Generator phase ring handling tool, system including a handling tool for servicing or installing one or more phase rings in a generator, and method for servicing or installing one or more phase rings in a generator with said system

Abstract

Generator phase ring handling tool, for servicing or installing one or more phase rings in a generator. [Solution] A generator phase ring handling tool (24), a phase ring mounting tool (26), and a base loader (28) are used to service or install one or more phase rings (20) on a generator (12). The phase rings (20) can be picked up, transported to the generator (12), inserted into the generator (12), adjusted within the generator (12), and removed. Installation, removal, and repair of rings within the generator (12) can be performed without the use of a crane, thereby reducing downtime of the generator (12). Avoiding the use of a crane for installation, removal, and repair operations improves the safety of personnel performing these operations. It also improves the accuracy of ring transportation, positioning, installation, removal, and adjustment, and minimizes the risk of damage to the rings and the generator (12).

Description

[Background technology]

[0001] FIELD OF THE DISCLOSURE Embodiments of the present disclosure relate generally to generators and, more specifically, to the installation and service of phase rings that surround the ends of a generator stator. [Technical field]

[0002] Generators driven by turbines are commonly used by power companies to generate electrical energy. A generator, such as a hydrogen or liquid cooled generator, typically includes a casing that houses a stator having stator windings formed from connected stator bars. A phase ring surrounding the stator is connected to the stator windings. A bushing that penetrates the casing is connected to the phase ring. In this manner, an electrical connection is made between the stator windings, the phase ring, and the bushing, allowing electrical energy to be transmitted from the stator through the casing to the power grid.

[0003] Leakage of coolant can lead to corrosion of the brazed joints at the connection of the phase rings to the stator windings. This can lead to the need to replace the phase rings if a leak is detected at any of the brazed joints. Replacement of the phase rings can be performed during generator rewinds. A crane is typically used to replace the phase rings with new ones. For example, a crane can be used to remove the used phase ring from the generator, pick up the new phase ring, carry it to the generator, and place the new phase ring in a position that is easy to install in the generator. Using a crane to install or remove a phase ring is a time-consuming and tedious process that can take up to 20 days in some cases. Not only is using a crane to install or remove phase rings a time-consuming and tedious task, but it can also be a challenge for plant operators to find a crane available to perform such work. The uncertainty of availability of a crane is a challenge from a service delivery perspective when the required work cannot be planned with confidence that it can be completed on time. For power plant operators, a generator outage lasting as long as 20 days would be extremely costly.

[0004] Other concerns with using cranes during phase ring installation and general maintenance activities relate to the safety of personnel performing such activities. For example, it may be difficult for a crane to control the load associated with the phase ring. This may result in uncontrolled swinging or rotation of the phase ring, which may be dangerous for personnel installing or servicing the phase ring. Uncontrolled swinging or rotation of the phase ring may also increase the risk of damage to the phase ring or other parts of the generator due to unintended contact by the crane.

[0005] No. 7,032,289 discloses a stator bar handler that is not suitable for handling phase rings and is only capable of axial and vertical movement.

[0006] Therefore, what is needed is an approach that does not rely on the use of a crane to facilitate the installation, removal, and maintenance of phase rings used in generators, and further, an approach that can reduce the time required to service the generator without compromising worker safety. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Patent No. 7,032,289 Summary of the Invention

[0008] Below is a general description of various embodiments that may or may not fall within the scope of protection provided by the claims. The purpose of this general description is to explain the object and function of the invention in its broadest sense and to discuss its various possible modifications.

[0009] Various embodiments of an electric generator phase ring handling tool avoid the need to use a crane to facilitate installation, removal and servicing of a phase ring deployed on a generator. Additionally, embodiments of the electric generator phase ring handling tool allow for repairs to be performed on the generator without removing the windings from the generator, thereby further reducing the time required to repair the generator. In one embodiment, the electric generator phase ring handling tool includes a base unit configured to move in a forward and backward direction. The base unit includes a front end part, a back end part and a vertical extending part between the front end part and the back end part. In this embodiment, the tool includes a vertical support structure coupled to the base unit, the vertical support structure configured to tilt toward and away from the vertical extending part. The tool further includes a phase ring support head coupled to the vertical support structure. The phase ring support head is configured to rotate and move along a vertically extending portion of the base unit. The tool includes at least three support arms coupled to the phase ring support head, the at least three support arms configured to support one or more generator phase rings. The use of three arms provides a stable grip that cannot be achieved with two arms. At the same time, the use of three arms provides maximum maneuverability within the generator. More support arms, for example, four, five, six, seven, etc., can be used with the tool to provide a more stable grip.In this tool, the vertically extending portion is coupled to a vertical support structure by a first drive system configured to tilt the vertical support structure toward and away from the vertically extending portion of the base unit.

[0010] The base unit moves back and forth, the vertical support structure tilts toward and away from the vertically extending portion, and the phase ring support head with the support arm coupled thereto can rotate and move along the vertically extending portion to provide tool movement in all directions necessary to install a phase ring or rings and service the phase ring or rings in a generator without the use of a crane and with the windings still installed in the generator.

[0011] The tool can be used with any size generator, so for example, the tool can be used with the largest generators combined with Arabelle® class nuclear steam turbines, or with smaller generators operating off of fossil fuel boiler steam sources.

[0012] In one embodiment, the first drive system may be exclusively manually operated and / or exclusively manually powered.

[0013] In one embodiment, the vertical support structure includes a second drive system operably coupled to the phase ring support head, the second drive system configured to rotate the phase ring support head relative to the vertically extending portion of the base unit.

[0014] In another embodiment, the second drive system is a screw drive system and / or the second drive system is exclusively hand-operated and / or exclusively hand-powered.

[0015] In one embodiment, the vertical support structure comprises a third drive system configured to vertically displace the phase ring support head along the vertical support structure. The third drive system may comprise a chain hoist assembly configured to vertically displace the phase ring support head along the vertical support structure. Further, the chain hoist assembly may comprise vertically extending spaced apart railings disposed on the vertical support structure, a phase ring support head trolley secured thereto and configured to move along the vertically extending spaced apart railings, and a pull chain operatively coupled to the phase ring support head trolley and configured to vertically translate the phase ring support head trolley along the vertically extending spaced apart railings. The phase ring support head trolley further includes horizontally extending, spaced apart railings oriented laterally relative to the vertical support structure, and a screw drive system operatively coupled to the phase ring support head trolley, the screw drive system configured to translate the phase ring support head trolley along the horizontally extending, spaced apart railings and move the phase ring support head trolley laterally relative to the vertical support structure.

[0016] In another embodiment, the third drive system is only hand-operated and / or only hand-powered.

[0017] In yet another embodiment, the rear end portion of the base unit includes a weight assembly to counter the weight of the one or more generator phase rings. This particular weight arrangement is beneficial in stabilizing the tool and moving the center of gravity toward the center of the tool.

[0018] In another embodiment, the generator phase ring handling tool further comprises a base loader for supporting a base unit thereon, the base loader including one, two or more rails configured to move the base unit forwards and backwards along the base loader, the base loader including industrial vehicle coupling receptacles configured to receive the forks of a forklift. The tool is easily transported around the power plant by being placed on the base loader, which can be safely transported by a forklift. The tool is also more available in the power plant, since forklifts are more readily available than, for example, cranes. As a result, the base loader and tool together further expedite the installation or removal of one or more phase rings from the generator, or the preparation and execution of service (repair) or installation. In another embodiment, the base loader can include a mounting fixture and can be configured to cooperate with a crane. Thus, the crane can also be used to transport the tool on the base loader.

[0019] The generator phase ring handling tool may further include a number of actuation tools to facilitate moving one or more of the components of the phase ring handling tool including the base unit, the vertical support structure, the phase ring support head, and the multiple support arms. The actuation tools may be manual and / or manually operated. For example, the base unit may be configured to cooperate with a trolley system to move the base unit in a forward and backward direction. The screw drive system may be operably coupled to the vertical support structure and the vertically extending portion of the base unit to tilt the vertical support structure relative to the vertically extending portion of the base unit. Additionally, the screw drive system may be operably coupled to the phase ring support head to rotate the phase ring support head relative to the vertical support structure and the vertically extending portion of the base unit. In one example, the aforementioned screw drive system may include a screw and a hand wheel configured to drive the screw to translate the components in a corresponding direction.

