386

GENERATOR MAINTENANCE,
INSPECTION AND TEST PROGRAMMES

Working Group
A1.07

August 2009
 WG A1.07

Generator Maintenance,
Inspection and Test Programmes

Members Contributors

John Linton, Convener AU Helen Rooke AU

Vojislav Skundric RS Erli Figueiredo BR
Philippe Machard FR Pedro Grossi BR
Reijo Manninen FI
Jean Ricoux FR
Giorgio Maccio IT
Kiyoshi Miyaike JP
Feodor Polyakov RU
Reinhard Joho CH
Robert Fenton US
Dave Berrong US
Jim Michalec US

Copyright©2009

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,6%1
TABLE OF CONTENTS
1. EXECUTIVE SUMMARY ......................................................................................................................3
1.1. Methodology ................................................................................................................................3
1.2. Access for Generator Maintenance.............................................................................................3
1.3. Generator Component Maintenance ................................................................................... ……5
1.4. Generator In-Service Diagnostic Testing ....................................................................................5
1.5. Generator Maintenance Practices...............................................................................................6
1.6. Conclusions .................................................................................................................................6
2. RESPONSES. ......................................................................................................................................7
2.1. Users. ..........................................................................................................................................7
2.2. Manufacturers. ............................................................................................................................7
3. GENERATOR MAINTENANCE OUTAGE SCHEDULING PRACTICES. ..........................................8
3.1. Shutdown Maintenance Access ..................................................................................................8
3.2. Shutdown Scheduling..................................................................................................................8
3.3. Outage Duration ..........................................................................................................................9
3.4. Generator Rotor Removal ...........................................................................................................9
3.5. Other Comments .......................................................................................................................10
4. PLANNED MAINTENANCE TASKS FOR GENERATOR COMPONENTS. ....................................11
4.1. Stator winding – slot content. ....................................................................................................12
4.2. Stator winding – end windings ..................................................................................................13
4.3. Stator winding - terminal box .....................................................................................................13
4.4. Bushings ....................................................................................................................................13
4.5. Core & frame .............................................................................................................................14
4.6. Stator cooling water system ......................................................................................................14
4.7. Stator water treatment ...............................................................................................................15
4.8. Rotor ..........................................................................................................................................15
4.9. Hydrogen cooling system ..........................................................................................................15
4.10. Hydrogen seals .........................................................................................................................16
4.11. Bearings ....................................................................................................................................16
4.12. Seal oil system ..........................................................................................................................16
4.13. Slip rings & brush gear (or diodes)............................................................................................17
4.14. Instrumentation..........................................................................................................................17
4.15. Neutral point grounding system ................................................................................................17
4.16. Generator electrical protection system......................................................................................17
4.17. Excitation system ......................................................................................................................18
5. GENERATOR IN-SERVICE DIAGNOSTIC TESTING ......................................................................19
5.1. Stator winding – slot content .....................................................................................................19
5.2. Stator winding – end windings ..................................................................................................19
5.3. Rotor ..........................................................................................................................................20
5.4. Core & frame .............................................................................................................................20
5.5. Hydrogen cooling system ..........................................................................................................20
5.6. Stator water treatment ...............................................................................................................20
5.7. Bearings ....................................................................................................................................21
5.8. Slip rings & brush gear (or diodes)............................................................................................21
6. GENERATOR MAINTENANCE PRACTICES ..................................................................................22
6.1. Scenario 1: ................................................................................................................................22
6.2. Scenario 2: ................................................................................................................................23
6.3. Scenario 3: ................................................................................................................................23
6.4. Additional Comments: ...............................................................................................................24
7. CONCLUSION ...................................................................................................................................24
8. APPENDIX 1 - Appendix to Chapter 4 ............................................................................................25
9. APPENDIX 2 - Appendix to Chapter 5 ............................................................................................56
10. APPENDIX 3 - Appendix to Chapter 6 ............................................................................................67

2
1. EXECUTIVE SUMMARY
The maintenance, inspection and testing of large hydrogen & water cooled turbo-generators remains one
of the most significant costs of asset ownership for electricity generation companies worldwide.
Competitive reforms in electricity marketing structures and ownership have imposed significant cost
pressures in many countries that have resulted in decisions to reduce maintenance and inspection
frequency and accept greater operating risk, albeit through managed risk assessment and mitigation
programs. There is both factual and anecdotal evidence that in some instances the risk envelope is being
stretched quite significantly compared to previous practice.
The objective of this study was to survey actual and recommended practice, and in so doing identify the
reasons and justification for differences. In addition, innovative and/or best practice maintenance
procedures and strategies were explored.
The information obtained may help all countries maintain or increase generator reliability, by providing
data that can be used to support review of maintenance practices, and providing information on improved
techniques.
The study covered four main topics:
1. Planned maintenance access – generating unit outage scheduling factors.
2. Planned maintenance tasks for generator components.
3. Generator in-service diagnostic testing.
4. Generator maintenance practices.

1.1. Methodology
The study used the survey methodology whereby members of Study Committee A1 were asked to obtain
responses from a cross-section of users (utilities) and manufacturers in their own countries. The
responses have been correlated and analysed to produce this report. The survey was limited to turbo-
generators with ratings > 250MVA.
The responses were segregated into users and manufacturers. These categories are reported separately
in chapter appendices, but combined in analysis of the relevant maintenance practices. There is no
reference to the origin of highlighted responses in the text, although the tables of responses in the
chapter appendices at the end of the report are presented under the name of the country of origin.
The survey obtained responses on utility practice from 11 countries, 4 of which also included responses
either from a manufacturer, or on behalf of their manufacturers. The responses cover a total of 423 utility
generators from 250MVA to over 800MVA, as well as manufacturers with combined annual production of
72 units in the same capacity range annually.
The results are presented in the Technical Brochure, including appendices with the response detail.

1.2. Access for Generator Maintenance

The study generally confirmed that generator outages for maintenance fall into two main categories –
minor and major – as follows:
“Minor” outage – limited duration; repair of known defects; plant surveys and inspections;
preventive maintenance.
“Major” outage – extended duration; major plant item(s) dismantled for inspection / repair /
replacement; repair of known defects; plant surveys and inspections; preventive maintenance.
The duration of outages varied as represented in Fig 1 that shows the most common duration for minor
outages is about 2 weeks, and for major outages 5 - 7 weeks. There was no consistency at all reported in
the intervals between outages – refer to the Technical Brochure.

3
 8

0
≤ 9 days 10 - 16 days 17 - 30 days 31 - 50 days >50 days

Minor outage duration Major outage duration

Fig 1: Outage durations reported.

In regard to practice in removing generator rotors for inspection, once again there was no consistency in
the durations reported between such events. Fig 2 shows that the most common period however is 8
years.

4
Responses

0
2 4 6 8 9 10 12
No. of Years

Fig 2: Periods Reported for Rotor Removal for Inspection

In general, a common response in regard to issues affecting access to generators for maintenance, was
that the timing and periodicity of such maintenance is determined by other factors, typically maintenance

4
requirements on turbines, boilers and nuclear reactors (including re-fuelling) around which the generator
maintenance program must fit.

1.3. Generator Component Maintenance

Seventeen generator components, most including sub-components, were identified by the Working
Group and included in the survey questionnaire. For each item, the following information was sought
from users:
 Recommended maintenance interval and the source of the recommendation.
 Actual maintenance intervals.
 The decision basis if actual interval is different to that recommended.

On the other hand, manufacturers were asked only for:

 Maintenance intervals recommended, and
 An acceptable basis for changing their recommendation.

As per the previous section, there was a significant disparity in responses, so for many or most items, it
was not possible to identify a preferred maintenance interval and accordingly the working group decided
to include the full set of responses for the benefit of readers of the Technical Brochure. However some
general remarks were possible:
 There was no general preference for either time based or service hour scheduling for maintenance
tasks.
 The dominant source of interval recommendation was manufacturers, followed by company
standards.
 There was a trend towards accepting the recommendation from the nominated source without
change.
 The dominant reason from users for changing the recommendation was prior maintenance
experience.
 One manufacturer stated an acceptable reason for changing their recommendation was through risk
assessment; another market driven needs, while others did not nominate an acceptable reason.

The Technical Brochure includes a brief summary of the responses received for each item.

1.4. Generator In-Service Diagnostic Testing

The Working Group identified eight generator components and systems for which in service diagnostic
tests were applicable, and a total of seventeen tests were listed. The survey sought information on:
 The past, present and/or future application of each test;
 Mode (i.e. continuous or intermittent) and frequency of testing; and
 Reasons for the test application.

Several of the identified diagnostic tests were reported as commonly used.

 For the generator stator, partial discharge monitoring is generally applied on an intermittent basis,
typically 6 monthly.
 For the generator rotor shorted turns detection is generally intermittently applied.
 For the Hydrogen cooling system, hydrogen dew-point and hydrogen purity are monitored on a
continuous basis.
 For the stator water system, stator cooling water conductivity is continuously monitored, as is
hydrogen leakage into stator water. Oxygen and copper concentration of the stator water are also
monitored in a variety of modes.
 For the generator bearings, journal vibration is continuously monitored using dual probe monitors.
Shaft grounds are also monitored but in a variety of modes.

5
Available diagnostic tests that were less commonly used included:
 Stator end windings vibration monitors.
 Stator core/frame vibration monitoring. This was nominated as being used generally only if a
vibration condition was occurring and known. Audio detection of stator core lamination vibration was
also not commonly applied.
 Hydrogen make up rate monitoring.
 Brush gear on-line condition monitoring, and diode breakdown detection, even though the latter was
generally recommended by manufacturers.

The information provided on reasons for using in-service diagnostics was patchy – the most common
reason being that it was company usual practice. All but two of the countries who responded said they
did not use any form of expert system to diagnose monitored variables and generate alarms or other
actions.

1.5. Generator Maintenance Practices

The survey questionnaire sought to identify best practice techniques for major preventive and corrective
maintenance tasks on generators, based on three common maintenance scenarios, ranging from a short
inspection shutdown with the generator de-gassed, to a long shutdown with the rotor removed. The
scenarios and responses to listed maintenance techniques applicable to each scenario, are detailed in
the Technical Brochure.

The most consistently used maintenance practices used included:

 Use of formal quality control systems;
 Formal confined space entry procedures for generator casing access;
 Controls on internal inspections and inspectors;
 Use and control of clean condition enclosures; and
 Documented procedures at critical stages.

1.6. Conclusions
The survey has provided a basis for comparison by utility engineers of maintenance practices across a
range of countries. The responses included with the Technical Brochure provide a library of maintenance
task recommendations and actual practices that could be considered by generator owners if new or
modified practices are being contemplated.
The most significant conclusion is that there is a considerable diversity in approach and practice in use
internationally. It has proven unrealistic to anticipate that a study such as this can identify best or
preferred practice in any particular area of generator maintenance.

6
2. RESPONSES.
The response details including number and rating of generators included is summarised in the following
tables – countries reported in alphabetical order:
2.1. Users.
The following table summarises the responses received from users (utilities). The response is taken to be
typical of country practice unless otherwise indicated. In this report, all separate responses have been
analysed and reported
In the case of Italy, two separate responses were received that related to base load and mid-load units.
For Australia, there were 3 separate responses received that were sufficiently different to not sensibly
enable combination to a unified response. For both countries, the responses are reported separately.

COUNTRY GENERATOR SIZE RANGE COMMENTS

250-500 500-800 > 800
MVA MVA MVA
Australia 1, 2 & 3 4 8 Responses from 3 separate utilities
Brazil 2 Utility – 2 synchronous condensers
Croatia 2
Finland 12 1 2
France 14 12 58
Italy – Base load 27 4 Base load units
Italy – Mid load 8 12 Mid load units
Japan 52 22 Thermal plant only
Serbia-Montenegro 10 2
Russia 108 14 1
USA 20 10 15 Single utility.
Switzerland 2 1

2.2. Manufacturers.
The following table summarises the responses received from manufacturers. Note that the generator
size range relates to the number of units in the size range manufactured annually. USA-2 is a response
from a consultant with significant experience in manufacturing.

COUNTRY GENERATOR SIZE RANGE COMMENTS

Annual production numbers
250-500 500-800 > 800
MVA MVA MVA
France 16 2 1
Italy 1
Japan 8 1
USA – 1 37 5 1
USA - 2 Response from consultant

7
3. GENERATOR MAINTENANCE OUTAGE SCHEDULING PRACTICES.
The questionnaire explored the practices amongst utilities associated with maintenance outage
scheduling for generators. The initial assumption was that planned unit shutdowns follow a pattern that
includes regular minor outages, interspersed with less frequent major outages, with the following
characteristics:
“Minor” outage – limited duration; repair of known defects; plant surveys and inspections;
preventive maintenance.
“Major” outage – extended duration; major plant item(s) dismantle for inspect / repair / replace;
repair of known defects; plant surveys and inspections; preventive maintenance.
Respondents were requested to confirm or otherwise their adherence to a pattern of this nature, and to
answer some questions on the basis and frequency of scheduling, and typical outage durations.
3.1. Shutdown Maintenance Access
13 of 14 respondents confirmed that they followed a shutdown pattern as described above. The
exception was a utility with significant nuclear generation where shutdowns were dependent on reactor
refuelling requirements.
The reasons for major and minor shutdowns were generally associated with maintenance access for
boilers/reactors and/or turbines. 5 utilities advised they may schedule a major outage for generator
maintenance primarily, with two advising similarly for minor outages.
3.2. Shutdown Scheduling
The contributing determinants of planned shutdown schedules could be time (calendar based) periods;
service hours; plant cycles; or another factor or combination. The total response is included in the
following table:

Factor Time (calendar) Service hours Plant cycles Other factor, or

periods – eg. no. of starts combination of
Outage Type nominated factors

Minor outage 8 2 8

Major outage 8 4 9

It is clear that time period scheduling is more dominant than service hours. Other factors affecting
scheduling that were nominated included:
- Plant condition (includes boiler, turbine and generator)
- Regulated inspection periods
- Reactor refuelling
- Market drivers
- Financial drivers

The period of time advised between calendar scheduled major outages was quite variable, ranging from
two to ten years. For service hour scheduled majors, the range was from 40K hours to >55K hours.
There was significant variation in the number of scheduled minor outages between majors, with some
respondents maintaining an evenly programmed major/minor/major schedule, whilst others had more
than one minor between consecutive major outages. A summary of reported patterns is included in the
following table:

8
Outage Pattern Number of Comments
Respondents
Major – Minor @ 1 yrs – Major @ 2 yrs 2

Major – Minor @ 1-2 yrs – Major @ 3 yrs 1

Major – Minor @ 2 yrs – Major @ 4 yrs 3

Major – Minor @ 3 yrs – Major @ 6 yrs 1

Major – Minor @ 4 yrs – Major @ 8 yrs 1

Major – Minor @ 20K+ hrs – Major @ 40K+ hrs 1

Major – Minor @ 40K+ hrs – Major @ 80K+ hrs 1 Intermediate load

plant
Major – Minor @ 2 yrs – Minor @ 4 yrs – Major @ 6 years 1

Major – Several Minors @ 1 yrs – Major @ 6+ yrs 2

Major – Several Minors @ 1-2 yrs – Major @ 10 yrs 1 Nuclear plant

3.3. Outage Duration

Reported major outage durations were in the range 17 to >50 days. The reported minor outage duration
range was <9 to 50 days. Response numbers are summarised in the following table:

Duration 9 days or less From 10 to 16 From 17 to 30 From 31 to 50 Greater than

days days days 50 days
Outage Type

Minor outage 1 6 3

Major outage 3 7 4

3.4. Generator Rotor Removal

Few countries reported removal of a generator rotor for inspection at minor outages, and then only on a
condition basis.
Rotors were routinely removed at major outages – a summary of the reported periods between removals
follows:

Years, or equivalent Number of respondents.

service hours, between
removal
2 1
4 2
6 2

9
 8 5
9 1
10 2
12 1
No firm program 1

3.5. Other Comments

Other comments made by respondents relevant to this topic included:
- Outage pattern is set by boiler or turbine maintenance. Generator work scope is determined prior to
each outage based on the condition of the machine.
- We have base load or mid merit units. The schedule of generator major outages depends on the
boiler, reactor refuelling, or the turbine and must find their time properly in synchronism with these
works.
- Following the manufacturer’s instructions we plan an outage after 8 to 10K working hours for new
generators to check winding fixation. We do the same after rewinding (partial or full), core
replacement, etc.
- Since the generating fleet is old, well used, and been inspected several times we have a good history
and this utility puts a lot of emphasis on maintaining inspection and maintenance records. We are
fortunate that we have several generators in a given series, e.g. one series has 9 identical units.
These two issues allow us to develop a dependable trend on generator condition. Another major
advantage that keeps outage time to a minimum is our spare part philosophy. We have a spare
generator rotor for every major unit and we have spare stator coils for the vast majority of our units.
This keeps major outage time to a minimum with regards to the generator.
- Period between shutdowns depends on the number of years in service. For generators having more
than 25 years of service and depending on fleet experience and application of video-inspection, the
overhaul intervals may be extended or shortened.
- For base load plants, service hours or years determine the frequency. For intermediate or peak load
plants, a combination of hours and starts determine the frequency.
- For good plants, the outage time between major outages should be 5 to 8 years (40,000 to 64,000
hours). One or two minor outages (rotor in place) should be scheduled between major outages.
- A few generator designs are known to have deficiencies that require a schedule different from the
average. Thus there are some designs which require a minor outage every year (I know of one
design requiring a minor every 6 months) and a major every 2 to 3 years. These are small in number
and exist for all manufacturers. A lot depends on the early history/reliability record
- Q2.4 depends on the number of years in service: For generators having more than 25 years of
service and depending on fleet experience and application of video-inspection the overhaul intervals
may be extended or shortened.
- Mid-life stator rewinding due to crevice corrosion and cracked strands is occurring at age about 20 –
25 years. Mid-life rotor inspections (and insulation repairs based on CM) at about 20 – 25 years.
Replace 18/05 retaining rings with 18/18 based on CM at 20 – 25 years.

