LM6000TM & LM2500®

Package Session
Fall 2006
© 2006 General Electric Company. All Rights Reserved. This
material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Ground Rules

• Please turn off or put your mobile phones on

vibrate/silence
• Please withhold from having side conversations
• Technical discussions only

Please feel free to ask questions of GE and other

Customers during the presentation…
dialog is good

2 GE Proprietary - Subject to Restrictions on Cover Page

Agenda

• Biodiesel and Plant Performance Optimization

• Package Reliability
• LM6000 Technical Programs
• Operation and Maintenance
• LM2500 Technical Programs
• Generator Reliability

3 GE Proprietary - Subject to Restrictions on Cover Page

Biodiesel as Alternative Fuel?

• Require performance test in controlled

environment, peaking units are more
suitable candidates
• Applicable to SAC Liquid or Dual fuel
with water injection units
• Fuel must meet GE and ASTM
specifications

Contact GE to discuss a
performance evaluation or required
engine/ package modifications

4 GE Proprietary - Subject to Restrictions on Cover Page

Plant Control Optimization Product
Customer Productivity:
• Reduces Excess Power
Delivered to Grid
• Reduces Risk of Penalties for
Power Delivery Shortfall
• Optimizes Unit Loading
Configuration
• Reduces Fuel Consumption

Available in 2007

Before After
All Major Factors Accounted For: 13.2 Optimization Optimization 170
• Current Electricity Pricing
• Current Fuel Pricing Fuel Cost ($1,000/hr) Fuel Cost
$100/hr fuel reduction

Power (MW)
• Actual Equipment Performance 13.1 $400,000/year savings 150

• Select most efficient prime mover

For example:
Automatically increase GT1 power output 13.0 GT1 Power 130

and decrease GT2 power output to

GT2 Power
optimize plant generating efficiency.
12.9 1 2 3 4 5 6 7 8 9 1 0
110

Optimize power delivered to the grid to reduce plant fuel consumption

5 GE Proprietary - Subject to Restrictions on Cover Page
LM6000
Units number in 2005: 179 GG Pkg BOP

LM6000 Package Reliability and Availability

12 Month Rolling Average
100
99.21

98
97.26

96
Percent

94

92 Package Reliability (%)

Package Availability (%)
Source: ORAP®; All rights reserved: SPS®
90
3
-03

5
4

-04

-05

6
-04

-05

-06
t-0

t-0

t-0
r-0

r-0

r-0
Jul

Jul

Jul
Jan

Jan

Jan
Oc

Oc

Oc
Ap

Ap

Ap
6 GE Proprietary - Subject to Restrictions on Cover Page
LM6000 Field Events – 2006 Pareto
Quantity
0 1 2 3 4 5 6

Generator Vent Fan Events

Woodward FMV Failures P/B 200

HMI/Woodward - Engine
Control/Communication Loss P/B 192
XNSD Speed Signal

Generator Rundown Tank Leaks

CDP Purge Valve Incorrect Operation P/B 212

Compressor Damage after Water Wash Future Product Letter

Norway - CT Damage Site specific issue

NexGen Generator Fan Expansion Joint Cracks and Holes

Last 12 Months
Higgett Kane Blower Motor Failure Prior 12 Months

Topic Addressed Later in Presentation

7 GE Proprietary - Subject to Restrictions on Cover Page
 Technical Programs

8 GE Proprietary - Subject to Restrictions on Cover Page

Agenda
• Integrated Generator Protection System
• Meidensha Generator
• Trip Multiplier
• Norway Inlet Screen Issue
• Generator Vent Fans
• Generator Run Down tanks
• Lineside/Neutral Cubicle
• Package Cranes and Lifts
• Sprint Pump Issues
• XNSD Speed Probe
• Starter Clutch Maintenance
• Generator Coupling Maintenance
9 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Generator Protection Settings
Background
• Reports of units tripping due
to conservative over voltage
protection settings
› Beckwith integrated
generator protection system
(IGPS)
Investigation
• Setting did not allow the
automatic voltage regulator
(AVR) time to react to the
transient conditions
› Nuisance trip activated in a
non-critical situation
10 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Generator Protection Settings

