Abstract: Methods and systems for maintaining a machine using an in-situ vehicle (IV) is provided. The IV may be used with a machine that includes a work-piece and an interference body positioned proximate a surface of the work-piece such that a relatively small gap extends between the work-piece and the interference body. The method includes transporting the IV from external to the machine into the gap, positioning the IV in the gap such that at least a portion of the IV circumscribes a work area of the work-piece, locking the IV between the work-piece and the interference body, and manipulating a tool coupled to the IV from external to the machine, the tool configured to transfer a component between the work-piece and a storage cassette on the IV.

Abstract: A stator bar installation fixture and method for installing stator bars into specific stator core slots within a stator core of rotating electrical equipment. The stator bar installation fixture includes rotating mechanisms, rotatingly fixed at each end of the rotating electrical equipment, for supporting and controlling an angular positioning of a stator bar insertion mechanism relative to the stator core. The stator bar insertion mechanism supports a stator bar within the stator core, angularly locates a stator bar in alignment with the specific stator core slot, and inserts the stator bar into the specific stator core slot.

Abstract: A slot wedge for a generator stator includes a wedge body having opposite side edges adapted to engage complimentary stator core slots. At least the opposite side edges are covered with an aramid paper or woven aramid fabric material.

Abstract: Methods and systems for maintaining a machine using an in-situ vehicle (IV) is provided. The IV may be used with a machine that includes a work-piece and an interference body positioned proximate a surface of the work-piece such that a relatively small gap extends between the work-piece and the interference body. The method includes transporting the IV from external to the machine into the gap, positioning the IV in the gap such that at least a portion of the IV circumscribes a work area of the work-piece, locking the IV between the work-piece and the interference body, and manipulating a tool coupled to the IV from external to the machine, the tool configured to transfer a component between the work-piece and a storage cassette on the IV.

Abstract: A slot wedge for a generator stator includes a wedge body having top and bottom surfaces and a pair of oppositely inclined side surfaces, wherein at least the oppositely inclined surfaces are covered with a woven aramid fabric. A related method includes the steps of: (a) providing a wedge shaped body having top and bottom surfaces connected by oppositely inclined side surfaces; and (b) covering at least the oppositely inclined side surfaces with a woven aramid fabric.

Abstract: A stator bar installation fixture and method for installing stator bars into specific stator core slots within a stator core of rotating electrical equipment. The stator bar installation fixture includes rotating mechanisms, rotatingly fixed at each end of the rotating electrical equipment, for supporting and controlling an angular positioning of a stator bar insertion mechanism relative to the stator core. The stator bar insertion mechanism supports a stator bar within the stator core, angularly locates a stator bar in alignment with the specific stator core slot, and inserts the stator bar into the specific stator core slot.

Abstract: A stator bar series loop connection is provided that is comprised of a solidified stator bar and a stranded stator bar disposed in a stator slot so that one of the bars is disposed as a top bar and the other of the bars is disposed as a bottom bar in the slot. A first side plate is brazed adjacent a first end thereof to a first side of an end of the solidified bar and adjacent a second end thereof to a first side of the stranded bar. Further, a second side plate is brazed adjacent a first end thereof to a second side of the end of the solidified bar and adjacent a second end thereof to a second side of the stranded bar. Accordingly, the stranded bar is series connected to the solidified bar.

Abstract: A method of sealing a generator stator bar and a stator bar end fitting receiving the end including the steps of: brazing the fitting to the end of the stator bar with a braze material; applying a powder coating material to the end of the stator bar in the fitting; and curing the powder coating material to form a barrier coating on the end of the stator bar and the adjoining interior surfaces of the fitting.

Abstract: A probe support carriage for use during probing an electrical device includes a body, means for supporting and positioning the body, a plurality of flux sensors and a position sensor. The body has a first end and a second end. The plurality of flux sensors are operatively connected to the body. Each flux sensor includes a probe having a core and a coil. The core includes a material having high initial permeability and high resistivity characteristics. The probe is adapted to being supported so that a sensing portion of the core is maintained in a contact-free spaced relationship between a predetermined surface of the electrical device and the sensing portion of the core. The position sensor is adapted to determine position along a longitudinal axis of the electrical device.

Abstract: An Advanced Data Logging kit for testing a generator's liquid cooled stator bar system for leaks is disclosed. The kit is installed in between the generator's header and the HIT Skid and in the generator's cooling system. The kit includes pressure and vacuum transducers, sensor arrays with thermocouples, and data acquisition circuits. The sensor arrays are used to plumb the thermocouples into the generator's header and cooling pipes. The pressure and vacuum transducers and the thermocouples are used to collect pressure, vacuum and temperature data that is used to conduct a Pressure Decay Test and a Vacuum Decay Test to determine whether or not a leak in the liquid cooled stator bar system exists. A computer included in the kit has the ability to analyze the data readings, perform calculations, and predict leak rates in the stator bar system.

Abstract: A method of sealing a generator stator bar and a stator bar end fitting receiving the end including the steps of: brazing the fitting to the end of the stator bar with a braze material; applying a powder coating material to the end of the stator bar in the fitting; and curing the powder coating material to form a barrier coating on the end of the stator bar and the adjoining interior surfaces of the fitting.

Abstract: A probe for use in detecting abnormalities in an electrical device having a wedge depression of no more than 100 mils. The probe includes a solid core surrounded by a sense coil. The ends of the core are arranged in a contact-free, spaced relationship between and at least partially above opposed surfaces of adjacent lamination teeth of a stator. Air gaps are maintained between the ends of the probe core and the opposed surfaces. The total of the two air gaps is constant. The probe is supported on a carriage arrangement and moved along the teeth. Variations in leakage flux produced with the stator energized with an energization winding to produce a flux which is a few percent of a normal energization level, are monitored.

Abstract: A probe for use in detecting abnormalities in an electrical device having a wedge depression of no more than 100 mils. The probe includes a solid core surrounded by a sense coil. The ends of the core are arranged in a contact-free, spaced relationship between and at least partially above opposed surfaces of adjacent lamination teeth of a stator. Air gaps are maintained between the ends of the probe core and the opposed surfaces. The total of the two air gaps is constant. The probe is supported on a carriage arrangement and moved along the teeth. Variations in leakage flux produced with the stator energized with an energization winding to produce a flux which is a few percent of a normal energization level, are monitored.