the blocking can become loose.
Operating Conditions
Unusual operating conditions could also be a root cause or at least an added factor for these issues:
37

Turbogenerator
▪ Cycled operation, related to the expansion / contraction process due to temperature changes
causing relative movement between components with different thermal coefficients.
▪ Withstand sudden short circuit currents, out-of-phase synchronization, etc. causing excessive
magnetic forces that break lashing ties and allow blocking to become loose.
▪ High thermal loads or lack of sufficient cooling causing insulation shrinkage and ties to come
loose.
Ag ein g / M
Main
ain ten anc e
Normal insulation ageing and support system relaxation, which could be normal for significant running
hours, could lead to endwinding vibration issues which could be solved or reduced with proper
maintenance or repairs including:
▪ Shrinkage of thermal aged insulation can loosen the bars sufficiently enough to vibrate. This
problem can also appear during the first year of operation in new machines due to a post-
manufacturing insulation curing process once the machine is in service.
▪ The presence of oil can affect some materials used for support elements. Conversely the
presence of oil could also have a catalytic effect, making the relative movement between
components easier and result in abrasion.
▪ The support system can also be affected by thermal shrinkage as well as oil contamination,
gradually becoming loose over time.
4.1.
4.1.5
5 Survey on actions taken to repair
repair degraded
degraded end
end windin gs
After the root cause of the endwinding mechanical integrity loss was identified several actions or repairs
r epairs
can be taken to retrieve reliable conditions for continuous operation of the generator.
Ac ti on t aken:
aken :
- Generator Replacement.
- Rewind.
- Partial rewind. - Full rewind.
- Repairs.
- Flooding loose ties with epoxy resin.
- Re-tying over old ties.
- Ties replacement. Tying system has been modified from____________ to ___________.
- Insulation local repairs.
- Re-tightening throw the provided system.
- Other. Description:________________________________________________________
- Endwinding support system design modification:
- Introduce new block/ties/support rings or modification of its position.
- Introduce new or add elements in endwinding radial support system.
- Introduce mobile or sliding systems to allow axial thermal expansion.
- Introduce Endwinding wedging or support rings close to the slot exist.
- Introduce wedging or support rings at bar ends series connections.
- Other. Description:________________________________________________________
In most cases minor repairs can re-establish the condition of the support system, however it has been
found to be very likely that these are not permanent, especially the repairs carried out on the original
ties, e.g. flooding with resin or re-tying over original ties.
38

Turbogenerator
Depending on the extent of the signs detected during inspections, as well as the success of previous
repairs, original ties and blocks can be replaced
replace d with new ones, often with wet tying systems. Installation
of additional blocks and bracing can also be installed to improve support performance, however thermal
cooling should be taken into account, especially in indirect cooled machines causing cooling gas (air or
H2) flow reduction.
When resonances are detected, changes in the endwinding structure will be needed to “detune” these
frequencies sufficiently away from rotor turning speed and twice power frequencies.
If axial thermal expansion of the bars becomes an issue, modification of current layout or installation of
a new sliding systems to allow this expansion can be introduced.
Slot exits or series connections can be strengthened with wedging or support rings.
Local insulation repairs can also be required if the ties have abraded the ground insulation. Normally
this is not a big issue in connection rings, however the effect on the ground insulation of the bars should
be analysed thoroughly.
Depending on the importance of the defects, particularly if the machine has suffered a fault (in service
or during a HI Pot test), the extension and scope of the repair or action taken could be as much as a
partial or full rewind. In these situations, a detailed evaluation of the root cause of the mechanism is
necessary in order to make the necessary modifications in the design of the support systems in the
endwinding area, especially identifying if there are any resonances with the rotor turning speed
frequency (50/60Hz for 2-pole machines) or Twice Power Natural Frequency (100/120 Hz). Also sub-
synchronous harmonics vibration may show up, especially in 4 pole machines. In the same way, after
any design modification, a bump test should be done to confirm that new natural frequencies are far
enough from these critical frequencies.
The following images show several endwinding support systems repair options:
Figure 4-23
4-23 Bracke
Brackets
ts and support ring s for small Figure 4-24
4-24 Coils Bracing (Court
(Court esy of Natio
Natio nal
machines (Courtesy of National Electric Coil). Electric Coil).
39

Turbogenerator
Figure 4-25 New and repositioned blocks and ties in Figure 4-26
4-26 Binding Bands Impregnation
Impregnation w ith Epoxy
Connection rings (Courtesy of Iberdrola (Spain)) Resin (Courtesy of Iberdrola (Spain))
Figure 4-27
4-27 Ties over origi nal tying at connectio n rings (Courtesy of Iberdro
Iberdro la (Spain))
(Spain))
Figure 4-28
4-28 Loos e Ties and
and dusti ng at connectio n rings (Courtesy of Iberdro
Iberdro la (Spain))
(Spain))
40

Turbogenerator
Figure 4-29
4-29 Insulation wear for improper t ying system (dry ties). Loose blocks / broken ties.
(Courtesy of Iberdrola (Spain)
Figure 4-30 Complete new blocks and ties system (wet ties) at connection rings.
Block l ocated in diff ere
erent
nt po sitions (C
(Courtesy
ourtesy of Iberdrola (Spain))
(Spain))
41

Turbogenerator
4.1.
4.1.6
6 Endwinding monit oring systems
Endwinding monitoring system installation is one of the most common industry responses to these
issues, both for new generators and for ones already in service.
Endwinding monitoring system:

system:
Technology:
Conventional vibration sensors Optical vibration measurement system
Monitored frequency:
- Wide range of frequencies. - Only twice power frequency.
Monitored Direction:
- Radial. - Tangential. - Axial.
Monitored Parameters:
- Displacement. - Velocity. - Acceleration.
Nº of sensors on each generator end: __________. Additional information:
Core vibration monitoring:
- No - Yes.
Have you set alarm level?
- No - Yes. Level (peak to peak/rms): ______________m/s 2 or g.
Have you set trip level?
Trip/Alarm levels established by:
- OEM. - Monitoring system supplier. - Generator owner/operator experiences.
Additional
information:___________________________________________________________________.
Endwinding Vibration Monitoring is the only way to get real information about the vibration behaviour
while a machine is in service, and therefore, when all the possible parameters that give effect to these
mechanisms are in force.
Endwinding vibration depend on the generator design, so installation during manufacturing and trending
levels throughout the operational life of the generator is the most advantageous strategy. However,
there is still
outage, even benefit
whenofthe
installing
rotor is this technology after the machine is in service during a regular scheduled
in place.
Modern sensors such as fiber optic accelerometers can be glued with special resins to the winding
surface. Sensors can be installed on both sides of the generator, monitoring the vibration behaviour in
a wide range of frequencies in axial, radial
ra dial and tangential direction. The number of sensors depends on
the machine design as well as if the sensors can measure in one or two axes.
The vibration level is typically highest at the bar ends and mainly in the radial direction. Therefore the
“global vibration level” is usually determined by the measurement of the radial deflection at the stator
bar ends”. [IEC TS 60034-32:2016].
The monitored parameter (displacement, velocity or acceleration) depends on the system manufacturer.
Trending analysis of the vibration behaviour of a specific machine or design as well as the correlation
with findings during visual inspections, allows for establishing alarm levels.
42

Turbogenerator
Figure 4-31
4-31 Endwind ing Vibratio n Coupler at Hydrog
Hydrog en Cool
Cool ed Generator
Generator (Court
(Court esy of Iberdro
Iberdro la (Spain))
(Spain))
43

Turbogenerator
4.2
4.2 Summary of endwindin g section answers
answers
Table 4-1 Endwind ing Answers Summary
Summary
OEM Mod. Cooling Problem? Design Where? Oil? Detectio n Fault?
45 -19 8MW EW Legs ties to rings

Rigid/Flexible YES (1/4
Indirect Connection Rings
Axial exp: Mech/slide YES / Low VI / Bump Test uds) In
Air Bracket/Braces
Wet/Dry ties Service
1982 -20 01 EW-Slot Series Loops
MNF A
300-700MW Direct No
- - - - -
water Problems
1978-95
530MW
H2 No
- - - - -
2008 Indirect Problems
300-375MW Flexible Legs ties to rings YES (1/10

H2
EW-Slot Axial Exp: Flex Connection Rings YES / Low-Med VI uds) Hi
Indirect
2005-2007 Dry/wet Ties Bracket/Braces Pot
350-475MW Rigid Legs ties to rings

H2
EW-Slot Axial exp: Mech/slide Connection Rings YES / Low-Med VI NO
Indirect
Wet ties Bracket/Braces
MNF B 2002-06
50MW
Legs ties to rings
Indirect Rigid
EW-Slot Connection Rings YES / Low VI / Bump Test NO
2004 Air Dry ties
Bracket/Braces
575MW
Rigid
Direct No
1967 water Problems Axial exp: Mech/slide No Problem s NO No Problem s NO
Wet ties
Flexible Legs ties to rings

170-300MW Indirect VI / Bump Test
EW Axial Exp: Flex Bracket/Braces NO NO
1995 Air EW Monitoring
Dry/wet Ties Block leds to CR
Rigid / re-tightable Legs ties to rings
800M W Direct H2 EW-Slot Other: Gap Bracket/Braces YES /N
/NO / Lo
Low VI / Bu
Bu mp
mp Te
Tes t
MNF C NO
Wet ties Block leads to CR
90’s
300-800 No
Direct H2 - No Problem s - - NO
MW 70's Problems
Rigid Legs ties to rings

445MW H2 VI / Bump Test
MNF D Slot Axial Exp: Mech Bracket/Braces NO NO
2007 Indirect EW Monitoring
Dry Ties Block leds to CR
Re-Tightable
300MW Indirect Axial Exp: Deform. Loosen blocks VI / Bump Test
EW NO NO
2006 Air Plate Springs between EW bars EW Monitoring
MNF E Wet Ties
Rigid
375MW Direct
EW-Slot Axial Exp: Mech YES / low VI / Bump Test NO
1975 water
Wet Ties
205MW Indirect
MNF F Slot Rigid No Problem as NO Bum p Test NO
2012 Air
Legs ties to rings

Rigid
388MW Direct Series loops
MNF G EW Axial Exp: Mech NO VI NO
1980 Water Braces
Wet Ties
Block leds to CR
50-150MW Indirect No
MNF H - No Problem s - - NO
1986-94 Air Problems
Legs ties to rings

665MW Direct Rigid/Re-Tightable
MNF I EW Braces NO VI / Bump Test NO
1974 Water Wet Ties
Leaks at tubes
770MW Direct Rigid Legs ties to rings

MNF J EW Bracket NO VI / Bump Test NO
1976 Water Wet Ties
Basket Displace
44

Turbogenerator
OEM Mod. Cooling Pro b lem? Roo t Cau se OEM Agree? A c t io n s EW V Mo n itor ing
Design
Rewind/replacement.
45-198MW Indirect EW Assembly
YES / NO EW system modification: VI / Bump Test
1982-2001 Air EW-Slot Unusual Operation
New block/ties
Normal Ageing
MNF A
300/700MW Direct No
- - - -
water Problems
1978-95
530MW H2 No
- - - -
Optical
Repairs: flooding, re- Wide range
300-375MW H2 Design tiying, dry to wet ties , Radial/tangential/axial

EW-Slot Improper Aplication YES local insulation repairs. Displacement
2005-2007 Indirect
Unusual Operation EW system modification: 9 sensors/side
New block/ties No alarm/ no trip
No core Vib. Monitor
Repairs: flooding, re-

Design tiying, dry to wet ties ,
350-475MW H2
EW-Slot Improper Aplication YES local insulation repairs. -
MNF B 2002-06 Indirect
Unusual Operation EW system modification:
New block/ties
Repairs: flooding, re-
tiying, dry to wet ties ,
50MW Indirect Design
EW-Slot - local insulation repairs. -
2004 Air Normal Ageing
EW system modification:
New wedging
575MW Direct No
- - - -
1967 water Problems
Optical
Repairs: flooding, re- Wide range
Design tiying, Tunning EW Radial

170-300MW Indirect basket. Acceleration
EW Assembly YES
1995 Air EW system modification: Sensors/side:
Unusual Operation
New block/ties, add new depends on design
radial support elements, No alarm/no trip
MNF C Repairs:Re-install Optical

support rings. Wide range
Design EW system modification: Radial/tangential
8 00
00 MW
MW 90
90 's
's Di
Dire
rect
ct H 2 EW-S
EW-Slo
lott Assembly NO New block/ties, add new Displace/acceleration
Unusual Operation radial support, slide 9 sensors/side
system. support rings Setting alarm/ no trip
close to exit. Core Vib. Monitor
300-800MW No
Direct H2 - - - -
70's Problems
445MW H2
MNF D Slot - - - -
2007 Indirect
Optical
Repairs:Re-tightening
Wide range
throw the provided
300MW Indirect system. Radial/tangential/axial
EW Unusual Operation YES Acceleration
2006 Air EW system modification:
MNF E 8 sensors/side
No
No alarm/ no trip
375MW Direct
EW-Slot Norm al Ageing YES - -
1975 water
205MW Indirect
MNF F Slot - - - -
2012 Air
Repairs:Re-tightening
Design throw the provided
388MW Direct
MNF G EW Assembly YES system.
1980 Water
Poor Maintenance EW system modification:
No
MNF H - - - -
665MW Direct
MNF I EW Des ign YES
1974 Water
Repairs:Ties and
tangential wedges
MNF J 770MW Direct EW Design YES replacement.
1976 Water Unusual Operation
EW system modification:
No
45

Turbogenerator
4.3
4.3 Endwinding support systems conclusions
4.3.1 Introduction
Almost all OEMs were represented in i n the survey and, in some way,
wa y, all show problems in the mechanical
integrity of the stator end windings, alone or combined with slot section issues. Combined endwinding
and slot section issues were not always considered to be related in this survey.
The following tables summarize the conclusions of the endwinding section:
Table 4-2 Cooling Systems Answers Summary
OEM Mod. Cooling Location Direct Water Direct H2 Inirect H2 Air

EW 3/6 0/ 2 0/4 2/ 6
18 Grups:
Air 6/18
Same Slot 0/6 0/ 2 1/4 1/ 6
H2 indirect 4/18
All affected MNF
H2 Direct 2/18 Both 1/6 1/ 2 2/4 2/ 6
Same
Directt Water 6/ 18
Direc
model No
2/6 1/ 2 1/4 1/ 6
problems
Table 4-3 End Windi

Windi ng Suppor t Systems
Systems Answers Summary
OEM Mod. Cooling Problem? Design Where? Oil?
Rigid 10/12
Legs ties to rings 10/10
Air 6/18 EW 5/18 Flexible 2/10
Flexible
18 Grups: Connection
Conne ction Rings 4/10
All H2 indirect 4/18 EW-Slot 5/18 Dry 5/12 YES 6/18
Same OEM Bracket/Braces
Bracke t/Braces 10/10
affected H2 Direct 2/18 Slot 2/18 Wet 7/10 NO 8/18
Same design Series Loops 2/10
Directt Water 6/18
Direc 6/1 8 No issue 6/18 Mech/Slide 5/10 Block leads
leads to CR 4/10
Flex/slide layer
layer 4/10
OEM Mod. Cooling P roblem? Det ection Fault? Root Cause
Only Two Machines, H2 Design 7/10

Air 6/18 EW 5/18
18 Grups: VI in all cases Indirect and indirect air. Assembly 3/10
All H2 indirect 4/18 EW-Slot 5/18
Same OEM Bump Test 10/12 One service and one Hipot. Improper Aplication 2/10
affected H2 Direct 2/18 Slot 2/18
Same design EW monitoring 3/12. Other Machines same Unusual Operation 7/10
Direct Water 6/18 No issue 6/18
model have not failed. Normal Ageing 2/10
OEM Mod. Cooling Pro blem? A ct i o n s OEM Ag ree? EW V Mo nit o rin g
Repairs: flooding or re-
Optical
tying Only a few were
Wide range
rewinded
rewinde d for t his iss ues.
Air 6/18 EW 5/18 Radial/tangential
All 18 Grups: H2 indirect 4/18 EW-Slot 5/18 EW system modification: YES 9/10 Displacement
Same OEM New block/ties. Some
affected H2 Direct 2/18 Slot 2/18 NO 2/10 Number sensors/side
Same design major modifications with
Directt Water 6/1 8
Direc No issue 6/18 depends on design
new radial support
No alarm/ no trip
elements
elements and new sliding
systems.
4.3.2 Design
Endwinding vibration symptoms appear in different basic design structures. Although machines with
stiffer support structures (documented in this sample) seem to be more prone to these issues according
to the results of the survey. The loss of mechanical integrity in flexible structure machines seemed to be
normally fleet problems and related to machine design.
Regarding the tying system, both main systems (wet or dry ties) shows endwinding vibration issues in
similar proportions. However, after analyzing the results of the survey, endwinding vibration symptoms
emerged in dry tie systems these ties where removed and replaced with wet tie systems. Also the
technology used
systems) does nottoseem
allow to
axial thermalthis
influence expansion
issue. (mechanical sliding systems or flexible support
46

Turbogenerator
4.3.
4.3.3
3 Location and
and oil infl uence
The most likely areas for endwinding vibration indications seemed to be the endwinding leg ties to radial
support rings or binding bands, the support brackets/braces, and the connection rings blocks and ties.
Another area found to be prone to endwinding vibration are the exit leads to connection rings blocking
and tying.
Regarding these survey results, the presence of oil was not found to be correlated to endwinding
vibration problems.
4.3.
4.3.4
4 De
Detection
Visual inspections were considered to be the main detection tool in all documented cases. In most of
these cases, Bump Tests to identify the potential for endwinding vibration problems were performed as
well. Driving point frequency measurements were mainly performed with some modal analysis. Twice
power frequency was the main frequency checked during Bump Tests.
The exclusion band was established by considering certain test limitations such as temperature,
response non-linearity, etc. 10 Hz over and below twice power frequency was the standard band.
ba nd. Some
users highlighted that results obtained at room temperature during this test should be translated to
operating temperature. A decrease of 5 to 12 Hz was considered the typical effect for these temperature
tem perature
differences.
Base line bump testing after manufacturing, significant repair or design modification was considered
important not only to validate the system, but to provide a baseline for future comparisons as well.
4.3
4.3.5
.5 Root Cause Analysi s
Only Two Machines reported had failed as a result of endwinding vibration issues, one H2 Indirect and
one indirect air. One in service and one during the voltage withstand (Hipot) test.
Regarding the Root Cause Analysis of Endwinding Vibration issues reported in the received answers,
several causes were reported for the problem in the same
sam e group of generators by different users. Design
was the main root cause for EW vibration problems in most answers (7/11). Other aspects like Unusual
Operation (cycling) was also present in most cases (7/10). Normal ageing and poor assembly or
maintenance was also considered to be the cause for some generators.
4.3.6
4.3.6 Act
Action
ion Taken
Regarding Actions Taken, in most situations simple repairs like flooding or re-tying was enough to
mitigate the problem. This loss of mechanical integrity was not solved in the first repair attempt and
required inspection and additional repair efforts in subsequent outages. If the problem was not detected
and mitigated with repairs, more extensive main insulation repairs were necessary. For only a few
machines was a rewind needed.
In most cases repairs were complemented with some endwinding system design modification, mainly
introducing new blocks and ties to reinforce the endwinding structure in weaker areas. Some major
modifications with new designs of radial support elements
elem ents and new sliding systems to allow axial thermal
expansion were also implemented.
4.3.
4.3.7
7 Endwinding Vibration
Vibration monitorin g systems
Endwinding Vibration Monitoring systems were not significantly present the answers to this survey, it
concerned only three machines. The reported systems are mainly optical sensors to monitor vibration
in the radial (or the radial and tangential) direction. Acceleration
Acce leration was the main used parameter. No alarm
or trip levels were set in the control systems. No core vibration sensors were included in any answer.
The maximum acceleration reported was between 9 g peak to 12,7 g peak. General pass/fail criteria
should be established for each specific design because of the strong dependence.
47

