GENERATOR ROTOR REPAIR FOLLOWING as a non-severe case, even though the thermal sensitivity on new parts.

as a non-severe case, even though the thermal sensitivity on new parts. The manufacturer provides one generator
THERMAL SENSITIVITY PROBLEM sign is revealed by the thermal sensitivity testing, no specialist and one lead winder to work with EGAT’s
significant change is revealed by operational data maintenance team for on-site guidance. The rewinding changed
Thikhumporn Daorote monitoring. all insulations and used new designed of migrated parts which
EGAT Public Company Limited, Thailand is provided by manufacturer. Whereas, retaining ring,
Thermal Sensitivity Testing conductors and wedges were cleaned, inspected and reused.
The test is conducted to prove whether the vibration
ABSTRACT problem is caused by field current changes or prime mover
Generator rotor thermal sensitivity is a phenomenon found on force changes. Vibration changing as a function of
the generator rotor causing change in vibration as the field megawatt loading is not a thermal sensitivity mechanism [1].
current is adjusted. The discussion in this paper has been The two generators did not involve the test under constant
experienced in the two-pole gas-turbine-driven generators field current due to certain constraints but they were
which are installed at South Bangkok Combine Cycle Power investigated under the constant megawatt.
Plant Block No.2. The second block consists of two 291 MVA
gas-turbine-driven generators and one 291 MVA steam-
turbine-driven generator. After careful investigation, the C
thermal-related problem has been found on both gas-turbine-
driven generators. In one generator, namely SB-C22, the B
thermal problem caused mal-operation in reactive power Figure 5 Sub slot cover migrated with maximum distance of
generation. The excitation controller failed to achieve its 300 mm.
maximum reactive power due to the excessive vibration in the The corrective actions were performed covering all possible
rotor. This problem was clearly observed and successfully causes which had contributed to the parts migration and
fixed. It has also been found that another generator, namely thermal sensitivity problem.
SB-C21, shows the similar manner as the SB-C22. A
(1) The problem of vent hole plugging was corrected by the
vent holes enlargement which is applied to new leaf spring
UNIT HISTORY AND DATA and new creepage block.
The South Bangkok Power Plant is a multi-unit plant located Figure 2 Shaft vibration changes proportional to the MVAR
(2) Leaf spring migration problem was mitigated by the
in Samutprakarn, a province in the outskirts of Bangkok. The variation.
smaller design clearance of leaf spring and providing
power plant has installed total capacity of 2,289 MW. Its positive stopper at both end of the slot armortisseur.
capacity is contributed of five thermal power plants and two The SB-C22 generator was tested at 130 MW while the
MVAR was varied from -30 to 65 MVAR. The results (3) Breakage of splice joint on the sub slot cover was avoided
blocks of combined cycle power plant. The second combined by using single piece sub slot cover.
cycle which is considered in this paper has been generating revealed serious condition of thermal sensitivity shown in
figure 2. The reactive power is -30 MVAR at point A then it (4) The problem associated with fallen locked button on the
power using two gas-turbine-driven generators since 1996 and sub slot cover was alleviated by reducing the radial
the steam-turbine-driven generator was completed in 1997. In was increased to 65 MVAR at point B. The vibration
reached to point C in 40 minutes while the reactive power clearance for the button.
2002, the second gas-turbine-driven generator, SB-C22, faced
the thermal sensitivity problem and it was unable to generate was fixed. Afterward, the vibration was decreased
reactive power due to its excessive vibration. It was able to immediately while the reactive power was reduced. The
generate real power up to based load but reactive power is results on the generator SB-C22 had been concerned as a
none. Highest field current is 950 A and the casing vibration critical reversible thermal sensitivity problem. Therefore the
at exciter-end bearing was limited at 0.5 in/s. Moreover, the unit was shutdown to perform the repair work.
vibration records showed that the generator had been
May 2004 Nov 2003
increased the vibration level remarkably after every trip. The 75 75

