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Problem:
Loss of compression allows laminations to vibrate High cycle fatigue cracks lamination Failed lamination migrates into coil ground wall insulation causing ground fault
Aging Mechanism:
Loss of core compression due to bolt mechanical stretch Shrinkage of lamination insulation due to time and temperature
Preventive Measures
Check core clamping bolt torque x Every 5 years or major outage x 80% of original OEM values 150 psi
x
Check for core looseness: 10 mil thick blade should not go more than 1/4
Problem/Aging Mechanism:
Loss of compression over time allows laminations to vibrate Thin coating on lamination wears away Laminations create short circuit, additional heating, possible melting
Preventive Measures
x x
Good visual inspection Look for damaged laminations that may be shorted Rotor removal and reinstallation often can damage laminations Foreign objects: balance weights, nuts, washers, etc. Local Repairs
x x
Excite core to rated flux density Wait one hour for heat to soak through View with infra-red Locations 10C above average core temperature should be corrected Need High Voltage
Preventive - El Cid
x
Excite core to only 4% of rated flux density Search coil on trolley detects any interlaminar circulating currents 100 -200 milliamp action threshold Uses 110 vac
Problem: Unit tripped off line at full load with electricity selling @ over $1000 per MWHr
Aging Mechanism: Mechanical Stress High Cycle Fatigue Cracking of Conductor Strand Vibration increases as blocking and bracing loosens
Preventive Measures
x
Visually inspect for dusting, greasing, signs of movement Phase to phase resistance check Flag if more than 3% unbalance Standard winding electrical tests
Checks for local and global natural frequencies near the 120 hz double operating frequency End winding can be stiffened after test results
Insulation Failure
Problem: Extensive PD (partial discharge) cause deterioration of ground wall insulation x Also can act internally
x
PD - Corona Attack
x
Aging Mechanism: High voltage, time, air, small gaps, coil spacing - all can be PD factors
Areas of corona/partial discharge
Preventive Measures
x
Corona Probe - can detect localized corona such as slot discharge hand held - voltage on winding SSC - Stator Slot Couplers - detects partial discharge in winding Bus Couplers - put on main buses
Problem: Relative movement between bar and brace wore through insulation and hollow conductor
EXPOSED TUBE
Aging Mechanism: Thermal forces on oil cooled conductor. Damage due to bar movement against the end turn support. Hollow conductor wall is worn through.
x x
Ripple Springs Provide Radial Pre-load Force on Coil Should be Compressed 80% As Coil Insulation Creeps, Radial Follow-up Maintains Coil Tightness Radial Pressure Should be Maintained at least two times Steady State Slot Pounding Forces
www.national-electric -coil.com
Adwel wedge tightness tester Takes the human error of hand held tap testing w/ hammer Set calibration different ways
Preventive Measures
Visual inspection for damaged insulation, cracks in paint, dusting greasing x Retrofit bracing system to allow for relative movement
x
New core with new lamination steel, lower losses, optimized slot for maximum copper
New coils with maximum copper and optimized arrangement for maximum output, highest efficiency, and lowest losses
Shorted Turns due to insulation deterioration or copper displacement can cause high vibration Blocked ventilation passages can create heating unbalance and vibration Cracked Components such as rotor copper turns, retaining rings, and fans can cause high vibration or more severe damage Rotor grounds can cause forging damage and severe rotor vibration
Rotor winding insulation gradually deteriorates over time, due to repeated temperature and stress cycles.
Shorted Turns
x
Over time, top turns can elongate to the point where they short with other turns.
Shorted Turns
x
Shorted Turns
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Shorted turns may affect the rotor balance. Shorts can be detected by certain stationary electrical tests, such as a pole drop measurement. Shorts can be detected on line by a flux probe test as shown here. Difference in Peak Magnitude indicates a short.
Fatigue crack in copper turn Can lead to arcing and burning, causing shorts and unbalance
Slot Wedge Radius Too Large at Ends Deformation Prevents Free Expansion and Contraction of Coils Thermal Bowing Forces Cause Unbalance
Insulation or copper move Vent passages blocked by dirt or debris Cooling not balanced, get uneven heating, creates thermal bow
If unbalance is severe due to shorted turns, cracked copper, blocked passageways, a rotor rewind using the old copper but new insulation may be necessary.
18.5 retaining rings (nonmagnetic) are susceptible to SCC and should be inspected or replaced
Hydrogen embrittlement of magnetic retaining rings Rings manufactured before 1960 Hardness greater than 350 BHN Operate in a hydrogen environment
Fan Cracking
x
Fan cracking can cause significant vibration and more severe damage Occurring more frequently on rotor repairs and rewinds that NEC has been involved in
Fan Cracking
x
Fan Cracking
x
This manufacturer has generic fan failure problem Failure of these style fans has occurred numerous times Replacement design includes reduced # of blades - thicker
Fan Cracking
x
Aluminum fan blade from older OEM machine Aluminum becomes embrittled Impossible to repair or replace on kind
Fan Replacements
x
New fans designed and manufactured to replace old style High strength alloyed steel Superior performance
Running Grounds
x
A running ground can be frustrating to locate The migrated bottom steel runner deflects upwards and grounds to the bottom turn only under centrifugal forces
Rotor Grounds
x
A double ground will cause current to flow through the rotor Severe forging damage can result This rotor was scrapped due to the extensive forging damage
x x x
Smaller burn marks and arcing damage can be repaired Nital Etch to identify the hardened material Grind Carefully Re-test Stress Analysis
ECT, MPT Small Cracks Enlarge Fillet Re-inspect Large Cracks Machine off Longer RR
This rotor was energized at standstill Severe forging damage mostly isolated to the tooth top area Forging was saved
Return to Service
x
Hardened material mapped and identified Hardened material machined away New, longer retaining rings installed