Exciter Center of Excelle 1

7/30/2019 Exciter Center of Excelle 1

1/11

EXCITER CENTER

OF EXCELLENCE

Parts and Service or the Global Power Industry


2/11

BRUSH IN THE U NITED STATES

Established in 1879, BRUSH has always been

intrinsically linked with the USA. Charles Francis

Brush ormed the Brush Electric Company in

Cleveland Ohio at the same time orming the

Anglo-American Electric Light Company in

London, England. Since those early days BRUSH

has grown to become the largest independent

manuacturer o turbo generators in the world

with the greatest concentration o our machines

installed in the United States.

We oer worldwide support or all BRUSH

products and equipment which includes three

manuacturing sites in Europe, a major repair

acility in Pittsburgh, PA and sales support ofces

in Houston, TX, Abu Dhabi and Malaysia.

Our Atermarket sales support provides ast

responsive support anywhere in the world. The

comprehensive services we oer concentrate on

maximizing the perormance o your generator

regardless o it being an original BRUSH

machine or that o any other OEM.

CONTENTS04 A History o Excellence05 Exciter Repairs & Service06 Case Studies08 Replacement Parts09 Brushless Exciters10 PPV Modication12 Service Recommendations14 NERC Requirements15 Prismic A5017 Case Study18 Pittsburgh - Our Hub

24 HOURGLOBALSUPPORTFOR ALLGENERATORS


3/11

BRUSH GMS has become an industry leader indemonstrating that brushless exciters, some inoperation or up to 40 years, may be overhauledand retrotted allowing up to 20 years o extended,reliable operation.

Over the past 5 years BRUSH GMS hasoverhauled, repaired and rewound over 50 BRUSH,Westinghouse, GE and EM exciters. Servicepersonnel have carried out inspection and testingon many more with outputs ranging rom 100KW -5000KW. BRUSH GMS can also recondition, modiyor replace all exciter components as well as improvethe exciter environment by perorming a positivepressure vent modication o the brushless exciterhousing.

Our expert teams are highly experienced in thedesign, manuacture, maintenance and testing orotating exciters. Our engineers have improvedexciter component design to improve reliability.

I your exciter is scheduled or an upgrade, BRUS HGMS solutions may include t emporary replacementexcitation or the supply o a brushless exciter romour extensive seed inventory.

BRUSH GMS services include:

Repairs o all types.

Rebuilding components.

Reurbishment program to disassemble allremovable components, testing each electricalcomponent to identiy its status.

Component replacement including diode wheelsand diode modules.

Rebanding services.

Complete rewinds o the stator and rotor windingassemblies.

PMG rewinds.

Full speed balance o all exciter rotors in a stat e-o-the-art balance acility.

Emergency excitation services, including a mobileexciter, which can be brought to site, andswap-out brushless exciters or use duringreurbishments.

Electrical testing, including:

Hi POT testing.

Thermocouple continuity.

Core testing.

PMGmagnet testing.

Resistance testing.

Supply o new brushless exciters.

Exciter housing modications.

HAT MAKES A CENTER OF EXCELLENCE?E HAVE ALL THE SKILLS YOULL EVER NEEDND PROBABLY A WHOLE LOT MORE...

Parts and Service or the Global Power I ndustryEXCITER CENTER OF EXCELLENCE

Housing upgrade/modifcation reduces risks

and improves operation.

Brush GMS can carry out a Positive Pressure VentModication (PPVM) to your existing exciter housing.This program has proven to signicantly reduce therate o dirt contamination and mitigate the potentialhazard o hydrogen gas ingress.

Housings are modied so the inside air pressuresurrounding the diode wheel zone is at a higherpressure level than the outside. This higher pressurereduces the intake o dirt and contamination duringoperation.

Cooler repairs

Forced outages can be caused by water leaks causedby pipe corrosion and joint ailure in exciter coolingsystems. When required, coolers are reurbishedto avoid cooler induced outages. Piping may becleaned and relined, coolers may be cleaned andtheir water boxes relined. The entire cooling systemis pressure tested and readied or long term use.

Base wiring up-grades

Base wiring on many older exciters containsasbestos insulation. During exciter overhauls

BRUSH GMS tests and replace connections,

terminal blocks and wiring with new, himaterials.

