GE Energy
Generator In-Situ Inspections A Critical Part o Generator Maintenance Cost Reduction GER-3954C
Authors Christopher Markman
Product Line Leader Lie Extension Services Ronald J Zawoysky
Generator Engineering Leader Power Generation Services
Contents Introduction 1 In-Situ Inspection – A Critical Part o Generator Maintenance Cost Reduction 2 Guidelines or Choosing In-Situ Inspection Versus Pulling the Rotor 3 In-Situ Inspection Technologies 3 Miniature Air Gap Inspection Crawler (MAGIC) 6 Remote Capacitance Probe 8 Retaining Ring NDE Scanner 8 Other Testing 9 MAGIC Acceptance and Experience 9 Industry Acceptance 9 System Design 9 Traditional vs In-Situ Cost Analysis 9 Reducing Outage Duration 10 Reducing Disassembly Requirements 10 Eliminating Consequential Damage 10 GE’s Position on In-Situ Inspection 11 Conclusions 11 List o Figures 12 List o Tables 12
GE Energy | GER-3954C (3/12)
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Introduction
• Updatingequipmentmaintenancerecommendationsbasedon
GE’s feet experience
This paper compares in-situ inspection techniques that allow testing with the rotor still installed, to rotor-out inspections While in-situ inspections provide an alternative to pulling the generator rotor,
• Developinginspectiontoolsandservicesthatacilitaterapid
ofine assessment o equipment conditions
additional electrical testing is required, at a minimum, to provide a thorough inspection Other additional tests may be indicated via a
Industry insurers also have a vested interest in these objectives and
Technical Inormation Letter (TIL) or based on past unit history
are understandably reluctant to assume greater risks by deviating rom proven maintenance practices Consequently, insurers review
As the increasingly competitive marketplace orces the power
proposed plant maintenance protocol modications with operators
generation industry to reduce operating costs, equipment
and oten require supporting recommendations and other evidence
maintenance programs are under increased scal scrutiny Plant
rom Original Equipment Manuacturers (OEMs) that new protocols
maintenance programs, based on periodic disassembly and
are unctionally equivalent or superior to the traditional
inspection o critical turbine-generator components, have proven remarkably eective—as evidenced by the industry’s consistently
This paper oers a comparison o the results, advantages and
avorable plant reliability and availability statistics However,
limitations o GE’s modied inspection protocol or generators
many plant operators are looking or ways to lower cost while
utilizing in-situ inspection tools compared to a traditional inspection
maintaining reliability
with the rotor removed
As a leading manuacturer o turbine-generators and a major supplier o power generation services, GE is assisting operators in this objective by: • Developingimprovedmonitoringanddiagnosticinstrumentation
or online predictive maintenance, allowing or better outage planning and scope control
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In-Situ Inspection – A Critical Part of Generator Maintenance Cost Reduction Visual and quantitative inspection techniques play an important role in assessing generator condition Online monitoring and diagnostic techniques are limited in detecting potential problems such as bar movement and vibration, component damage, copper dusting, coil distortion, and oreign object damage (FOD) Since many o these conditions can lead to a major equipment ailure i let unresolved or a period o time, periodic visual inspections are
During minor outages, in-situ inspections can be used to assess generator condition and help plan generator maintenance at uture outages The inspection results can indicate i the eld will need to be pulled and which components will require maintenance during current or uture outages I the generator condition is acceptable, the eld can remain in place and a uture in-situ inspection can be planned GE’s in-situ inspection techniques can also be used with traditional inspection and test techniques to provide a complete “major” inspection without eld removal
needed to supplement online monitoring and diagnostics I n-situ inspection oers an economical alternative to the traditional rotor
GE’s recommended standard tests or a major outage are described
pull inspection Table 1 lists typical generator-related inspections
in Technical Inormation Letter-1154 and GEK-103566 When
and when they occur in a traditional maintenance plan
generator problems are known or suspected to exist, applying
Continuous Online
Periodic Online
Minor Outage
Major Outage
STATOR
Stator Wedge Tightness
X
Bar Movement
X
Stator Winding Leaks
SLMS
X
Core Insulation Stator Winding Insulation Integrity
X X
ePDA
PD
X
Greasing
X X
Cracked Connections/Integrity
X
X
Oil Contamination
X
X
HV Connection Bolts
X
X
FIELD
Blocked Vent Ducts
X
RR NDT
X
Field Coil Distortion
X
X
Field Coil Loose Blocks
X
X
Field Wedge Migration Field Winding Insulation Integrity
