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

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[@DrewskisBrews]

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

[@SamSitar]

yes smoke is very entertaining. a certain UK electrician did that by sending things way off the scale.

[@ericlunneborg907]

@@SamSitar photonicinduction?

[@jwalster9412]

People who own massive, straight piped diesel truck: "am I a joke to you?"

[@maxasaurus3008]

😂😂

[@Idrinklight44]

Applies to a whole lot of machines....bad when your up in air and that smoke comes out

[@gregkocher5352]

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.

[@kls2020]

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 .

[@tedrex8959]

Thank you, I know nothing about this type of thing and found that really interesting. I am grateful that you took the time to explain it so well.

[@kls2020]

@@tedrex8959 Thanks Ted I don't know much about drama but I do know something about the workings of a hydro plant

[@MrRadar88]

It's called selective action.

[@joaquingomezullrich878]

Not the first instance of a runaway reaction caused by grafite

[@shelbybaker6443]

I don't do anything near as interesting or important as this but your attitude always refreshes me. It reminds me of how I scare the hell out of new technicians by being funny and still doing the job the right way. Keeps the new cats loose and not afraid to get into the job.

[@burks1993]

@shelbybaker6443 even when I do get frustrated or mad I try to keep it cool. Idt the complaining does anyone a favor either. when ppl do start complaing I usually try to lighten it up or simply/nicely remind em the sooner we get this done the sooner we're back in the shop and it's a non issue. it doesn't help though at most places maintenance gets put under unrealistic stress during down times. then they get so focused on production tht when you have a list of problems thatd require every down day for a month to fix they still don't wanna fix it. that'd be my only complaint like I've told ya for how long this was an issue and we chose to run 100-400-1000 hours later on it and I'm the bad guy here that needs the tight deadline.

[@Fireship1]

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!

[@LasseAlber]

@@Fireship1 I have a question: will those brushes ( I count 4) flow all the electricity from this generator? The wires seemed a little small… I don’t really have a clue, just curious

[@Reman1975]

What you do is appreciated Chris. YOU are appreciated........ Never forget that.

[@nixxonnor]

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.

[@Adam-hp5hj]

Why anyone else?

[@ZlotyCK89]

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

[@SamSitar]

they are very informative.

[@donparker8246]

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

[@aleks138]

now I want a video of the dungeon

[@MrWaalkman]

One of the more interesting carbon-copper devices that I got to work on was an Otis elevator contactor from around 1915 that had carbon cups that the copper pads would be driven into. The cups were about the size of a silver dollar, and the copper pads about a half dollar. The reason for this setup is that there would never be a chance of the contacts welding together. Another interesting thing was that the pads (this was a three pole contactor) would swing them back to the 90 degree position about three inches away.

[@bobkoure]

'Finger tight plus a quarter turn' - we used to joke that it was 'tighten until it strips, back off a quarter turn'. FWIW, a threaded fastener stretches as you tighten it, so it's working like a spring to hold friction on those threads - and the threads deform a bit as well. The Brits in the 1800s had fasteners with asymetrical threads - asymetrical enough that they'd deform into being symetrical under the corect tension. Tech we forgot - and then rediscovered as there are now fancy-ass aerospace fasteners that use the same idea. To be fair, we forgot because our materials got a lot better. Loving your series, BTW. Also, was that anti-sieze I saw going on there? That'd mess up your torque readings - if you were using a torque wrench.

[@krl9747]

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

[@Physicsduck]

Thank you! :) I put a LOT of work into that joke and a very few people have ever discovered it. :) I'm thankful that you did!

[@Seebaer-wg6jh]

As a former Navy electrician and current shipyard electrician, I can state that you are doing electrician's work.

[@ripinskimoinskidoinski]

Never send a millwright to do a cameraman's job... LOL... I love the work you do!

[@Physicsduck]

Check out my other Hydro Dam videos here: kzbin.info/aero/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

[@clifffarion7448]

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.

[@stephenrice4554]

Man I enjoyed that , you and bootsy making sure the pixies flow

[@350zoomin3]

"The Knack" is knowing what "feels happy" is

[@SeanBZA]

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.

[@mnFlatLander]

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

[@mfbfreak]

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.

[@pyrobeav2005]

Thanks for sharing! Is this for most of Europe or a specific country?

[@Zander10102]

Shill

[@uzaiyaro]

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

[@kainhall]

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

[@TheCrazzyToobinator]

This actually looks like so much fun I would be very much okay with doing this sort of work, looks a bit easier than rebuilding a drill motor when it is that size lol

[@krz8888888]

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

[@brothertyler]

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

[@everettplummer9725]

I thought you would show how to seat them with emery. Could also show seating stones.

[@luanzdark]

and as his talking about water infiltration and dungeons you can see a water pump in the back with the tiniest hose attached 😂

[@davidbudka1298]

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

[@user-cs1ne8gx9u]

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

[@nixxonnor]

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?

[@andrewfurlotte8307]

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

[@dillonlapointe636]

2:52 , me changing the "i dont need any extras" customer's brakes

[@jimmddaniel]

Im from coopersville and he aint lying

[@paulbacklund4770]

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

[@garylozowski1419]

Brush hardness in most cases is the least significant property to insure good brush operation.

