Authorized Personnel Only - How To Change Brush Holders On A Hydroelectric Turbine Generator 

Any machine is a smoke machine if you operate it wrong enough

Around 2000 I got be the manager of a pickling line and a single stand cold rolling mill electrical maintenance. It was all MG sets and DC motors. We were nearly bankrupt too. Early on my best motor inspector alerted me to the state the brushes were in. We had very little stock and most were down to barely acceptable nubs. My bosses ahout sh!t when I reported we needed to replace hundreds of brushes. My explanation that the damage to commutators, slip rings and brushholders flummoxed them. But we got the brushes. And over the next 3 years we were able to get that division into good shape. Sadly the overall corporation failed. This is a great video. I saw hundreds of DC motors and there is always something new to learn.

Carbon brushes are constructed primarily of graphite and have a negative temperature coefficient ( the hotter they get the less resistance which allows even more current to flow resulting in more heat ) The brush holders are typically arranged in pairs or groups in parallel on each of the Positve and Negative slip rings . If one brush loses contact due to sticking in the holder , losing spring tension due to brush wear or burning up all of the remaining brushes have to pick up the current from the failed brush . This increases the current and heat of the remaining brush(es) and leads to thermal runaway that can destroy every brush one at a time leading to a slip ring flash over/ loss of excitation condition to the generator that will trip it offline . Daily inspection and periodic maintenance is key with this equipment . Brushes should all be checked with an infra red heat monitor to catch hot brushes before damage occurs , Constant tension brush holders like those being installed in the video will compensate for brush wear and reduce problems .

Used to work for a company that operated and maintained six car airport monorails. There was six traction motors that had twelve brushes each. (3 phase motors) They looked similar to these and at 600 volts DC and running 24/7 they wore down in a hurry!

love your no-fucks-given attitude combined with the know-what-the-fucks-up attitude. Im a deck builder/GC, if you were in my business we would both be the last on the list to talk to the customer. Good shit man, keep doin what you're doin.

now I want a video of the dungeon

I like those sneak peeks to daily work at hydro plant.

I enjoy watching these videos. To get a glimpse of how they do interesting stuff like operating and maintaining a hydroelectric power plant. Anyone else than Chris Boden should probably follow a checklist in accordance with a procedure when doing this job. The procedure should probably include using a calibrated torque wrench to be able to verify that the bolts were tightened just right.

My Dad was a union millwright and I've heard him talk about whose job it was. Millwrights, electricians, or outside contractors.

Check out my other Hydro Dam videos here: ru-vid.com/group/PL-3Y2XexL9dRz9zskedt9vejSoNFmAESQ If you like what you see here, I'd appreciate your help to continue making free, educational videos for all: ko-fi.com/captainboden

So can we expect a "How not to synchronize a generator to the grid" video soon ? ;)

I love how old and sturdy it is. That really must have been satisfying installing that hardware that, as you said, may last 100 years.

An electrician hands over to the millwright when the thing to be moved or installed is too heavy to lift, then just does the connections. As instrumentation, we handled the cobnnections to sensors and actuators, except for power, and would have the entire run for temperature sensing, because electricians are totally mystified by having a sensor and wiring that is a short circuit, but which still works while it is that. Even more fun when your calibration of the unit was to adjust a resistor, so that the short circuit now had a specific resistance, and this now made it read correctly. As to the small guy getting jobs, know of a few motor dealerships where the smallest skinniest mechanic is a specialist, there to go under the footwells and do clutch, brake pedals and linkages, because he fits there without needing to remove the front seats.

The way unions work in the USA is really weird. Over here, unions bargain for everyone in the sector. Every worker benefits from it, regardless whether you're a union member or not. Being in a union doesn't give you extra rights or privileges (though many offer legal assistance or social services) but being part of one makes the union more powerful. They generally bargain over base line stuff like the lowest number of vacation days you get (generally 4 weeks per year), wages, extra retirement days if you've worked your ass off your whole life and are worn out at 65 years old, and stuff like it. Every worker can still individually ask the employer for higher wages, bonuses and other stuff. Most don't get extras, but if you're a highly skilled worker that's highly needed by multiple companies, you bet your ass you get all the sweet sweet benefits you want. You don't like the pay? You can ask for more and get it too, if you have highly wanted skills. But yeah. We don't have stuff like 'that's a union job' right here. Any worker can do any job, as long as they are skilled enough to not kill themselves or others on the job. We have like 3 'general' unions representing workers from all walks of life (the christian union, the standard/social (not socialist) union, a union for company owners and management (yes really). And then 5 or 10 unions for sectors of the labor market like health care, education, construction etc etc. It all works pretty well. The only criticism they sometimes get, is being too soft when talking to corporations and tolerating too much bullshit from them. Dues are like 20 euro a month. Sometimes more if you make a LOT of money, sometimes less if you make minimum wage.

