stator visual inspection - frame 6 users...
TRANSCRIPT
![Page 1: Stator Visual Inspection - Frame 6 Users Groupframe-6-users-group.org/wp-content/uploads/2018/06/2019...2013 Minor Bus bar heating, Minor Grease 2015 Major Stator cleaned, field insulation](https://reader030.vdocument.in/reader030/viewer/2022040301/5e7264330cde9a184b6d488f/html5/thumbnails/1.jpg)
AGTServices, Inc.Generating timely repair solutions
2019 Frame 6 User’s
Conference
2 GE Frame 6/6A3 “Minor” Outages,
Turned to Majors with Field Rewinds
Presented By:
Jamie Clark – AGTServices
www.agtservices.com
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AGTServices, Inc.Generating timely repair solutions
Agenda Summary
• Unit Details
• Unit Inspection History
• Unit “B” Minor – Fall ‘18
• Unit “A” Minor – Spring ‘19
• Findings/Root Cause
• Field Rewind
• Additional Stator Work
• Unit “C” Plans – Fall ‘19
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AGTServices, Inc.Generating timely repair solutions
Unit Inspection HistoryYear Unit A Unit B Unit C STG Findings
2001 Minor Major Minor B EW greasing, wedge greasing. C
partial rewedge, EW greasing
2002 Major Major B End Wedge Rewedge, STG Full
Rewedge
2003 Forced Forced A Repair/Replace 2 bottom bars, B
water ingress, no issues.
2007 Minor Noted more turn insulation migration
2008 Minor
2009 Minor Mag Particles, Rub Ring wear
2011 Minor Minor EW Greasing
2012 Minor EW Repairs w/ field in
2013 Minor Bus bar heating, Minor Grease
2015 Major Stator cleaned, field insulation
migration
2018 Minor Turned Major, Field RW, Rewedge
2019 Minor Turned Major, Field RW, Rewedge
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AGTServices, Inc.Generating timely repair solutions
Minor Inspection Scope (Both B-A)
• Outer end covers removed
• GAC in place
• Field installed
• Borescope aided visual inspection
• Standard Stator Electrical Testing
• Standard Field Electrical Testing
• Standard, limited disassembly, brushless exciter tests
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Summary Findings
Global, aluminum
metallic particle
contamination
from rub ring
wear.
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Summary Findings
Rub Ring
Inner Oil
Deflectors
Contamination Ingress:
• Aluminum Particles
caused by rubbing of the
Inner Oil Seals or Inner
Ring.
Possible Contributors:
• Field Vibration
• Tilt Pad Bearing Wear.
• Alignment ??
Rub Ring
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Summary Findings
• GE – 6A3 - S/N: 336X402
• Significant Amount of End Turn Insulation Migration
End Turn Insulation
FIELD WINDING:
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Summary Recommendations
Generator Field – To Remove Metallic Particles from Winding:• Remove field from stator.
• Perform a complete rewind with a new Class F Insulation.
• Perform a HSB with Running Electrical Tests.
Duration: Rewind – 21 Days / With HSB – 28 Days
Brushless Exciter: • Remove Diodes and Fuses.
• Clean.
• Replace All Fuses with New. Test & replace any bad Diodes.
• Replace Insulators and Hardware with new.
• Replace missing hardware from GFD.
• (Owner to supply Parts).
Stator – To Remove Oil Contamination & Assess Wedge System:• Clean Windings.
• Perform a Complete Wedge Tightness Survey – Perform Rewedge, if necessary.
• Ultimately, a full stator rewedge was required.
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Rewind
Global, and GROSS, turn
insulation migration
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Rewind
Significant End Winding
Elongation/Distortion
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Rewind
Numerous End Creepage
Blocks Broken
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Unit “B” Rewind
Top Coil To Coil Connectors
Undersized, Top Turn
Distortion From Soft Copper
FACTORY DEFECTS
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AGTServices, Inc.Generating timely repair solutions
Unit “B” Rewind
Numerous Slot Armors
Damaged/Compromised, and
numerous turn insulation
migration or cracking
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AGTServices, Inc.Generating timely repair solutions
Unit “A” Summary Findings
No Rub Ring
Aluminum
Contamination,
but GLOBAL and
GROSS turn
insulation
migration
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AGTServices, Inc.Generating timely repair solutions
Unit “A” Summary Findings
Second Verse, Same as the
First…but Worse!