[@deezelfairy]

It's a trade off between brush wear and commutator/slip ring wear. If it's an application like this generator where brushes are real easy to change, you'd nearly always go for a very soft brush to minimise wear on the slip rings. On something like a forklift (my profession) where sometimes changing drive motor brushes means the removal of both drive motors/gearboxes to access them (couple of days work) you'd engineer that brush compound a lot harder to last many thousands of hours but the commutator would normally be significantly worn and require skimming & undercutting before new brushes can be installed. I've seen many DC electric forklifts with 10K+ plus hours on them and still on their original drive motor brushes.

[@peterburi2727]

Nothing beats percussive maintenance.

[@markopolo1271]

It's amazing how many things can be fixed with a thump or two

[@Raintiger88]

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

[@randywilson3572]

Coming from a Union Electrician, It’s your work If you know how to do it. lol I love non-union, no excuses, just get the job done.

[@m163224p90]

How much power is running through those relatively small wires on the brushes?

[@autismisnotacrime8007]

Finger tight plus a quarter turn? I use German torque guten tite.😊😊

[@Kubla84]

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

[@Kenionatus]

Electrician's hammer 😂

[@bobkoure]

Exactly - but was it made by Klein?

[@walterfarley9230]

How many volts and amps on that rotor

[@Thefreakyfreek]

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

[@franconianbike]

Is that an SKF bearing?

[@jimnasby]

Is the drive for the exciter basically a paddle wheel?

[@wgmskiing]

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

[@Physicsduck]

We call him....Lunchbox.

[@wgmskiing]

@@Physicsduck haha fair enough Chris. Thanks for showing us this beautiful old machinery

[@ericlil305]

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

[@davidbudka1298]

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

[@garylozowski1419]

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

[@KurtBarcelona]

how do you often change them?

[@joshjones3408]

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

[@scrapeteel1999]

The mobility scooter used to hack Grammahs Treadmill😂🎉🎉just to watch Ren And Stimpy😅😅

[@DimSimSam]

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

[@kylehenline3245]

Nope. In Brushless DC motors the rotor is just a permanent magnet that doesn't have any electrical connections going to it, So no need for brushes and commutator.

[@walterfarley9230]

Well you didn’t explain what the brushes were for . They apply current to the rotor . DC current . One pole get negative one pole gets positive. Making one pole north and one pile south thus creating AC currently.

[@jonathancarr5537]

Are those old Westinghouse generators

[@Jumansa19]

Ty to let us watch

[@hanswichmann5047]

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

[@MikeJones-ll1fc]

Between the humor, the drawl, and the... well... boots.... this boy was a Jarhead. I know those boots well, said good morning to me on some very cold (and very hot) mornings. Semper Fi, Boots.

[@alexandern8hgeg5e9]

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

[@africanelectron751]

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

[@gabiold]

Since sliprings are in use still this day, I assume he bought some available similar sized parts. The brush size doesn't have to be that exact to the original, and if nothing else, you can turn differently-sized holding pins for the assembly on a lathe. Quite easy to fix. This is the nice thing in proper industrial stuff, everything is metal or machined industrial plastic, put together by thinking people, thus repairaple. (as opposed to consumer stuff. And cars. Since the past two decades or so...)

[@ged5868]

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.

[@josephjorgensen3282]

It's all electrical tell proven wrong

[@clarkwg247]

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

[@SamSitar]

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

[@randacnam7321]

Any tool can be precision iffen used in the right way.

[@Kenionatus]

I think big precision machines are usually squared up with mallets. "Give it another .5 microns" Tap Tap.

[@killernat]

@@Kenionatus can confirm I use a 20 lb deadblow mallet to align a 30 ton press brake to be less than 50micron out of parallel with a robot

[@scrapeteel1999]

Used business card like setting points🎉

[@PublicMeetings]

How do you get a job like this!!!???

[@russclifton2026]

Don’t tell me someone brought silicon maybe sealant somewhere near the building. ? . ? .

[@daintree98]

And they still manufacture the brush holders after 100 years? Unbelievable.

[@russianwhoopiecushion]

"...about 20 minutes after fumblefuck turns it back on" wait, pause lemme write that down

[@carlubambi5541]

it's electrical work

[@ipha]

Not every day you hear about Coopersville on the internet!

[@Physicsduck]

Born and raised! :)

[@SamSitar]

@@Physicsduck I wonder how many people outside of Michigan know about it?

[@miketrissel5494]

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.😉

[@zanewatkinsinthegamewithza5145]

I deal with electric brushes every day because I’m an electrician

[@waterlife.1905]

Not if you have a brushless motor.

[@markkennard861]

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

[@russclifton2026]

Where can I get a job in Hydro plant. They don’t like it when you upset passion fingers around here. ? .

[@thepubliceye]

Finger paint for men. Never seize

[@graywolf2694]

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

[@chrism4008]

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

[@DeadlinePhil]

you know you´re laughing but i heard of people who can´t swim who work on cargo ships

[@jwalster9412]

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. 🤔🤔

[@lazloslozar]

cool

[@coolruehle]

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

[@gizmothewytchdoktor-419]

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

[@johnmcgovern3806]

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

[@markopolo1271]

Excit'er i barely even know er

[@dougbeckwith768]

I see chatter....