High speed balance and over spe

BRUSH GMS will balance rotors at 36ater overhauls and over speed test at 3Experienced BRUSH GMS engineers balance even the largest o rotors withi

PMG output testing

The primary purpose o high speed tesrecord displacement data used to balaexciter rotor. We also conduct PMG ouwhich is also conducted with the unit aThis running test can be done ater thebalance with the PMG attached to t heor with the PMG removed rom the exusing a tolling shat. The purpose o thveriy adequacy o all repairs completestator or magnets to insure trouble ree

Transportation o equipment

BRUSH GMS will pick up and deliver yand doghouse. I you have any logistic in moving your existing equipment to oback, Brush GMS will provide a comple

solution.

EXCITER REPAIRS,EXCITER SERVICES &MOBILE EXCITATIONSERVICES

OUR EXPERT TEAMS AREHIGHLY EXPERIENCED I NTHE DESIGN, MANUFACTURMAINTENANCE AND TESTINBRUSHLESS EXCITERS.

HISTORY OFXCELLENCE


4/11

ASE STUDIESRUSH GMS TO THE RESCUE


Cracks in the banding material o the exciter hadbeen repaired annually or some years and nally arecommendation was made to replace t he bandingat the next opportunity.

BRUSH GMS was selected to replace the bandingon the unit and review or other recommendations.

The exciter rotor was transported rom Israel toPittsburgh, USA. The rotor was inspected and testedto ascertain the physical condition o armatureassembly including coils. A ull inspection report tothe customer revealed that coils had lited, groundwall insulation was brittle, one phase had highresistance and the diode wheels were extremelydirty. Upon our recommendation, the client elected toproceed to a complete rewind o the armature.

The lead time quoted to complete the rewind was 47days and customer requested temporary solutions totheir excitation needs in the interim. BRUSH G MSoered them a ully operational brushless exciter asa replacement rom the inventory o seed excitersin Pittsburgh. All that was needed was or a new

coupling to be installed to mate with thgenerator. BRUSH GMS engineered athe backup unit or deployment and paproceeded to rewind the clients excite

The complete rewind o the clients rothigh speed balance and shipment bacclient was expedited in such a timely mit allowed or the client to suspend anytemporary seed exciter.

The BRUSH GMS seed is a valuable asupporting temporary excitation duringeorts on original equipment. From repto rewind capabilities to engineered altexcitation. B RUSH GMS inventory masolution required or many customers.

A LARGE UTILITY INISRAEL WAS OPERATINGA COAL FIRED POWERSTATION UTILIZINGSIEMENS GENERATORAND EXCITEREQUIPMENT.

THE CUSTOMER COMMENTTHE ON TIME PERFORMANCAND EXCELLENT TECHNICACOMMERCIAL SUPPORT FRBRUSH GMS.

N ENERGY SUPPLIERSOAL FIREDENERATING STATIONERE PURSUINGCONTRACTOR TOEFURBISH THEIRXISTING EXCITER TORIGINAL EQUIPMENTPECIFICATIONS.

THE CONTRACT UTILIZEDBRUSH GMSS EXPERTISE ANDEXTENSIVE EXPERIENCE OFWORKING ON EXCITERS. TODAYTHE UNIT IS 43 YEARS OF AGEAND STILL GOING STRONG.

BRUSH GMS were selected to rewind and reurbishtheir AC armature and make repairs to the exciterand permanent magnet generator.

The power stations unit was a Westinghouse turbinegenerator and was placed in service in 1968. Theturbine was a tandem compound, our fow, reheat,type steam turbine and the generator a hydrogeninner cooled design. The latter was coupled toa brushless exciter and a permanent magnetgenerator (PMG).The exciter model a MARK II,double wheel, air cooled brushless exciter, rame121C oering 2900KW at 560 volts.

The work began with the pick-up o the exciterat the customer location just days ater their alloutage began and the reurbishment process wasscheduled to be complete in 36 days.

The work scope was extensive and included:

Complete disassembly o exciter and housing.

All incoming electrical and NDE inspections andtests carried out.

TIR was done in the lathe.