• Field Plan
• Product Letter LM6000-IND-05-003 released to
LM6000 customers outlining improvements
› Revised over voltage settings as follows:
› 59-1 set at 1.2 per unit with 4 second time delay
› 59-2 set at 1.38 per unit with 1 second time delay

11 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Meidensha Generator

Background
• LM6000 Generators affected
› 19 units in operation
• 6 of 19 units have experienced at least one of the
following issues:
› High bearing temperature
– Additional temperature measurements planned
› High vibration

12 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Meidensha Generator… High Bearing
Temperature
Background
• Multiple units exhibit bearing high temperature alarms
(>100C Alarm, 105C Shutdown)
• One unit has had multiple bearing events
• Meidensha has new bearing design from a second source
• New bearings have passed factory and field tests in 4 units
Field Action
• Units with temperature >212 Deg F (100C) will have new design
bearing installed
› Bearing temperatures to be wired into control and software modified
• Product Bulletin 4Q 2006
13 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Meidensha Generator… High Vibration
Background
• Some new generators experienced high vibration
during start-up (>3.0 mils Alarm, 4.0 mils Shutdown)
Field Action
• Operating units field balanced
• Implement “Generator Trip Multiply” on fleet
• Implement new bearing design on selected units
› New bearing design has improved vibration characteristics
› Vibration >3 mils after field balance will have new design
bearing installed
› Product Bulletin 4Q 2006
14 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Generator Trip Multiply
Background
• Some users (all generator manufacturers) have
experienced nuisance vibration alarms/trips during
start up of the unit
› Drive end and non-drive end probes of the generator
› Trip multiply was only used on selected units in the past

Field Action
• Upgrade Bently Nevada configuration software and
GE’s package control software
› The generator vibration alarm and trip set points are
increased by a factor of 1.5X during the speed range of
1000-3450 RPM
– PB-LM6000-IND-211 issued
15 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Norway Inlet Screen Wear

Background
• 2 reported wear events
• Inlet screen loosening
› Allows high amplitudes of
vibration against the
support bars
› Worn screen material
observed after 7500 hours
– Potential source of gas
turbine damage if pieces
dislodged

16 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Norway Inlet Screen Wear
Field Action
• Service Letter 6000-02-05 describes inlet inspection
interval… inspect semi-annually
• Product Letter 6000-05-01 asks for an inspection and
report of the inlet screen
• Product Bulletin 4Q 2006 to insure the inlet screen is
properly secured to the support structure
› Will alleviate chafing that my cause the screen material to
become loose
› Based on inspection results, one of two methods will be
used to repair the inlet screen

17 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Norway Inlet Screen Wear
Field Action (continued)
• Method 1
› Less than 30% reduction in wire diameter and the overall
condition of the screen looks good
– Inlet screen does not need to be replaced
– Fastening U-clamps are welded to the existing FOD screen

• Method 2
› Any missing, cracking or tearing parts found on the FOD
screen or greater than or equal to 30% reduction in wire
diameter on any screen area is found, replacement of the
FOD screen required
– Inlet screen must be replaced
– Fastening U-clamps are welded to the new Inlet screen

18 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Generator Vent Fan

Background
• Generator ventilation fan events experienced by some
units in the fleet
Investigation
• Possible root cause(s) still under evaluation
› Maintenance
› Mounting
– False brinelling
› Factory balancing
› Shipping

19 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Generator Vent Fan… Maintenance

Background
• IM-100 calls out for routine monthly operation/storage
maintenance

20 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Generator Vent Fan… Mounting

Background
• Fan mounting possibly contributor to the transmission
of vibration from one fan to another
› False brinelling on the bearings
Investigation
• Tests to stiffen mounting at two different sites, six units
› Test results showed that there was no vibration transition
from one fan to other
› Vibration levels caused by misalignments of fan to shaft or
system imbalance
– Check alignment to IM-100

21 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Generator Vent Fan… Factory Balancing

