g

GEK 95122b
Revised February 2010

GE Energy

Maintenance and Care

for Open Ventilated Air-Cooled Generator

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the
matter should be referred to the GE Company.
General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.
 Maintenance and Care for Open Ventilated Air-Cooled
GEK 95122b Generator

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

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Maintenance and Care for Open Ventilated Air-Cooled
Generator GEK 95122b

TABLE OF CONTENTS

I. INTRODUCTION.......................................................................................................................... 4

II. OPERATING MAINTENANCE .................................................................................................. 4

A. Air Filters ................................................................................................................................. 5
B. Brush Rigging and Collector Rings (Static Excitation Systems)............................................. 5
C. Shaft Grounding Brush ............................................................................................................ 5
D. Excitation Equipment (Non-Static Excitation Systems) .......................................................... 5
E. Excitation Equipment (Static Excitation Systems) .................................................................. 5

III. SHUTDOWN MAINTENANCE .................................................................................................. 5

A. Frequency of Inspection........................................................................................................... 5
B. Care of Generator Prior to Shutdown....................................................................................... 6
C. Reparing the Generator at Shutdown ....................................................................................... 6

IV. INSPECTION OF PARTS............................................................................................................. 6

A. Armature Core.......................................................................................................................... 6
B. Armature Windings .................................................................................................................. 7
C. Rotor......................................................................................................................................... 7
D. Insulation Testing ..................................................................................................................... 7
E. Cleaning ................................................................................................................................... 7
F. Removal and Assembly of Collector (Static Excitation Systems)........................................... 8
G. Removal and Assembly of Armature Bars............................................................................... 8
H. Removal and Assembly of Field Coils..................................................................................... 9

V. PROTECTION OF GENERATOR DURING PERIODS OF SHUTDOWN OF INDEFI-

NITE DURATION ......................................................................................................................... 10
A. Protection at Shutdown ............................................................................................................ 10
B. Additional Protection For Static Excitation Systems............................................................... 10
C. Periodic Maintenance During Shutdown ................................................................................. 10
D. Procedure Prior to Resumption of Operation........................................................................... 10
E. Renewal Parts........................................................................................................................... 11

VI. PERIODIC MAINTENANCE AND CHECKS .......................................................................... 11

VII. PROCEDURE BEFORE STARTUP ........................................................................................... 11

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 Maintenance and Care for Open Ventilated Air-Cooled
GEK 95122b Generator

I. INTRODUCTION

Even though modern turbinegenerators are designed and constructed to operate for long periods of time
without shutdown, a wellplanned maintenance program, strictly followed, can greatly increase the relia-
bility of the generator and reduce the number and duration of unscheduled shutdowns.

The maintenance programs should include an operational log on the type of duty, any known incidents of
misoperation, conditions found during inspection or test, any repairs or modifications made, etc. Opera-
tional events which should be carefully noted are:

Errors in synchronizing

Under or overfrequency operation

Lightning surges or other transients

Faults (such as short circuits) on system or adjacent machines

Singlephase or outofphase operation

Unbalanced load

Overload

Overvoltage or undervoltage

Loss of field

Each of these events would have a different impact on the necessary planning for maintenance and inspec-
tion. Depending on the circumstances, some of them might dictate that the machine be shut down for an
immediate inspection, whereas in others it would be reasonable to wait until the next scheduled inspection.
Contact a GE Company representative for recommendations should these events occur.

Each complete inspection should involve visual inspection, and a selected number of electrical tests based
on the history of the generator, conditions found, future requirements for the generator, etc.

II. OPERATING MAINTENANCE

The maintenance program planned for a particular generator should include the auxiliary equipment which
is part of, or closely associated with, the generator. Maintenance on many of these items can be performed
with the generator in service. Most of these items are described elsewhere in the instruction book, and
include the following maintenance recommendations.