[0020] The at least three support arms can be configured in any of several arrangements to facilitate support of one or more phase rings. For example, each support arm can be spaced a predetermined distance from the other support arms. The support arms, which can extend radially outward from the phase ring support head, can be configured in any number of spacing arrangements to support the phase rings during pick-up, transportation, installation, removal, and maintenance. Additionally, each support arm can include a gripper portion at an end distal from the phase ring support head that is configured to support the phase ring. The gripper portion can support one or more phase rings from an inner side of one or more phase rings or an outer side of one or more phase rings.

[0021] In some embodiments, one support arm comprises a gripper portion supporting one or more phase rings from the inside of said phase ring or rings, and the other, e.g. two arms comprise gripper portions supporting one or more phase rings from the outside of said phase ring or rings. The particular configuration of three arms with gripping portions defined above is advantageous in that it provides the most stable gripping of one or more phase rings when using the tool according to the invention, without the need to increase the number of arms.

[0022] The phase ring handling tool described herein can be used to pick up a new phase ring, transport it to the generator, and place it in place to facilitate installation on the generator. Additionally, the phase ring handling tool can also be used to remove used phase rings from the generator and facilitate maintenance of phase rings installed on the generator. All of these operations can avoid or at least minimize the use of a crane. Since no crane is required to perform these operations, installation and maintenance of one or more phase rings can be performed more quickly and / or more flexibly without having to wait in line for a crane. This also improves worker safety since uncontrolled swinging, rotating, and pivoting of the phase ring, which is an issue when using a crane, is no longer an issue that can cause harm to workers. Additionally, the phase ring handling tool's ability to accommodate a range of movements allows installation, removal, and repair of phase rings with greater precision than using a crane. This is further enhanced by the fact that workers can easily adjust the tool while closely observing the position of one or more phase rings relative to other elements of the generator. As a result, the use of the phase ring handling tool significantly minimizes the risk of damage to the phase ring and other components of the generator during installation and maintenance operations and during the time required for maintenance or installation. Similar advantages are obtained when the use of cranes is minimized.

[0023] Furthermore, in embodiments, the phase ring handling tool allows one or more phase rings to be supported at all times during the entire maintenance or installation process. Another advantage of this tool is that it increases safety since the operator does not need to manually hold the one or more phase rings.

[0024] In one embodiment, the phase ring handling tool can include a base loader. The base loader can include a platform having an upper surface and a lower surface, a plurality of lower beams coupled to the lower surface of the platform, one, two or more rails coupled to the upper surface of the platform, and a phase ring handling tool carriage configured to receive the phase ring handling tool and run along the one or more rails with the phase ring handling tool mounted thereon. A plurality of bottom beams coupled to a bottom surface of the platform support the platform and define a space between the platform and the ground.

[0025] In another embodiment, the phase ring handling tool includes at least two base loaders, at least one of which includes a platform having an upper surface and a lower surface, and at least two bottom side beams coupled to the lower surface of the platform, the bottom beam being longer than the platform and configured to support at least one base loader on another base loader. The bottom beams in this configuration allow for a fixed spacing between the phase ring handling tool and the phase ring loading tool described herein. This allows for easier preparation and therefore faster overall process of using the tool. Additionally, the bottom beams allow for two base loaders to be stacked on top of each other and transported with the phase ring handling tool located on top of them. This allows for compact, easy and fast transport of the entire unit to where the tool is needed. Also, a smaller phase ring handling tool can be used, which further facilitates the use and transport of the tool. Using two base loaders as described herein allows for one base loader to be placed next to a generator and the other base loader to be placed next to, for example, a phase ring loading tool. This allows servicing of the generator to be performed faster and safer, as only the phase ring mounting tool carrying one or more phase rings needs to be transported to the generator and there is no need to relocate the base loader.

[0026] In one embodiment, a phase ring mounting tool is disclosed that is configured to cooperate with a phase ring handling tool in loading, transporting, and installing one or more phase rings into a generator. It is also configured to cooperate with removing one or more phase rings from the generator. Thus, this embodiment relates to a system for servicing or installing one or more phase rings into a generator. The phase ring mounting tool is configured to support one or more phase rings when said one or more phase rings are oriented parallel to the ground and perpendicular to the ground. A phase ring handling tool is defined in another embodiment and is used in the system to remove said one or more phase rings from the phase ring mounting tool and facilitate installation of the one or more phase rings in the generator. In the same or another embodiment, the phase ring handling tool facilitates removal of one or more phase rings from the generator and places one or more phase rings on the phase ring mounting tool.

[0027] In an embodiment, the phase ring mounting tool can include a frame structure including a first end portion, a second end portion, and an intermediate portion between the first end portion and the second end portion. The frame structure has spaced beams extending from the first end portion to the second end portion, first end protruding beams extending outwardly from each spaced beam at the first end portion, and second end protruding beams extending outwardly from each spaced beam at the second end portion. The frame structure can include a truss assembly at the intermediate portion to provide geometric stability to the spaced beams extending from the first end portion to the second end portion, and can include at least three arms parallel to the spaced beams and configured to support one or more phase rings, and the second end portion is configured to support the phase ring mounting tool in an upright position.

[0028] In another embodiment, the phase ring mounting tool may include a first arm bracket support assembly coupled to the frame structure between the first end portion and the intermediate portion and a second arm bracket support assembly coupled to the frame structure between the intermediate portion and the second end portion, the first arm bracket support assembly may include at least one said arm and the second arm bracket support assembly may include at least two said arms.

[0029] In yet another embodiment, the first arm bracket support assembly can include two arms and the second arm bracket support assembly can include four arms. This particular arm configuration is beneficial in terms of stability of one or more phase rings supported on the phase ring mounting tool.

[0030] The phase ring loading tool can be operated in one of several different configurations. For example, the phase ring loading tool can be configured to receive one or more phase rings while remaining in a horizontal position. In another scenario, one or more phase rings can be removed from the phase ring loading tool by tilting the phase ring handling tool from a horizontal position to a vertical position. The phase ring loading tool can prepare one or more phase rings, which allows for faster repair / installation. For example, the ring replacement can be completed within 13 days. The phase ring loading tool also has the advantage that crane availability is not affected when replacing or installing phase rings, since six phase rings can be tilted at a time using a crane. The loading tool allows the phase rings to be loaded from the shipping box to the phase ring loading tool without tilting them. This makes the handling of the phase rings easier and improves worker safety. In addition, the tool allows inspection of the phase rings without stopping the generator, so that if any problem occurs with the phase rings, the problem can be detected without stopping the generator, for example. This prevents situations where a generator is shut down simply because, for example, it is discovered that maintenance or installation cannot be completed due to incompatibility or defects in the phase rings.

[0031] In one embodiment, a method for servicing or installing one or more phase rings in a generator is provided. The method includes the use of a system for servicing or installing one or more phase rings in a generator as disclosed herein. In particular, the system includes a phase ring mounting tool configured to receive the one or more phase rings as defined herein, and a phase ring handling tool for removing the one or more phase rings from the phase ring mounting tool and facilitating installation of the one or more phase rings in the generator. The method includes assembling the one or more phase rings on a phase ring mounting tool and obtaining one or more phase rings assembled on the phase ring mounting tool, the phase ring mounting tool being in a horizontal position. This particular step allows for the one or more phase rings to be assembled while the generator is still running and producing power. This is beneficial as it limits outages of the generator. Furthermore, assembling in this position allows for greater control over the entire process of repairing or installing one or more phase rings in a generator, improving the safety of the entire process. The one or more phase rings may be inspected without shutting down the generator, thus minimizing power shortages. This is followed by a step of lifting the phase ring loading tool with the assembled phase ring or rings to an upright position. This particular step has the same advantage as the previous step in terms of limiting the time during which the generator is not in operation for maintenance. This lifting step can be performed using any machine suitable for lifting, for example a crane. It should be noted that if a crane is used to lift and lower the tool, the crane does not need to be used for a long time, i.e., queuing of the crane is easy. The method then includes removing the phase ring or rings from the phase ring loading tool using a phase ring handling tool. It should be noted that during this step, the generator can still generate power. Finally, the method includes installing the generator phase ring or rings to the generator using a phase ring handling tool.

[0032] In an embodiment, the method may be specifically directed to servicing of a generator. For servicing, one or more phase rings already installed need to be removed from the generator. The servicing procedure may involve one or at least two phase ring handling tools. In one embodiment, after the step of raising the phase ring mounting tool to an upright position, the method further comprises a step of removing one or more phase rings from the generator using a phase ring handling tool before a step of removing one or more phase rings from the phase ring mounting tool using the phase ring handling tool. It should be noted that in this particular servicing, only one phase ring handling tool is required, which is beneficial in terms of the time and effort required to transport two or more phase ring handling tools to a generator in need of servicing one or more phase rings. In another embodiment, after the step of removing one or more phase rings from the phase ring mounting tool using the phase ring handling tool, the method further comprises a step of removing one or more phase rings from the generator using another phase ring handling tool before a step of installing one or more generator phase rings to the generator using the phase ring handling tool.