TB 772 - T
Turbogenerator experience
48

TB 772 - T
5. Slot are
area
a suppo rt s ystems
5.1
5.1 Que
Question
stion naire section descri
descri ption for slot are
area
a suppo rt systems
In this section slot area support system issues were analysed in a similar way
wa y compared to the preceding
section regarding endwinding support systems.
5.1.1 Design
Slot Section
Section s uppor t syst em design. (Mark
(Mark all
all whi ch are present
present in you r generator).
Insulation system:
- Global Vacuum Pressure Impregnation (GVPI).
- Individual Coils/bars. Non-Global Vacuum Pressure Impregnation (Non-GVPI).
Radial support system:
- Wedging type
- Flat. - Concave/convex. -One part wedge. - Two Part Wedge - Other.
Description:_________________.
- Radial Fillers materials (between bars and at the bottom of the slot):
- Top Ripple Springs - Conforming material - Dry material. - Other.
Description:__________________________.
Side support system.
- Side
Side Ripple
Ripple Springs
Springs.. - Side
Side Wedges.
Wedges. - Round
Round Packing
Packing.. - Other.
Other.
Description:_______________.
- End Flux Shields.
- Step Iron at core ends.
Information concerning insulation system (global or individual impregnation) was requested due to the
effect that this has on the overall robustness of the stator winding. In large machines, most of the stator
bars can be individually impregnated. A global impregnation process can provide additional robustness.
The slot Support system has the following aims:
▪ Contain the bars in the slot.
▪ Eliminate the bar vibration.
▪
Manage the unequal thermal expansion between copper, insulation and iron.
▪ Provide proper contact between the bar surface and core.
▪ Allow proper ventilation.
The slot support system could be divided into two main components: radial and side support.
5.1
5.1.1.
.1.1
1 Ra
Radial
dial sup port
The radial support system in the slot section depends on the OEM design and is also related to the
current through the bars and therefore the expected forces in the slot, both in normal operating
conditions and in case of sudden short circuit or fault conditions. The force in the top bar is three times
that of the bottom bar in slots with bars of the same phase. If the two bars in a slot belong to the same
phase, force is toward the bottom
bottom of the slot. If the two bars belong to different phases, force has an
upward component.
The radial support system is divided into two parts:
parts : wedge and radial filler material. The main aim of the
radial support is to avoid any radial clearance in the slot: at the bottom, between the bars, and between
49

TB 772 - T
the top bar and wedge. The correct bedding of the bottom bar as well as the clearance between bars
should be thoroughly checked during the installation of the bars in the slots.
Depending of the design, several wedging systems and filling materials can be used:
▪ Wedging type:
 Flat.
 Concave/convex.
 One part wedge.
 Two Part Wedge.
▪ Radial Filler materials (between bars and at the top/bottom of the slot):
 Top Ripple Springs (TRS).
 Composite fillers.
 Conforming material.
 Dry material.
5.1
5.1.1.
.1.2
2 Side sup por t
The side support system can be designed to not only form the mechanical support, but it has to provide
an electrically conductive path to prevent slot voltage discharge as well as to promote thermal
conduction from the bar insulation to the core iron. Conductive treatments or compounds can be
included for this reason.
Side support system could be:
▪ Side Ripple Springs (SRS).
▪ Side Wedges.
▪ Round Packing.
Other aspects such as end flux shields or step iron at the core ends were also requested. Step iron has
an important influence on the integrity of the winding in the slot exit region due to the distance from the
last wedge and the first fixation point in the endwinding support system.
50

TB 772 - T
Figure 5-1
5-1 Slot cross section for in directly cooled turbogenerators (air
(air or h ydrogen cooled) from 100
100 to
650 MVA
MVA (Cour
(Cour tesy of Ansald o)
Figure 5-2 Typical Slot Contents (Extracted fro m EPRI

EPRI 102
102177
1774
4 Stator
Stator Endwi ndin g Vibration Guid e)
(Courtesy o f EPRI)
EPRI)
51

TB 772 - T
Figure 5-3 Fillers at the bottom of the slot (Courtesy of Iberdrola (Spain))
Figure 5-4 Bott om bars and

and side rippl e sprin gs (Court
(Court esy of Iberdrol a (Spain))
Figure 5-5 Bott om bars and between bars fill er (Courtesy

(Courtesy of Iberdrol a (Spain))
(Spain))
52

TB 772 - T
Figure 5-6 Between bars filler and fil lers between top bar and wedges (Court
(Court esy of Iberdrola (Spain))
Figure 5-7 Top and side ripple spring s (Court

(Court esy of Iberdro
Iberdro la (Spain))
(Spain))
Figure 5-8
5-8 Turb
Turb ogenerator wedge installati on (Courtesy of Iberdro
Iberdro la (Spain))
(Spain))
53

TB 772 - T
5.1.
5.1.2
2 Location of degradation
degradation and
and oil influence
The main areas of the slot support systems were listed in the questionnaire for the OEM / users to
identify where the vibration symptoms / loss of mechanical integrity evidence were detected.
Indicate areas
areas where you have detected
detected vibration / loss of mechanical integrity s ymptom s in
the slot sectio n (Mark
(Mark all in you r generator).
- Signs of loose top wedges.
- Red Dusting. - Wedge migration. - Others.
Description:______________________________.
- Greasing in the bars side at the slot ends.

- Side support side. - Opposite side. - Both.
- Bar Side Abrasion.

- Side support side. - Opposite side. - Both.
- Side support system axial migration.
- Bottom bar / core clearance at the slot ends.
- Bottom Bar damages at the bottom of the slot side.
- Conductive coating wear.
- Visual partial discharge activity.
- Insulation and/or copper strand cracks or damage just at the slots exits.
- Vibration Sparking. Have you checked the bar surface resistance value? _______________
ohm/square.
- Stator frame vibrations.

- Noise. - Cracks. - Terminal box vibration signs. - Core/frame interface.
- Stator Core Vibration.

- Local. - Global.
The initial indication that the bars lost mechanical integrity in the slot section was typically loose radial
wedges. Poor wedge tightness could be detected with a visual inspection. Red dusting of iron oxide may ma y
also be present due to the friction of the wedge against the core when loose. Also, some wedge axial
migration could be detected.
54

TB 772 - T
Figure 5-9 Red Dust/Grea

Dust/Greasing
sing in the Slot for Wedge Vibratio n (Court
(Court esy of Iberdrol a (Spain)
Lost mechanical integrity of the bars in the slot could also be detected by visual inspection. Greasing at
the sides of the bars at the slot ends were the most typical signs. This greasing can develop if oil mixes
with the slot bar conductive coating or side support dust produced by relative movement and wear
between components. It can also be caused by side support system axial migration.
If the bars were not properly seated at the bottom of the slots some greasing could develop at the bottom
of the slot. Bar wear can occur with very small clearances less than 0,075 mm or 3 mils and although
this is difficult to see directly, it can often be detected with gauges.
Figure 5-10 Greasing at Slot

Slot exit . (Courtesy
(Spain))
As a result of the bar vibration in the slot and the relative movement with the core (sides or bottom) or
side support elements, bar abrasion could develop, which could be detected after bar removal or, in
some severe situations, after removing the radial fillers. Endoscopic inspections through cooling
passages could also help detect bar abrasion without bar removal.
55

TB 772 - T
Figure 5-11
5-11 Greasing at slot bo ttom . (Courtesy
(Spain))
Figure 5-12 Bar abrasion against Side Ripple Spring (SRS).

(SRS). (Courtesy
(Courtesy of Iberdr ola (Spain)
56

TB 772 - T
Figure 5-13 Bar abrasion against cor e. (Courtesy of Iberdrola (Spain))
Figure 5-1
5-14
4 Bott om Bar abrasion at the slot bot tom (Courtesy of Iberdrol a (Spain).
Another consequence of loose windings in the slot is Partial Discharge activity due to damage of the
conductive surface coating against the laminated stator core. At the abraded conductive coating
locations, the bar surface is not grounded and a voltage stress appears between the bars and stator
core. If the voltage stress exceeds the electrical breakdown of the medium or tracking resistance of the
insulation (air or pressurized hydrogen), a discharge develops. This activity increases with the
operational load since it is directly related with bar vibration, which increases the gap between the bar
side and core. High voltage bars near phase connections are the most likely to experience this activity.
Although this mechanism can appear in air or hydrogen cooled machines, partial discharge activity and
its magnitude is lower in hydrogen cooled machines.
Another degradation mechanism found related to bar vibration in the slots was vibration sparking, which
can appear at any location in slot part of the winding. This mechanism appears when the bar vibration
occurs and the surface resistance of the conductive coating is too low. If the bar vibrates, the current
loop (axially along the bar, radially through the core, axially along the key bars at the back of the stator
core, and radially back to the bar) could be interrupted
interrup ted at a contact point between the bar and core. The
interruption of this current can form a stable arc to the core. If the conductive coating of a bar is too low
this current can be as high as to trigger a stable arc and the resulting arc can damage the groundwall
insulation by an erosion process.
The unusual presence of oil over the winding surface
surf ace and its level is not a necessary condition for these
issues, however it could have a “catalyst effect”. Therefore, it was also included in the questionnaire to
evaluate the influence on these issues.
57

TB 772 - T
Have
Have you detected unusual oil presence over the windi ng surf ace?
- No
- Yes.
Level: - Low. - Medium. - High.
5.
5.1.
1.3
3 De
Detection
In additional to Visual Inspection, other techniques used to detect or confirm the mechanical integrity
loss of the winding at the slot section were listed.
Further Visual Inspection, Have
Have you de
detected
tected or conf irmed bar suppor t mechanical integrit y
lost at the slot areas by other techniques?
- Wedge tightness.
- Robotic/handheld instruments. - ECOTip hardness. - Manual/sound.
Pass/fail
limits:____________________________________________________________________.
- Partial Discharges.
- Capacitive Couplers. - Slot Couplers.
- Slot Bar vibration monitoring system.
- Bar vibration monitoring system.
- Bar Seating checks at the bottom of the slot.
- Bar-Jacking. - Gauges.
- Other.
Description:________________________________________________________________.
The main method to determine if the bar can vibrate in the slot, is to check the tightness of the radial
wedges. If the wedges are tight, then it is less likely that the winding will be loose, although as it was
explained in preceding paragraphs, it is not a necessary
necessar y condition if the radial clearance is at the
th e bottom
of the slots or between the bars.
Several methods have been developed for wedge tightness evaluation. One of the method that is still
widely used, is to tap each wedge with a hammer or spanner. If the
th e wedge is hollow or loose, it will make
a “thud” sound and the wedge vibration can be felt with a finger over the wedge.
However, this method is subjective and depends strongly on the operator experience. For this reason,
other methods have been developed in order to consistently measure wedge tightness:
▪ Durometer: Traditionally used to determine materials hardness and is also widely used to
measure stator wedge tightness. The diagnostic criteria depend on generator size and
wedging type but lower than 550 HLD (lb) is generally considered a minimum value and higher
than 750 HLD (lb) is considered good. This method requires the removal of the rotor.
▪ Hammer/accelerometer methods: A calibrated hammer strikes the wedge and an
accelerometer placed over the wedge measures the vibration in response to the impact. The
tightness is determined as a percentage of a fully tight reference wedge. Some robotic testing
systems usable without rotor removal are using this method (Other robotic systems use acustic
sensors). Although standard calibration is available, a calibration for each generator is
recommended.
▪ Ripple springs deflection: Measurement of the load on the stator coil's ripple spring through
pre-drilled holes along the length of the stator wedge. At each of these holes the height of the
ripple spring is measured. The maximum height of the ripple spring and the load on the ripple
spring can be determined in accordance with the ripple
r ipple spring manufacturer specification. This
method requires the removal of the rotor.
▪
Stator spring
ripple wedgeload.
tightness determination
This method requiresbythe
pressing
removaldown
of theonrotor.
the slot wedge to determine the
58

TB 772 - T
▪ Concave/convex wedges: a dial gauge is used to determine the deflection of the wedge, on
the side edges with respect of the centre-line.
Figure 5-1
5-15
5 Wedge Tightn ess Test
Test using a Durometer (C
(Court
ourt esy of Iberdro
Iberdro la (Spain))
(Spain))
As was introduced in preceding sections, another consequence of loose windings in the slot is Partial
Discharge activity due to damage of the conductive surface coating against the laminated stator core.
On-Line PD testing systems are frequently installed in most turbogenerators and the PD activity can be
continuously monitored or periodically collected in a time-based testing program. Loose windings at the
slot section exhibit load dependent PD activity, increasing with load due to an increase in magnetic
forces and coil movement; also temperature may play a role to open up side airgap, thus promoting
discharging activity. This effect is more noticeable on thermoset insulation systems than thermoplastic
systems because thermoplastics expand with temperature, therefore fixing the coils in the slot and
reducing coil movement.
Also, bar vibration

for these monitoring
systems can systems
be installed areor
under available for direct
over radial wedgeson-line bar vibration
at several monitoring.
positions Sensors
in the winding or
with fiber optic accelerometers installed on the stator bar right outside the slot exit.
59

TB 772 - T
Bar seating checks at the bottom of the slot exits could be performed. Significant clearance could be
detected by trying to introduce fillers or gauges between the bottom bar and slot bottom at slot exits
(less than 10 mils or 0,25 mm is a standard criteria).
However, as bar wear can occur with a very small clearance (less than 0,075 mm or 3 mils), bar jacking
at the end of the slot can be used to detect smaller clearances. End wedges are removed and a radial
pressure on the top bar is applied. Jacking force has to be in the range of the bottom bar force. The
displacement is measured with a core mounted dial indicator. Extreme care should be taken to avoid
bar insulation cracks.
If the bars are allowed to vibrate in the slot, a dielectric failure can occur either in service or during
voltage withstand (Hi-Pot) tests due to ground insulation abrasion.
Has
Has generator experienced a fault in service or HiPot failure for thi s endwindi ng prob lem?
- No
- Yes.
- In Service. - Hi Pot.
5.1.4
5.1.4 Root cause analysis
Possible Root Cause. (Ma
(Mark
rk all h ypotheses for your generator).
generator).
- Design.
- Poor maintenance.
- Normal winding ageing / support system relaxation.
- Other.
Description:________________________________________________________________.
Detailed description of the possible root cause:
3.4. Has this RCA been agreed with the generator manufacturer?
- No
- Yes.
In the questionnaire options for a possible Root Cause were listed as well as if this RCA had been
agreed upon with the manufacturer. In most of the cases several of the causes were suggested.
Manufacturer participation in this analysis is very valuable due to the knowledge of the design
parameters related to expected electromagnetic efforts in each area of the basket and support system.
All the causes were related to the presence of electromagnetic forces in the stots that produces bar
vibration at twice power frequency as well as the slot support systems aptitude to limit the vibration
preventing relative movement or friction between slot area components.
5.1.4.1 Design
Regarding design, the root cause was related to magnetic force calculations and the proper design of
the support systems, considering all possible factors that can lead to bar vibration in the slot section and
resulting bar abrasion. This was a less important problem in thermo-elastic insulation systems, which
expand with increasing temperature caused by losses in the copper due to the current
c urrent flow. This winding
expansion, even though it may have certain clearances when cold, causes the bars to be strongly held
in the winding as the load, hence the electromagnetic forces, increases. In newer thermoset insulation
60

Turbogenerator
systems, the thermal expansion is lower, so the importance of a properly designed slot support system
becomes more relevant.
Winding and core thermal expansion (as well as the difference between them)
them ) should be carefully taken
into account for both the endwinding and slot support system design: thermal expansion coefficients of
all elements, thermal expansion between top and bottom bars, radial support position, and bar to bar
axial blocking.
Possible relative movement between slot components should be considered in order to properly select
materials: bar armour, insulation softer than side support, aggressive core end stepping.
Support systems improper selection of materials or manufacturing can be a more immediate cause of
failure: excessive
insufficient dimensional
thickness, impropertolerances of support
height, sharp components,
corners, improper fatigue strength
materials shrinkage/creep, of materials,
sliding properties of
contact areas between bars and bottom fillers, etc.
Endwinding vibration issues can be transmitted to the bars at the end of the slot section and also lead
to bar abrasion at the slot exits.
Core vibration can also be a factor that contributes to these issues. Electromagnetic force on the core
rotates as a traveling wave with the rotor rotations. It causes core deflection or ovalization at twice per
revolution (for 2-pole machines) that changes the slot dimension and contributes to the relative
movement, mainly tangentially, between the bars andan d the core as well as between the bars and the side
support systems promoting abrasion. To some extent it also exerts a compression and buckling force
on the sides of the wedges, with a potential effect on radial clearance at the top of the slot.
5.1.
5.1.4.
4.2
2 Assembly / Workmanship issues
Regarding assembly or workmanship issues the following causes can be present: lack of proper
dimensional control (bars, slot, wedges and other support system elements), insufficient wedge
tightness, less ripple spring deflection (both side or radial), side support location or percentage
coverage, bars not properly seated at the bottom of the slots, clearance between top and bottom bars,
lack or improper end-wedges blocking systems, bars held off the bottom of the slot for improper
endwinding support systems stress.
5.1.4.
5.1.4.3
3 Operation con dit
dition
ion s
Unusual operational conditions could also be a root cause or at least an additional factor for these
issues:
▪ Cycled operation, related to the expansion – contraction process linked to temperature changes
and therefore to bar axial expansion and insulation thickness changes.
▪ Withstand capability to sudden short circuit currents.
▪ High thermal loads and lack of sufficient cooling.
5.1
5.1.4.
.4.4
4 Ageing / maint
maintenance
enance
Also, normal insulation ageing and support system relaxation, which could be normal for a significant
number of running hours, can lead to bar vibration issues in the slot area, some of them that could be
solved or reduced with proper maintenance or repairs:

▪ Shrinkage and creepage of thermally aged insulation that leads to the bars becoming sufficiently
loose to vibrate in the slots. This problem could also appear during the first year of operation in
new machines due to a post-manufacturing insulation curing process after the machine goes
into service.

▪ Although some systems, like those that use ripple springs, are designed to compensate this
gradual shrinkage, these systems also have the ability
abilit y to distribute the load sufficiently over the
windings to avoid excessive vibration.

