Services for Liquid-Cooled Generators

The Lowest Outage Time in the Industry

As the typical water-cooled generator approaches 30 years of service, winding failures associated with water leaks become increasingly likely. Stator bar insulation failures that occur in service can cause extensive collateral damage to the generator stator core and field, which can extend a forced outage several months. The severe impact of a winding or stator insulation failure on generator availability demonstrates the importance of a thorough, routine leak testing and repair plan.

Services

Epoxy Injection

Epoxy injection is a low-cost, long-term repair solution that addresses the water leak maintenance issue affecting both GE and other OEM-designed liquid-cooled generators. GE's epoxy repair is a simple, non-invasive, high-technology solution that results in lower outage and maintenance costs. The end result: improved reliability and availability of your liquid-cooled generator at a fraction of the cost of a more expensive outage due to stator failure.

While the optimum solution to preventing generator water leaks is a full rewind, GE has developed a patent-pending epoxy injection procedure that provides a fast, highly reliable and low-cost alternative. Epoxy injection can be used as a corrective or preventative measure. As a corrective measure, a stator bar or clip that has a water leak can be repaired using the epoxy injection procedure. As a preventative strategy, epoxy is injected into all of the stator bar clips.

The repair procedure is the same whether it is corrective or preventative. The procedure consists of using a specialized borescope with a heads-up display in conjunction with a variable, air-powered, epoxy injection syringe dispenser. This dispenser injects precise amounts of epoxy between the strands at the braze without removing the bar. The epoxy is a specially formulated compound developed specifically for this application. A qualified epoxy injection specialist performs the procedure.

Liquid-Cooled Rewind

A liquid-cooled rewind is a proactive repair solution that addresses key maintenance issues facing GE-designed liquid-cooled generators. GE's rewind program greatly improves the reliability and availability of your liquid-cooled generator by using OEM parts produced to current specifications. As an added benefit, current engineering considerations may improve efficiency and output as well.

To restore a generator stator to its original condition or better, GE recommends performing a complete rewind using new design bars and wedging systems. In the past, the time required to replace stator bars presented an obstacle to performing this service. GE has addressed this problem with our innovative short-cycle rewind program that can completely rewind your generator in less than 30 days.

A Wide Range of Services

We also offer the following services for liquid cooled stators:

  • Stator core re-stack (full or partial)
  • Rewedge (full or partial)
  • Stator core tightening
  • El-Cid core inspection
  • Bump test (end winding resonance test)
  • Oil control modifications
  • Stator cleaning
  • Bushing box repairs

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