[0033] In one embodiment, the maintenance or installation method involves a generator coupled to a nuclear steam source in a nuclear power plant, or a generator coupled to a fossil steam source in a fossil fuel power plant, or the generator being a mock-up. It should be noted that not all tools can be used on both fossil fuel power plants and generators used in nuclear power plants because some maintenance tools are limited to a particular size or configuration of generators. The phase ring handling tool and phase ring installation tool according to the present disclosure can be used on generators of all sizes and configurations. In particular, the phase ring handling tool and phase ring installation tool can be used on the largest generators combined with the largest steam turbines (Arabelle™ class) and the smallest generators used in fossil fuel power plants. The tool can also be used to train operators and maintenance teams using the generator mock-up, thereby reducing the time required to maintain or install one or more phase rings, and also impacting the safety of the maintenance or installation. Specifically, in an embodiment, the method can reduce the likelihood of a rare but significant risk event from a low probability to an extremely low probability by training the team.

[0034] The phase ring handling tool, phase ring mounting tool, and base loader described herein may also be used in a system and method for simulating the installation of a phase ring on a generator for training purposes. This method may increase the safety of the personnel while improving the quality and productivity of these operations. In these embodiments, a stator end mockup of a generator may be provided. The stator end mockup may include a stator body having a plurality of axial slots extending radially outward from a center of the stator body configured to receive stator windings. The phase ring handling tool, phase ring mounting tool, and base loader may be used to facilitate the installation of one or more phase rings at the stator end of the mockup.

[0035] The term "only hand-operated" means that a particular part or tool is operated by the operator's hands. In some embodiments, no mechanical and / or electronic devices are used to operate the part or tool. Embodiments of tools according to the invention that include only hand-operated parts are beneficial because they allow precise manipulation of tools according to the invention within a generator and allow for fast and accurate positioning of tools according to the invention, which is necessary to service generators having windings, without risking damage to the windings by quickly and accurately manipulating the tool.

[0036] The term "only hand-powered" means that a particular component or tool is powered using only the muscles of that operator. In some embodiments, no mechanical device additionally powers that component or tool. An embodiment of the invention that includes only hand-powered components is beneficial because it allows tools to be safely operated in accordance with the invention within the generator without risk of damaging elements within the generator. A beneficial embodiment of the present invention incorporates components that are both only hand-operated and only hand-powered. This allows a worker performing service or building a new generator to perform their work quickly and accurately without damaging components of the generator.

[0037] The various embodiments disclosed in this specification and claims can be combined in any order and number to produce new embodiments from the parts of the disclosure. [Brief description of the drawings]

[0038] The invention will be better understood on reading the following description of non-limiting embodiments, with reference to the accompanying drawings, in which: [Figure 1] FIG. 2 is a perspective view of a schematic diagram of a stator end of a generator according to an embodiment of the present invention; [Diagram 2] FIG. 1 is a schematic diagram of a phase ring handling tool, a phase ring mounting tool, and a base loader operating in conjunction to prepare a phase ring for installation on a generator according to one embodiment of the present invention. [Diagram 3] FIG. 1 is a schematic diagram of a phase ring handling tool and a base loader working in conjunction to load a phase ring into a generator according to an embodiment of the present invention. [Figure 4] FIG. 2 is a schematic diagram illustrating a more detailed view of a phase ring loading tool according to one embodiment of the present invention. [Diagram 5]FIG. 5 is a schematic diagram showing further details of the arm bracket support assembly of the phase ring mounting tool depicted in FIG. 4 in accordance with one embodiment of the present invention. [Figure 6] FIG. 1 is a schematic diagram illustrating a horizontal phase ring loading tool configured to receive a phase ring, in accordance with an embodiment of the present invention. [Figure 7] FIG. 5 is a schematic diagram illustrating the phase ring loading tool shown in FIG. 4 with a vertical phase ring configured to remove the phase ring, according to an embodiment of the present invention. [Figure 8] 13A-13C are schematic diagrams illustrating how a phase ring loading tool is tilted by a phase ring handling tool according to an embodiment of the present invention and a phase ring is subsequently removed therefrom. [Figure 9] FIG. 4 is a schematic diagram showing further details of the base loader depicted in FIGS. 2 and 3 according to an embodiment of the present invention. [Figure 10] FIG. 10 is a schematic diagram showing further details of the base loader depicted in FIG. 9 without the phase ring handling tool carriage, according to an embodiment of the present invention. [Figure 11] FIG. 11 is a schematic diagram illustrating a more detailed view of a fixed pinion-rack system configured to facilitate translation of a phase ring handling tool carriage along the rail depicted in FIGS. 9 and 10. [Figure 12] FIG. 13 is a schematic diagram illustrating a phase ring handling tool in a position to remove a phase ring from a phase ring mounting tool after being tilted vertically in accordance with one embodiment of the present invention. [Figure 13] FIG. 1 is a perspective schematic view of a phase ring handling tool in accordance with an embodiment of the present invention; [Figure 14] 14A and 14B show side and front elevation views, respectively, of a phase ring handling tool according to one embodiment of the present invention. [Figure 15] 1 shows a more detailed view of the vertically extending portion of the base unit and the vertical support structure of a phase ring handling tool according to an embodiment of the present invention; [Figure 16] FIG. 2 is a more detailed view of a phase ring support head of a phase ring handling tool according to one embodiment of the present invention. [Figure 17] FIG. 2 is a more detailed view of the vertical support structure of the phase ring handling tool with chain hoist assembly according to one embodiment of the present invention. [Figure 18] FIG. 18 is a more detailed view of the phase ring support head bracket shown in FIGS. 13, 14B, and 17 in accordance with one embodiment of the present invention. [Figure 19] FIG. 13 is a more detailed view of multiple support arms of a phase ring handling tool coupled to a phase ring support head according to one embodiment of the present invention. [Figure 20] 20A-20F show various spacing arrangements of multiple support arms according to embodiments of the present invention. [Figure 21] 21A and 21B are more detailed views of the support arm for supporting the phase ring depicted in FIG. 21C according to an embodiment of the present invention. [Figure 22] FIG. 1 is a schematic diagram illustrating a stator end mockup of a generator for use with a phase ring handling tool to simulate and train personnel on the installation of a phase ring on a generator in accordance with an embodiment of the present invention; [Diagram 23] FIG. 23 is a schematic diagram illustrating a phase ring handling tool and base loader used with the generator stator end mockup depicted in FIG. 22 in accordance with one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] Exemplary embodiments of the present invention will now be described in more detail with reference to the accompanying drawings, although not all embodiments are shown. The present invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Hereinafter, like numbers may refer to like elements.

[0040] Turning now to the figures, FIG. 1 is a perspective view of a schematic diagram of a stator end 10 of a generator, such as generator 12. As shown in FIG. 1, generator 12 includes a casing 14 that houses a stator 16 having stator bars arranged around the circumference of the stator with stator or armature windings 18 formed thereon. A phase ring 20 that surrounds the stator 16 is connected to the stator windings 18. A bushing 22 that passes through the casing 14 to the stator 16 is connected to the phase ring 20. In order to clearly illustrate the components of generator 12 relevant to the various embodiments described herein, other components that may form part of generator 12 are not shown. For example, generator 12 may include a rotor and rotor shaft mounted within stator 16. The rotor may be wrapped in a field winding that generates a constant magnetic field that may interact with the stator windings 18 that are powered by a system of three-phase alternating current voltage. Electrical energy generated by the interaction of the field windings and the stator windings 18 is transmitted from the generator 12 to the electrical grid via a phase ring 20 which surrounds the windings and a bushing 22 which connects the phase ring through the stator 16 and casing 14.

[0041] In some cases, the phase ring 20 may require servicing. Servicing the phase ring 20 may include replacing the ring after a coolant leak is detected at the brazed joint at the connection between the phase ring 20 and the stator winding 18. Various embodiments described herein are directed to installing a new phase ring 20 after removal of a used ring. In addition to being used to install a new phase ring 20, the embodiments may be utilized during routine maintenance, such as during a generator rewind or while the windings are still installed in the generator 12. The embodiments are also useful in removing the phase ring 20 from the generator 12 after the stator windings 18 have been decoupled from the ring.

