The complete turnkey generator inspection, maintenance, repair and replacement service solution exclusively from Brush.
GENERATOR Support
- Service Scheduling
- Service Scheduling
- Generator Inspections
- Generator Inspections
- Robotic Generator Inspection
- Robotic Generator Inspection
- Field or Factory Repair
- Field or Factory Repair
- Upgrades & Modifications
- Upgrades & Modifications
- Rotor Balance
- Rotor Balance
- Swap Outs
- Swap Outs
SERVICE SCHEDULING
BRUSH Aftermarket Support services are fully equipped to provide all existing operators with a comprehensive, standard or bespoke support package, that may be adapted to suit each and every individual operator’s need, wherever the installation be situated.
Regular maintenance
The notion that "prevention is better than cure" lies at the heart of any maintenance programme. Regular maintenance may be categorised into the following terms:
- Preventative maintenance utilising regular inspection packages and the holding of strategic stock of parts.
- Predictive maintenance utilising specific maintenance based on regular inspections and assessments of equipment condition and replacement material requirements.
- Life-cycle maintenance utilising maintained stock of parts and exchange of strategic parts.
Recommended servicing for BRUSH DAX 2 pole generators
Service Interval
(whichever occurs first)Item
Procedure
Running Hours
Time Period (Months)
Number of Starts
2000
3
.
Enclosure Seals
Look for water or dust leaks. Seal as necessary. Replace seals as required.
2000
3
.
Oil Pump Gear Type Coupling
Inject approximately 0.01 - 0.015kg of fresh Shell Retinax HDX2 grease into the coupling. Do not overfill the coupling sleeve.
2000
3
.
Oil
Check oil level and top up as required.
2000
3
.
Rotor Earth Fault Monitor (REFM)
Press test button to test monitor.
4000
6
.
Oil Pipes & Flanges
Joints & Gaskets
Inspect for leaks. When the opportunity arises, attention should be given to joints that are hidden i.e. within bedplates.
4000
6
.
Earthing/Grounding Brush
Inspect. Brush must be free in holder. Replace when worn down to 14mm long with genuine BRUSH replacement brush.
4000
6
.
Lube Oil Sample
Examine for oil contaminants: water, acidity and general condition in conjunction with local oil supply agent. Replace if oil does not meet original specification and/or is not in accordance with local oil supply agent's recommendations.
4000
6
.
Air Inlet Seals
Check seals and ensure that no oil or dirt is penetrating the machine enclosure.
4000
6
.
Bearing Oil Seals
Check that bearing oil seals are not leaking.
4000
6
.
Door hinges, locks & catches
Apply drops of oil to ensure proper operation. Use dry graphite lubricant on cylinder locks.
4000
6
.
Inlet Air Filter
Inspect and replace with genuine BRUSH replacement filters when the differential pressure switch indicates increased pressure drop.
4000
6
.
Air Make-Up Filter
Inspect and replace and replace filter as necessary.
8000
12
.
Oil Filter
Replace with genuine BRUSH replacement filter element every 12 months or when the pressure switch or transmitter indicates increased differential pressure, whichever occurs first.
8000
12
.
Bearing Insulation
Check resistance.
8000
12
.
Blow Open Shutters
Stainless steel shutters have nylon bearings, lubrication is not required but check that they operate correctly.
8000
12
.
Protection Devices
Check mechanical and electrical protective devices to supplier’s specifications/manual settings.
8000
12
.
Electrostatic Precipitator
Check operation by absence of oil vapour in discharge during normal running of generator.
8000
12
.
Jacking Oil
Measure shaft lift adjacent to each bearing to verify operation of jacking oil system.
10000
18
.
Oil Pump Gear Type Coupling
The coupling must be dismantled and the grease completely replaced. If excessive gear mesh wear is evident complete coupling must be replaced. During assembly the coupling must be lubricated with grease Typically approximately 0.12kg of Shell Retinax HDX2). The external teeth of both hubs must be well coated with grease and a small amount applied to the rubber sealing rings. The remainder of the grease should be applied to the internal teeth at both ends of the coupling sleeve and smoothed around the inside of the sleeve. Care must be taken not to overfill the coupling with grease since this may cause leakage from the seals.
16000
24
.
Paint work
Check paintwork to ensure that it is in good condition. If it has become damaged then the affected areas should be repainted.
25,000
50*
.
Knife Edge Seals
Check air pipes for signs of deterioration. Replace if necessary.
25,000
50*
.
