Handbook of Large Hydro Generators. Geoff Klempner
found in a typical generator and its associated auxiliary systems. Described therein are the functions that the components perform, as well as all relevant design and operational constrains. Some additional insight into design methods and calculations are also provided.
Chapter 4 (Operation and Control) introduces the layperson to the many operational variables that describe a generator. Most generator–grid interaction issues and their effect on machine components and operation are covered in great detail.
Chapter 5 (Monitoring and Diagnostics) and Chapter 6 (Generator Protection) serve to introduce all aspects related to the online and offline monitoring and protection of a large hydro generator. Although not intended to serve as a guideline for designing and setting up the protection systems of a generator, they provide a wealth of background information and pointers to additional literature.
Chapters 7 (Inspection Practices and Methodology), leads off the second part of the book with a look at preparing for a hands‐on inspection of large hydro generators. The chapter discusses the issues of concern for both safety of personnel and the equipment as well as the types of tools and approaches used in inspecting large hydro generators. This chapter also contains a collection of inspection forms that can be used for inspecting large hydro generators. These forms are very useful and can be readily adapted to any machine and plant.
Chapter 8 (Stator Inspection), Chapter 9 (Rotor Inspection), and Chapter 10 (Auxilliaries Inspection) constitute the core of this book. They describe all components presented in Chapters 2 and 3, but within the context of their behavior under real operational constraints, modes of failure, and typical troubleshooting activities. These chapters provide detailed information on what to look for, and how to recognize problems in the machine during inspection. Chapters 8 and 9 also contain hundreds of pictures to assist in the inspection process in a methodical step‐by‐step crawl through of the machine.
Chapter 11 (Maintenance and Testing) contains a comprehensive summary of the many techniques used to test the many components and systems comprising a generator. The purpose of the descriptions is not to serve as a guide to performing the tests as there are well established guides and standards for this purpose. Rather, they are intended to illustrate the palette of possible tests to choose from. Provided as well is a succinct explanation of the character of each test and explanations of how they are carried out.
Chapter 12 (Maintenance Philosophies, Upgrades and Uprates) is included to provide some perspective to the reader on the many choices and approaches that can be taken in generator and auxiliary systems maintenance, as well as upgrading equipment and uprating of the machine. Often, there are difficult decisions on how far to take maintenance. In some cases, only basic maintenance may be required, and on other occasions, it may be appropriate to carry out extensive rehabilitation of existing equipment or even replacement of components that can yield a higher efficiency or higher rating for the machine. This chapter discusses some of the issues that need to be considered when deciding on what, how much, and where to do it.
We hope that this book will be not only useful to the operator in the power plant but also to the design engineer and the generator operations engineer. We have provided a wealth of information obtained in the field about the behavior of such machines, including typical problems and conditions of operation. The book should also be useful to the student of electrical rotating machines as a complementary reference to the books on machine theory. When read in its entirety, this book will assist the user in performing a complete machine inspection and understand with reasonable clarity, what they are observing, if there is a problem, and how to go about finding a solution to fix it.
Although we have tried our best to cover each topic as comprehensively as possible, the book should not be seen as a guide to troubleshooting. In each case in which a real problem is approached, a whole number of very specific issues only relevant to that very unique machine come into play. These can never be anticipated or known and thus described in a book. Thus, we recommend the use of this book as a general reference source, but that the reader should always obtain adequate on‐the‐spot expertise when approaching a particular problem.
Glenn MottersheadStefano BombenIsidor KerszenbaumGeoff KlempnerOakville, Ontario, CanadaMississauga, Ontario, CanadaToronto, Ontario, CanadaIrvine, California
About the Authors
Mr. Mottershead has worked or consulted on rotating apparatus for over 45 years with 33 of these years as an engineer at Westinghouse, where he was mentored by a select group of electrical and mechanical generator design and manufacturing engineers. These mentors had lineage that reached back to Nikola Tesla, George Westinghouse, and other key pioneers of the early power generation industry. His objective in writing this book with the other expert authors is to pass on lessons he was fortunate to receive to those working at all levels of hydro power generation. Mr. Mottershead is an IEEE Life Member and a Principle Consultant at HDR.
Mr. Bomben is a Sr. Engineer at Ontario Power Generation (formerly Ontario Hydro) with over 29 years of experience inspecting large hydro generators, providing oversight on rewinds, overhauls, new machines, failure investigations, repairs and testing, and writing technical specifications. He is a senior member of the IEEE with many contributions to the development of generator operation, maintenance, and insulation standards. The inspiration for this book was to produce a comprehensive written knowledge base for use by any power engineer interested in large hydro generators, informed by theory, operational history and physical inspection.
Mr. Klempner is an IEEE Fellow and large rotating electrical machines specialist in the power industry for over 43 years. He provides electrical machine technical services on a global basis, regarding large generators and motors. This includes inspection, testing, design evaluation, failure analysis, life assessment, preparation of technical specifications, and test procedures. Previously, he worked with Ontario Hydro (now Ontario Power Generation) for over 25 years, and then NSS (Nuclear Safety Solutions) and Kinectrics Inc. He has authored or coauthored 65 papers and articles, and 4 textbooks. He also has an extensive background of professional activities, with IEEE, EPRI, and CIGRE.
Dr. Kerszenbaum has been involved in design, manufacturing, maintenance, and operation of large electrical machines for about 40 years. He also has been a contributor in writing IEEE standards for this type of equipment. He authored and coauthored several books on the subject, and educated hundreds of engineers over the years.
Acknowledgments
The contents of this book are in part the result of personal experience accumulated over years of working with large hydro generators. It is also the result of the important long‐term contribution of coworkers and associates. Each author was motivated by an important individual at an early stage of his career, and by many outstanding individuals in the profession over subsequent years. Two engineers, Frank Barnard and John F. Lyles, need to be recognized here as they had significant hydro generator mentoring roles for Mottershead and Bomben, respectively. Coauthors Geoff Klempner and Izzy Kerszenbaum are also important mentors as they pioneered the writing of the book Operation and Maintenance of