X STMS
Thermal Sensitivity
X
X
X
X
Rotor Surace Heating
X
Table 1 Generator inspection items STMS: Shorted Turn Monitoring System – continuously monitors a fux probe and sends an alarm when a shorted turn is detected ePDA: Enhanced Partial Discharge Analysis – continuously monitors the generator and takes partial discharge data at specied intervals or later analysis PD:
Traditional Partial Discharge Testing where data is taken by a technician
SLMS: Stator Leakage Monitoring System – continuously monitors stator cooling water or the presence o hydrogen indicating a leak
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periodic in-situ inspections can postpose the need or eld removal until a more convenient time When abnormal operation such
In-Situ Inspection Technologies
as a negative sequence event warrants a “suitability or service”
GE’s in-situ generator inspection capabilities (listed below) were
inspection beore the generator can be returned to service, the
developed to address areas requiring eld removal or inspection
in-situ inspection is a valuable tool or providing a quick, accurate,
(Figure 1)
documented inspection with minimal generator disassembly In-situ inspection reduces overall outage duration while gathering highquality condition assessment data
• GE’sproprietaryMiniatureAirGapInspectionCrawler(MAGIC)system
− MAGIC Visual Inspection − Stator Wedge Tightness Assessment
Guidelines for Choosing In-Situ Inspection Versus Pulling the Rotor
− Electromagnetic Core Imperection Detection (EL CID) − Borescope Inspection
One question requently asked is “What i the in-situ inspection nds something and I have to pull my eld? I wasted time and money on the in-situ inspection” The answer to this question can
• RemoteCapacitanceProbe • RetainingRingNon-DestructiveEvaluation(NDE)Scanner
be ound in previous inspection reports and the operating history o the unit I there is any indication that the rotor needs signicant repair (such as multiple shorted turns, a eld ground or thermal
• Othertestsandinspections,includingelectricaltestingand
hydraulic testing
sensitivity), then the rotor should be pulled Similar judgements should be made regarding the stator However, i the unit has had
The in-situ inspection consists o the basic MAGIC visual inspection
no known problems and previous inspections have not indicated
as well as one or more additional tests or inspections based on the
any issues, then an in-situ inspection is appropriate GE experience
circumstances and customer needs Table 2 lists critical generator
reveals that 1 percent o in-situ inspections uncover an issue which
components and the in-situ inspection techniques used or each
requires that the rotor to be pulled In many cases, conditions requiring repair are ound early enough to allow the repair to be postponed until the next planned outage Conditions ound by in-situ inspections that required the rotor to be pulled or repairs include oreign object damage, damage rom negative sequence
Note: While a borescope inspection is a normal part o a MAGIC
inspection, it may also be perormed independently This is typically done when a ast assessment o the generator, especially the end regions, is desired ater an event outside o normal operation
events, ailure o electrical testing indicating the need or rotor rewind, and loose wedges These conditions are listed in order o highest to least prevalence Since GE’s goal is to ensure the generator runs trouble-ree to the next outage, any signicant problem will bring a recommendation to pull the rotor and complete the necessary repairs For maximum benet, the in-situ inspection should be planned as early as possible during the outage so that any necessary repairs can be carried out during the planned outage, or at worst, the inspection will cause the minimum delay to restart
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Stator Wedge Tightness Assessment MAGIC Visual •CoreLaminations •SpaceBlocks •StatorBars,Wedges •FieldSurace,Wedges •RetainingRingNose
Electromagnetic Core Imperection Detection (ELCID) Stator Insulation Capacitance Measurement
Stator Clearance Measurement
Remote Access Cameras •FieldCoilEndturns •ConnectionRings •StatorBars •EndWindingsupportSystem •FluxShield •LowerFrameExtension
Retaining Rings •OutsideSurace
Eddy Current •InnerSurace Ultrasonic
Figure 1 Generator in-situ inspection capabilities
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Component
Common Problems
MAGIC Visual
Borescope Visual
Wedge Tapping
ELCID
RR NDE
Capacitance
Clearance Meas
Stator/Core
Core Laminations
Foreign object damage, hot spots, evidence o movement
X
Space Blocks
Migration, cooling passage blockage
X
X
Gas Gap Bafe Studs
Cracked welds, looseness
X
X
Stator Wedges
Looseness, loss, sparking damage
X
Stator Bars
Foreign object damage, sparking, girth cracks, movement
X
X
X
X
X
Wet groundwall insulation
X
End Windings and Connection Rings
