POST
500 MW Generator Failure: Lesson Be Observant

A 500 MW generator failed catastrophically, it had an internal short that resulted in a phase to phase short. The generator stopped so suddenly that it sheared off 24 2 ½” bolts in the coupling between the generator and the turbine. The problem was traced to the phase leads resonance shifting to 120HZ as the generator aged. This problem resulted in the annual testing of the phase leads for the unit that had the failure and also on its sister machine. One of the key lessons learned during many hours of testing these generators was that for electrical components, the stiffness of the insulating materials is affected significantly by temperature. For instance, if a phase lead tested as acceptable at room temperature, it might experience a 10-15 HZ drop when it was at operational temperature, thereby being unacceptable in the loaded state. The extent of this effect was discovered by accident when the windows to the turbine building were left open on a cold night. It was discovered that the natural frequency results on the phase leads were significantly different when the leads were cold versus at room temperature. The lesson to learn here is to always be observant. The natural frequency of a vertical pump which is made of steel will not vary much whether the surrounding temperature is zero or 100 degrees, but electrical components that are covered with insulation can change.
Other Posts
Chiller 1000HP Soft Starter
An ethanol facility that processes corn into fuel recently upgraded a critical chiller application with the installation of a 1000 HP, 4160V Benshaw medium-voltage soft starter. What began as a transformer repair discussion ultimately evolved into a full system improvement [...]
Combine Vibration Troubleshooting
Horner Field Service was recently asked to troubleshoot a vibration issue with a combine. The call came in to Ralph Coonce on a Thursday afternoon. It didn’t take long for Ralph to determine that he was going to send me. [...]
Rubber Plant Motor Failure
A 400HP WEG motor on the hydraulic power unit of a plant’s main mixer failed due to a catastrophic drive-end (DE) bearing issue. The bearing failure generated sparks and halted the production of raw rubber critical for automotive products. With [...]