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Maintenance and Care for Open Ventilated Air-Cooled
Generator GEK 95122b

A. Air Filters

CAUTION

Dirty air filters reduce the amount of cooling air circulated in the housing and may
result in excessive temperature rises.

Increased dirt content reduces filter efficiency and may allow passage of some dirt and carbon dust.
Filters must not be allowed to become clogged or overloaded to the point of physical damage. Foreign
materials passed by the filter or dislodged from excessive filter accumulation contribute to outage time.
Examine the filter at least once a week.

B. Brush Rigging and Collector Rings (Static Excitation Systems)

Keep the rings and rigging as clean as possible. Carbon dust must not be allowed to accumulate on the
brush rigging, and the brushes should not be allowed to wear beyond their limit.

C. Shaft Grounding Brush

Check the voltage from shaft to ground at least once a week to insure the shaft grounding brush assem-
bly is functioning properly. See instructions in GEK 85803 for checking voltage and maintenance if
unsatisfactory indication is obtained. Brushes must not be allowed to wear beyond their limit.

D. Excitation Equipment (Non-Static Excitation Systems)

See EXCITATION EQUIPMENT instructions for other equipment maintenance.

E. Excitation Equipment (Static Excitation Systems)

Normally, the static components require little or no maintenance. The equipment should be kept dry
and clean. All screwtype connections should be checked regularly to determine that they are properly
tightened. See instruction book Table of Contents for other equipment maintenance. Operating main-
tenance for brushless exciters is covered in GEK 95130 for TEWAC units (Totally Enclosed Water to
Air Cooled) and in GEK 95122 for open ventilated units.

III. SHUTDOWN MAINTENANCE

A. Frequency of Inspection

It is recommended that the generator be given a complete inspection at the end of the first year of
service. The subsequent interval between inspections may vary, but in general a three to five year cycle
is suggested.

Conditions found during the last inspection or recommendations by the manufacturer may influence
when the owner may elect to open the machine for the next inspection.

Due to the many variations in the design of generator components it is not practical to provide detailed
generator disassembly instructions. Should it be necessary to remove the generator rotor, instructions
for ASSEMBLY AND DISASSEMBLY OF ROTOR should be studied in addition to the complete
assembly before any work is started. It is highly desirable that a trained GE field representative conduct
the complete dismantling, inspection and reassembly procedures.

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 Maintenance and Care for Open Ventilated Air-Cooled
GEK 95122b Generator

CAUTION

Care should be exercised in removing the rotor to avoid damage to the armature
punchings or windings, the machined surfaces of the stator and rotor, the exciter,
the fans, the journals, or the retaining rings.

After removal, the rotor should be supported on wooden blocks placed under the pole area of the rotor
body or under the journals after they are protected. Do not support the rotor in the region of the coil
slots or on the retaining rings.

B. Care of Generator Prior to Shutdown

CAUTION

Where the generator will be exposed to relatively sudden or extreme changes in

temperature, humid or saltladen atmosphere, acid fumes or abrasive dust, more
careful and extensive Actions preparation may be required. Please follow your
local EHS Standards.

When planning the preparation of generator and associated equipment for a shutdown period, plan to
disassemble and prepare the equipment only to the extent necessary to protect it during that period.

Only a moderate amount of preparation may be needed for generators exposed to clean, dry atmo-
spheres and relatively uniform temperatures. Under such conditions, simply coat the surfaces of the
parts to be protected with lubricating oil, and insure that all electrical insulation remains dry.

Occasional inspection is advisable to make sure that the proper condition is being maintained.

C. Reparing the Generator at Shutdown

1. Drain and thoroughly dry the coolers completely.

2. Coat all exposed shaft surfaces with a light lubricating oil.

3. Keep the lubrication system in operation to provide continuous flushing.

4. Prevent condensation of moisture on the generator windings by energizing the stator frame heaters.
Additional stator frame heating can be accomplished by adding external heaters and/or using a
small blower to circulate dry heated air through the frame.

