Generator Stator End Windings PB2-22-0006-GN-EN-01
Risk of Property Damage
UNITS HAVE BEEN REPORTED TO HAVE EXPERIENCED FAULTS AND ARC FLASH EVENTS WHICH LED TO SIGNIFICANT ADDITIONAL DAMAGE TO THE GENERATOR, WHICH WERE ATTRIBUTED TO STATOR END WINDING LOCAL RESONANCE. OTHER UNITS HAVE BEEN OBSERVED WITH DUSTING OR OTHER INDICATIONS OF RELATIVE MOTION BETWEEN THE SERIES OR PHASE CONNECTIONS AND THE SUPPORT RINGS, WHICH IS INDICATIVE OF SUCH STATOR END WINDING LOCAL RESONANCE, AND WHICH CAN RESULT IN HIGH CYCLE FATIGUE OF THE WINDINGS’ COPPER STRANDS AND/OR INSULATION WEAR. THIS CAN RESULT IN OVERHEATING, ARCING, A STATOR FAULT, AND AN ARC FLASH EVENT.
FAILURE TO FOLLOW THE RECOMMENDATIONS, INSTRUCTIONS AND ADVICE SET
FORTH IN THIS PRODUCT WARNING MAY RESULT IN SERIOUS DAMAGE TO THE PRODUCTS REFERENCED, EQUIPMENT OR OTHER PROPERTY.
Supersedes: PB3-15-5053-GN-EN-01 Generator, End Windings, Inspection and Enhancements,
Certain SGen5-1000A Generators. Note: Your unit may not have received the aforementioned bulletin.
Technical Information equipment damage may occur can be predicted.
The insulation wear from relative motion can
The end winding structure on SGen5-1000A propagate until a ground or phase fault occurs. Generators are located at both ends of the stator When the copper strands experience fatigue and core. The end windings are located where the separate, higher current densities in the top and bottom coils are connected, as well as remaining strands may lead to overheating of where the phase coils attach to the parallel ring the insulation, arcing and eventually lead to assembly. Figure 1 shows the layout of a SGen5- ground or phase fault. Copper strand high cycle 1000A generator. fatigue and insulation wear can also result in an Generator end windings have local and global arc flash event which can lead to significant natural frequencies that if excited can result in additional damage to the generator. elevated vibration levels. These frequencies change with time and temperature. Siemens Energy has developed a series and phase blocking modification developed to add The global natural frequencies occur, stiffness locally to the series and phase when the entire basket is excited and connections. Refer to Figure 2 on page 3 for an moves as a single structure. illustration of the series and phase blocking The local natural frequencies occur when modification. individual components of the end Prior to the installation of this modification, an winding basket are excited. end winding assessment should be performed on both ends of the generator. This assessment includes:
A visual inspection of the end windings
including the bottom coil to parallel ring interface for signs of dusting.
An impact modal test of the end windings
to assess the current local frequencies.
A voltage drop or radiographic test1 on
Figure 1: Typical SGen5-1000A Generator each winding to evaluate the likelihood The series and phase coils are characterized by a that copper strand separation is present. cantilevered portion outboard of the bottom coil Additional recommendations including but not support ring. If an individual series connection limited to installing additional insulation on becomes excited, that single component may select series connections or performing vibrate. When the series and phase connections additional electrical testing may be made based are locally excited, relative motion between upon the end winding assessment. support ring and coils may occur. This can cause insulation wear and may subsequently lead to The access required to perform this work is high cycle fatigue in coil copper strands. The similar to a medium inspection, and generally progression of the fatigue is dependent upon a requires removal of the air seals, blower shroud number of factors and can vary between and blower blades. generators. Neither the progression of the fatigue or the time when potential resultant
The following actions should be performed at Siemens Energy currently offers an end winding the earliest opportunity, with the generator shut vibration monitoring product – GenAdvisor™ End down, de-energized, and following all required Winding Vibration Monitor. This product can be safety precautions: retrofitted into all generator models and operated as a stand-alone system or integrated Perform the end winding assessment described into the GenAdvisor™ online monitoring in the Technical Information section above. platform. Refer to the GenAdvisor™ On-Line Install the series and phase blocking Monitoring and Condition Assessment Product modification described above to the series and Bulletin for more details. If you have not received phase connections. Impact modal testing should a copy of this bulletin, your Siemens Energy be repeated after blocking is installed, to confirm representative can provide upon request. the shift in local natural frequencies. The recommendations in this Product Warning Additional recommendations may be made are based on the applicable units being operated based upon the end winding assessment. and maintained in accordance with Siemens Energy recommendations and/or the original It is recommended that this inspection and equipment manufacturer’s recommendations product change be implemented by Siemens and documentation. Energy authorized personnel only. Please contact your Siemens Energy representative for further information and/or if you have any question in relation to the contents of this Product Warning.
Figure 2: Illustration of Installed Series and Phase Blocking
This Product Warning is confidential to Siemens Energy. It is to be used solely by the user for the purpose for which it is furnished, which, as described, is to warn the user of a potential risk in respect of a Siemens Energy product, component or service that may require the user’s attention. Except to warn persons that may be in immediate risk of death or personal injury from this potential risk, this Product Warning may not be shown, transmitted, or disclosed to any third party in whole or in part without the prior written authorization of Siemens Energy. The user may disclose this Product Warning to a third party on a strictly confidential basis solely to the extent necessary to take any actions recommended in this Product Warning, provided that (a) the user advises Siemens Energy in writing prior to such disclosure of its intent to do so with identification of the proposed recipient(s) thereof; (b) said recipient(s) agree(s) in writing with user to (i) not further disclose this Product Warning, (ii) use it solely for the purpose of effecting such actions for the user, and (iii) return this Product Warning and all copies thereof or destroy the same immediately after performance of said actions, and (c) on request, the user furnishes Siemens Energy a copy of said written agreement.
THIS PRODUCT WARNING IS PROVIDED WITHOUT CHARGE ON THE BASIS OF INFORMATION
REVIEWED BY SIEMENS ENERGY PRIOR TO ISSUING IT. ALTHOUGH SIEMENS ENERGY HAS MADE REASONABLE EFFORTS TO PREPARE THIS PRODUCT WARNING BASED ON THAT INFORMATION, IT SHALL BE NOT RESPONSIBLE FOR ANY ERRORS, OMISSIONS, INCONSISTENCIES IN OR LIABLE FOR THE ACCURACY, COMPLETENESS OR USEFULNESS OF THIS PRODUCT WARNING.
To the fullest extent permitted by law, neither Siemens Energy nor any of its affiliates, nor any of their respective contractors, subcontractors or suppliers will be liable in contract, tort (including negligence or strict liability) or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever, loss or loss of use of or damage to property, equipment, power system or plant, infringement of intellectual property rights, loss of profit or revenues, cost of purchased or replacement power, loss of data, additional costs and expenses in the use of existing power facilities, or claims against the user by its customers, for, arising out of, resulting from or in any way connected with this Product Warning.
Published by
Siemens Energy 2022
Siemens Energy Global GmbH & Co. KG
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Siemens Energy Inc.
4400 Alafaya Trail Orlando, FL 32826-2399, U.S.
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