10
4. PLANNED MAINTENANCE TASKS FOR GENERATOR COMPONENTS.
Information was sought on the recommended and actual frequencies of maintenance for a range of
generator components and systems, and maintenance tasks including long period diagnostic tests.
This was broken down into 3 major and 6 minor categories, with multiple choice responses
recommended as follows:
Recommended maintenance intervals – including:
 the basis of the recommendation:
- elapsed time;
- service hours;
- operation (speed) cycles;
- a combination of these; or
- on condition.
 the period between recommended maintenance tasks; and
 the source of the recommendation:
- manufacturer;
- government;
- company standard;
- national standard;
- international standard; or
- other source.
Actual service intervals:
 the type of outage in which maintenance inspections are done:
- minor outage;
- major outage – rotor in;
- major outage – rotor out;
- major outage – either of the above;
- no outage required; or
- task not done.
 the actual period between maintenance tasks.
The basis of the decision if the actual interval adopted is different to that recommended:
- not applicable (recommendation being followed);
- risk assessment;
- prior maintenance experience;
- maintenance cost saving;
- market needs – maximise availability; or
- other.

Utilities were asked to respond to all questions.

Manufacturers were asked to respond only to the three questions:
 maintenance interval basis (as above);
 period between maintenance tasks; and
 an acceptable basis for changing a manufacturer’s recommendation.

There were 17 generator components addressed in the question, and a number of potential maintenance
tasks per component identified. In general, there was a significant disparity in responses – and for this
reason the full responses received have been included in appendices linked to this chapter, for

11
reference. In the appendices, blank cells either indicate no response or a response that was considered
to be inconsistent with the question.
Note that as an aid to understanding the USA utility response, the respondent provided the following
explanation:
We did not respond for ‘Recommended maintenance intervals’. For ‘Actual period’ we took the
liberty of using CB (condition based) in several situations. For every task, ‘Actual/recommended
change decision basis’ could be nominated as ‘risk assessment’; ‘prior maintenance experience’;
‘maintenance cost saving’; or ‘market needs – maximise availability’ or a combination of these.
Basically, the "calendar" does not dictate maintenance.

Where possible, dominant practices are summarised in this report under each listed task. Attention is
also drawn to any exceptions that may be of interest.
Some general observations can be made:
 There was no general preference overall for planning of periodic maintenance tasks between
time based scheduling and service hour scheduling – some countries preferred one, some
the other. The inclusion of operational cycles in the scheduling was present in some
applications, but was not widespread.
 Manufacturer recommendation was a dominant factor in the source of planned maintenance
scheduling. However company standard was significant also. There was a lesser reliance on
national standards. International standards and government requirements were also present
in a limited number of specific areas.
 There was a trend towards accepting the recommendation from the nominated source for
maintenance task scheduling. The main reason for changing this was prior maintenance
experience, while cost savings and market needs also featured to a small extent. Risk
assessment was nominated by utilities on a small number of specific tasks.
 Manufacturers, however, advised that the dominant acceptable reasons for altering their
recommended schedules were risk assessment and market needs.

4.1. Stator winding – slot content.

4.1.1. Inspect wedges and repair or replace
- Major outage task generally with rotor removed – frequency depends on actual
scheduling of major outage (rotor removed). Some condition based scheduling
nominated. Main reason for changing recommended interval is prior experience.
4.1.2. Inspect slot insert migration
- As for 4.1.1
4.1.3. General inspection, clean, and paint as required.
- Generally per 4.1.1 – some more frequent attention including inspection in outages
with rotor in.
4.1.4. Electrical tests: IR; PI; winding resistance; DLA/DDF/tan δ.
- Generally per 4.1.1. However some advise more frequent testing, including annual
tests.
4.1.5. HV withstand.
- Variety of responses, including either not recommended or condition based. Refer
Appendix.

12
4.2. Stator winding – end windings
4.2.1. Test for water leaks, and repair
- Wide range of responses received – known condition of winding or prior experience
is a key determinant.
4.2.2. Test for water leaks – no repair
- As for 4.2.1. Survey did not explore reasons for not repairing leaks if found during
tests.
4.2.3. Inspect end windings, including supports, spacers and phase connection rings
- Commonly done during a major outage.
4.2.4. Inspect/test/repair temperature sensors
- Commonly done during a major outage. In some cases this was nominated as a
minor outage task also.
4.2.5. General inspection for contamination and insulation state; clean as required.
- Commonly done during a major outage. In some cases nominated as a minor outage
task also.
4.2.6. Capacitance mapping
- Variety of responses. Common major outage test – however not done in some
countries, and not recommended by one manufacturer.
4.2.7. Tracer gas leak test
- Commonly recommended as a standard or condition based test. Timing either
follows the recommended interval, or is modified based on prior experience.
Manufacturers all recommend this test but based on condition.
4.2.8. Modal response
- Generally either not a recommended test, or performed if condition dictates.
However it is a routine test for some.

4.3. Stator winding - terminal box

4.3.1. General inspection and clean; including support insulators, flexibles & CT stack.
- Common and regular maintenance task, averaging every 4 years or hours
equivalent. Few reasons given for deferral, but these were prior experience or
market needs.
4.3.2. Disconnect flexibles; inspect; replace as required; reconnect.
- Similar to 4.3.1. Not recommended by one manufacturer.
4.3.3. CT electrical and ratio tests etc.
- Variety of responses, including not done or condition based.

4.4. Bushings
4.4.1. Inspection & clean, external.
- Responses were similar to 4.3.1. The test was not recommended by one
manufacturer.

13
 4.4.2. Internal inspection – gas cooled bushings
- Similar to 4.3.1. Not done in one country, and on condition in another. Not
recommended by one manufacturer.
4.4.3. Leakage test - replace gaskets and seals if required.
- Variety of responses received – on condition basis of test was common.
4.4.4. Leakage test - replace bushings if required.
- Some time or hours based maintenance nominated, but mainly on condition.

4.5. Core & frame

4.5.1. Visual inspection & clean.
- This is a common major outage task. Change to the recommended period in a few
cases was based on prior maintenance experience
4.5.2. Frame cracking NDT & repair.
- Routine task for some – condition based for others. Not done or recommended in a
few responses.
4.5.3. Check liquid level detectors
- This is a routine task for many utilities with widely varying frequency. Majority of
manufacturers recommend condition based.
4.5.4. Check longitudinal core tightening screws.
- Major outage task for a majority of utilities. Varying response from manufacturers,
split between not recommended, and major outage task.
4.5.5. Check gas flow control rings, baffles etc.
- There was a varied response from utilities. This was a consistent recommendation
from manufacturers at about 5 year intervals.
4.5.6. Inspect end shields.
- Common major outage task for utilities, although not done by some. Not
recommended by one manufacturer only.
4.5.7. El-Cid test
- A common major outage with rotor removed task for utilities, however condition
based for some, and also not done by others. Manufacturer response varied.
4.5.8. Ring flux test
- Generally condition based – not done in some cases. One country only nominates
as a regular major/rotor out task.

4.6. Stator cooling water system

4.6.1. Inspect heat exchangers
- This is a regular utility outage task with a variety of nominated frequencies, ranging
from annual to 7-10 years. Consistently recommended by manufacturers, at periods
ranging from 2 years to 90K hours.

14
 4.6.2. Mechanical maintenance of pumps, valves etc.
- As per 4.6.1.
4.6.3. Pressure test
- Major outage task for some utilities; condition based for others; and not done or
recommended by some utilities and one manufacturer. Some manufacturers
recommend on condition.
4.6.4. Vacuum test
- Generally consistent with 4.6.3.

4.7. Stator water treatment

4.7.1. Replace resin
- This is a common relatively frequent task, often condition based. It is recommended
generally by manufacturers.
4.7.2. Component inspection & repair
- There were a variety of responses, however the task is commonly periodically
performed by utilities and recommended by manufacturers.
4.7.3. Calibrate conductivity instruments.
- This is a common periodic task.

4.8. Rotor
4.8.1. Remove rotor for inspection - inspect accessible rotor components, including
fan; NDT of rotor bore.
- The task is done or recommended by all respondents in major outages with rotor
removed. Time period ranged from 3-5 years to 15 years. Change from the
recommended period where applicable was prior experience for utilities, and market
needs for manufacturers.
4.8.2. Remove retaining rings – inspect & NDT rings, wedges & slots.
- Responses generally followed 4.8.1, except that a decision based on condition was
nominated in some cases.
4.8.3. Electrical tests: IR; PI; RSO; winding resistance.
- This task is also commonly done at varying frequencies by all utilities – not
recommended by one manufacturer.
4.8.4. Time of flight diffraction
- Rarely done. Not recommended by any manufacturer.

4.9. Hydrogen cooling system

4.9.1. Remove, inspect & repair hydrogen coolers.
- This is a common task done by all utilities, generally in a major outage. Reasons for
interval variance given were prior experience or cost saving.

15
 4.9.2. Pressure test cooling water piping.
- A task generally done by utilities on a periodic basis, with some exceptions. Not
recommended by one manufacturer.
4.9.3. Calibrate dewpoint instrumentation
- Periodically done by the majority of utility respondents at varying frequency. Not
recommended by one manufacturer.

4.10. Hydrogen seals

4.10.1. Inspect, including NDT
- A common major outage task with some exceptions.
4.10.2. IR testing
- Similar to 4.10.1 – more frequent for some.

4.11. Bearings
4.11.1. Inspection including NDT
- A regular maintenance task at mainly major outages. Similarly recommended by
manufacturers. Variation is due to prior maintenance experience or market needs.
4.11.2. IR testing
- Similar to 4.11.1 but more frequent for some.
4.11.3. Shaft earthing system inspect & repair
- A frequent inspection task – annual or at a major outage.

4.12. Seal oil system

4.12.1. Mechanical maintenance of pumps, strainers etc.
- A regular task at major outages, or more frequently.

16
4.13. Slip rings & brush gear (or diodes)
4.13.1. Inspection, including brush wear
- Frequent inspection nominated for most – on average with annual frequency.
Performed more often for some – responses include a recommendation of daily
inspection by one manufacturer.
4.13.2. Cleaning, including clean/replace filters
- Recommendation or actual inspection interval ranges from one week to more than
two years
4.13.3. Slipring grinding
- Generally done or recommended on condition. Time based intervals for some
utilities.
4.13.4. IR testing
- A regular task based on time or service hours. Condition based for one utility, and
not recommended by one manufacturer.

4.14. Instrumentation
4.14.1. Calibration & circuit checks
- A regular task – varied frequency. Condition based for two utilities,

4.15. Neutral point grounding system

4.15.1. Inspection & cleaning
- A regular task with varied frequency. On condition for one utility.
4.15.2. Resistance or impedance measurement
- Similar to 4.15.1.

4.16. Generator electrical protection system

4.16.1. Protection trip checks
- A common major outage task – more frequent by some utilities.
4.16.2. Relay injection
- Similar to 4.16.1.
4.16.3. Circuit checks
- There was a varied response in terms of maintenance period – however task is done
by most.
4.16.4. CT IR and continuity
- Similar to 4.16.3 – however several utilities advised condition based.

17
 4.17. Excitation system
4.17.1. AVR characteristic checks
- There were varied time intervals advised – however 3-5 years was common.
4.17.2. AVR limit checks
- Generally the same as 4.17.1.
4.17.3. Demagnetisation checks.
- A task done on time or condition basis – not done or recommended by one
manufacturer and two utilities.

Comments made relevant to this section of the survey were:

- Replies to Q3 were difficult to condense. Some generators have e.g. good service openings for
access to internals, some not. This kind of things in addition to service hours and type of loading
affect to the scope of revisions.
- Standard recommendation for steam turbine generators based on ‘equivalent operating hours’
(eoh):
- 1. minor overhaul after 25,000eoh
- 2. minor overhaul after 50,000eoh
- 3. major overhaul after 75,000eoh
- 4. minor overhaul after 100,000eoh
- 5. minor overhaul after 125,000eoh
- 6. major overhaul after 150,000eoh – etc.

- Standard recommendation for eoh count: eoh = oh + 20 * (no. of starts)

- In addition: rotor sealing tightness test at >90K hours.

- For the most part, on the generator and exciter, the calendar does not dictate maintenance
intervals. The machine history, the last inspection, the present condition, and the judgement of
the inspection engineer determine the next inspection interval or maintenance activity.
-
Appendices (at end of report):
 Planned maintenance tasks for generator components – Utilities (30 pages)
 Planned maintenance tasks for generator components – Manufacturers (11 pages)

18
5. GENERATOR IN-SERVICE DIAGNOSTIC TESTING
This section of the questionnaire sought information on the usage and frequency of in service diagnostic
tests for eight generator components and systems. One or more tests were nominated for each, and the
respondents were asked to advise information on the usage of the diagnostic test; the mode and
frequency of use; and the reason it was used.
A standard set of responses were listed as follows:
Usage of diagnostic test:
 Not used
 Used now
 Used in the past, (but not now)
 Will be used in the near future (but not used now).
Mode and frequency of use.
 Continuous use – data stored & reviewed regularly
 Continuous use – data monitored and alarmed continuously
 Intermittent use – weekly testing
 Intermittent use – monthly testing
 Intermittent use – 6 monthly testing
 Intermittent use – greater than 6 months between tests.
 Initiated if specific known condition arises
Reason for use
 Manufacturer’s recommendation
 Company usual practice
 Test equipment supplier recommendation
 Response to potential fault in generator
 Other reason

For this question also, the responses received are included in an appendix linked to this chapter. The
following summaries highlight any commonality or significant exceptions present in the responses.

5.1. Stator winding – slot content

5.1.1. Partial discharge monitoring – various types
- Where used by utilities, monitoring is generally on an intermittent basis – typically at
6 month intervals. The testing is recommended by most manufacturers on a
continuous or intermittent basis.