IV. INSPECTION OF PARTS

A. Armature Core

The armature core should be inspected, particularly for evidence of hot spots or damaged punchings.
Such damage, if observed, requires very careful and expert repair.

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Maintenance and Care for Open Ventilated Air-Cooled
Generator GEK 95122b

CAUTION

No attempt to grind or repair core damage should be undertaken except by a person

who has had previous training. An inexperienced person can easily cause addi-
tional damage, which could result in a serious core burnout.

If the core needs painting, all surfaces should be cleaned and the punchings sprayed with GE epoxy or
Glyptal paint. The inside of the generator should be checked for evidence of oil which would indicate
oil leakage past the oil deflectors.

B. Armature Windings

Inspect the ends of the armature windings for deposits of oil and evidence of corona discharge, or
mechanical damage such as vibration, chafing, loose blocks and ties, etc. If cleaning is necessary,
carefully inspect the windings and insulation afterward. Under ordinary conditions, it should not be
necessary to repaint the end windings more frequently then once in five years. To repaint the end
windings, it is recommended that GE epoxy or Glyptal paint be sprayed on after the windings have
been thoroughly cleaned and dried.

CAUTION

Caution is necessary in the use of a spray because of the fire hazard involved,
since practically all insulating varnishes and paints are combustible and have a
low flash point; and ignition is readily caused by a spark, flame, or excessive heat
of any kind. To reduce this risk, all metal parts, both of the spraying apparatus and
the machine to be sprayed, should be grounded to a common ground.

C. Rotor

If necessary, clean the outside surfaces of the rotor body and spray with Bassolene coating (C1175,
BlueAir Dry) to prevent rusting. Only a thin coat should be applied since the rate of heat transfer from
the rotor surface may be reduced by too heavy a coat.

D. Insulation Testing

It is not possible or practical to perform a visual inspection on all parts of the insulation system and
thus, to verify the capability of the system, electrical testing is needed. The purpose and value of such
testing is to determine conditions and trends and to search out weaknesses, and if any corrective action
is needed, to allow the owner to make any needed repairs at a time of his choice, instead of under
adverse conditions dictated by a forced outage.

For detailed instructions regarding these tests, refer to instructions on INSULATION TESTING.

E. Cleaning

Before cleaning, refer to instruction on CLEANING FLUIDS. Any cleaner is more or less a solvent
for insulating compounds; hence the application of these fluids in large quantities should be avoided.
Also, cleaning fluids should not be allowed to stand in contact with the windings any longer than is
necessary to remove the oil and dirt.

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 Maintenance and Care for Open Ventilated Air-Cooled
GEK 95122b Generator

In many cases, the cleaning fluids may be applied to the windings by means of a spray as an alternative
to the use of brushes or cloths. The spray nozzle should be held close to the work to obtain the greatest
benefit from the cleaning fluid.

The object of using any cleaning fluid is to soften the accumulated foreign matter. The best results,
therefore, will be obtained by moistening a small area at a time and then wiping clean before the solvent
has had sufficient time to dry and the accumulation again becomes hard. By following the above, less
cleaning fluid will be used, the fire hazard will be decreased, and the annoyance to the workmen will
be minimized. Two or three applications of the cleaning fluid may be necessary depending upon the
amount of oil and dust; after each application, the parts should be wiped dry. In case handscraping
of parts is necessary, wooden sticks should be used instead of metal scrapers to avoid damaging the
insulation.

F. Removal and Assembly of Collector (Static Excitation Systems)

In the event of major damage to the collector rings, a complete new collector should be installed. Re-
move the shaft extension and disconnect the collector leads from the connection bars.

When the collector has been disconnected, attach a pulling ring to the threaded holes provided in the
outboard end of the collector shell. Apply heat uniformly to the collector rings, bringing the rings up
to a temperature of about 150C (302F). This relieves the fit of the collector on the shaft and allows
the rings to be pulled off.

