SERVICES
We specialise in the service, overhaul and repair of Brush TurboGenerators
We provide repair, rewind, refurbishment and retrofitting of rotating electrical machines.
Our engineers have formerly trained and worked at Brush Electrical Machines Ltd in Loughborough (UK), starting with engineering apprenticeships and growing in the company all the way to becoming Senior Winding Engineers, acquiring a knowledge that is second to none on these machines. We now can put this wealth of experience to the benefit of our customers.
We strive to establish strong relationships with our customers, supporting them with a flexible, tailored and personal approach that global companies are unlikely to offer. Whether as part of a maintenance programme designed to increase failure prediction and maximise plant availability, or as a single service working in partnership with your on-site maintenance team, Gusto can provide:
Minor inspections for motors and generators
Major inspections for motors and generators
Overhaul and refurbishment work
Spare Parts and Kits
generators
Brush generators
More specifically we focus on Brush 2-pole Generators, and have extensive experience with BDAX7-146, BDAX7-290, BDAX72-340, and BDAX8s.
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Our engineers have formerly trained and worked at Brush Electrical Machines Ltd in Loughborough (UK), starting with engineering apprenticeships and growing in the company all the way to becoming Senior Winding Engineers, acquiring a knowledge that is second to none on these machines. We now can put this wealth of experience to the benefit of our customers.
Generator SERVICES
From minor inspections to full rewinds
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Overhauls & Full Rewinds
Full range of Testing
Non-Destructive Testing
Commissioning
Condition
Monitoring
Training
Diagnosis Consultants
Generator Parts
Recommended Spares, Kits and Consumables
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Extraction Equipment
Service Kits
Winding Kits
RTD's
Seals
Gaskets
F-class Coils
Coils for Hydro Generators
SERVICES FOR STATORS:
Inspection, refurbishment and repair.
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Full or partial rewinds
Winding Contamination
Loose Wedges
Slot and Slot exit Corona Damage
Interface Corona Damage
Overhang Phase coil-to-coil Corona Damage
Overhang Phase coil-to-phase-coil Gapping
Full range of Testing
SERVICES FOR ROTORS AND EXCITERS
Inspection, diagnosis, refurbishment & repairs
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Boroscope Inspection
Winding Contamination
Winding Repairs
Full range of Testing
OUR RANGE OF MECHANICAL SERVICES INCLUDES:
Dismantling, Rebuilds, Rotor Pulls and Re-assembly
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Rotor removal
Retaining ring removal
Bearing Inspections and change out
Cooler Inspections and testing
Di-penetrant checks on Retaining rings and Cooling fans
Full range of testing
Models we support
We are experts on BDAX 2-pole generators and have experience with HMA 4 pole machines
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B.DAX 6 Series
B.DAX 7 Series
B.DAX 72 Series
B.DAX 75 Series
B.DAX 8 Series
B.DAX 9 Series
Brush BDAX 62-170 ER
BDAX 70-66P
BDAX 70-76P
BDAX 70-76PH
BDAX 70-84P
BDAX 70-92PH
BDAX 7-145
Brush BDAX 7-146
Brush BDAX 7-167
BDAX 7-193PBDAX 7-225PH
BDAX 7-265PH
BDAX 7-275PH
Brush BDAX 7-290ERJT (LM6000)
Brush BDAX 7-290ERH (LM5000)
Brush BDAX 7-340PH
Brush BDAX 7-365ER (71-EA)
BDAX 75-250PH
BDAX 75-275PH
BDAX 75-290E
BDAX 75-305PH
BDAX 75-84PH
BDAX 75-92PH
BDAX7-84PH
BDAX 7A-167E
BDAX 8-280
BDAX 8-300E
BDAX 8-355E
BDAX 8-400E
BDAX 82-445 ERH
BDAX 9-450EH
Test services
Key Tests
We can offer some of the most comprehensive testing in the industry.
STATOR | ROTOR | EXCITER +
Insulation Resistance (IR) & Polarisation Index (PI)
Winding resistance
Electromagnetic Core Imperfection Detection (ELCID)
Power Factor (Doble)
Tan delta loss factor measurement
RSO (Recurrent Surge Oscilloscope)
Corona Probe Test (Note: Requires local power source)
High Voltage Testing (DC)
Partial discharge analysis
Wedge tightness assessment
Winding Pole Balance (Shorted turns Test)
Winding Impedance
Field Poles and Permanent Magnet Generator (PMG)
COMPLEMENTARY TESTS +
Boroscope Inspection
Wedge Tightness
Doppler flow
Rotor shaft voltage monitoring
Winding vibration and temperature monitoring
Rotor pressure
Pressure and vacuum tests
VLF measurement
Hydrogen leakage
RTD checks
Neutral Earthing Transformer including Ratio checks
Neutral Earthing Resistor
Anti-condensation Heater checks
Diode and Fuse checks
Air intake RTDs
Air Outlet RTDs
Bearing Oil RTDs
Bearing Metal RTDs
Oil Seal Air Pressure readings
INSTRUMENTS
Comprehensive Testing for Turbogenerators
CORONA PROBE TEST +
For this type of test we use IRIS Power equipment. The generator windings need to be energised to do this test. This can be done using a Doble set, but in cases where resources are limited, we have also designed a safe procedure using a step up transformer.