Background
• Vendor balancing has been identified to be a possible
root cause
Investigation
• GE currently performing back-to-back balance testing
of assembly at vendor and independent test facility
Field Plan
• Customers experiencing high fan vibration or bearing
events, should balance fans locally
› Consult IM-100 for balance criteria
22 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Generator Vent Fan… Shipping

Background
• Fan shipping procedure identified potential
contributors to field damage
• Improvement Plans
› Fans to be shipped, on roof skid, by air ride
› Shipping fans without belts to eliminate belt tension on the
shaft that could possibly cause bent shafts

23 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Generator Vent Fan
Summary
• Operate/store fans consistent with IM-100
• Continue investigation targeting factory alignment
and balancing
• Fans to be shipped, on roof skid, by air ride… belts not
installed
Improvement Plans
• Logic under development to alternate fans based on
hours of operation
• New units have direct driven generator fan assemblies
› 27 packages have shipped with this configuration
24 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Generator Rundown Tank

Background
• Multiple units have seen leaking of the run down tanks
at the gaskets or through the bolt holes.
› 2 events resulted in oil going into the generator

Existing neoprene material gasket

25 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Generator Rundown Tank
Investigation
• Improper assembly
• Warped flanges and/or lid
• Material may become too brittle over time
Field Action
• Product Letter will be issued 3Q 2006… inform
customers about recommended improvements
› Release of new gasket material (Nitrile)
› Release of installation assembly instructions
– Silicone to compensate for flange tolerance
– Bolts torqued to 20 then 40 ft-lbs in a cross pattern
› Semi-annual inspection (minimum)
26 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
Generator Rundown Tank

Product Improvement
• Release of new gasket material (Nitrile)
• Change tolerance on rundown tank flanges to improve
gasket fit
• Improved installation instructions

27 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Lineside/Neutral Cubicle Water Ingress

Background
• One reported event of arcing in lineside cubical due to
water / moisture ingress
• LM6000 50HZ and 60HZ units affected
Investigation
• Arcing inside the cubical due to the presence of
moisture
• Insufficient sealing applied to access panels

28 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Lineside/Neutral Cubicle Water Ingress
Field Action
• Product Letter LM6000-IND-06-003 released to
LM6000 customers outlining recommended
inspection/action

Gasket material
added to eye
bolts & access
panels

29 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
Lineside/Neutral Cubicle Water Ingress

Improvement Plans
• Product Bulletin providing long term corrective actions
to eliminate the potential for water ingress - 4Q 2006
› Add seal material around outside edges
› Add drain hole
› Recommend back-up heater

30 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD D D
Hilliard Starter/Clutch Field Inspection

Field Plan
• Maintenance of the starter clutch is recommended
every 8,000 to 10,000 hours of turbine operation if
there is no clutch monitoring system in place
• An inspection overhaul should be conducted every
20,000 to 25,000 hours of turbine operation and it is
recommended the unit be returned to the factory for
overhaul and test.
• Product Letter 06-004 issued with inspection criteria
from Hilliard

31 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD D D
LM6000 Turbine Lift Fixture Houston and Hungary units

Background
• The engine lift fixture has no marks
to indicate the center of gravity for
lifting different engine configurations
› Causes the engine to be potentially lifted
off center
• Center gravity lift point for the new
style bracket is incorrectly marked
(limited to 20 lift brackets) Inside of VBV Duct
• Could cause injury to personnel or
equipment.
› Refer to the safety precautions in the
GEK105059 WP30100 00

32 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD D D
LM6000 Turbine Lift Fixture Houston and Hungary units

Field Action
• Use caution when lifting engine lift fixture with or
without engine installation
› Verify center of gravity before installing lift bracket on
engine
› Lift engine slowly to validate center of gravity, otherwise
replace engine in dolly and change pin location
Improvement Plan
• Product Bulletin will provide direction for marking lift
bracket center of gravity for different engine
configurations
› Expected release in 3Q06
33 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD

PT Perkasa H Frame Houston and Hungary units

DD

Background
• Field inspections indicate some H Frames
manufactured by PT Perkasa are not built/installed per
the GE specification
› “Doublers” insufficient thickness
– Causes the 10 ton lifting capacity marked on the H Frame to be
invalid based on a 2.0 safety factor

Trolley
frame
shown…
Additional
doublers on
external
frame

34 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD

PT Perkasa H Frame Houston and Hungary units

DD

Field Action
• Do not use a H Frame manufactured by PT Perkasa to
install or remove an engine until proper inspections
are performed and action taken if necessary
• Do not modify the H frame without first consulting GE
Improvement Plan
• Product Letter and Bulletin will be released outlining an
inspection and recommended actions
› Expected release in 3Q06

35 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
SPRINT®Issues on Salem Control Systems

Background
• SPRINT® water injection pump continues operating
after SPRINT® operation has been deselected
› Water may enter the gas path until the pump is shut down
manually
• Two units suffered damage due to operating after
ingesting water into the LPC and HPC rotors
• LM6000 PC units with a Mark VI/Mark VIe control
system and S5 Software

36 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
SPRINT® Issues on Salem Control Systems
Investigation
• The SPRINT® system remains engaged when one or
both of the following conditions are met in the control
system:
› The SPRINT® bias tunable is set to less than 0 on the HMI.
(The total range of the tunable is –4 to +4 GPM)
› If the SPRINT® flow adjustment parameter for inlet pressure
(P0SEL) exceeds 14.85 PSIA in the control system.

37 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
SPRINT® Issues on Salem Control Systems
Field Plan
• Product Letter LM6000-IND-06-01 released to affected
LM6000 customers outlining necessary short term
actions.
› SPRINT® bias removed from all HMI screens
› Software changed to resolve inlet pressure issue
Improvement Plans
• Software action request (SAR) 434 has been
incorporated to eliminate issue in future S5
applications

38 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
XNSD Probe

Background
• XNSD Speed signal jumping 75-150 RPM.
• Spurious XNSD speed signal loss, overspeed and “rotor failed”
shutdowns
› Mark VIe (Nxgen) packages more sensitive

Investigation
• When probe loading is excessive, (impedance too low) “wide
tooth” does not register due to Zero-Crossing Error
• Processed speed signal shows low indications (75-150 RPM)
approximately equivalent to a loss of “n teeth”
• Decreasing the probe load impedance increases crossover
margin
39 GE Proprietary - Subject to Restrictions on Cover Page
 Applicable to: PA PB PC PD
DD
XNSD Probe
Zero-Crossing Signal
• Signal strength is higher between normal-
tooth gap compared to wide-tooth, due to
response speed of probe
• Trailing-end gap signal is lower than normal
gap signal
Wide-tooth
• Leading-end signal is lower than trailing-end Trailing-end
Phenomenon
Normal-
tooth gap Wide-tooth
width

Wide-tooth
Leading-end
Phenomenon
Wide-tooth Wide-tooth
Leading-end Trailing-end
gap width gap width

40 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD
XNSD Probe

Field Action
• Design XNSD Signal Conditioner
› Unload XNSD probe and boost output to eliminate speed
value jumps due to Wide-tooth induced crossover errors
• Signal Conditioner available 4Q 2006

41 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD D D
Hilliard Starter/Clutch Field Inspection

Background
• Users have experienced
shutdowns / trips due to failures of
the overrunning clutch for the
hydraulic starter drive due to lack
of maintenance.