To assemble a new collector on the shaft, heat the collector to not over 130C (266F) in an oven and
slip rings into position on the shaft, making sure that collector leads are properly lined up with the
connection bars. After carefully making and insulating the connections, reassemble the shaft extension
or collector lead cleats.

After a new collector is installed, it is often necessary to polish the rings to obtain minimum brush
vibration. Detailed instructions are included in BRUSH RIGGING AND COLLECTOR RINGS.

G. Removal and Assembly of Armature Bars

NOTE

It is recommended that experienced supervisors and armature winders from the

GE Company be obtained for making such repairs.

The stator winding is made up of complete coils, formed by connecting together the ends of individual
half coils, or stator bars. These connections are made external to the core at a series loop.

Removal of the radially inner (top) bar is relatively straightforward, but to remove a radially outer
(bottom) bar, a number of top bars have to be removed to expose the full length of the bottom bar.

To permit removal of the stator bars, the insulation at the ends must be removed, the end electrical
connections unbrazed, and the glass ties cut. The wedges must be carefully driven out of the slots
without damaging the punchings. Since the end arms of the bars are securely anchored by cementing all
contact points and by the use of thermosetting resin in the ties and blocks, special skill and experience
are required in disassembly of the end structure. The bars are removed cold, therefore care should be
taken not to bend the bars, which could crack the mica ground insulation, or otherwise damage the
insulation. Metal tools should never be used to pull the bars out of the slot. A strong web tape should

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Maintenance and Care for Open Ventilated Air-Cooled
Generator GEK 95122b

be looped around the bar on the straight portions just outside the slot for lifting. Fiber wedges may be
used to start the bars at the ends and the tape loop moved along the bar as it is lifted.

Reassembly of a stator bar in the slot requires careful fitting of the bar to the slot and to the end winding
support structure. The bar should be jacked down to assure that it is bottomed in the slot space as the
slot wedges are assembled. Always consult detailed instructions applicable to the specific machine in
question before starting such work.

Thermosetting materials are used extensively in the winding support structure and if repair work is
done, heating of the end winding will usually be required to set the replacement material. To accom-
plish this, the end winding region can be enclosed and hot air furnished from a portable heaterblower.
Temperature control and accurate monitoring must be accomplished in accordance with specific in-
structions from the GE Company, depending on the particular work involved.

H. Removal and Assembly of Field Coils

NOTE

It is recommended that an experienced GE field representative be obtained for

making such repairs.

In order to remove the field coils, the generator rotor must first be removed from the stator and the re-
taining rings disassembled. Each retaining ring must be marked so it can be put on in the same position.
See instructions on ASSEMBLY AND DISASSEMBLY OF RETAINING RINGS. The external insu-
lation and end blocking around the coils in question must be removed. The connections between coils
are brazed, the coil connections being made from the top turn of one coil to the top turn of the adjacent
coil and from the bottom turn of the latter coil to the bottom turn of the succeeding coil. Silver solder
is used for the brazing material and the brazed joints must be unbrazed before a coil can be removed.

The slot wedges are carefully fitted in the slot dovetails and should be numbered before removal to
allow accurate placement when reassembled. These wedges must be driven out from the slots carefully;
otherwise deformation of the wedges will prevent their reassembly in the slots. Care must be taken not
to produce slivers which can lodge within the slots.

The coils should be removed one turn at a time, working them up from one end and progressively
along the slot. If the coils are to be used again, great care must be taken not to bend the turns since this
will make the reassembly difficult, if not impossible. Coils to be reused must be cleaned, straightened,
annealed on the ends and reinsulated.

