2Q’19 Product Service Generator

Touchpoint
© 2019, General Electric Company.
GE Proprietary Information - The information contained in this document is General Electric Company (GE)
proprietary information. It is the property of GE and shall not be used, disclosed to others or reproduced
without the express written consent of GE. In no circumstances shall the use of this document by any person
or by GE in any presentation, meeting or discussion with any person imply that any such authorisation is
given. This report is an executive summary aiming to identify the most likely cause contributing to the failure
and possible corrective actions, based on the information made available to GE at this stage. GE reserves
the right to vary its findings and conclusions should any fact or technical knowledge come to GE after the
date of this document. This report does not vary any contractual relationship between GE and the customer.
NO REPRESENTATION OR WARRANTY IS MADE OR IMPLIED AS TO ITS COMPLETENESS, ACCURACY, OR
FITNESS FOR ANY PARTICULAR PURPOSE.

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GEK 103566
Creating and Effective Generator Maintenance
Program
GEK 103566 – Creating an effective generator maintenance program
Revision L Updates

Combining GE with Alstom Borescope inspection:

Added Low Oxygen Stator Cooling Water System recommendations Visual inspection through the end shields or cooler(s)
Combined Stator & Rotor Test and Inspections Electrical tests per Tables 3 → 5

Added retaining ring and “when to remove rotor” Robotic inspection:

recommendations Rotor In-Situ inspection via robotics
Stator and rotor tests and inspections per Tables 3 → 5
Updated Rotor Life Management recommendations
Remove Rotor only for Repairs, NOT Inspections
Terminology changes:
1st Year Inspection (Major Scope) →First Inspection
Minor inspection/Inspection A → Borescope inspection
Major inspection/Inspection B→ Robotic inspection
MAGIC/DIRIS → Robotics

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GEK 103566 – Creating an effective generator maintenance program
Revision L - Rotor removal recommendations

Events or Trends Predicating Rotor Removal Required Maintenance or Repair Activities

Abnormal operating events as listed in Section 2: Rotor tooth and wedge inspection and repair to remove
Maintenance Planning hardened material
Rotor vibration trends coupled with flux probe shorted turns or
Rings off cleaning up to field rewind
blocked ventilation passages
Stator wedge looseness trends Partial or full stator re-wedge, retighten
Air gap foreign object damage Core or wedge repair
Stator winding insulation degradation indicated through DC
Partial or Full stator rewind
leakage or Partial Discharge trending

Driving towards online trending, in-situ testing and inspection and rotor removal
for repair purposes
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GEK 103566 – Creating an effective generator maintenance program
Revision L updates – Inspection and maintenance intervals

Rev K Rev L

Alternate borescope and robotic inspections

Follow figures 1 and 2 as examples

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GEK 103566 – Creating an effective generator maintenance program
Revision L updates – Rotor and retaining ring life management

Rotor Life Management Retaining Ring Inspection- New guidance is given in this
revision
GENERATOR FIELD
INSPECTIONS REQUIRED
CHARACTERISTICS

In-service and has a main body bore

Full suite of NDT inspections based 18Mn-5Cr RR - Older Configuration
on re-inspect recommendations
• Should be replaced due to history of stress corrosion cracking
Full suite of NDT inspections except
In-service with no main body bore
bore inspections
• If not at a minimum inspected at each outage interval
▪ Borescope Inspections- Visual inspections should be
Recommendations going forward…. completed
• First in-service inspection required at 20 years or 2000 ▪ Robotic Inspection- NDT should be completed
starts/stops from COD.
• Re-inspect based on number of starts only; however, GE 18Mn-18Cr RR - Current Configuration
would may add year based recommendations dependent on • The ID inspected at each time they are removed using
age of the unit and/or operation profile. fluorescent penetrant
• 2000 starts/stops is currently the maximum • NDT of the retaining ring
recommendation. ▪ prior to 30 years of service or 10,000 start/ stops
• Final revision of TIL 1920- Recommendations for NDT and ▪ then every 10 years or 2000 start/stops
evaluation of generator fields

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TIL Review
TIL 1701R-1 - Improving the reliability of medium
and high voltage auxiliary equipment
TIL 1648- Maintenance of LCI 89SS and 89ND
switches
TIL 1701R-1 (Improving the reliability of medium and high voltage
auxiliary equipment)
Compliance Category: M - Maintenance
Timing Code: 4 – At First Exposure
AUL
• All Legacy GE Generators
• Fleet experience used to develop a maintenance profile
Recommendations
• During inspection the interior of the enclosures and compartments should also be
inspected for cleanliness.
• Insulating media within the equipment should be cleansed with a clean, dry cloth
if contaminated. Even if the particulate contamination is not conductive,
combination of the particulate with moisture may cause electrical creepage and
tracking across insulating materials, resulting in phase-to-ground or even phase-
to-phase faults.
• Inspect gaskets for proper sealing and replace gaskets if damaged or worn.
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Overview of GTE, Generator, ISO phase bus and collector