42 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD D D
Generator Lube Pump Coupling Maintenance

Background
• There have been multiple reports from the field of
premature failures of the mechanical lube oil pump
coupling
› Results in shutdown
› AC lube pump
provided backup
lubrication

43 GE Proprietary - Subject to Restrictions on Cover Page

 Applicable to: PA PB PC PD
DD D D
Generator Lube Pump Coupling Maintenance

Investigation
• Lack of lubrication at recommended maintenance intervals
Field Plan
• Consult generator operation and maintenance manual
› Brush generator
– 2,000 hours: lubricate coupling
– 10,000 hours: dismantle coupling and lubricate coupling
› Meidensha generator
– 4000 hours: lubricate coupling through fitting on coupling case
› GE generator
– Biannually: dismantle and lubricate coupling

• Product letter highlighting recommended maintenance

intervals 3Q 2006
44 GE Proprietary - Subject to Restrictions on Cover Page
 Operations & Maintenance

45 GE Proprietary - Subject to Restrictions on Cover Page

Product Bulletins
• Purpose
› Ensure safe operation
› Improve reliability
› Reduce life-cycle maintenance costs
› Improve performance
› Customer responsibility
• Customer Responsibility
› Review Service Bulletins
– Planning Information and Accomplishment Instructions
› Assess and manage compliance benefits vs. costs
› Develop maintenance plans for compliance
› Schedule, document and report compliance

46 GE Proprietary - Subject to Restrictions on Cover Page

Product Bulletins Issued Since September 2005

47 GE Proprietary - Subject to Restrictions on Cover Page

Product Letters Issued Since September 2005

48 GE Proprietary - Subject to Restrictions on Cover Page

 LM2500 Package
Programs

49 GE Proprietary - Subject to Restrictions on Cover Page

PS3 Transmitter
Applicable to: BASE PLUS
SAC DLE SAC DLE
D D D D
• Background
› Customers are experiencing calibration issues on the PS3
transmitters
• Investigation Status/Results
› Current transmitter may degrade to a point where the
calibration drifts and the device accuracy is affected
• Field Action
› Druck transmitters meet the requirements for the PS3
indicator and maintain accuracy over the lifetime of
transmitter
• Incorporate PB-161 (Issued 6/04)
50 GE Proprietary - Subject to Restrictions on Cover Page
 Vibration Trip Reduction
Applicable to: BASE PLUS
SAC DLE SAC DLE
D D D D
• Issue
› Vibration is the No. 1 cause of trips
› Trips due to vibration system self
diagnostics, signal noise, transients
Vibe
• Investigation Noise System

› Eliminate trips on vibe system self-

diagnostics (Bently Systems) Vibe
Trips
› Added delay to reduce noise and transients
› Redundant kit with improved selection logic HW GT
Problem Transient
• Status Vibrations

› Incorporate PB 159 & PB 160 (Issued 6/04)

› Fleet leader running approx. 1 year
› Estimate 60% reduction in vibe trips
51 GE Proprietary - Subject to Restrictions on Cover Page
Gas Purge System
Applicable to: BASE PLUS
SAC DLE SAC DLE
D D D D
• Background
› Customer experienced power swing performing a fuel
transfer after implementing LM2500-IND-PB-156R1
• Investigation/Results
› Investigation into power swing revealed purge tap point
relocation and the 1” purge line increase caused power
swing
› Relocation of tap point and increased line size allowed
larger volume of gas purge to liquid fuel manifold causing
sudden increase in power
› Optimum line size identified as ¾ in.
• Status
› PB 156 R2 has been issued to address this. Issue date
11/04.
52 GE Proprietary - Subject to Restrictions on Cover Page
Gas Fuel Control Valve Vent Drains
Applicable to: BASE PLUS
SAC DLE SAC DLE
D D D D
• Background
› Customer experienced problems w/ our new gas fuel
systems utilizing Woodward GS6/GS16 fuel valves.
• Investigation/Results
› Investigation revealed an issue with the plumbing of the
valve seal vent connection into our standard process vent
lines due to overpressure of the valve seal.
› The seal vent line will now be run as a separate vent line to
avoid possible overpressure issues.
• Status
› PB 162 has been issued to address this. Issue date 3/05.

53 GE Proprietary - Subject to Restrictions on Cover Page

LM2X – Woodward Service Bulletin No. 01352
Applicable to: BASE PLUS
SAC DLE SAC DLE
D D
• Background
› Woodward has issued a service bulletin concerning a
software error with the “Configuration File Editor”.
• Investigation/Results
› The service tool is used to configure the VSV controls.
› Woodward recommends that when using the Configuration
File Editor, “always select the ‘No” option” if downloading a
new configuration is NOT required.
• Status
› PL2500-06-02 has been issued. Issue date 4/06.

