One Call One Source Powerful Solutionss/MDA_GeneratorServices_Brochure1.pdfand temperature control to assure the quality of environmentally sensitive materials. MD&A maintains flush

Generator Services Capabilities

The Turbine-GeneratorEngineering & Outage Services Company

Mechanical Dynamics & Analysis, Ltd.19 British American Blvd.

Latham, NY 12110Tel: (518) 399-3616Fax: (518) 399-3929

www.MDAturbines.com

One Call One Source

Powerful Solutions

CORPORATE OFFICES518-399-3616

High Voltage Bushing Repair

Installation of GE style hydrogen-cooled bushing.

New small GE style hydrogen-cooled bushing.

Large porcelain and composite GE style 6” hydrogen-cooled bushings.

Large Westinghouse refurbished porcelain, hydrogen-cooled bushings.

HIGH VOLTAGE BUSHINGS:• New and rebuilt bushings

• Porcelain and composite

• Complete reverse engineering

• Patented flange seal design

• Variety of OEMs and styles

• Finished inventory available

HIGH VOLTAGE BUSHING AUXILAIRIES:

New Bushings• New porcelain or composite

• Electrical and pressure tested

Rebuilt Bushings• Evaluation and cleaning

• Inspection of all components

• Replacements of seals, flanges and insulating materials

• Reused porcelain or composite


For more information on MD&A’s products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com


Turbine-Generator Repair Facility

MD&A’s state of the art turbine-generator repair facility is centrally located just outside of the St. Louis, Missouri city limits. Renovation of the facility was completed in 2006 and includes 80 ton overhead crane capacity. The 100,000 square foot facility houses both portable and stationary equipment for machining, repair and overhaul of turbine-generator components. The building was designated to accommodate the rapid growth of our Repairs Division and has allowed us to consolidate several of our regional shops into one centrally located facility.

An abbreviated list of the generator-related capabilities and equipment located in this facility includes:

• A clean room with temperature and humidity control for in-shop stator and field rewinds

• An industrial paint booth for refurbishment of miscellaneous equipment

• Seven portable Conex trailers stocked with all tools necessary for on-site field and stator rewinds and repairs

• A fully stocked refrigeration unit for temperature-sensitive epoxies, tapes and other materials

• A dedicated department for refurbishment and manufacture of new air-cooled, hydrogen-cooled and water-cooled high voltagebushings

• Patented Hydraulic Integrity Test (HIT) skids for testing of large liquid-cooled stators

• All equipment necessary to perform full electrical testing, including 60 cycle resonance tuned AC Hi Pot test set

• Digital EL-CID testing equipment for core iron evaluation

• Flush and bake skid for partial and full rewinds

Inventories of epoxies, resins and replacement parts are kept in stock for immediate use in shop repairs or for on-site projects.

Our turbine-generator repair facility, located near St. Louis, Missouri is equipped to address all your field machining needs.

Our facility contains a clean room with humidity and temperature control to assure the quality of environmentally sensitive materials.

MD&A maintains flush and bake skids in our St. Louis facility that enable us to reduce the overall bake cycle time needed to cure new stator rewinds.

TURNKEY REMOVAL AND INSTALLATION:• Clam shells, isophase bus duct, CT’s

• Flex leads and shunts

• Neutral and line boxes

• Stand-off insulators

Flex Leads• Resurface

• Silver plate

Stand-off Insulators• Inventory of new insulators

Circuit Breakers• Refurbish

Silver Plating• Shunts, Flex leads, Bushings, Connections

Generator Field Services

MD&A has the necessary equipment, materials and trained crews to provide exceptional domestic and international service on generating fields ranging from less than 1 MW to 1300 MW. Our staff of winders and technicians are experienced in successfully meeting the demands of conducting genera-tor field rewinds anywhere in the world. Our focus on quality assurance procedures and electrical testing has enabled MD&A to enjoy the reputation of one of the industry’s most accom-plished providers of technical knowhow in the industry. Our technical breadth is complimented by design and engineering resources from Hitachi Power Systems. MD&A’s consulting engineers provide clients with the perspective gained from many years of working for various OEMs in the are areas of service, design and manufacturing. It is this expertise that allows us to confidently provide clients with technical insight on nearly all makes and models of machines.

