GENERATOR ROTOR REPAIR FOLLOWING

THERMAL SENSITIVITY PROBLEM

Thikhumporn Daorote
EGAT Public Company Limited, Thailand
ABSTRACT
Generator rotor thermal sensitivity is a phenomenon found on
the generator rotor causing change in vibration as the field
current is adjusted. The discussion in this paper has been
experienced in the two-pole gas-turbine-driven generators
which are installed at South Bangkok Combine Cycle Power
Plant Block No.2. The second block consists of two 291 MVA
gas-turbine-driven generators and one 291 MVA steamturbine-driven generator. After careful investigation, the
thermal-related problem has been found on both gas-turbinedriven generators. In one generator, namely SB-C22, the
thermal problem caused mal-operation in reactive power
generation. The excitation controller failed to achieve its
maximum reactive power due to the excessive vibration in the
rotor. This problem was clearly observed and successfully
fixed. It has also been found that another generator, namely
SB-C21, shows the similar manner as the SB-C22.
UNIT HISTORY AND DATA
The South Bangkok Power Plant is a multi-unit plant located
in Samutprakarn, a province in the outskirts of Bangkok. The
power plant has installed total capacity of 2,289 MW. Its
capacity is contributed of five thermal power plants and two
blocks of combined cycle power plant. The second combined
cycle which is considered in this paper has been generating
power using two gas-turbine-driven generators since 1996 and
the steam-turbine-driven generator was completed in 1997. In
2002, the second gas-turbine-driven generator, SB-C22, faced
the thermal sensitivity problem and it was unable to generate
reactive power due to its excessive vibration. It was able to
generate real power up to based load but reactive power is
none. Highest field current is 950 A and the casing vibration
at exciter-end bearing was limited at 0.5 in/s. Moreover, the
vibration records showed that the generator had been
increased the vibration level remarkably after every trip. The
unit was closely monitored and tested in order to investigate
whether it is the severe problem of thermal sensitivity. The
results indicated that the generator was in critical condition
and then the repair work was set up with the cooperation of
the manufacture. Meanwhile, the first gas-turbine-driven
generator, SB-C21, also shows the sign of thermal sensitivity
behavior but it is not severe and it has been operating without
any significant sign.
The generators are indirect H2-cooled, 291 MVA, 15 kV, 0.85
power factor and 3000 rpm. Their two-pole cylindrical rotor
consists of 32 slots containing 13 turns of copper winding on
each slot. Rated field current is 1,672 A and rated field
voltage is 550 V. The cooling system of the rotor is radial
flow cooling using two axial flow fans.
DIAGNOSIS TESTING
The operational condition monitoring and online thermal
sensitivity testing were performed on both generators in order
to diagnose the severity of the problem.
SB-C22 BearingVibration

as a non-severe case, even though the thermal sensitivity

sign is revealed by the thermal sensitivity testing, no
significant change is revealed by operational data
monitoring.
Thermal Sensitivity Testing
The test is conducted to prove whether the vibration
problem is caused by field current changes or prime mover
force changes. Vibration changing as a function of
megawatt loading is not a thermal sensitivity mechanism [1].
The two generators did not involve the test under constant
field current due to certain constraints but they were
investigated under the constant megawatt.

on new parts. The manufacturer provides one generator

specialist and one lead winder to work with EGATs
maintenance team for on-site guidance. The rewinding changed
all insulations and used new designed of migrated parts which
is provided by manufacturer. Whereas, retaining ring,
conductors and wedges were cleaned, inspected and reused.

C
B

A
Figure 2 Shaft vibration changes proportional to the MVAR
variation.
The SB-C22 generator was tested at 130 MW while the
MVAR was varied from -30 to 65 MVAR. The results
revealed serious condition of thermal sensitivity shown in
figure 2. The reactive power is -30 MVAR at point A then it
was increased to 65 MVAR at point B. The vibration
reached to point C in 40 minutes while the reactive power
was fixed. Afterward, the vibration was decreased
immediately while the reactive power was reduced. The
results on the generator SB-C22 had been concerned as a
critical reversible thermal sensitivity problem. Therefore the
unit was shutdown to perform the repair work.
May 2004

Nov 2003

75

50

75

Exs

Exs

50

Figure 6 New designed leaf springs (left) and the positive

stopper (right).

