Generator Services. WGGS Capabilities Presentation

Transcription

1 WGGS Capabilities Presentation

2 Our Location LOCATION: New Farmington, Wood Four Mexico, Corners, Group USA New Generator Mexico Services, Inc.

3 Turbo Power Hydro Power Petroleum Steel Paper Our Focus Turbo Generator Stators and Rotors

4 Turbo Power Hydro Power Petroleum Steel Paper Our Focus Hydro Generator Stators and Rotors

5 Turbo Power Hydro Power Petroleum Steel Paper Our Focus AC Electric Motor Stators and Rotors

6 Fully Integrated Capabilities / Project Management Coil Manufacturing Roebel Bars Multi Turn Coils Field Services Inspection & Diagnostics On Site Stator Rewinds Preventative Maintenance Fully integrated coil facility design, manufacture, testing Generator/Motor Shop Services Stator/ Rotor Rewinds & Core Restacks In stock Retaining Rings, Full Machining capabilities High Speed Balance and Testing Site Inspection and tests VPI coils, B-Stage Up to 15 KV Rotor Clean Rooms for Rotor rewinds & repairs High Speed Bunker Electrical Testing at speed Generator Monitoring and On-line Diagnostics Short Lead Times Rotor coil manufacture Cylindrical and salient pole windings On-Site Repairs (rewedge, end winding stability system, core restack/rewind)

7 Technical Presentation Presentation Chapters WGGS Generator Assessment Program Tour WGGS Electric Motor Rewind Tour WGGS Hydroelectric Generator Tour WGGS Project Management Philosophy WGGS Generator and Electric Motor Wear Factor Tour WGGS Turbine Generator Rotor Tour WGGS Turbine Generator Stator Tour

8 WGGS Generator Assessment Program Tour

9 Technical Presentation Generator Assessment Program Tour Wood Group Generator Services, Inc. Generator Assessment Program (GAP)

10 Technical Presentation Generator Assessment Program Tour Generator Assessment Program, Option #1 12 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 Perform tests on rtd s, armature winding, and rotor winding Armature Winding Test IR, PI and Res. TGR Test IR, PI, Res., and Impedance Exciter inspection - Visual inspection, insulation resistance tests

11 Technical Presentation Generator Assessment Program Tour Generator Assessment Program, Option #2 3-4 Day Assessment (to fit valve inspection or auxiliary inspection ) Unit condition - Rotor installed but top half of end brackets removed Inspections/tests performed: Visual and Borescope inspection of rotor winding and blocking, stator core laminations and fingerplates (as accessible). Insulation tests on rtd s, armature winding, and rotor winding. Winding tests IR, PI, and Resistance - (armature winding and rotor winding). Core tightness checks (visual indications of looseness). Doble - Power Factor and Tip up. Corona tests, as assessable, to determine areas and severity of any corona activity. 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.

12 Technical Presentation Generator Assessment Program Tour Generator Assessment Program, Option # Day Assessment (to fit cylinder inspection or major inspection ) Unit condition - Rotor removed Inspections/tests performed: 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 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) Core El Cid test Wedge Tightness Detection Doble Power Factor and Tip up Rotor impedance and pole balance tests Generator rotor retaining ring NDE inspection (based on OEM requirements) Exciter inspection: Visual inspection Insulation resistance tests

13 Technical Presentation Generator Assessment Program Tour Generator Assessment Program, Option #4 3-4 Day Assessment (to fit valve inspection or auxiliary inspection ) Unit condition - Rotor installed but top half of end brackets removed Inspections/tests performed: Visual and Borescope inspection of rotor winding and blocking, stator core laminations and fingerplates (as accessible). Insulation tests on rtd s, armature winding, and rotor winding. Winding tests IR, PI, and Resistance - (armature winding and rotor winding). Core tightness checks (visual indications of looseness). Doble - Power Factor and Tip up. Corona tests, as assessable, to determine areas and severity of any corona activity. 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). Robotic El CID core test (as accessible). Robotic wedge tightness mapping (as accessible). Exciter inspection: Visual inspection. Insulation resistance tests.

14 Generator Assessment Program Tour Generator Assessment Program, Option # Day Assessment (to fit cylinder inspection or major inspection ) Unit condition - Rotor installed but one top half of end bracket removed Inspections/tests performed: Visual and Borescope inspection of rotor winding and blocking, stator core laminations and fingerplates (as accessible). Insulation tests on rtd s, armature winding, and rotor winding. Winding tests IR, PI, and Resistance - (armature winding and rotor winding). Core tightness checks (visual indications of looseness). Doble - Power Factor and Tip up. Corona tests, as assessable, to determine areas and severity of any corona activity. 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). Robotic El CID core test (as accessible). Robotic wedge tightness mapping (as accessible). Exciter inspection: Visual inspection. Insulation resistance tests.

15 Technical Presentation Generator Assessment Program Tour Off-Line Inspection, Tests & Examinations 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.

16 Technical Presentation Generator Assessment Program Tour Tests, Inspections, and Examinations Off-Line Inspection, Tests & Examinations Polarization 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.

