Generator Services WGGS Capabilities...

Generator Services

WGGS Capabilities Presentation

Generator Services

LOCATION: New Mexico, USALOCATION: Four Corners, New Mexico

LOCATION: Farmington, New Mexico

LOCATION: Wood Group Generator Services, Inc.

Our Location

Generator Services

Turbo Generator Stators and Rotors

Turbo Power Hydro Power Petroleum Steel Paper

Our Focus

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Generator Services


Hydro Generator Stators and Rotors

Our Focus






Generator Services


AC Electric Motor Stators and Rotors

Our Focus






Generator Services

Coil Manufacturing

Roebel BarsMulti Turn Coils

Generator/Motor Shop Services

Stator/ Rotor Rewinds & Core RestacksIn stock Retaining Rings, Full Machining

capabilitiesHigh Speed Balance and Testing

Field Services

Inspection & DiagnosticsOn Site Stator Rewinds

Preventative Maintenance

Rotor Clean Roomsfor Rotor

rewinds & repairs

High Speed Bunker

Electrical Testing at speed

Fully integrated coil facility

design, manufacture,

testing

VPI coils,B-Stage

Up to 15 KV

Short Lead Times

Site Inspection and tests

On-Site Repairs (rewedge, end

winding stability system, core

restack/rewind)

Generator Monitoring and

On-line Diagnostics

Rotor coil manufacture

Cylindrical and salient pole

windings

Fully Integrated Capabilities / Project Management

Generator Services

WGGS Project Management PhilosophyWGGS Project Management Philosophy

WGGS Generator and Electric Motor Wear Factor TourWGGS Generator and Electric Motor Wear Factor Tour

WGGS Turbine Generator Rotor TourWGGS Turbine Generator Rotor Tour

WGGS Turbine Generator Stator TourWGGS Turbine Generator Stator Tour

WGGS Hydroelectric Generator TourWGGS Hydroelectric Generator Tour

WGGS Electric Motor Rewind TourWGGS Electric Motor Rewind Tour

WGGS Generator Assessment Program TourWGGS Generator Assessment Program Tour

Technical Presentation Presentation Chapters

Generator Services

WGGS WGGS Generator Generator Assessment Assessment Program Program TourTour

Generator Services

Wood Group Generator Services, Inc.

Generator Assessment Program (GAP)

Technical Presentation Generator Assessment Program Tour

Generator Services

Generator Assessment Program, Option #112 hour Assessment (to fit “engine borescope”)

Unit condition - Generator assembled but inspection access covers removed

Inspections/tests performed:●

Borescope inspection of armature winding, rotor winding and blocking (as accessible), stator core step laminations and fingerplates

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Perform tests on rtd’s, armature winding, and rotor winding

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Armature Winding Test –

IR, PI and Res.

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TGR Test –

IR, PI, Res., and Impedance

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Exciter inspection

- Visual inspection, insulation resistance tests


Generator Services

Generator Assessment Program, Option #23-4 Day Assessment (to fit “valve inspection” or “auxiliary inspection”)

Unit condition - Rotor installed but top half of end brackets removed


Visual and Borescope inspection of rotor winding and blocking, stator core laminations and fingerplates (as accessible).

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Insulation tests on rtd’s, armature winding, and rotor winding.

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Winding tests –

IR, PI, and Resistance -

(armature winding and rotor winding).

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Core tightness checks (visual indications of looseness).

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Doble -

Power Factor and Tip up.

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Corona tests, as assessable, to determine areas and severity of

any corona activity.

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Step voltage tests (d.c. step voltage / dielectric absorption or

high potential) to determine insulation integrity of armature windings.

●

End winding stability test (end winding basket frequency check).

Exciter inspection: ●

Visual inspection.

●

Insulation resistance tests.


Generator Services

Generator Assessment Program, Option #37 – 10 Day Assessment (to fit “cylinder inspection” or “major inspection”)

Unit condition - Rotor removed


Visual inspection stator and rotor

●

Borescope inspection of rotor winding and blocking (as accessible)

●

Perform tests on rtd’s, armature winding, and rotor winding.

●

Winding resistance checks (armature winding and rotor winding).