MD&A’s generator field services offerings include:

• Complete and partial field rewinds

• Technical direction or turnkey management of disassembly andassembly

• Retaining ring change outs using state-of-the-art induction heating

• Supply of retaining ring forgings and machining

• Field coil repairs to address elongation, foreshortening and top turn isolation

• Main lead manufacturing and replacements

• Copper dust inspections

• Bore copper inspection, repairs and replacement

• NDE of body wedges, forging and rings using magnetic particle and dye penetrant

• Main lead stud and collector stud hydrogen seal inspection and replacements

• Collector ring inspection, replacements and machining

• Balancing of fields

• Manufacture of coil-to-coil and pole-to-pole jumpers

• Removal, inspection, cleaning and replacement of copper turns

• Painting of forgings and spray application of tagging compounds

• Complete testing services including AC Hi Potential testing

• Resistance brazing equipmentClean coil layers are brazed together to prevent the recurrence of problems associated with copper-dusting.

On-site and in-shop testing & rewinds are conducted on fields in accordance with quality control procedures and upgrade specifications.

Hundreds of successful rewinds have provided MD&A with the broad range of experience necessary to address any unique or unexpected challenges.

Our clean room was designed to accommodate even the largest generator fields and is supplied with all the necessary tools and equipment to conduct a complete rewind.



Testing & Inspection Services

MD&A performs electrical tests and visual inspections on both rotating and stationary generator components. The goal of our Generator Specialists is to provide data from a series of appli-cable tests that collectively help owners make intelligent decisions about the necessity of repairs. Test series vary according to each customer’s defined work-scope. Our specialists use state-of-the-art equipment and computer generated report templates. Histori-cal data is used in every possible case to trend current test results with those of past outages. Specific test procedures are followed in accordance with OEM recommendations and published mainte-nance and technical letters.

An abbreviated list of the tests and inspections that are performed by our engineers includes:

• 60 Cycle resonance tuned AC Hi Pot testing

• DC Hi Potential testing

• AC impedance tests

• Hydraulic Integrity Testing (HIT skid tests)

• Digital EL-CID testing

• Partial discharge testing

• Borescopic inspections and complete visual inspections

• Pole balance testing of fields

• DC leakage testing

• Wedge surveys and mapping

• Resistance & insulation testing of RTDs

• 120 Hz vibration testing / bump testing

• Helium tracer gas testing (for water cooled stators)

• Flux probe sales and installation, testing and data analysis

• Capacitance mapping (for water cooled stators)

• Complete TIL-1098 testing of water-cooled windings

• Retaining ring inspections & replacement with 18MN-18CRnon-magnetic retaining rings as necessary

• Complete TIL-1292 inspections

• Inspection of brushes and brush rigging

• Diode cleaning and refurbishment

• Collector ring and main lead condition assessment

• Building & thru bolt breakaway torque checks

• Transposition testing of copper bar strands Complete sets of portable test equipment are available for immediate dispatch to any power plant in the world.

MD&A provides patented Hydraulic Integrity Test skids to identify leaks in liquid-cooled stator windings.

Digital EL-CID equipment is used to evaluate stator core iron condition before and after each project as well as during routine inspections.

Stator & field visual inspections are conducted by our Generator Specialists to identify non-electrical areas of concern.

Patent Number 5,287,726

The MD&A Two-Piece Clip

Leaks in the cast water box components and braze joints on inner water-cooled stator bar connections can eventually cause irrepa-rable damage to the bar insulation system. Wet bars may lead to an unexpected and catastrophic failure of the winding. Early leak detection and corrective action can significantly prolong the life of water-cooled windings and can potentially avert an unplanned outage.

The patented MD&A two-piece clip, by design, addresses all known leakage and porosity issues with General Electric’s water-cooled stator bars as stated in Technical Information Letter 1098 (TIL-1098).

Depending on the number and location of leaks, it may be more economical to remove the field prior to installing two-piece clips. However, in many cases the two-piece clip can be installed with the generator field still in place. With thousands of successful installations, the two-piece clip has proven itself to be a reliable, effective and economically flexible option for repairing leaking bars and as a key component in successful stator winding life extension programs.

The Patented MD&A Two-Piece Clip Offers Inner Water-Cooled Generator Owners The Following Benefits:

• The two-piece clip eliminates cast components and therefore also elimi-nates any remaining concerns associated with future porosity issues

• MD&A’s two-piece clip has no window box and therefore eliminates any associated window braze issues

• The two-piece clip corrects, by design, any clip-to-strand-braze leak concerns

• The two-piece clip also corrects the strand-to-strand braze leak issues associated with the OEM strand package braze

• The MD&A two-piece clip allows for crevice-free brazes that virtually eliminate the possibility of any post-repair crevice corrosion issues

No re-flow of previous braze joints is required when using the clip. In-process / multiple pressure tests are conducted to assure integrity and quality.