▪ Oil presence: some materials used for support elements are affected by oil. Conversely, the
presence of oil
components could in
resulting also have a catalytic effect, promoting relative movement between the
abrasion.
61

Turbogenerator
▪ Wedges are also affected by their own thermal

t hermal shrinkage, as well as oil contamination, gradually
loosening slot wedges.
5.1.5
5.1.5 Act
Action
ion taken
After identifying the root cause of the loss of the mechanical integrity of the windings in the slot section,
several actions or repairs can be taken to retrieve reliable conditions for continuous operation of the
generator.
Action taken:
- Rewind.
- Partial rewind. - Full rewind.
- Bar dimension modification (if it was rewind).
- Extensive bar seating checks during rewind.
- Repairs.
- Re-Wedge.
- Partial. - Full.
Use of original wedging type. Use of other wedging type
Improvement/Modification? Description:________________________________.
- Side Support replacement. Improvement / modification.
- Resin or other material injection in the slot.
- Introduce Endwinding wedging or rings close to the slot exist.
- Other.
Description:________________________________________________________________.
In the same way that it was indicated in the endwinding section, depending on the criticality of the defects
and especially if the machine has suffered a fault (in
( in service or during a withstand voltage (Hi Pot) test),
the extension of the scope of the repair / action taken was generally larger than in the end winding
issues (generator replacement or partial/full rewind was often required). Therefore,
Theref ore, a detailed root cause
analysis should always precede any extended scope of repair to evaluate the necessity of design
modifications
assembly. or implement improvements / intensification of quality control both in manufacturing and
Before this occurs, minor repairs can be performed to establish the integrity of the winding in the slot
area. Early detection generally reduces the scope of the repair significantly.
Loose radial wedges lead to their replacement. The
T he criteria for making the decision of a partial or full re-
re -
wedge are affected by the insulation system (thermoset or thermoplastic), the total percentage of loose
wedges and their position in the slot:
▪ Loose end wedges should be replaced.
▪ Three or more adjacent loose wedges in the same slot should have the slot wedges in the whole
slot replaced.
▪ More than 25% of loose wedges will require a full re-wedge.
Depending on the root cause analysis, the original wedging method can be changed or improved, for
example, replacing flat wedges with wedges and ripple springs or two part wedges, thicker or higher top
ripple
or springs
shorter top or stronger top wedges (more height and materials are capable to withstand higher loads)
wedges.
62

Turbogenerator
Some OEMs have developed other wedge tightening processes based on shims at both dovetail sides
which is applied only to lose wedges. This process is applicable for tightening body wedges that uses a
wedge system with a top ripple spring. End wedges would still require replacement.
Figure 5-16 Rewedging

Rewedging (C
(Court
ourt esy of Iberdr ola (Spain)). Figure 5-17 Re
Rewedgin
wedgin g (Courtesy of Iberdro la
(Spain)).
Figure 5-18
5-18 Stronger wedges at the core ends Figure 5-
5-19
19 Thicke
Thickerr and taller top ripple spri ng
(Courtesy of Iberdr ola (Spain)). (Courtesy of Iberdr ola (Spain)).
Side support elements could be replaced or improved with a change in the geometry or materials:
replace flat side packing with side ripple springs, any sharp corners can be changed to round ones,
taller or thicker side ripple springs, positioned before end core stepping, etc.
If the conductive surface coating has been damaged by loose windings in the slot, carbon loaded paint
injection can reduce PD activity. Another possibility for bar mechanical integrity improvements can be
resin or silicon injection in the slots. These materials have to maintain electrical properties of low
resistance contact between the bar surface and core.
63

Turbogenerator
Figure 5-20
5-20 SRS Installatio n (Court
(Court esy of Iberdro (Spain)
Iberdro la (Spain) Figure 5-21
5-21 SRS Design modifi cation (Courtesy
of Iberdrola (Spain))
5.1.
5.1.6
6 Bar vibration monitori ng systems
Bar Vibration monitoring system installation can be one of the possibilities to monitor bar vibration in
the slot section.
Bar Vibration monitoring system:
Installation:
- Under the wedge. - As part of the wedge. - Mounted on bar slot exit.
Nº of sensors: __________. Additional
information:_______________________________________________.
Monitored Parameters:
- Displacement. - Velocity. - Acceleration.
Have you set alarm level?
Have you set trip level?
Trip/Alarm levels established by:
- OEM. - Monitoring system supplier. - Generator owner/operator experiences.
Additional
information:___________________________________________________________________.
Bar Vibration Monitoring is the only way to get real information about the vibration behaviour while the
machine is in service and when all the possible parameters present during operation are affecting these
mechanisms.
At large, bar are not meant to vibrate at all. Acceptable or normal vibration depends strongly on the
generator design and the installation during manufacturing. Recording of baseline levels and vibration
trended during operational life is the most advantageous strategy.
These systems can also be installed once the machine is in service during a regularly scheduled outage.
Sensors can be installed in the air gap and are based on a capacitive measurement technology. The
sensor acts as a capacitor plate where the top bar is the second plate. The insulation and radial
rad ial wedging
components (depending on the sensor location) form the insulation between the plates. If the bar
becomes loose, the radial distance between the capacitor plates changes along with the capacitance.
Installation of these sensors requires an outage with the rotor out.
64

Turbogenerator
Preferably, fibre optic accelerometers are installed permanently on the stator bar right outside the slot
exit and on the core (as a reference). Measuring the vibration directly at this location has been used to
verify the results obtained by the indirect capacitive approach and is less invasive since the wedge does
not need to be modified. These sensors can be installed during an outage, but the rotor does not
necessarily need to be removed as long as there is sufficient space at the slot exit to affix the
accelerometer.
The number of sensors depends on the generator configuration as well as economic constraints. A
normal installation could be one sensor at each generator side in the high voltage slots of each phase
parallel circuit. Therefore, a two parallel per phase generator installation would have 12 sensors (6 on
each end).
Trending analysis of the vibration behaviour on a specific machine or design as well as the correlation
with findings during visual inspections, allows establishing alert levels.
65

Turbogenerator
5.2
5.2 Summary of slot area
area section answ
answ ers
Table 5-1
5-1 Slot area answers summary
OEM Mod. Cooling Problem? Design Where? Oil? Detection Fault?
Non-GVPI
4 5-198MW EW Loose Top Wedges
Flat Wedges
Indirect Side Support Migration VI / Wedge
TRS/Dry/Dry YES / Low NO
Air Bottom Clearance Thigtness (ECOTip)
Flux Shields
19 82-200 1 EW-Slot Core Vibration
Step Iron
MNF A
300/700MW Direct No
- - - - -
water Problems
1978-95
530MW H2 No
2008 Indirect Problems - - - - -
Loose Top Wedges
Non-GVPI
Greasing at Slot Ends
Flat Wedges
300-375MW H2 Bar Abrassion VI / Wedge YES(1/10 uds)
EW-Slot TRS/SRS YES / Low
2005-2007 Indirect SRS Migration Thigtness (ECOTip) Hi Pot
Flux Shields
Bottom Clearance
Step Iron
Core Vibration
Non-GVPI Loose Top Wedges
350-475MW Flat Wedges Greasing at Slot Ends VI/Wedge
H2
EW-Slot TRS/SRS Possible Bar Abrassion YES / Low Thigtness NO
Indirect
Flux Shields Conductive Coating (WTD/ECOTip)
2002-06
MNF B Step Iron Wear PD Activity
Non-GVPI
Loose Top Wedges VI / Wedge
Flat Wedges
50MW Indirect Greasing al Slot Ends Thigtness
EW-Slot Conforming/SRS YES / Low NO
2004 Air Bar Abrassion (Manual Sound)
Flux Shields
SRS Migration Partial Discharges
Step Iron
575MW Non-GVPI
Flat Wedges
Direct No
TRS/SRS No Problems NO No Problems NO
1967 water Problems
Flux Shields
Step Iron
Non-GVPI
170-300MW Indirect TRS/SRS
EW No Problems YES No Problems NO
1995 Air Flux Shields
Step Iron
Non-GVPI Loose Top Wedges
800 MW Direct H2 EW-Slot VI / Wedge
MNF C Flat Wedges Conductive Coating
Thigtness
TRS/SRS Wear Bottom NO NO
(WTD/ECOTip)
Flux Shields Clearance
90’s Partial Discharges
Step Iron Core Vibration
300-800MW No
Direct H2 - No Problems - - NO
70's Problems
Non-GVPI
Greasing al Slot Ends
Flat Wedges
445MW H2 SRS Migration VI / Wedge
MNF D Slot TRS/SRS YES /High Yes Service
2007 Indirect Bottom Clearance Thigtness (ECOTip)
Flux Shields
Core Vibration
Step Iron
300MW Indirect
EW - No Problems - - NO
2006 Air
MNF E Non-GVPI VI / Wedge

375MW Direct
EW-Slot One Part Wedges - YES / low Thigtness NO
1975 water
Dry Material (Manual Sound)
205MW Indirect
MNF F Slot - Fault at Slot Area NO - YES
2012 Air
Non-GVPI
Two Part
Direct Wedges Silicone
MNF G 388MW 1980 EW No Problems - - NO
Water Rubber/Side
Wedge
Flux Shields
MNF H - No Problems - - NO
Non-GVPI
Flat Wedges
Direct
MNF I 665MW 1974 EW TRS/SRS Flux No Problems - - NO
Water
Shields
Step Iron
Non-GVPI
Flat Wedges
Direct
MNF J 770MW 1976 EW TRS/SRS No Problems - - NO
Water Flux Shields
Step Iron
66

Turbogenerator
OEM Mo d. Co o ling P ro b lem? Ro ot Cause OEM Agree? A ct io n s SV Mo n it o rin g
EW
Rewind: Partial
Partial
45-198MW Indirect Other: Generator Repairs: full rewedge.
NO -
1982-2001 Air EW-Slot circuit braker faliure ype..
Original wedging t ype
System modifica
modification:
tion: No
MNF A 300/700MW Direct No
- - - -
1978-95 water Problems
530MW
H2 No
- - - -
Rewind (2 in a 10 u./fleets)
Repairs:partial/full
Repairs :partial/full
rewedge. Original wedging
type. Side support
300-375MW H2 replacement. Improved.
EW-Slot Design YES -
2005-07 Indirect System modifica
modification:
tion:
Stronger Radial Wedge and
TRS, Stronger and Higher
SRS, RTV resin injection at
slot at sides.
MNF B
rewedge. Original wedging
350-475 MW H2 type. Side support
EW-Slot Design YES -
2002-06 Indirect replacement. Improved.
System modifica
modification:
tion:
Strongger and higher SRS.
50MW Assembly Repairs:partial

Repairs :partial rewedge.
Indirect
Air EW-Slot Unusual Operation NO Original wedging type.
t ype. -
2004 Normal Ageing System modifica
modification:
tion: No.
575MW
Direct No
- - - -
1967 water Problems
170-300MW Indirect
EW - - - -
1995 Air
Rewind (1 in a 6 u./fleets)
800MW Design
MNF C Dir
ire
ect H2 EW-Sl
Slot
ot NO Repairs:
Repairs: -
90's Unusual Operation
System modifica
modification:
tion:
300-800MW No
Direct H2 - - - -
70's Problems
Rewind: Partial Rewind.

Rewind: Partial
Repairs:: Partial rewedge.
Repairs
Side support replace
replacement.
ment.
445MW H2
MNF D Slot Unusual Op
Operation YES Improved. -
2007 Indirect
System modifica
modification:
tion:
Aditional Spacer between
bar and SRS
300MW Indirect
EW - - -
2006 Air
MNF E Repairs: Full rewedge.

Repairs:
Direct
375MW 1975 EW-Slot Normal Ageing YES Origina wedging type. -
water
System modifica
modification:
tion: No
Indirect
MNF F 205MW 20
2012 Slot Assembly No Generator Remplacement -
Air
Direct
MNF G 388MW 1980 EW
Water
MNF H - - - -
Direct
MNF I 665MW 1974 EW
Water
Direct
MNF J 770MW 1976 EW - - -
Water
67

Turbogenerator
5.3
5.3 Slot are
area
a suppo rt sys tems concl usion s
5.3.1 Introduction
Almost all OEM were represented in the survey and, in some way or some designs, show problems in
the mechanical integrity of the stator bars at the slot area, alone or combined with endwinding issues.
As indicated in the previous section, issues at the slot and the endwindings were not always considered
related in this survey.
The following tables summarize the conclusions of the slot area section:
Table 5-2 Cooling systems answers summary
OEM Mod. Cooling Location Direct Water Direct H2 Inirect H2 A ir

EW 3/6 0/2 0/4 2/ 6
18 Grups:
Air 6/18
Same Slot 0/6 0/2 1/4 1/ 6
H2 indirect 4/18
All affected MNF
H2 Direct 2/18 Both 1/6 1/2 2/4 2/ 6
Same
Directt Water 6/ 18
Direc
model No
2/6 1/2 1/4 1/ 6
problems
Table 5-3 Slot area concl usio ns summary
OEM Mod. Cooling P roblem? Design W here? Oil?
Non-GVP
Wedge:
Flat Weges 6/7
One Part Wedges 1/7 Loose Top Wedges 5/7
Air 6/18 EW 5/18 Radial: TRS 5/7 Side Support Migration 3/7
18 Grups:
All H2 indirect 4/18 EW-Slot 5/18 Conforming 1/7 Bottom Clearance 4/7 YES 6/7
Same OEM
affected H2 Direct 2/18 Slot 2/18 Dry Material 1/7 Core Vibration 4/7 NO 1/7
Same design
Direct Water 6/18 No issue 6/18 Side: SRS 5/7 Bar Abrassion 3/7
Conforming 1/7 Greasing 3/7
Dry 1/7
Flux Shields 6/7
Step Iron 6/7
OEM Mod. Cooling Problem? Detection Fault? Root Cause
Visual Inspection 7/7

Air 6/18 EW 5/18 Design 3/7
18 Grups: Wedge Tightness 7/7 Only Two Machines, H2
All H2 indirect 4/18 EW-Slot 5/18 Assembly 2/7
Same OEM EquoTip 5/7 Indirect. One service and
affected H2 Direct 2/18 Slot 2/18 Unusual Operation 3/7
Same design Sound 2/7 one Hipot.
Direct Water 6/18 No issue 6/18 Normal Ageing 2/7
Partial Discharges 2/7
OEM Mod. Cooling Problem? Act ions OEM Agree? S V Mon it orin g
Rewind: full or partial 4/7.

Repairs:
Air 6/18 EW 5/18
18 Grups: Full or partial rewidge 6/7. No in
All H2 indirect 4/18 EW-Slot 5/18 YES 4/7
Same OEM Most original design. documented
affected H2 Direct 2/18 Slot 2/18 NO 3/7
Same design System modifica
modification:
tion: machines
Direct Water 6/18 No issue 6/18
Improved radial and side
supports, RTV injection
68

Turbogenerator
5.3.2 Design
Regarding cooling system, Indirect air and H2 Indirect were most likely to show problems in this area.
In affected machines, all Non-GVPI, flat wedges and top ripple springs (TRS) were the most common
system for radial support, as well as side ripple springs for side support.
5.3.
5.3.3
3 Location and
and oil infl uence
The most likely locations for bar vibration or loss of mechanical integrity
integrit y indications in the slot area were
loose top wedges.
Greasing at the slot ends and side support migration, consequently bar abrasion were also reported
with most cases that had slot issues. Bottom Bar clearance was also detected in these cases.
Core vibration was also reported, usually when loss of integrity of the winding was detected in the slot.
Oil presence in the generator was found in most of the cases where slot area issues were reported.
5.3.
5.3.4
4 De
Detection
Visual inspection, which is the main detection technique in all reported cases, confirmed loss of
mechanical integrity in the slot section through wedge tightness test, most using handheld instruments
which indicate wedge tightness with a numerical value. Tap test / sound test were also used in some
cases. Base line after manufacturing was considered important for future analysis.
Partial discharge analysis was also indicated as a tool to detect a loose winding in the slot section.
EMI technique is also used, although not so wide-spread and the interpretatioin straightforward.
5.3.5
5.3.5 Root cause analysis
Only two machines reported had failed due to slot issues, both H2 Indirect cooled. One in service and
one under a voltage withstand (Hipot) test. Indications were that the machine that failed belonged to a
fleet of 10 machines, which although reported problems of lack of mechanical integrity in the slot area,
no other failures were reported at the time of the survey. Design and Unusual operating conditions were
the main root cause for bar vibration problems in the slot area. Other aspects like normal ageing or poor
assembly were also present in this survey.
In more than a half of the situations, root cause and a solution was agreed with the OEM.
5.3.6
5.3.6 Act
Action
ion taken
Regarding Actions Taken, a significant number (4/7) of machines were rewound, full or partial, to resolve
these
rewedgeissues.
wasIn needed,
addition the cases
which that carried
were a patial/full
outrewind
with was
the needed,
original in most situations,
wedging systems.fullTherefore,
or partial
consequences of mechanical integrity lost in the slot area had significant economical and operational
effects. Also, it is important to consider that the incipient detection of these issues significantly reduce
this impact due to the fact that while a partial or full
f ull generator rewedge takes 4 to 7 days,
da ys, a partial or full
rewind goes several weeks or even months depending of the availability of spare bars at site.
In some machines, the repair also introduced some improvements in the side support, with stronger
systems (more SRS thickness). However, this solution was only applicable to the top bars if bar removal
was not required.
Another repair option was to inject additional resin, such as Room Temperature Vulcanizing (RTV) resin,
through the cooling channels between the side support elements and slot. This solution will impact the
ability to remove the bars and side support during a partial rewind in the future, as well as the core
cleaning method.
5.3.
5.3.7
7 Bar Vibration monit oring systems
Bar Vibration Monitoring systems were not represented in any machine in this survey.
69

Turbogenerator
70

Turbogenerator
6. Fina
Finall conclusi
concl usions
ons
Almost all OEMs were represented in the survey and, in some
som e way, showed problems in the mechanical
integrity of their stator windings. Most of the problems were in the endwindings or in both the
endwindings and slot area (not necessarily related). Slot section problems required more extensive
repairs, both in time and cost.
Larger machines (mainly direct water cooling generators), with stronger support systems did not show
problems or were considering normal wear due to operation. Although this is not something extracted
directly from the answers to the questionnaire, it should be considered that normally these machines
area less
of affected
massive by the pricing
implementation of negotiations andplants
combined cycle cost reduction that
in late 90’s have
and been
early seen during the period
2000’s.
In newer machines, the character of the problem was normally considered excessive due to some factor
related with design and abnormal operation. These
T hese machines (from the late 90’s) show more mechanical
m echanical
integrity loss than older ones, the effects start to appear in the first (1 to 5) years of operation and were
considered design/fleet problems. In most cases, cycling operation was a contributing factor.
Although this is not something extracted directly
directly from the answers to the questionnaire, manufacturing
costs reduction could be the one of the factors involved in the root of these issues.
71

Turbogenerator
72

Turbogenerator
APPENDIX
AP PENDIX A. Defi
Def i n i t i o n s , abr
ab r evi at
atii o n s an
andd s ym b o l s
A.1. General
Gener al t erm s
App
Ap p Tab le A .1 Defi ni ti on of gen eral ter ms u sed in th is TB
Acronym Phrase Definition

TB Technical Brochure A publication produced by CIGRÉ representing the
state-of-the-art guidelines and recommendations
produced by an SC WG. Hardcopy TBs can be
purchased [B1],
purchased [B1], or
or Individual Members, or staff of a
Collective Member can download the PDF for free
using their login credentials (copyright restrictions
for use within their own CIGRE Membership only)
SC Study Committee One of the 16 technical domain groups of CIGRE
WG Working Group A group formed by a SC to develop a TB on a
particular subject of interest
A.2. Spec if ic t erm s
App
Ap p Tab le A .2 Defi ni ti on of tec
techn
hn ic
ical
al t erm
ermss u sed in th
this
is TB
Acronym Phrase Definition
SRS Side Ripple Spring Graphite

bar coated
and stator ripple
slot springcontinuous
to ensure placed between stator
electrical
contact between stator bar semi conductive coating
and stator core
73

Turbogenerator
74

Turbogenerator
APPENDIX
AP PENDIX B. L i n k s an
andd r ef
efer
eren
encc es
[B1] Generator Stator Endwinding Vibration Guide: Tutorial, EPRI 1021774

[B2] Electrical Generators, EPRI 5036: V1
[B3] Maintenance Guidelines for Generators Used in Simple and Combined Cycle Plants, EPRI
3002003590
[B4] Generators in Combustion Turbine (CT) Applications: Failure Mechanisms, EPRI 3002000441
[B5] Guide for Online Monitoring of Large Synchronous Generators (10 MVA and Above), IEEE 1129-
2014
[B6] Rotating electrical machines - Part 32: Measurement of stator end-winding vibration at form-wound
windings, IE CTS 60034-32:2016
[B7] Electrical Insulation for Rotating Machines, Stone, Boulter, Culbert, Dhirani, IEEE Press Series
[B8] Operation and Maintenance of Large Turbo-Generators, Klempner, Kerszenbaum
[B9] Design of Electrical Rotating Machines, Pyrhönen, Jokinen, Harbovcová, Jhon Wiley & Sons
[B10] Stator Endwinding Vibration Measurement, Clyde V. Maughan
75