[0042] In general, the present embodiments are directed to a phase ring handling tool that can be used to install, service, and remove the phase ring 20, a phase ring loading tool that can be used to prepare the phase ring 20 for installation on the generator 12, and a base loader that can be used with both the phase ring handling tool and the phase ring loading tool to facilitate installation, removal, and maintenance of the phase ring. FIG. 2 is a schematic diagram of the phase ring handling tool 24, phase ring loading tool 26, and base loader 28 operating together in preparation for installation on the generator 12. FIG. 3 is a schematic diagram of the phase ring handling tool 24 and base loader 28 operating together as part of a system for installing the phase ring 20 on the generator 12. Details of the phase ring handling tool 24, phase ring loading tool 26, and base loader 28 are provided below.

[0043] FIG. 4 is a schematic diagram illustrating a more detailed view of a phase ring mounting tool 26 that may be configured to receive one or more phase rings, according to an embodiment of the present invention. As shown in FIG. 4, the phase ring mounting tool 26 may include a frame structure 30 having a first end portion 32, a second end portion 34, and an intermediate portion 36 between the first end portion and the second end portion. The frame structure 30 may include spaced apart beams 38 extending from the first end portion 32 to the second end portion 34. A first end overhanging beam 40 may extend outwardly from each of the spaced apart beams 38 of the first end portion 32, and a second end overhanging beam 42 may extend outwardly from each of the spaced apart beams 38 of the second end portion 34. As shown in FIG. 4, the first end overhanging beams 40 may include a stabilizing brace 58 that provides stability to the beams 40. In this regard, the stabilizing brace 58 can provide more stability to the first end portion 32 of the frame structure 30 such that the phase ring loading tool 26 can better support the weight of the phase ring 20. Additionally, the stabilizing brace 58 can provide stabilization to any phase ring 20 placed on the phase ring loading tool 26, whether in a vertical orientation, as shown in Figures 4 and 7, or in a horizontal orientation while the ring is loaded onto the tool, as shown in Figure 6.

[0044] The frame structure 30 may further include a truss assembly 44 at the mid-portion 36 to provide improved geometric stability to the spaced beams 38 extending from the first end portion 32 to the second end portion 34, and the protruding beams 40 and 42 at the first end portion 32 and the second end portion 34. In one embodiment, the truss assembly 44 may include a first truss 46 between the first end portion 32 and the mid-portion 36, and a second truss 48 between the mid-portion 36 and the second end portion 34. A first arm bracket support assembly 50 may be coupled to the first truss 46, and a second arm bracket support assembly 52 may be coupled to the second truss 48. The first arm bracket support assembly 50 and the second arm bracket support assembly 52 may each include an arm 54 protruding outwardly from the spaced beams 38. In this manner, the first arm bracket support assembly 50 and the second arm bracket support assembly 52 may support one or more phase rings 20 which may be received by the phase ring mounting tool 26 .

[0045] In one embodiment shown in FIG. 4, the first arm bracket support assembly 50 includes two arms 54 spaced apart and the second arm bracket support assembly 52 includes four arms 54 spaced apart, some of which are located at different heights. The number of arms 54 in the first arm bracket support assembly 50 and the second arm bracket support assembly 52 is not limiting. It is understood that more arms 54, and possibly fewer arms, can be provided in the first arm bracket support assembly 50 and the second arm bracket support assembly 52. ​​Similarly, the positioning of the arms 54 in both bracket support assemblies 50, 52 can be varied.

[0046] 5 shows further details of the arm 54 available on the arm bracket support assemblies 50, 52 of the phase ring mounting tool 26. In one embodiment, the arm 54 may be configured as an arm that is tiltable into one of a number of positions relative to the frame structure 30. Additionally, the arm 54 may be configured with a locking system to keep the position of the arm locked in place to receive the phase ring 20.

[0047] The phase ring mounting tool 26 may include other components that improve its ability to receive and support one or more phase rings for installation on a generator. For example, as shown in FIG. 4, the phase ring mounting tool 26 may include support legs 56 located about the second end portion 34 and the intermediate portion 36 of the frame structure 30. In one embodiment, the support legs 56 are retractable relative to the spacing beam 38. As such, the support legs 56 may extend outwardly from the spacing beam 38 when the phase ring mounting tool 26 is oriented vertically as depicted in FIGS. 4 and 7. Alternatively, the support legs 56 may retract inwardly to be flush with the spacing beam 38 when the phase ring mounting tool 26 is oriented horizontally, which is the typical orientation of the phase ring mounting tool 26 when receiving a phase ring.

[0048] The phase ring mounting tool 26 can be tilted from a horizontal position to a vertical position to move the phase ring mounting tool 26 with the phase ring 20 loaded from a horizontal orientation to a vertical orientation where the phase ring can be removed by the phase ring handling tool 24. The phase ring mounting tool 26 with the phase ring 20 loaded can be tilted from a horizontal position to a vertical position by any of a number of industrial machines configured to lift heavy loads. For example, in one embodiment shown in FIG. 8, the phase ring loading tool 26 with the phase ring 20 loaded can be tilted from a horizontal position to a vertical position by a crane 59 equipped with lifting and support devices such as wire ropes, chains and sheaves.

[0049] The phase ring handling tool 24 provides several advantages. For example, in the configuration described above, the phase ring handling tool 24 can hold up to six phase rings. Additionally, by using the phase ring handling tool 24 to preload the phase rings, an operator can visually inspect the phase rings for quality issues before beginning installation. In this way, if there is an issue with a phase ring, the issue can be addressed prior to installation rather than while the generator is offline. As a result, unnecessary shutdowns of the generator can be avoided.

[0050] The discussion now turns to the base loader 28 mentioned with respect to Figures 2 and 3. Figure 9 shows a more detailed view of the base loader 28 that is operable to facilitate both loading of the phase ring 20 by the phase ring mounting tool 26 and installation or removal of the phase ring within the generator 12 by the phase ring handling tool 24, according to an embodiment of the present invention. As shown in Figure 9, the base loader 28 can include a platform 60 having a top surface 62 and a bottom surface 64. A plurality of bottom beams 66 can be coupled to the bottom surface 64 of the platform 60. A plurality of rails 68 can be coupled to the top surface 62 of the platform 60. A phase ring handling tool carriage 70 can be configured to receive the phase ring handling tool 24 and run along the plurality of rails 68 with the phase ring handling tool 24 loaded thereon. Although not shown in Figure 9, bearings can be used in conjunction with the rails 68 to facilitate running of the phase ring handling tool carriage 70 and the phase ring handling tool 24 along the rails.

[0051] As shown in FIG. 9, the plurality of bottom beams 66 may include two spaced apart beams located at a middle portion of the platform 60 extending from a first end 72 of the bottom surface 64 of the platform 60 to a second end 74 of the bottom surface 64 of the platform 60. The two beams 66 located at the middle portion of the platform 60 may have ends vertically aligned with the first and second ends 72, 74 of the bottom surface 64 of the platform 60, respectively. FIG. 9 also shows that the plurality of bottom beams 66 may further include two outer beams surrounding the two beams located at the middle portion of the bottom side 64 of the platform 60. In one embodiment, the two outer beams 66 may extend from the first end 72 of the bottom surface 64 of the platform 60 to the second end 74 of the bottom surface 64 of the platform 60. In this regard, one end of both outer beams 66 may extend beyond one of the first and second ends 72, 74 of the bottom surface 64 of the platform 60. With this configuration, the ends of the outer beams 66 that extend beyond one of the first and second ends 72, 74 of the bottom surface 64 of the platform 60 can be configured to operatively engage the phase ring mounting tool 26, while the opposing ends of the outer beams 66 at the bottom surface 64 of the platform 60 can be configured to receive an industrial vehicle 76, such as a forklift as shown in Figures 2 and 3, operable to transport the base loader 28 and phase ring handling tool 24 in a position adjacent the phase ring mounting tool 26 and the generator 12. In one embodiment, the first end 72 of the bottom surface 64 of the platform 60 can receive the industrial vehicle 76 and the second end 74 of the bottom surface 64 of the platform 60 can be positioned adjacent the phase ring mounting tool 26 to facilitate removal of the phase ring 20 resting thereon.