Pressurised Seals
Check that air gap pressure at intermediate seal compartments is higher than in main bearing housing. If it is not, check air pipes and seal clearance.
25,000
50*
2,500
Main Exciter
Rectifier Assembly
Remove any accumulated dust from the rotating rectifiers and the main exciter. Check electrical connections are secure. Verify integrity of armature end winding banding.
25,000
50*
.
Rotor End Windings
Remove excess deposits using vacuum cleaner, small bottle-brushes and dry, lint-free rags to achieve a uniform state on both sides of a diameter. CAUTION: Avoid moving contaminants further into the windings.
25,000
50*
.
Stator End Winding
Inspect and remove excess deposits of dust and grease. Use vacuum cleaner, brushes and lint-free cloth. If the dirt proves to be stubborn, wipe sparingly with `Pro Natur' Orange Oil) or equivalent. CAUTION: Avoid washing contaminants further into the windings.
40,000
60*
5,000
Main Bearings
Bearing Check - remove bushes. Examine for pressure concentration, scoring and drag marks. Damaged areas may be carefully scraped, taking care not to destroy bearing profile. Check bearing top clearance at each end of the bush by means of lead strips. Check bearing side clearances with feeler gauges.
Note: Hoses, along with other pipework and associated connectors, should be inspected for signs of deterioration during bush removal/reassembly and replaced as necessary.
100,000
12½ years
10,000
Complete Machine
Review with manufacturer for recommendations for full inspection/overhaul.
100,000
12½ years
10,000
Rotor End Caps
Perform non-destructive testing. Check for cracks on surfaces of rings, remove if necessary.
The schedule provided is an overview of the different kinds of condition inspections that are recommended to be carried out during inspection rounds.
The mentioned intervals are an indication only, and can be adjusted according to the maintenance rounds of the turbine, actual service duty and local circumstances
Recommended servicing for BRUSH DG 4 pole generators
Service Interval
(whichever occurs first)Item
Procedure
Running Hours (min)
Time Period
Number of Starts
24
Daily (2)
.
Electrical maintenance periods
Replacement of brushes
24
Daily
.
Others
General external visual inspection: look at, listen to and feel the machine
24
Daily
.
Lubrication system
Lubrication piping (leakage, operation)
24
Daily
.
Lubrication system
Lubrication oil (quality, quantity, flow)
24
Daily
.
Lubrication system
Oil ring/ flow regulator (operation)
24
Daily
.
Lubrication system
Oil tank (Cleanliness, leakage)
24
Daily
.
Electrical maintenance periods
Check/logging load conditions (kV, 3xAmps, kW, kVA, power factor, Hz)
24
Daily
.
Electrical maintenance periods
Check/logging excitation volts / amps
24
Daily
.
Electrical maintenance periods
Winding temperature check/logging
24
Daily
.
Electrical maintenance periods
Oil pumps and equipment
24
Daily
.
Cooling system maintenance
Cooling system temperature checks/loggings
24
Daily
.
Cooling system maintenance
Check pressure drop across air inlet filters (if applicable)
24
Daily
.
Bearings
Metal temperature check/logging
4000
6 months (3)
.
Lubrication system
Re-lubrication / Oil change
35000
4 years(1)
.
Electrical maintenance periods
Insulation Resistance measurements/ Anti-condensation heaters good operation
35000
4 years
.
Others
Check Spare Parts (general conditions, availability)
35000
4 years
.
Others
Jacking oil system (operation)
35000
4 years
.
Electrical maintenance periods
Polarization Index test (stator)
35000*
4 years
.
Electrical maintenance periods
Dielectric Loss Factor measurements (tan delta)
35000*
4 years
.
Electrical maintenance periods
Partial discharge analysis
35000
4 years
.
Electrical maintenance periods
Winding resistance measurements (stator, rotor, exciter, exc. field)
35000
4 years
.
Electrical maintenance periods
Cleaning/Inspection of stator (MV) - Windings
35000
4 years
.
Electrical maintenance periods
Cleaning/Inspection of rotor, exciter windings, diodes and fuses
35000
4 years
.
Electrical maintenance periods
Inspection/Cleaning of slip rings (wear, roundness, patina), brush gear (arching, clearance)
35000
4 years
.
Electrical maintenance periods
Inspection of brush holders (alignment)
35000
4 years
.
Electrical maintenance periods
Brushes conduction resistance measurements
35000
4 years
.
Electrical maintenance periods
Carbon brushes check
35000
4 years
.
Electrical maintenance periods
Inspection Terminal Boxes (Insulators, Neutral Earthing Resistors, Measuring Transformers, Connections etc.)