5.2. Stator winding – end windings

5.2.1. Stator end winding vibration monitor.
- A variety of responses – recommended by some manufacturers.

19
5.3. Rotor
5.3.1. Rotor shorted turns detection
- Generally used by utilities, but not universally, with intermittent monitoring at typically
6 month intervals. Recommended by manufacturers with one exception.
5.3.2. Shaft torsional oscillation monitoring
- Generally not used with two exceptions – one advising use on known condition only.
One manufacturer similarly advises use on a known condition basis.

5.4. Core & frame

5.4.1. Stator core/frame vibration monitoring
- Where used, generally on a known condition basis – exceptions are one country
using the diagnostic with continuous monitoring; another advising that it will be used
in the future continuously with regular review of data (manufacturer’s response from
the same country concurs).
5.4.2. Stator core lamination vibration – audio detector
- Not commonly used – some exceptions. Not recommended in any manufacturers
response.

5.5. Hydrogen cooling system

5.5.1. Dew point monitoring
- Generally used – mainly continuously but some intermittently. Not used in one
country, nor recommended in the country’s manufacturer response.
5.5.2. Hydrogen make up rate monitoring
- Some usage – not recommended in the response of manufacturers in three
countries, nor used in the utility response for the same countries.
5.5.3. Hydrogen purity analysis
- Universal continuous usage (one exception only). Recommended by all
manufacturers.

5.6. Stator water treatment

5.6.1. Stator cooling water conductivity
- Universal continuous usage – recommended by all manufacturers.
5.6.2. Hydrogen leakage into stator water
- Generally used in continuous mode, however intermittent for some. Not used in one
country, nor recommended in the same country’s manufacturer response (although it
had been recommended in the past).
5.6.3. Oxygen concentration
- Used generally by utilities – mode & frequency of use vary. Not used in one country,
nor recommended in the same country’s manufacturer response.

20
 5.6.4. Copper concentration
- Commonly used most often in continuous mode, but some intermittent monitoring
was reported. Not used in one country, nor recommended in the same country’s
manufacturer response.

5.7. Bearings
5.7.1. Bearing journal vibration – dual probe monitor.
- Universal continuous usage was reported (one exception only). Recommended by
all manufacturers.
5.7.2. Shaft grounding monitoring
- Commonly used, but not universally – a variety of modes and frequency. Not
recommended by one manufacturer.

5.8. Slip rings & brush gear (or diodes)

5.8.1. Brush on-line condition monitor
- Rarely used by utilities. Not recommended in manufacturer responses with one
exception.
5.8.2. Diode breakdown detection
- Generally recommended by manufacturers. Used by utilities in some countries.

Utilities were also asked if they have and use an expert system that considers some or all of the tests
performed and synthesises a diagnosis or actions (eg. alarms, or auto-generation of maintenance work
orders). All but two countries – Switzerland and Finland – answered in the negative.
Additional comments made were:
- Some techniques of monitoring systems already used all over the world should be included such
as:
- AGMS - air gap monitoring systems;
- SBV - Stator bar vibration;
- FOA - Fiber optics accelerometers;
- MFM - Magnetic flux measurement;
- Capacitive proximity sensors;
- Digital temperature monitoring systems - stator and rotor.

Appendix (at end of report):

 Generator in service diagnostic testing – Utilities & manufacturers (7 pages)

21
6. GENERATOR MAINTENANCE PRACTICES

The questionnaire sought to identify best practice techniques for major preventive and corrective
maintenance tasks on generators. Three scenarios were postulated for different levels of generator
outage maintenance, and typical maintenance techniques listed under each. Respondents were also
invited to add additional techniques used, and to advise any additional maintenance practices used. The
results are included in the following tables – the number of respondents answering in each category was
counted and entered into the tables. Total numbers may not be consistent as there were some
responses received in which some of the table cells were left blank. Total response number was 15 (the
Swiss response for this question was provided from two utilities).
From the responses, the most consistently used maintenance practices include:
- Application of formal quality control systems.
- Formal confined space entry procedures for access to generator casings.
- Control of internal inspections and inspectors, including training; protective clothing; and tool
control
- Use and control of clean condition enclosures for stator work (rotor in or out) and for work on a
rotor after its removal.
- Documented inspection procedures at critical stages, especially on final box-up of stator casings.

6.1. Scenario 1:
Short shutdown – generator de-gassed to air. Covers removed for internal inspection.

Usage
Always Sometimes Never
Maintenance technique
1. Dry air circulation, or heaters installed 4 3 7
2. Continuous internal air quality monitoring 1 5 7
3. Internal human access for inspection. 11 3 0
4. Formal confined space entry procedures. 10 3 1
5. Formal checks on internal inspectors:
10 3 0
 training & certification;
 protective clothing; 12 1 0
 tool controls. 11 3 0
6. Internal inspection by remote device only
0 7 5
– eg. video.
7. Documented inspection procedure before
9 1 4
box-up

22
 6.2. Scenario 2:
Generator de-gassed to air. Covers removed for internal inspection. End-shields fully or partially
removed. Rotor not removed.

Usage
Sometim
Always Never
Maintenance technique es
1. Formal Quality Control system used? 9 5 1
2. Dry air circulation, or heaters installed 4 7 4
3. Clean condition enclosure set up. 10 2 0
a. Security & access controls for
8 3 4
enclosure.
b. Formal checks on workers in
enclosure – Training & 9 3 3
certification; protective clothing.
c. Component tracing & tool control
8 3 4
procedures.
4. Formal confined space procedures for
10 2 3
generator entry.
5. Robot coil capacitance tests 0 5 10
6. Physical coil capacitance tests 1 8 6
7. Robot wedge tightness checks 0 7 7
8. Tracer gas winding leakage tests 3 10 2
9. Documented inspection procedure before
9 2 4
box-up
10. Other – please add below
1
Internal inspection by remote device

6.3. Scenario 3:

Long outage – generator rotor removed.

Usage
Sometime
Always Never
Maintenance technique s
1. Formal Quality Control system used? 10 3 1
2. Dry air circulation, or heaters installed 4 6 3
3. Clean condition enclosure set up for
10 3 0
stator.
a. Security & access controls for
7 2 4
enclosure.
b. Formal checks on workers in
enclosure – Training & 9 2 3
certification; protective clothing.
c. Component tracing & tool control
8 2 4
procedures.

23
 4. Clean condition enclosure set up for rotor. 9 5 1
a. Security & access controls for
8 3 3
enclosure.
b. Formal checks on workers in
enclosure – Training & 8 2 4
certification; protective clothing.
c. Component tracing & tool control
7 1 5
procedures.
5. Documented inspections before rotor re-
10 0 3
installation
6. Documented inspections before box-up. 9 1 3

6.4. Additional Comments:

USA:
- This utility relies heavily on ElectroMagnetic Interference (EMI) testing for all large electrical rotating
equipment. This testing is performed at frequencies from 10 K Hz through 1 G Hz. We have been
successfully using this non-invasive, on line, condition evaluation technique for over 20 years now.
EPRI is very familiar with this testing having held three seminars on the topic and performing a few
industry studies.

- Maintaining a history of inspection records in mandatory to a quality inspection program.

- The industry must not overlook the significance of a thorough visual inspection by a qualified and
experienced machinery engineer. Money spent on the education and training of an engineer
provides the greatest return on investment that any utility can earn. Relying on OEMs is not always
the most cost effective inspection method.

Switzerland:

- Responsibilities between generator-owner and maintenance supplier have to be clarified and agreed
on by both parties.

- Another item to check for old units is for asbestos fibre concentration in the generator.

7. CONCLUSION
The survey has provided a basis for comparison by utility engineers of maintenance practices across a
range of countries. The responses reported in the appendices provide a library of maintenance task
recommendations and actual practices that could be considered if new or modified practices are being
contemplated.
The aims of the study have largely been met, although the reasons for the differences in approach
highlighted in the various areas of maintenance practice surveyed were not adequately explained by the
data received. The most significant conclusion is that there is a considerable diversity in approach and
practice in use internationally. It has proven unrealistic to anticipate that a study such as this can identify
best or preferred practice in any particular area of generator maintenance.

24
8. APPENDIX 1 – Appendix to Chapter 4

Planned maintenance tasks for generator components – Utilities (pp 26 to 55)

25
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Stator winding – slot content
1. Inspect wedges and repair or
replace
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 10 years 7- 10 years 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer National Standard Manufacturer
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out
Actual
Period 7-10 years 15 years 7- 10 years 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience experience experience

2. Inspect slot insert migration

Not Service hours &
Basis Time Time Time Service hours Service hours
recommended operation cycles

Recommended Period > 10 years 10 years 7- 10 years 20K to 40K hours 40K to 60K hours > 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Any Major - rotor out Major - rotor out
Actual
Period > 10 years 15 years 7- 10 years Only if necessary 20K to 40K hours 40K to 60K hours > 90K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce

Decision Basis Risk assessment Not applicable Not applicable Not applicable
change experience experience experience
3. General inspection, clean, and
paint as required.
Service hours &
Basis Time Time Condition Based Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 4 years 3 - 5 years 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer National Standard Manufacturer
standard standard
Major - rotor in or
Outage type Major - rotor out Any Major - rotor out Major - rotor out Major - rotor out Major - rotor out
out
Actual
Period 7-10 years 4 years 2 years 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience experience

4. Electrical tests: IR; PI; winding

resistance; DLA / DDF/ tan δ.
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 4 years 3 - 5 years 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

International Company Company

Source Manufacturer Manufacturer National Standard Manufacturer
standard standard standard
Major - rotor in or
Outage type Major - rotor out Any Major - rotor out Major - rotor out Major - rotor out Major - rotor out
out
Actual
Period 7-10 years 4 years 3 - 5 years 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience

5. HV withstand
Not Service hours &
Basis Condition based Condition Based Time Service hours Service hours
recommended operation cycles

Recommended Period 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Company Company
Source Manufacturer National standard National Standard Manufacturer
standard standard

Outage type Task not done Major - rotor out Major - rotor out Major - rotor out Major - rotor out
Actual
Period 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience

26
 Finland Russia USA Japan France Croatia Switzerland
(Refer note - p9 of
Stator winding – slot content report)
1. Inspect wedges and repair or
replace
Time, service Service hrs or Service hours &
Basis Condition based Time Service hours
hours or cycles Condition based operation cycles
20K - 40K hrs
Recommended Period 5-7 or 7-10 years 3-5 years 3-5 years 40K - 60K hrs 40K to 60K hours
60K - 90K hrs
Mfr or Company Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Any
Actual
Period 5-7 or 7-10 years 3-5 years 5-7 years 3-5 years More than 7 years 7-10 years 3-5 years

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience

2. Inspect slot insert migration

Time, service Service hrs or Service hours &
Basis Time Time Service hours
hours or cycles Condition based operation cycles

Recommended Period 5-7 or 7-10 years 3-5 years 3-5 years 40K - 60K hrs 40K to 60K hours 20K to 40K hours

Mfr or Company Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Any
Actual
Period 5-7 or 7-10 years 3-5 years 5-7 years 3-5 years More than 7 years 40K to 60K hours 3-5 years

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience
3. General inspection, clean, and
paint as required.
Service hrs or Service hours &
Basis Condition based Time Time Service hours
Condition based operation cycles

Recommended Period 3-5 years 3-5 years 40K - 60K hrs 40K to 60K hours 20K to 40K hours

Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Any
out
Actual
Annual or 3-5
Period 5-7 or 7-10 years 3-5 years 5-7 years 3-5 years 7 - 10 years 40K to 60K hours
years
Actual/Recommended Prior mtce Prior mtce
Decision Basis Not applicable Not applicable Not applicable
change experience experience

4. Electrical tests: IR; PI; winding

resistance; DLA / DDF/ tan δ.
Time, service or Service hours &
Basis Time Time Service hours Time
condition operation cycles
Annual & 3 - 5
Recommended Period 3-5 years 7-10 years 10K - 20K hrs 3-5 years 20K to 40K hours
years
Company Mfr or Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Any Major - rotor out Any Major - rotor in Any
out out
Actual
Annual & 3 - 5 Annual or 3-5
Period 3-5 years 5-7 years 7-10 years Annual or 2 years 3-5 years
years years

Actual/Recommended Experience or Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change cost saving experience

5. HV withstand
Time or Condition Not Service hours &
Basis Time Condition based Time
based recommended operation cycles
20K - 40K hrs
Recommended Period 5-7 or 7-10 years 3-5 years 7-10 years
40K - 60K hrs
Company Mfr or Company
Source Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Task not done Major - rotor out Major - rotor out Major - rotor out
out out
Actual
3 - 5 years, or
Period 5-7 or 7-10 years 3-5 years Condition based 7 - 10 years 7-10 years
7 - 10 years
Actual/Recommended Maintenance cost
Decision Basis Not applicable Not applicable Not applicable
change saving

27
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Stator winding – end windings
1. Test for water leaks, and repair
Not Service hours &
Basis Time Time Time Service hours Condition based
recommended operation cycles

Recommended Period 3-5 years 2 years 2 years 60K to 90K hours 40K to 60K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Any Minor Major - rotor out Minor Major - rotor in
out out
Actual
Period 3-5 years 4 years 2 years Annual 60K to 90K hours 40K to 60K hours < 10K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Market needs
change experience experience experience experience
2 years. Test for water leaks – no
repair
Not Service hours &
Basis Time Time Time Service hours Service hours
recommended operation cycles

Recommended Period 3-5 years 2 years 2 years 60K to 90K hours 40K to 60K hours > 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or
Outage type Major - rotor in Any Minor Major - rotor out Minor Major - rotor in
out
Actual
Period 7-10 years 4 years 2 years Annual 60K to 90K hours 40K to 60K hours > 90K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience experience experience experience
3. Inspect end windings, including
supports, spacers and phase
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 4 years 2 years 5-7 years 60K to 90K hours 40K to 60K hours > 90K hours

Manufacturer, or Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
National std. standard standard
Major - rotor in or Major - rotor in or
Outage type Any Major - rotor out Major - rotor out Minor Major - rotor in
out out
Actual
Period 3-5 years 4 years 2 years 5-7 years 60K to 90K hours 40K to 60K hours > 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable
change experience
4. Inspect/test/repair temperature
sensors
Service hours &
Basis Time Time Time Time Service hours Condition based
operation cycles

Recommended Period 3-5 years 4 years 2 years 5-7 years 60K to 90K hours 60K to 90K hours < 10K hours

Manufacturer, or Company Company Company

Source Manufacturer Manufacturer Manufacturer
National std. standard standard standard
Major - rotor in or
Outage type Major - rotor out Any Major - rotor out Major - rotor out Major - rotor out Major - rotor in
out
Actual
Period 7-10 years 4 years 2 years 5-7 years 60K to 90K hours 60K to 90K hours < 10K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Market needs
change experience
5. General inspection for
contamination and insulation state;
Service hours &
Basis Time Time Time Time Service hours Condition based
operation cycles

Recommended Period 3-5 years 4 years 2 years 5-7 years 60K to 90K hours 40K to 60K hours < 10K hours

Manufacturer, or Company Company Company

Source Manufacturer Manufacturer Manufacturer
National std. standard standard standard
Major - rotor in or
Outage type Major - rotor in Any Major - rotor out Major - rotor out Minor Major - rotor out
out
Actual
Period 3-5 years 4 years 2 years 5-7 years 60K to 90K hours 40K to 60K hours > 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Market needs
change experience

28
 Serbia - Italy - Base Italy - Mid
Stator winding – end windings Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
6. Capacitance mapping
Not
Basis Time Time Service hours
recommended

Recommended Period 3-5 years 2 years > 90K hours

Source Manufacturer Manufacturer Manufacturer

Outage type Major - rotor out Major - rotor out Task not done Major - rotor in
Actual
Period 7-10 years 15 years > 90K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis On condition On condition Not applicable
change experience experience

7. Tracer gas leak test

Not
Basis Time Time Condition Based Condition based
recommended

Recommended Period 3-5 years 2 years < 10K hours

Company
Source Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or
Outage type Major - rotor out Any Minor Major - rotor in
out
Actual
Period 7-10 years 15 years Only if necessary < 10K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce Prior mtce