[0052] 10 and 11 show details of a trolley system 78 that is used with the base loader 28 to move the phase ring handling tool carriage 70 in a forward and backward direction. In particular, FIG. 10 removes the phase ring handling tool carriage 70 from the base loader 28 depicted in FIG. 9 to provide a view of more elements of the trolley system 78, while FIG. 11 shows the trolley system 78 in more detail. In one embodiment, as shown in FIGS. 10 and 11, the trolley system 78 may include a fixed pinion rack system 80 configured to facilitate translation of the phase ring handling tool carriage 70 along the rails 68. FIGS. 10 and 11 show that the fixed pinion rack system 80 may include a pinion 82 that operates to engage a rack 84. In operation, teeth of the pinion 82 mesh with the rack 84, translating rotational motion of the pinion 82 into linear motion along the rack 84. At the same time, linearly driving the rack 84 rotationally drives the pinion 82. Although not shown in Figures 10 and 11, rotation of the pinion 82 along with the rack 84 can be accomplished through the use of any of a number of actuators. One example of an actuator that can be used to facilitate interaction between the pinion 82 and the rack 84 is a ratchet wrench 85, shown in Figure 12. In this regard, when positioned on the base loader 28, the phase ring handling tool carriage 70 and phase ring handling tool 24 can be moved forward and backward by depressing the ratchet wrench to impart motion in either a forward or rearward direction.

[0053] 10 and 11, to facilitate use of the base loader 28 with the phase ring handling tool 24 and the phase ring mounting tool 26, the base loader 28 can be configured with a number of locking pins 86 that are adjustable to keep the phase ring handling tool carriage 70 locked in the rear position. This feature is beneficial during transportation and handling of the base loader 28.

[0054] The base loader 28 described with respect to Figures 9-11 is useful for both the phase ring handling tool 24 and the phase ring mounting tool 26. In one embodiment shown in Figure 12, the base loader 28 can be positioned adjacent to the vertically oriented phase ring mounting tool 26 to facilitate removal of the phase ring 20 by the phase ring handling tool 24. For example, the base loader 28 can be positioned adjacent to the phase ring mounting tool 26 by an industrial vehicle 76 (not shown in Figure 12). The industrial vehicle 76 can then carry the phase ring handling tool 24 to the base loader 28 so that it can be positioned to run along the rails 68 of the base loader 60. In this manner, the phase ring handling tool 24 can be moved to a position close enough to remove the phase ring 20 from the phase ring mounting tool 26. It will be appreciated that depending on the industrial vehicle 76, it may be possible to position the base loader 28 with the phase ring handling tool 24 already positioned on the rails 68 to expedite the process. In any event, the phase ring handling tool 24 can then remove the phase ring 20 from the phase ring loading tool 26. Once the phase ring 20 has been removed from the phase ring loading tool 26, the industrial vehicle 76 can be deployed to position the base loader 28 and the phase ring loading tool 24 with the phase ring 20 loaded therein into position for loading and installing the ring onto the generator 12 as shown in FIG. 3. In another embodiment, the base loader 28 and the phase ring handling tool 24 can be moved into position adjacent the generator 12 to facilitate removal of the used phase ring from the generator.

[0055] Consider now the details of the components of the phase ring handling tool 24 that, when operating in conjunction with the base loader 28, remove the phase ring 20 from the phase ring loading tool 26 and facilitate the installation of the ring on the generator 12 or the removal of a used ring from the generator. For example, FIG. 13 shows a perspective view of some of the components that may form the phase ring handling tool 24, and FIGS. 14A and 14B show side and front elevation views, respectively, of the phase ring handling tool and its components. As shown in FIGS. 13 and 14A, the phase ring handling tool 24 can include a base unit 88 configured to move in a forward and backward direction. The base unit 88 can include a front end part 90, a back end part 92, and a vertical extending part 94 disposed between the front end 90 and the back end 92 to provide stabilization between the front end and the back end. A vertical support structure 96, having a set of wheels 97 at a lower end portion of the vertical support structure 96, may be coupled to the front end portion 90 and the vertically extending portion 94 of the base unit 88. The wheels 97 may facilitate axial movement of the vertical support structure 96 along with the base unit 88.

[0056] The phase ring handling tool 24 may further include a phase ring support head 98 coupled to a vertical support structure 96 that may support a plurality of support arms 100, as shown in Figures 13, 14A, 14B, and 19. The phase ring support head 98 may be configured to move relative to the vertical support structure 96 and the vertically extending portion 94 of the base unit 88, and the plurality of support arms 100 may be configured to support one or more generator phase rings 20 during operation of the phase ring handling tool 24.

[0057] The phase ring handling tool 24 of FIGS. 13, 14A, and 14B can be configured to move up to five degrees of movement to facilitate installation and removal of the phase ring on the generator. One of these movements includes movement in the fore-aft direction of the base unit 88. As previously described, the phase ring handling tool 24 can be disposed on a phase ring handling tool carriage 70 of the base loader 28. The phase ring handling tool carriage 70 carrying the phase ring handling tool 24 can move along a number of rails 68 of the base loader 28. A trolley system 78 of the base loader 28, which can include a fixed pinion rack system 80, can translate the phase ring handling tool 24 and the phase ring handling tool carriage 70 in the fore-aft direction along the rails 68 by depressing an actuator, such as a ratchet wrench, which drives the axial movement.

[0058] Another degree of movement that the phase ring handling tool 24 can have is tilting along a horizontal axis. For example, the vertical support structure 96, the phase ring support head 98, and the plurality of support arms 100 can be tilted along a horizontal axis toward or away from the vertically extending portion 94 of the base unit 88 of the phase ring handling tool 24. In one embodiment, a screw drive system 102 can be operatively coupled to the vertical support structure 96 and the vertically extending portion 94 of the base unit 88 to provide tilting movement of the vertical support structure 96, the phase ring support head 98, and the plurality of support arms 100. The screw drive system 102 includes a screw 104 coupled to the vertical support structure 96 and the vertically extending portion 94 of the base unit 88, and a hand wheel 106 configured to drive the screw 104 to move the vertical support structure 96 relative to the vertically extending portion 94 of the base unit 88 such that the vertical support structure 96, the phase ring support head 98, and a plurality of support arms 100 coupled to the vertical support structure 96 can tilt relative to the vertically extending portion 94;

[0059] FIG. 15 shows a more detailed view of the screw drive 102 including the screw 104 and the hand wheel 106. As shown in FIG. 15, the screw 104 is secured in place by a fastener, such as, for example, a nut and bolt assembly 110, via a screw bracket 108 extending from the underside of the vertical support structure 96. The other side of the screw 104 may be attached to the vertically extending portion 94 via a screw bracket 112 extending from the underside of the vertically extending portion 94 which is secured in place by a fastener, such as, for example, a nut and bolt assembly 110. In operation, manually turning the hand wheel 106 causes axial linear movement of the screw 104, which results in the vertical support structure 96 tilting toward or away from the vertically extending portion of the base unit 88. The direction in which the hand wheel 106 is rotated determines whether the vertical support structure 96 moves away from or forward of the front end portion 90 of the base unit 88. This tilting provides an advantage to the phase ring handling tool 24 when performing operations on the phase ring 20 (insertion, adjustment, removal, pick-up, etc.).

[0060] Rotation of the phase ring support head 98 is another degree of movement that the phase ring handling tool 24 can perform during the operation of installing or removing a phase ring on a generator. For example, FIGS. 13, 14A, 14B, and 16 show that the phase ring handling tool 24 can include a screw drive system 114 operatively coupled to the phase ring support head 98 configured to rotate the phase ring support head 98 relative to the vertically extending portion 94 and the vertical support structure 96 of the base unit 88. Details of the screw drive system 114 are shown in FIG. 16. As shown in FIG. 16, the screw drive system 114 can be comprised of a screw 116 coupled to the phase ring support head 98 and a hand wheel 118 configured to drive the screw 116 to rotate the phase ring support head 98 relative to the vertically extending portion 94 and the vertical support structure 96 of the base unit 88. In one embodiment, the screw drive system 114 can include a worm screw system with a worm gear in the form of a screw that meshes with a worm wheel. As shown in FIG. 16, the back side of the phase ring support head 98 can include a drive screw bracket 120 that secures the screw 116 and the hand wheel 118. In addition, the back side of the phase ring support head 98 can further include a drive screw rotation bracket 122 that secures the screw 116 and the hand wheel 118 and facilitates the rotation of the phase ring support head 98 according to the rotational translation motion provided by the hand wheel 118 and the screw 116. FIG. 16 also shows that the back side of the phase ring support head 98 can further include a mounting bracket 124 that can be used to secure a portion of the screw drive system 114. As shown in FIG. 16, a portion of the screw 116 used to provide the rotational motion of the phase ring support head 98 can be coupled to the mounting bracket 124. Having the ability to rotate the phase ring support head 98 in this manner is advantageous to the phase ring handling tool 24 when performing operations on the phase ring 20 such as insertion, adjustment, removal, and pick-up.