35000
4 years
.
Cooling system maintenance
Inspection of Air Inlet Filters (if applicable)
35000
4 years
.
Cooling system maintenance
Check on Water Leakages/Detectors (if applicable)
35000
4 years
.
Cooling system maintenance
Inspection of the Cooling Fans and motors
35000
4 years
.
Cooling system maintenance
Cleaning of the air guiding shields
35000
4 years
.
Cooling system maintenance
Water flow regulator (operation)
35000
4 years
.
Cooling system maintenance
Seals and gaskets (leakage, conditions)
35000
4 years
.
Bearings
Cleaning/Inspection Bearings, Bearing Houses, Journals, Clearance measurement
35000
4 years
.
Bearings
Seals and gaskets (leakage)
35000
4 years
.
Bearings
Dye check of Babbitt bonding
35000
4 years
.
Bearings
Check vibration level history and perform frequency analysis on existing data, if required
35000
4 years
.
Bearings
Check bearing instrumentation
100000
12 years
.
Stator
Whole structure (general conditions, visual inspection for oil leaks, rust patches or other defects)
100000
12 years
.
Stator
Core (fixing, cracks, welds)
100000
12 years
.
Stator
Slot wedges (movement, tightness)
100000
12 years
.
Stator
Terminal bars (fixing)
100000
12 years
.
Stator
Windings (general conditions, connections, insulation, tightness of bracing and tying material)
100000
12 years
.
Stator
Cable terminal fastenings and crimps (tightness, general conditions)
100000
12 years
.
Rotor
Remove, clean and inspect rotor
100000
12 years
.
Rotor
Poles (movement, tightness, fixing)
100000
12 years
.
Rotor
Coil supports (movement, bending)
100000
12 years
.
Rotor
Balancing weights (movement)
100000
12 years
.
Rotor
Shaft and rotor centre (crack, corrosion)
100000
12 years
.
Rotor
Air gap (equality)
100000
12 years
.
Rotor
Application of varnish layer
100000
12 years
.
Rotor
Balance Check
100000
12 years
.
Others
Alignment
100000
12 years
.
Others
Inspection Bolted Connections (tightness of all fastenings)
100000
12 years
.
Others
Inspection Machine housing (rust, leakage, general conditions)
100000
12 years
.
Cooling system maintenance
Inspection of the Cooling Circuit (flanges, tubes, etc.) (if applicable)
100000
12 years
.
Cooling system maintenance
Cleaning of the Air Cooler Pipes (if applicable)
100000
12 years
.
Cooling system maintenance
Pressure Test (Water Cooler)
(4)
(4)
.
Control and Protection equipment
Confirm generator breaker and HV line are tested
(4)
(4)
.
Control and Protection equipment
Functional test protection system
(4)
(4)
.
Control and Protection equipment
Confirm generator protection system is in good working operation
(4)
(4)
.
Control and Protection equipment
Confirm AVR is in good working conditions
The schedule provided is an overview of the different kinds of condition inspections that are recommended to be carried out during inspection rounds.
The mentioned intervals are an indication only, and can be adjusted according to the maintenance rounds of the turbine, actual service duty and local circumstances.
Schedule notes:
- Insulation resistances of stator windings, rotor winding, exciter windings, exciter field winding, brush gear, slip-rings, diode wheel (diodes to be short-circuited), heaters, temperature detectors, insulation of bearings should be measured.
- To avoid any risks for damages, brushes should be replaced at the moment the original brush length has been reduced to approximately 35% of original length.
- The oil change interval is dependent on the condition of the oil. BRUSH advises samples to be taken every 6 months.
- According to manufacturer's manual.
Generator Inspections
As the original generator manufacturer, Brush is best equipped to offer turnkey inspections of your existing 2-Pole or 4-Pole generator(s). With access to original schematics, genuine replacement parts and factory trained engineers, outage time is minimized and repairs guaranteed.