OMM 057 was perormed on t he pole supportmounting bolts.

Diode wheels were completely stripped downand all components cleaned and tested.

All contact suraces were re-plated with silverplate and all components completely reurbishedand re-installed.

Old armature coils were stripped, core tested ortightness and new coils installed.

New insulation or radial leads.

New axial lead insulation installed.

New neutral rings and parallel rings installed

New banding was wound over phase leadsection and coil ends.

Unit was readied and placed at the balance pitor over speed & balance.

Base o the exciter was completelydisassembled and each component cleaned,insulation replaced, painted and reassembled.

All testing o electrical components perormed

Exciter rotor was installed in base complete aterbalancing procedure.

Doghouse was reurbished in our paint shop.


5/11


MANUFACTURERWestinghouseBrushless

WestinghouseBrushless

BRUSHBrushless x2

EMBrushless x2

BRUSHBrushless

EB

MODELA081CFully OperationalBrushless Exciter

A141C/141CFully OperationalBrushless Exciter

BXJ-40Armature Only

7A6 rameCompleteArmature &Stator

BXJ-40Armature

FH

GENERATOROR TURBINEPACKAGEREFERENCE

WestinghouseGenerator Frame2-102x170

WestinghouseGenerator Frame2-104x245

BDAX7.290ER72.290ER72.340ER8.335ER

GE 7EA Seriesand BRUSHBDAX- 8.365ER

BDAX- 8.365BG

Mobile exciter

Mobile exciters are either skid mounted or trailermounted. This includes PPT and provides DCexcitation current in various amperage ratingsdepending on need and equipment availability. Theunits are properly installed and their on-board AVRsystem is calibrated at site to operate successully.

Collector ring assemblies

Rental Collector Ring Assemblies are aoperation with mobile DC power supplyoption to purchase.

Swap-out brushless exciters are available to customers or use during reurbishment operationmodels are regularly available to rent or buy.

TERME

FUSES CAPACITORS DIODES HEAT SINKS PMG MAGNETS TCSGROUNDDETECTION

TERMINALBLOCKS

HOUSINGGASKETS

nghouse

C Stocked Available Stocked Stocked Available Available Stocked Available Available Stocked








ME 6 Stocked Available Stocked Stocked Available Available Stocked Available Available Stocked



ME 16 Stocked Available Stocked Stocked Available Available Available Available Stocked

SH

40 Stocked Stocked Available Available Available



Stocked Stocked Available Available Available

BRUSHLESSEXCITERS

EPLACEMENT PARTSRUSH GMS OFFERS A COMPLETE LINE OF PARTS TO SUPPORTOTH OEM AND NON-BRUSH UNITS.

WE HAVE AN EXTENSIVEINVENTORY IN OUR PITTSBURGHFACILITY AND IF YOUR PART ISNTSTOCKED WE HAVE THE DESIGNAND ACCESS CAPABILITIES TOMAKE THE PARTS YOU REQUIREAVAILABLE.


6/11

EXCITER CENTER OF EXCELLENCE

PV MODIFICATIONOR DRAMATIC DIRTONTAMINATIONEDUCTION

The BRUSH GMS P PV (Positive Pressure Vent)upgrade signicantly reduces dirt contamination,whilst also reducing the potential hazard ohydrogen ingress.

Lacking external blowers and motors, the BRUSHGMS PPV gives a passive upgrade to the existingexciter housing. Many BRUSH customersundergoing an initial PPV upgrade have returned tous or additional unit upgrades because o the manybenets that such a procedure can bring.

Dirt contaminationaecting

brushless exciters

Dirt contamination is a common problem orbrushless exciters, with unltered ambient air beingingested by the exciter an to replenish air thatleaks out o the exciter housing. Typical leakageareas include door seals, base seal and the shatseal. Miscellaneous openings, which also contributeto dirt contamination, include those or entry o thecooling water piping, as well as oil piping, electricalwiring and conduit into the housing.

Make-up air vents a major cause o

dirt-laden air ingress

Adding to the problem o dirt ingress is t he excitersventilation scheme. There are three zones in theOEM brushless exciter the an, bearing and diodewheel zones; and because the make-up air ventsare located in the diode wheel zone, it will inherentlyoperate at negative pressure (below atmosphericpressure), providing a virtually unlimited opportunityor dirt-laden air to enter the exciter. The PPVupgrade reduces the rate o air exchange andprovides a hydrogen-ree exciter environment.