Bar movement, loose/broken ties, supports, etc, excessive corona activity
X
Copper Flux Shield
Overheating, looseness, general condition
X
Instrumentation
RTD, thermocouple wiring ties, fux probe, general condition
X
Field
Field Surace
Heating, arcing, oreign object damage
X
Body Weights
Looseness, staking
X
Field Wedges
Arcing, migration, cracking
X
X
Retaining Ring
Wedge contact , arcing, oreign object damage, material cracks, pitting
X
X
Coil End Turns
Blocked ventilation, damaged insulation, coil distortion, contamination
X
X
General
All
Lower Frame Ext Bus Leads and Connections
Excessive oil or other contamination, oreign object damage, blocked cooling Insulation condition, connection integrity (i exposed), high voltage bushing condition
X
X
X
Table 2 In-Situ Inspection capabilities
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Miniature Air Gap Inspection Crawler (MAGIC) The cornerstone o the MAGIC system is its visual inspection capability In addition, the system can perorm a stator wedge tightness assessment and ELCID testing
Stator Wedge Tightness Assessment – This test examines the
slot support system or any signs that the stator bars are ree to move A “tight” stator winding can last two or three times as long as a winding that is not rmly held in the stator core The test perormed by the MAGIC system is similar to the test used in the actory or new units
MAGIC Visual Inspection – Trained specialists can use GE’s exclusive MAGIC robotic devises to perorm a visual inspection o the generator stator and eld within the bore region GE now oers three dierent MAGIC robots that allow the inspection o generators in a variety o sizes
One component o this assessment is the wedge tightness or wedge tapping test that examines the tightness o the stator slot wedges The standard method used to determine when a stator rewedge is required is to perorm this test on the most critical wedges (the last 36 inches o each end o the generator) and then
Each crawler robot is a precision device that carries two high-
visually inspect the remaining wedges in the center o the core
resolution video cameras through the gap between the stator
When the rotor is removed, the tapping test can be perormed
core and eld Full inspection coverage o the core inner diameter
manually using a 2-inch hammer or a piece o equipment that
(ID) and eld surace is made possible by the crawler’s axial and
can mechanically evaluate wedge tightness During a MAGIC
transverse motion capability This capability also allows the crawler
inspection, a specialized test head is used to perorm a wedge
to navigate around the gas bafes p resent on many generator
tightness map o the critical areas The remaining wedges can
designs High-resolution video provides the specialist with a clear
then be visually inspected or any indications o looseness (such as
view o the stator core laminations, stator wedges, eld wedges a nd
dusting created by the wedge rattling in the dovetail)
surace on the inboard ends o the retaining rings Figure 2 shows some core damage captured using the wide angle and close-up cameras on the MAGIC robot
The MAGIC system determines wedge tightness by measuring the response o the wedge to a mechanical stimulus (impact) Inspection data is stored in a le and provided with the nal report that evaluates the winding condition to determine when repairs are needed The data is also used to generate a color-coded “wedge tightness map” that clearly shows the wedge tightness within the generator (Figure 3) Some generator designs limit access to all wedges and permit only a pa rtial inspection The most critical wedges, located closest to the slot ends, are inspected in all cases Note: The tapping test does not apply to units with asphalt stator
windings or the camelback wedge system For these units only a visual wedge assessment is perormed
Figure 2 View o core damage taken with MAGIC robot
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Core Lamination Insulation Core Laminations
Damaged Insulation
Core Vent Duct Stator Winding
Stator Core
Circulating Current
Figure 3 Generator Wedge Tightness
Figure 4 Circulating current due to damaged core insulation
Electromagnetic Core Imperfection Detection (EL CID*) Testing – One
Borescope Inspection – Our in-situ inspections also use the latest
o the optional tests that GE perorms during generator testing is
borescope technology to provide a high-resolution visual inspection
the ELCID test This test oers an accurate and economical way
o normally inaccessible areas on the generator, outside o the bore
to know the condition o the stator core lamination insulation
region While the MAGIC robots travel in the air gap between the
Damaged insulation can result in circulating currents that can
rotor and stator, the borescopes inspect the end windings and other
eventually lead to core overheating, stator damage, or even ailure
areas not associated with the air g ap To provide the most thorough
(Figure 4) GE typically recommends perorming EL CID tests as a