Three types of generator inspections are offered dependent on age and running hours:
- Minor Inspections are carried out with the rotor in-situ during outages of the prime mover
- Major Inspections are the most comprehensive inspection available and includes rotor removal
- Robotic generator inspection (RoGIS)
DOWNLOAD
ROBOTIC GENERATOR INSPECTION SYSTEM (ROGIS)
RoGIS is a robotic inspection system that carries out EL CID tests, stator wedge tightness assessment and a full visual inspection of the stator and rotor. Watch the RoGIS system in action on our YouTube channel
Downloads:
RoGIS makes a fully automated inspection of the stator core:
- The Generator Inspection Vehicle (GIV) is placed in a docking station mounted as a link in a chain around the retaining ring. By remote control the chain rotates around the ring and the docking link is placed exactly in front of a slot
- The GIV is then guided through the gap between the retaining ring and stator and will magnetically attach to the core iron. When the GIV returns into the docking link the chain will be rotated until the dock can move into the next slot
- The unique docking system ensures precise release and return of the generator inspection vehicle from the stator slot. Four high resolution on-board cameras provide BRUSH service engineers with clear views of the stator core laminations, field and stator wedges, cooling slots and an on-board view of the retaining rings.
CUSTOMER BENEFITS
The cost reductions in comparing in-situ inspection to traditional inspection methods are achieved through the following:
- Reducing downtime.
- Eliminating consequential damage.
- Reducing disassembly requirements.
- Depending on the type of in-situ inspection carried out the reduction to your outage period can be between 4 to 12 days.
- Enhanced more efficient maintenance planning for future outages.
field repairs
In the event of an unplanned outage, the quickest way to return the generator to normal functioning is to repair on site. Global service locations are complemented with accredited companies that are regularly audited to maintaing our high standards whilst providing a locally responsive service.
To arrange an immediate onsite repair click here, or in emergency contact Service 24.
FACTORY REPAIRSWhere local conditions prevent repair, Brush offers a turnkey factory repair programme. With skilled engineers and specialist technical equipment on hand, repairs and overhauls can be carried out quickly with a rigorous testing regime to align to orignal exacting tolerances.
Typical repair services include:
- Stator core replacement
- Stator rewind
- Bearing replacement or refurbishment
- Rotor overhaul and end winding refurbishment
- Rotor-end cap/retaining rings
- Rotor rewind
- Rotor high speed balancing including over speed
- High voltage testing
upgrades & Modifications
One important part of the success of our Aftermarket sales support lies with our ability to upgrade and modify equipment to keep your plant functioning at peak performance levels.
Product upgrades
Replacing major assemblies, such as stators and rotors, in both BRUSH and third party products can improve the operation of your plant and extend the life of your equipment. We offer engineered solutions for the following upgrade packages:
- MW output
- Equipment cooling system
- Machine excitation system
- Retrofit rotor earth fault monitor
- Generator auxiliary equipment (lubricating oil systems, sealing oil systems and cooling gas systems)
- Analogue to digital excitation controller (automatic voltage regulator)
- Power management system
Plant upgrades
Because of our extensive knowledge of your existing equipment and design, we can tailor fully engineered solutions which are electrically and mechanically compatible with the existing units and power system.
Modifications
If the demands of your business change and you need your equipment to respond, we can carry out modifications to your existing BRUSH equipment, such as power management systems and exciter systems, which bring it up to date and enable you to optimize operations.
Re-engineering and reverse engineering
Our expert BRUSH engineers don’t just specialize in our own products. They have comprehensive technical skills and are able to carry out extensive work on equipment produced by third party manufacturers, such as reverse engineering, re-engineering and servicing.
Their extensive engineering capabilities include:
- Mechanical engineering
- Electrical/electromagnetic engineering
- Thermal engineering
- Insulation engineering
- Control and protection
Developed in conjunction with rotor balance technology leaders Schenck, the Pittsburgh facility is world class. A below ground bunker arrangement with DH9 pedestals and CABFLEX3 software shortens testing cycles that result in significant financial savings compared with dated technology alternatives.
Investing in a state of the art high speed balance pit ensures that Brush Aftermarket can offer the most advanced OEM testing in the Americas today at the lowest possible price.
- Unbeatable low cost rotor balancing from only $20,000
- Unmatched 130 years of OEM expertise in designing, manufacturing & servicing rotors
- Uncompromising $9,000,000 investment in the very latest rotor balance technology
- Urgent 24 hour turnaround capability to minimise downtime
Low cost, expert and technologically advanced rotor balancing has finally arrived!
Contact us now to discover rotor balancing that doesn’t cost the earth.
SWAP OUTS
Some customers have made substantial winding repairs more than once, in some cases spending excessive amounts of money. BRUSH can offer an alternative solution to endless repairs with a customized solution for your replacement generator.
BRUSH has broad experience in supplying generators for all types, ratings and configurations of turbine. We do not supply one generator to fit one turbine – we have multiple generator selections with many alternate fittings already developed; we mix & match detail to suit the customers turbine.
Contact us today to explore if a generator swap out could be a cost efficient investment option.
