Former Projects of note :
Parameter Derivation of Synchronous Machines.
Using Stator and Rotor, Voltage and Current data logging during Load Rejections, along with a Power System Model to determine Machine Parameters (Reactances and Time Constants mostly) for the publication of Models to be used by Power System Operators.
Testing and data gathering and reduction capabilities were developed and System models were created in Matlab/Simulink/SimPower + Control SystemsToolboxes.
This produced the first Parameter Estimation by the GE Parts and Repair Services Group, not a part of the GE Power Systems Consultancy Group, the entity who had been usually required to perform this service.
3D Model of Stator Bars
A 3D Solidworks model built from the ground-up, accounting for the 3 or 4 major bends and the involute-on-the-cone section, as well as the on-the-cone or on-the-cylinder lead arrangement.
This coupled with a flexible spreadsheet, allowed for the reverse engineering of any imaginable stator bar.
This later proved its value on the first 3D bending/shaping jig developed and constructed for the last set of Stator Bars GEESA produced, with considerable savings in time and materials.
No-Load Testing of Large Motors.
The testing of large Motors is a rather challenging proposition, as large currents at large voltages are required (albeit at a rather low power factors).
The use of a Large Variac and a Multitap Transformer is usually specified, but due to incoming power supply limitations, this is sometimes difficult.
An alternative that was selected and later implemented was the use of a specially modified 1.25 MVA Diesel Generator, with field control thru the use of a DECS relay.
This allowed for testing of large synchronous motors, as well as the more usual Induction (Squirrel Cage and Wound Rotor) Motors.
Motors upwards of 8.0 MW have been successfully and safely started and test ran with this setup.
Complete 3D Model of a Synchronous Condenser
A large synchronous condenser installed in New Zealand, with Skewed Slots, required a full rewind.
Previous developments had enabled the manufacture of such Stator bars with a continuous twist along their slot length, even with hard pressed insulation.
This along with the Short and Long Jumpers required for its end winding connections, complemented the parts that were manufactured from digital models.
This novel design and manufacturing process shaved substantial time and trial-and-error passes to get a first part to match the as-built stator.
This generated considerable savings of resources and helped finish the rewind in record time and exceeding the customers expectations on time and quality.