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Bmp-Turbines-Condition Assessment PDF
Bmp-Turbines-Condition Assessment PDF
GENERAL
The hydraulic turbine is a critical component of a hydroelectric powerplant but it may not be
apparent that degradation of the condition of the turbine has occurred. Weld repairs, operation in
a rough zone, and operation on Automatic Generation Control (AGC) all take their toll on the
overall condition of the turbine. Efficiency losses are usually gradual and are not noticeable
unless efficiency tests are performed. New turbine runners are often not considered unless a
considerable uprate is possible or the existing runner is physically failing. Assessing the overall
condition of the turbine may show that a replacement runner with a state-of-the-art hydraulic
design, fabricated from modern materials and refurbishing other components, may provide
economic benefits when compared to the current costs of repair and the efficiency of the existing
runner.
Determining the present condition of a turbine is an essential step in analyzing the risk of failure.
This appendix provides a process for arriving at a Turbine Condition Index which may be used to
develop a business case addressing risk of failure, economic consequences, and other factors.
E6.2
SCOPE / APPLICATION
The turbine assessment methodology outlined in this appendix applies to Francis, Kaplan, and
propeller (reaction type) hydraulic turbines. The entire turbine is considered in this assessment
tool, with the turbine runner as a major component. At the Facility Managers discretion, the
assessments can be performed on individual turbines or a family of identical or near-identical
turbines. This appendix is not intended to define turbine maintenance practices or describe in
detail inspections, tests, or measurements. Utility-specific maintenance policies and procedures
must be consulted for such information.
E6.3
This appendix describes the condition indicators generally regarded by hydro plant engineers as
providing the basis for assessing turbine condition. The following four indicators are used in the
initial, or Tier 1, assessment:
Age
Runner Physical Condition
Operational Conditions/Restraints
E6-1
Maintenance
The Tier 1 condition indicators are based on the known turbine runner condition and/or
inspections conducted by utility staff or contractors over the course of time and as part of routine
maintenance activities. Numerical scores are assigned to each turbine condition indicator, which
are then weighted and summed to determine the Turbine Condition Index.
An additional stand-alone indicator is used to reflect the quality of the information available for
scoring the turbine condition indicators. In some cases, data may be missing, out-of-date, or of
questionable integrity. Any of these situations could affect the accuracy of the associated
condition indicator scores as well as the validity of the overall Condition Index. Given the
potential impact of poor or missing data, the Turbine Data Quality Indicator is used as a means
of evaluating and recording confidence in the final Turbine Condition Index.
Additional information regarding turbine condition may be necessary to improve the accuracy
and reliability of the Turbine Condition Index. Therefore, in addition to the Tier 1 condition
indicators, this appendix describes a toolbox of Tier 2 inspections, tests, and measurements
that may be applied to adjust the Turbine Condition Index, depending on the specific issue or
problem being addressed. Tier 2 tests are considered non-routine. However, if Tier 2 data is
readily available, it may be used to supplement the Tier 1 assessment. Alternatively, Tier 2 tests
may be deliberately performed to address Tier 1 findings. Results of the Tier 2 analysis may
either increase or decrease the score of the Turbine Condition Index. The Data Quality Indicator
score may also be revised during the Tier 2 assessment to reflect the availability of additional
information or test data.
The Turbine Condition Index may be used as the sole justification for replacing or rehabilitating
a turbine. The Turbine Condition Index may also be used as an input to a computer model that
assesses risk and performs economic analyses.
Note: A severely negative result of ANY inspection, test, or measurement may be adequate in
itself to require immediate corrective action, regardless of the Turbine Condition Index score.
E6.4
Inspections, tests, and measurements should be conducted and analyzed by staff suitably trained
and experienced in turbine diagnostics. The more basic tests may be conducted by qualified staff
that are competent in these routine procedures. More complex inspections and measurements
may require a turbine diagnostics expert.
Inspections, tests, and measurements should be conducted on a frequency that provides accurate
and current information needed by the assessment.
Turbine condition assessment may cause concerns that justify more frequent monitoring.
Utilities should consider the possibility of taking more frequent measurements or installing online monitoring systems that will continuously track critical parameters. This will provide
E6-2
additional data for condition assessment and establish a certain amount of reassurance as turbine
alternatives are being explored.
E6.5
SCORING
Condition indicator scoring is somewhat subjective, relying on the experience and opinions of
plant staff and turbine experts. Relative terms such as Results Normal and Deterioration
refer to results that are compared to industry-accepted levels; or to baseline or previous
(acceptable) levels on this equipment; or to turbines of similar design, construction, or age
operating in a similar environment.