Why did I get all choked up when I watched your thank you message....

As a union millwright that makes a living doing boilermaker work I approve wholeheartedly.

Electrician's hammer 😂

Oh my god this channel is a gem. I love it.

I love your videos -That installation is a nice open structure to work on. You want to try the same operation on Siemens 700 kw unit in the belly of a boat.

Sir your disclaimers are pure comedy gold. Everyone should stop to read them!

You remind me of myself when I used to work on old military aircraft. Same mindset.

Can a newly installed brush carry full operational current, or do you let it rotate for a while first to let it adjust to the exact slip ring shape?

0:32 you instantly became more "human" and relatable thank you for cussing (and leaving it in) . also.... a proper use of cussing i have NO CLUE what im looking at..... but i know its REALLY bad

We sand the brushes when we install them. To ensure good contact on startup.

I want to know the layout of this power plant. It apparently has both horizontal and vertical shafted turbines and generators!

changed many brushes on older DC drive elevators and the motor-generator that powered it

Hah. . my first job at Beth Steel. . .changing brushes in big ass MG sets. Good times.

how do you often change them?

It's all electrical tell proven wrong

do you use an orange stick or anything to seat the brushes?

I would like to hear about brush hardness and how to determine optimal hardness for a particular unit.

Is that a horizontally shafted, water wheel, direct current dynamo?

Is the drive for the exciter basically a paddle wheel?

How many volts and amps on that rotor

I started on lightbulbs and battery stuf but my first payed job was fixing vacuum cleaners among other things

Is that an SKF bearing?

I got a “brushless” Drill, Circular Saw and numerous other tools so do digital motors have brushes?

Nice vid! Nothing new personally but really well done. Love your shit.. Oh, Mr.Boots is a fucking riot! More Boots - more Boots!!

Brush holders should be .080” to 125” above the OD of the slip ring for best operation. 1/2” is way too high.

Are those old Westinghouse generators

What do you think burned them up in the first place?

Ty to let us watch

Did the Mill Billy run? No? Then ya got nutt'n ta worry 'bout

Surprised you could even find those holders or did you have them in the back?

I think the brush holder needs to be closer to the ring.

It was demonetized about 6½ fucks ago ...great video tho👌👍👍

old brush holders are ruined. how can a mallet be precise?

cool

Not every day you hear about Coopersville on the internet!

i mean if they want to pay me to NOT work, im ok with that.

it's electrical work

woooo! pay me bitch! we must have worked with the same people at some point. ;-)

Not if you have a brushless motor.

Can't help but think that those are the exciter brushes for an alternator, not a generator, but then, I'm not there. Rule of thumb, buy the right brushes ... when they are 30% worn out, just like 70 % is a D in school, 69% is failing, you won't have a problem. The insulator on the back keeps current from flowing thru the spring, heating it up and weakening it. After 47 years, I'm glad it's you not me - job is great ... idiot managers that think they are wise ... not so much. On OEM brushes of most older brands, when the back of the brush is even with the back of the brush holder, it's time to pick up the phone and order new ones, before the arcing starts from weak pressure. Good job keeping the ball rolling.😉

Does that mean only authorized people can watch the video, and change the brush handles, or does it only mean the authorized can change the brushes, and anyone can watch the video. 🤔🤔

"It sorts its self out when you stick it in the hole".. First and only mistake ..

You tighten it until it breaks and then go another 1/4 turn. Millwrights can be aged by how many 5 gallon bucket rings they have on their ass.

You work in a hydro plant and cant swim?!?! 🤣🤣🤣

Who the HELL makes a brush holder for 100+ year old equipment??

Brush holder should be closer to avoid brush tipping in holder and jamming.

Finger paint for men. Never seize

I see chatter....