[0061] Vertical displacement of the phase ring support head 98 is another degree of movement that the phase ring handling tool 24 can perform during an operation to install or remove a phase ring in a generator. For example, FIGS. 13, 14A, 14B, and 17 show that the phase ring handling tool 24 can include a chain hoist assembly 126 configured to vertically displace the phase ring support head 98 and the support arm 100 relative to the vertical support structure 96. The chain hoist assembly 126 can include a pull chain 128 with at least one hook 130. As shown in FIG. 17, the hook 130 can be located at an intermediate position of the pull chain 128. Additionally, another hook 130 can be used to secure the chain hoist assembly 126 to a chain hoist support bar 132 that extends to an upper portion of the vertical support structure 96.

[0062] The chain hoist assembly 126 may further include vertically extending spaced apart railings 134 disposed on the vertical support structure 96. A phase ring support head trolley 136 to which the phase ring support head 98 is secured is configured to move along the vertically extending spaced apart railings 134 along with the phase ring support head and support arm 100. The phase ring support head trolley 136 is configured to receive the mounting bracket 124 on the underside of the phase ring support head 98 as shown in FIG. 16. In one embodiment, a pull chain 128 is operatively coupled to the phase ring support head trolley 136. In operation, the pull chain 128 may move the phase ring support head trolley 136 vertically along the vertically extending spaced apart railings 134 depending on the direction the chain is pulled. Vertical displacement of the phase ring support head trolley 136 together with the phase ring support head 98 and the support arm 100 secured thereto allows the phase ring handling tool 24 to easily manipulate the phase ring 20, including inserting, adjusting, removing and picking up.

[0063] The phase ring support head trolley 136 may be configured to allow the phase ring handling tool 24 to perform additional directional movements. In particular, the phase ring support head trolley 136 may move the phase ring support head 98 in a lateral direction relative to the vertical support structure 96 and the vertically extending portion 94 of the base unit 88. As shown in Figures 17 and 18, the phase ring support head trolley 136 may be comprised of horizontally extending spaced apart railings 138 oriented transversely relative to the vertical support structure 96. Figure 18 illustrates a screw drive system 140 operatively coupled to the phase ring support head trolley 136, configured to translate the phase ring support head trolley 136 along the horizontally extending spaced apart railings 138. In this regard, the screw drive system 140 can move the phase ring support head trolley 136 and thus the phase ring support head 98 and support arm 100 laterally relative to the vertical support structure 96 and vertically extending portion 94 of the base unit 88.

[0064] As shown in FIG. 18, the screw drive system 140 may include a screw 142 extending through an outer portion of the phase ring support head trolley 136 and a hand wheel 144 configured to drive the screw 142 to move the phase ring support head 98 laterally relative to the vertical support structure 96 and the vertically extending portion 94 of the base unit 88. FIG. 18, viewed from the rear end of the phase ring support head trolley 136, shows that the phase ring support head trolley 136 may be coupled to a mounting bracket 124 on the underside of the phase ring support head 98. In operation, manually rotating the hand wheel 144 causes the drive screw 142 to impart lateral movement to the phase ring support head trolley 136 along the horizontally extending spaced apart railings 138. The lateral direction in which the phase ring support head trolley 136 moves along the railings 138 is determined by the direction of rotation of the hand wheel 144. The phase ring support head 98 and support arm 100 are coupled to the phase ring support head trolley 136 via a mounting bracket 124, such that lateral movement of the trolley results in lateral movement of the phase ring support head 98 and support arm 100. This ability to move the phase ring support head 98 and support arm 100 laterally is also advantageous for the phase ring handling tool 24 when performing operations on the phase ring 20, such as insertion, adjustment, removal, pick-up, etc.

[0065] Although the phase ring handling tool 24 is described with a manually powered screw drive system (102, 114, 140), this is not intended to limit the various embodiments described. The use of a manually powered screw drive system can be advantageous in that it avoids injury to personnel responsible for installing and removing the phase ring from the generator. Additionally, a manually powered screw drive system allows the personnel more control and precision over how to manipulate the phase ring handling tool 24 when installing or removing the phase ring from the generator, minimizing the risk of damage to generator components. Nevertheless, the phase ring handling tool 24 can be implemented with a motorized screw drive system.

[0066] Further, it is understood that the use of a screw drive system in the phase ring handling tool 24 is not intended to limit various embodiments. It is contemplated that other types of actuators, whether mechanical or electromechanical, may be used to impart motion to the various components of the phase ring handling tool 24, including axial movement, tilt, rotation, vertical displacement, and lateral displacement. Examples of mechanical or electromechanical actuators suitable for use with the phase ring handling tool 24 to facilitate such movement include, but are not limited to, rodless actuators (e.g., belt and pulley, linear motion actuators, hydraulic actuators, pneumatic actuators).

[0067] In addition to the aforementioned components, the phase ring handling tool 24 may include other elements to facilitate operations performed when installing and removing a phase ring from a generator. For example, as shown in FIGS. 13 and 14A, the rear end portion 92 of the base unit 88 may include a weight assembly 146 to counter the weight of any phase ring 20 supported by the multiple support arms 100. In this regard, the weight assembly may help stabilize the phase ring handling tool 24 when lifting or traveling with the phase ring 20. In one embodiment, the weight assembly 146 may be configured to distribute the weight of the phase ring 20 evenly around the periphery of the base unit 88. Also, by providing the weight assembly 146 at the rear end portion 92 of the base unit 88, the center of gravity of the phase ring handling tool 24 may be closer to an industrial vehicle 76, such as a forklift, that may be used to transport the phase ring handling tool 24 and the base loader 28 in certain embodiments, as previously described.

[0068] Other components of the phase ring handling tool 24 may include an industrial vehicle coupling receptacle 148 configured to receive an industrial vehicle that may be used to facilitate operations performed by the phase ring handling tool 24. In one embodiment, as shown in FIG. 13 and FIG. 14A, a pair of industrial vehicle coupling receptacles 148 may be located on opposing sides of the base unit 88 of the phase ring handling tool 24. If the industrial vehicle 76 used with the phase ring handling tool 24 is a forklift, the industrial vehicle coupling receptacle 148 may be configured to receive the forks of the forklift. In this manner, the forklift forks may be inserted into the industrial vehicle coupling receptacle 148. The forklift may then pick up the phase ring handling tool 24 and move it to a desired location. Although not shown, the phase ring handling tool 24 may include various fasteners, including but not limited to screws and chains, to secure the phase ring handling tool 24 while traveling.

[0069] Consider now the details regarding the support arms 100 that may be deployed with the phase ring handling tool 24. FIGS. 19 and 20A-20F illustrate how the support arms 100 may be positioned relative to a phase ring support head 98 configured to receive the support arms. In one embodiment, the support arms 100, which may be comprised of at least three support arms, are positioned about a central location 150 of the phase ring support head 98. In one embodiment, the central location 150 may be comprised of a hole drilled in the center of the phase ring support head 98. As shown in FIGS. 19 and 20A-20F, the multiple support arms 100 may be spaced apart a predetermined distance from one another and extend radially outward from the central location 150 of the phase ring support head 98. A central fastener 152, such as a nut and bolt assembly, may secure the support arms 100 together at the central location 150. Corresponding perimeter fasteners 154, such as a nut and bolt assembly, may be used to secure each support arm 100 to a hole formed adjacent the perimeter of the phase ring support head 98. Although Figures 19 and 20A-20F show three support arms 100 coupled to the phase ring support head 98, it will be appreciated that more than two arms may be provided.

[0070] 20A-20F also show that the location of the support arm 100 on the phase ring support head 98 is variable. In general, the location of the support arm 100 will depend on the particular configuration of the phase ring. Factors to consider when determining the location of the support arm 100 include the location of the phase ring clamp connection 156, which can be used to secure the open end portion of the ring, and the location of the connection ring tang 158. As shown in FIGS. 20A-20F, the phase ring support head 98 can have one support arm 100 above the midline 155 that intersects with the central location 150, two support arms below the midline, two support arms below the midline (FIGS. 20A, 20C, 20D, 20F), and all support arms 100 below the midline (FIGS. 20B, 20E).