E6.6
WEIGHTING FACTORS
Weighting factors used in the condition assessment methodology recognize that some Condition
Indicators affect the Turbine Condition Index to a greater or lesser degree than other indicators.
These weighting factors were arrived at by consensus among turbine design and maintenance
personnel with extensive experience.
E6.7
MITIGATING FACTORS
Every turbine is unique and, therefore, the methodology described in this appendix cannot
quantify all factors that affect individual turbine condition. Mitigating factors not included in
this Guide may determine the final Turbine Condition Index and the final decision on turbine
replacement or rehabilitation. If the Turbine Condition Index triggers significant follow-up
actions (e.g., major repairs or a Tier 2 assessment), it may be prudent to first have the index
reviewed by turbine experts. Mitigating factors specific to the utility may affect the final
Turbine Condition Index and the final decision on turbine replacement or rehabilitation.
E6.8
DOCUMENTATION
E6.9
Age
(Partial Rehabilitation)
< 25 years
< 15 years
45 years
35 years
A partial rehabilitation is defined as a new runner with the majority of remaining critical turbine
components not restored, or an existing turbine repaired and the majority of remaining critical
components restored. The remaining critical turbine components include:
E6-4
The intent of the age criterion for the turbine condition assessment is to indicate performance
degradation.
Turbine Condition Indicator 2 Physical Condition
The surface condition of the waterway is important, especially since it affects the efficiency and
capacity of the machine. Areas in the waterway that see the highest velocities will have the
largest effects on efficiency. The surface condition of metal components may deteriorate over
time due to erosion, corrosion, operating in cavitation zones, and cavitation and cracking damage
and repairs. The following can be evaluated through inspection of the turbine and its
components: the runner, wicket gates, stay vanes, and discharge ring. The photographs in
Annex A are intended to assist in evaluating the surface condition of the runner.
Results of the physical inspection are analyzed and applied to Table 2 to arrive at condition
indicator scores.
Table 2 Physical Condition Scoring
Cracks
Results*
No Cracking
Inactive Cracks
Active Cracks
Results
Good Surface/Minimal Cavitation Damage
Fair Surface/ Moderate Cavitation Damage
Poor Surface/Severe Cavitation Damage
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No corrective maintenance
1.5
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1.0
0.5
0
Results
All Tier 1 inspections, tests and measurements were completed
within the normal frequency.
One or more of the Tier 1 inspections, tests and measurements were
completed 6 and < 24 months past the normal frequency.
One or more of the Tier 1 inspections, tests and measurements were
completed 24 and < 36 months past the normal frequency, or
some of the results are not available.
One or more of the Tier 1 inspections, tests and measurements were
completed 36 months past the normal frequency, or no results are
available.
Data Quality
Indicator Score
10
7
4
Enter the Turbine Data Quality Indicator Score from Table 5 into the Turbine Condition
Assessment Summary form at the end of this document.
E6-7
Visit the plant to perform a physical inspection of a turbine and interview O & M
staff.
Determine current performance and perform a simplified field test, if necessary.
Review and, if necessary, adjust the Tier 1 Condition Index based upon the inspection
and comparison with the condition of other similar families of units.
For each Tier 2 test performed, add or subtract the appropriate amount to/from the Turbine
Condition Index. Many of the following Tier 2 tests are used to detect or confirm a similar
defect or state of deterioration. In the event that more than one Tier 2 tests are performed to
assess the same problem or concern, then the test with the largest adjustment shall be used to
recalculate the Turbine Condition Index. It is important to avoid adjusting the Condition Index
downward twice or more simply because multiple tests are completed for the same suspected
problem. Since the Tier 2 tests are being performed by and/or coordinated with knowledgeable
technical staff, the decision as to which test is more significant and how different tests overlap is
left to the experts.
E6-8
Adjustment to
Condition Index Score
Add 0.5
No Change
Subtract 1.0
E6-9
Adjustment to
Condition Index Score
Add 0.5
No Change
Subtract 0.5
Adjustment to
Condition Index Score
No Change
Subtract 0.5
Adjustment to
Condition Index Score
Add 0.5
No Change
Subtract 0.5
E6-10
Surface quality comparison test results are analyzed and applied to Table 10 to arrive at a
Turbine Condition Index score adjustment.