Decision Basis On condition On condition Market needs
change experience experience experience experience

8. Modal response
Not Not
Basis Time Service hours
recommended recommended

Recommended Period 3-5 years > 90K hours

Source Manufacturer Manufacturer

Major - rotor in or
Outage type Major - rotor out Task not done Task not done Minor
out
Actual
Period 7-10 years Only if necessary > 90K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis On condition On condition Not applicable
change experience experience

29
 Finland Russia USA Japan France Croatia Switzerland

Stator winding – end windings

1. Test for water leaks, and repair
Service hrs or
Basis Condition based Time Time Service hours Condition based
Condition based

Recommended Period 3-5 years Two years 10K - 20K hrs 40K to 60K hours 20K to 40K hours

Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Task not done
out out out out
Actual
Period 3-5 years Condition based Two years 40K to 60K hours Annual

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable Market needs
change

2. Test for water leaks – no repair

Time, service Not Service hours &
Basis Condition based Service hours Service hours
hours or cycles recommended operation cycles

Recommended Period 2 - 5 years 10K - 20K hrs 40K to 60K hours 20K to 40K hours

Manufacturer &
Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std
Major - rotor in or Not
Outage type Major - rotor out Major - rotor out Task not done
out recommended
Actual
Period Annual 7 - 10 years 40K to 60K hours Annual

Actual/Recommended
Decision Basis Risk assessment Not applicable Not applicable Market needs
change
3. Inspect end windings, including
supports, spacers and phase
Time, service Service hours &
Basis Time Time Service hours Service hours
hours or cycles operation cycles

Recommended Period 3 - 7 years 3-5 years Two years 10K - 20K hrs 20K to 40K hours 20K to 40K hours

Manufacturer & Mfr or Company Company

Source Manufacturer Manufacturer Manufacturer
Company std standard standard
Minor, or Major - Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor in
rotor out out out out
Actual
Annual or 3-5
Period Annual 3-5 years 5-7 years Two years 3 - 5 years 20K to 40K hours
years
Actual/Recommended Prior mtce Prior mtce
Decision Basis Risk assessment Not applicable Not applicable
change experience experience
4. Inspect/test/repair temperature
sensors
Service hrs or Service hours &
Basis Time Time Time Service hours
Condition based operation cycles
Annual or 3-5
Recommended Period 2 - 5 years Two years 40K - 60K hrs 40K to 60K hours 20K to 40K hours
years
Manufacturer & Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or
Outage type Any Minor Major - rotor out Major - rotor out Major - rotor out Any or none
out
Actual
Annual or 3-5
Period Annual Condition based Two years 7 - 10 years 40K to 60K hours Annual
years
Actual/Recommended
Decision Basis Risk assessment Not applicable Not applicable Not applicable Market needs
change
5. General inspection for
contamination and insulation state;
Time, service Service hrs or Service hours &
Basis Time Time Service hours
hours or cycles Condition based operation cycles

Recommended Period 2 - 5 years 3-5 years Two years 40K - 60K hrs 40K to 60K hours 20K to 40K hours

Company
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or
Outage type Major - rotor out Major - rotor out Minor Major - rotor out Major - rotor out Any
out
Actual
Annual or 3-5
Period 2 - 5 years 3-5 years 5-7 years Two years 7 - 10 years 40K to 60K hours
years
Actual/Recommended Prior mtce
Decision Basis Not applicable Not applicable Market needs
change experience

30
 Stator winding – end windings Finland Russia USA Japan France Croatia Switzerland

6. Capacitance mapping
Time or Condition Not Service hrs or Service hours &
Basis Time Service hours
based recommended Condition based operation cycles
10K - 20K hrs or
Recommended Period 7-10 years 3-5 years 20K to 40K hours 40K to 60K hours
40K - 60K hrs
Company
Source Manufacturer Manufacturer Manufacturer
standard
Not
Outage type Major - rotor out Task not done Major - rotor out Major - rotor out Major - rotor in
recommended
Actual
Period 7-10 years Condition based 3-5 years 20K to 40K hours

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable Risk assessment
change

7. Tracer gas leak test

Time, service
Basis Time Condition based Service hours Condition based Condition based
hours or cycles

Recommended Period Two years 3-5 years 40K - 60K hrs 20K to 40K hours 20K to 40K hours

Company Mfr or Company

Source Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor in
out out
Actual
Period Two years 3-5 years Condition based 7 - 10 years 20K to 40K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Other Market needs
change experience

8. Modal response
Time, service Not
Basis Service hours Condition based
hours or cycles recommended

Recommended Period 5-7 or 7-10 years 40K - 60K hrs 20K to 40K hours

Company
Source Manufacturer
standard

Outage type Major - rotor out Task not done Major - rotor out
Actual
Period 7-10 years Condition based 7 - 10 years

Actual/Recommended Prior mtce

Decision Basis Market needs
change experience

31
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Stator winding - terminal box.
1. General inspection and clean;
including support insulators, flexibles
Service hours &
Basis Time Time Time Time Service hours Condition based
operation cycles

Recommended Period 3-5 years 4 years 2 years 5-7 years 20K to 40K hours 20K to 40K hours 20K to 40K hours

Manufacturer or Mfr or National Company Company Company

Source Manufacturer Manufacturer
other standard standard standard standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Minor Minor Major - rotor in
out out out
Actual
Period 3-5 years 4 years 2 years 5-7 years 20K to 40K hours 20K to 40K hours 40K to 60K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience
2. Disconnect flexibles; inspect;
replace as required; reconnect.
Not Service hours &
Basis Time Time Time Service hours Condition based
recommended operation cycles

Recommended Period > 10 years 3 - 5 years 5-7 years 20K to 40K hours 20K to 40K hours 20K to 40K hours

Mfr or National Company Company Company

Source Manufacturer Manufacturer
standard standard standard standard
Major - rotor in or Major - rotor in or
Outage type Task not done Major - rotor out Minor Minor Major - rotor in
out out
Actual
Period > 10 years 3 - 5 years 5-7 years 20K to 40K hours 20K to 40K hours 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Other Not applicable Not applicable Not applicable Not applicable
change experience

3. CT electrical and ratio tests etc.

Not
Basis Condition Based Time Condition based
recommended

Recommended Period 5-7 years 20K to 40K hours

Mfr or National Company

Source
standard standard

Outage type Task not done Major - rotor out Major - rotor in
Actual
Period 5-7 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable
change experience

32
 Finland Russia USA Japan France Croatia Switzerland

Stator winding - terminal box.

1. General inspection and clean;
including support insulators, flexibles
Service hours &
Basis Time Time Time Service hours Service hours
operation cycles

Recommended Period Annual 3-5 years Two years 10K - 20K hrs 40K to 60K hours 20K to 40K hours

Company
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Minor Major - rotor out Major - rotor out Any
out out out
Actual
Annual or 3-5
Period Annual 3-5 years 5-7 years Two years 3-5 or 7-10 years 40K to 60K hours
years
Actual/Recommended Prior mtce
Decision Basis Not applicable Not applicable Market needs
change experience
2. Disconnect flexibles; inspect;
replace as required; reconnect.
Time, service Service hrs or
Basis Time Time Service hours Condition based
hours or cycles Condition based

Recommended Period 5-7 or 7-10 years 3-5 years 7-10 years 10K - 20K hrs 20K to 40K hours 20K to 40K hours

Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor in Major - rotor in
out out
Actual
Period 5-7 or 7-10 years 3-5 years Condition based 7-10 years 3 - 5 years 20K to 40K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience

3. CT electrical and ratio tests etc.

Not Service hours &
Basis Time Condition based Time Service hours
recommended operation cycles
Annual or 3-5
Recommended Period 5-7 or 7-10 years 7-10 years 40K to 60K hours 40K to 60K hours
years
Company Company Company
Source Manufacturer
standard standard standard
Major - rotor in or No outage Major - rotor in or
Outage type Major - rotor out Major - rotor out
out required out
Actual
Period 5-7 or 7-10 years Condition based 7-10 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable
change experience

33
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Bushings.
1. Inspection & clean, external.
Not Service hours &
Basis Time Time Time Service hours Service hours
recommended operation cycles

Recommended Period Annual 4 years 7- 10 years 20K to 40K hours 20K to 40K hours 20K to 40K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Minor Minor Major - rotor in
out out out
Actual
Period 3-5 years 4 years 3 - 5 years 5-7 years 20K to 40K hours 20K to 40K hours 40K to 60K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience experience experience
2. Internal inspection – gas cooled
bushings
Service hours &
Basis Time Time Time Service hours Service hours
operation cycles

Recommended Period > 10 years 4 years 7- 10 years 20K to 40K hours 20K to 40K hours 20K to 40K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Minor Minor Major - rotor out
out out
Actual
Period > 10 years 4 years 7- 10 years 20K to 40K hours 20K to 40K hours > 90K hours

Actual/Recommended Prior mtce

Decision Basis Risk assessment Not applicable Not applicable Not applicable Not applicable
change experience
3. Leakage test - replace gaskets
and seals if required.
Not
Basis Time Time Time Service hours
recommended

Recommended Period 3-5 years 10 years 7- 10 years 20K to 40K hours

Company
Source Manufacturer Manufacturer Manufacturer
standard
No outage Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor in
required out
Actual
Period Two years 20 7- 10 years 5-7 years 40K to 60K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce Prior mtce

Decision Basis Not applicable On condition On condition
change experience experience experience experience
4. Leakage test - replace bushings
if required.
Not Not
Basis Time Time Service hours
recommended recommended

Recommended Period > 10 years 7- 10 years 20K to 40K hours

Company
Source Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or
Outage type Task not done Major - rotor out Minor
out out
Actual
Period > 10 years 7- 10 years Only if necessary > 90K hours

Actual/Recommended Prior mtce Prior mtce Prior mtce

Decision Basis Not applicable On condition On condition
change experience experience experience

34
 Finland Russia USA Japan France Croatia Switzerland

Bushings.
1. Inspection & clean, external.
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period Annual 3-5 years Two years 10K - 20K hrs 3-5 years 20K to 40K hours

Company Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or
Outage type Minor Minor Major - rotor out Major - rotor in Any
out out
Actual
Period Annual 3-5 years 5-7 years Two years 7 - 10 years 3-5 years 3-5 years

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Market needs
change experience experience
2. Internal inspection – gas cooled
bushings
Not Service hours &
Basis Time Time Time Time
recommended operation cycles

Recommended Period 5-7 or 7-10 years 3-5 years 3-5 years 3-5 years 20K to 40K hours

Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor in
out out
Actual
Period 5-7 or 7-10 years 3-5 years Condition based 3-5 years 3-5 years 3-5 years

Actual/Recommended Rec being Prior mtce

Decision Basis Not applicable Market needs
change followed experience
3. Leakage test - replace gaskets
and seals if required.
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period > 7 years 3-5 years Two years > 90K hours 5-7 years 40K to 60K hours

Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Any
out out out
Actual
Annual or 3-5
Period > 7 years 3-5 years Condition based Two years 5-7 years
years
Actual/Recommended Prior mtce
Decision Basis Not applicable Market needs
change experience
4. Leakage test - replace bushings
if required.
Service hours &
Basis Time Time Condition based Condition based Time
operation cycles

Recommended Period > 7 years 3-5 years 5-7 years 40K to 60K hours

Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out
out out
Actual
Period > 7 years 3-5 years Condition based 5-7 years Annual

Actual/Recommended Prior mtce

Decision Basis Not applicable Market needs
change experience

35
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Core & frame
1. Visual inspection & clean.
Service hours & Not
Basis Time Time Time Time Service hours
operation cycles recommended

Recommended Period 3-5 years 4 years 7- 10 years 5-7 years 60K to 90K hours 60K to 90K hours

Mfr or National Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out
out out
Actual
Period 3-5 years 4 years 3 - 5 years 5-7 years 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience

2. Frame cracking NDT & repair.

Not Not Not
Basis Time Time
recommended recommended recommended

Recommended Period 3-5 years 7- 10 years

Source Manufacturer

Outage type Major - rotor out Task not done Major - rotor out Minor
Actual
Period > 10 years 7- 10 years Only if necessary

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable On condition On condition
change experience

3. Check liquid level detectors

Service hours &
Basis Time Time Time Service hours
operation cycles

Recommended Period Daily 3 - 5 years Annual 20K to 40K hours 20K to 40K hours

Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or
Outage type Minor Minor Minor
out
Actual
Period Daily 3 - 5 years Annual 20K to 40K hours 20K to 40K hours

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable Not applicable
change
4. Check longitudinal core
tightening screws.
Service hours & Not
Basis Time Time Time Time Service hours
operation cycles recommended

Recommended Period 3-5 years 4 years 7- 10 years 5-7 years 60K to 90K hours 60K to 90K hours

Mfr or National Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out
out
Actual
Period > 10 years 4 years 7- 10 years 5-7 years 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience
5. Check gas flow control rings,
baffles etc.
Service hours &
Basis Time Time Time Time Service hours
operation cycles

Recommended Period 3-5 years 4 years 7- 10 years Annual 20K to 40K hours 20K to 40K hours

Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Minor Minor Minor
Actual
Period 7-10 years 15 years 7- 10 years Annual 20K to 40K hours 20K to 40K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience experience

36
 Serbia - Italy - Base Italy - Mid
Core & frame Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
6. Inspect end shields.
Not
Basis Time Time Time
recommended

Recommended Period 3-5 years 3 - 5 years 5-7 years

Mfr or National
Source Manufacturer Manufacturer
standard
Major - rotor in or
Outage type Major - rotor out Task not done Major - rotor out
out
Actual
Period 7-10 years 3 - 5 years 5-7 years

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable
change experience

7. El-Cid test
Not Service hours & Not
Basis Time Condition based Condition Based Service hours
recommended operation cycles recommended

Recommended Period 3-5 years 60K to 90K hours 60K to 90K hours

Company Company
Source Other
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out
Actual
Period > 10 years 5-7 years 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Market needs Not applicable Not applicable
change experience experience

8. Ring flux test

Elcro
Basis Condition Based Time
recommended

Recommended Period 5-7 years

Source National standard

Outage type Major - rotor out

Actual
Period 5-7 years

Actual/Recommended
Decision Basis Not applicable On condition On condition
change

37
 Finland Russia USA Japan France Croatia Switzerland

Core & frame

1. Visual inspection & clean.
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period 5-7 years 3-5 years 3-5 years 40K - 60K hrs 5-7 years 20K to 40K hours

Manufacturer &
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
Company std
Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Any
out
Actual
Annual or 3-5
Period 5-7 or 7-10 years 3-5 years 5-7 years 3-5 years 7 - 10 years 5-7 years
years
Actual/Recommended Prior mtce Prior mtce
Decision Basis Not applicable Not applicable
change experience experience

2. Frame cracking NDT & repair.

Not
Basis Condition based Condition based Condition based Time Condition based
recommended

Recommended Period 5-7 years 40K to 60K hours

Source Manufacturer Manufacturer

Outage type Major - rotor out Task not done Major - rotor out
Actual
Period Condition based 5-7 years 3-5 years

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable
change experience

3. Check liquid level detectors

Service hours &
Basis Time Time Time Condition based Time
operation cycles

Recommended Period Annual Annual Two years Annual 20K to 40K hours

Manufacturer & Company

Source Other Manufacturer Manufacturer
Company std standard
Major - rotor in or No outage Major - rotor in or Major - rotor in or No outage
Outage type Minor Any
out required out out required
Actual
Annual or 3-5
Period Annual Annual Two years 7 - 10 years Annual
years
Actual/Recommended
Decision Basis Not applicable National Standard Market needs
change
4. Check longitudinal core
tightening screws.
Time, service Not Not
Basis Time Time Time
hours or cycles recommended recommended

Recommended Period 2 - 5 years 3-5 years 3-5 years 5-7 years

Manufacturer &
Source Manufacturer Manufacturer Manufacturer
Company std
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out Task not done
out out
Actual
Period 2 - 5 years 3-5 years 7-10 years 3-5 years 5-7 years