By providing manageable control o the make-up airand improved sealing the BRUSH GMS PPV canprovide the ollowing benets.

Both the diode wheel and bearing zones operatewith positive pressure.

The an zone is now the only area with negativepressure, so its the only zone in which make-upair can enter. This reduces the potential or air toenter the housing via the door, base and bulkheadinterace seals by around 75%.

With the potential or air entering the system limitedto the an zone, it is now possible to control airquality, whilst also minimizing the volume o make-up air via use o a properly designed ltration unitand improved sealing. The make-up air enters thelter unit, passes through the pre-lter and primarylter and then through a pressure-actuated fowcontrol valve, which uses static pressure in thediode wheel zone to maintain approximately 1 inchwater gauge.

Improved compression

As well as changing the air intake locatBRUSH GMS PPV completely strips thrubber seals throughout the housing annew seals. In addition, the doors are ttelatches to provide greater seal compresall penetrations into the housing area aas well. The housing is cleaned, re-assethen painted to match the existing colo

Reducing

As an eective means o reducing dirt iinto the OEMs brushless exciters, the BGMS PPV oers the opportunity to redmaintenance and the risk o electrical aarising rom dirt accumulation on the elcomponents. In addition, the PPV upgradecreases the risk o hydrogen ingress

BRUSH GMS PPV,DELIVERING ANIDEAL SOLUTION

Parts and Service or the Global Power Industry


7/11

EXCITER CENTER OF EXCELLENCE Parts and Service or the Global Power IndustryParts and Service or the Global Power I ndustry

ERVICE RECOMMENDATIONSOR THE BEST PERFORMANCE

EXCITER CENTER OF EXCELLENCE

A proper maintenance plan will use predictive anddiagnostic ndings to ensure the maintenanceperormed on an exciter is optimized.

The most eective predictive set o data will resultrom vibration monitoring, lube oil monitoring,annual electrical testing, temperature data andthermography.

Collecting data rom minor inspections and reviewingmonitored data will help determine the plannedmajor inspection work interval and requirement.

On a minor inspection basis, BRUSH GMS canperorm the ollowing work in a short outage.

Limited access to components with housing

in place may allow or minor inspections and

cleaning which may include:

Cleaning components inside housing and diodewheel.

Perorm electrical testing on PMG and excitereld.

Visual inspection o any heat aected areas.

Inspect ground detection system or wear.

Check insulation or deterioration.

Visual inspection or movement o components.

Inspect banding risers and channels.

Inspect bearing insulation.

Removing exciter housing and disconnecting

generator leads.

Perorm all the visual and electrical inspectionsreerenced above.

Perorm additional electrical testing on uses,diodes, windings.

Replace any components testing outside oacceptable measurement criteria..

Perorm additional cleaning and inspection obearings and wear components.

Replace gaskets, lters, brushes, t erminal blocksas necessary.

Inspect magnets.

Perorm AC stator winding resistance testingand AC stator pole balance test.

Perorm additional PMG testing.

Inspect and report on doghouse heat exchangerpiping and coolers condition.

BRUSH GMS Major Inspection Package.

A complete disassembly o the housing rom thebase unit.

Removal o the red iron and rotor rom base.

Complete removal o all diode wheel componentsor complete testing and cleaning.

Replacement any components including uses,diodes, capacitors, heat sinks, old wiring harness,gauges, TCs and terminal blocks.

Repair work on banding i necessary. Repair workon bearing i necessary.

NDE examination o journals, coupling, diodewheels.

All electrical testing perormed.

Phase lead risers inspected and replaced inecessary.

Cleaning o entire exciter and doghouse.

Coolers removed and pressure tested andrepaired i necessary.

Ground detection system components may betested, replaced i necessary. Ground ringsinspected and improved i necessary. Wiringto ground rings inspected and repaired inecessary.

I necessary, unit may be sent to balance pit orhigh speed balancing or balanced on turninggear.