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TIL 1701R-1 Applicable Enclosures and Compartments

• Generator Auxiliary Compartment (GAC) • Medium Voltage Cell (EPE units)

• Generator Excitation Compartment (GEC) • Generator Voltage Transformer Cubicle
• Metal Clad Switchgear • Generator Neutral Grounding Cubicle
• Generator Terminal Enclosure (GTE) • Bus Auxiliary compartment (BAC)
• Generator Line terminal Enclosure (GLTE) • DC Link Reactor/AC link reactor
• Generator Neutral terminal Enclosure (GNTE) • ISO Phase Bus Duct (IPBD)
• Packaged Electrical and Electronic control compartment (PEECC) • Segregated Bus Duct
• Generator Line Accessory Compartment (GLAC) • Non Segregated Bus Duct
• Generator Neutral Accessory Compartment (GNAC) • Generator Line Enclosure (GLE)
• Load Commutated Inverter & Excitation Compartment (LEC) • Generator Neutral Enclosure (GNE)
• Generator Circuit Breaker • Generator Lower Frame Extension

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Generator Terminal Enclosure Background

Components
1) Generator Voltage Bus Work (Line and Neutral Side)
2) Line and Neutral Side Current Transformers (4 sets each side Max)
3) Lightning Arrestors (Line Side)
4) Static Start Disconnect Switch (89SS)
Line & Neutral Side Current Generator Terminal Enclosure
5) Voltage Transformers (VTs) w/ fused primary and secondary (2 sets) Transformers (CTs)
6) Static Start Neutral Disconnect Switch (89ND)
7) Neutral Grounding Transformer
8) Neutral Grounding Resistor
9) Hydrogen Sensors
10) Junction Boxes
11) Space heaters Isometric View of GTE VT and fuse inside GTE
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 Generator Enclosures Fleet Experience

• Recent event caused by lack of maintenance

o Short circuit damage in GAC due to water & dirt ingress
o Dirt in the GTE lead to failure of insulators

Carbon dust on CT Arc on Stand off insulators Damaged VT

Vendor required maintenance

Dust and dirt in GAC leads to SC
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 ISO Phase Bus Duct Fleet Experience

• Recent event caused by lack of maintenance… vendor

recommendations:
o Perform complete visual inspection on annual interval Water in bus duct & around bus bar leading to failure
of the external duct including any external gaskets
o Perform complete visual inspection per vendor
guidelines for internal duct components, all seals,
gaskets, etc.

Water leaking from bus duct Isolated Phase Bus Duct

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TIL 1648- Maintenance of LCI 89SS AND 89ND switches

Compliance Category: M - Maintenance

Timing Code: 5 – At Scheduled Component Part Repair or Replacement
AUL
• This TIL applies to all 7F and 9F Gas Turbines with LCI static start equipment
Recommendation
Fleet experience indicates that proper switch maintenance may be effective at
reducing fail-to-start and trip events due to 89SS and 89ND switch malfunction.
Maintenance of 89SS and 89ND
Customers should refer to the manufacturer’s instruction manual provided by
each vendor for recommended maintenance.
All mechanical and electrical equipment should be inspected per these
instructions.

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 Static Start Disconnect Switch (89SS)

The 89SS static start disconnect switch connects the main bus to the static start
system. This switch is closed during the generator start-up and open during
normal use
Gas turbine failed starts have been experienced due to:
• 89SS switch failed to close
• Switch contacts are improperly aligned
• 89SS switch malfunction
• 89SS mechanical problems
• Incorrect limit switch setting

STACE 89SS switch PowerGear 89SS switch

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 Static Start Neutral Disconnect Switch (89ND)

The 89ND neutral disconnect switch connects the generator neutral tie
to the neutral grounding protection equipment. This switch is open during the
generator start to isolate the neutral grounding equipment and then closed during
normal use.
• 89ND switch malfunction
• Loose limit switch assembly
• 89ND switch failed to open to allow LCI breaker to close
• 89ND DC motor failure

STACE 89ND switch PowerGear 89ND switch

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 Summary

• It is strongly recommended that site follow the maintenance manuals

provided by vendors to increase the reliability of their equipment,
particularly as related to TILs 1701R1 and 1648
• All manuals should be available in customer instruction books.
• For harsh environments, it is suggested to have additional
maintenance intervals

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