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Generator In-Situ Inspection

Fast, accurate generator inspectionwithout field removal
Visual Inspection Stator Wedge Tightness Assessment Core Insulation Testing (ELCID) Stator Clearance Measurement Stator Capacitance Mapping Retaining Ring NDE
MAGIC Visual Core Laminations Space Blocks Stator Bars, Wedges Field Surfaces, Wedges Retaining Ring Nose

GE Power Systems

The power generation industry is undergoing major changes requiring power producers, OEMs and insurers to adapt. One way GE has responded to these market changes is through the development of tools that enable in-situ inspections of generators. In-situ inspection offers an acceptable, low cost alternative to traditional field out inspection in many cases.
Stator Wedge Tightness Assessment Electromagnetic Core Imperfection Detection (ELCID) Stator Insulation Capacitance Measurement

Stator Clearance Measurement Remote Access Camera Field Coil End Turns Stator Bars End Winding Support System Flux Shield Lower Frame Extension
RDC27466-6-10

Retaining Rings Outside Surface: Eddy Current Inner Surface: Ultrasonic

RDC26839

MAGIC (Miniature Air Gap Inspection Crawler)

Visual Inspection
Visual inspection of the generator is performed by a trained specialist using GEs exclusive MAGIC inspection robot and remote access camera (RAC). The robot is a precision crawler carrying two high resolution video cameras that move through the gap between the stator core and field. The RAC is used to perform visual inspection of normally inaccessible areas on the generator. The high resolution video provides the specialist with a clear view of the stator core laminations, stator windings, field surface, wedges, coil end turns, the surfaces on the inboard ends of the retaining rings and the stator high voltage leads and connections.

results are used to generate a color coded wedge tightness map which clearly shows the wedge tightness within the generator.

S L O T S

1 2 3 4 5 6 7

WEDGES 1 93 69 85 50 91 26 40
Indicates Tight Wedge

2 88 70 30 87 90 80 41

3 39 62 65 88 18 43 80
Indicates Hollow Wedge

4 75 55 66 83 42 51 72

5 60 84 69 90 25 73 32
Indicates Loose Wedge

Color Coded wedge tightness map

Stator Wedge Tightness Assessment

This test is performed to accurately quantify stator wedge tightness and is used to assess the need for wedge tightening or replacement. A tight stator winding can last two or three times as long as a winding that is not firmly held in the stator core. Test

Benefits
Shorter Outage Duration Reduced Inspection Cost Extended Time Between Field Pulls Early Problem Detection Less Risk of Disassembly Damage

GT25680

Electromagnetic Core Imperfection Detection (ELCID)

ELCID is an accurate and economical means of testing the condition of the stator core lamination insulation. Damaged insulation can result in circulating currents that can lead to core overheating and stator damage or even failure. ELCID uses a low core excitation level to establish a magnetic field Core melting as a result of within the core. A highly insulation damage sensitive, miniature sensing coil, or chattock, is used along the core surface to detect fault currents which will result from core insulation damage. ELCID has been proven to be especially valuable on machines where core loosening has been more prevalent.

Stator Capacitance Mapping

Capacitance mapping requires placing a conductive electrode on the surface of the stator bars groundwall
Copper Conductors

Test Area
150

NUMBER OF OCCURRENCES

Groundwall Insulation
100

Test Electrode

50 SUSPECT BAR 0 32 42 52 62 72 82 92 102 112 122 132

RDC27552-3

CAPACITANCE (PICOFARADS)

Statistical analysis of capacitance data

insulation at the location where the bar exits the core slot. Each bar in the winding is measured on both ends of the core. High capacitance is a good indicator of moisture in the insulation and has been used successfully to detect bars damaged by water leaks.

Retaining Ring NDE

Stress corrosion cracking (SCC) of 18Mn-5Cr retaining rings is a well documented industry-wide concern. GE recommends replacement of 18-5 rings with the improved 18Mn-18Cr alloy. For customers who choose to periodically inspect and repair rings, GE offers a complete inspection program. GE provides a scanner assembly which performs ultrasonic (UT) inspection of ring IDs and eddy current (EC) inspection of ring ODs, without removing the field from the stator.

Stator Clearance Measurement

Radial clearance between the stator winding and core permit unwanted motion of the stator bars during
Field Body

Stator Clearance Measurement System

Retaining Ring

Stator Wedge

Top Stator Bar Stator Clearance Bottom Stator Bar

GT25775

GE Position On In-Situ Inspection

GE can provide generator component assessment capabilities comparable or superior to that routinely achieved by rotor removal inspections for many applications. Periodic in-situ inspections, together with electrical testing and hydraulic checks, provide an acceptable alternative to many traditional OEM maintenance protocols. Skillful interpretation of in-situ data can provide plant operators with cost effective opportunities to reduce outages and outage duration while maintaining the reliability and availability of their generators.

Stator winding clearance measurement

operation. In some cases, radial motion has led to severe abrasion damage to the stator groundwall insulation and ultimately electrical failure. GE has developed specialized tooling to accurately measure slot clearance while avoiding damage to the stator winding.

@
GE Power Generation One River Road, Bldg. 2-103 Schenectady, New York 12345

For more information, contact your local GE Power Systems Office.

GE Power Systems

GEA-12527A (8/00, 5K)

GT23013/GT25552