These are inspections, tests and repairperormed in the eld. BRUSH GMS cextensive list o eld service work recoor any given outage opportunity and wschedule.

I you want to extend the time betweeoverhauls, consult with BRUSH GMS minor and major eld inspections.

NOR BRUSHLESSXCITATIONSPECTIONS

MAJOR BRUSHLESSEXCITATIONINSPECTIONS

Parts and Service or the Global Power I ndustry


8/11

The PRISMIC A50 excitation system delivers

unsurpassed levels o power and fexibility. This

makes it ideal or hydroelectric, coal, steam, gas

and nuclear power plants, plus its equally suited to

synchronous motors and condensers.

The PRISMIC A50 is also suitable or new

installations, and it lets you upgrade outdated

equipment without incurring the cost and downtime

o installing a complete new system.

The PRISMIC A50s strikingly compact and

elegant design requires ew additional components,

allowing or a control panel design thats both

simple to use and easy to maintain. In addition,

the A50 comes with all the necessary rmware

and application logic, so a microsystem or

programmable logic controller is not required.

The PRISMIC A50 boosts peror

several key areas:

Synchronization

You can synchronize generators tdistribution system which can replace stand-alone synchronizers.

Interacing

Advanced digital technology allows ocontrol, high-speed parameter settingdiagnostics.

Regulation

Secure the stable regulation o machines in a variety o operating modsteady-state and transitional conditions

THE PRISMIC A50EXCITATION SYSTEM

EXCITATION SYSTEM D (DC) B (BRUSHLESS) S (STATIC) A (AUX

Response speed Low Low High High

PSS efciency Low Low High High

Fast de-excitation Yes No Yes Yes

Steady state short circuit current Yes Yes No No

Suitable or new generators No Yes Yes Yes

Output Low/Medium Full Range High

Reurbishment B,S S A,S

ERCEQUIREMENTSEY PURPOSEROM NERCERSPECTIVE

Key purpose rom NERC perspective

...to ensure that generators will not trip o lineduring specied voltage and requency excursionsor as a result o improper coordination betweengenerator protective relays and generator voltageregulator controls and limit unctions.From NERC PRC-024-1

Verifcation requirement

MOD-026 will require owners to veriy coordinationo protection systems or all generators every 10years (identical units on the same site: vericationonly on one unit)

Reactive power problems are mostly localin nature and it is t hereore crucial to providea necessary level o reactive power support andvoltage control in a distributed manner on allnetwork levels and especially at the sendingand receiving ends o transmission lines.Voltage and reactive power problems cannot beresolved centrally.

It has become standard industry practice ortransmission operators to require generatingacilities to provide a level o reactive powersupport and to maintain voltage schedules.

This is especially important or large generatingacilities (20 megawatts and above) thatgenerally supply power at a signicant distancerom load centres.

At BRUSH GMS we understand the ongoingregulatory requirements and can support yourbusiness needs by providing most modeling andtest requirements as well as through the built ineatures in many o our products.

EXCITER CENTER OF EXCELLENCE Parts and Service or the Global Power Industry


9/11


THE SEED ROTOR WAS REPWITH THE CUSTOMER ONLYLOSING POWER WHEN THECHANGEOVERS TOOK PLAC

Banding ailure inspection

The band ailure caused damage to the Inconelresistor assemblies and exciter armature coilends. It was determined that the unit needed tobe completely rewound and rebanded.

Full inspection and testing o all componentstook place at this time.

Exciter rewind

The exciter was stripped and rewound withnew coils and new class F insulation.

All exciter bands were replaced.

All components were cleaned.

Electrical contact suraces were silver plated.

All diode wheel uses were replaced.

Following the rewind the exciter was balancedat 3000 RPM operating speed.

Inconel resistor removal

The unit was designed with Inconel rebalance phase resistance. Through exknown these had been a component pand were determined to not be necessGMS replaced the Inconel resistor assfexible phase comprised o laminated

The diodes in the rotating rectier werstud diodes with a aster reaction timevoltage rating. The existing heat sinks to accept the stud diodes.

Seed exciter installation

An A061 seed exciter was modied toat the customers site while the rewindThe higher power rating o the A061 eor the generator to run at the same ra

The two exciters have dierent couplino transmitting power to the generatoradapter was manuactured to convert leads to a butterfy style main lead.

