generator assessment process - an overview
TRANSCRIPT
GAPGAPGAPGAPGAPGAPGAPGAP********generator assessment processgenerator assessment processgenerator assessment processgenerator assessment process
a solution to life assessment of large generators
[email protected]@gmail.com
The deterioration of large generators or forthat matter any electrical equipment isnormal, and this process begins as soon asgenerator is installed.
If deterioration is not checked, it can causeIf deterioration is not checked, it can causeelectrical failures and malfunctions.
In addition a TEAM of stresses
- Thermal
- Electrical
- Ambient
- Mechanical- Mechanical
further contributes to thedeterioration process.
TTTThermalhermalhermalhermal EEEElectricallectricallectricallectrical
StressStressStressStress
MMMMechanicalechanicalechanicalechanical AAAAmbientmbientmbientmbient
StressStressStressStress
TheTheTheThe purposepurposepurposepurpose ofofofof aaaa goodgoodgoodgood maintenancemaintenancemaintenancemaintenanceprogramprogramprogramprogram shallshallshallshall bebebebe• totototo discoverdiscoverdiscoverdiscover thethethethe potentialpotentialpotentialpotential reasonsreasonsreasonsreasons ofofofofdeteriorationdeteriorationdeteriorationdeterioration• taketaketaketake remedialremedialremedialremedial measuresmeasuresmeasuresmeasures forforforfor correctioncorrectioncorrectioncorrectiontotototo avoidavoidavoidavoid catastrophiccatastrophiccatastrophiccatastrophic failuresfailuresfailuresfailures....
TheTheTheThe otherotherotherother importantimportantimportantimportant purposepurposepurposepurpose ofofofofmaintenancemaintenancemaintenancemaintenance programprogramprogramprogram isisisis totototo maximizemaximizemaximizemaximizereliabilityreliabilityreliabilityreliability andandandand availability,availability,availability,availability, improveimproveimproveimproveoperationaloperationaloperationaloperational efficiencyefficiencyefficiencyefficiency andandandand productivityproductivityproductivityproductivity....
GAPGAPGAPGAP**** is the answeris the answeris the answeris the answerGAPGAPGAPGAP**** is the answeris the answeris the answeris the answer
GAPGAPGAPGAP**** is a proactive action and the solution to
ensure availability and reliability of generators as well as improve operational efficiency and
productivity to ensure smooth and trouble free running of the plant.
GAPGAPGAPGAP**** is an inspection and maintenance process GAPGAPGAPGAP is an inspection and maintenance process
during the lifetime of a generator and is planned for during either operation or outage.
GAPGAPGAPGAP**** can be linked to the generator planned outage time thereby ensuring minimum downtime of the plant and at the same time assessing the
healthiness of the [email protected]
GAPGAPGAPGAP1111 GAPGAPGAPGAP2222
GAPGAPGAPGAP****
GAPGAPGAPGAP4444 GAPGAPGAPGAP3333
GAPGAPGAPGAP****
GAPGAPGAPGAP1111
• During operation of the
generator
• Data collection and on-
line measurement when
the generator is in
operation
• Recommended after GAPGAPGAPGAP1111 • Recommended after
8,000 hours of
operation
• Usually takes 1 day
GAPGAPGAPGAP1111 deliverables
Thermal Life Assessment by Arrhenius EquationThermal Life Assessment by Arrhenius Equation
Thermal Life Assessment by N-Y method
Schedule for GAPGAPGAPGAP2222,,,, GAPGAPGAPGAP3333 and GAPGAPGAPGAP4444
GAPGAPGAPGAP2222
• During outage with
power cables removed
from the generator
• Data collection and off-
line electrical
measurements
• Recommended after GAPGAPGAPGAP2222 • Recommended after
16,000 hours of
operation
• Usually takes 2 days
GAPGAPGAPGAP2 2 2 2 deliverables
Condition Assessment based on Diagnostic TestsCondition Assessment based on Diagnostic Tests
Residual Life Assessment by D-map Method
May include GAPGAPGAPGAP1111 deliverables
Schedule for GAPGAPGAPGAP3333,,,, GAPGAPGAPGAP4444 and GAPGAPGAPGAP1111
GAPGAPGAPGAP3333
• During outage on
partially disassembled
generator (end-covers
and inspection windows
removed)
• Inspection and tests to
the extent possibleGAPGAPGAPGAP• Recommended after
32,000 hours of
operation
• Usually takes 3-5 days
GAPGAPGAPGAP3 3 3 3 deliverables
Visual Examination and inspectionVisual Examination and inspection
Residual Life based on Stress Analysis
May include GAPGAPGAPGAP1111 & GAPGAPGAPGAP2222 deliverables
Schedule for GAPGAPGAPGAP4444, , , , GAPGAPGAPGAP1111 and GAPGAPGAPGAP2222
GAPGAPGAPGAP4444
• During outage on fully
disassembled generator
with rotor threaded-out
• Inspection and
appropriate testing
• Recommended after
64,000 hours of GAPGAPGAPGAP4444 64,000 hours of
operation
• Usually takes 10-12
days
GAPGAPGAPGAP4 4 4 4 deliverables
Residual Life based on Stress Analysis
Condition Assessment and IndexCondition Assessment and Index
Risk Assessment and Index
may include GAPGAPGAPGAP1111, GAPGAPGAPGAP2222 & GAPGAPGAPGAP3333 deliverables
Schedule for GAPGAPGAPGAP1111, , , , GAPGAPGAPGAP2222 and GAPGAPGAPGAP3333
Continuous
Upgrading/
Replacement
Overhaul
Maintenance
Aging
Optimized Maintenance Line
Value to Customerthrough Maintenance
}
Life Cycle ConceptLife Cycle Concept
Upgrade and Modernization Period Warranty Period
AgingRepair
Time
Maintenance Period
Replacement & Recycle Period
Customer Project Lifecycle
Stress calculated
Stress calculated
from GAP2
Strength Calculated
from GAP2
Strength Calculated
from GAP3
Stress calculated
from GAP1
Strength Calculated
from GAP1
Stress calculated
from GAP4
calculated
from GAP3
Strength Calculated
from GAP4
Failure statisticsFailure statistics
37%3%5%
11%Bearing
Winding
Detection during Normal Operation
37%
33%
5%
6%3% Winding
Rotor
Shaft/coupling
Brushes/slipring
External devices
Not specif ied
Failure statisticsFailure statistics
7%
4%10%
Bearing
Winding
Detection during maintenance or test
8%
2%
8%
61%
Rotor
Shaft/coupling
Brushes/slipring
External devices
Not specified
Failure Statistics ConclusionFailure Statistics Conclusion
• Bearings fail frequently
• Windings also share a significant failure rate
• Very few winding failures are detected• Very few winding failures are detectedin maintenance (8.3%) as against thetotal failure of 33% in normal operation
• This indicates poor insulation problemsdetection technique
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