Turbogenerator
76

Turbogenerator
APPENDIX
AP PENDIX C. TB Spec
Sp ecii f i c ap
appp en
enddix
C.1.
C.1. Affected gene
generators
rators answers chart
ANSWER NUMBER 1 2 3 4
Acti ti ty Gene rato r Ow ner Gene rat or Own er Gene rat or Own er Gene rato r Ow ner
1 Affected Generator
1.1 Generator Data:
Manufacturer A A A A
Power output (MVA) 198 45 387 687
Rated Volt age (kV) 18 11 23 20
Rated Current (A) 6351 2390 11233 19822
Power Fact or 0.85 0.85 0, 8 0, 9
Speed (rpm) 3600 3000 3000 3000
Nº of Pol es: 2 2 2 2
Frequency (Hz): 60 50 50 50
Manufacturi ng Year: 2001 1994 1995 1978
Operati ng Time (hours): approx.20, 000 15
152
2
Gl obal VPI: No No No No
St ator wi ndings cooli ng t ype Indi rect air cooled Indirect Air Cool ed Direct wat er cooled Direct water cooled
1.2 Is it a fle
leet
et pr
prob
oble
lem?
m? SaSame
me or simi
simila
larr type/
type/mo
mode
dell of
YES NO
generators
genera tors show similar problems. NO PROBLEMS NO PROBLEMS
1.3 How many simil ar generators shows these
2 1 5 1
symptoms?
1.4 W h he
ere have y o ou
u det e ecc te
ted l os
os s of mec ha
hani ca
cal
EW EW - SLOT
integrity of the stator winding support systems?
- If both areas are i nvnvol ved, i s the
there any c on
onnec titi on
on
YES
between both problems?
The generator stator

wedge usually inspected
the tightness when Gas
Turbine Major Overhaul
(48000 Hr.) – Generator
- Description:
rotor withdraws. If we
found the loosen
wedge, Corrective action
by replace the wedge &
slot fillers.
1.5 When havehave you detected t he symptoms?:

- After years / Hours of operati on. 20 years and 152000 hours
X (generator out of
- After event . Descri ption: (St ator winding short wi ndin synchronize to grid via
via
unit transformer )
- After Repair.years / Hours of operation after repair.
- After Rewind.years / Hours of operation after rewind.
- Others. Description:

1.6 Opera
Operation
tion c onditions:
- Base operati on. X X
_____________.
1.7
1.7 Op
Oper
erat
atio
ion
n im
impa
pact
ct of mech
mechan
anic
ical
al inte
integr
grit
ityy loss
loss of the
the
stator winding support system.
- No impact.
- Restricted output. Description:
- Forced outage. X X
- Durat i on: days/ weeks. 110 days 35 DAYS
- Scheduled Outage extension.
- Duration:
Duration: days/weeks.
Force outage 35 day for
partial rewind the stator
- Other. Description:
bar, Rotor retaining ring
remove & inspection.
1.8 Charac te
ter of t h
he
e probl em
em: Do y ou
ou c on
ons id
ider t hi
hi s
symptom
As an expected normal wear and tear of the generator
As an ex
exce
cessi
ssivve pr
prob
oble
lem
m du
due
e to some
some facto
factorr (l
(like
ike desig
design,
n,
X X
abnormal operation, unexpected event, or other)
77

Turbogenerator
ANSWER NUMBER 5 6 7
Acti tity
ti ty Gene rator
ra tor Ow
Owner
ner Gene ra
rator
tor Ow
Owner
ner Gene ra
rator
tor Own er
1.1 Generator Data:
Manufacturer A A A
Power output (MVA) 312,5 110 530
Rated Voltage (k V) 21 10,5 21
Rated Current (A) 8592 6050 14581
Power Factor 0,8 0,8 0,8
Speed (rpm) 3000 3000 3000

Nº of Poles : 2 2 2
Frequency (Hz): 50 50 50
Manufacturing Year: 1981 1982 2008
Operating Time (hours ): Out of service Out of Servic e
Global VPI: No No No
Stator windings cooling type Direct water cooled Indirect air c ooled Indirec t H2 cooled
1.2 Is it a fle
leeet proble
lem?
m? Same
Same or si
simi
mila
larr ty
typpe/m
/moodel of
NO PROBLEMS NO PROBLEMS
generators show s imilar problems . NO PROBLEMS
1.3 How many similar generators shows these
1 1 2
symptoms?
1.4 W hheere have you dete teccte
tedd loss of mec hhaanic aall
- If both areas are in invvolv
lveed, is the
there any co connnect
ctiion
- Description:
1.5 When have have you detected the t he symptoms?:
- After years / Hours of operation.
- After event. Description:
1.6 Opera
Operation
tion conditions:
- Base operation.
- Load Cycling. Nº Starts / week: _____ __________
________.___.
1.
1.77 Ope
Operaratition
on impa
impact
ct of mech
mechaani nica
call inte
integr
gritityy loss
loss of the
the
- No impact.
- Forced outage.
- Duration:
- Duration:
1.8 Charac te
ter of the
the problem: Do y oouu c oonnsider th
thiis
symptom
As an expe
xpecte
cted norma
mall wear and tea
tear of the
the generator tor
operation
As an ex
exce
cessiv
ssivee pr
prob
oble
lem
m due
due to som
somee facto
factorr (l(like
ike desig
design,
n,
abnormal operation, unexpected event, or other)
78

Turbogenerator
Acti tit y Gene rat or Own er Gene ra tor Ow ner Gene rat or Ow ner Gene ra tor Ow ner
1.1 Generator Data:
Manufacturer B B B B
Power out put (MVA) 312-375 355-467 575 51
Rated Voltage (kV) 17 19 20 11.5
Rated Current (A) 10596-12728 13613-14211 16. 599 2573
Power Factor 0,8 0’8 0.85
Speed (rpm) 3000 3000 1.500 3000
Nº of Poles: 2 2 4 2
Manufacturing Year: 2005-2007 2002-2006 1967 2004
Operating Time (hours): 18000-28000 24000 ≈ 340.000 72264.6
Global VPI: No No NO NO
Stat or windings cooling type Indirect H2 Indirect H2 Direct water cooled Indirect Air Cooled
1.2 Is it a fleet
leet pr
prob
oble
lem?
m? Same
Same or si
simi
mila
larr ty
type
pe/m
/mod
odel
el of
YES
generators show similar problems. Y ES YES
1.3 How many s im
imi lar generat oorrs s ho
hows t he
hes e
1
symptoms? 10 6
1.4 W he here have y ouou det eecct eedd los s of mec hhaani ccaal
EW - SLOT
integrity of the stator winding support systems? EW -SLOT EW-SLOT
- If both areas are invinvolve
lved, is the there any c oonnnec ttio
ionn
NO
between both problems? Y ES NO
Degradation
Degradation mechanisms
detected in slot area has
- Description:
been directly related with
EW ones by the OEM.
1.5 When have have you detected the symptoms?:
- Af
Afte
terr y eeaars / Hours of operatio
tion. 1-2 y eeaars and 1000 hours 1-
1-22 y eeaars and 1000 hours 11 y eeaars and 72264 hours
1.6 Opera
Operation
tion conditions:
- Base operation. X (First years of operation) X (First years of operation) X X
- Load Cycling. Nº Starts / week: _____________. X (at least 7) X (at least 2)
1.
1.77 Oper
Operat
atio
ionn imp
impac
actt of mech
mechananica
icall inte
integr
grity
ity loss
loss of the
the
stator winding support
support sys tem.
- No impact. X
- Forced outage.
- Dura
Duration:
tion: days/weeks.
- Scheduled Outage extension. X X
90 days/weeks more. In 30 days/weeks more. In
- Dura
Duration:
tion: days/weeks. the worst case (2 the worst case (First
generator full rewind) generator detected)
End-winding repairs
(most repairs were
scheduled): • Small local
repaired with epoxy resin: End-winding repairs
Not affection.• Global (most repairs were
repairs with new ties and scheduled): • Small local
blocks: 1 week.• Full repaired with epoxy resin:
tying system change: 2 Not affection.• Global
- Other. Description: weeks. Slot section (most repairs with new ties and
repairs were scheduled):• blocks: 1 week. Slot
Slot side support section (most repair
repairss
repairs at slot ends: 1 were scheduled):• Slot
month irst machines side support repairs at
repaired / 2 weeks. • Full slot ends: 1 month irst
re-wedges:
re-we dges: 2 weeks.• machines repaired
repaired / 2
Generator full rewind: 3 weeks. • Full re-wedges: 2
months. weeks.
1.8 Charac te
ter of th
thee problem:
lem: Do y oouu c oonns iidder this
this
symptom
As an exexpe
pect
cted
ed nonorrmal
mal wear
ear and
and te
tear
ar of th
thee ge
gene
nerrat
ator
or
operation
As an excessiv
excessivee pr
prob
oblem
lem du
duee to som
somee fa
factor(like
ctor(like de
desig
sign,n,
X
abnormal operation, unexpect ed event , or ot her) X X
79

Turbogenerator
Acti tit y Manu facture
fact ure r Gene
Generat
rator
or Ow ner Gene
Generat
rator
or Owner
Own er Generat
Gene rator
or Ow ner
1.1 Generator Data:
Manufacturer C C C C
Rated Voltage (kV) 16,5 22 22 21
Rated Current (A) 21257 10300
Power Factor 0,85 0,9 0.9 0,8
Speed (rpm) 3000 3000 3000 3000

Manufacturing Year: 1995 Circa 1990 1986 - 1990 1973
Operating Time (hours): 50000-100000 Circa 83 000 hours Out of Service
Global VPI: NO No Yes No
Stator windings cooling type Indirect Air Direct H2 cooled Direct H2 cooled Direct H2 cooled
1.2 Is it a fle
leeet pr
prob
oble
lem?
m? Sa
Same
me or si
simi
mila
larr typ
typee/mod
/model
el of
generators show similar problems. YES Y ES YE S NO PROBLEMS
1.3 How many similar generat oorrs sh
shoows these
symptoms? 50-100 6 6 2
1.4 WhWheere have yo youu dete
tect
cteed lo
loss
ss of mechchaanica
call
integrity of the stator winding support systems? EW EW -SLOT EW -SLOT
- If both areas are invinvolve
lved, is th
theere any co
connnect
ctio
ionn
between both problems? Y ES NO

Looseness of end winding Poor assembly
support structure led to workmanship in slot
- Description:
looseness in slot section section (end wed
wedges)
ges)
area
5 years 50000-100000 10 years and 75000 hours
hours
- After Rewind.years / Hours of operation after rewind. X (2 YEARS)
- Base operation. X
X (MEDUIM AND PEAK
_____________.
LOAD OPERATION) X
1.7
1.7 Op
Oper
erat
atio
ionn im
impa
pact
ct of me
mech
chan
anica
icall in
inte
tegr
gritityy lo
loss
ss of th
thee
- No impact. X
- Forced outage. X
- Duration: days/weeks. 120 days (two sifts)
- Scheduled Outage extension. X
- Duration: days/weeks. Few days (EW TUNNING)
1.8 Charact
cteer of th
thee problem
lem: Do yo
youu co
connsider th
this
is
symptom
As an expe
expecte
ctedd norm
normalal wea
earr an
andd te
tear
ar of th
thee ge gene
nerrat
ator
or
operation
As an excess
excessiv
ivee pr
prob
oble
lem
m du
duee to som
somee fa
facto
ctorr (liike
ke de
desig
sign,
n,
abnormal operation, unexpected event, or other) X
As
As unexpected in this generator type and design X
80

Turbogenerator
ANSWER NU
NUMBER
MBER 16 17 18 19
Actitit
Acti tityy Generator
Genera tor Owne
Ownerr Genera
Generator
tor Owner
Owne r Generator
Genera tor Owner Generator
Genera tor Owner
Owne r
1.1 Generator Data:
Manufacturer C C C C
Rated Voltage (kV) 20 10,5 15,75 15,75
Rated Current (A) 21000 7423 8923 8923
Power Factor 0,8 0,85 0,85 0,85
Speed (rpm) 3000 3000 3000 3000
Manufacturing Year: 1975 1987 1995 1998
Operating Time (hours): Out of Service 122057 118954
Global VPI: No No Yes Yes
Stator windings cooling type Direct H2 cooled Indirect air cooled Indirect air cooled Indirect air cooled
1.2 Is it a fle
leet
et prob
proble
lem?
m? Sa
Same
me or simil
similar
a r type/
type/mo
mode
dell of
generators show similar problems. NO PROBLEMS NO PROBLEMS Yes Yes
1.3 How many similar generator
tors sh
shoows these
symptoms? 1 1 5 5
1.4 Whe
Where have you you dete tect
cteed loss of mech chaanica
call
integrity of the stator winding support systems? EW EW
- If both arareeas are in
invvolv
lveed, is th
theere any
any co
connnect
ctio
ionn
- Description:
- After years
y ears / Hours of operation.
5 years
years and 3000
300000 hours
hours 7 yea
years
rs and 5000
500000 hours
hours
Malsynchronisation after
75000 hours
- After Repair.years / Hours of operation after repair. 1 year and 5000 hours
- Base operation.
- Load Cycling. Nº Starts / week: _____________. X X (2-3 week)
1.7
1.7 Op
Oper
erat
atio
ionn im
impa
pact
ct of mech
mechananica
icall in
inte
tegr
gritityy lo
loss
ss of the
the
- No impact.
- Forced outage. X X
- Duration: days/weeks. 3-5 days every 1-2 years 3-5 days every 1-2 years
- Duration: days/weeks.
1.8 Characte
cter of th
thee problem: Do yo
youu co
connsider th
this
is
symptom
As an expe
expecte
ctedd norm
normal
al wear
wear and
and tear
tear of the
the gene
genera
rato
tor r
operation
As an excess
excessiv
ivee prob
proble
lem
m due
due to some
some facto
factorr (liike
ke desig
design,
n,
abnormal operation, unexpected event, or other) X X
81

Turbogenerator
ANSWER NU
NUMBER
MBER 20 21 22 23
Actitit
Acti tityy Generator
Genera tor Owne
Ownerr Genera
Generator
tor Owner
Owne r Manufa ctur
cturer
er Generator
Genera tor Owner
Owne r
1.1 Generator Data:
Manufacturer C D E E
Power output (MVA) 230 445MVA 300 376,47
Rated Voltage (kV) 15,75 15kV 19 20
Rated Current (A) 8431 17.129kA 9116 10688
Power Factor 0,85 0.9 0,85 0,85
Speed (rpm) 3000 3000rpm 3000 3000
Nº of Poles: 2 2pole 2 2
Frequency (Hz): 50 50Hz 50 50
Manufacturing Year: June 2007 – operation start 1975

1998 2006
Operating Time (hours): 115541 June 2007 – October 2012 67151 150.000
Global VPI: Yes NO
Stator windings cooling type Indirect air cooled Indirect H2 Indirect Air Direct water cooled
1.2 Is it a fleeetet prob
proble
lem?
m? Sa
Same
me or simil
similar
a r typ
type/
e/mo
mode
dell of
NO
generators show similar problems. Yes NO NO
1.3 How many similar generato
torrs sh
shoows th
theese
symptoms? 5 Just 1 1
1.4 Wh
Wheere have yo
youu dete
tect
cteed loss of mech
chaanica
call
EW - SLOT
integrity of the stator winding support systems? EW SLOT EW
- If both arareeas are in
invvolv
lveed, is th
theere an
anyy co
connnect
ctio
ionn
NO
- Description:

5 yea
years
rs aand
nd 50
5000
0000 hhou
ours
rs 5 year
yearss and
and 4 months
months 3 years
years and
and 23000
23000 hour
hourss 19 years
years and 8000
800000 hours
hours
- After event. Description: X
- Base operation. X X
- Load Cycling. Nº Starts / week: _____________. X (20 starts a year) X (2)
1.
1.77 Op
Oper
erat
atio
ionn impa
impact
ct of mech
mechan
anica
icall inte
integr
grity
ity loss
loss of th
thee
- No impact. X X
- Forced outage. X
- Duration: days/weeks. 97 days
- Duration: days/weeks. 1 week more
1.8 Charact
cteer of th
thee problem: Do yo
youu co
connsider th
this
is
symptom
As an ex
expe
pecte
ctedd no
norm
rmal
al we
wear
ar an
andd te
tear
ar of th
thee gegene
nera
rato
tor r
X
operation
As an excess
excessiv
ivee prob
proble
lem
m du
duee to som
somee fa
factor
ctor (liike
ke de
desig
sign,
n,
abnormal operation, unexpected event, or other) X X X
82

Turbogenerator
ANSW ER NUMBER 24 25 26
Act itit
it it y Gen er at
ator
or Ow ne r Man ufa ctu re r Gen er ato r Ow ne r
1.1 Generator Data:
M anufac t urer F G H
P ower out put (M V A ) 205 388 625
Rated V olt age (k V ) 15. 75 24 21
Rated Current (A ) 13000 9334 17184
P ower Fac tor 0. 85 0.85 0, 86
S peed (rpm ) 3000 3000 3000
Nº of P oles : 2 2 2
Frequenc y (Hz ): 50 50 50
M anufac t uring Y ear: 2012 1980 1974
Operat ing Tim e (hours ): 8303 > 150000 300000
Global V P I: No NO
S t at or windings c ooling t y pe Indirec t air c ooled Direc t wat er c ooled Direc t wat er c ooled
1.2 Is it a fleet
leet pr
proobl
blem
em?? Same
Same or simi
simila
larr type
type/m
/moodel
del of
NO
generators show similar problems. YES YES
1.3 How many s imilar generat ors s hows t hes e
symptoms? 2 to 7 2
1.4 W hheere have y ou det ec te ted los s of m ec ha
hanic al
SLOT
integrity of the stator winding support systems? EW EW
- If bot h areas are involved, is t he
here any c on
onnec tition
The visual inspection
carried out inside the
stator bore showed two
core
packet melted , one
- Description:
located on the tooth
nearby the slot nr. 50,
where the earth fault is
located

2 years and
and 88303
303 hhours
ours 25 years and 110000 hours
Various water leaks over
the years
- B as e operat ion. X X
- Load Cy c ling. Nº St art s / week : _____________. X (3)
1.7
1.7 Oper
Operaatio
tion im
imppact
act of me
mechchan
anic
icaal inte
integr
grit
ityy loss
loss of the
the
stator winding support
support sys tem.
- No impac t. X
- Forc ed out age. X
- Durat ion: day s / week s . 6 W EEKS
- S c heduled Outage ex t ens ion. X
- Durat ion: day s / week s . 10 DA Y S M ORE
1.8 Charac te
ter of t hhee problem: Do y oouu c on
ons id
ider this
symptom
As an expe
expectcted
ed nor
norma
mall wear and
and teteaar of the
the gener
eneraator
tor
operation
As an ex
exce
cessi
ssivve prob
proble
lem
m due
due to so
someme facto
actorr (l
(like
ike desig
design,
n,
abnormal operation, unexpected event, or other) X X
As
A s unex pec t ed in this generat or ty pe and des ign X
83

Turbogenerator
Acti titity
ty Gene rato r Ow ner Gene rator
rat or Own er Gene rator
rat or Own
Owner
er Gene rato r Ow ner
1.1 Generator Data:
Manufacturer I I J J
Rated Voltage (kV) 10,5 17 21 21
Rated Current (A) 2750 4967 23094 23094
Power Factor 0,8 0,8 0,8 0,8
Speed (rpm) 3000 3000 3000 3000

Manufacturing Year: 1986 1994 1976 1976
Operating Time (hours): Out of Service 102000 150000
Global VPI: No No NO NO
Stator windings cooling type Indirect air cooled Indirect air cooled Direct water cooled Direct water cooled
1.2 Is it a fle
leet
et pr
prob
oble
lem?
m? SaSame
me or simil
similar
ar typ
type/
e/mo
mode
dell of
NO PROBLEMS NO PROBLEMS YES YE S
generators
genera tors show similar
s imilar problems.
1.3 How many similar generators sh
shoows these
4 1 2 2
symptoms?
1.4 WhWheere have yo youu detetect
cteed lo
loss
ss of mechchaanic
icaal
EW EW
- If both areas are invinvolv
lveed, is th
theere any co
connnect
ctio
ionn