New turn insulation and slot armors must be used when assembling new or repaired rotor coils. To
assemble a coil in the slots, the coil is suspended above the rotor on padded hooks from which it may
be fed down into the slots one turn at a time. Any sharp bends or kinks in the turns will prevent flattening
the turns in the slot. Temporary blocking made of hardwood is used to support the end turns during the
brazing and clamping operations. The coils are heated and pressed firmly into the slots. The wedges
are then driven into the dovetails in the slots, each wedge being placed in its original position, with
protective filler strips under the wedges to fill the space below the wedges and maintain the coil radial
position.

The connections must be rebrazed and the blocking around the end turns reinstalled. New molded
retaining ring insulation is placed over the ends of the coils and the retaining ring reassembled.

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 Maintenance and Care for Open Ventilated Air-Cooled
GEK 95122b Generator

V. PROTECTION OF GENERATOR DURING PERIODS OF SHUTDOWN OF INDEFINITE

DURATION

A. Protection at Shutdown

To prevent condensation of moisture on the generator windings, keep the temperature of the air inside
the generator above the temperature of the ambient air. Strip heaters with thermostatic controls may
be used, or light bulbs may be installed and energized continuously if they are placed at least twelve
inches from any part of the windings. A total wattage of approximately 100 watts per 1000 kW of
generator rating should be sufficient.

B. Additional Protection For Static Excitation Systems

1. Lift collector brushes clear of the collector rings and leave in this position until operation of the
machine is resumed.

2. Coat collector rings with a film of light oil. Use care to assure that oil does not accumulate on the
insulation adjacent to the rings.

C. Periodic Maintenance During Shutdown

Periodically check the strip heaters or other heating devices to make sure they are functioning properly.

For brushless exciter maintenance instructions refer to the Brushless Exciter Instruction Manual
found elsewhere in your instruction book.

D. Procedure Prior to Resumption of Operation

1. Deenergize the strip heaters or other heating device.

2. Before operating the machine, the insulation resistance of the armature and field windings should
be measured. Refer to instructions on INSULATION TESTING.

3. Remove protective coating of oil from collector rings where applicable with mineral spirits. Use
care to ensure that solvent does not come in contact with insulation between rings.

4. Replace brushes if applicable. See GEK 35474, BRUSH RIGGING AND COLLECTOR RINGS
for details.

An appreciable amount of moisture in a generator affects the resistance of the winding insulation, and
the moisture must be removed before the machine is placed in operation. Refer to instructions on
DRYING TURBINEGENERATOR WINDINGS.

CAUTION

Do not use a 1000 volt insulation meter for measuring insulation resistance of
the field winding. A GE Company insulation resistance meter or any 500 volt
insulation resistance meter should be used.

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Maintenance and Care for Open Ventilated Air-Cooled
Generator GEK 95122b

E. Renewal Parts

Order renewal parts in accordance with RENEWAL PARTS instructions.

VI. PERIODIC MAINTENANCE AND CHECKS

1. As indicated in the turbine instruction, turn the rotor assembly occasionally to insure that the journals
remain coated with oil. If possible, the generator rotor should be at rest with the pole axis in the vertical
direction. This can be determined from the balance position numbers which are 5 and 11 for the cen-
terline of the poles. Balance position numbers are stamped on the centering rings and fan hubs inside
the unit, and on either the main coupling or expansion recorder ring.

2. Megger the field once a month per instructions entitled Insulation Testing located elsewhere in the
main instruction book. Maintain records in order to monitor any downward trend. It will normally not
be necessary to megger the armature winding unless the field megger is very low, as the field megger
is usually a good indication of the amount of moisture inside the casing.

3. Inspect exposed shaft surfaces to insure that the oil film is adequate.

4. Visually check all equipment occasionally to insure that no unexpected events are occurring.

VII. PROCEDURE BEFORE STARTUP

1. Remove the blower if one was used, remove all heaters which were not installed permanently.

2. From this point the procedure outlined in the instruction entitled Operation can be followed as ap-
plicable.

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 Maintenance and Care for Open Ventilated Air-Cooled
GEK 95122b Generator

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GE Energy
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