visual inspection possible with the eld in place, the normal scope
quality check to look or any possible sta tor core iron damage when
or a MAGIC robotic inspection includes a borescopic examination
generator repair work is perormed in the stator core, such as a
A complete inspection includes wedge tapping and any necessary
stator rewedge or stator rewind It can also optionally be perormed
electrical testing
during a minor or major test and inspection A borescopic examination o the generator can be made While the MAGIC crawlers have the ability to p erorm an EL CID
independent o a MAGIC inspection This is typically done when
inspection, there is little to no benet gained by perorming an EL
a ast assessment o the generator, especially the end regions, is
CID test during a routine MAGIC Inspection, because:
desired ater an event outside o normal operation
• Thegeneratorfeldisnotbeingremoved,sothereislittle
possibility o damaging the stator core iron during the inspection
To acilitate a complete inspection, both end shields must be removed Figure 5 shows a picture o eld coils taken by borescope
• Theunitwaspreviouslyrunningatratedux(vs.the4percent
o rated fux at which EL CID is perormed) and i there was any preexisting core iron damage o concern, there should be signs o overheating that can easily be spotted during the visual inspection • I there are any signs o the core iron overheating or mechanical damage, GE will recommend that the eld be removed and the core iron repaired It should be noted that i visual core damage is ound, then a core ring test at close to rated fux will be recommended
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recommendation presented a roadblock to implementing an in-situ inspection program on water-cooled generators A tool recently developed by GE engineers now solves that problem, enabling capacitance testing to be perormed without removing the eld rom the stator As part o the in-situ inspection program, the new tool uses an infatable electrode, similar to that used with the eld removed, and a remote actuator arm or locating the probe
GE’s remote access camera is also used or positioning the probe and identiying its location This system is being used successully and provides results similar to those obtained during eld-out inspections
Figure 5 Field coils picture taken by borescope
Test Area
Remote Capacitance Probe
Copper Conductors
GE water-cooled generators manuactured beore 1986 are
Ground-wall Insulation
susceptible to water leaks and the resulting concerns as described Test Electrode
in Technical Inormation Letter-1098 One o the periodic tests recommended in TIL-1098 is capacitance mapping o the stator
Figure 6 Stator bar capacitance test
bars This test has proven to be very reliable in identiying stator bars with deteriorated ground-wall insulation resulting rom a water leak
Retaining Ring NDE Scanner Stress Corrosion Cracking (SCC) o 18 Mn-5Cr generator retaining
Capacitance mapping requires placing a conductive electrode on the surace o the bar’s ground-wall insulation at the location where the bar exits the core slot (Figure 6) A meter is used to measure the capacitance across the insulation between the electrode and the stator bar conductor Each bar in the winding is measured on both ends o the core and statistical analysis is
rings is a well-documented industry-wide concern or generator maintenance SCC develops on the surace o the material in the presence o moisture and stress As a result o the stress concentration and geometry, which tends to hold moisture, the retaining ring inside diameter (ID) surace tends to be more susceptible to this phenomenon
used to identiy those bars with higher than normal expected capacitance High capacitance is a good indicator o moisture presence in the insulation
GE recommends replacement o 18 Mn-5 Cr rings with the improved 18 Mn-18 Cr alloy, which has not been susceptible to SCC However, or those customers who choose to periodically inspect
TIL-1098 recommends that a capacitance test be perormed at each major outage (approximately every ve years) Because perorming the capacitance test required eld removal, this
GE Energy | GER-3954C (3/12)
and repair the rings, GE oers a complete inspection program The most thorough NDE inspection can be per ormed with the rings removed rom the eld, permitting access to the ID surace
8
where eddy current testing is used to detect very small surace
O the more than 1,000 MAGIC inspections perormed by GE,
indications The rings can be tested while installed on the eld,
over 190 units have had two or more inspections, including
however, with less sensitivity to crack detection on the ID surace
several located at nuclear plants GE has also perormed nearly 100 inspections on generators built by other OEMs Ater more
Testing, similar to that perormed with the eld removed rom the
than a decade o experience, many insurers now accept MAGIC
stator, can now be completed on many units without removing the