- Description:
25 years and 150000
- After years / Hours of operation. 18 years and 95000 hours
hours
- After event.
event. Description:
- Base operation.
- Load Cycling. Nº Starts / week: _____________. X (120 total) X (500 total)
1.7
1.7 Op
Opererat
atio
ionn im
impa
pact
ct of me
mech
chan
anic
ical
al in
inte
tegr
gritityy lo
loss
ss of th
thee
- No impact.
- Forced outage.
- Duration:
- Duration: days/weeks. 12 WEEKS
Scheduled Rewind on-site
(6 months)
1.8 Charact
cteer of th
thee problem
lem: Do yo
youu co
connsi
sidder th
this
is
symptom
As an ex
expe
pecte
ctedd no
norm
rmal
al wea
earr an
andd te
tear
ar of th
thee ge gene
nera
rato
tor r
operation
As an excess
excessiv
ivee pr
prob
oble
lem
m du
duee to som
somee fa
facto
ctorr (liike
ke de
desig
sign,
n,
abnormall operation, unexpected event, or other)
abnorma
As
As unexpected in this generator type and design X X
84

Turbogenerator
C.2. Enwinding answers chart

Acti tit y Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r Ge n e r a to r Ow ne
ne r Ge n e r a to r Ow n e r
MANUFACTURER A A B B
2 End
End Windi ng: DETECT
DETECTEDED PRO PROBLEM
BLEMS S DET
DETECT
ECTEDED PROBLEM
PROBLEMS S DETECT
DETECTEDED PROBLEM
PROBLEMS S DET
DETECT
ECTEDED PROBLEM
PROBLEMS S
2.1 End Windi
Winding
ng suppo
support rt syste
system
m de
desig
sign.
n. (Mar
(Markk al
alll
which are present in your generator).
- Rigid structure (with
(with massive rings to support the
winding and resist motion) X X
- Fle
Flexib
xible
le str
struct
ucturure(
e(aa liligghter
hter str
struc
uctu turre that
that buil
buildds
stre
strengngthth into
into the inter
intercon
conne nectio
ctions
ns betw
betwee eenn the stato
stator
r X
bars) X
- Suppor
Supportt stru
structur
cturee re
re-ti
-tighta
ghtable
ble or de-de-coup
coupledled.. (Allow
(Allow
to cor
correct
ect th
thee lo
looosen
senin
ingg of end ndw
win
indi dinngg or to be de de--
coupl
coupled ed by the adopadoptiotionn of ininsul
sulaatitinngg bo
bolts
lts,, spr
sprin
ings,
gs,
etc).
Support Brac ket s. X X
· At tached to Core: X X X
· At tached to Frame. X X
Int
nter
erfface
ace to alllowow axia
axiall thther
erma
mall ex
expa pans
nsioionn bebetw
twee
eenn
brackets and the rest of the support system.
- Mechanic al Mobile or sliding sy s tems . X X
Flexible system allows
axial expansion.
- Support s Brac es . X X X
- Support s Rings . X X X X
- Out er Diamet er. X X X X
- Inner Diameter.
- Block ing between top and bott om bask et s. X X X
- Rings . X X
- Bloc k s. X X
- Conforming mat erials: X X
- Impregnat ed Felt s . X X X X
- Flexible Tubes.
- Block ing of phase c onnec tions. X X X X
- Block ing between adjac ent winding bars . X X X X
- By pairs . X X X (By Groups )
- W hole Bask et . X
-Tying System.
- W et ties. X X X
- Dry ties : X
Depends on the
manufacturing year (Last
- Other:
4 machines were dry ties
and were changed to wet).
- Connect ion rings support s. X X X X

- Dedic at ed supports at tac hed t o c ore/frame. X X X X
- Using or attached to basket supports.
- End winding bloc ks or rings c los e to the s lot ex ist . X X
- Block s or rings at bar ends s eries connect ions. X X X X
- Ba
Barr ends
ends seri
series
es conn
connec
ectition
onss supp
suppor
ortt at
atta
tach
ched
ed to
frame/ c ore. X
- Bushing/ Phase leads s upport s. X X
- Bushing/ Phase leads flex ibilit y sy stems. X X X X
85

Turbogenerator
Acti tit y Ge n e ra to r Ow n e r Ge n e r a to r Ow n e r Ge n e ra to r Ow n e r Ge n e ra to r Ow n e r
2 EEnd
nd Wind ing: DETECT
DETECTEDED PROPROBLEM
BLEMSS DET
DETECT
ECTEDED PRO PROBLEM
BLEMSS DET
DETECT
ECTEDED PROPROBLEM
BLEMSS DET
DETECT
ECTEDED PROPROBLEM
BLEMSS
2.2 Indic icaate areas where you
you have dete tect
cteed
vibration / lost of mechanical integrity
sym
sympto
ptoms/e
ms/evvid
iden
ence
ce in the en
end-
d-wi
windin
n dingg (M
(Mar
arkk all in
your generator).
- End winding legs ties to support rings. X X X
- Dusting. X X
- Greasing. X X X
- Broken ties.
- Abraded Insulation.
- Support Brackets. X X X
- Supports Braces. X X X
- Connection rings blocks and ties. X X X
- Dusting. X X
- Greasing. X X X
- Broken ties. X X X
- Abraded Insulation. X X
- Series loops (bar to bar) connections. X
- Dusting.
- Greasing. X
- Broken cooper strands.
- Broken connection. X
- Type of bar-to-bar connection:
- Strand-to-strand.
- Solid cooper connection. X X X
- Blocking of Phase leads to connection rings. X X X
- Dusting.
- Greasing. X X X
- Insulation and/or copper strand cracks or damage
just at the slots exits.
- Loose or lost connection.
- Broken copper strands.
- Broken Stand off insulators.
- Cooling tubes.
- Fatigue of cooling tubes.
- Leakages.
- Water nozzels.
- Cracked bar connections.
- Water Leaks.
No signs of vibration or
lost of mechanical
- Other. Description: integrity symptoms were
detected prior to the
failure.
2.3. Hav
Have yo
youu de
dete
tecte
ctedd un
unus
usua
uall oil
oil pr
pres
esen
ence
ce over
over
the winding surface?
- No X
- Yes. X X X
- Level Low. . X X X
- Level Medium. X X
- Level High
86

Turbogenerator
Acti tit y Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r
2 End
DETECTEDED PROBLE
PROBLEMS MS DET
DETECT
ECTEDED PRO PROBLEM
BLEMS S DET
DETECT
ECTEDED PROPROBLE
BLEMS MS DET
DETECT
ECTEDED PRO PROBLEM
BLEMS S
2.4 Furt
Furthe
herr Visua
Visuall In
Insp
spec
ectio
tion,
n, Ha
Havve you
you dete
detecte
ctedd or
con
confifirm
rmed
ed en
endd wind
windiningg mech
mechananica
icall integ
integri
rity
ty lost
lost by
other technique?
- End winding vibration monitoring system.
- Max
Maximu
imum
m Displa
Displaceme
cementnt or acce
accele
lera
ratio
tion(
n(pe
peak
ak
to peak): m/s 2 or g.
- Direction:
- Radial.
- Tangential.
- Axial.
- Bump Tes t . X X
- Power Natural Frequenc y (50/ 60Hz ). X
- Twice Power Natural Frequency (100/120 Hz).
- Esta
Estabblish
lisheed ma
margrgin
in to take
take into
into ac
acco
coununtt te
test
st
limitations (t empera
emperature,
ture, response non-linearity,
non-linearity, etc).
- Description:
- Water Cooled
Cooled::
- Filled with water.
- Empty
- Base line test after manufacturing.
manufacturing.
- Any differences?
- Description:
- Does thisthis expe
xperien
ience of you
yours reininfforce ththee
ne
nece
cessi
ssity
ty of bas asee line
line tetest
st afte
afterr ma
mannufac
ufactuturi
rinng for
fingerprint ? NO X X
- Yes
- No
No signs of vibration or
lost of mechanical
integrity symptoms were Glow Energy has
detected prior to the installed the online PD.
failure. Sensor at this generator
2.5. Ha
Hass gene
generarator
tor exp
exper
erie
ience
ncedd a fault
fault in serv
service or
HiPot failure for this end winding problem?.
- No X X X
- Yes. X
- In Servic e. X
- Hi Pot.
2.6.
2.6. Possi
Possibl
blee Roo
oott Caus
Causee. (M
(Mar
arkk all hypo
ypoth
theesi
siss for
your generator).
- Des ign. X X X
- Ass embly / workmans hip. X
- Improper Applic at ion. X X
- Unus ual operat ion conditions. X X X
- Poor maintenance.
- Normal winding ageing / tying relaxation regarding
age/running hours. X
X (Failure from other
equipment that create
fault & mechanical
stress & End winding )
Dry ties: non effective
design. It was change for
wet ties after about 18000
hours/2-3 years under Wet ties: It was related
Low cycle fatigue at one
manufacturer with improper method
- Detailed description of the possible root cause: stator coil / circuit ring
recommendation.
recommenda tion. W et application. Some ties
connection.
ties: It was related with were removed an re-tied.
improper method
application. Some ties
were removed an re-tied.
2.7.
2.7. Has th
this
is RCA be
been
en ag
agre
reeed wit
ithh th
thee gen
eneerato
rator
r
manufacturer?.
- No X
- Yes. X X X
87

Turbogenerator
ANSWER NUMBER
NUMBER 1 2 8 9
Actit ity Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r
2 End
End Wind ing: DETEC
DETECT
TED PROBL
PROBLEMS
EMS DET
DETECT
ECTED
ED PROBL
PROBLEMS
EMS DET
DETECTED
ECTED PROBL
PROBLEMS
EMS DET
DETEC
ECT
TED PROBL
PROBLEMS
EMS
2.8. Action taken.
- Generator Replacement. X
- Rewind. X X
- Partial rewind.
- Full rewind. X
- Repairs. X X X X
- Flooding loose ties with epoxy resin. X X
-- Ties
Re-tyreplacement.
ing over oldt.tiTying
replacemen es. system
sys tem has been X (MICA TAPE TO PLY X X
modified from/to GLASS TYPE) X (DRY TO W ET)
- Insulation local repairs. X X
- Re-tightening throw the provided system.
sy stem.
Replacement of all stator
Replacement
coils / circuit rings
- Other. Description
connections, with a new
connection design.
- End winding support system design modification:. X X X
- Intro
Introduce
duce new block/ties/s upport rings or
modification of its position. X X X
- Introduce new or add elements in end-winding
radial support
support sys tem.
- Intro
Introduce
duce mobile or sliding systems
sys tems to allow
axial thermal expansion.
- Introduce End winding wedging or support
rings close to the slot exist.
- Introduce wedging or support rings at bar ends

series connections.
2.9. End winding
winding monitoring system:
sys tem:
- Technology:
- Conventional
Conventional vibration sensors
- Optical vibration measurement system X
- Monitored frequency:
- W ide range of frequencies. X
- Only twic
twicee power frequency.
- Monitored Direction:
- Radial. X
- Tangential. X
- Axial. X
- Monitored Parameters:
- Displacement. X
- Velocity.
- Acceleration
Acc eleration..
- Nº of sensors on each generator end: 9
- Additional information: 3 positions (3 axes)
- Core vibration monitoring:
- No X X X X
- Yes.
- Have you set alarm level? X
- No X
- Yes.
- Level (peak to peak/rms): m/s2 or g.
- Have you set trip level? X
- No X
- Yes.
- Trip/Alarm levels established by:
- OEM.
- Monitoring system supplier.
- Generator owner/operator experiences.
experienc es.
There is no endwinding Only one unit have EWV No EWV monitoring
vibration monitoring monitoring system in our system on this model in
- Additional information: system. fleet.. our fleet..
88

Turbogenerator
ANSWER NU NUMBER
MBER 12 13 14 18
Actitity
Acti tity Ma nufacture r Ge ner ator Ow ne r Gene rator Ow ner Gen era tor Ow ne r
MANUFACTURER C C C C
2 EEnd
nd Windi ng: DETECT
DETECTED
ED PROBLEM
PROBLEMSS DET
DETECT
ECTED
ED PRO
PROBLEM
BLEMSS DET
DETECT
ECTED
ED PRO
PROBLEM
BLEMSS DET
DETECT
ECTED
ED PRO
PROBLEM
BLEMSS
2.1 EnEndd Windi
Windinngg susupppporortt system
system desig
design.n. (M
(Mar
arkk all
- Rigid structure ( with massive rings to support the
X
winding and resist motion) X
- Fleexib
xible
le struc
structur e(a light
ture( hteer str
struc
uctuturre that
that bubuililds
ds
stre
streng
ngthth in
into
to the interco
interconnnnecti
ectioons
ns betwee
betweenn the stator
stator
bars) X
- Suppo
Supportrt stru
structur
cturee re
re-tig
-tighta
htable
ble or de-co
de-coupupled
led.. (Allow
low
to co
corrrect th
thee lo
looose
sennin
ingg of endwind inding
ing or to be de-
X
coupl
coupleedd by ththee ad
adopoptio
tionn of ininsu
sula
latin
tingg bolts,
bolts, sp
sprirings,
ngs,
etc).
Support Brackets.
· Attached to Core: X
· Attached to Frame. X
Inter
Interfa
face
ce to alllow
ow ax axia
iall th
thererma
mall ex
expapans
nsio
ionn betw
betwee eenn
- Mechanical Mobile or sliding syst systems.
ems. X
- Sliding layer in between.between.
- Other. Description: X X (6mm GAP)
- Supports Braces. X X
- Supports Rings. X X X X
- Outer Diameter. X X X
- Inner Diameter. X
- Blocking between top and bottom baskets. X X X
- Rings. X
- Blocks. X X X
- Conforming materials: X X
- Impregnated Felts. X X X
- Flexible Tubes. X X X
- Blocking of phase connections. X X X
- Blocking between adjacent winding bars. X X X X
- By pairs.
- Whole Basket. X X X X
-Tying System.
- Wet ties. X X X
- Dry ties:
- Other: GVPI
- Connection rings supports. X X X X
- Dedicated supports attached to core/frame.
core/frame. X
- Using or attached to basket supports. X X X
- End winding blocks or rings close to the slot exist. X X
- Blocks or rings at bar ends series connections. X X X
- Ba
Barr ends
ends seri
series
e s conn
conneections
o ns sup
suppor
port atta
attach
cheed to
frame/core.
- Bushing/Phase leads supports. X X X
- Bushing/Phase leads flexibility systems. X X X
89

Turbogenerator
ANSWER NUMBER
NUMBER 12 13 14 18
Actitity
Acti tity Ma n ufa ctu re r Ge ne r ato r Ow ne r Ge ne r ato r Ow n e r Gen e ra to r Ow n er
2 End Winding: DETECT
DETECTED
ED PROBLEMS
PROBLEMS DETECT
DETECTED
ED PRO
PROBLEMS
BLEMS DETECT
DETECTED
ED PRO
PROBLEMS
BLEMS DETECT
DETECTED
ED PRO
PROBLEM
BLEMSS
2.2 Indica
icate areas where yo youu have dete tect
cteed
sympt
symptomoms/e
s/evvid
iden
ence
ce in th
thee en
end-
d-wi
windin
n dingg (M
(Mar
arkk all in
your generator).
- End winding legs ties to support rings. X X X X
- Dusting. X X X X
- Greasing. X
- Broken ties. X X X
- Abraded Insulation. X
- Support Brackets. X X X
- Connection rings blocks and ties. X X
- Dusting. X X
- Greasing.
- Broken ties. X
- Series loops (bar to bar) connections. X X
- Dusting. X X
- Greasing.
- Broken cooper strands. X
- Broken connection.
- Strand-to-strand. X
- Solid cooper connection.
- Blocking of Phase leads to connection rings. X X X
- Dusting. X X X
- Greasing. X
- Cooling tubes. X
- Fatigue of cooling tubes. X
- Leakages.
- Water nozzels.
- Water Leaks.
2.3. Ha
Havve you de
detec
tecte
tedd un
unusu
usual
al oil pr
prese
esence
nce ov
over
er
- No X X X
- Yes. X
- Level Low. . X
- Level Medium.
Medium .
- Level High
90

Turbogenerator
ANSWER NUMBER
NUMBER 12 13 14 18
Acti ti ty Ma n u f a c tu r e r Ge n e r a to r Ow n e r Ge n e r a t o r Ow n e r Ge n e r a t o r Ow n e r
2E End
nd Winding : DETECT
DETECTED PROBL
PROBLEMS EMS DETECTED
ECTED PR PROBL
OBLEMS
EMS DET
DETECT
ECTED PR PROBL
OBLEMS
EMS DET
DETECT
ECTED PR PROBL
OBLEMS
EMS
2.4 Furth
Further
er Visua
Visuall Insp
Inspec
ectio
tion,
n, Ha
Havve you
you detec
detecte ted
d or
con
confifirm
rmed
ed end
end wi
wind
ndining
g me
mech
chan
anica
icall in
inte
tegr
grity
ity lo
lost
st by
other technique?
- End winding vibration monitoring sys tem. X
- Max
Maximu
imum
m Di
Displ
splace
aceme
mentnt or acce
accele
lera
ratio
tion(
n(pe
peak
ak
to peak): m/s 2 or
or g. Depends s trongly on des ign
- Direction:
- Radial. X
- Tangential.
- Axial.
- Bump Tes t . X Rewind, including modal analy sis X
- Power Natural Frequency (50/60Hz).
- Twice Power Natural Frequenc y (100/120 Hz). X
- Esta
Estab
blish
lished
ed ma
marg
rgin
in to take
take in
into
to acco
accouunt tetest
st
limit ations (t emperat ure, res pons e non-linearit y, et c). X X
bump test at room temp
- Description: has to be translated to
operat ing temperature. . 10 Hz
- Water Cooled:
- Empty
manufacturing. X
- Any differences?
Is now a standard to avoid
- Description: later on running at
resonance. No manufac turing base line
- Does th thii s ex pe
peri en
enc e of y ou
ours rei n
nfforc e th
the
e
nece
necessi
ssityty of basease lin
line test
test after
ter ma
mannuf
ufac
actuturi
ring
ng for X
fingerprint ?
- Yes X
- No
- Part ial Dis charges Test s. X
TG monitoring before
shutdown, and after star-
up and post
- Other. Description: Visual Inspection.
synchronization (this
included comparison and
trending)
2.5. Ha
Has s gene
generarator
tor exp
exper
erie
ience
nced
d a fa
fault
ult in ser
serv
vice or
- No X X X X
- Yes.
- In Service.
- Hi Pot.
2.6
2.6. Possi
Possibl
ble
e Root Cause
use. (M
(Mar ark
k al
alll hypot
ypoth
hesis
esis for
your generator).
- Design. X X X
- As sembly / work mans hip. X X X
- Unus ual operation c onditions . X X
- Poor maintenance.
age/running hours.
The original root cause

presented by the
manufacturer
manuf acturer is that
global endwinding
resonance was the root
cause. However even in
endwindings with a 4 node
First design has not taken
natural frequency mode
into account the long term
20-30Hz above the 100Hz
relaxation of insulation
excitation freq
frequency
uency we
- Detailed description of the possible root cause: material under peak load
have seen similar
operation and high Poor design: No sliding
symptoms. Our view view is
temperature (non-linear mechanism for expansion
that the original design
material effects) owing to temperature
had insufficient
insufficient flexibility
increase. Assembly /
to allow for thermal
workmanship: Improper
expansion during load
resin mix, dry tie chords.
cycling / two shifting, this
Unusual operation
has lead to cracking and
conditions: Two GSU
decohesion of the
transformer faults on Unit
endwinding structure
2 transformer
2.7
2.7. Has this
this RCA been
been agre
greed wit
ith
h th
the
e gene
generrat
ato
or
manufacturer?.
- No X X
- Yes. X
91