Tus
Tus

25

25

0
-75

-50

-25

0
0

25

50

75 -75

-50

-25

-25

-25

-50

-50

-75

Figure 5 Sub slot cover migrated with maximum distance of

300 mm.
The corrective actions were performed covering all possible
causes which had contributed to the parts migration and
thermal sensitivity problem.
(1) The problem of vent hole plugging was corrected by the
vent holes enlargement which is applied to new leaf spring
and new creepage block.
(2) Leaf spring migration problem was mitigated by the
smaller design clearance of leaf spring and providing
positive stopper at both end of the slot armortisseur.
(3) Breakage of splice joint on the sub slot cover was avoided
by using single piece sub slot cover.
(4) The problem associated with fallen locked button on the
sub slot cover was alleviated by reducing the radial
clearance for the button.

Unit: mp-p

25

50

75

-75

Figure 3 Polar plot showing once-per-revolution vibration

vector comparison on the generator SB-C21

After the repair work, thermal sensitivity investigation was

performed when the unit starts and the test was repeated three
month later. The result indicated that generator had been
operating without thermal sensitivity problem. However, the
test did not involve online flux-probe test, an additional test
which is recommended by the manufacturer, because this case
revealed obviously that it is associated with the vent holes
blockage.

The non-severe thermal sensitivity case reveals on the

generator SB-C21 which is tested periodically in order to
follow the changes in the problem. The vibration vectors
which are shown in figure 3 are compared between the tests
in 2003 and 2004. The record shows both increasing and
decreasing at 0 MVAR, 60 MVAR and 100 MVAR at 100
MW constant. The results indicate that the generator SBC21 is able to operate without any limitation.

0.4
0.35
Casing vibration (in/s

0.3
0.25
0.2

Figure 7 Overall shaft vibration record during thermal

sensitivity investigation test at varied reactive power
(0, 60 and 100 MVAR) under constant 100 MW.

0.15
0.1
0.05
0
700

750

800

850

900

950

1000

Field current(A)

BB1

BB2

BB4

BB5

BB7

BB8

BB9

Figure 1 Bearing vibration variation due to the increasing

field current
Investigation Using Operational Data
The operational data of SB-C22 was collected during 28 to 31
January 2003. The result in the figure 1 shows that the
vibration of generator bearing changes directly due to the
change in field current. At exciter end (BB9), the increment
reveals obviously while it is smaller change on turbine end
(BB7, BB8). Whereas, none of significant change appears on
the other bearings neither located at turbine or compressor
(BB1, BB2, BB4 and BB5). For SB-C21 which is considered

Figure 4 Slot configuration of the generator field.

INSPECTION RESULTS
The generator SB-C22 was shut-down in order to conduct
the repair work on the rotor. The migrated parts are slot
armorisseur, leaf spring, creepage block and sub slot cover.
The root cause analysis done by GEPS Energy Services
concluded that the leaf spring contributed to the vent holes
plugging and it caused the thermal sensitivity [2].
REPAIR WORK
The repair work of the generator SB-C22 was done by total
field rewinding including corrective action which is applied

CONCLUSION
The thermal sensitivity problem due to vent holes blockage
which is taken place on the two generators shows that the risk
of thermal sensitive rotor can be governed under appropriate
monitoring and testing. This thermal sensitivity contributes to
the reversible vibration, nevertheless, the generator is still able
to operate if the vibration does not exceed the limit. Otherwise,
the problem is needed to mitigate.
REFFERENCES
[1] Ronald J. Zawoysky, Wiliam M. Genovese, Generator
Rotor Thermal Sensitivity-Theory and Experience,
GE Power Systems, New York, April, 2001
[2] GEPS Energy Services, Investigation of Thermal
Sensitivity, Product/Technical Support-Asia, June, 2003