For clients conducting a full stator rewind, the MD&A two-piece clip is factory-installed on all new inner liquid-cooled bars that we install.

Installation can be tailored to accommodate specific needs and applied as a retrofit item or the two-piece clip can be installed as a global replacement on all bars in the machine.

The MD&A two-piece clip is a permanent fix that has been proven to be reliable over the course of thousands of installations on a multitude of machines.

Generator Stator Services

MD&A provides turnkey services for water-cooled, hydrogen-cooled, and conventionally-cooled generators of all sizes and makes by most manufacturers. We have developed an extensive list of satisfied customers in the US, South Africa, Australia, Canada and Asia with many projects involving unique engineering achievements and challenges. MD&A is one of the few organizations in the United States capable of providing complete turnkey liquid-cooled stator rewinds on a short-cycle basis. Our ability to provide new liquid-cooled bars, global clip replacements and comprehen-sive testing along with technical direction and experienced project managers has helped to make us one of the fastest growing and most reputable turbine-generator engineering service organizations in the world.

An abbreviated list of our stator services includes:

• Full and partial stator rewinds including liquid-cooled units

• Project management and technical direction

• Stator water leak investigation & repairs

• Stator bar insulation repairs and evaluations

• Comprehensive TIL-1098 testing

• 60 Cycle Resonance tuned AC Hi Pot Test set

• Replacement and repair of core iron

• Stator core tightening for many manufacturers with core loop testing

• End winding support system repairs, redesign and installation

• Global and partial clip replacement using patented two-piece clips

• Full & partial stator re-wedging and wedge system upgrades with Top Ripple Springs

• Engineering redesign and power uprating analysis

• High voltage bushing refurbishment and installation

• Application of “tagging compounds” for core monitoring systems

• Installation of flux probes and stator slot couplers

• Installation of new RTDs and TCs

• Turnkey disassembly and assembly services

Thorough electrical testing is conducted following each rewind to insure the integrity of the repair before the unit goes back on line.

Large liquid-cooled generators can be completely rewound, including the provision of 540 degree Robel-wound copper strands and NECOBOND bar armor.

The installation of MD&A’s patented 2-piece clips on new stator bars eliminates porosity leaks associated with OEM’s original design.

The installation of upgraded ripple springs and wedges reduces vibration that can chafe new bars and lead to failure.

Patent Number RE40585



The MD&A Two-Piece Clip

Leaks in the cast water box components and braze joints on inner water-cooled stator bar connections can eventually cause irrepa-rable damage to the bar insulation system. Wet bars may lead to an unexpected and catastrophic failure of the winding. Early leak detection and corrective action can significantly prolong the life of water-cooled windings and can potentially avert an unplanned outage.

The patented MD&A two-piece clip, by design, addresses all known leakage and porosity issues with General Electric’s water-cooled stator bars as stated in Technical Information Letter 1098 (TIL-1098).

Depending on the number and location of leaks, it may be more economical to remove the field prior to installing two-piece clips. However, in many cases the two-piece clip can be installed with the generator field still in place. With thousands of successful installations, the two-piece clip has proven itself to be a reliable, effective and economically flexible option for repairing leaking bars and as a key component in successful stator winding life extension programs.

The Patented MD&A Two-Piece Clip Offers Inner Water-Cooled Generator Owners The Following Benefits:

• The two-piece clip eliminates cast components and therefore also elimi-nates any remaining concerns associated with future porosity issues

• MD&A’s two-piece clip has no window box and therefore eliminates any associated window braze issues

• The two-piece clip corrects, by design, any clip-to-strand-braze leak concerns

• The two-piece clip also corrects the strand-to-strand braze leak issues associated with the OEM strand package braze

• The MD&A two-piece clip allows for crevice-free brazes that virtually eliminate the possibility of any post-repair crevice corrosion issues

No re-flow of previous braze joints is required when using the clip. In-process / multiple pressure tests are conducted to assure integrity and quality.

For clients conducting a full stator rewind, the MD&A two-piece clip is factory-installed on all new inner liquid-cooled bars that we install.

Installation can be tailored to accommodate specific needs and applied as a retrofit item or the two-piece clip can be installed as a global replacement on all bars in the machine.

The MD&A two-piece clip is a permanent fix that has been proven to be reliable over the course of thousands of installations on a multitude of machines.

