The complete turnkey generator inspection, maintenance, repair and replacement service solution exclusively from Brush.

GENERATOR Support

VF Programme
VF Programme
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
  • VF From BRUSH

    Keeping the power on is the most critical factor for a generator owner. The VF programme delivers technical security to generator owners through enhanced support, maintenance, spares package provisions, technical assistance and regular account management. Visit vf.brush.eu for more information and to join the VF revolution!

    not sure about joining?
    VF BENEFITS
    • Exclusive 7 week replacements for selected rotors and 10 week replacement generators
    • 10% discount off all spares and kits
    • 10% discount on our field service rates
    • Preferential rates on Annual, Minor, Major and RoGIS inspections
    • Dedicated Account Manager
    • Dedicated 24hr technical helpline
    • Regular service bulletins and latest industry information
    • Agreed service performance levels
    • Spares inventory stockholding proposal
    • Disaster recovery planning
  • 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:

    1. 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.
    2. 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.
    3. The oil change interval is dependent on the condition of the oil. BRUSH advises samples to be taken every 6 months.
    4. 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 REPAIRS

    Where 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.

    Download USA Balancing Pit

  • 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. 

    Download Replacement Generators