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience
5. Check gas flow control rings,
baffles etc.
Time, service Service hours &
Basis Condition based Time Service hours Time
hours or cycles operation cycles

Recommended Period 5-7 or 7-10 years 3-5 years 40K - 60K hrs 5-7 years 20K to 40K hours

Manufacturer &
Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Any
out out
Actual
Period 5-7 or 7-10 years Condition based 3-5 years 5-7 years Annual

Actual/Recommended Rec being Prior mtce

Decision Basis Not applicable
change followed experience

38
Core & frame Finland Russia USA Japan France Croatia Switzerland

6. Inspect end shields.

Time, service Service hours &
Basis Time Time Service hours Time
hours or cycles operation cycles

Recommended Period 5-7 or 7-10 years 3-5 years 3-5 years 40K - 60K hrs 5-7 years 40K to 60K hours

Company
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out
out out
Actual
Period 5-7 or 7-10 years 3-5 years 5-7 years 3-5 years 7 - 10 years 5-7 years 3-5 or 7-10 years

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable
change experience experience

7. El-Cid test
Time, service Not Service hours &
Basis Time Service hours Service hours
hours or cycles recommended operation cycles

Recommended Period 5-7 or 7-10 years 3-5 years 40K - 60K hrs 40K to 60K hours 20K to 40K hours

Company
Source Other Manufacturer Manufacturer Manufacturer
standard

Outage type Major - rotor out Major - rotor out Major - rotor out Task not done Major - rotor out Major - rotor out Any
Actual
Period 7-10 years 3-5 years Condition based 7 - 10 years 40K to 60K hours 3-5 years

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable Market needs
change

8. Ring flux test

Not
Basis Condition based Time Condition based Condition based
recommended

Recommended Period 3-5 years 20K to 40K hours

Company Mfr or Company

Source
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Task not done
Actual
Period > 10 years 3-5 years Condition based

Actual/Recommended
Decision Basis Not applicable Not applicable Risk assessment
change

39
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Stator cooling water system
1. Inspect heat exchangers
Service hours & Not
Basis Time Time Time Time Service hours
operation cycles recommended

Recommended Period 3-5 years 4 years 7- 10 years Annual 60K to 90K hours 60K to 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or
Outage type Major - rotor out Major - rotor out Minor Major - rotor out Major - rotor out
out
Actual
Period 7-10 years 4 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience
2. Mechanical maintenance of
pumps, valves etc.
Service hours & Not
Basis Time Time Time Time Service hours
operation cycles recommended

Recommended Period Annual 4 years 7- 10 years Annual 60K to 90K hours 60K to 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or
Outage type Major - rotor out Major - rotor out Minor Major - rotor out Major - rotor out
out
Actual
Period 4 years 7- 10 years Annual 60K to 90K hours 60K to 90K hours

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change

3. Pressure test
Not Service hours & Not
Basis Time Time Time Service hours
recommended operation cycles recommended

Recommended Period 3-5 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or
Outage type Task not done Minor Major - rotor out Major - rotor out
out out
Actual
Period 3-5 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience

4. Vacuum test
Not Not Service hours & Not
Basis Condition based Time Service hours
recommended recommended operation cycles recommended

Recommended Period 7- 10 years 60K to 90K hours 60K to 90K hours

Company Company
Source Manufacturer
standard standard
Major - rotor in or
Outage type Task not done Major - rotor out Major - rotor out Major - rotor out
out
Actual
Period 7-10 years 7- 10 years 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience

40
 Finland Russia USA Japan France Croatia Switzerland

Stator cooling water system

1. Inspect heat exchangers
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period Annual 1 - 2 years 3-5 years > 90K hours 3-5 years 20K to 40K hours

Manufacturer & Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or
Outage type Minor Minor Major - rotor out Major - rotor in Major - rotor in Any
out
Actual
Period Annual 1 - 2 years 5-7 years 3-5 years 3 - 5 years 3-5 years 7-10 years

Actual/Recommended
Decision Basis Not applicable Not applicable Market needs
change
2. Mechanical maintenance of
pumps, valves etc.
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period Annual 3-5 years 3-5 years 40K - 60K hrs Annual 20K to 40K hours

Company Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or No outage
Outage type Minor Minor Major - rotor out Any
out required
Actual
Period Annual 3-5 years 5-7 years 3-5 years Annual 3-5 years

Actual/Recommended
Decision Basis Not applicable Not applicable Market needs
change

3. Pressure test
Service hours &
Basis Time Time Time Condition based Service hours
operation cycles

Recommended Period 3 - 10 years 3-5 years 3-5 years 40K to 60K hours 40K to 60K hours

Company Mfr or Company

Source Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out
out out
Actual
Period 5-7 or 7-10 years 3-5 years Condition based 3-5 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable
change experience

4. Vacuum test

Basis Time Time Time Service hours Service hours Condition based

Recommended Period 3 - 10 years 1 - 2 years 3-5 years 10K - 20K hrs 40K to 60K hours 20K to 40K hours

Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out
out out
Actual
Period 5-7 or 7-10 years 1 - 2 years Condition based 3-5 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable
change experience

41
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Stator water treatment
1. Replace resin
Technical Not
Basis Time Condition Based Time Time
diagnostic recommended

Recommended Period 20months Annual Annual

Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard
No outage No outage No outage
Outage type
required required required
Actual
Period As required Annual Annual

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience

2. Component inspection & repair

Service hours & Not
Basis Time Condition Based Time Service hours
operation cycles recommended

Recommended Period 2 years Annual 60K to 90K hours 60K to 90K hours

Company Company
Source Manufacturer Manufacturer
standard standard
Not
Outage type Minor Major - rotor out Major - rotor out
recommended
Actual
Period Annual 60K to 90K hours 60K to 90K hours

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable
change
3. Calibrate conductivity
instruments.
Not Service hours & Not
Basis Time Time Time Service hours
recommended operation cycles recommended

Recommended Period Annual 5-7 years 60K to 90K hours 60K to 90K hours

Company Company
Source Manufacturer Manufacturer
standard standard
Major - rotor in or No outage Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out
out required out out
Actual
Period 3-5 years 4 years 2 years 5-7 years 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience

42
 Finland Russia USA Japan France Croatia Switzerland

Stator water treatment

1. Replace resin
Time or Condition
Basis Condition based Condition based Service hours Time Condition based
based

Recommended Period 1 - 2 years 2 years Two years 20K to 40K hours

Manufacturer & Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
No outage No outage No outage No outage
Outage type Minor Minor Any
required required required required
Actual
Period 1 - 2 years Annual or 2 years Two years 5-7 years

Actual/Recommended Rec being Prior mtce

Decision Basis Not applicable Market needs
change followed experience

2. Component inspection & repair

Time & operation
Basis Time Time Service hours Time Condition based
cycles

Recommended Period Annual 3-5 years Two years 40K - 60K hrs Annual 20K to 40K hours

Manufacturer &
Source Other Manufacturer Manufacturer Manufacturer Manufacturer
Company std
Major - rotor in or Major - rotor in or Major - rotor in or No outage
Outage type Minor Any
out out out required
Actual
Period Annual 3-5 years Two years Annual Annual

Actual/Recommended
Decision Basis Not applicable Not applicable Market needs
change
3. Calibrate conductivity
instruments.
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period 1 - 2 years 3-5 years Annual 40K - 60K hrs Annual 20K to 40K hours

Company
Source Other Manufacturer Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or Major - rotor in or No outage No outage
Outage type Manufacturer Any
out out out required required
Actual
Period 1 - 2 years 3-5 years Annual 3 - 5 years Annual Annual

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable
change experience

43
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Rotor
1. Remove rotor for inspection -
inspect accessible rotor components,
including fan; NDT of rotor bore.
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 10 years 7- 10 years 5-7 years 60K to 90K hours 60K to 90K hours > 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out
Actual
Period 7-10 years 15 years 7- 10 years 5-7 years 60K to 90K hours 20K to 40K hours > 90K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience

2. Remove retaining rings –

inspect & NDT rings, wedges & slots.

Basis Time Time Time Time Service hours

Recommended Period 3-5 years 10 years 7- 10 years >7 years > 90K hours

Source Other Manufacturer Manufacturer Manufacturer Manufacturer

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out
Actual
Period > 10 years 25 years 7 - 10 years >7 years > 90K hours

Actual/Recommended Maintenance cost Prior mtce

Decision Basis Not applicable Not applicable On condition On condition Not applicable
change saving experience

3. Electrical tests: IR; PI; RSO;

winding resistance
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 10 years 3 - 5 years 5-7 years 20K to 40K hours 20K to 40K hours > 90K hours

International Mfr or National Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Any Major - rotor out Major - rotor out Minor
out out
Actual
Period 7-10 years 4 years 3 - 5 years 5-7 years 20K to 40K hours 20K to 40K hours > 90K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience

4. Time of flight diffraction

Not Not
Basis Time Time
recommended recommended

Recommended Period 3-5 years 5-7 years

Source Manufacturer Other

Major - rotor in or
Outage type Major - rotor out Major - rotor out
out
Actual
Period 7-10 years 15 years 5-7 years

Actual/Recommended Prior mtce Prior mtce Prior mtce

Decision Basis
change experience experience experience

44
 Finland Russia USA Japan France Croatia Switzerland

Rotor
1. Remove rotor for inspection -
inspect accessible rotor components,
including fan; NDT of rotor bore.
Time, service Service hours &
Basis Time Time Service hours Service hours
hours or cycles operation cycles

Recommended Period 5-7 or 7-10 years 3-5 years 3-5 years 40K - 60K hrs 40K to 60K hours 40K to 60K hours

Manufacturer & Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out
Actual
2-5 years OR
Period 5-7 or 7-10 years 3-5 years 5-7 years 3-5 years 7 - 10 years 40K to 60K hours
7-10 years
Actual/Recommended Prior mtce Prior mtce
Decision Basis Not applicable Not applicable
change experience experience

2. Remove retaining rings –

inspect & NDT rings, wedges & slots.
Time, service Service hours &
Basis Time Time Service hours Service hours
hours or cycles operation cycles

Recommended Period 5-7 or 7-10 years 3-5 or >10 yrs >10 yrs 40K - 60K hrs 40K to 60K hours 60K to 90K hours

Company Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard

Outage type Major - rotor out Major - rotor out Major - rotor out Major - rotor out Major - rotor out
Actual
Period 5-7 or >10 years 3-5 or >10 yrs Condition based >10 yrs 40K to 60K hours >7 years

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable
change experience
3. Electrical tests: IR; PI; RSO;
winding resistance
Time or Condition Service hours &
Basis Time Time Service hours Time
based operation cycles
Annual or 3-5
Recommended Period Annual 3-5 years 10K - 20K hrs 3-5 years 20K to 40K hours
years
Manufacturer & Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or
Outage type Minor Major - rotor out Major - rotor out Any Major - rotor in Any
out
Actual
Annual or 3-5
Period Annual 3-5 years 5-7 years 3-5 years 2 years 3-5 years
years
Actual/Recommended Prior mtce
Decision Basis Not applicable Not applicable Market needs
change experience

4. Time of flight diffraction

Not Not Not
Basis Time Time
recommended recommended recommended

Recommended Period 7-10 years Two years

Source Manufacturer Other

No outage
Outage type Major - rotor out
required
Actual
Period Condition based 7-10 years Two years

Actual/Recommended Prior mtce

Decision Basis
change experience

45
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Hydrogen cooling system
1. Remove, inspect & repair
hydrogen coolers.
Service hours &
Basis Time Time Time Time Service hours Condition based
operation cycles

Recommended Period 3-5 years 4 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours > 90K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Minor Major - rotor out Major - rotor out Major - rotor out
out out out
Actual
Period 7-10 years 4 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours > 90K hours

Actual/Recommended Prior mtce Maintenance cost

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience saving
2. Pressure test cooling water
piping.
Not Service hours &
Basis Time Condition based Time Service hours Service hours
recommended operation cycles

Recommended Period 3-5 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Task not done Minor Major - rotor out Major - rotor out Minor
out out
Actual
Period 7-10 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours < 10K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience
3. Calibrate dewpoint
instrumentation
Not Service hours &
Basis Time Time Time Service hours Service hours
recommended operation cycles

Recommended Period Two years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer
standard standard standard
Major - rotor in or No outage Major - rotor in or
Outage type M Major - rotor out Major - rotor out Minor
out required out
Actual
Period 7-10 years Monthly 3 - 5 years Annual 60K to 90K hours 60K to 90K hours < 10K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience

Hydrogen seals
1. Inspect, including NDT
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 4 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Minor Minor Minor Minor
out out
Actual
Period 3-5 years 15 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable
change experience

2. IR testing
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 4 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Minor Minor Minor Minor
out out
Actual
Period 3-5 years 15 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable
change experience

46
 Finland Russia USA Japan France Croatia Switzerland

Hydrogen cooling system

1. Remove, inspect & repair
hydrogen coolers.
Time, service Service hrs or Service hours &
Basis Time Time Service hours
hours or cycles Condition based operation cycles
2 years or 5-7 20K-40K or 60K-
Recommended Period 2 or 3-5 years 3-5 years 40K - 60K hrs 40K to 60K hours
years 90K hours
Manufacturer & Mfr or Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Manufacturer Major - rotor out Any
out out out
Actual
Annual or 7-10
Period 3 - 7 years 2 or 3-5 years Condition based 3-5 years 5 - 7 years 40K to 60K hours
years
Actual/Recommended Prior mtce
Decision Basis Not applicable Not applicable
change experience
2. Pressure test cooling water
piping.
Not Service hours &
Basis Time Time Time Service hours
recommended operation cycles

Recommended Period 5-7 years 3-5 years 3-5 years 40K to 60K hours 40K to 60K hours

Company Mfr or Company

Source Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor out
out out
Actual
Period 5-7 or 7-10 years 3-5 years Condition based 3-5 years 7 - 10 years 40K to 60K hours

Actual/Recommended
Decision Basis Not applicable Not applicable Market needs
change
3. Calibrate dewpoint
instrumentation
Not Service hours &
Basis Time Time Service hours
recommended operation cycles

Recommended Period 2 - 5 years 3-5 years 40K - 60K hrs 20K to 40K hours

Company
Source Other Manufacturer Manufacturer
standard
No outage Major - rotor in or
Outage type Task not done Major - rotor out Any
required out
Actual
Period 3-5 years 3-5 years Condition based 7 - 10 years Annual

Actual/Recommended
Decision Basis Not applicable Market needs
change

Hydrogen seals
1. Inspect, including NDT
Time, service Service hours &
Basis Time Time Service hours Service hours
hours or cycles operation cycles

Recommended Period 3 - 7 years 2 or 3-5 years 3-5 years 40K - 60K hrs 20K to 40K hours 40K to 60K hours

Manufacturer & Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor in
out out out
Actual
Period 3 - 7 years 2 or 3-5 years 5-7 years 3-5 years 7 - 10 years 20K to 40K hours 3-5 years

Actual/Recommended Maintenance cost

Decision Basis Not applicable Not applicable
change saving

2. IR testing
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period Annual 2 or 3-5 years Two years 10K - 20K hrs Annual 40K to 60K hours

Manufacturer & Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or Major - rotor in or Major - rotor in or Major - rotor in or No outage
Outage type Minor
out out out out required
Actual
Period Annual 2 or 3-5 years 5-7 years Two years 3 - 5 years Annual 3-5 years

Actual/Recommended Prior mtce Maintenance cost

Decision Basis Not applicable Not applicable
change experience saving

47
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Bearings
1. Inspection including NDT
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 4 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours 20K to 40K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or
Outage type Major - rotor out Major - rotor out Minor Minor Minor Major - rotor in
out
Actual
Period 3-5 years 15 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours 20K to 40K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable
change experience

2. IR testing
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period Two years 4 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or
Outage type Major - rotor out Major - rotor out Minor Minor Minor Minor
out
Actual
Period 3-5 years 15 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience
3. Shaft earthing system inspect &
repair
Service hours &
Basis Time Time Time Service hours Service hours
operation cycles