Generator Stator Services

MD&A provides turnkey services for water-cooled, hydrogen-cooled, and conventionally-cooled generators of all sizes and makes by most manufacturers. We have developed an extensive list of satisfied customers in the US, South Africa, Australia, Canada and Asia with many projects involving unique engineering achievements and challenges. MD&A is one of the few organizations in the United States capable of providing complete turnkey liquid-cooled stator rewinds on a short-cycle basis. Our ability to provide new liquid-cooled bars, global clip replacements and comprehen-sive testing along with technical direction and experienced project managers has helped to make us one of the fastest growing and most reputable turbine-generator engineering service organizations in the world.

An abbreviated list of our stator services includes:

• Full and partial stator rewinds including liquid-cooled units

• Project management and technical direction

• Stator water leak investigation & repairs

• Stator bar insulation repairs and evaluations

• Comprehensive TIL-1098 testing

• 60 Cycle Resonance tuned AC Hi Pot Test set

• Replacement and repair of core iron

• Stator core tightening for many manufacturers with core loop testing

• End winding support system repairs, redesign and installation

• Global and partial clip replacement using patented two-piece clips

• Full & partial stator re-wedging and wedge system upgrades with Top Ripple Springs

• Engineering redesign and power uprating analysis

• High voltage bushing refurbishment and installation

• Application of “tagging compounds” for core monitoring systems

• Installation of flux probes and stator slot couplers

• Installation of new RTDs and TCs

• Turnkey disassembly and assembly services

Thorough electrical testing is conducted following each rewind to insure the integrity of the repair before the unit goes back on line.

Large liquid-cooled generators can be completely rewound, including the provision of 540 degree Robel-wound copper strands and NECOBOND bar armor.

The installation of MD&A’s patented 2-piece clips on new stator bars eliminates porosity leaks associated with OEM’s original design.

The installation of upgraded ripple springs and wedges reduces vibration that can chafe new bars and lead to failure.




Generator Field Services

MD&A has the necessary equipment, materials and trained crews to provide exceptional domestic and international service on generating fields ranging from less than 1 MW to 1300 MW. Our staff of winders and technicians are experienced in successfully meeting the demands of conducting genera-tor field rewinds anywhere in the world. Our focus on quality assurance procedures and electrical testing has enabled MD&A to enjoy the reputation of one of the industry’s most accom-plished providers of technical knowhow in the industry. Our technical breadth is complimented by design and engineering resources from Hitachi Power Systems. MD&A’s consulting engineers provide clients with the perspective gained from many years of working for various OEMs in the are areas of service, design and manufacturing. It is this expertise that allows us to confidently provide clients with technical insight on nearly all makes and models of machines.

MD&A’s generator field services offerings include:

• Complete and partial field rewinds

• Technical direction or turnkey management of disassembly andassembly

• Retaining ring change outs using state-of-the-art induction heating

• Supply of retaining ring forgings and machining

• Field coil repairs to address elongation, foreshortening and top turn isolation

• Main lead manufacturing and replacements

• Copper dust inspections

• Bore copper inspection, repairs and replacement

• NDE of body wedges, forging and rings using magnetic particle and dye penetrant

• Main lead stud and collector stud hydrogen seal inspection and replacements

• Collector ring inspection, replacements and machining

• Balancing of fields

• Manufacture of coil-to-coil and pole-to-pole jumpers

• Removal, inspection, cleaning and replacement of copper turns

• Painting of forgings and spray application of tagging compounds

• Complete testing services including AC Hi Potential testing

• Resistance brazing equipmentClean coil layers are brazed together to prevent the recurrence of problems associated with copper-dusting.

On-site and in-shop testing & rewinds are conducted on fields in accordance with quality control procedures and upgrade specifications.

Hundreds of successful rewinds have provided MD&A with the broad range of experience necessary to address any unique or unexpected challenges.

Our clean room was designed to accommodate even the largest generator fields and is supplied with all the necessary tools and equipment to conduct a complete rewind.



Testing & Inspection Services

MD&A performs electrical tests and visual inspections on both rotating and stationary generator components. The goal of our Generator Specialists is to provide data from a series of appli-cable tests that collectively help owners make intelligent decisions about the necessity of repairs. Test series vary according to each customer’s defined work-scope. Our specialists use state-of-the-art equipment and computer generated report templates. Histori-cal data is used in every possible case to trend current test results with those of past outages. Specific test procedures are followed in accordance with OEM recommendations and published mainte-nance and technical letters.