54 GE Proprietary - Subject to Restrictions on Cover Page

LM2X NOX Water Pump
Applicable to: BASE PLUS
SAC DLE SAC DLE
D D
• Background
› Customer experienced problems with the NOx water pumps.
• Investigation/Results
› Investigation revealed the pumps are being over pressurized
at the inlet.
› This has been caused due to a design change from the
pump manufacturer Danfoss, which was not properly
communicated to GE .
• Status
› PL will be issued by the end of 3Q 06.

55 GE Proprietary - Subject to Restrictions on Cover Page

GE Energy
Generator
Reliability
Aero Gas Turbine –Brush Installed Base

• Numbers of “DAX” range generators…

› General Electric LM2500 163
› General Electric LM2500+ 43
› General Electric LM5000 57
› General Electric LM6000 343
–

57 GE Proprietary - Subject to Restrictions on Cover Page

58 GE Proprietary - Subject to Restrictions on Cover Page
Stator Buildup

• The stator winding is

of the two layer
diamond type, half
coils being used for
ease of handling
during manufacture
and winding
• To satisfy the
electrical design
requirements, the
winding may be of the
single or multiple
connector type with
parallel connections
where necessary
59 GE Proprietary - Subject to Restrictions on Cover Page
Stator Buildup
• Graded high
voltage tests are
carried out at
stages during
manufacture of the
coils and assembly
of the winding. This
ensures a high
standard of
insulation and
faults are detected
at the earliest
stage possible

60 GE Proprietary - Subject to Restrictions on Cover Page

Stator Buildup

• Stator core
laminations being
put into place on
the key bars to
form stator core

61 GE Proprietary - Subject to Restrictions on Cover Page

Stator Buildup

• Wedges being
fitted to retain
windings in slots

62 GE Proprietary - Subject to Restrictions on Cover Page

Stator Buildup

• In order to withstand
the forces which could
result in the event of an
accidental short circuit,
the end winding is
securely braced to
insulated brackets
supported from the
stator frame. Spacer
blocks are fitted
between adjacent coil
sides to produce a
strong archbound yet
resilient composite
structure
63 GE Proprietary - Subject to Restrictions on Cover Page
Rotor Machining
• Axial grooves are
milled along the
top of both
winding and
ventilation slots to
hold the slot
closing wedges. At
the exciter end, a
hole is bored along
the axis of the
shaft to take the
leads from the
main exciter to the
rotor winding
64 GE Proprietary - Subject to Restrictions on Cover Page
Rotor Winding
• The rotor winding
conductor material is
high conductivity
copper silver alloy
strip.The pre-formed
coils are inserted into
the slots, each turn
being insulated from
the next
• The class F insulation
system is moisture
resistance, shockproof
and capable of
withstanding high
centrifugal forces
65 GE Proprietary - Subject to Restrictions on Cover Page
The Finished Rotor

66 GE Proprietary - Subject to Restrictions on Cover Page

Rotor Cooling

• The rotor is cooled by air

flowing under the endcap,
past the winding and
through axial slots
(interslots) between the
winding slots
• Exhaust ducts in the
closing wedges of the
interslots allow the air to
escape at the centre of
the rotor

67 GE Proprietary - Subject to Restrictions on Cover Page

Ventilation Systems

68 GE Proprietary - Subject to Restrictions on Cover Page

Stator Heaters
• Stator heaters
should to be
energised with
temporary
power supply as
soon as
alignment is
completed
• Stator heaters
should to be
energised
during normal
operations
whenever
generator is
stopped
69 GE Proprietary - Subject to Restrictions on Cover Page
Bad Things Happen
To Generators
Transportation

71 GE Proprietary - Subject to Restrictions on Cover Page

Stator Contamination

72 GE Proprietary - Subject to Restrictions on Cover Page

Stator Contamination

73 GE Proprietary - Subject to Restrictions on Cover Page

Stator Contamination

74 GE Proprietary - Subject to Restrictions on Cover Page

Corona

75 GE Proprietary - Subject to Restrictions on Cover Page

Generator Reliability – The Starting Point

• Reliability = Maintenance
› Understanding the Manufacturers Recommendations
› Operation Observations
› Site Log Books
› Trending
› Technical Information Bulletins
› Previous Findings and Reports
› Networking
› Rhythm …..