inspections in lieu o major inspections Because the rotor is not
eld The NDE test equipment has been modied by miniaturizing
removed, the risk o consequential damage is reduced to the
the scanner assembly using the same signal processing system
benet o the insurer and utility alike
as that used with the eld removed The system provides an ultrasonic test (0050”/127 mm crack detection threshold) on the ring ID and an eddy current test (0050”/127 mm crack detection threshold) on the ring OD
System Design MAGIC robotic devices were designed to work without any negative impact to generator components Each crawler has emergency retrieval capability that is also designed to cause no damage to the generator
Other Testing In addition to the above tests and inspections, there are several
Because GE takes Foreign Material Exclusion (FME) very seriously,
others that are recommended during minor and major outages
GE’s technicians conduct a thorough inspection o the crawler
They include electrical testing o the stator and eld windings and
beore and ater the generator inspection to ensure no parts were
Resistance Temperature Detectors (RTDs), as well as hydraulic
let behind in the generator In addition, pictures o the crawler are
testing o water-cooled stator windings A complete description
taken beore and ater the inspection or reerence purposes
o GE-recommended tests is provided in Technical Inormation Letter-1154 and GEK-103566 In-situ inspection o the generator does not change the need or importance o these tests
Traditional vs In-Situ Cost Analysis Reduced cost to the equipment owner is a signicant actor in
MAGIC Acceptance and Experience Industry Acceptance
comparing in-situ inspection programs to traditional inspection programs Cost reduction is achieved due to three major actors: • ReducedOutageDuration–In-situinspectionreducesthetime
For many years, generator inspection consisted o a minor
required to complete a major generator inspection The duration
outage every two-and-a-hal years and a major outage with the
o a generator inspection includes the time required or removal
eld removed every ve years This practice proved to be quite
rom service, disassembly, inspection and reassembly, and
successul in maintaining a high level o reliability o the generator
preparation or service
feet As deregulation led the power generation industry to rethink its philosophy on equipment maintenance, GE developed generator
• ReducedDisassemblyRequirements–In-situinspection
in-situ inspection tools to help our customers reduce cost and cycle
signicantly reduces the time required or disassembly and
The in-situ inspection strategy has proven successul—providing
reassembly o the generator, although it does add some time to
similar accuracy, sensitivity, and thoroughness as a eld-removed
the actual inspection process
inspection In addition, in-situ inspection does not pose a signicant increase in the risk o ailure over traditional inspection techniques
• EliminationoConsequentialDamage–Sincetherotordoesnot
have to be removed, damage that could result rom the rotor removal process is eliminated
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Net time savings vary based on the plant and generator design Table 3 below provides a good estimate o the time savings experienced or a typical large generator at a nuclear plant
Reducing Disassembly Requirements In-situ inspection oers signicantly reduced cycle time due to the greatly reduced level o generator disassembly required to complete the inspection However, reducing the level o
Type of Visual Inspection
Visual and Visual, Wedge Wedge Tightness Tightness and ELCID
disassembly has a number o benets beyond reduced cycle time, including cost savings that result rom reduced disassembly and
Traditional
14 Shits 16 Shits
18 Shits
reassembly labor, repair, and planning In addition, overhead crane
In-Situ
6 Shits
9 Shits
12 Shits
availability is not required or the inspection, reeing it up or use on
Savings
8 Shits
7 Shits
6 Shits
other parts o the outage
Table 3 Inspection time savings comparison
The total cost o eld removal and reassembly has been ound to be $50,000 to $250,000 or ossil plants and $250,000 to $500,000
Reducing Outage Duration When a generator is on an outage critical path, the ability to
or nuclear plants The cost associated with partial disassembly to allow in-situ inspection varies with the scope o the inspection, but generally runs about one-third the cost o complete disassembly
signicantly reduce generator inspection time is crucial Suitability or service inspections are generally recommended or generators ollowing an abnormal operating event that may have caused generator damage, including breaker ailures, short circuits, and loss o cooling Each o these can cause generator damage that can lead to an online major ailure i the damage is not repaired These circumstances provide an ideal application o in-situ inspection technology, where every hour saved directly aects the time spent ofine