Recommended Period Two years Weekly < 10K hours 20K to 40K hours 20K to 40K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer
standard standard standard
Major - rotor in or No outage No outage
Outage type Minor Minor Minor
out required required
Actual
Period Annual 2 week < 10K hours 20K to 40K hours 20K to 40K hours < 10K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience experience

Seal oil system

1. Mechanical maintenance of
pumps, strainers etc.
Service hours &
Basis Time Time Time Time Service hours Condition based
operation cycles

Recommended Period Two years 4 years 2 years Annual 60K to 90K hours 60K to 90K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or
Outage type Minor Minor Major - rotor out Major - rotor out Minor
out out
Actual
Period 3-5 years 4 years 2 years Annual 60K to 90K hours 60K to 90K hours < 10K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable
change experience

48
 Finland Russia USA Japan France Croatia Switzerland

Bearings
1. Inspection including NDT
Time, service Time & operation Service hours &
Basis Time Service hours Service hours
hours or cycles cycles operation cycles

Recommended Period 2 - 5 years 3-5 years 3-5 years 40K - 60K hrs 20K to 40K hours 20K to 40K hours

Manufacturer &
Source Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
Company std
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Major - rotor out Major - rotor out Major - rotor in Any
out out out
Actual
Period 2 - 5 years 3-5 years 5-7 years 3-5 years 7 - 10 years 20K to 40K hours 3-5 years

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable
change experience

2. IR testing
Time & operation Service hours &
Basis Time Time Service hours Time
cycles operation cycles

Recommended Period Annual 3-5 years Two years 10K - 20K hrs Annual 20K to 40K hours

Manufacturer & Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or Major - rotor in or Major - rotor in or Major - rotor in or No outage
Outage type Minor Any
out out out out required
Actual
Period Annual Annual 5-7 years Two years 3 - 5 years Annual 3-5 years

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable
change experience experience
3. Shaft earthing system inspect &
repair
Service hours &
Basis Time Condition based Time Service hours Time
operation cycles

Recommended Period Annual Two years 10K - 20K hrs Annual 20K to 40K hours

Manufacturer & Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
No outage Major - rotor in or No outage
Outage type Minor Minor Any
required out required
Actual
Annual & 3 - 5
Period Annual Two years Annual 1 or 2 years
years
Actual/Recommended
Decision Basis Not applicable Not applicable Market needs
change

Seal oil system

1. Mechanical maintenance of
pumps, strainers etc.
Time, service
Basis Time Time Service hours Time Condition based
hours or cycles

Recommended Period 2 - 5 years 2 or 3-5 years 3-5 years 10K - 20K hrs Annual 20K to 40K hours

Manufacturer & Mfr or Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or Major - rotor in or No outage
Outage type Minor Major - rotor out Major - rotor out Any
out out required
Actual
Period 2 - 5 years 2 or 3-5 years 5-7 years 3-5 years 7 - 10 years Annual 3-5 years

Actual/Recommended Maintenance cost

Decision Basis Not applicable Not applicable
change saving

49
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Slip rings & brush gear (or
diodes)
1. Inspection, including brush
wear
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period Annual Weekly < 10K hours Annual 20K to 40K hours 20K to 40K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
No outage No outage No outage
Outage type Minor Minor Minor Minor
required required required
Actual
Period Annual 2 week < 10K hours Annual 20K to 40K hours 20K to 40K hours < 10K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience
2. Cleaning, including
clean/replace filters
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period Two years Weekly 2 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or No outage
Outage type Minor Minor Minor Minor Minor
out required
Actual
Period Two years 2 week 2 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience experience

3. Slipring grinding

Basis Condition based Condition based Time Time Service hours

Recommended Period > 10 years 2 years 5-7 years < 10K hours

Company
Source Manufacturer Manufacturer Manufacturer
standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Any Minor
out out out
Actual
Period > 10 years 20 years 2 years Only if necessary < 10K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable On condition On condition Not applicable
change experience experience

4. IR testing
Service hours &
Basis Time Time Time Time Service hours Service hours
operation cycles

Recommended Period 3-5 years 4 years 2 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Minor Minor Minor Minor
out out out
Actual
Period 3-5 years 4 years 2 years Annual 20K to 40K hours 20K to 40K hours < 10K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable
change experience

Instrumentation
1. Calibration & circuit checks
Service hours &
Basis Time Time Time Service hours
operation cycles

Recommended Period Two years 4 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Minor Major - rotor out Major - rotor out
out out out
Actual
Period 3-5 years 4 years 3 - 5 years Annual 60K to 90K hours 60K to 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable Not applicable
change experience

50
 Finland Russia USA Japan France Croatia Switzerland
Slip rings & brush gear (or
diodes)
1. Inspection, including brush
wear
Time, service Time & operation Service hours &
Basis Time Service hours Service hours
hours or cycles cycles operation cycles

Recommended Period Annual Annual Two years 10K - 20K hrs 20K to 40K hours 20K to 40K hours

Manufacturer & Manufacturer or Company

Source Manufacturer Manufacturer Manufacturer
Company std other source standard
No outage Major - rotor in or
Outage type Minor Minor Manufacturer Major - rotor in Any
required out
Actual
Period Annual < 10K hours Two years Annual or 2 years 20K to 40K hours Annual

Actual/Recommended Prior mtce Maintenance cost

Decision Basis Not applicable
change experience saving
2. Cleaning, including
clean/replace filters
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period Annual Annual Two years 10K - 20K hrs Annual 20K to 40K hours

Manufacturer & Company

Source Other Manufacturer Manufacturer Manufacturer
Company std standard
Major - rotor in or No outage
Outage type Minor Minor Minor Manufacturer Any
out required
Actual
Period Annual Annual Two years Annual or 2 years Annual Annual

Actual/Recommended Maintenance cost

Decision Basis Not applicable Not applicable
change saving

3. Slipring grinding
Service hrs or
Basis Condition based Time Condition based Service hours Condition based
Condition based

Recommended Period 2 or 3-5 years 40K - 60K hrs 20K to 40K hours 20K to 40K hours

Manufacturer & Company

Source Other Manufacturer Manufacturer
Company std standard
Major - rotor in or
Outage type Minor Any Major - rotor in
out
Actual
Period 2 - 5 years 2 or 3-5 years Condition based >10 years 20K to 40K hours

Actual/Recommended Maintenance cost

Decision Basis Not applicable Other Not applicable
change saving

4. IR testing
Time or Condition Service hours &
Basis Time Time Service hours Time
based operation cycles

Recommended Period Annual Annual Two years 10K - 20K hrs Annual 20K to 40K hours

Company Company
Source Other Manufacturer Manufacturer Manufacturer
standard standard
Major - rotor in or No outage
Outage type Minor Minor Any Major - rotor out
out required
Actual
Annual or 7-10
Period Annual Annual Condition based Two years 2 years Annual
years
Actual/Recommended Maintenance cost
Decision Basis Not applicable Not applicable
change saving

Instrumentation
1. Calibration & circuit checks
Service hours &
Basis Time Condition based Time Service hours Time
operation cycles

Recommended Period 3-5 years Two years 40K - 60K hrs Annual 20K to 40K hours

Manufacturer & Company

Source Other Manufacturer Manufacturer Manufacturer
Company std standard
No outage Major - rotor in or No outage
Outage type Minor Minor Any
required out required
Actual
Period 2 - 5 years Condition based Two years Annual Annual

Actual/Recommended
Decision Basis Not applicable Not applicable Market needs
change

51
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load

Neutral point grounding system

1. Inspection & cleaning

Service hours &
Basis Time Time Time Service hours Service hours
operation cycles

Recommended Period Two years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours 20K to 40K hours

Company Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Minor Minor Minor
out out out
Actual
Period 3-5 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours 40K to 60K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience experience
2. Resistance or impedance
measurement
Service hours &
Basis Time Time Time Service hours Service hours
operation cycles

Recommended Period Two years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours 20K to 40K hours

Company Company Company Company

Source Manufacturer Manufacturer
standard standard standard standard
Major - rotor in or Major - rotor in or Major - rotor in or
Outage type Minor Minor Minor
out out out
Actual
Period 3-5 years 3 - 5 years Annual 20K to 40K hours 20K to 40K hours 40K to 60K hours

Actual/Recommended Prior mtce Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience experience

Excitation system checks

1. AVR characteristic checks

Basis Time Time Time Time Time Service hours

Recommended Period 3-5 years Annual 3-5 years 3-5 years > 90K hours

Company Company
Source Manufacturer Government Manufacturer Manufacturer
standard standard
Major - rotor in or No outage No outage Major - rotor in or
Outage type Minor
out required required out
Actual
Period 3-5 years Annual 3-5 years 3-5 years > 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience

2. AVR limit checks

Basis Time Time Time Time Time Service hours

Recommended Period 3-5 years Annual 3-5 years 3-5 years > 90K hours

Company Company
Source Manufacturer Government Manufacturer Manufacturer
standard standard
Major - rotor in or No outage No outage Major - rotor in or
Outage type Minor
out required required out
Actual
Period 3-5 years Annual 3-5 years 3-5 years > 90K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience

3. Demagnetisation checks

Basis Condition based Time Time Time Time Service hours

Recommended Period Annual 3-5 years 3-5 years > 90K hours

Company Company
Source Manufacturer Manufacturer Manufacturer
standard standard
No outage No outage Major - rotor in or
Outage type Major - rotor out Minor
required required out
Actual
Period 7- 10 years Annual 3-5 years 3-5 years > 90K hours

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable Not applicable
change

52
 Finland Russia USA Japan France Croatia Switzerland

Neutral point grounding system

1. Inspection & cleaning

Service hours &
Basis Condition based Time Time Service hours Time
operation cycles

Recommended Period 3-5 years 3-5 years 40K - 60K hrs Annual 40K to 60K hours

Company Mfr or Company Company

Source Manufacturer Manufacturer Manufacturer
standard standard standard
No outage
Outage type Minor Major - rotor out Major - rotor out Manufacturer Any
required
Actual
Period Annual 3-5 years Condition based 3-5 years Annual or 2 years Annual Annual

Actual/Recommended
Decision Basis Not applicable Not applicable Market needs
change
2. Resistance or impedance
measurement
Not Service hours &
Basis Time Time Time Time
recommended operation cycles

Recommended Period 2 - 5 years 3-5 years Two years Annual 40K to 60K hours

Company Mfr or Company Company

Source Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or No outage
Outage type Major - rotor out
out out required
Actual
Period 2 - 5 years 3-5 years Condition based Two years Annual

Actual/Recommended
Decision Basis Not applicable Not applicable Not applicable Market needs
change

Excitation system checks

1. AVR characteristic checks
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period 3-5 years 3-5 years Two years > 90K hours Annual 20K to 40K hours

Company Mfr or Company Company Company

Source Manufacturer Manufacturer
standard standard standard standard
Major - rotor in or Major - rotor in or No outage
Outage type Minor Any
out out required
Actual
Period 3-5 years 3-5 years 3-5 years Two years Annual 3-5 years

Actual/Recommended Maintenance cost

Decision Basis Not applicable Other Not applicable
change saving

2. AVR limit checks

Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period 3-5 years 3-5 years Two years > 90K hours 5-7 years 20K to 40K hours

Company Mfr or Company Company Company

Source Manufacturer Manufacturer
standard standard standard standard
Major - rotor in or Major - rotor in or No outage
Outage type Minor Any
out out required
Actual
Period 3-5 years 3-5 years 3-5 years Two years 5-7 years 3-5 years

Actual/Recommended
Decision Basis Not applicable Other Not applicable Market needs
change

3. Demagnetisation checks
Not
Basis Time Time Condition based Time Time
recommended

Recommended Period 3-5 years 3-5 years Annual Annual

Company Mfr or Company Company Company

Source Manufacturer
standard standard standard standard
Major - rotor in or No outage No outage
Outage type Minor Task not done
out required required
Actual
Period 3-5 years 3-5 years Condition based Annual Annual

Actual/Recommended
Decision Basis Not applicable Other Not applicable Not applicable
change

53
 Serbia - Italy - Base Italy - Mid
Australia 1 Australia 2 Australia 3 Brazil
Montenegro Load Load
Generator electrical protection
system
1. Protection trip checks

Basis Time Time Time Time Time Time

Recommended Period 3-5 years 3 - 5 years Annual 3-5 years 3-5 years 20K to 40K hours

Company Company Company Company

Source Other Manufacturer
standard standard standard standard
Major - rotor in or No outage No outage
Outage type Minor Minor Minor
out required required
Actual
Period 3-5 years 3 - 5 years Annual 3-5 years 3-5 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Risk assessment Not applicable Not applicable Not applicable Not applicable
change experience

2. Relay injection

Basis Time Time Time Time Time Time

Recommended Period 3-5 years 3 - 5 years Annual 3-5 years 3-5 years 20K to 40K hours

Company Company Company Company

Source Other Manufacturer
standard standard standard standard
Major - rotor in or No outage No outage
Outage type Minor Minor Minor
out required required
Actual
Period 3-5 years 3 - 5 years Annual 3-5 years 3-5 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Risk assessment Not applicable Not applicable Not applicable Not applicable
change experience

3. Circuit checks

Basis Time Time Time Time Time

Recommended Period 3 - 5 years Annual 3-5 years 3-5 years 20K to 40K hours

Company Company Company Company

Source Manufacturer
standard standard standard standard
Major - rotor in or No outage No outage
Outage type Minor Minor
out required required
Actual
Period 3 - 5 years Annual 3-5 years 3-5 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable Not applicable Not applicable Not applicable
change experience

4. CT IR and continuity
Not Not
Basis Condition Based Time Time
recommended recommended

Recommended Period 5-7 years 20K to 40K hours

Company
Source Manufacturer
standard

Outage type Minor Minor

Actual
Period 5-7 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Not applicable On condition On condition
change experience

54
 Finland Russia USA Japan France Croatia Switzerland

Generator electrical protection

system
1. Protection trip checks
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period 3-5 years 7-10 years Two years > 90K hours Annual 20K to 40K hours

Company Mfr or Company Company

Source Manufacturer National Standard Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or No outage
Outage type Minor Minor Manufacturer Any
out out required
Actual
Annual or 3-5
Period 3-5 years 7-10 years 3-5 years Two years Annual or 2 years Annual
years
Actual/Recommended Maintenance cost
Decision Basis Not applicable Not applicable
change saving

2. Relay injection
Time & operation Service hours &
Basis Time Time Service hours Time
cycles operation cycles

Recommended Period 3-5 years > 90K hours Two years > 90K hours Annual 20K to 40K hours

Company Mfr or Company Company

Source Manufacturer National Standard Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or No outage
Outage type Minor Minor Manufacturer Any
out out required
Actual
Annual or 3-5
Period 3-5 years > 90K hours 3-5 years Two years Annual or 2 years Annual
years
Actual/Recommended Maintenance cost
Decision Basis Not applicable Not applicable
change saving

3. Circuit checks
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period 3-5 years 7-10 years Two years > 90K hours Annual 20K to 40K hours

Company Mfr or Company Company

Source Manufacturer National Standard Manufacturer
standard standard standard
Major - rotor in or Major - rotor in or No outage
Outage type Minor Minor Manufacturer Any
out out required
Actual
Annual or 3-5
Period 3-5 years 7-10 years 3-5 years Two years Annual or 2 years Annual
years
Actual/Recommended Maintenance cost
Decision Basis Not applicable Not applicable
change saving

4. CT IR and continuity
Service hours &
Basis Time Time Time Service hours Time
operation cycles

Recommended Period 3-5 years 7-10 years Two years > 90K hours Annual 20K to 40K hours

Company Mfr or Company Company

Source Manufacturer National Standard
standard standard standard
Major - rotor in or Major - rotor in or No outage
Outage type Minor Minor Manufacturer
out out required
Actual
Period 3-5 years 7-10 years Condition based Two years Annual or 2 years Annual

Actual/Recommended Maintenance cost

Decision Basis Not applicable Not applicable
change saving

55
9. APPENDIX 2 - Appendix to Chapter 5

Planned maintenance tasks for generator components – Manufacturers

(pp 57 to 66)