The exciter base plate was modied oinstalled on the current sole plate.

Ater the customer witnessed nal comtests including high pot testing o the the exciter was shipped back to Spain

SPAIN - SEED ROTOR REPLACEMENTA CUSTOMERS WESTINGHOUSE A161EXCITER WAS REBANDED IN EUROPEAND WAS ONLY IN OPERATION FOR A HOURS BEFORE SUFFERING A CRITICBAND FAILURE.


10/11

PITTSBURGH, PAOUR HUB INTHE USA

From our Pittsburgh base BRUSH has provided

engineering driven solutions or generation

equipment in electric utility and industrial plants

or over 20 years. With a ull range o inspection,

testing, repair and patented retrofts, BRUSH ensure

our customers receive a timely and quality service

incorporating custom engineering or lie extension

and maintenance o a wide range o generators and

excitation systems.

BRUSH is dedicated to upholding our high

standards o excellence and we oer value solutions

or all 3rd party generators providing technical

qualifcations in line with the OEM and utilizing

our own OEM expertise and support network or

BRUSH generators and control systems.

Our highly skilled and uniquely qualifed service

engineers are dedicated to providing timely

service to meet both scheduled and emergency

outage needs. Our support teams can answer any

queries you have about our capabilities and deliver

quotations and technical advice.

Our comprehensive capabilities ocus on maximizingthe perormance o your generator, with the ultimate

aim o extending its lie, and include:

Rotor repairs

BRUSH-oer complete rotor servicing including:

inspection, testing, rewind, machining, lie extension

and engineering. BRUSH has experience rewinding

the felds o all the major OEMs. BRUSH has

capability in its 50,000 sq t manuacturing plant

to handle rotors up to 100 tons. With two heavy

duty lathes and a complete compliment o milling

machines, BRUSH can perorm any necessary

machine operation.

Stator repairs

BRUSH can oer complete stator services rom

a visual inspection and testing by experienced

personnel to a complete rewind. BRUSH provides

all the standard electrical and mechanical testing and

inspections plus EL-CID, loop test and end winding

stiness (Bump) testing and analysis.

With manuacturing plants worldwide, we have the

capability to reach you anywhere in the world.

ASED INITTSBURGH :ERVICING THE

WORLD

BRUSHFACILITIES

BRUSHSHOPTOOLING

50,000 sq t o high bay space Capable o 100 Ton lit Clean environment 24/7 security Truck and rail access

Two 50 x 72 horizontal boring mills Two lathes 60 swing and 600 centers 90 swing and 480 centers (transportable) Two vertical boring mills

Rotor winding clean room 1800 sq t clean room Air conditioning & humidity co

EXCITER CENTER OF EXCELLENCE Parts and Service or the Global Power IndustryParts and Service or the Global Power I ndustry


11/11

www.brush.eu

For more information aboutBRUSH Aftermarket, pleasecall us direct, email or visitour website.

BRUSH Aftermarket

T +1 412 829 7500F +1 412 829 1692E [email protected]

BRUSH AftermarketP.O. Box 111209, Abu Dhabi,

United Arab EmiratesT + 971 4362 6391F + 971 2550 1920E [email protected]

BRUSH AftermarketLot 7 Jalan Majustret U1/26,Hicom Glenmarie Ind. Park,40150 Shah Alam,Selangor DE, Malaysia

T + 60 3 7805 3736F + 60 3 7803 9625E [email protected]

BRUSH AftermarketNottingham Road,Loughborough, Leicestershire,LE11 1EX, United Kingdom

T + 44 (0) 1509 611511F + 44 (0) 1509 612436E [email protected]

BRUSH AftermarketP.O. Box 3007, 2980 DA,

Ridderkerk, The NetherlandsT + 31 (0) 180 445500F + 31 (0) 180 445445E [email protected]

BRUSH AftermarketTr. Edvarda Benee 39/564,301 00 Plzen,Czech Republic

T + 420 37 8210717F + 420 37 8210337E [email protected]

601 Braddock Ave.Turtle Creek, PA.15145, USA

Documents

Exciter Center of Excelle 1