●

Core tightness checks

●

Corona tests to determine areas and severity of any corona activity

●


high potential) to determine insulation integrity of armature windings

●

End winding stability test (end winding basket frequency check)

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Core El Cid test

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Wedge Tightness Detection

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Doble Power Factor and Tip up

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Rotor impedance and pole balance tests

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Generator rotor retaining ring NDE inspection (based on OEM requirements)

Exciter inspection:●

Visual inspection

●

Insulation resistance tests


Generator Services

Generator Assessment Program, Option #43-4 Day Assessment (to fit “valve inspection” or “auxiliary inspection”)

Unit condition - Rotor installed but top half of end brackets removed



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Winding tests –



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Doble -


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Robotic El CID core test (as accessible).

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Robotic wedge tightness mapping (as accessible).


Visual inspection.

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Generator Services

Generator Assessment Program, Option #57-10 Day Assessment (to fit “cylinder inspection” or “major inspection”)

Generator Assessment Program Tour

Unit condition - Rotor installed but one top half of end bracket removed



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Winding tests –



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Doble -


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Robotic El CID core test (as accessible).

●

Robotic wedge tightness mapping (as accessible).


Visual inspection.

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Generator Services

Insulation Resistance Test

An insulation resistance test is a low voltage test (typically 500 to 2,500 VDC) utilized to determine only the most general condition

of a winding. It can indicate only the most severe or significant degree of insulation damage and is typically used as a prelude to most searching tests.

Off-Line Inspection, Tests & Examinations


Generator Services

Off-Line Inspection, Tests & ExaminationsPolarization Index Test

A polarization index test is another relatively low voltage examination. Once again, this test is utilized to determine only the most general condition of a winding. A P.I. test is generally performed in order to determine whether or not more stringent testing can be performed.

Tests, Inspections, and Examinations


Generator Services

Off-Line Inspection, Tests & ExaminationsDC Ramp or Step Voltage Test

The data concerning winding condition offered by a DC high potential test can be significantly improved by observing the difference in current as the test voltage is increased. If a flaw exists in the ground wall insulation system, a failure is often preceded by an abrupt rise

in current. This allows the operator to terminate the test at the first sign of warning.



Generator Services

Off-Line Inspection, Tests & ExaminationsPower Factor Tip-Up Test (Doble)

Power Factor Tip-up testing examines the windings at various voltage levels. This test is significant in the degree of detail it can provide with regard to the serviceability of a winding. Factors such as contamination, corona suppression system degradation, partial discharge activity, insulation delamination, and voids all impact the results of this testing.



Generator Services

Off-Line Inspection, Tests & ExaminationsCorona Camera Examination

A corona camera is a specially designed video instrument, utilized to record the presence of partial discharge activity other wise invisible to the naked eye under normal turbine deck lighting conditions. With this instrument one can see what a particular winding look like under normal operating conditions.



Generator Services

Off-Line Inspection, Tests & ExaminationsWedge Tightness MappingComputerized wedge tightness testing is a method of precisely measuring the stator slot wedge system for its degree of tightness within the core iron wedge grooves. An automatic hammer, attached to an accelerometer, is used to tap each and every individual wedge. The computer measures, and compares all reading against predefined calibration parameters.



Generator Services

Off-Line Inspection, Tests & ExaminationsEnd Winding Stability ExaminationPremature winding failure may occur due to excessive end winding

vibration. Large turbine generators and hydro generators are most susceptible. Routine measurement of vibration amplitude and frequency is important in detecting looseness, which can lead to fatigue and failure of copper conductors and insulation systems.



Generator Services

Off-Line Inspection, Tests & ExaminationsWinding Resistance Measurements

Performed with a Digital Low Resistance Ohm (DLRO) meter, this test measures the resistance across individual phases, phase groups, or coils. Measurement of winding resistance can determine incorrect connections, cold or broken braze joints, severe mismatches, and/or opens.



Generator Services

Off-Line Inspection, Tests & ExaminationsElectro-Magnetic Core Imperfection Detection (El CID) TestElectromagnetic Core Imperfection Detection (EL CID) core testing is a means by which the integrity of stator core intra-laminar insulation can be measured, utilizing minimal electrical input to excite the iron. EL CID is excellent in its ability to pin point and accurately measure even the smallest defect.



Generator Services

Off-Line Inspection, Tests & ExaminationsAC Impedance TestAn AC impedance test is performed by inducing into the rotor windings incrementally increasing voltages. The voltage and amperage are

measured and recorded. The ohm values are calculated and graphed against the applicable voltage levels. This is another method of testing for turn-to-turn shorts. An AC impedance test may be performed either with the rotor at rest, or at any desired speed.