56
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Stator winding – slot content

1. Inspect wedges and repair or
replace
Service hours & Service hours or
Basis Time Condition based Time
operation cycles Condition based
Recommended
Period 3-5 years 40K to 60K hours 5-7 years 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

2. Inspect slot insert migration

Service hours & Time & operation Service hours or
Basis Time Condition based
operation cycles cycles Condition based
Recommended
Period 3-5 years 40K to 60K hours 3-5 years 40K to 60K hours

Actual/Recommended Prior mtce

Decision Basis Market needs
change experience
3. General inspection, clean, and
paint as required.
Service hours & Service hours or
Basis Time Time Time
operation cycles Condition based
Recommended
Period 3-5 years 40K to 60K hours 3-5 years 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs Other
change

4. Electrical tests: IR; PI; winding

resistance; DLA / DDF/ tan δ.
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period 3-5 years 20K to 40K hours 3-5 years 3-5 years 10K to 20K hours

Actual/Recommended
Decision Basis Risk assessment
change

5. HV withstand
Not Service hours &
Basis Time Condition based Condition based
recommended operation cycles
Recommended
Period 40K to 60K hours 3-5 years

Actual/Recommended
Decision Basis Other
change

Stator winding – end windings

1. Test for water leaks, and repair

Service hours or
Basis Time Condition based Condition based Time
Condition based
Recommended
Period Two years 5-7 years 10K to 20K hours

Actual/Recommended
Decision Basis Market needs
change

2. Test for water leaks – no repair

Not Service hours & Not
Basis Condition based Service hours
recommended operation cycles recommended
Recommended
Period 40K to 60K hours 10K to 20K hours

Actual/Recommended
Decision Basis Risk assessment
change
3. Inspect end windings, including
supports, spacers and phase
connection rings
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period 3-5 years 40K to 60K hours 3-5 years 5-7 years 10K to 20K hours

Actual/Recommended
Decision Basis Market needs Risk assessment
change

57
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
4. Inspect/test/repair temperature
sensors
Not Service hours & Service hours or
Basis Condition based Condition based
recommended operation cycles Condition based
Recommended
Not
Period 40K to 60K hours 3-5 years 40K to 60K hours
recommended
Actual/Recommended
Decision Basis
change
5. General inspection for
contamination and insulation state;
Service hours & Service hours or
Basis Time Time Time
operation cycles Condition based
Recommended
Period 3-5 years 40K to 60K hours 3-5 years 3-5 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

6. Capacitance mapping
Not Service hours or
Basis Time Condition based Time
recommended Condition based
Recommended
10K to 20K hrs
Period 3-5 years 5-7 years
40K to 60K hrs
Actual/Recommended
Decision Basis Risk assessment
change

7. Tracer gas leak test

Basis Condition based Condition based Condition based Condition based Service hours
Recommended
Period 40K to 60K hours

Actual/Recommended
Decision Basis
change

8. Modal response
Not Service hours &
Basis Condition based Condition based Service hours
recommended operation cycles
Recommended
Not
Period 5-7 years 40K to 60K hours
recommended
Actual/Recommended Maintenance cost
Decision Basis
change saving

Stator winding - terminal box.

1. General inspection and clean;
including support insulators, flexibles
& CT stack.
Service hours &
Basis Time Time Condition based Service hours
operation cycles
Recommended
Period 3-5 years 20K to 40K hours 3-5 years 10K to 20K hours

Actual/Recommended Maintenance cost

Decision Basis Market needs
change saving

2. Disconnect flexibles; inspect;

replace as required; reconnect.
Not Service hours & Service hours or
Basis Condition based Condition based
recommended operation cycles Condition based
Recommended
Period 20K to 40K hours 10K to 20K hours

Actual/Recommended Maintenance cost

Decision Basis
change saving

3. CT electrical and ratio tests etc.

Service hours & Not
Basis Time Condition based Condition based
operation cycles recommended
Recommended
Period 3-5 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs Other
change

58
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Bushings.
1. Inspection & clean, external.
Not Service hours &
Basis Time Condition based Service hours
recommended operation cycles
Recommended
Period 20K to 40K hours 3-5 years 10K to 20K hours

Actual/Recommended
Decision Basis Risk assessment
change
2. Internal inspection – gas cooled
bushings
Service hours & Not
Basis Time Condition based Condition based
operation cycles recommended
Recommended
Period Two years 20K to 40K hours

Actual/Recommended
Decision Basis Market needs Risk assessment
change
3. Leakage test - replace gaskets
and seals if required.
Basis Time Condition based Condition based Condition based Service hours
Recommended
Period 7-10 years > 90K hours

Actual/Recommended
Decision Basis Market needs Risk assessment
change
4. Leakage test - replace bushings
if required.
Not
Basis Condition based Condition based Condition based Condition based
recommended
Recommended
Period

Actual/Recommended
Decision Basis Risk assessment
change

Core & frame

1. Visual inspection & clean.
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period 3-5 years 40K to 60K hours 3-5 years 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

2. Frame cracking NDT & repair.

Not Service hours &
Basis Condition based Condition based Condition based
recommended operation cycles
Recommended
Period 40K to 60K hours

Actual/Recommended
Decision Basis Risk assessment rare
change

3. Check liquid level detectors

Not Service hours &
Basis Condition based Condition based Condition based
recommended operation cycles
Recommended
Period 20K to 40K hours

Actual/Recommended
Decision Basis
change

59
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer
4. Check longitudinal core
tightening screws.
Not Service hours & Not
Basis Time Time
recommended operation cycles recommended
Recommended
Period 40K to 60K hours 3-5 years 5-7 years

Actual/Recommended
Decision Basis
change
5. Check gas flow control rings,
baffles etc.
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period 3-5 years 20K to 40K hours 5-7 years 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

6. Inspect end shields.

Not Service hours &
Basis Time Time Service hours
recommended operation cycles
Recommended
Period 20K to 40K hours 5-7 years 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis
change

7. El-Cid test
Not Service hours & Condition based Condition based
Basis Service hours
recommended operation cycles or Time or Time
Recommended
Period 40K to 60K hours 5-7 years 7-10 years 40K to 60K hours

Actual/Recommended
Decision Basis
change

8. Ring flux test

Not
Basis Condition based Condition based Condition based Condition based
recommended
Recommended
Period

Actual/Recommended
Decision Basis Risk assessment
change

60
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Stator cooling water system

1. Inspect heat exchangers
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period Two years 40K to 60K hours 3-5 years 5-7 years > 90K hours

Actual/Recommended
Decision Basis Market needs
change
2. Mechanical maintenance of
pumps, valves etc.
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period Two years 40K to 60K hours 3-5 years 3-5 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

3. Pressure test
Not Service hours &
Basis Condition based Condition based Condition based
recommended operation cycles
Recommended
Period 40K to 60K hours

Actual/Recommended
Decision Basis
change

4. Vacuum test
Not Service hours &
Basis Condition based Condition based Service hours
recommended operation cycles
Recommended
Period 40K to 60K hours 10K to 20K hours

Actual/Recommended
Decision Basis
change

Stator water treatment

1. Replace resin
Condition based Condition based
Basis Time Time Service hours
or Time or Time
Recommended
Period Two years Annual Two years Two years Two years

Actual/Recommended
Decision Basis Market needs
change

2. Component inspection & repair

Service hours &
Basis Time Condition based Condition based Service hours
operation cycles
Recommended
Period Two years 40K to 60K hours 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change
3. Calibrate conductivity
instruments.
Service hours &
Basis Time Time Service hours
operation cycles
Recommended
Period Two years 40K to 60K hours 3-5 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

61
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Rotor
1. Remove rotor for inspection -
inspect accessible rotor components,
including fan; NDT of rotor bore.
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period 3-5 years 40K to 60K hours T4/T5 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs Market needs
change

2. Remove retaining rings –

inspect & NDT rings, wedges & slots.

Basis Time Condition based Condition based Service hours

Recommended
Period > 10 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs Other
change

3. Electrical tests: IR; PI; RSO;

winding resistance
Not Service hours & Time or Condition
Basis Time Service hours
recommended operation cycles based
Recommended
Period 20K to 40K hours 3-5 years 5-7 years 10K to 20K hours

Actual/Recommended
Decision Basis
change

4. Time of flight diffraction

Not Not Not
Basis
recommended recommended recommended
Recommended
Period

Actual/Recommended
Decision Basis
change

62
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Hydrogen cooling system

1. Remove, inspect & repair
hydrogen coolers.
Service hours & Service hours or
Basis Time Time Time
operation cycles Condition based
Recommended
Period Two years 40K to 60K hours 5 to 10 years 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs Risk assessment
change
2. Pressure test cooling water
piping.
Service hours & Not
Basis Time Condition based Condition based
operation cycles recommended
Recommended
Not Not
Period > 10 years 40K to 60K hours
recommended recommended
Actual/Recommended
Decision Basis Market needs
change
3. Calibrate dewpoint
instrumentation
Not Service hours &
Basis Time Service hours
recommended operation cycles
Recommended
Period 40K to 60K hours 3-5 years 40K to 60K hours

Actual/Recommended
Decision Basis
change

Hydrogen seals
1. Inspect, including NDT
Service hours & Condition based
Basis Time Time Service hours
operation cycles or Time
Recommended
Period Two years 20K to 40K hours 3-5 years 5-7 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

2. IR testing
Service hours &
Basis Time Time Condition based Service hours
operation cycles
Recommended
Period 3 or 6 mths 20K to 40K hours 3-5 years 10K to 20K hours

Actual/Recommended
Decision Basis
change

63
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Bearings
1. Inspection including NDT
Service hours & Condition based Condition based
Basis Time Service hours
operation cycles or Time or Time
Recommended
Period Two years 20K to 40K hours 3-5 years 3-5 years 40K to 60K hours

Actual/Recommended
Decision Basis Market needs
change

2. IR testing
Service hours & Condition based
Basis Time Condition based Service hours
operation cycles or Time
Recommended
Period 3 or 6 mths 20K to 40K hours 3-5 years 10K to 20K hours

Actual/Recommended
Decision Basis
change
3. Shaft earthing system inspect &
repair
Service hours & Condition based Condition based
Basis Time Service hours
operation cycles or Time or Time
Recommended
Period Annual 20K to 40K hours 3-5 years 3-5 years 10K to 20K hours

Actual/Recommended
Decision Basis Market needs
change

Seal oil system

1. Mechanical maintenance of
pumps, strainers etc.
Service hours &
Basis Time Time Time Service hours
operation cycles
Recommended
Period Annual 40K to 60K hours 3-5 years 3-5 years 10K to 20K hours

Actual/Recommended
Decision Basis Market needs
change

64
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Slip rings & brush gear (or

diodes)
1. Inspection, including brush
wear
Basis Time Time Time Time Service hours
Recommended
Less than one Less than one
Period Daily Annual 10K to 20K hours
year year
Actual/Recommended
Decision Basis
change
2. Cleaning, including
clean/replace filters
Basis Clean filters Time Time Time Service hours
Recommended
Period Annual Annual Annual 10K to 20K hours

Actual/Recommended
Decision Basis
change

3. Slipring grinding
Service hours or
Basis Condition based Condition based Condition based
Condition based
Recommended
Period 40K to 60K hours

Actual/Recommended
Decision Basis Other
change

4. IR testing
Not Service hours &
Basis Time Service hours
recommended operation cycles
Recommended
Period 20K to 40K hours 10K to 20K hours

Actual/Recommended
Decision Basis
change

Instrumentation
1. Calibration & circuit checks
Service hours &
Basis Time Service hours
operation cycles
Recommended
Period 3 or 12 months 40K to 60K hours 40K to 60K hours

Actual/Recommended
Decision Basis
change

Neutral point grounding system

1. Inspection & cleaning

Not Service hours &
Basis Service hours
recommended operation cycles
Recommended
Period 20K to 40K hours 40K to 60K hours

Actual/Recommended
Decision Basis
change
2. Resistance or impedance
measurement
Not Service hours & Not
Basis
recommended operation cycles recommended
Recommended
Period 20K to 40K hours

Actual/Recommended
Decision Basis
change

65
 Japan Italy USA 1 USA 2 France
Manufacturer Manufacturer Manufacturer Manufacturer Manufacturer

Generator electrical protection

system
1. Protection trip checks

Basis Time Time Service hours

Recommended
Period Two years Annual > 90K hours

Actual/Recommended
Decision Basis Market needs
change

2. Relay injection

Basis Time Time Service hours

Recommended
Period Two years Annual > 90K hours

Actual/Recommended
Decision Basis Market needs
change

3. Circuit checks
Service hours &
Basis Time Service hours
operation cycles
Recommended
Period Two years 20K to 40K hours > 90K hours

Actual/Recommended
Decision Basis Market needs
change

4. CT IR and continuity
Service hours &
Basis Time Service hours
operation cycles
Recommended
Period Two years 40K to 60K hours > 90K hours

Actual/Recommended
Decision Basis Market needs
change

Excitation system checks

1. AVR characteristic checks
Service hours &
Basis Time Time Service hours
operation cycles
Recommended
Period Two years 20K to 40K hours 3-5 years > 90K hours

Actual/Recommended
Decision Basis
change

2. AVR limit checks

Service hours &
Basis Time Time Service hours
operation cycles
Recommended
Period Two years 20K to 40K hours 3-5 years > 90K hours

Actual/Recommended
Decision Basis
change

3. Demagnetisation checks
Not Service hours &
Basis Condition based Condition based
recommended operation cycles
Recommended
Period 20K to 40K hours

Actual/Recommended
Decision Basis
change

66
10. APPENDIX 3 - Appendix to Chapter 6

Generator in service diagnostic testing – Utilities & manufacturers (pp 68 to 78)

67
UTILITIES

Serbia -
Australia 1 Australia 2 Australia 3 Italy - Base Load Italy - Mid Load Brazil
Montenegro
Stator winding – slot
content
1. Partial discharge
monitoring – various
types

Usage - Used now Used now Used now Future use Used now Used now Not used

Intermittent - 6 Intermittent - 6 Intermittent - > 6 Intermittent - > 6 Intermittent - > 6

Mode & frequency -
month month mths mths mths

Potential fault Company usual Company usual Company usual

Reason for use - Other reason Other reason
response practice practice practice
Stator winding – end
windings
1. Stator end winding
vibration monitor

Usage - Not used Not used Not used Used now Not used Not used Future use

On known Intermittent - > 6

Mode & frequency -
condition mths

Company usual
Reason for use -
practice

Rotor

1. Rotor shorted turns

detection

Usage - Used now Used now Used now Used now Used now Used now Future use

Continuous use -
Intermittent - > 6 Intermittent - 6 On known Intermittent - > 6 Intermittent - > 6 Intermittent - > 6
Mode & frequency - regular data
mths month condition mths mths mths
review
Potential fault Potential fault Company usual Company usual Company usual Company usual
Reason for use - Other reason
response response practice practice practice practice
2. Shaft torsional
oscillation monitoring

Usage - Not used Not used Not used Not used Not used Not used Not used

Mode & frequency -

Reason for use -

68
 Finland Russia USA Japan France Croatia Switzerland

Stator winding – slot

content
1. Partial discharge
monitoring – various
types

Usage - Used now Used now Not used Not used Not used Used now Used now

Intermittent - > 6 Intermittent - > 6 Intermittent - > 6

Mode & frequency - Various
mths mths mths

Company usual Company usual Mfrs Mfrs rec or

Reason for use -
practice practice recommendation Company practice

Stator winding – end

windings
1. Stator end winding
vibration monitor

Usage - Used now Used now Not used Not used Used now Used now Used now

Continuous OR
On known Intermittent - > 6
Mode & frequency - Intermittent - > 6 Continuous Various
condition mths
mths
Company usual Potential fault Mfrs Mfrs rec or
Reason for use - Any or all reasons
practice response recommendation Company practice