Minimize Consequential Damage Another economic benet o in-situ inspection is the reduction o generator damage resulting rom rotor removal during the outage Rotor removal requires uncoupling the turbine-generator shats; careul disassembly o stator end shields on both ends o the generator; removal o bearings, hydrogen seals, oil defectors and exciter assemblies; and the skillul reassembly and realignment o these same components Improper end shield reassembly may result in: oil ingestion problems; expensive and time-consuming
In-situ inspection can also be used or advanced outage planning
oil cleanup; undesirable lubrication o the armature slot and
By perorming an in-situ inspection during a minor outage—prior to
endwinding restraining systems; increased armature motion; and
a planned major outage—you can help determine the necessity and
accelerated armature insulation wear (Reer to TIL-1098-3R2 or
scope o the major outage The major outage may be postponed
additional inormation on the adverse eects o oil ingestion)
altogether i the generator is ound to be in good condition I problems
In addition, rotor removal incurs risk o damage to the precision
are ound, the inormation gathered during the in-situ inspection can
components o the hydrogen seal oil assemblies and requires
be used to make preparations or repair at the next outage These
the heavy liting and temporary warm, dry storage o the rotor
preparations include planning the repair, identiying labor and material
Because the problems or damage resulting rom disassembly
needs and developing contingency plans When it comes to generator
can lead to very costly repairs, the best policy is to minimize
maintenance, experience has shown that preparation and planning
disassembly requirements
are critical to eciently executing an outage
The results are a result o the comparison o two dierent outage schedules or the same unit Length o the generator, stator diameter, and the number o slots in both the eld and stator are signicant variables GEII can work with each customer to develop time savings or each individual unit 1
2
Result o job cost estimations
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GE’s Position on In-Situ Inspection
Conclusions
For many applications, GE’s MAGIC inspection provides generator
The power generation industry is undergoing major changes
component assessment capability comparable to that routinely
requiring power producers, OEMs, and insurers to adapt One
achieved by rotor removal inspections Close-up, detailed views o
way that GE has responded to these changes is through the
the core and rotor suraces, stator and rotor wedges, retaining ring
development o advanced-technology tools that enable in-situ
tips and vent ducts allow a generator specialist to detect and assess
inspection o generators In many cases, in-situ inspection oers
potential problems not generally discernible by electrical testing
an excellent, reduced cost alternative to traditional eld-out
or other online monitoring—oten prior to the occurrence o any
generator inspection GE continues to work to gain acceptance o
signicant generator damage
in-situ inspection techniques throughout the industry
Periodic in-situ inspections, together with electrical testing and hydraulic checks, can provide an excellent alternative to many traditional OEM maintenance protocols Skillul interpretation o in-situ inspection observations and related data can provide plant
GE is working on enhancing the capabilities o our in-situ inspection service and expanding the application to smaller generators In-situ inspection will play an increasing role in reducing power producers’ cost o generation
operators with cost-eective opportunities to deduce outages and outage duration while maintaining the outstanding reliability and availability o their generators Recommended maintenance schedules or traditional and in-situ inspection protocols are compared in Table 4
Traditional
MAGIC In-Situ
First year Inspection
Inspection Interval (years) 2.5
5
Major
Minor
Major
•Visual •Wedge
•Visual
•Visual •Wedge
In-Situ
In-Situ
In-Situ
•Visual •Wedge
•Visual
•Visual •Wedge
Table 4 Recommended generator inspection schedules Notes: Electrical and hydraulic testing continue at recommended intervals; NDE testing
and TILs may require rotor removal or completion
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List o Figures
List o Tables
Figure 1 Generator in-situ inspection capabilities 4
Table 1 Generator inspection items 2
Figure 2 View o core damage taken with MAGIC robot 6
Table 2 In-Situ Inspection capabilities 5
Figure 3 Generator Wedge Tightness 7
Table 3 Inspection time savings comparison 10
Figure 4 Circulating current due to damaged core insulation 7
Table 4 Recommended generator inspection schedules 11
Figure 5 Field coils picture taken by borescope 8 Figure 6 Stator bar capacitance test 8
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