Generator Maintenance

Assessments and Repairs

Nicolas Dehlinger, Electrical Engineer, PhD
NWHA Technical Seminar, Hood River, OR
5-7-2015
 Introduction - Some statistics…

Hydro-generators can fail !

[%] [%]
50 50
Failure rate
45 45

40 40
35 35
30 30
25 25
20 20
15 15
10 10
5 5
0 0

Sources: Start and stop costs for hydropower plants, Bakken, B.H.; Bjoerkvoll, T.; New developments in diagnostic and monitoring techniques for hydro-
Belsnes, M.M.; Skaare, P.E., Report #TR A5351, 2001-02-02 generators, G. Galasso, M. Märke, 1995 Waterpower and Dams
conference, Barcelona, Spain
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© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Introduction – What is maintenance and why ?

What ?

Actions taken to preserve or restore

an asset in operable condition to
achieve its maximum useful life.

Why ?

• Prevent downtime
• Maximize useful life
• Save money

Generator Maintenance- 05/07/2015 – P 3

© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda

Introduction
1. 2 types of maintenance: preventive and corrective

2. Maintenance typical timeline

3. Generator preventive maintenance

4. Generator corrective maintenance

Conclusion

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© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
1. 2 types of maintenance : Preventive & Corrective

Preventive
Prevent equipment failure

Corrective
Repair and return to service

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© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
2. Generator Typical Maintenance timeline

Generator Maintenance- 05/07/2015 – P 6

© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
Routine checks
Recommended checks Frequency
• Winding temperatures Daily
• Flow and cooling temp. Daily
• Bearing oil flow and temp. Daily
• Walk-around Daily
• Visual on brushes Weekly
• Brush pressure and wear Monthly
• Collector filters Monthly
• Oil sample analysis Annually

… Please consult your O&M manual

Generator Maintenance- 05/07/2015 – P 7
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
Generator assessments

What is an assessment ?

Assessing = getting an accurate

picture

Typical assessment :

• A visual inspection
• Electrical and mechanical tests

Generator Maintenance- 05/07/2015 – P 8

© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 3. Generator Preventive Maintenance
Generator assessments
Level of dismantling determines the extent of the assessment.

Light assessment Extensive assessment

Duration: - Several days - Several weeks
Access: - Partial (some covers - Full (all covers
removed, rotor in) removed, rotor out)

Frequency: - Every 3-5 years - Every 5-10 years*

* Or whenever the rotor is pulled out.
Generator Maintenance- 05/07/2015 – P 9
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
Visual inspection, what is inspected ?
Stator winding

Winding cleanliness Partial discharge Bar/coils side packing

Ties movement, vibrations Insulation damage Bar caps looseness Wedge cracks,
Generator Maintenance- 05/07/2015 – P 10
migration
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
Visual inspection, what is inspected ?
Stator core

Core cleanliness Lamination damage “Buckling”

“Chevrons” Corrosion fretting Vent. Ducts, clamping system

Generator Maintenance- 05/07/2015 – P 11
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
Visual inspection, what is inspected ?
Rotor poles

Pole cleanliness Ground and turn insul. Pole connections

Damper bars Pole winding blocks

Generator Maintenance- 05/07/2015 – P 12
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
Visual inspection, what is inspected ?
Misc. components
(organized)
Spare parts

Collector

…
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Bearings
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 3. Generator Preventive Maintenance
Electrical & Mechanical tests

Light assessment Extensive assessment

Stator • Insulation resistance and • Insulation resistance and
winding: polarization index polarization index
• Direct-current ramp test • Direct-current ramp test
• Stator power factor and loss • Stator power factor and loss
dissipation test dissipation test
• Dc phase resistance test • Dc phase resistance test
• Stator wedge tap test • Wedge tightness test
(random sampling) (selected or complete slots)
• Winding RTD tests
Optional:
• Blackout test
• Corona probe test
• Stator winding ac high pot.
Generator Maintenance- 05/07/2015 – P 14
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 3. Generator Preventive Maintenance
Electrical & Mechanical tests

Light assessment Extensive assessment

Stator • Knife test • EL-CID test
core: Optional:
• Stator core loop test
• Stator roundness
Rotor • Insulation resistance test. • Insulation resistance test.
winding: • Winding resistance. • Winding resistance.
• Winding high potential test • Winding high potential test
• Pole drop test (when • Pole drop test
possible) Optional:
• Rotor concentricity
Bearings: • Insulation Resistance test • Insulation Resistance test

Generator Maintenance- 05/07/2015 – P 15

© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
What after the assessment?

Assessment report

• Inspection and test results analysis

• Compare with history data
• Conclusions & recommendations

Next steps

• Plan on a maintenance repair ?

• Plan on a refurbishment ?
• Schedule the next maintenance

Generator Maintenance- 05/07/2015 – P 16

© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3. Generator Preventive Maintenance
Examples of preventive repairs

• Generator cleaning

• Stator winding rewedge

• Stator winding corona repair

• Generator phase reversal

• Bearing re-babitting

• Rotor balancing

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© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
4. Generator Corrective Maintenance
Generator failures

[%]
• Common failures: 50 Unavailability hours following a fault

Excitation and Auxiliary systems. 45 Failure frequency

Downtime: short (hours-days) 40

35
30
25
• Least common failures: 20
Insulation failure. 15

Downtime: long (weeks-months) 10

5
0
How to react to minimize the
repair outage time ?
Source: New developments in diagnostic and monitoring techniques for hydro-
generators, G. Galasso, M. Märke, 1995 Waterpower and Dams
conference, Barcelona, Spain
Generator Maintenance- 05/07/2015 – P 18
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 4. Generator Corrective Maintenance
Store and prepare to react efficiently
Maintain spares at site
• Critical spare parts
(coils, wedging matl, bearing…)
• Proper inventory
• Contacts, vendors …

Prepare for the worst

• Typical procedures & docum.
(Coil bypass, insulation repair…)
• Trained teams or contacts
• Testing & repair equipment at site
Generator Maintenance- 05/07/2015 – P 19
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 4. Generator Corrective Maintenance
Assess the situation & apply the right solution

Start fast and right

• Failure sequence of event
• Perform an assessment
(visual inspection + testing)
• Root cause analysis

Apply the best solution

• Refer to experts
in-house or OEM
• Costs/benefits analysis
Ex: Coil bypass vs coil replacement
Generator Maintenance- 05/07/2015 – P 20
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 4. Generator Corrective Maintenance
Example – Stator air gap bar replacement

Context
• Failure to ground, 40 y/o winding
• “High voltage” air gap bar
• High penalty for loss of production

Solution: Stator bar replacement

• Fast repair: 2 weeks !
• Key elements :
- Spare matl and eqpt at site
- Trained teams with procedures
- Rotor not removed
Generator Maintenance- 05/07/2015 – P 21
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Conclusion

”An ounce of prevention is worth a pound of cure”

• Maintenance program to slow ageing and prevent failures.

• Generator preventive assessment = tool to prevent unscheduled

outages and reduce their duration.

• Corrective repairs: Carefully prepare and act fast and efficiently

• Maintenance to be performed by skilled and trained personnel

Generator Maintenance- 05/07/2015 – P 22

© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Thank you !
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With Alstom, preserve the environment.

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