76 GE Proprietary - Subject to Restrictions on Cover Page

Generator Reliability – Manufacturer
Recommendations

77 GE Proprietary - Subject to Restrictions on Cover Page

Generator Reliability – Manufacturer
Recommendations

78 GE Proprietary - Subject to Restrictions on Cover Page

Generator Reliability – Operational Observations
• Daily Operational Observations
• Oil Leakage - Exterior of Generator
› Observed around shaft rotating seals, rundown tanks, MLO piping, bilge
• Oil Leakage - Interior of Generator
› Observed via the cooling air intake on air cooled generators, anchor bolt
access plates, space heater access plates
• Abnormal oil reservoir levels – low / high
› There should be no notable consumption
• Oil flow from bearing drains – normal / abnormal level
• Water Leakage (TEWAC Only)
• Vibration levels
• Bearing temperatures
• Excitation – load versus level
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Generator Reliability – Operational Observations
• Daily Operational Observations…
› Errors in synchronizing
› Under or over frequency operation
› Lightning surges or other transients
› Faults (such as short circuits) on system or adjacent
machines
› Unbalanced load, including single phase operation
› Overload
› Over-voltage or under-voltage
› Loss of field
› Loss of cooling water (TEWAC)
› Out of synchronism operation
• Site log book should contain operational observations
in a trending format
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Generator Reliability – Minor/Major Inspections
• These Inspections Should Include
› Operational review of site log book, detailed trending data and a
discussion with plant personnel of the current operation
› Review of previous inspection reports and repairs
› Photographic recording of the complete inspection
› Generator – Turbine alignment (optional during minor inspection)
› Cooling Fan tip clearance / FOD
› Rotor Bearing inspection - dimensional and visual checks
› Thrust Bearing inspection
› Oil supply line integrity
› Bearing RTD integrity
› Rotor bearing journals – dimensional and visual checks
› Mechanical oil pump, coupling (spline wear)
› Exciter condition, diode wheel including diode and fuse checks,
fan tip clearance / FOD
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Generator Reliability – Minor/Major Inspections
• These Inspections should Include…
› Rotor end caps (applicable testing for the machine as
required)
› Rotor earthen grounding brush inspection
› Rotor ground fault system verification
› Megger testing to 500V
– Rotor winding insulation test
– Stator winding insulation test
– Exciter winding insulation test
› Generator space heater operation verification
› Bearing alignment - skew
› Oil seal clearance, retainers
› Operational check of the lube oil system
› Oil analysis
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Generator Reliability – Minor/Major Inspections

• Inspection purpose
› Using applicable test methods, determine the overall
operating condition of observable components
• If abnormal condition is found
› determination of further disassembly and the time
associated for the required work will requires discussion

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Generator Reliability – What are we looking for?

• Typical Problems – Generator Stators

› Loose Wedges
› Greasing & Dusting
› Oil Ingestion
› Blocked or Contaminated cooling passages
› Loose End Windings
› Broken or missing Ties / Blocking
› Grounded Phase
› Insulation Failure
– Corona
› Bar Abrasion Insulation – Dusting/Greasing
› Abnormal or Mis-operation (Motoring, Faults, Overtemp)
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Generator Reliability – What are we looking for?