An abbreviated list of the tests and inspections that are performed by our engineers includes:

• 60 Cycle resonance tuned AC Hi Pot testing

• DC Hi Potential testing

• AC impedance tests

• Hydraulic Integrity Testing (HIT skid tests)

• Digital EL-CID testing

• Partial discharge testing

• Borescopic inspections and complete visual inspections

• Pole balance testing of fields

• DC leakage testing

• Wedge surveys and mapping

• Resistance & insulation testing of RTDs

• 120 Hz vibration testing / bump testing

• Helium tracer gas testing (for water cooled stators)

• Flux probe sales and installation, testing and data analysis

• Capacitance mapping (for water cooled stators)

• Complete TIL-1098 testing of water-cooled windings

• Retaining ring inspections & replacement with 18MN-18CRnon-magnetic retaining rings as necessary

• Complete TIL-1292 inspections

• Inspection of brushes and brush rigging

• Diode cleaning and refurbishment

• Collector ring and main lead condition assessment

• Building & thru bolt breakaway torque checks

• Transposition testing of copper bar strands Complete sets of portable test equipment are available for immediate dispatch to any power plant in the world.

MD&A provides patented Hydraulic Integrity Test skids to identify leaks in liquid-cooled stator windings.

Digital EL-CID equipment is used to evaluate stator core iron condition before and after each project as well as during routine inspections.

Stator & field visual inspections are conducted by our Generator Specialists to identify non-electrical areas of concern.


High Voltage Bushing Repair

Installation of GE style hydrogen-cooled bushing.

New small GE style hydrogen-cooled bushing.

Large porcelain and composite GE style 6” hydrogen-cooled bushings.

Large Westinghouse refurbished porcelain, hydrogen-cooled bushings.

HIGH VOLTAGE BUSHINGS:• New and rebuilt bushings

• Porcelain and composite

• Complete reverse engineering

• Patented flange seal design

• Variety of OEMs and styles

• Finished inventory available

HIGH VOLTAGE BUSHING AUXILAIRIES:

New Bushings• New porcelain or composite


Rebuilt Bushings• Evaluation and cleaning

• Inspection of all components

• Replacements of seals, flanges and insulating materials

• Reused porcelain or composite




Turbine-Generator Repair Facility

MD&A’s state of the art turbine-generator repair facility is centrally located just outside of the St. Louis, Missouri city limits. Renovation of the facility was completed in 2006 and includes 80 ton overhead crane capacity. The 100,000 square foot facility houses both portable and stationary equipment for machining, repair and overhaul of turbine-generator components. The building was designated to accommodate the rapid growth of our Repairs Division and has allowed us to consolidate several of our regional shops into one centrally located facility.

An abbreviated list of the generator-related capabilities and equipment located in this facility includes:

• A clean room with temperature and humidity control for in-shop stator and field rewinds

• An industrial paint booth for refurbishment of miscellaneous equipment

• Seven portable Conex trailers stocked with all tools necessary for on-site field and stator rewinds and repairs

• A fully stocked refrigeration unit for temperature-sensitive epoxies, tapes and other materials

• A dedicated department for refurbishment and manufacture of new air-cooled, hydrogen-cooled and water-cooled high voltagebushings

• Patented Hydraulic Integrity Test (HIT) skids for testing of large liquid-cooled stators

• All equipment necessary to perform full electrical testing, including 60 cycle resonance tuned AC Hi Pot test set

• Digital EL-CID testing equipment for core iron evaluation

• Flush and bake skid for partial and full rewinds

Inventories of epoxies, resins and replacement parts are kept in stock for immediate use in shop repairs or for on-site projects.

Our turbine-generator repair facility, located near St. Louis, Missouri is equipped to address all your field machining needs.

Our facility contains a clean room with humidity and temperature control to assure the quality of environmentally sensitive materials.

MD&A maintains flush and bake skids in our St. Louis facility that enable us to reduce the overall bake cycle time needed to cure new stator rewinds.

TURNKEY REMOVAL AND INSTALLATION:• Clam shells, isophase bus duct, CT’s

• Flex leads and shunts

• Neutral and line boxes

• Stand-off insulators

Flex Leads• Resurface

• Silver plate

Stand-off Insulators• Inventory of new insulators

Circuit Breakers• Refurbish

Silver Plating• Shunts, Flex leads, Bushings, Connections

Generator Services Capabilities

The Turbine-GeneratorEngineering & Outage Services Company

Mechanical Dynamics & Analysis, Ltd.19 British American Blvd.

Latham, NY 12110Tel: (518) 399-3616Fax: (518) 399-3929

www.MDAturbines.com

One Call One Source

Powerful Solutions

CORPORATE OFFICES518-399-3616

Documents

One Call One Source Powerful Solutionss/MDA_GeneratorServices_Brochure1.pdfand temperature control to assure the quality of environmentally sensitive materials. MD&A maintains flush