1520 Garcia Araco Jose Luis Presnid55ver30

Survey on Hydro Generator Failures
Mr. Jos Lus Garca Araco

Convenorr
WG A1.10
SCA1 Meeting Sydney 2009.
Agenda
1.
2.
3.
4.
Introduction
Information gathered
Results of the Survey - Analysis
Conclusions
1.- Introduction
Issue: LARGE FAILURES in HYDRO GENERATORS
Aspects:
Repairing cost
Lost of profit
~
~
damage extent
outage
Damage / performance recovery
Analisys
PREVENTION
2.- Information gathered

No. of
companies
No. of hydro
generators
Total power
of hydro
generators
(MVA)
Australia
1 (Utility)
31
3.756
145
Germany
5 (Utilities)
111
3.785
597
Norway
2 (1 Utility +
1 OEM)
410
20.000
11
1.343
Spain
4 (Utilities)
409
16.384
37
2.700
Sweden
5 (Utilities)
238
13.317
15
804
1.199
48.692
69
5.589
Country
Incidents Reported
Number
Total Power
(MVA)
3.- Results of the survey - Analysis

Damage Typology of damages:
Damage
Severity
- Extent of damage
- Outage
Typology of damages
Failure root causes
Nature of failures
Risk reduction methods
Condition monitoring

Damage Severity - Extent of damage:
Extent of damage (%)
70
60
Insulation root causes
50
Thermal root causes

Mechanical root causes
40
Bearing root causes

30
Thermal and mechanical root causes
20
10
0
1
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55
Incidents

Damage Severity - Outage:
300
Insulation root causes
Forced Outage (days)
250
Thermal root causes

Mechanical root causes
200
Bearing root causes

150
Thermal and mechanical root causes
100
50
0
1
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67
Incidents

Damage Typology of damages:

Damage Typology of insulation damages:

Damage Typology of thermal damages:

Damage Typology of mechanical damages:

Damage Typology of bearing damages:

Failure root causes:

Failure vs Root causes:

Insulation root causes:

Thermal root causes:

Mechanical root causes:

Bearing root causes:

Nature of failure:

The more important natures of failure:
Nature of failure
AGE average
(years)
Run average
(hours)
Material weakness
30.4
130,567
Design weakness
28.8
126,222
Manufacturing weakness
23.1
56,567

Risk reduction methods: influence on the insulation root causes
Improved detection and alarm systems

Improved control systems
Improved protection systems (including fire protection)
Major refurbishment / upgrade
14
15
2
17
Improved maintenance techniques
12
Significant help
0
0
Increased spares stock
Marginal help
3
Increased design requirements

Improved quality control during design, manufacture
and assembly
14
4
13
10
Times of appearance
15
20

Risk reduction methods: influence on the thermal root causes
2
1
0
1
2
1
Significant help
0
1
1
Marginal help
Improved quality control during design, manufacture and

assembly
3
2
0
2
Times of appearance

Risk reduction methods: influence on the mechanical root causes
Improved protection systems (including fire

protection)
0
0
3
Significant help
4
Marginal help
3
5

0

1
7
Improved quality control during design, manufacture

and assembly
2
0
11
10
Times of appearance
15

Risk reduction methods: influence on the bearing root causes
0
0
0
0
Improved quality control during design, manufacture and

assembly
0
0
0
1
2
1
1
Marginal help
1
Times of appearance
Significant help

Condition monitoring: influence on the insulation root causes
0
Other new monitoring (specify)
Significant help
3
Brush condition monitor.

0
Rotor shorted turn monitor.
Marginal help
7
4
Stator frame and core vibration monitor.
13
Stator end winding vibration monitor.
10
On line partial discharge monitoring.
14
Shaft torsional monitor.
0
0
Shaft orbit analyser.
0
0
Shaft line / bearing vibration monitoring and protection
0
0
10
2
10
Times of appearence
12
14
16

Condition monitoring: influence on the thermal root causes

0
0
0
1
1
Significant help
Marginal help
3
1
1
2
1
Times of appearance

Condition monitoring: influence on the mechanical root causes
Significant help
Marginal help
1
2

0
0
0
0
1
2
2

0
Times of appearence

Condition monitoring: influence on the bearing root causes
0
0
0
0
0
0
Significant help
0
0
Marginal help
0
0
0
0
1
1
1
1

0
1
Times of appearence
4.- Conclusions
Insulation damages are the most frequent failures (57%) and
those that produce the greater extent of damage (in some cases
above 30%)
The failure root causes distribution is similar to the damage one,
but some of the insulation failures are originated by mechanical
root causes
The severity of a failure is related with the extent of damage and
the outage produced
The severity of a mechanical, thermal or bearing failure can be as
important as that of an insulation failure
Insulation failure root causes seems to be more evolutionary and
time sensitive than others (mechanical, thermal and bearing).
Responsibility for mechanical, thermal and bearing root causes
diminution falls mainly on manufacturers (accurate design, high
quality standards, etc.
4.- Conclusions
Responsibility for condition assessment, falls on users (partial
discharges monitoring and vibration monitoring are the more
valuable)
It is really important to foresee next failure occurrence to plan
adequate corrective measures
Condition monitoring methods show quite high effectiveness to
deal with insulation failure root causes, but they are not so
effective with the others

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Survey on Hydro Generator Failures

Mr. Jos Lus Garca Araco

SCA1 Meeting Sydney 2009.

SCA1 Meeting Sydney 2009.

Damage / performance recovery

SCA1 Meeting Sydney 2009.

2.- Information gathered

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

Extent of damage (%)

Insulation root causes

Thermal root causes

Bearing root causes

Thermal and mechanical root causes

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

Forced Outage (days)

Thermal root causes

Bearing root causes

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

Improved detection and alarm systems

Improved protection systems (including fire protection)

Major refurbishment / upgrade

Improved maintenance techniques

Increased spares stock

Increased design requirements

SCA1 Meeting Sydney 2009.

3.- Results of the survey - Analysis

Improved detection and alarm systems

Improved control systems

Improved protection systems (including fire protection)

Major refurbishment / upgrade

Improved maintenance techniques

Increased spares stock

Increased design requirements