17 Technical Presentation Generator Assessment Program Tour Tests, Inspections, and Examinations Off-Line Inspection, Tests & Examinations DC 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.

18 Technical Presentation Generator Assessment Program Tour Off-Line Inspection, Tests & Examinations Power 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. Tests, Inspections, and Examinations

19 Technical Presentation Generator Assessment Program Tour Tests, Inspections, and Examinations Off-Line Inspection, Tests & Examinations Corona 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.

20 Technical Presentation Generator Assessment Program Tour Tests, Inspections, and Examinations Off-Line Inspection, Tests & Examinations Wedge Tightness Mapping Computerized 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.

21 Technical Presentation Generator Assessment Program Tour Tests, Inspections, and Examinations Off-Line Inspection, Tests & Examinations End Winding Stability Examination Premature 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.

22 Technical Presentation Generator Assessment Program Tour Off-Line Inspection, Tests & Examinations Winding 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. Tests, Inspections, and Examinations

23 Technical Presentation Generator Assessment Program Tour Off-Line Inspection, Tests & Examinations Electro-Magnetic Core Imperfection Detection (El CID) Test Electromagnetic 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. Tests, Inspections, and Examinations

24 Technical Presentation Generator Assessment Program Tour Off-Line Inspection, Tests & Examinations AC Impedance Test An 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. Tests, Inspections, and Examinations

25 Technical Presentation Generator Assessment Program Tour Off-Line Inspection, Tests & Examinations AC or DC Pole Drop Test A 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. Tests, Inspections, and Examinations

26 Technical Presentation Generator Assessment Program Tour Tests, Inspections, and Examinations Off-Line Inspection, Tests & Examinations Static 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.

27 Back Generator Services Technical Presentation Generator Assessment Program Tour Tests, Inspections, and Examinations Off-Line Inspection, Tests & Examinations Visual Inspection 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.

28 WGGS Electric Motor Rewind Tour

29 Electric Motor Rewind Tour 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

30 Electric Motor Rewind Tour The existing stator windings are carefully removed. The iron damage was severe and deep. A view of the failed stator coil, melted in half by the event. The customer elected to replace the entire stator core. The existing stator core iron was removed and disposed of. The existing stator housing was grit-blasted clean.

31 Electric Motor Rewind Tour All new compression thrubolts were manufactured. All new end compression rings were manufactured. All new stator laminations were procured. The new compression thrubolts were installed. The new core iron was installed and compressed. The new core iron was full flux core tested and El CID tested.

32 Electric Motor Rewind Tour Wood Group Generator Service, Inc. (WGGS) offers our OMEGA-Pac TM and OMEGA-Vac TM insulation systems for generator and electric motor stator windings.

33 Electric Motor Rewind Tour The throw of new stator windings is installed. The installation of the new windings approaches the lap. The lap windings are lifted as the last coils are installed. A new stator wedge system ins installed. The stator end connections are formed, brazed, and taped. A view of the completed windings.

34 Back Generator Services Electric Motor Rewind Tour The motor rotor was at-speed balanced at 1,800 RPM. The rewound motor was assembled and prepared for delivery. The completed product being loaded out for delivery. Typical Project Final Report

35 WGGS Turbine Generator Rotor Tour

36 Turbine Generator Rotor Rewind Tour 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

37 Turbine Generator Rotor Rewind Tour 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

38 Turbine Generator Rotor Rewind Tour All TGR retaining rings are removed by highly experienced WGGS Generator Techs, utilizing induction heating equipment. No open flame will ever touch your rings. Typical Project Status Report

39 Turbine Generator Rotor Rewind Tour 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.

40 Turbine Generator Rotor Rewind Tour 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.

41 Turbine Generator Rotor Rewind Tour Picture-Frame Style Coils: All new CC107 Silverbearing copper is used. CNC mills accurately profile the corner connections. Continuous-Wound Style Coils: Corner connections are silver-brazed by qualified WGGS Techs. Each and every new coil is carefully scrutinized prior to installation 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.

42 Turbine Generator Rotor Rewind Tour 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.

43 Turbine Generator Rotor Rewind Tour 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.

44 Turbine Generator Rotor Rewind Tour 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 environmentallycontrolled 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.

45 Turbine Generator Rotor Rewind Tour 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

46 Turbine Generator Rotor Rewind Tour 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.

47 Turbine Generator Rotor Rewind Tour 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 Back Ḃack

48 WGGS Turbine Generator Stator Tour

49 Turbine Generator Stator Rewind Tour A WGGS Generator Assessment Program (GAP) may indicate a terminal condition, such as extreme Partial Discharge Activity (PDA). Typical Project Status Report

50 Turbine Generator Stator Rewind Tour 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

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

52 Turbine Generator Stator Rewind Tour WGGS Generator Technician install the OMEGA-Pac TM 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.

53 Turbine Generator Stator Rewind Tour 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 ovencured. The completed and fully-cured windings are allowed to cool. The completed windings are coated with epoxy-buff paint.

54 Back Generator Services Turbine Generator Stator Rewind Tour 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