•Typical Problems – Generator Rotors

› Coil Insulation - Turn Shorts and Grounds
› Thermal Sensitivity
– Vibration
› Contamination
– Uneven cooling
› Forging Concerns
› Retaining Ring Cracking
› Maladjusted Oil Seals

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Partial Discharge – Corona

Partial discharge, sometimes called corona, is quite

common in air-cooled generators. It is caused by a
partial voltage breakdown within the generator coil
insulation, in gaps between the coil and the stator core,
or in the end turns when the coils are in close
proximity. Because it is not a complete breakdown of
the insulation system, it doesn’t cause a full electrical
ground. Over time, however, these discharges can “eat”
at the insulation, causing its deterioration until a full
ground does occur and the unit trips offline. Evidence
of partial-discharge (PD) activity often is visible to the
eye, appearing as a white powder dusting the surface
of the stator winding

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Generator Reliability – Inspection of Corona

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Generator Reliability – Inspection of Corona

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Generator Reliability – Seal Inspection

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Generator Reliability – Seal Inspection

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Generator Reliability – Bearing Inspection

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Generator Reliability – Bearing Inspection

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Generator Reliability – Rotor Bearing / Seal
Journals

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Generator Reliability – Diode/Fuse Wheel
Inspection

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Generator Reliability – End Cap & Cooling
Passages

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Generator Reliability – End Cap & Cooling
Passages

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Generator Reliability – Weight Staking

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Generator Reliability – Stator Cleaning /
Inspection

Before After
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Generator Reliability – Technical Issues

• Brush
› Improper stake of balance weights
› Rotor winding end cap cracking
› Corona
• GE
› Rotor winding end cap cracking
› Generator Field End Winding Insulation Migration
(GETIL1308-2R2)
• Meidensha
› Rotor core shift
› Bearings
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Generator Reliability
•Factors affecting the generator field reliability:
Abnormal operation Cyclic duty
• Field overheating • Pole-to-pole connectors, Main Leads, coil -
• Negative sequence/motoring incident to - coil connectors, and endwindings are
susceptible to frequent start-stop duty
• Overspeed along within load cycling
• Synchronizing out of phase • Other components may also be susceptible
• Voltage spikes
• Electrical faults

Shorted turns Area affected the most – rotor end winding

• Flux probe provides best
diagnosis
• Over 90% of grounds found in
endwindings, bore copper or
collector areas
• Contamination will cause shorts
and grounds

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Generator Reliability - Repairs
Repair solutions
• Field rewind using existing copper
› Copper cannot be worn or distorted.
› A full field re-insulating rewind kit typically consists of new ground
insulation, new retaining ring insulation, new blocking and filler and
most importantly, new end turn insulation with A584 adhesive

• Field rewind using new copper

› If the copper distorted (usually identified through visual inspection)

• Exchange field program. GE and Some Brush Generators.

• Exchange field program provides a completely refurbished rotor
in exchange for your existing rotor.
› Cycle time reduced from several weeks to several days.
› Check availability for your prototype via GE sales representative
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Generator Reliability - Repairs

Field Rewinds and Refurbishment

1. Modern materials
2. Field forgings
3. Bearing journals and couplings
4. 18 MN-18 Cr retaining rings
5. Balanced, fully tested
6. Slot and wedge geometry
7. Class-F insulation system
8. Copper windings
9. Field winding blocking
10. Reconditioned collector rings Throughout field

11. Asbestos-free construction Not shown

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Generator Reliability - Repairs

Stator Rewinds

When a turbine-generator is rewound, care must be taken

to maintain or exceed the design characteristics built into
the original equipment. To achieve maximum reliability, a
high quality insulation system must be used. How do you
know which system is best for your generator?
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GE AES & I&RS - Generator Technology…
Addressing Your Service Needs

Non-GE Stator Rewind

Exchange Field

Arnie Schaub
GE AES Generator Services Mgr
Office 281-864-2623
Cell 281-910-0295
Flux Probe

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 LM1600®, LM2500®, LMS100® and SPRINT® are registered trademarks of the General Electric Company
(USA)
LM6000TM is a pending trademark of the General Electric Company (USA)

Strategic Power Systems, Inc. (SPS®) and the ORAP® family of products & services, including ORAP Parts
TrackingTM and ORAP Cycles TrackingTM, are registered trademarks comprising the intellectual property of
SPS, with patents pending. All rights reserved.

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