lloyd price - ge power solutions
TRANSCRIPT
See tutorial regarding confidentiality
disclosures. Delete if not needed.
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10 20 35
TEAM FactorsT
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Me
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255 15 30
Generator Lifecycle Air Cooled
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Fo
rced
Ou
tag
e P
rob
ab
ilit
y
10 20 35
TEAM FactorsT
he
rma
lE
lec
tric
al
Am
bie
nt
Me
ch
an
ica
l
255 15 30
Generator Lifecycle Air Cooled
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Generator Maintenance Overview
Diagnostic, Monitoring and Assessment
StoppedDiagnostic Inspections
(off-line)
Rotor pulled Full Inspection
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Key Areas to Address
How can I reduce the risk of a forced
generator outage?
How can I support my decision making
as to the timing of planned outages
without increasing the risk of failure?
How can I optimise my generator scope
of work during an outage ?
How can I optimise the timing and order
of my life time extension program?
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Generator Maintenance Overview
Diagnostic, Monitoring and Assessment
Operating on-line Monitoring
Partially opened
Diagnostic Inspection
with Rotor in Situ
(Robotic Inspection)
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Generator Maintenance Overview
Diagnostic, Monitoring and Assessment
Operating on-line Monitoring
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Generator Health Monitoring
Title or Job Number | XX Month 201X 12
L1 Sensors
Permanently installed, including cabling & connection boxes (GE or third party)
L2 GOLD® Service
• Portable DAU• Site visit twice a year• Report on collected data
Periodical Monitoring Continuous Monitoring
• Permanently installed DAU• Permanent data link &
storage• Weekly checks• Quarterly full report
L3 Service L4 Remote Service
• Permanently installed DAU• Half yearly full report
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Cost-effective solution for online monitoring
L2 GOLD® Service - Generator Health Monitoring
Title or Job Number | XX Month 201X 13
SOFTWARE SOLUTIONS
Power Plant
Sensors• Partial Discharge
• Rotor Flux
• Rotor Shaft Voltage
On-site visit
Portable
DAU
Half yearly full report
based on collected data (snap
shot)
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Data accessible at plant level with download option for analysis to GE
L3 Service - Generator Health Monitoring
Title or Job Number | XX Month 201X 14
SOFTWARE SOLUTIONS
Power Plant
• Partial Discharge
• Rotor Flux
• Rotor Shaft Voltage
• End Winding
Vibration
• Stator Temperatures
• Collector Health
Monitor*
• Stator Leakage
Monitoring System*
Server
On-site Monitoring
DCS
Half yearly full report
based on 6 months of data
USB,
CD,
DVD,
….
Sensors
Local Network
* stand alone
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Data accessible at plant level with direct feed to GE
L4 Remote Service - Generator Health Monitoring
Title or Job Number | XX Month 201X 15
SOFTWARE SOLUTIONS
GE Monitoring & Diagnostics
• Weekly checks
• Quarterly full reports
• Permanent data storage
Power Plant
Server
On-site Monitoring
DCSSensors
Local Network
• Partial Discharge
• Rotor Flux
• Rotor Shaft Voltage
• End Winding
Vibration
• Stator Temperatures
• Collector Health
Monitor*
• Stator Leakage
Monitoring System*
* stand alone
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Moving to condition-based maintenance
Generator Health Monitoring
Title or Job Number | XX Month 201X 16
Rotor Shaft
Voltage
Partial
Discharge
Rotor Flux End Winding
VibrationStator
Temperature
Leakage*Collector*
* Stand alone, check for applicability
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disclosures. Delete if not needed.
GHM - Partial Discharge Sensors
• Capacitive Bus Couplers
• Low Frequency 9 nF sensors
• 1 Per phase + 1 at neutral point
Monitoring• Slot PD
• Void / Delamination PD
• Surface PD
• Phase to Phase PD
• Vibration sparking
• Partial Discharge location
Identification of• Stator bar insulation condition
– Aging of insulation
– Semi-conductive coating deterioration
• Loose stator bars
• Generator contamination
See tutorial regarding confidentiality
disclosures. Delete if not needed.
GHM - Rotor Flux
Sensors• Rod-Type Probe
• Wedge Mounted Flip-up Probe
• Wedge Mounted Pop-up Probe
Monitoring• Rotor Inter-turn short circuits
• Accurately identification of effected slot
• Magnitude of fault
• Trend deterioration
Identification of• Electrical breakdown of interturn insulation
• Mechanical breakdown of interturn insulation
• Carbon and Oil Contamination of windings
• Copper dusting due to excessive barring
• Turn to turn contact due to coil shorting,
distortion or elongation
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disclosures. Delete if not needed.
GHM - Rotor Shaft Voltage
Sensors• Shaft grounding with copper braids
• Good contact even at high surface velocity
• High performance in contaminated conditions
(Oil and Dirt)
Monitoring• Electric discharge
• Shaft magnetization
• Shaft rubbing
• Grounding problems
• Brush sparking
• Rotor interturn faults
Identification of• Bearing damage
– Electro pitting
– Voltage tracking
− Electric erosion
− Frosting
• Insulation breakdown
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disclosures. Delete if not needed.
GHM - End Winding Vibration
Sensors• HV Protected Piezo-Electric Accelerometers
− Uniaxial or Tri-axial measurement
• Biaxial Fibre Optic Accelerometers
Monitoring• Overall vibration amplitude of end winding
structure
• Vibration in relation to operating parameters.