[0071] 21A and 21B are more detailed views of a support arm 100 according to one embodiment of the present invention for supporting a phase ring 20 depicted in FIG. 21C. As shown in FIGS. 21A and 21B, the support arm 100 can include a gripper portion 160 configured to secure one or more phase rings 20 at an end 162 distal from the phase ring support head 98. The gripper portion 160 can include a planar platform 164 that abuts a vertical wall 166 perpendicular to the platform 164 and the distal end 162 of the support arm 100. Gripping material 168 can be applied to a portion of the platform 164 to provide a form of grip for a phase ring 20 disposed on the platform. A notch 170 can be formed in an outer upper surface of the vertical wall 166, and a notch 172 can be formed in an outer surface of the platform 164. In this manner, a strap 174 extending from a proximal end 176 of the support arm 100 can be used to extend past the notches 170 and 172 to secure the phase ring 20 on the platform 164 relative to the vertical wall 166. The strap 174 can extend through the platform 164, the vertical wall 166, and to the proximal end 176 of the arm 100. In one embodiment, the gripper portion 160 is adjustable to move radially relative to the phase ring support head. That is, the gripper portion 160 can be extended outward or retracted inward. In one embodiment, a pin 178 can be used to fix the position of the gripper portion 160 relative to the distal end 162 of the support arm 100.

[0072] The configuration of gripper portion 160 depicted in Figures 21A and 21B is not intended to be limiting of various embodiments. It is contemplated that the gripper portion can take the form of many different configurations. Those skilled in the art will understand how the particular configuration of phase rings and number of rings supported by the support arm will play a role in the design best suited for grasping.

[0073] According to one embodiment of the present invention, the aforementioned phase ring handling tool 24, phase ring mounting tool 26, and base loader 28 can be used in a method of mounting one or more phase rings to a generator. The method can include loading one or more phase rings 20 into the phase ring mounting tool 26. The phase ring 20 can be removed from the phase ring mounting tool 26 using the phase ring handling tool 24 after tilting the phase ring mounting tool from a horizontal to a vertical orientation. The phase ring handling tool 24 can then be used to install one or more phase rings 20 onto the generator 12. The method can further include using the base loader 28 to facilitate loading the phase ring 20 into the phase ring mounting tool 26 and mounting the rings to the generator 12. In particular, the method can include positioning the base loader 28 adjacent to the phase ring mounting tool 26 in a vertical position to facilitate removal of the phase ring 20 from the phase ring mounting tool 26 using the phase ring handling tool 24. Additionally, the method may position the base loader 28 adjacent the generator 12 to facilitate installation of the phase ring 20 onto the generator using the phase ring handling tool 24. Installation of the phase ring 20 onto the generator 12 may involve moving the phase ring handling tool 24 up to 5 degrees to facilitate installation of the ring onto the generator.

[0074] According to another embodiment, the phase ring handling tool 24, the phase ring mounting tool 26, and the base loader 28 can be used for training personnel in a system and method for simulating the installation of a phase ring on a generator. FIGS. 22 and 23 show a mockup of a stator end 180 of a generator 12 that can be used with the phase ring handling tool 24 to simulate the installation of a phase ring 20 on the generator 12 for training personnel. As shown in FIG. 22, the stator end mockup 180 can include a scaled-up replica of the casing 14, the stator 16 within the casing, and the stator windings 18 distributed around the circumference of the stator end. FIG. 23 shows the phase ring handling tool 24 and the base loader 28 adjacent to the stator end mockup 180 and ready for personnel to use to simulate the installation or removal of a phase ring on the mockup. In particular, the phase ring handling tool 24 can be moved along the base loader 28 to be positioned closer to the stator end mockup 180. Once the phase ring handling tool 24 is moved to the desired location, one or more personnel may practice installation of the phase ring 20 using the phase ring handling tool 24. In particular, the personnel may practice manipulating the phase ring handling tool 24 moving through any of the five degrees of motion previously discussed to facilitate installation of the phase ring 20 in the stator end mockup 180.

[0075] Practicing the installation of the phase ring 20 on the stator end mockup 180 is beneficial in that personnel become proficient in installing and removing phase rings. As a result of this practice, the quality and productivity of personnel performing these tasks is significantly improved as more time is spent learning and practicing the tasks. Additionally, this training improves personnel safety, minimizing serious injuries that typically occur when installing and removing phase rings from generators.

[0076] From the description of the illustrated embodiments presented herein, it should be apparent that the present disclosure presents an effective solution for installing phase rings on a generator. It also presents removing used phase rings from a generator in a manner that eliminates the need to use a crane to perform these tasks. In particular, the use of a phase ring handling tool, a phase ring loading tool, and a base loader avoids the aforementioned problems associated with using a crane to install, remove, and repair phase rings. It has been found that these components described in the various embodiments allow a phase ring to be installed and removed from a generator in 13 days or less. This significantly reduces the time that a generator is offline during installation or removal of a phase ring. The shorter the generator downtime, the more profitable the utility. From a service perspective, there is confidence that required service work can be performed on a specified schedule, as opposed to when crane availability is compromised. Additionally, the use of a phase ring handling tool, a phase ring loading tool, and a base loader for installing, removing, and repairing phase rings eliminates the hazards of uncontrolled crane loads, improving worker safety and reducing the risk of serious injury. The precision and control of the phase ring handling tool's range of motions also reduces the risk of unintended damage to the phase ring or other generator components. This precision and control allows installation and removal of the phase ring to be performed while the stator windings remain inside the generator, avoiding undesirable rewinding. Additionally, workers can use the phase ring handling tool on the stator end mockup to practice and hone their skills in installing, removing and servicing the phase ring, increasing productivity, improving the quality of work, and improving worker safety.

[0077] The above description of the illustrated embodiments of the present disclosure (including the contents described in the Abstract) is not intended to be exhaustive or to limit the disclosed embodiments to the precise form disclosed. Although specific embodiments and examples are described herein for purposes of illustration, various modifications are possible within the scope of such embodiments and examples, as will be recognized by those skilled in the relevant art. For example, parts, components, steps, and aspects from different embodiments may be combined or adapted for use in other embodiments, even if not described in the disclosure or illustrated in the drawings. Thus, since certain changes may be made in the above-described invention without departing from the spirit and scope of the present invention, all of the subject matter of the above description shown in the accompanying drawings should be interpreted as merely examples illustrating the concepts of the present invention, and not as limiting the invention.

[0078] In this regard, although the disclosed subject matter has been described in connection with various embodiments and corresponding figures, it should be understood that, where applicable, other similar embodiments may be used, or modifications or additions may be made to the described embodiments, to perform the same, similar, alternative, or substitute function of the disclosed subject matter. Thus, the disclosed subject matter should not be limited to a single embodiment described herein, but rather should be construed broadly and comprehensively in accordance with the following appended claims. For example, references in this specification to "one embodiment" are not intended to be construed as excluding the existence of additional embodiments incorporating the described features.

[0079] In the appended claims, the terms "including" and "in which" are used as the plain English equivalents of the terms "comprising" and "wherein," respectively. Moreover, in the following claims, the terms "first," "second," "third," "upper," "lower," "bottom," "above," and the like are used merely as labels and are not intended to impose numerical or positional requirements on their objects. The terms "substantially," "approximately," and "about" indicate conditions within reasonably achievable manufacturing and assembly tolerances as compared to ideal desired conditions suitable for achieving the functional purpose of a part or assembly. Moreover, the limitations of the following claims are not written in a means-plus-function format, nor are they intended to be construed in such a format, unless such a claim limitation expressly uses the term "means" followed by a description of a function that does not require further structure.

[0080] Additionally, the articles "a" and "an" as used in this specification and the accompanying drawings should generally be construed to mean "one or more" unless otherwise specified or the context clearly indicates a singular reference. Additionally, the term "plurality" should also be understood to mean "at least one."

[0081] The above description includes examples of systems and methods that illustrate the disclosed subject matter. Of course, it is not possible to describe every possible combination of elements and methodologies herein. Those skilled in the art will recognize that many more combinations and permutations of the claimed subject matter are possible. Furthermore, when terms such as "including," "having," and "comprising" are used in the detailed description, claims, appendices, and drawings, these terms are intended to be used in an inclusive sense, as is the term "consisting of" when used as a connective in the claims. That is, unless expressly stated to the contrary, an embodiment that includes or has an element or elements having a particular characteristic may also include additional elements that do not have that characteristic.