Turbogenerator
ANSWER
ANSWE R NU
NUMBE
MBER
R 12 13 14 18
Actiti ty Ma nu fa ctur er Gen e ra to r O
Ow
w ne r Gen er ato r O
Ow
w ner Ge ne ra tor Ow
Ow n er
2E
End
nd Windi ng: DETEC
DETECT
TED PROBL
PROBLEMS
EMS DET
DETECT
ECTED
ED PROBL
PROBLEMS
EMS DET
DETECTED
ECTED PROBL
PROBLEMS
EMS DETEC
DETECT
TED PROBL
PROBLEMS
EMS
2.8. Action taken.
- Rewind. X
- Partial rewind.
- Full rewind. X
- Repairs. X X X
- Flooding loose ties with epoxy resin. X
- Re-tying over
over old ties.
- Ties replacement. Tying sys
system
tem has been
modified from/to X
- Re-tightening throw the provided sys
system.
tem.
Tuning end winding Removed and re-installed

- Other. Description basket by modification of support ring. Modification
local fixing elements of resin mat to Dacron
felt/Dacron wrapped shims
- End winding support system design modification:. X X X X
- Introduce
Introduce new block/t ies/support rings or
X X
modification of its position. X X
X X
radial support system. X
- Introduce
Introduce mobile or sliding sys
systems
tems to allow
X
X
X
series connections.
Cutting of a slit through
the endwinding support
brackets to provide
- Other. Description: flexibility between the
endwinding bar fixing and
the fixed metal support
brackets.
2.9. End winding
winding monitoring sys
system:
tem:
- Technology:
- Conv
Conventional
entional vibration sensors X
- Optical vibration measurement system X
- Wide range of frequencies. X X X
- Only twice power frequ
frequency.
ency.
- Radial. X X X
- Tangential. X X
- Axial.
Parameters:
- Displacement. X
- Velocity.
- Acceleration. X X
- Nº of sensors on each generator end: Depends on design
- Additional informa
information:
tion:
- No X
- Yes. X X
- Have you set alarm level?
- No X X
- Yes. X
- Lev
Level
el (peak to peak/rms): m/s2 or g.
- Have you set trip level?
- No X X X
- Yes.
- OEM.
- Generator owner/operator experiences. X
Installed vibration
Trending information in monitoring system has
correlation to gener
generator
ator been out of commission
load parameter is most for a while. No data
- Additional
Additi onal information: important available.
92

Turbogenerator
Acti tity
ti ty Ge n e r a to r Ow
Ow n e r Ge n e ra to r Ow
Ow n e r Ge n e r a to r O
Oww n e r Ma n u fa ctu r e r
MANUFACTURER C C D E
2 End
DETECTEDED PROBL
PROBLEMSEMS DET
DETECT
ECTEDED PR PROBL
OBLEMS
EMS O PR
PROBL
OBLEMS EMS DDET ETECT
ECTEE DET
DETECT
ECTED
ED PR PROBL
OBLEMS EMS
2.1 EnEndd Windi
Windinngg sup
suppo
portrt system
system dedesig
sign.
n. (M
(Mararkk all
- Rigid structure (with massive rings to suppor
s upportt the
X
winding and resist motion) X X
- Fle
Flexib
xible
le struc
structur e(a lighte
ture( g hterr str
struc
uctu
turre th
that
at buil
builds
ds
stren
strength
gth into
into the inter
intercon
conne
nectio
ctions
ns betw
betwee eenn the stat
stator
or
bars)
- Suppo
Supportrt structur
structuree re-tig
re-tighta
htable
ble or dede-co
-coup
upled
led.. (Allow
(Allow
to co
corrrect ththee lo
looose
sennin
ingg of endwin inddiningg or to be de-
coup
coupleledd by the adadop
optio
tionn of in
insul
sulati
a tinngg bo
bolts,
lts, sp
spririnngs,
gs,
etc). X
Support Brackets. X
· Attached to Core: X X X X
· Attached to Frame.
In
Inter
terfa
face
ce to alllow
ow axiaall therm
thermalal ex
expa pansi
nsioonn be
betwtweeeenn
brackets and the rest of the support system. X
- Mechanical Mobile or sliding systems. syst ems. X
between.
Deformable plate springs
(leaves)
- Supports Rings. X X X X
- Outer Diameter. X X X X
- Inner Diameter.
- Blocking between top and bottom baskets. X
- Rings.
- Blocks. X
- Conforming materials: X
- Flexible Tubes. X X
- Blocking of phase connections. X X X
- Blocking between adjacent winding bars. X X X
- By pairs. X
- W hole Basket. X X
-Tying System.
- W et ties. X
- Dry ties: X
- Other: GVPI GVPI
- Connection rings supports. X X X X
- Dedicated supports attached to core/frame. X
- Using or attached to basket supports. X X X
- End winding blocks or rings close to the slot exist. X
- Ba
Barr en
ends
ds se
seriries
e s conn
connec
ectition
onss su
supp
ppor
ortt at
atta
tach
ched
ed to
frame/core.
- Bushing/Phase leads supports. X X X
93

Turbogenerator
Acti tity
ti ty Ge n e r a to r Ow
Ow n e r Ge n e ra to r Ow
Ow n e r Ge n e r a to r O
Oww n e r Ma n u fa ctu r e r
2 End
DETECTEDED PROBLEMS
PROBLEMS DETDETECT
ECTEDED PROBLEMS
PROBLEMS O PROBLEMS
PROBLEMS DETECT DETECTEE DET
DETECT
ECTED
ED PROBLEMS
PROBLEMS
2.2 Indica
icate areas where yo youu have dete tect
cteed
sympt
symptomoms/e
s/evvid
iden
ence
ce in the
the end-
end-wi
windin
n dingg (Mar
(Markk all in
your generator).
- End winding legs ties to support rings. X X
- Dusting. X X
- Greasing.
- Broken ties. X X
- Support Brackets. X X
- Supports Braces.
- Connection rings blocks and ties. X X
- Dusting. X X
- Greasing.
- Broken ties.
- Series loops (bar to bar) connections. X X
- Dusting. X X
- Greasing.

- Strand-to-strand.
Strand-to-s trand.
- Blocking of Phase leads to connection rings. X X
- Dusting. X X
- Greasing.
ex its.
- Bushing/Phase leads suppor
s upports.
ts.

insulat ors.
- Cooling tubes.
- Leakages.
- Water nozzels.
- Water Leaks.
End of core location
- Other. Description: Bolt in the endwinding Bolt in the endwinding where the bar exits the Loosen blocks betwee
betweenn
structure become loose structure become loose slot bars endwinding
2.3. Hav
Have you dete
detecte
ctedd unus
unusua
uall oil prese
presenc
ncee ov
over
er
- No X X X
- Yes. X
- Level Low. .
- Level Medium.
- Level High X
94

Turbogenerator
ANSWER NU NUMBER
MBER 19 20 21 22
Actit ity Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r Ge n e r a to r Ow n e r Ma n u fa ctu r e r
DETECTED
ED PROBLEMS
PROBLEMS DET
DETECT
ECTED
ED PRO
PROBLEM
BLEMS
S O PR
PROBLE
OBLEMS
MS DET
DETECT
ECTE
E DET
DETECT
ECTED
ED PROBLEM
PROBLEMS
S
2.4
2.4 Fu
Furt
rthe
herr Vi
Visu
sual
al Inspe
nspecti
ction
on,, Ha
Havve yo
you
u dete
detecte
cted
d or
conf
confir
irme
medd end
end windi
inding
ng me
mech
chan
anic
ical
al in
inte
tegr
grity
ity lo
lost
st by
other technique?
- End winding vibration monitoring syst em. X
- Maximu
Maximum m Displ
Displace
aceme
ment
nt or acceler
accelerati
ation
on(p
(pea
eak
k
to peak): m/s2 o
orr g. 6g
- Direction:
- Radial. X
- Tangential.
- Axial.
- Bump Test. X X X
- Twice Power Natural Frequency (100/120 Hz). X X
- Es
Estatabl
blis
ish
hed marg
marginin to ta
take
ke ininto
to acco
accoun untt te
test
st
limitations (temperature, response non-linearity, etc). X X
- Description: 10 Hz 10 Hz
- Water Cooled:
- Empty
- Base line test after manufacturing. X
- Any differences?
- Description: No manufacturing base line N
No
o manufacturing base line
- Does t hi hi s ex pe
peri en
enc e of y ouours rei n
nfforc e t h
he
e
neces
ecessisity
ty of base
base line
line tetest
st afte
terr manu
manuffactu
acturiring
ng for
fingerprint ?
- Yes X X
- No X
Due to oil contamination
of the stator bars
2.5. Has
Has gegene
nera
rator
tor exper
experien
ienced
ced a fa
fault
ult in ser
serv
vice or
- No X
- Yes. X X
- In Service. X
- Hi Pot. X
2.6.
.6. Po
Poss
ssib
ible
le Root
oot Cause
ause.. (Mark
Mark al
alll hypo
hypoth
thes
esis
is for
your generator).
- Design. X X
- Ass embly / workmanship.
- Unusual operation conditions. X X
- Poor maintenance.
age/running hours.
The original root cause

presented by the
The original root cause manufacturer is that
presented by the global endwinding
manufacturer is that resonance was the root
global endwinding cause. However even in
The unit suffered a sudden
resonance was the root endwindings with a 4
short circuit at line
cause. However even in node natural frequency
terminals. The restoration
endwindings with a 4 node mode 20-30Hz above the
activities did not include
natural frequency mode 100Hz
100H z excitation
retightening of adjustable
20-30Hz above the 100Hz frequency we have seen The generator was
clamping system. The
excitation frequency we similar symptoms. Our operated with seal oil
- Detailed description of the possible root cause: unit came back in
have seen similar view is that the original contamination in the
operation and after a few
symptoms. Our view is design had insufficient stator slots
years , during a minor
that the original design flexibility to allow for
inspection, the vibration
had insufficient flexibility thermal expansion during
were detected (by means
to allow for thermal load cycling / two shifting,
of visual inspection of
expansion during load this has lead to cracking
endwindings).
cycling / two shifting, this and decohesion of the
has lead to cracking and endwinding structure.
decohesion of the Recent OEM information
endwinding structure suggests lack of flexibility
is a contributing factor to
cracking / dusting.
2.7.
.7. Has th
this
is RCA been
been agr
agree
eed
d wit
ith
h th
the
e gener
enerat
ator
or
manufacturer?.
- No X X
- Yes. X X
95

Turbogenerator
Acti tit y Ge n e r a to r O
Ow
w ner Ge n e r a to r O
Ow
w n er Ge n e r a to r O
Ow
w ner Ma n u f a c t u r e r
2E End
nd Wind ing: DETECT
DETECTEDED PROBL
PROBLEMS
EMS DET
DETECT
ECTED ED PROBL
PROBLEMS EMS O PRO
PROBLEM
BLEMS S DET
DETECT
ECTE
E DET
DETECT
ECTED
ED PROBL
PROBLEMS EMS
2.8. Action taken.
- Rewind. X
- Partial rewind. X
- Full rewind.
- Repairs. X X X
- Flooding loose ties with epoxy resin. X X
- Re-tying over old ties.
- Ties replacement.
replacement. Tying syst em has been
modified from/to X X
- Re-tightening throw the provided system. X
Additional spacers and
binding was done. New
- Other. Description end wedges were
installed for increased
robustness_
- End winding support system design modification:. X X
- Introduce
Introduce new block/ties/s
block/ties/suppor
upportt rings or
X
modification of its position. X X
radial support
support sy
system.
stem.
- Introduce
Introduce mobile or sliding syst ems to allow
series connections.
- Other. Description: X X
2.9. End winding mo monitoring
nitoring system:
- Technology:
- Conve
Conventional
ntional vibration sens
sensors
ors
- Optical vibration measurement system X X
- W ide range of frequencies. X
- Only twice power frequency.
- Radial. X X
- Tangential. X X
- Axial. X X
- Displacement.
- Velocity. X
- Acceleration. X
- Additi
Additional
onal information:
- No X X
- Yes.
- No X
- Yes. X
- Level (peak to peak/rms): m/s2 or g. 75 mm/s
- No X X
- Yes.
- OEM.
- Monitoring system supplier
s upplier..
- Additional information:
96

Turbogenerator
ANSWER NUMBE
ANSWER NUMBERR 23 24 25 26
Actiti ty Gener ator Ow ne
ner Generator Ow ne
ner Manufactur er Generator Ow nneer
MANUFACTURER E F G H
2 EEnd
nd Windi ng: DETECT
DETECTED
ED PROBLEMS
PROBLEMS O PROBLEMS
PROBLEMS DET
DETECT
ECTEE DET
DETECT
ECTED
ED PRO
PROBLEMS
BLEMS DET
DETECT
ECTED
ED PROB
PROBLEMS
LEMS
2.1 En
Endd Windi
Windinngg suppo
supportrt system
system desig
design.
n. (M
(Mar
arkk all
- Rigid structure (with massive rings to support the
X X X
winding and resist motion) X
- Fle
Flexib
xible
le struc
structur e(a lighte
ture( g hterr struc
structu
ture
re th
that
at bu
buililds
ds
streng
strengthth into
into the interco
interconnnnecti
ectioons
ns betwee
betweenn the stator
stator
bars)
- Suppo
Supportrt stru
structur
cturee re
re-tig
-tighta
htable
ble or de-co
de-coupupled
led.. (Allow
low
to co
corrrect th
thee lo
looose
sennin
ingg of endwindinding
ing or to be de-
X
co
coup
uple
ledd by the adadopoptio
tionn of in
insul
sulati
ating
ng bolts,
bolts, sp
sprirings,
ngs,
etc).
Support Brackets. X
· Attached to Core: X X X
· Attached to Frame. X
Inter
Interfa
face
ce to alllow
ow axiaall the
therm
rmal
al ex
expa
pansi
nsion
on betw
betwee
eenn
- Mechanical Mobile or sliding systems. X X
between.
- Supports Braces. X
- Supports Rings. X X X
- Outer Diameter. X X
- Inner Diameter.
- Blocking between top and bottom baskets. X X X
- Rings. X X
- Blocks. X
- Conforming materials: X X
- Flexible TubTubes.
es.
- Blocking of phase connections. X X
- Blocking between adjacent winding bars. X X X
- By pairs. X X
- Whole Basket. X
-Tying System.
- Wet ties. X X X
- Dry ties:
- Other:
- Connection rings supports. X X
- Dedicated supports attached to core/frame
core/frame.. X
- Using or attached to basket supports. X X
- End winding blocks or rings close to the slot exist. X X
- Ba
Barr ends
ends seri
series
e s conn
connec
ectio
tionns su
supp
ppor
ortt atta
attach
ched
ed to
frame/core.
- Bushing/Phase leads supports. X X
97

Turbogenerator
ANSWER NU
ANSWER NUMBER
MBER 23 24 25 26
Actitity
Actit ity Gener ator Ow ne
ner Gene rator Ow ne
ne r Man ufactur er Gener ator Ow ne
ner
2 EEnd
nd Windi ng: DETECT
DETECTED
ED PROBL
PROBLEMS
EMS O PROBLE
PROBLEMS
MS DET
DETECT
ECTEE DET
DETECT
ECTED
ED PR
PROBL
OBLEMS
EMS DETECT
DETECTED
ED PR
PROBL
OBLEMS
EMS
2.2 Indicaicate areas where youyou have detect tecteed
sympto
symp toms/
ms/ev
evid
iden
ence
ce in th
thee en
end-
d-wi
windin
n dingg (M
(Mar
arkk all in
your generator).
- End winding legs ties to support rings. X X
- Dusting. X
- Greasing. X
- Broken ties.
- Support Brackets.
- Dusting.
- Greasing.
- Broken ties.
- Series loops (bar to bar) connections. X
- Dusting.
-- Broken
Greasincooper
g. strands. X
- Strand-to-strand. X
- Blocking of Phase leads to connection rings. X
- Dusting. X
- Greasing. X
just at the slots
slots exits.
- Bushing/Phase leads supports. X
- Broken Stand off insulators. X
- Cooling tubes.
- Leakages. X
- Water nozzels.
- Water Leaks.
2.3. Hav
Have yo
youu de
detec
tected
ted un
unus
usua
uall oil pres
presen
ence
ce ov
over
er
- No X X X
- Yes. X
- Level Low. . X
- Level
Level Medium.
- Level
Level High
98

Turbogenerator
ANSWER NUMBE
NUMBERR 23 24 25 26
Actitity
Acti tity Ge ner ator Ow ne
ner Gen era to r Ow nnee r Ma nufa ctur er Gene ra to r Ow ne
ne r
2 EEnd
nd Windi ng: DETECT
DETECTED
ED PROBLEMS
PROBLEMS O PR
PROBL
OBLEMS
EMS DETDETECT
ECTEE DETECT
DETECTED
ED PROBLEM
PROBLEMSS DETECT
DETECTED
ED PROBLEM
PROBLEMSS
2.4
2.4 Furt
Furthe herr Vi
Visua
suall Inspe
nspecti
ction,
o n, Ha
Havve you dete
detecte ctedd or
con
conffirirme
medd end
end windin
n dingg mecha
mechani niccal
al in
inte
tegr
gritityy lo
lost
st by
other technique?
- Ma
Maximu
ximum m Displ
splaceme
acement nt or acceler
accelerati ation(p
on(pea
eakk
to peak): m/s 2 or g.
- Direction:
- Radial.
- Tangential.
- Axial.
- Bump Test. X X
- Power Natural Frequency (50/60Hz). X
- Twice Power Natural Frequency (100/120 Hz). X X
- Es
Esta
tabl
blishe
i shedd mar
margin to ta
take
ke in
into
to ac
acco
couunt te
test
st
limitations (temperature,
(temperature, response non-linearity,
non-linearity, etc).
- Description:
- Water Cooled:
- Empty X
- Any differences?
- Description:
- Does th this
is expe
xperien
ience of yoyouurs reinf
inforce ththee
nece
necessi
ssittyy of base
base line
n e te
test
st aftter
er manu
manuffacactu
turring
ing for
fingerprint ?
- Yes X X
- No X
- Partial Discharges Tests. X
2.5. Has
Has gene
genera
rator
tor exper
experie
ience
ncedd a faul
fault in serv
service or
- No X X X
- Yes.
- In Service.
- Hi Pot.
2.6.
2.6. Po
Possi
ssible Root
oot Cause
ause.. (M
(Maark all hy
hyppot
othhes
esis
is for
your generator).
- Design. X X
- Assembly / workmanship. X X
- Poor maintenance. X
X
age/running hours.
- Detailed description of the possible root cause:
2.7.
2.7. Has ththis
is RCA been
een agre
agreed
ed with
ith th
thee gen
generat
erator
or
manufacturer?.
- No X
- Yes. X X X
99

Turbogenerator
ANSWER NU
ANSWER NUMBE
MBER
R 23 24 25 26
Actiti ty Ge ne ra tor Ow ne
ner Gen e ra to r Ow nnee r Man ufa ctur er Ge ne ra tor Ow nneer
2 End
DETECTED
ED PROBLEMS
PROBLEMS O PRO
PROBLEMS
BLEMS DET DETECT
ECTE E DET
DETECT
ECTED
ED PROBLEMS
PROBLEMS DET
DETECT
ECTED
ED PROBLEMS
PROBLEMS
2.8. Action taken.
- Rewind.
- Partial rewind.
- Full rewind.
- Repairs.
- Flooding loose ties with epoxy resin.