Rotor

1. Rotor shorted turns

detection

Usage - Future use Not used Used now Not used Future use Used now Used now

On known Intermittent - > 6 Intermittent - Intermittent - > 6

Mode & frequency - - Various
condition mths monthly mths

Company usual Company usual Mfrs rec or Mfrs

Reason for use - - Any or all reasons
practice practice potential fault recommendation

2. Shaft torsional
oscillation monitoring

Usage - Past use Used now Not used Not used Not used Used now

On known On known Continuous use -

Mode & frequency -
condition condition regular data review

Company usual
Reason for use - Other reason Other reason
practice

69
 Serbia -
Australia 1 Australia 2 Australia 3 Italy - Base Load Italy - Mid Load Brazil
Montenegro

Core & frame

1. Stator core/frame
vibration monitoring

Usage - Not used Not used Not used Used now Used now Used now Future use

On known On known On known Intermittent - > 6

Mode & frequency -
condition condition condition mths

Company usual
Reason for use - Other reason Other reason Other reason
practice
2. Stator core
lamination vibration –
audio detector

Usage - Not used Not used Not used Used now Used now Used now Not used

On known On known On known

Mode & frequency -
condition condition condition

Reason for use - Other reason Other reason Other reason

Hydrogen cooling
system
1. Dew point
monitoring

Usage - Used now Used now Used now Not used Used now Used now Not used

Continuous use - Continuous use -

Continuous use & Continuous use & Continuous use &
Mode & frequency - regular data regular data Other reason
monitoring monitoring monitoring
review review
Potential fault Mfrs Mfrs Company usual Company usual
Reason for use - Other reason
response recommendation recommendation practice practice

2. Hydrogen make up
rate monitoring

Usage - Used now Used now Used now Used now Not used Not used Used now

Continuous use - Continuous use -

Continuous use & Continuous use & Intermittent -
Mode & frequency - regular data regular data
monitoring monitoring weekly testing
review review
Potential fault Potential fault Company usual Company usual
Reason for use - Other reason
response response practice practice

3. Hydrogen purity
analysis

Usage - Used now Used now Used now Used now Used now Used now Used now

Continuous use -
Continuous use & On known Continuous use & Continuous use & Continuous use & Intermittent - 6
Mode & frequency - regular data
monitoring condition monitoring monitoring monitoring month
review
Potential fault Potential fault Mfrs Company usual Company usual Company usual
Reason for use - Other reason
response response recommendation practice practice practice

70
 Finland Russia USA Japan France Croatia Switzerland

Core & frame

1. Stator core/frame
vibration monitoring

Usage - Not used Used now Not used Future use Not used Not used

Continuous use & On known Continuous use - On known

Mode & frequency -
monitoring condition regular data review condition

Mfrs
Reason for use - Other reason Other reason Other reason
recommendation
2. Stator core
lamination vibration –
audio detector

Usage - Not used Past use Other reason Not used Not used Not used Not used

On known On known
Mode & frequency -
condition condition

Reason for use - Other reason Other reason

Finland Russia USA Japan France Croatia Switzerland

Hydrogen cooling
system
1. Dew point
monitoring

Usage - Used now Used now Used now Not used Used now Not used Used now

Continuous use & Continuous use & Intermittent - Intermittent - On known

Mode & frequency - Continuous
monitoring monitoring weekly testing weekly testing condition

Company usual Mfrs rec or Company usual Mfrs

Reason for use - Other reason Other reason
practice Company practice practice recommendation

2. Hydrogen make up
rate monitoring

Usage - Used now Used now Used now Not used Not used Used now

Continuous use & Cont monitored or Continuous use & Cont monitored or
Mode & frequency -
monitoring Int monthly test monitoring Int monthly test

Mfrs rec or Mfrs rec or Company usual Mfrs rec or

Reason for use -
Company practice Company practice practice Company practice

3. Hydrogen purity
analysis

Usage - Used now Used now Used now Used now Used now Used now Used now

Continuous use & Cont monitored or Continuous use & Continuous use & Continuous use & Continuous use - Continuous use &
Mode & frequency -
monitoring Int weekly test monitoring monitoring monitoring regular data review monitoring

Mfrs rec or Mfrs rec or Company usual Potential fault Mfrs Mfrs Mfrs
Reason for use -
Company practice Company practice practice response recommendation recommendation recommendation

71
 Serbia -
Australia 1 Australia 2 Australia 3 Italy - Base Load Italy - Mid Load Brazil
Montenegro
Stator water
treatment
1. Stator cooling
water conductivity

Usage - Used now Used now Used now Used now Used now Used now

Continuous use - Continuous use -

Continuous use & Continuous use & Continuous use & Continuous use &
Mode & frequency - regular data regular data
monitoring monitoring monitoring monitoring
review review
Potential fault Potential fault Mfrs Company usual Company usual
Reason for use - Other reason
response response recommendation practice practice
2. Hydrogen leakage
into stator water

Usage - Used now Used now Used now Used now Used now Used now

Continuous use - Continuous use - Continuous use -

Continuous use & Continuous use & Continuous use &
Mode & frequency - regular data regular data regular data
monitoring monitoring monitoring
review review review
Test equip
Potential fault Potential fault Company usual Company usual
Reason for use - supplier Other reason
response response practice practice
recommendation
3. Oxygen
concentration

Usage - Used now Used now Used now Used now Used now Used now

Continuous use - Continuous use - Continuous use -

Continuous use & Continuous use & Continuous use &
Mode & frequency - regular data regular data regular data
monitoring monitoring monitoring
review review review
Test equip
Potential fault Potential fault Company usual Company usual
Reason for use - supplier Other reason
response response practice practice
recommendation
4. Copper
concentration

Usage - Used now Used now Used now Not used Used now Used now Used now

Continuous use -
Intermittent - 6 Intermittent - Intermittent - Intermittent - > 6
Mode & frequency - regular data
month monthly monthly mths
review
Potential fault Potential fault Company usual Company usual
Reason for use - Other reason
response response practice practice

Bearings
1. Bearing journal
vibration – dual probe
monitor.

Usage - Used now Used now Used now Used now Used now Used now Used now

Continuous use -
Continuous use & Continuous use & Continuous use & Continuous use & Continuous use & Intermittent - > 6
Mode & frequency - regular data
monitoring monitoring monitoring monitoring monitoring mths
review
Potential fault Potential fault Mfrs Company usual Company usual
Reason for use - Other reason Other reason
response response recommendation practice practice
2. Shaft grounding
monitoring

Usage - Used now Used now Used now Not used Used now Used now Used now

Continuous use -
Intermittent - 6 Intermittent - Intermittent - Intermittent - > 6
Mode & frequency - regular data *
month monthly monthly mths
review
Potential fault Potential fault Company usual Company usual
Reason for use - Other reason Other reason
response response practice practice

72
 Finland Russia USA Japan France Croatia Switzerland

Stator water
treatment
1. Stator cooling
water conductivity

Usage - Used now Used now Used now Used now Used now Used now Used now

Continuous use & Continuous use & Continuous use & Continuous use & Continuous use -
Mode & frequency - Continuous Continuous
monitoring monitoring monitoring monitoring regular data review

Mfrs rec or Mfrs rec or Company usual Potential fault Mfrs rec or Mfrs Mfrs
Reason for use -
Company practice Company practice practice response potential fault recommendation recommendation
2. Hydrogen leakage
into stator water

Usage - Used now Used now Used now Not used Used now Not used Used now

Continuous use & Cont monitored or Intermittent - 6 Intermittent - On known

Mode & frequency - Continuous
monitoring Int weekly test month weekly testing condition

Company usual Mfrs rec or Company usual Mfrs Mfrs

Reason for use - Other reason
practice Company practice practice recommendation recommendation
3. Oxygen
concentration

Usage - Used now Used now Used now Not used Used now Not used Used by some

On known On known Intermittent - 6 Intermittent - On known Continuous use -

Mode & frequency -
condition condition month weekly or monthly condition regular data review

Company usual Mfrs rec or Company usual Mfrs Mfrs

Reason for use - Other reason
practice Company practice practice recommendation recommendation
4. Copper
concentration

Usage - Used now Used now Used now Not used Used now Used now Used now

Continuous use & On known Intermittent - Intermittent - Continuous use - Continuous use &
Mode & frequency -
monitoring condition weekly testing weekly or monthly regular data review monitoring

Company usual Company usual Company usual Mfrs Mfrs

Reason for use - Other reason
practice practice practice recommendation recommendation

Bearings
1. Bearing journal
vibration – dual probe
monitor.

Usage - Used now Used now Used now Used now Used now Used now Used now

Continuous use & Continuous use & Continuous use & Continuous use & Continuous use & Continuous use - Continuous use &
Mode & frequency -
monitoring monitoring monitoring monitoring monitoring regular data review monitoring

Company usual Mfrs rec or Company usual Potential fault Mfrs Mfrs
Reason for use - Various
practice Company practice practice response recommendation recommendation

2. Shaft grounding
monitoring

Usage - Used now Used now Used now Used now Not used Used now Used now

Continuous use & On known Intermittent - Continuous use & Continuous use - Continuous use &
Mode & frequency -
monitoring condition weekly testing monitoring regular data review monitoring

Company usual Company usual Company usual Mfrs Mfrs

Reason for use - Other reason
practice practice practice recommendation recommendation

73
 Serbia -
Australia 1 Australia 2 Australia 3 Italy - Base Load Italy - Mid Load Brazil
Montenegro

Slip rings & brush

gear (or diodes)
1. Brush on-line
condition monitor

Usage - Used now Not used Not used Not used Not used Not used Future use

Continuous use & Intermittent -

Mode & frequency -
monitoring monthly

Potential fault Company usual

Reason for use -
response practice

2. Diode breakdown
detection

Usage - Not used Not used Not used Not used Not used Not used Not used

Mode & frequency -

Reason for use -

Finland Russia USA Japan France Croatia Switzerland

Slip rings & brush

gear (or diodes)
1. Brush on-line
condition monitor

Usage - Past use Used now Not used Not used Not used Used now Not used

Cont monitored or Continuous use -

Mode & frequency -
Int weekly test regular data review

Company usual Mfrs

Reason for use -
practice recommendation

2. Diode breakdown
detection

Usage - Used now - Not used Used now Used now Used by some

Continuous use & Continuous use & Continuous use & Continuous use -
Mode & frequency - -
monitoring monitoring monitoring regular data review

Mfrs rec or Potential fault Mfrs Mfrs

Reason for use - -
Company practice response recommendation recommendation

74
MANUFACTURER RESPONSES

M - Japan M - Italy M - France USA - 1 USA - 2

Stator winding – slot content

1. Partial discharge monitoring –

various types

Usage - Future use Used now Used now Used now Used now

Intermittent - > 6 Cont stored or Continuous use & Cont stored or Cont stored or
Mode & frequency -
mths Inter > 6 mths monitoring Inter > 6 mths Inter > 6 mths

Mfrs Mfrs rec or Potential fault

Reason for use - Other reason Other reason
recommendation potential fault response

Stator winding – end windings

1. Stator end winding vibration

monitor

Usage - Past use Future use Used now Used now infrequently

Continuous use & Cont stored or Continuous use &

Mode & frequency - Various CM when used
monitoring Inter > 6 mths monitoring

Potential fault Mfrs rec or Company usual Company usual

Reason for use - Other reason
response potential fault practice practice

Rotor

1. Rotor shorted turns detection

Usage - Past use Used now Used now Used now Used now

Continuous use -
On known Intermittent - > 6 Cont monitored or Continuous use &
Mode & frequency - regular data
condition mths Int monthly test monitoring
review
Mfrs Mfrs rec or Company usual Mfrs
Reason for use - Other reason
recommendation potential fault practice recommendation

2. Shaft torsional oscillation

monitoring

Usage - Past use Not used Not used Used now Very rarely

Continuous use -
On known
Mode & frequency - regular data CM when used
condition
review
Potential fault Response to
Reason for use - Other reason
response system

75
 M - Japan M - Italy M - France USA - 1 USA - 2

Core & frame

1. Stator core/frame vibration

monitoring

Usage - Not used Not used Future use Used now Very rare

Continuous use -
On known
Mode & frequency - regular data CM when used
condition
review
Company usual Company usual
Reason for use - Other reason
practice practice

2. Stator core lamination vibration –

audio detector

Usage - Not used Not used Not used Not used Not used

Mode & frequency -

Reason for use -

Hydrogen cooling system

1. Dew point monitoring

Usage - Not used Used now Used now Used now Used now

Continuous use & Intermittent - Continuous use & Continuous use &
Mode & frequency -
monitoring weekly testing monitoring monitoring

Mfrs Mfrs Company usual

Reason for use - Other reason
recommendation recommendation practice

2. Hydrogen make up rate

monitoring

Usage - Past use Not used Not used Used now Used now

Continuous use - Continuous use - Continuous use -

Mode & frequency - regular data regular data regular data
review review review
Mfrs Mfrs
Reason for use - Other reason
recommendation recommendation

3. Hydrogen purity analysis

Usage - Used now Used now Used now Used now Used now

Continuous use & Continuous use & Continuous use & Continuous use & Continuous use &
Mode & frequency -
monitoring monitoring monitoring monitoring monitoring

Mfrs Mfrs Mfrs Mfrs Mfrs

Reason for use -
recommendation recommendation recommendation recommendation recommendation

76
 M - Japan M - Italy M - France USA - 1 USA - 2

Stator water treatment

1. Stator cooling water conductivity

Usage - Used now Used now Used now Used now Used now

Mode & frequency -

Continuous use & Continuous use & Continuous use & Continuous use & Continuous use &
monitoring monitoring monitoring monitoring monitoring

Mfrs Mfrs Mfrs Mfrs Mfrs

Reason for use -
recommendation recommendation recommendation recommendation recommendation
2. Hydrogen leakage into stator
water

Usage - Past use Used now Used now Used now Sometimes

Continuous use - Continuous use -

Intermittent - 6 Intermittent - Continuous use &
Mode & frequency - regular data regular data
month weekly testing monitoring
review review
Mfrs Mfrs Mfrs Company usual
Reason for use - Other reason
recommendation recommendation recommendation practice

3. Oxygen concentration

Usage - Not used Used now Used now Used now Rarely

Intermittent - 6 Intermittent - Continuous use &

Mode & frequency -
month weekly or monthly monitoring

Reason for use -

Mfrs Mfrs Mfrs
recommendation recommendation recommendation

4. Copper concentration

Usage - Not used Used now Used now Used now Used now

Continuous use & Continuous use & Continuous use & Continuous use &
Mode & frequency -
monitoring monitoring monitoring monitoring

Reason for use -

Mfrs Mfrs Mfrs Mfrs
recommendation recommendation recommendation recommendation

Bearings

1. Bearing journal vibration – dual

probe monitor.

Usage - Used now Used now Used now Used now Used now

Continuous use & Continuous use & Continuous use & Continuous use & Continuous use &
Mode & frequency -
monitoring monitoring monitoring monitoring monitoring

Reason for use -

Mfrs Mfrs Mfrs Mfrs Mfrs
recommendation recommendation recommendation recommendation recommendation

2. Shaft grounding monitoring

Usage - Not used Used now Used now Used now Used now

Mode & frequency -

Continuous use & Continuous use & Continuous use & Continuous use &
monitoring monitoring monitoring monitoring

Reason for use -

Mfrs Mfrs Mfrs Mfrs
recommendation recommendation recommendation recommendation

77
 M - Japan M - Italy M - France USA - 1 USA - 2

Slip rings & brush gear (or

diodes)

1. Brush on-line condition monitor

Usage - Past use Not used Not used Used now Y-occasionally

Continuous use & Continuous use & Continuous use &

Mode & frequency -
monitoring monitoring monitoring

Company usual Company usual

Reason for use - Other reason
practice practice

2. Diode breakdown detection

Usage - Used now Not used Used now Used now Used now

Continuous use & Continuous use & Continuous use & Continuous use &
Mode & frequency -
monitoring monitoring monitoring monitoring

Mfrs Mfrs Mfrs Mfrs

Reason for use -
recommendation recommendation recommendation recommendation

78
ISBN: 978- 2- 85873- 073-5