• Trending of vibration
Identification of• End winding looseness
• Insulation fretting and contamination
• Insulation damage due to vibration
• Overhang support cracking
See tutorial regarding confidentiality
disclosures. Delete if not needed.
GHM - Stator Temperatures
Sensors• Original installed Termo Couples
• Original installed RTD’s
• Customised condition based installed
sensors
Monitoring• Stator temperatures
• Deviation from average temperature
• Temperature in relation to operating parameters
• Deviation from design parameters
• Trending of deterioration
Identification of• Blocked water cooled stator bars
• Stator cooling efficiency decrease
• Stator core defects
• H2 cooler effectiveness
See tutorial regarding confidentiality
disclosures. Delete if not needed.
GHM – Collector Health Monitor*
Sensors• Radio Frequency Current Transformers
Monitoring• Milliamp variation in excitation current
• Disruption of current flowing from the
collector brushes to the collector rings
• Trend the variation
Identification of• Sparking which is correlated to Collector
Ring Flashover
*stand alone
See tutorial regarding confidentiality
disclosures. Delete if not needed.
GHM – Stator Leakage Monitoring System*
Sensors• Optical Dissolved Oxygen Sensor
• Thermal Conductivity Hydrogen Sensor
Monitoring• Hydrogen Leakage into the Stator Cooling
Water System with high oxygen regime
• Stator Cooling Water Dissolved Oxygen
• Purges the airspace at the top of the Stator
Cooling Water Tank
• Injects oxygen to ensure the formation of
cupric oxide (CuO)
Identification of• Breakdown of the copper barrier between the
stator cooling water and the generator air
space
• Calculates the hydrogen leakage rate into the
Stator Cooling Water system
• Loss of oxygen leading to destabilization of
the protective cupric oxide (CuO) layer
*stand alone
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Generator Health Monitoring Customer Training
Duration: 1 Day per Module
Generalities about generator monitoring:
Principles and constitution,Electrical power generation,PQ diagram and operating limits,GHM Generator monitoring system operation.
Module 1 - Partial Discharge Monitoring:
Functional description, Instrumentation and protections,Voids and electrical discharges,Partial discharge measurement, Data display and presentation.
Module 2 - Shaft Voltage Monitoring:
Functional description,Instrumentation and protections, Electro erosion, Sources of shaft voltages,Data display and presentation.
Module 3 - Rotor Slot Leakage Flux Monitoring:
Functional description,Operation and maintenance,Effects of rotor shorted turns,Data display and presentation.
Module 4 - Stator End-Winding Vibrations Monitoring:
Functional description,Instrumentation and signal conditioning,Issue caused by end-winding vibrations,Data display and presentation.
SOFTWARE SOLUTIONS
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Generator Maintenance Overview
Diagnostic, Monitoring and Assessment
Partially opened
Diagnostic Inspection
with Rotor in Situ
(Robotic Inspection)
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Generator In-Situ Inspections
28
Alstom –
DIRIS®GE –
MAGIC®
• Two Technologies
• Great Coverage
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disclosures. Delete if not needed.
In-Situ (Air Gap) Inspection GE offers fast and reliable inspection of the turbogenerator without the need to pull
the rotor out. (OEM & OOEM)
1. Robotic Visual Inspection (via air gap)
2. Robotic Low Flux / EL-CID
3. Robotic Slot Wedging Tightness Test
4. HV tests (optional)
5. Brush gear & Exciter inspection
Customer benefits
Up to 40% time saving compared to
conventional inspection with rotor out
Reduced costs by keeping rotor in, simplify
crane support and lay down space
Reduced risk during overhauls due to
reduced dismantling
Accurate and reproducible assessments
Faster Return to Grid without sacrificing
safety and quality
Supports condition-based maintenance
program development
6. Partial Visual Inspection (End winding)
7. Insulation Resistance Measurement
8. Rotor Inter Turn Short Circuit Detection
(optional on Legacy GE)
9. Instrumentation check
10. Bump test (optional)
SERVICES
Several robots to fit a broad range of generator types
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Flexible Robot Inspections
2016 32
Diris robot installed in sub 50MVA generator
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Typical inspections
recommendations:
Generator in
cycled
operation or
on stand-by
on turning
gear
18-18 Retaining Rings
18-5 Retaining Rings
Every
5 Y
ears
Fro
m 9
to
12
Ye
ars
Every
3 Y
ears
Generator
in base-
load
operationCustomer benefits
Shorter down time periods due to reduced
dismantling (rotor in-situ ; end bells in place)
without sacrificing safety and quality
Increased generator availability with faster returns
to service
Accurate and reproducible assessments
Supports condition-based maintenance program
development
In-Situ Retaining Ring Inspection
GE utilizes an inspection robot to detect indications of impeding cracks
with the rotor in or out.
SERVICES
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disclosures. Delete if not needed.
In-Situ Retaining Ring Inspection
Dec 2015 35
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disclosures. Delete if not needed.
Flexible Robot Inspections
Dec 2015 36
Ultrasonic inspection of the retaining rings
Inside surfaces: UT (Phased Array), outside surfaces: EC (Eddy Current)
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disclosures. Delete if not needed.
– Inspection Options Take aways
38
Generator Health Monitoring Generator In-Situ Inspections)