- Re-tying over
over old ties.
- Ties replacement. Tying syssystem
tem has been
modified from/to
- Re-tightening throw the provided system. X
- End winding support system design modification:.
- Introdu
Introduce
ce new block/t
block/ties/support
ies/support rings or
modification of its position.
radial support system.
- Introdu
Introduce
ce mobile or sliding sys
systems
tems to allow
series connections.
2.9. End winding monitoring system:
- Technology:
- Conv
Conventional
entional vibration sensors X
- Optical vibr
vibration
ation measuremen
measurementt sys
system
tem
- Wide range of frequencies
frequencies..
- Only twice power frequency. X
- Radial. X
- TanTangential.
gential.
- Axial.
- Monitored Parameter
Parameters: s:
- Displacement.
- Velocity. X
- Acceleration.
information:
tion:
- No X
- Yes.
- No X
- Yes.
- No X
- Yes.
- OEM. X
- Monitoring syst system
em supplier.
- Additional
Additi onal information:
100

Turbogenerator
ANSWER NUMBER
NUMBER 29 30
Actit
Act it i ty Ge n e r a t o r Ow ne
ne r Ge n e r a t o r Ow n
ne
er
MANUFACTURER J J
2 End
End Win ding : DETECT
DETECTEDED PROBLPROBLEMS
EMS DETECT
DETECTEDED PRO PROBLEMS
BLEMS
2.1 EnEndd Win
Windin
ing
g sup
support syste
system m desigsign. (Ma
Marrk all
(with massive rings to support the
- Rigid structure (with
X X
winding and resist motion)
- Fle
Flexib
xible
le struc
structu
turre(a lighte
e(a terr st
strruct
ctu
ure th
tha
at bu
buiild
lds
s
stren
str ength
gth into
into the ininte
terco
rconn
nnect
ectio
ions
ns betwee
between n th
the
e stator
stator
bars)
- Su
Supp ppor
ortt struct
structur
uree re-tig
e-tight
htab
ablele or de
de--coupl
coupled
ed.. (A
(Allo
llow
w
to c ororrec t t he loos enening of endwinding or t o be de-
co
cou upleled
d by th thee adoptio
tion of insu
insula
lati
tin
ng bolts,
lts, spr
spring
ings,
etc).
Support Brackets.
· Attac
Attached
hed to Core
Core:: X X
· Attac
Attached
hed to Frame.
Inte
terrface to allo llow axia
xial the
thermal
mal expa
xpansio
sion betw twe
een
- Mechanical Mobile or sliding sys tems.
- Support s Brac es . X X
- Support s Rings . X X
- Out er Diameter. X X
- Inner Diameter.
- Bloc k ing bet ween t op and bot tom bas k et s . X X
- Rings.
- Bloc k s . X X
- Conforming materials:
- Impregnat ed Felts . X X
- Flexible Tubes.
Tubes.
- Bloc k ing of phas e connec tions . X X
- Bloc k ing bet ween adjac ent winding bars . X X
- By pairs.
- W hole Bas k et . X X
-Tying System.
- W et ties. X X
- Dry ties:
- Other:
- Connect ion rings s upport s . X X
- Dedic ated s upports at tac hed t o c ore/frame. X X
- Using or attached to basket supports.
- End winding blocks or rings close to the slot exist.
- Bloc k s or rings at bar ends s eries c onnec tions . X X
- Bar
Bar ends ser series con
connectio
ctionns sup
support atta
ttache
ched to
frame/core.
- Bus hing/Phas e leads supports . X X
- Bus hing/Phas e leads flex ibilit y s y s tems . X X
101

Turbogenerator
ANSW ER NUMBER
ANSWER NUMBER 29 30
Act it i ty Ge n e r a t o r O
Ow
w ne
ne r Ge n e r a t o r O
Ow
w ne
ne r
MA NUFACTURER J J
2 End
End Wi nding : DETECT
EMS DET
DETECT
ECTED PROBL PROBLEMS
EMS
2.4 Fu
Furrth
the
er Vi
Visu
sua
al Inspe
specti
ctio
on, Have you
you de
dete
tecte
ctedd or
con
confir
irme
medd end winind
din
ing
g mech
mecha anica
ical in
inte
teg
grity
ity lo
lost
st by
other technique?
- Maxim
Maximum
um DiDispl
splace
aceme
mentnt or accel
acceler
erat
atio
ion(
n(pe
peak
ak
2
to peak): m/s or g.
- Direction:
- Radial.
- Tangential.
- Axial.
- Bump Tes t . X X
- Twic e Power Nat ural Frequenc y (100/ 120 Hz ). X X
- Es
Esttablishe
shed m ar
argin t o t ake
ake int o acco
ccount t e
est
st
limitations (temperature, response non-linearity, etc).
- Description:
- Water
Wat er Cooled:
- Empty
- Any differences?
- Description:
- Does t his ex peperienc e of y ou
ours reinforc e t he
necess
cessiit y of base line test aft eerr manufactu
cturing for
fingerprint ?
- Yes X X
- No
2.5. Has gene
generrat
ator
or exp
exper
erie
ience
nced
d a fault
ault in serv
service or
- No X X
- Yes.
- In Service.
- Hi Pot.
2.6.
.6. Po
Possi
ssib
ble Root Cause se.. (Ma
Marrk all hypo
ypoth
the
esis
sis for
your generator).
- Des ign. X X
- Assembly
Ass embly / workmanship.
workmanship.
- Unus ual operat ion c onditions . X
- Poor maintenance.
age/running hours.
2. 7.
7. Has t hi
his RCA been agreed wit h t h he
e generat o
orr
manufacturer?.
- No
- Yes. X X
102

Turbogenerator
ANSWER NUMBER 29 30
Act i ti ty Ge n e r a to r Ow n
ne
er Ge n e r a to r Ow n
ne
er
MA NUFA CTURER J J
DETECTEDED PRO PROBLEMS
BLEMS DET
DETECT
ECTEDED PRO PROBLEMS
BLEMS
2.8. Action taken.
- Rewind. X
- Parti
Partial
al rewind.
- Full rew
rewind.
ind. X
- Repairs . X
-- Re-tying
Flooding over
loose
ov ties
er old with
ties . epoxy resin.
- Tie
Ties
s replacement. Tying system
sy stem has been
X
modified from/to
- Insulation local repa
repairs.
irs.
- Re-tighteni
Re-tightening
ng throw the prov
provided
ided sy stem.
st em.
Tangential wedges
replaced
- End winding support system design modification:.
- Intro
Introduce
duce new block/t ies/s uppor
upportt rings or
modification of its position.
- Introduce new or add element
elementss in end-winding
radial support system.
- Intro
Introduce
duce mobile or sliding systems
sy stems to allow
rings
rings c lose to the slot exist.
series connections.
2.9. End w winding
inding monitoring sys tem:
- Technology:
- Conv
Conventional
entional vibrati
ibration
on sens ors
- Optical vibration measurement system
- Wide range of frequencies.
- Only twic
twice
e power frequency.
- Radial.
- Tangential.
- Axial.
- Displacement.
- Velocity.
- Acceleration.
- Nº of sensors on each generator end:
- Additional infor
information:
mation:
- No
- Yes.
- No
- Yes.
- No
- Yes.
- Trip/Alarm levels
levels es
established
tablished by:
- OEM.
- Generator owner/operator experienc es.
103

Turbogenerator
ANSW ER NUMBER 29 30
Act i ti ty Ge n e r a t o r Ow ne
ne r Ge n e r a t o r Ow ne
ne r
MANUFA CTURER J J
EMS DETECT
EMS
2.2 Indic at e areas where y o ou
u have det ec t ed
vibrat ion / los t of mec hanic al int egrit y
symp
sym ptotoms
ms/e
/ev vidence in th
the
e end-win
ind
ding (Mar
Mark all in
your generator).
generator).
- End winding legs t ies t o s upport rings . X
- Dus t ing. X
- Greasing.
- Broken ties.
- Support B rac k et s . X
- Supports Braces.
- Dusting.
- Greasing.
- Broken ties.
- Series loops (bar to bar) connections.
- Dusting.
- Greasing.
- S t rand-t o-s t rand. X
- Solid cooper connect ion.
- Block ing of Phase lead leads
s t o connection rings.
rings.
- Dusting.
- Greasing.
just at the
t he slots
slot s ex its
its..
- Bushing/Phase leads suppo s upports.
rts.
insulators .
- Cooling tubes.
- Leakages.
- Water nozzels.
- Cracked bar connect ions.
- Water Leaks.
Basket was completely
- Other. Description: moved radially /
tangencially
2.3. Hav
avee you
you det
ete
ecte
cted
d un
unus
usua
uall oil pr
pre
esenc
sence
e over
- No X X
- Yes.
- Level Low. .
- Level Medium.
Mediu m.
- Level High
104

Turbogenerator
C.3.
C.3. Slot area answers chart
ANSW ER NUMBER 1 2 8 9
Act it it y Gen er ato r Ow ne r Gen er ato r Ow ne r Gen er ato r O w ne r Gen er ato r O w ne r
M A NUF A CT URER A A B B
3 Slot section:
section: NO PROBL
PROBLEMS
EMS DETECT
DETECTEDED DETECT
DETECTED
ED PROBLE
PROBLEMS MS DETECT
DETECTED
ED PROBLE
PROBLEMS MS DETECT
DETECTED
ED PROBLE
PROBLEMS MS
3.1. Sl
Slotot Secti
Section
o n sup
suppor
port sys
syste
tem
m de
desi
siggn. (M
(Mar
arkk all
- Insulation system:
- Global Vacuum Press ure Impregnation (GVPI).
- Individual Coils / bars . (Non-GV P I). X X X X

- Radial support system:
- Wedging type
- F l at . X X X X
- Concave/convex.
Concave/convex.
- One part wedge. X
- Two Part Wedge
- Radi
Radialal Fill
Filler
erss ma
mate
teri
rial
alss (b
(bet
etwe
ween
en ba
bars
rs an
andd at
the bottom of the slot):
- Top Ripple S prings . X X X
- Conforming material
- Dry m at erial. X
- Side support system.
- S ide Ripple S prings . X X
- Side Wedges.
- Round Packing.
- Ot her. Des c ript ion: Dry mat erial flat s ide fillers
- E nd Flux S hields . X X X
- S t ep Iron at c ore ends . X X X X
3.2. Indi
Indicate
cate area
areass wher
wheree you hahavve de
detect
tected
ed vib
ibra
ratio
tionn
/ lost
lost of m eech
chan
anicicaal inte
integr
grit
ityy sympt
symptoom s in th
thee slo
slot
section (Mark all in your generator).
- S igns of loos e t op wedges . X X X
- Red Dus ting. X X
- W edge m igration. X
Hollow sound tightness
- Others. Description
test
- Greas ing in t he bars s ide at the s lot ends . X X
- Side support side.
- Opposite side .
- B ot h. X X
- B ar S ide Abras ion. X
- Side support side. X
- Oppos it e s ide .. X
- Both
- S ide s upport s y s t em ax ial m igrat ion. X X X
- Bottom bar / core clearance
clearance at the slot ends. X
- Bottom Bar damage

damagess at the bottom of the slot side. X
- Conduc t ive c oating wear. X
- Insula
nsulatition
on and/
and/or
or copp
copper
er str
stran
andd crac
cracks
ks or da
dama
mage
ge
just at the s lots exits .
- Vibration Sparking.
- Hav
Have you check
checkeded th
thee ba
barr su
surf
rfac
acee re
resis
sista
tanc
ncee
value? ohm/square.
- Noise.
- Cracks.
- Terminal box vibration signs .
- Core/frame interface.
- S t at or Core V ibration. X X
- Local.
- Global. X X
No signs of vibration or lost

- Other. Description: of mechanical integrity
symptoms were detected

prior to the failure
105

Turbogenerator
ANSWER NUMBER NUMBER 1 2 8 9

Acti tit y Gene rator
rat or Own er Gene rat
rator
or Own er Gene rat
rator
or Own er Gene rat
rator
or Own er
3 Slot section: NO PROBLEM
PROBLEMS S DETE
DETECT
CTED
ED DET
DETEC
ECTE
TEDD PROBLEM
PROBLEMS S DETEC
DETECTE
TEDD PROBLEM
PROBLEMS S DE
DETE
TECT
CTED
ED PROBLE
PROBLEMS MS
3.3. Hav Have you dedete
tecte
ctedd un
unus
usua
uall oil
oil pres
presen
ence
ce over
over
- No X
- Yes . X X X
- Level Low. . X X X
- Level Medium.
- Level High
3.4. Fur Furthe
therr Visual
Visual In
Inspe
spectio
ction,
n, Hav
Have you detecte
detectedd
or conf
confir
irme
medd ba
barr supp
supporortt me
mech
chan
anica
icall integ
integri
rity
ty lost
lost at
the slot areas by other techniques?
- W edge tightnes s. X X X
- Robotic /handheld ins truments. X X
- ECOTip hardnes s. X X X
- Manual/s
Manual/sound.
ound.
- Pass/fail limits:
- Partial Disc harges . X
- Capacitive Couplers. X
- Slot Couplers.
- Slot Bar vib
vibration
ration monitorin
monitoringg sys tem.
- Bar Seating c hec ks at the bottom of the slot. X
- Bar-Jacking.
- Gauges . X
No signs of vibration or lost
- Other. Description: of mechanical integrity

symptoms were de detected
tected
prior to the failure
3.5. Ha
Hass ge
gene
nera
rator
tor exp
exper
erie
ience
ncedd a faul
faultt in ser
servvice or
- No X X X
- Yes. X
- In Service.
- Hi Pot. X
3.6
3.6. Po
Possi
ssibl
blee Root Cause.
use. (Ma
Mark
rk all hypo
hypoth theesis
sis for
your generator).
- Design. X X
- Poor maintenance.
X (Generator circuit
breaker failure )
Unit GT1A the stator bar
short circuit to stepping “Bar abrasion caused by
core and the blocking & SRS wearing the stator
tie were broken due to bar insulation due to
excessive mechanic
mechanical al relative motion between
the two. “Motion is
force from short circuit
- Detailed description of the possible root cause: caused by lateral
root cause from circuit
displacement produced
breaker closely speed to by the large reaction
slower than forces at the core exit
specification,
specification, this is due ti core and end
result to generator winding vibration.
synchronize
3.7
3.7. Has th
this
is RCA bee
eenn agre
agreeed with
ith the
the gen
generat
eratoor
manufacturer?.
- No X
- Yes . X X
106

Turbogenerator
ANSWER NUMBERNUMBER 1 2 8 9
Acti tit y Gene rat or Own er Gene rat
rator
or Own er Gene rat
rator
or Own er Gene rat or Own er
3 Slot section: NO PROBLEMS
PROBLEMS DET DETECT
ECTED
ED DET
DETECT
ECTED
ED PROBLEMS
PROBLEMS DET
DETECT
ECTED
ED PROBL
PROBLEMS
EMS DET
DETECT
ECTED
ED PROBL
PROBLEMS
EMS
3.8. Action taken.
- Rewind. X X
- Partial rewind. X
- Full rewind. X
- Bar dimension modification (if it was rewind)
rewind)..
- Extens ive bar seating checks during rewind. X
- Repairs. X X X
- Re-W edge. X X X
- Partial. X X
- Full. X X X
- Use of original wedging type. X X X
- Use of other wedging type
- Improv
Improvement/
ement/Modificat
Modificat ion? Descript ion:
- Side Support replacement. X X
- Improv
Improvement/
ement/Modificat
Modificat ion? Descript ion:
- Resin or other material injection in the s lot. X
- Introduce End winding wedging or rings close
clos e
to the slot exist.
SRS improvements were
been implemented
SRS improvements have
without proper results.
- Other. Description: Final solutioninclude also been implemented.
Results should be
resin injection in the slot
evaluated
evaluated next outages.
and improvements in top
wedging system.
3.8. Bar Vibration monitoring system:
- Installation:
- Under the wedge.
- As part of the wedge.
- Mounted on bar slot exit.
- Nº of sensors:
information:
tion:
- Displacement.
- Velocity.
- Acceleration.

- No
- Yes.
- Level
Level (peak to peak/rms):m/s2 or g.
- No
- Yes.
- Level
Level (peak to peak/rms): m/s2 or g.
- OEM.
- Generator owner/operat
owner/operator
or experienc
experiences.
es.
107

Turbogenerator
ANSWER NUMBERNUMBER 11 12 13 14
Acti tity Generat
Gene rat or Own
Owner
er Manufact
Manu fact ure r Generat
Gene rat or Ow ner Generato
Gene rato r Ow ner
MANUFACTURER B C C C
3 Slot section: DETECT
DETECTED
ED PROBL
PROBLEMS
EMS O PR
PROBL
OBLEMS
EMS D DET
ETECT
ECTE
E DETECT
DETECTED
ED PROBL
PROBLEMS
EMS DETECT
DETECTED
ED PROBL
PROBLEMS
EMS
3.1. Sl
Sloot Se
Secti
ction
on su
supp
ppoort syste
system
m de
desi
sign
gn.. (Mar
(Markk al
alll
- Global Vacuum Pressure Impregnation (GVP I). X
- Individual Coils/bars. (Non-GVPI). X X X

- Radial support
support system:
sy stem:
- Wedging type
- Flat. X X
- Concave/convex. X
- One part wedge.
- Two Part Wedge
- Ra
Radi
dial
al Fi
Fillller
erss ma
mate
teri
rial
alss (b
(bet
etwe
ween
en ba
bars
rs an
andd at
- Top Ripple Springs. X X
- Conforming material X
- Dry material. X
- Side Ripple Springs. X X X X
- Side Wedges.
- Round Packing.
- End Flux Shields. X X X X
- Step Iron at core ends. X X X X
3.2. In
Indic
dicate
ate ar
area
eass wh
whereree you ha havve detect
detected
ed vibr
ibrati
ation
on
/ lo
lost
st of me
mechchaani
nica
call in
inte
tegr
gritityy sympt
symptomomss in the
the slo
slot
- Signs of loose top wedges. X X
- Red Dusting.
- Wedge migration.
- Others. Description W hite/cream dust
- Greasing in the bars side at the slot ends. X
- Opposite side .
- Both. X
- Bar Side A brasion. X
- Opposite side ..
- Both X
- Side support syst em axial migration.
- Bottom Bar damages at t he bottom of the slot side.
- Conductive coating wear. X X

- Visual partial discharge activity. X
- Ins
nsul
ulat
atio
ionn an
and/
d/or
or coppe
copperr str
stran
andd cracks
cracks or dama
damage
ge
just at the slots exits .
- Ha
Havve you checke
checkedd th
thee bar
bar surf
surfac
acee re
resist
sistan
ance
ce
value? ohm/square.
- Noise.
- Cracks.
- Terminal box vibration signs
signs..

- Local.
- Global.
108

Turbogenerator
Acti tit y Generat
Gene rator
or Owner
Own er Manu fact ure r Gene
Generat
rator
or Own er Gene
Generat
rat or Own er
3 Slot section: DETECTED
DETECT ED PROBL
PROBLEMS
EMS O PROBL
PROBLEMS
EMS D DET
ETECT
ECTEE DET
DETECT
ECTED
ED PROBL
PROBLEMS
EMS DET
DETECT
ECTED
ED PROBL
PROBLEMS
EMS
3.3. Hav Have yo
youu de
dete
tecte
ctedd un
unus
usua
uall oil
oil pr
pres
esen
ence
ce over
over
- No X
- Yes. X X
- Level Low. . X
- Level
Level Medium.
- Level High
3.4. Fu Furth
rther
er Visual
Visual Inspe
Inspectioction,
n, Ha
Havve you detecte
detectedd
or con
confifirmed
r med ba barr sup
suppoportrt mecha
mechani nical
cal inte
integr
grity
ity lost
lost at
- Wedge tightness. X X
- Robo
Robotic/handheld
tic/handheld instruments. X
- ECOTip hardness.
- Manual/sound. X X
- Pass/fail limits:
- Partial Discharges. X X
- Capacitive Couplers. X X
- Slot Coup
Couplers.
lers.
- SSlot
lot Bar vibra
vibration
tion monitoring syst system.
em.
- BBar
ar vibration
vibration monitorin
monitoringg syssystem.
tem.
- Bar-Ja
Bar-Jacking.
cking.
- Gauges.
3.5. Has Has genegenera rator
tor exp
exper erien
ienced
ced a fault
fault in serv
service or
- No X X
- Yes.
- In Service.
- Hi Pot.
3.6.
3. 6. Po
Possi ssibl
b le Root Causeause.. (Mar
(Markk all hypot
ypothe
hesi
siss for
your generator).
- Design. X
- Assembly / workmanship. X
- Unusual operation conditions. X X
- Poor maintenance.
- Normal winding ageing / s up

upport s ys
ys tteem relaxat ion. X
Root cause: Poor design
of stator end windings
has led to loss in
mechanical integrity of
the bars in slot section.
c ause:
Contributory
Contrib utory ccause:
ause:
Faults close to the power
station and 2 GSU
transformer failures at
Unit 2.
3.7.
.7. Has this
this RCA been agreed witithh the
the generato
tor
r
manufacturer?.
- No X X
- Yes.
109

Turbogenerator
Acti tit
tityy Gen
Genera
era tor Ow
Owne
nerr Manufa
Man ufa ctu rer Gene rat
rator
or Ow
Owne
nerr Gene rat or Own er
DETECTED
ED PPRO
ROBLEM
BLEMSS O PR
PROBL
OBLEMS
EMS DETDETECTECTEE DET
DETECT
ECTED
ED PPRO
ROBLEM
BLEMSS DET
DETECT
ECTED
ED PPROROBLEM
BLEMSS
3.8. Action taken.
- Rewind. X
- Partial rewind.
- Full rewind. X
- Repairs. X
- Re-W edge. X
- Partial. X
- Full.
- Use of original wedging type. X
- Improv
Improvement/Modification?
ement/Modification? Description:
- Side Support replacement.
- Improvement/Modification?
Improvement/Modification? Description:
to the slot exist.

