GLOBAL PROVIDER OF HIGH-QUALITY BRUSH HOLDERS, CASTINGS, SPRINGS AND REFURBISHMENT SERVICES COMPANY OVERVIEW Fulmer Facility Perma-Cast Facility Fulmer’s major aftermarkets include: ■ Power Generation ■ Railroad ■ Transit ■ Mining ■ Steel ■ Motor Repair Shops Located in Export, Pennsylvania (approximately 25 miles east of Pittsburgh), Fulmer Company is the largest North American manufacturer of brush holders for DC machines and AC generators and a supplier to major global OEMs, such as GE, Siemens Toshiba and Mitsubishi, as well as aftermarket customers. Within Fulmer’s 34,000-square-foot facility, the company hosts a precision CNC machine shop with fabrication capabilities that include a spring shop and assembly department. Throughout the years, Fulmer’s in-house design and engineering capabilities have been crucial in support of concurrent engineering and retrofit projects for customers who sought to improve quality and performance while reducing costs. Additionally, Fulmer possesses a high quality, non-ferrous permanent mold and sand cast foundry, Perma-Cast. Occupying a separate but adjacent 13,000-square-foot facility, Perma-Cast provides permanent mold castings, which offer many benefits (such as casting integrity, surface finish, homogenous grain structure and tight dimensional tolerances) over other casting methods. These dynamic capabilities have established Fulmer as an industry leader both as a supplier of machined generator component parts and as an innovator of engineered designs for new and direct retrofit applications. ADVANCING THE POWER GENERATION INDUSTRY Brush Changing Made Easy – The Fulmer Way Fulmer has the safe, reliable and economic solution for brush changing on live machines. Featuring a state-of-the-art design, the single pocket, cartridge-style plug-in holder (FC101) offers a revolutionary approach to brush changing on turbine-generators. Using the same design concepts found in multi-pocket magazine holders that have been commonly fitted to larger generators for over 40 years, Fulmer has successfully adapted this model into a unique single pocket holder. Coupling technical, design and manufacturing expertise with substantial experience working with OEMs in the power generation field, Fulmer has created a holder concept built around the principles of employee safety, superior technical performance and value. Product Features ● Lightweight and ergonomic, Fulmer’s patented, OEM-approved design is a direct replacement for original brush holders with no rigging modification required. ● Fulmer’s holder offers constant force springs and insulated handles for quick and safe brush changing under load. ● Both brush and brush holder can be removed while the generator is on-line, without any service interruption. ● Utilization of a constant pressure “cartridge” design eliminates the need to periodically adjust brush force as the brush wears (saving valuable maintenance man-hours). ● The constant pressure spring is radially mounted over each brush, while the concentrically coiled spring applies force on the center line of the brush. ● Individual brushes can be changed on an “as-required” basis, safely away from the electrically energized components. Fulmer’s single pocket cartridgestyle holder is designed as a direct replacement for a wide variety of OEMs’ turbo generator holders. In fact, Fulmer’s brush holders take only minutes to install, can be placed in the exact location and use the same mounting hardware as existing holders. Additionally, they are available in numerous brush sizes and mounting arrangements. THE FULMER ADVANTAGE Fulmer’s Cartridge-Style Plug-In Brush Holder (FC101): ■ Eliminates the use of high resistance and mechanically inferior connection plates and contacts. ■ Allows for superior electrical contact, improving current flow to the brush. ■ Has a longer brush box, creating better brush support and accommodating brushes up to four inches in length. ■ Lengthens brush life and reduces the frequency of brush changes. ■ Utilizes any brush supplier’s recommended brush grade for high speed generator service. ■ Facilitates brush wear evaluation though a convenient window in the brush holder. ■ Offers handle versatility – the shorter handle’s flash guard keeps fingers away from brush shunts, while the extended handle (optional) can be used for holders that are difficult to access. ■ Enables operators to quickly and easily change brushes once the holder has been removed from the generator using a portable Brush holder with removable short brush load fixture. handle ■ Utilizes standard brushes and terminals. ■ Is economically priced. ■ Improves machine performance by reducing brush selectivity and enhancing airflow and cooling. ■ Eliminates the need to change springs when the brush is changed. ■ Reduces the chance of a flashover. ■ Accommodates both North American and internationally designed machines. “A good engineer can usually design a device to accomplish some particular function – it may be very complicated, but it will probably work most of the time. A superb engineer will find a way to accomplish the same function, but in a simple, elegant way: safe, reliable and affordable.” -- Clyde Maughan, Maughan Engineering Consultants, upon review of Fulmer’s FC101 single pocket, cartridge-style plug-in brush holder Brush holder with removable long handle Brush changing fixture U.S. Patent No. 7,365,470 U.S. Patent No. 7,608,970 BRUSH HOLDERS THAT DELIVER RESULTS Several thousand of Fulmer’s cutting-edge brush holders are currently in use on newly commissioned OEM generators (both air and hydrogen cooled, ranging from 25 to 450 MW) and aftermarket conversions. Customers can attest that selectivity issues with the original OEM holders were drastically reduced upon the installation of Fulmer holders, and there have been dramatic improvements in operator ease and safety. Contact Fulmer for a complete brush holder catalog or a copy of the technical paper, “Carbon-Brush Collector Maintenance on TurbineGenerators Retrofitted with On-Line Removable Plug-In Brush Holders.” REFURBISHMENT The scope of a refurbishment project: ■ Returned holders are disassembled into their individual component parts. ■ Brush holder castings are visually inspected for signs of damage. ■ Brush boxes are gauged to ensure that they are still within prescribed tolerances. ■ Brush holders are cleaned to remove all grease, carbon dust and any other contaminants, with particular attention paid to the inside of the brush boxes. ■ Required parts are re-plated to OEM specifications. ■ New constant force springs are installed. ■ All mounting hardware, terminal screws and washers are replaced. ■ Component parts are reassembled to meet OEM specifications and tolerances. Significant capital funds are spent during planned turbine-generator outages for any number of costly rebuild items, yet turbinegenerator brush holders are nearly always neglected. Over years of service, springs can weaken and cause performance issues such as: damaging arcing, selective action or increased brush wear due to electrical erosion. Additionally, brush holders will gradually become covered in dirt, carbon and other contaminants that can cause brush hang-up. A planned outage is an excellent opportunity to have brush holders refurbished to “as new” condition at a significantly reduced cost. At Fulmer, refurbished holders can be turned around within one to two weeks of receipt, which will easily accommodate a planned maintenance outage schedule. A one-year warranty on all parts and service is offered. Fulmer Company 3004 Venture Court Westmoreland Industrial Park III Export, Pennsylvania 15632 www.fulmercompany.com Phone 724-325-7140 Fax: 724-327-7459