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AGTServices, Inc.Generating timely repair solutions
Unit “A” Rewind
End Creepage Blocks Broken
– Same as Unit “B”
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Unit “A” Rewind
Main Lead Leaf Broken and
Spun Up. Numerous slot
armors nearly worn through
near slot exit.
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AGTServices, Inc.Generating timely repair solutions
Unit “A” Rewind
Slot Armor Patch
FACTORY FIX
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AGTServices, Inc.Generating timely repair solutions
Unit “A” Rewind
Numerous Areas of Turn
Insulation Breaks and Pulling
Away
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AGTServices, Inc.Generating timely repair solutions
Unit “A” Rewind
Turn Insulation Severe
Enough to Expose Copper
Turns
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AGTServices, Inc.Generating timely repair solutions
Unit “B” vs “A” Differences and
Similarities
Condition Unit “B” Unit “A”
Aluminum Contamination Yes No – but present in ‘03
Loose Distance Blocks Yes Yes
Turn Insulation Migration Yes Yes
Creepage Block Breaks Yes Yes
Top Turn Distortion/Soft Cu Yes No
Turn Insulation Crack/Splits Yes Yes
Main Lead Cracks No Yes
Coil Crossover Undersize Yes Yes
Slot Armor Damage Yes Yes (worn)
Also “Patched”
End Turn Distortion Yes No
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Generator Field
Rewind
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Generator Field
Rewind
![Page 24: Stator Visual Inspection - Frame 6 Users Groupframe-6-users-group.org/wp-content/uploads/2018/06/2019...2013 Minor Bus bar heating, Minor Grease 2015 Major Stator cleaned, field insulation](https://reader030.vdocument.in/reader030/viewer/2022040301/5e7264330cde9a184b6d488f/html5/thumbnails/24.jpg)
AGTServices, Inc.Generating timely repair solutions
GE 6A3 Generator Field
Rewind
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Generator Field
Rewind
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Generator Field
Rewind
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Generator Field
Rewind
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Generator Field
Rewind
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Rewind Complete
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AGTServices, Inc.Generating timely repair solutions
GE 6A3 Rewind Complete….
But What About the
Stator(s)???
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AGTServices, Inc.Generating timely repair solutions
Stator Endwindings
Unit B Unit A
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AGTServices, Inc.Generating timely repair solutions
Stator Connection Rings
Unit B Unit A
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AGTServices, Inc.Generating timely repair solutions
Stator Connection Rings
Unit B Unit A
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AGTServices, Inc.Generating timely repair solutions
Stator Axial Support Hardware
Unit B Unit A
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AGTServices, Inc.Generating timely repair solutions
Stator Wedge System
Unit B Unit A
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AGTServices, Inc.Generating timely repair solutions
Stator Wedge System
Only 21% are tight
Unit B
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AGTServices, Inc.Generating timely repair solutions
Stator Wedge System
80% are tight, so marginal. Due to
desired duration until next major,
rewedge recommended and approved
Unit A
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AGTServices, Inc.Generating timely repair solutions
Summary
Stator Area Unit B Unit A Comments
Endwinding Greasing Greasing Global cleaning,
partial block/retye
Stator Core No Issues No Issues
Wedge System 79% loose 20% loose Rewedge req’d
Buss/Lead Connections Minor retape Replace
some leads
Electrical Testing Passed Passed
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AGTServices, Inc.Generating timely repair solutions
Stator Repairs and Rewege
(similar for both)
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AGTServices, Inc.Generating timely repair solutions
Stator Repairs and Rewege
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AGTServices, Inc.Generating timely repair solutions
Stator Repairs and Rewege
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AGTServices, Inc.Generating timely repair solutions
Stator Repairs and Rewege
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AGTServices, Inc.Generating timely repair solutions
Stator Repairs and Rewege
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AGTServices, Inc.Generating timely repair solutions
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AGTServices, Inc.Generating timely repair solutions
Conclusions/Summary
• Most 6A3’s at/beyond 30 year service life
• Oil is the enemy!
• Unit “C” at this site is in the same boat – Fall’19 Plans
• Many “minor” inspections turning into MAJORS
• Get your units baselined NOW, and fix it as a SYSTEM
• Cycling Duty is negatively impacting BOTH field and
stators
• Stator rewinds are next – 8-12 week winding cycle!
• Add 24-28 days to wind it!!