Generator Services

Off-Line Inspection, Tests & ExaminationsAC or DC Pole Drop TestA pole drop test is performed by inducing a voltage into a rotor

winding, measuring the voltage drop across each individual pole,

and then comparing the two against one another. If the reading are off more than 5-percent, turn-to-turn shorts are suspected in the pole generating the lower reading.



Generator Services

Off-Line Inspection, Tests & ExaminationsStatic Turn Insulation Integrity Test (STIIT) A static turn insulation integrity test (STIIT™) is utilized to measure and compare readings for each and every individual coil within a 2-pole rotor. Readings for like coils of opposing poles are compared to one another as well as industrial standards. Difference in readings are applicable to the degree of turn-to-turn shorts within any particular coils.



Generator Services

If any of the afore-mentioned tests produce negative results, a thorough visual inspection is imperative. In other instances, a visual inspect will produce results, which indicate further testing. A visual inspection is quite inexpensive, while being extremely telling about the condition of your generator.

WGGS archives all photographic record of each and every visual inspection performed.

Off-Line Inspection, Tests & ExaminationsVisual Inspection


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Generator Services

WGGS WGGS Electric Electric Motor Motor Rewind Rewind TourTour

Generator Services

Wood Group Generator Service, Inc. (WGGS) reconditions, repairs, rebuilds, and rewinds electric motors of all shapes and sizes. This particular unit failed to ground when a balance weight came loose and struck the stator core iron.

Typical Project Status Report

Electric Motor Rewind Tour

Generator Services

A view of the failed stator coil, melted in half by the event.

The iron damage was severe and deep.

The existing stator windings are carefully removed.

The existing stator housing was grit-blasted clean.

The existing stator core iron was removed and disposed of.

The customer elected to replace the entire stator core.


Generator Services

All new stator laminations were procured.

All new end compression rings were manufactured.

All new compression thru- bolts were manufactured.

The new core iron was full flux core tested and El CID tested.

The new core iron was installed and compressed.

The new compression thru- bolts were installed.


Generator Services

Wood Group Generator Service, Inc. (WGGS) offers our OMEGA-PacTM and OMEGA-VacTM insulation systems for generator and electric motor stator windings.


Generator Services

The lap windings are lifted as the last coils are installed.

The installation of the new windings approaches the lap.

The throw of new stator windings is installed.

A view of the completed windings.

The stator end connections are formed, brazed, and taped.

A new stator wedge system ins installed.


Generator Services

Typical Project Final Report

The completed product being loaded out for delivery.

The rewound motor was assembled and prepared for

delivery.

The motor rotor was at-speed balanced at 1,800 RPM.

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Generator Services

WGGS WGGS Turbine Turbine Generator Generator Rotor Rotor TourTour

Generator Services

Wood Group Generator Service, Inc. (WGGS) utilizes a very select group of Heavy Haulers, highly experienced with the handling of Turbine Generator Rotors (TGRs). Seismic recording of the transport is available upon request.

Typical Seismic Recording Report

Turbine Generator Rotor Rewind Tour

Generator Services

A complete and comprehensive incoming mechanical, electrical, and visual inspection is performed on every TGR as received and prior to disassembly.

Typical Incoming Inspection Report


Generator Services

All TGR retaining rings are removed by highly experienced WGGS Generator Techs, utilizing induction heating equipment. No open flame will ever touch your rings.



Generator Services

Block migration and partial end winding collapse.

Pole face block breaking and migration.

Tooth top cracking.

Aluminum saddles fitted over soft copper.

Severe end winding contamination.

Significant end winding turn elongation and deformation.


Generator Services

Existing windings are carefully removed, cleaned, straightened, annealed as required, further cleaned, and inspected in preparation for re-installation.

All existing winding copper is subjected

to a metallurgical analysis prior to

reuse.


Generator Services

Again, all new CC107 Silver-bearing copper

is used.

Spools of new copper are setup on a tension

dereeling devise

Continuous-wound coils are generated on the “Merry-go-Round”.

All end windings are annealed in order to

facilitate forming.

All new CC107 Silver- bearing copper is

used.

CNC mills accurately profile the corner

connections.

Corner connections are silver-brazed by

qualified WGGS Techs.

