Service Bulletin

SENSOPLAN
Generator Services
End Winding Solutions
Stator end winding vibration problems
solved in a responsive and
qualified manner

Problems with the end winding?

Friction dust, friction greasing?
Excessive vibrations?
Short-circuits in the transmission grid?
...then we recommend using this service!

SB SENSOPLAN End Winding Solutions, SENSOPLAN 03/2007

SENSOPLAN AG Gewerbestr. 6
79801 Hohentengen a.H., Germany
Phone +49 7742 9298-0
SENSOPLAN Inc. 1020 e Wall Street
Mt. Pleasant, SC 29464, USA
Phone +1 843 329 0275
Please visit us at www.sensoplan.com, or send us a note to info@sensoplan.com

Fax +49 7742 9298-10

Fax +1 843 329 0956

SENSOPLAN End Winding Solutions

Operative restrictions and downtime of generators must be regarded as the most unwanted and costly
incidents in power generation units. A frequent cause of operative generator problems is the end winding,
since it is very complex in design and electro-mechanically heavily loaded.
With the SENSOPLAN End Winding Solutions service approach, SENSOPLAN is able to offer a
comprehensive and systematic package providing qualified and economical solutions to any
problem concerning the end windings in generators of all sizes including analysis, repair and recommissioning.

Step 1: ANALYSIS
Prior to any analysis, a thorough visual
inspection of the end winding under concern is
performed. Traces of friction dust or greasing,
as well as potentially loose bandages, provide
valuable information regarding the condition of
the end-winding and the further problem
solution.

Your Requirements:

Maximum service life

Maximum availability and reliability

No reduction in performance
of your generator.

The subsequent modal analysis determines

the vibration behavior of the complete end
winding by means of a bump test using highly
sensitive and sophisticated measurement and
calculation equipment.
Step 2: DIAGNOSIS
The measured raw data is then used by
SENSOPLAN in a second step, the diagnosis,
to determine the specific characteristics of the
end winding.
To this end, powerful calculation programs are
applied to determine and graphically depict
frequencies, amplitudes and locations of the
crucial n-node-vibrations. In conjunction with
this, end winding stiffness (compliance) is
calculated at critical locations.
In parallel, the end winding is modeled in a 3DFinite-Element (FE) model, with characteristics
matching the results of the measurements
obtained previously (validation).
With all relevant data of the end winding
available in data sets ready for further
evaluations, the diagnosis step, i.e. the
determination of the actual characteristics and
condition of the end winding, is completed
within the shortest possible amount of time.

Modal Analysis: Spectra of the

measurements

SB SENSOPLAN End Winding Solutions, SENSOPLAN 03/2007

SENSOPLAN AG Gewerbestr. 6
79801 Hohentengen a.H., Germany
Phone +49 7742 9298-0
SENSOPLAN Inc. 1020 e Wall Street
Mt. Pleasant, SC 29464, USA
Phone +1 843 329 0275
Please visit us at www.sensoplan.com, or send us a note to info@sensoplan.com

Fax +49 7742 9298-10

Fax +1 843 329 0956

End Winding Problems

Solved in a responsive and qualified manner
Step 3: DESIGN SOLUTION
The third step is comprised of the determination
of the origin (root cause analysis) of the
problems identified and the identification of
proposals for their solution using the FE
methodology with consideration given to all
technical and economic boundary conditions.
The primary target is to bring the generator
back into operation as soon as possible
without any restrictions to power output or
service intervals.
To determine the root cause, the data sets of
the end winding generated in step 2 are used to
calculate absolute and relative movements of
bars, connectors, stiffeners, supports, etc. at
different electrical operating conditions. These
results, in combination with the results of the
natural
frequency
and
n-node-vibration
calculations, allow the areas of concern to be
precisely identified.
With the precise problem identified, proposals
for solution can be generated. Using a
methodology
invented
by
experienced
SENSOPLAN experts, design modifications are
built into the FE-model of the end winding at
different locations, and their effects are
determined and evaluated. This methodology
delivers sound solutions to the problems quickly,
including clear statements regarding the extent
of the required measures to be taken. Thus, the
usual trial-and-error approach, which can result
in serious operating problems and extensive
delays, is avoided.

3D-Finite-Element-Model of a
generator end winding

Your Benefits:

Avoidance of costly downtime

Fast problem solution

Expert proposals for economical
modifications

Qualified and speedy implementation

Based
on
the
information
obtained,
SENSOPLAN decides, together with the client,
on the technically and economically feasible
solution to be implemented.
Step 4: REPAIR & RE-COMMISSIONING
In the final step, SENSOPLAN executes the
implementation of the selected end winding
repair solution and supports the client with recommissioning of the generator.
The repair package determined in step 3 allows
for a precisely defined installation, which is
performed within the shortest possible amount of
time. Finally, the project is completed by
successful re-commissioning of the generator,
supported by SENSOPLAN.

Repaired end winding with improved

supports
SB SENSOPLAN End Winding Solutions, SENSOPLAN 03/2007

SENSOPLAN AG Gewerbestr. 6
79801 Hohentengen a.H., Germany
Phone +49 7742 9298-0
SENSOPLAN Inc. 1020 e Wall Street
Mt. Pleasant, SC 29464, USA
Phone +1 843 329 0275
Please visit us at www.sensoplan.com, or send us a note to info@sensoplan.com

Fax +49 7742 9298-10

Fax +1 843 329 0956

SENSOPLAN we have got the right solution:

Generator-Services:
 Stator:
Stator Vibration Services: Analysis and elimination of stator frame vibration problems
SENSOCORE HI Checkup: Reliable on-site diagnosis of the generator stator lamination
stack using a high induction loop test under close-to-operating conditions
SENSOCORE-Inject: Patented repair of lamination stack hot spots in deep layers
Stator End Winding Vibration Services: Stator end winding vibration problems solved
in a responsive and qualified manner
Resin Pressure Injection RPI: Repair of the coupling between stator winding bar and
slot wall by injection of resin
Stator Rewind Services: Dedicated improvement of the stator winding design

 Rotor:
Rotor Vibration Services: Rotor vibration problems solved in a responsive and qualified
manner
Rotor Rewind Services: Dedicated improvement of the rotor winding design
Top Tooth Cracking: Modification of the rotor shrink fit area
Hydrogen Sealing Contour: Modification of the hydrogen sealing rings

Turbine-Services:
Analysis and elimination of casing and shaft vibration problems
Determination of residual life of steam turbines
Steam Path Audit

Would you like more information?

Please contact:
Europe
SENSOPLAN AG
+49 7742 9298-0
info@sensoplan.com

USA
SENSOPLAN Inc.
+1 843 329 0275
info@sensoplan.com

SB SENSOPLAN End Winding Solutions, SENSOPLAN 03/2007

SENSOPLAN AG Gewerbestr. 6
79801 Hohentengen a.H., Germany
Phone +49 7742 9298-0
SENSOPLAN Inc. 1020 e Wall Street
Mt. Pleasant, SC 29464, USA
Phone +1 843 329 0275
Please visit us at www.sensoplan.com, or send us a note to info@sensoplan.com

Fax +49 7742 9298-10

Fax +1 843 329 0956