unit was closely monitored and tested in order to investigate 50 Ex’s 50

Ex’s
whether it is the severe problem of thermal sensitivity. The Tu’s Figure 6 New designed leaf springs (left) and the positive
results indicated that the generator was in critical condition 25 Tu’s 25 stopper (right).
and then the repair work was set up with the cooperation of
the manufacture. Meanwhile, the first gas-turbine-driven
0 0
After the repair work, thermal sensitivity investigation was
-75 -50 -25 0 25 50 75 -75 -50 -25 0 25 50 75
generator, SB-C21, also shows the sign of thermal sensitivity -25 -25
performed when the unit starts and the test was repeated three
behavior but it is not severe and it has been operating without month later. The result indicated that generator had been
any significant sign. -50 -50 operating without thermal sensitivity problem. However, the
test did not involve online flux-probe test, an additional test
-75
Unit: μmp-p -75
The generators are indirect H2-cooled, 291 MVA, 15 kV, 0.85 which is recommended by the manufacturer, because this case
power factor and 3000 rpm. Their two-pole cylindrical rotor Figure 3 Polar plot showing once-per-revolution vibration revealed obviously that it is associated with the vent holes
consists of 32 slots containing 13 turns of copper winding on vector comparison on the generator SB-C21 blockage.
each slot. Rated field current is 1,672 A and rated field
voltage is 550 V. The cooling system of the rotor is radial The non-severe thermal sensitivity case reveals on the
flow cooling using two axial flow fans. generator SB-C21 which is tested periodically in order to
follow the changes in the problem. The vibration vectors
DIAGNOSIS TESTING which are shown in figure 3 are compared between the tests
The operational condition monitoring and online thermal in 2003 and 2004. The record shows both increasing and
sensitivity testing were performed on both generators in order decreasing at 0 MVAR, 60 MVAR and 100 MVAR at 100
to diagnose the severity of the problem. MW constant. The results indicate that the generator SB-
C21 is able to operate without any limitation.
SB-C22 BearingVibration
0.4

0.35

0.3
Casing vibration (in/s

0.25

0.2

0.15
Figure 7 Overall shaft vibration record during thermal
0.1
sensitivity investigation test at varied reactive power
0.05
(0, 60 and 100 MVAR) under constant 100 MW.
0
700 750 800 850 900 950 1000 CONCLUSION
Field current(A) The thermal sensitivity problem due to vent holes blockage
BB1 BB2 BB4 BB5 BB7 BB8 BB9 which is taken place on the two generators shows that the risk
of thermal sensitive rotor can be governed under appropriate
Figure 4 Slot configuration of the generator field. monitoring and testing. This thermal sensitivity contributes to
Figure 1 Bearing vibration variation due to the increasing the reversible vibration, nevertheless, the generator is still able
field current to operate if the vibration does not exceed the limit. Otherwise,
INSPECTION RESULTS
The generator SB-C22 was shut-down in order to conduct the problem is needed to mitigate.
Investigation Using Operational Data
The operational data of SB-C22 was collected during 28 to 31 the repair work on the rotor. The migrated parts are slot
armorisseur, leaf spring, creepage block and sub slot cover. REFFERENCES
January 2003. The result in the figure 1 shows that the
The root cause analysis done by GEPS Energy Services [1] Ronald J. Zawoysky, Wiliam M. Genovese, “Generator
vibration of generator bearing changes directly due to the
concluded that the leaf spring contributed to the vent holes Rotor Thermal Sensitivity-Theory and Experience”,
change in field current. At exciter end (BB9), the increment
plugging and it caused the thermal sensitivity [2]. GE Power Systems, New York, April, 2001
reveals obviously while it is smaller change on turbine end
[2] GEPS Energy Services, “Investigation of Thermal
(BB7, BB8). Whereas, none of significant change appears on
REPAIR WORK Sensitivity”, Product/Technical Support-Asia, June, 2003
the other bearings neither located at turbine or compressor
(BB1, BB2, BB4 and BB5). For SB-C21 which is considered The repair work of the generator SB-C22 was done by total
field rewinding including corrective action which is applied