Each and every new coil is carefully

scrutinized prior to installation

Picture-Frame Style Coils:

Continuous-Wound Style Coils:


Generator Services

All TGR components are thoroughly cleaned, inspected, and rehabilitated as part of the rewind process.

The rotor body forging is grit-blasted, utilizing

a soft media.

Following cleaning, the rotor body forging is thoroughly NDE’d

All rotor body wedges are cleaned and NDE’d

for cracks.

All wedges are hand-fit to their respective slot

locations

The existing retaining rings are cleaned and

NDE’d.

The radial and bore copper assemblies are

reconditioned.

The fan assemblies, coupling, etc, are

cleaned and NDE’d.

The existing end winding blocking is inspected for re-use.


Generator Services

WGGS has the in-house capability to manufacture each and every component found on a Turbine Generator Rotor.

Special retaining rings insulation.

18Mn18Cr retaining rings from our stock

inventory.

All new fan blades and blower hubs.

All new end winding blocking.

Al new oil defectors, seals, and baffles.

All new diffuser blades.

All new rotor body wedges, including specialized plating.

Completely new diode wheel assemblies.


Generator Services

The WGGS rewind methodology produces a highly accurate and concentric winding, assuring a smooth-running TGR.

All new ground wall insulation is utilized

on every rewind.

All TGR’s are rewound in an environmentally- controlled clean room.

Temporary blocking is inserted into the end

winding.

Specially-manufactured compression fixtures are

installed.

The compressed windings are induction

baked.

The winding heads and temporary

blocking is removed.

The permanent blocking system is

installed.

The windings are compressed and

induction baked again.


Generator Services

As part of the final assembly process, all new retaining ring insulation is installed. Induction heating equipment is utilized to install the retaining rings.

Typical TGR In-process Report


Generator Services

The fully assembled TGR is loaded into the WGGS bunker and subjected to high speed balance, over speed confirmation, and running electrical testing.

Typical High Speed Balance Report, Including Flux Probe.


Generator Services

The final acceptance process consists of a myriad of highly detailed operations in order to assure that you receive a quality end product.

Our large lathe is utilized to grind and

polish journals.

All final acceptance electrical testing is

performed.

A borescopic inspection is performed under the

retaining rings.

Components such as fan blades are

mounted and secured.

The entire TGR is hand-cleaned and visually inspected.

The TGR is rotated while final run outs measured

and recorded.

The finished product is loaded out and vacuum-sealed.

Protected and secured, the TGR is ready for delivery.

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Generator Services

WGGS WGGS Turbine Turbine Generator Generator Stator Stator TourTour

Generator Services

A WGGS Generator Assessment Program (GAP) may indicate a terminal condition, such as extreme Partial Discharge Activity (PDA).


Turbine Generator Stator Rewind Tour

Generator Services

WGGS Generator Specialists carefully remove the existing coils or bars and prepare the stator core iron to accept all new and modern windings.

Typical Engineering Design & Drawings


Generator Services

All new WGGS OMEGA-PacTM Roebel half-coils can be designed and manufactured. As an alternative, an all new WGGS OMEGA-PacTM insulation system can be installed over top of the existing copper. Application of IEEE 1043 endurance testing is a standard operating procedure.


Generator Services

WGGS Generator Technician install the OMEGA-PacTM new windings, following highly detailed written procedures and processes.

Bottom bars are laid-in over new or rebuilt

surge ring assemblies.

Bars are carefully spaced and lashed to

the surge rings.

Six rows of blocks and ties, where the OEM

winding had only three.

Top bars installed and tightly side-packed

into position.

An all new stator slot wedge system is

installed.

In process high potential testing is performed prior to connection.

No less than three (3) El CID tests are

performed.

The second El CID test is performed after wedge installation.


Generator Services

With the new winding installed, the WGGS Generator Technicians focus on processing the end connections and final processes.

End winding connections are

induction brazed.

Bar-to-circuit ring connections are

brazed and insulated.

Additional filler blocking is installed

behind the clips.

Epoxy/Glass boots are filled with a special

epoxy.

The end connection boots are carefully

installed.

The completed windings are enclosed and oven-

cured.

The completed and fully-cured windings are allowed to cool.

The completed windings are coated

with epoxy-buff paint.


Generator Services

The final acceptance process consists of a myriad of highly detailed tests in order to assure that you a quality end product. Assemble then ensues.

Typical Project Final Report

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Generator Services WGGS Capabilities...

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