ON LINE/OFF LINE PARTIAL DISCHARGE: IRIS TGA +
On Line test normally involves permanently installed coupling capacitors. Data is collected while the machine is operating at load and data is sent to IRIS Power for analysis. The IRIS TGA instrument is required to collect the information. We have installed several coupling capacitor installations and own the signal generator required to commission these installations. Off Line involves temporary installation of one or two coupling capacitors, powering the windings, usually with a Doble set, and downloading the data to be analysed by IRIS Power. A TGA set is required to capture the data.
INSTRUMENTS
IRIS trained testing engineers
ELCID: IRIS ELCID Evolution +
We have an Evolution test set for performing this test and all our field personal have considerable experience with it.
STATOR WEDGE TIGHTNESS: IRIS Stator Wedge Analyzer: +
We complement this automated test with manual tap tests as per Brush OEM standard practise.
INSTRUMENTS
POWER FACTOR - TIP UP/ TAN-DELTA: Double M4000 +
We have this instrument along with the resonator required to energise windings of larger machines to the desired voltage.
HIGH POT: Megger 220072- 120 kV DC +
We rarely use DC overpotential testing. DC overpotential testing can be a destructive test and Brush state in their owners manual that they do not recommend it for routine testing. At our customer’s request would normally carry out an overpotential test on a Brush machine following major stator repairs or rewinds, however we still caution our customers on the hazards. The procedure is more accepted on US machines such as GE or E-M.
INSTRUMENTS
BLACK OUT TEST +
This is the most basic electrical test for electrical generators. It involves energising the windings, turn out the lights and look at where discharge creates visible light. Winding must be energised to line voltage, ideally using a Doble set. However, the use of a step up transformer as shown is possible.
THERMOGRAPHIC CAMERAS +
Useful for detecting hot spots. We have mid to high range models.
VIDEOSCOPE | BOROSCOPE +
Borescopes are used often during generator and rotor inspections. We have our own videoscope and have done hundreds of borescope inspections.
repairs
Partial rewind
With a failure to one of the bottom half coils, approximately 40% of the top half coils had to be removed to give access to the faulty coil. With a new bottom half coil inserted the top 40% were re-instated.
Stator Full rewind
A complete rewind was carried out on this 20MW stator in the USA after a major failure due to corona discharge damage within the slot section of the generator. We can provide ‘F’ class coils up to a slot length 3.04 metres in length, and also supply coils for most hydro generators.
Stator End Repairs
The pictures show examples of some of the work undertaken.
Other repairs
Repairs to dolls eyes
Robotic Inspections
GUSTO XRIS GII FOR GAPS 17MM AND UP
Complete Visual, ELCID and Wedge Test
Types of tests +
ELCID - Low Flux Leakage Test
Wedge Tightness Test: Equipped with a stator wedge tap tester that determines wedge tightness based on the spectral analysis of the sound response
Visual Inspection with 4 cameras: one for inspection of the stator teeth and wedges, one for the rotor body and cooling slots and two cameras for inspecting the stator cooling slots.
GUSTO VRIS for gaps 10mm and up
Ultra-thin robot providing comprehensive visual Inspection
Types of tests +
Visual Inspection with 5 LED-powered high resolution cameras: three at the front, one at the bottom and one at the rear. Focal length and angles can be optimised for inspecting stator teeth, cooling slots/air ducts, windings, wedges, stator laminations, rotor upper coil “V” blocks, contamination, coils stress, semi conductive tapes and any evidence of corona discharge.
Magnetic grip ensures the robot can be run either on the stator or the rotor.
The Robot is run in conjunction with a Test Package that includes:
Polarization Depolarization Current Analysis
Tan Delta and Capacitance Analysis
Non-Linear Insulation Behavior Analysis
Partial Discharge Analysis
Stator Winding Resistance measurement
Wedges are not physically tapped, but a measure of their tightness is achieved through harmonics.
remote support
The guidance you need fast
Changing fuses and diodes +
Full walk through carefully explaining how to dismantle and refit ensuring good electrical contact and safety procedures
Troubleshooting the AVR +
Live video indicating all the points and areas to assess augmented with real time hand overlays for better and more efficient communication.
Inspecting the Exciter +
No problem, we’ll walk with you through every stage, every safeguard and every check that needs to be done.
Running Tests +
We can help you run the necessary tests ensuring the safety of your personnel, the equipment and the generator windings. Hand gestures or tool manipulation overlays can be extremely helpful to make sure things are done correctly, avoiding costly mistakes.
GET TO KNOW US
Get in touch with us today to find out how we can help.