- Installation:
- Under the wedge.
- Nº of sensors:
- Displacement.
- Velocity.
- Acceleration.

- No
- Yes.
- Level
- No
- Yes.
- Trip/Alarm levels
levels est ablished by:
- OEM.
- Generator owner/oper
owner/operator
ator experiences.
110

Turbogenerator
ANSWER NUMBER
NUMBER 18 19 20 21
Acti tit y Gene rat or Own er Gene rat or Own er Gene rat
rator
or Own er Gene rat
rator
or Own er
3 Slot section: NO DETECT
DETECTEDED PROBL
PROBLEMSNO
EMSNO DET
DETECT
ECTEDED PROBLEM
PROBLEM O DETECTED
DETECTED PROBLEM
PROBLEM DETECT
DETECTED
ED PROBLEMS
PROBLEMS
3.1. Slot
Slot Se
Secti
ction
on su
supp
ppoort sys
syste
tem
m desig
esign.
n. (Ma
Mark
rk all
- Global Vacuum Press

Pressure
ure Impregnation (GVPI).
X X X
- Individual
Individual Coils/bars . (Non-GVPI).
- Wedging type
- Flat. X
- Concave/conv
Concave/convex. ex.
- One part wedge.
- Two Part Wedge
- Radi
Radial
al Fi
Fillller
erss ma
mater
teria
ials
ls (bet
(betwe
ween
en bars
bars and
and at
- Top Ripple Springs. X
- Dry material.
- Side Ripple Springs. X
- Side Wedges.
- Round Packing.
- End Flux Shields . X
- Step Iron at core ends . X X X X
3.2. In
Indi
dicate
cate area
areass wh wher
eree you hav
have detecte
detectedd vibrati
ibration
on
/ lost
lost of me
mechchaanica
ical in
inte
teggrit
ityy sy
symp
mpto
toms
ms in the
the slo
slot
- Red Dusting.
- Wedge migration.
- Greasing in the bars s ide at the s lot ends . X
- Side s upport s ide. X
- Opposite side .
- Both.
- Side suppor
supportt side.
- Opposite side ..
- Both
- Side suppor
supportt syst em axial migration. X

- Vis ual partial discharge
discharge activity.
- In
Insu
sulalatio
tionn an
and/
d/or
or copp
copper
er str
stran
andd cracks
cracks or dama
damagege
just at t he slots exits .
- Hav
Have youyou chec
checke
kedd th
thee bar
bar surf
surfac
acee resis
resista
tanc
ncee
value? ohm/square.
- Noise.
- Cracks.
- Terminal box vibration signs.
- Local.
- Global.
111

Turbogenerator

Acti tit y Gene rat or Own er Gene rator
rat or Own er
3 Slot section: NO DETECTED
DETECTED PROBLEMSNO DETECTED
DETECTED PROBLEM
PROBLEM O DETECT
DETECTEDED PROBLEM
PROBLEM DETECTED
DETECTED PROBLEMS
PROBLEMS
3.3. Ha
Havve you de
detect
tected
ed un
unusu
usual
al oil
oil prese
presence
nce ov
over
er
- No X X X
- Yes. X
- Level Low. .
- Level
Level Medium.
- Level High X
3.4. FuFurth
rther
er Visual
Visual InInspe
spectio
ction,
n, Ha
Havve you de detect
tected
ed
or confi
confirm
rmed
ed ba
barr suppo
supportrt me
mecha
chani
nical
cal integ
integririty
ty lost
lost at
- Wedge tightness.
- Robotic/
Robotic/handheld
handheld instruments.
instrument s.
- ECOTip hardness.
- Manual/sound.
- Pass/fail limits:
- Capacitive Couplers.
- Slot Couplers.
- Bar-Jacking.
- Gauges.
3.5. Ha
Hass ge
gene
nera
rator
tor exper
experie
ience
ncedd a fa
faul
ultt in serv
service or
- No X X X
- Yes. X
- In Service. X
- Hi Pot.
3.6.
3.6. PoPossi
ssibl
blee Ro
Root
ot Ca
Caus
use.
e. (Mar
(Markk all
all hy
hypopoth
thes
esis
is fo
for
r
your generator).
- Design.
- Ass embly / workmanship.
workmanship.
- Unusual operation conditions. X
- Poor maintenance.
Due to oil contamination
of the stator bar slots
3.
3.77. Ha
Hass th
this
is RC
RCA
A been agree
reed with
with th
thee gene
nera
rato
tor
r
manufacturer?.
- No
- Yes. X
112

Turbogenerator
Acti tit y Gen era tor Own er Gene rat or Ow ne r Gene rat or Own er Gene rat or Own er
3 Slot section: NO DETEC
DETECTED
TED PROBLEMS O DET
DETECT
ECTEDED PROBLEMS
PROBLEMS O DETECT
DETECTEDED PROBLEM
PROBLEM DET
DETECT
ECTED
ED PROBLEMS
PROBLEMS
3.8. Action taken.
- Rewind. X
- Partial rewind. X
- Full rewind.
- Repairs.
- Re-W edge. X
- Partial. X
- Full.
- Use of original wedging type.
- Use of other wedging
wedging type
- Improv
ement/Modification? Description:
- Side Support replacement. X
Additional spacer added
- Improv
ement/Modification? Description: between the bar and the
side ripple spring
to the slot exist.

- Installation:
- Under the wedge.
- Nº of sensors:
- Displacement.
- Velocity.
- Acceleration.
- No
- Yes.
- Level
Level (peak to peak/rms):m/s 2 or g.
- No
- Yes.
- OEM.
- Generator owner/oper
owner/operator
ator experiences.
113

Turbogenerator
ANSW ER NUMBER 23 24 25 26
Act itititit y Gen er at
ator
or Ow ne r Gen er ator
at or Ow ne r Man uf ac ture
tu re r Gen er ator
at or Ow ne r
M ANUFACTURER E F G H
3 Slot section: DET
DETECT
ECTED
ED PROBL
PROBLEMS
EMS NO PRO
PROBLEMS
BLEMS DET DETECT
ECTEE NO PROBLEMS
PROBLEMS DETECT
DETECTED
ED NO DETECT
DETECTED ED PROBLEMS
PROBLEMS
3.1. Sl
Slot ot Se
Secti
ction
on su
supp
ppor
ortt syste
system
m desi
design
gn.. (Ma
Marrk all
all
generator).
- Global Vacuum Pressure Impregnation
Impregnation (GVPI).
- Individual Coils / bars . (Non-GV P I). X X X

- Wedging type
- F l at . X
- Concave/convex.
Concave/co nvex.
- One part wedge.
- Two P art W edge X X
- Ra
Radi
dial
al FiFillller
erss ma
mater
teria
ials
ls (bet
(betwe
ween
en bars
bars and
and at
- Top Ripple S prings . X
- Dry mat erial. X
- Ot her. Des c ript ion: Silic one Rubber
- Side Ripple Springs. X
- Side Wedges. X
- Round Packing.
- E nd Flux Shields . X
- S t eIndica
3.2. Inpdicate
Ironteatareas
arceas
ore ewhe
ndsre
where . you have
have detecte
detectedd vibr
ibratio
ationn X
/ l os
os t of m eecc hhaanic aall i nnte
tegr
griity s yym
m pto
ptom
m s in the
the s lot
lot
section (Mark all in your generator). generator).
- Red Dusting.
- Wedge migration.
- Opposite side .
- Both.
- Opposite side ..
- Both
- Side support system axial migration.

- Insula
nsulatio
tionn an
and/o
d/orr coppe
copperr stran
strandd cr
crack
ackss or dama
damage
ge
just at the
t he s lots exits.
exit s.
- Havavee you
you ch
chececke
kedd the
the bar
bar sur
surface
ace resis
esista
tanc
ncee
value? ohm/square.
- Noise.
- Cracks.
- Terminal box vibration signs .
- Core/frame interface
interface..
- Local.
- Global.
114

Turbogenerator
Acti tit y Gene rat or Own er Gene rat or Own er Manu fact ure r Gene rat or Own er
DETECTED
ED PROBLEM
PROBLEMS S NO PROBLEMS
PROBLEMS DETEC
DETECTED
TED NO PROBL
PROBLEMS
EMS DETEC
DETECTED
TED NO DET
DETECT
ECTEDED PROBLEM
PROBLEMSS
3.3. Hav Have you dete
detecte
ctedd unus
unusua
uall oi
oill pres
presen
ence
ce ov
over
er
- No X
- Yes. X
- Level Low. . X
- Level Medium.
- Level High
3.4. Fur Furthe
therr Visual
Visual Inspe
Inspectio
ction,
n, Hav
Have you de detecte
tectedd
or conf
confir
irme
medd bar
bar supp
supporortt mecha
mechani
nica
call inte
integr
grity
ity lost
lost at
the slot areas by other technique
techniques?
s?
- W edge tightnes s . X
- Robotic/handh
Robotic/handheld eld instruments.
- ECOTip hardness.
hardness. X
- Manual/soun
Manual/sound. d. X
- Pass/fail limits:
- Capaciti ve Couplers.
- Slot Couplers.
- Slot Bar vibration
vibration monitoring system.
- Bar vibration monitoring
monitoring sys tem.
- Bar-Jacking.
- Gauges.
3.5. Ha Hass gene
generarator
tor exper
experien
ienced
ced a fa
fault
ult in serv
service or
- No X
- Yes.
- In Service.
- Hi Pot.
3.6.
3.6. PoPossi
ssibl
ble Ro
Root
ot Cause
ause.. (Mar
(Markk all hyp
ypooth
thes
esis
is for
your generator).
- Design.
- P oor maintenan
maintenance.
ce.
- Normal winding ageing / s uuppport s ys

yst eem
m relaxation. X
Damages was caused by a
.
foreign body
3.7.
3.7. Ha
Hass this
this RC
RCA
A been
een agre
agreed
ed witthh th
thee gen
generat
erator
or
manufacturer?.
- No X
- Yes. X
115

Turbogenerator

Acti ti ty Gener ator Own er Gener ator Own er Manu fact ure r Gener ator Own er
DETECTED
ED PRO
PROBLE
BLEMS
MS O PROBLEM
PROBLEMS S DETECT
DETECTEE NO PROBL
PROBLEMS
EMS DETECT
DETECTED
ED NO DETE
DETECT
CTEDED PROBLE
PROBLEMSMS
3.8. Action taken.
- Rewind.
- Partial rewind
rewind..
- Full rewind.
- Bar dimension modification (if it was rewind
rewind).
).
- Repairs.
- Re-W edge. X
- Partial.
- Full. X
- Use of original wedging type. X
- Improvement/Modification?
Improvement/Modific ation? Description:
Descri ption:
- Side S uppo
upport
rt replacement.
- Improvement/Modification? Description:
to the slot exist.

- Installation:
- Under the wedge.
- Nº of sensors:
- Monitored Paramete
Parameters:
rs:
- Displacement.
- Velocity.
- Acc eleration
eleration..
- No
- Yes.
- Level
- No
- Yes.
- Level
Level (peak to peak/rms): m/ s2 or g.
- OEM.
- Monitoring system s upplier.
- Generator owner/operator experiences .
116

Turbogenerator
ANSW ER NU
ANSWER NUMBER
MBER 29 30
Act i ti ty Gen er at or Ow ne r Gen er at or Ow ne r
MA NUFA CTURER J J
DETECTED ED PROBLEMS NO D
DETECT
ETECTED ED PROBLEMS
3.1. Sl
Sloot Se
Sect
ctio
ion
n su
sup
pport sy
syst
ste
em desi
sig
gn. (Mar
Mark all
- Global Vacuum Press ure Impregnation

Impregnation (GVPI).
- Individual Coils / bars . (Non-GVPI). X X

- Wedging type
- Flat. X X
- Concave/convex.
- One part wedge.
- Two
Two Part Wedge
- Other. Descripti
Description:
on:
- Radia
iall Fill
Fille
ers ma
mateterria
ials
ls (be
(betw
twe
een bar
ars
s and at
- Top Ripple Springs . X X
- Conforming
Conforming material
- Dry material.
- Other. Descripti
Description:
on:
- Side Ripple Springs . X X
- Side Wedges.
- Round Packing.
- Other. Descripti
Description:
on:
- End Flux Shields.
- Step Iron at core ends.
3.2. Indica
ndicate
te ar
area
eas
s whehere
re you ha havve de
detecte
tected
d vib
ibra
ratio
tion
n
/ los t of mec ha
hanic al
al int eg
egrit y s ym
ympt om
oms in t he
he s lo
lot
- Red Dusting.
- Wedge migration.
- Others.
Others. Description
- Opposite side .
- Both.
- Opposite side ..
- Both
- Side support syst em axial migramigration.
tion.


- Insu
nsula
lati
tio
on and/o
d/or co
cop
pper str
stra
and cra
cracks or da
dama
magge
- Have yoyou
u ch
cheeck
cke
ed th
the
e bar susurrface resi
sist
sta
ance
value? ohm/square.
- Noise.
- Cracks
Cracks .
- Terminal
Terminal box vibration signs.
signs .
- Core/frame
Core/frame interface.
- Local.
- Global.
117

Turbogenerator
ANSWER NUMBER 29 30
Actii ti ty
Act Gen er
erat
ator
or Ow ne r Gen er
erat
ator
or Ow ne r
MANUFACTURER J J
3 Sl ot section: NO DETECTED
DETECTED PROBLEMS NO DET
DETECTED
ECTED PROBLEMS
3.3. Have yo youu detecte
tected
d unusu
nusua
al oil prese
sen
nce over
- No X X
- Yes.
- Level Low. .
- Lev
Level
el Medi
Medium.
um.
- Lev
Level
el High
3.4. Furt
Furthe
herr Visu
Visual
al Inspe
nspectio
ction,
n, Have
ave yoyouu dete
detecte
ctedd
or co
connfir
irme
med d bar su
supppor
port me
mechchaanica
icall inte
integgrity lost
lost at
the slot areareas
as by other techniqu
techniques?
es?
- Wedge tightness.
- Rob
Robotic/
otic/han
handhe
dheld
ld instruments.
- ECOTip hardness.
- Manual/sound.
- Pass/fail limits:
- Capaciti
Capacitiv ve Couplers.
- Slot Couplers.
- Bar-Jacking.
- Gauges.
- Other
Ot her.. Description:
3.5. Has Has gene
generarator
tor expe
experirien
ence
cedd a fauault
lt in se
serv
rvice or
- No X X
- Yes.
- In Service.
- Hi Pot.
3.6
.6.. Poss
Possib ible
le Root Cause se.. (Mar
Mark all hyp ypooth
the
esi
sis
s for
your generator).
- Design.
- Poor maintenance.

- Other
Ot her.. Description:
3. 7.
7. Has t hi
his RCA been agreed wit h t h he
e generat o
orr
manufacturer?.
- No
- Yes.
118

Turbogenerator
ANSWER NUMBER NUMBER 29 30

Actit
Act it it y Gener
Gen er at
ator
or Ow ne r Gen
Gener
er at
ator
or Ow ne r
MANUFACTURER J J
DETECTED ED PROBLEMS NO DET
DETECT
ECTED ED PROBLEMS
3.8. Action taken.
- Rewind.
- Partial rewin
rewind.
d.
- Full rewind.
- Bar dimensi
dimension
on modificat
modification
ion (if it was rewind).
- Extensi
Ex tensiv
ve bar seati
seating
ng check s during rewind.
- Repairs.
- Re-Wedge.
- Partial.
- Full.
- Use of original wedging type.
- Use
Use of other wed
wedging
ging type
- Improv
Improvement/
ement/Modificat
Modification?
ion? Descri
Description:
ption:
- Side Support replacement.
- Improvement/Modification? Description:
to the slot exist.

- Installation:
- Under the wedge.
- Nº of sensors:
- Displacement.
- Velocity.
- Acceleration.
- No
- Yes.
- Lev
Level
el (peak to peak/rms
peak/rms):m/
):m/ s2 or g.
- No
- Yes.
- OEM.
- Generator owner/operator experiences
experiences..
119

CIGRE
21, rue d'Artois
75008 Paris - FRANCE
© CIGRE
ISBN : 978-2-85873-474-0

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Turbogenerator stator windings

A. VILLARRUBIA, Convenor SP S. RODRIGUEZ, Secretary SP

“All rights to this Technical Brochure

▪ Winding support integrity evaluation techniques during commissioning, operation and

Executive summary ............................................................................................................................... 5

2. Surv ey - Met ho do lo

3. Af fec ted gen erat or s .................................................................................................................. 15

4.2 Summar y o f endw ind in g secti on answ ers ............

5. Slot area su pp

5.2 Summar y of slo t area sect ion answ ers .......

C.3. Slot area answers chart ........................................................................................................................ 105

Figures and Illustrations

1. Technical backgro und : Sta

Answer Distribution for Countries and activity:

Country An sw ers Ac ti vi ty

1.2 How many similar generators show these symptoms?

300-375 Problem due to 1-2 years

350-475 Problem due to 1-2 years Scheduled

205MW Problem due to 2 years

OEM Mod. Cooling Location Direct Water Direct H2 Inirect H2 A ir

300-375 MW Problem due to 1-2 years Scheduled

445MW Problem due to 5 years

OEM Mod. Cooling Fleet? Problem?

4. Endwin ding su pport systems

- By pairs. - Whole Basket.

Figure 4-2 Siemens Rigi

Figure 4-3 Endwind ing Design o f a Direct Water

Figure 4-4 Stator Endwindi ng Design

Figure 4-5 Overview of Alstom’s winding head designs (Courtesy of ALSTOM)

Figure 4-8 Wate

c) Tangential packing bl ocks (with hairli ne

Water cooled endwinding showing support

- Connection rings blocks and ties.

The unusual presence

Differences with a base line test after manufacturing

Figure 4-14 Phase Lead

Endwinding monitoring system:

45 -19 8MW EW Legs ties to rings

300-375MW Flexible Legs ties to rings YES (1/10

350-475MW Rigid Legs ties to rings

Flexible Legs ties to rings

Rigid Legs ties to rings

Legs ties to rings

Legs ties to rings

770MW Direct Rigid Legs ties to rings

300-375MW H2 Design tiying, dry to wet ties , Radial/tangential/axial

Repairs: flooding, re-

Design tiying, Tunning EW Radial

MNF C Repairs:Re-install Optical

OEM Mod. Cooling Location Direct Water Direct H2 Inirect H2 Air

Table 4-3 End Windi

OEM Mod. Cooling Problem? Design Where? Oil?

OEM Mod. Cooling P roblem? Det ection Fault? Root Cause

Only Two Machines, H2 Design 7/10

OEM Mod. Cooling Pro blem? A ct i o n s OEM Ag ree? EW V Mo nit o rin g

Figure 5-2 Typical Slot Contents (Extracted fro m EPRI

Figure 5-4 Bott om bars and

Figure 5-5 Bott om bars and between bars fill er (Courtesy