[0082] This specification uses examples to disclose certain embodiments of the invention, including the best mode, and also to enable any person skilled in the art to practice the embodiments of the invention, including making and using any devices or systems, and performing the incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ insubstantial from the literal language of the claims. [Explanation of symbols]

[0083] 10: stator end 12: generator 14: casing 16: stator 18: stator winding / armature winding 20: phase ring 22: bushing 24: phase ring handling tool 26: phase ring mounting tool 28: base loader 30: frame structure 32: first end section 34: second end section 36: middle section 38: spaced beam 40: first end overhanging beam 42: second end overhanging beam 44: truss assembly 46: first truss 48: second truss 50: first arm bracket support assembly 52: second arm bracket support assembly 54: arm 56: support leg 58: stabilizing brace 59: crane 60: platform 62: top surface 64: bottom surface 66: bottom beam 68: rail 70: phase ring handling tool carriage 72: first end 74: second end 76: industrial vehicle 78: trolley system 80: fixed pinion rack system 82: pinion 84: rack 85: ratchet wrench 86: locking pin 88: base unit 90: front end portion 92: rear end portion 94: vertically extending portion 96: vertical support structure 97: wheel 98: phase ring support head 100: support arm 102: first drive system / screw drive system 104, 116, 142: screws 106, 118, 144: hand handle / hand wheel 108, 112: screw bracket 110: nut / bolt assembly 114, 120: drive screw bracket 122: drive screw rotation bracket 124: mounting bracket 126: third drive system / chain hoist assembly 128: pull chain 130: hook 132: Chain hoist support bar 134: Railing 136: Phase ring support head trolley 138: Railing 140: Screw drive system 142: Drive screw 146: Weight assembly 148: Industrial vehicle coupling receiver 150: Center position 152: Center fastener 154: Periphery fastener 155: Midline 156: Phase ring clamp connection 158: Connection ring tongue 160: Gripper portion 162: Distal end 164: Planar platform 166: Vertical wall 168: Grip material 170, 172: Notch 174: Strap 176: Proximal end 178: Pin180: Mockup

Claims

1. A motor-generator phase ring handling tool (24), comprising: a base unit (88) configured to move in a forward and backward direction, the base unit (88) including a front end portion (90), a rear end portion (92), and a vertically extending portion (94) between the front end portion (90) and the rear end portion (92); a vertical support structure (96) coupled to the base unit (88), the vertical support structure (96) configured to tilt toward and away from the vertically extending portion (94); a phase ring support head (98) coupled to the vertical support structure (96), the phase ring support head (98) configured to rotate and move along the vertically extending portion (94) of the base unit (88); At least three support arms (100) coupled to the phase ring support head (98); Including, The at least three support arms (100) are configured to support one or more generator phase rings (20); The vertically extending portion (94) is coupled to a vertical support structure (96) having a first drive system (102); The first drive system (102) is configured to tilt the vertical support structure (96) toward and away from the vertically extending portion (94) of the base unit (88).

2. The generator phase ring handling tool (24) of claim 1, wherein the first drive system (102) is a screw drive system (102).

3. The generator phase ring handling tool (24) of claim 1, wherein the first drive system (102) is exclusively manually operated and / or exclusively manually powered.

4. 2. The generator phase ring handling tool of claim 1, wherein the vertical support structure includes a second drive system operably coupled to the phase ring support head, the second drive system being a screw drive system configured to rotate the phase ring support head relative to the vertically extending portion of the base unit.

5. 5. The generator phase ring handling tool of claim 4, wherein the second drive system is a screw drive system, and / or the second drive system is manually operated only, and / or the second drive system is manually powered only.

6. 2. The generator phase ring handling tool of claim 1, wherein the vertical support structure includes a third drive system configured to vertically displace the phase ring support head along the vertical support structure.

7. 7. The generator phase ring handling tool of claim 6, wherein the third drive system includes a chain hoist assembly configured to vertically displace the phase ring support head along the vertical support structure.

8. 8. The generator phase ring handling tool of claim 7, wherein the chain hoist assembly (126) is disposed on the vertical support structure (96) and includes: vertically extending, spaced apart rails (134); a phase ring support head trolley (136) to which the phase ring support head (98) is secured and configured to move along the vertically extending, spaced apart rails (134); and a pull chain (128) operatively coupled to the phase ring support head trolley (136) and configured to move the phase ring support head trolley (136) vertically along the vertically extending, spaced apart rails (134).

9. 9. The generator phase ring handling tool of claim 8, wherein the phase ring support head trolley includes horizontally extending, spaced apart rails oriented laterally relative to the vertical support structure and a screw drive system operatively coupled to the phase ring support head trolley, the screw drive system configured to move the phase ring support head trolley along the horizontally extending, spaced apart rails and to move the phase ring support head trolley laterally relative to the vertical support structure.

10. The generator phasing ring handling tool (24) of claim 6, wherein the third drive system (126) provides power solely under manual operation and / or solely under manual power.

11. The generator phase ring handling tool of claim 1, wherein the aft end portion of the base unit includes a weight assembly for countering a weight of the one or more generator phase rings.

12. 2. The generator phase ring handling tool of claim 1, further comprising at least one base loader supporting a base unit, the base loader including one, two or more rails configured to move the base unit forwards or backwards along the one, two or more rails, the base loader including an industrial vehicle coupling receiver configured to receive forks of a forklift.

13. 2. The generator phase ring handling tool of claim 1, comprising at least two said base loaders, at least one of the base loaders including a platform having a top surface and a bottom surface, and at least two base beams coupled to the bottom surface of the platform, the base beams being longer than the platform and configured to support the at least one base loader on another base loader.

14. 1. A system for servicing or installing one or more phase rings (20) in a generator (12), comprising: a phase ring mounting tool (26) configured to support one or more phase rings (20) when the one or more phase rings (20) are parallel to the ground and perpendicular to the ground; A phase ring handling tool (24) according to any one of claims 1 to 13.

15. The phase ring mounting tool (26) a frame structure (30) including a first end portion (32), a second end portion (34), and a central portion (36) between the first end portion (32) and the second end portion (34), the frame structure (30) having spaced beams (38) extending from the first end (32) to the second end (34); a first end projection beam (40) extending outwardly from each of the spaced apart beams (38) at the first end portion (32); a second end projection beam (42) extending outwardly from each of the spaced apart beams (38) at the second end portion (34); a truss assembly (44) at the intermediate portion (36) that provides geometric stability to spaced beams (38) extending from the first end portion (32) to the second end portion (34); at least three arms (54) configured to support one or more phase rings (20) parallel to the spaced beams (38); The system of claim 14, wherein the second end portion (34) is configured to support the phase ring mounting tool (26) in an upright position.

16. The phase ring mounting tool (26) further includes a first arm bracket support assembly (50) coupled to the frame structure (30) between the first end portion (32) and the intermediate portion (36), and a second arm bracket support assembly (52) coupled to the frame structure (30) between the intermediate portion (36) and the second end portion (34); The system of claim 15, wherein a first arm bracket support assembly (50) includes at least one said arm (54) and a second arm bracket support assembly (52) includes at least two arms (54).

17. The system of claim 16, wherein the first arm bracket support assembly (50) includes two arms (54) and the second arm bracket support assembly (52) includes four arms (54).

18. The phase ring handling tool (24) includes a base loader (28); The base loader (28) is a platform (60) having a top surface (62) and a bottom surface (64); a plurality of bottom beams (66) coupled to a bottom surface (64) of the platform (60); one, two or more rails (68) coupled to the upper surface (62) of the platform (60); and a phase ring handling tool carriage (70) configured to receive the phase ring handling tool (24) and travel along the one or more rails (68) with the phase ring handling tool (24) mounted thereon.

19. 1. A system for servicing or installing one or more phase rings (20) in a generator (12), comprising: The system includes a phase ring loading tool (26) configured to receive one or more phase rings (20) and a phase ring handling tool (24) as described in any one of claims 1 to 12, a phase ring handling tool (24) configured to remove one or more phase rings (20) from the phase ring loading tool (26) and facilitate installation of the one or more phase rings (20) onto the generator (12); The method is: Assembling one or more phase rings (20) on a phase ring mounting tool (26) to obtain one or more phase rings assembled on the phase ring mounting tool; When the phase ring mounting tool (26) is in a horizontal position, Raising the phase ring loading tool (26) with the assembled phase ring or rings (20) to an upright position; removing the phase ring (20) from the phase ring loading tool (26) using a phase ring handling tool (24); and installing one or more generator phase rings (20) on the generator (12) with a phase ring handling tool (24).

20. removing the one or more phase rings (20) from the generator (12) with the phase ring handling tool (24) after the step of raising the phase ring mounting tool (26) to an upright position and prior to the step of removing the one or more phase rings (20) from the phase ring mounting tool (26) with the phase ring handling tool (24); or After the step of removing one or more phase rings (20) from a phase ring installation tool (26) using a phase ring handling tool (24), removing the phase rings (20) from the one or more generators (12) using the phase ring handling tool (24) and prior to the step of installing the one or more generator phase rings (220) on the generator (12) using the phase ring handling tool (24).

20. The method of claim 19, further comprising:

21. The generator (12) is coupled to a nuclear steam source at a nuclear power plant. The generator (12) is coupled to a fossil steam source at a fossil fuel power plant. or The method of claim 19, wherein the generator (12) is a mock-up including a stator.

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