Table 10 Surface Roughness of Runner and Discharge Ring Test Scoring
Adjustment to
Condition Index Score
Add 0.5
No Change
Subtract 0.5
Surface Quality
Good
Moderate
Severe
Test T2.6: Cracking of Runner and Discharge Ring Test
O & M personnel will be interviewed to determine and document the cracking repair history. If
a cracking problem has been permanently solved (i.e., no cracks have occurred in the last
10 years), it will be scored as minimal. If cracking occurs, but in non-critical areas, it will be
scored as moderate. See the sketches in Annex B. Critical areas are those labeled I and II. All
other areas are considered non-critical.
The cracking repair test results are analyzed and applied to Table 11 to arrive at a Turbine
Condition Index score adjustment.
Table 11 Cracking of Runner and Discharge Ring Test Scoring
Adjustment to
Condition Index Score
Add 1.0
No Change
Subtract 1.0
E6-11
Cavitation Damage
Minimal:
Stainless frosting only (in small areas)
Carbon frosting only (in small areas)
Moderate: Depth
Area
Stainless < 1/8 < 5%
Carbon
< 3/8
< 5%
Severe:
Depth
Area
Stainless 1/8 5%
3/8
5%
Carbon
No Change
Subtract 0.3
Subtract 0.6
Gate mechanism (servo motors, shift ring, wicket gate locking mechanisms, bushings)
Guide bearings
Seals
Oil-head (if Kaplan)
Blade adjusting mechanism (if Kaplan)
Alignment/verticality
Concrete growth
Run-out
Vibration
Noise
Greasing system
Oil circulating pumps
Headcover drains or pumps
Vacuum breakers
Test results from the condition of all remaining parts and systems are analyzed and applied to
Table 13 to arrive at a Turbine Condition Index score adjustment.
E6-12
Equipment Condition
All sub-systems are normal and there are no major issues in any of
the listed areas. In general, very little maintenance is required.
Some sub-systems require frequent maintenance or do not operate
well. Frequent minor maintenance is needed to keep the unit
running well.
The unit runs but takes significant or frequent maintenance. Some
more important components are damaged or broken.
Adjustment to
Condition Index Score
Add 0.2
No Change
Subtract 0.7
Environmental Conditions
There are no perceived environmental issues and rehabilitation of
the turbine would have minimal positive effect on the environment.
Little or no oil or grease is released into the environment and no
DO improvements can be gained by a turbine replacement.
There is some history of negative impacts (occasional minor oil
releases, some mortality of fish which transit the turbine, and most
years, the desired dissolved oxygen content of released water is met
or exceeded during all months).
There are known negative impacts which regularly occur which can
be mitigated by a turbine rehabilitation. Significant amounts of oil
or grease are occasionally released into the environment. Or, DO
improvements or fish passage survival improvements can be gained
by a turbine replacement.
Adjustment to
Condition Index Score
No Change
Subtract 0.3
Subtract 0.6
E6-13
Test results from the operating conditions are analyzed and applied to Table 15 to arrive at a
Turbine Condition Index score adjustment.
Table 15 Operating Conditions Test Scoring
Adjustment to
Condition Index Score
Add 0.2
No Change
Subtract 0.5
Base loaded.
Maintenance Performed
Normal maintenance.
Adjustment to
Condition Index Score
Add 0.2
No Change
Subtract 0.5
E6-15
TURBINE
TIER 1 CONDITION ASSESSMENT SUMMARY
Date: ________________________ Location: ________________________________________
Turbine Identifier: ______________ Manufacturer: _________________Yr. Mfd.: ___________
Tier 1 Turbine Condition Summary
(For instructions on indicator scoring, please refer to condition assessment guide)
No.
1
Condition Indicator
Age
Physical Condition
Operations
Maintenance
(Score must be 0, 1, 2, or 3)
1.250
(Score must be 0, 1, 2, 3, or 4)
1.000
1.000
E6-16
TURBINE
TIER 2 CONDITION ASSESSMENT SUMMARY
Date: ________________________ Location: ________________________________________
Turbine Identifier: ______________ Manufacturer: _________________Yr. Mfd.: ___________
No.
Individual Adjustments
to Tier 1 Condition Index
Tier 2 Test
T2.1
Efficiency
T2.2
Capacity
T2.3
Off-Design
T2.4
T2.5
Surface Roughness
T2.6
Cracking
T2.7
Cavitation
T2.8
T2.9
Environmental
E6-17
( 0 and 10)
To calculate the Net Turbine Condition Index (Value should be between 0 and 10), subtract the Tier 2
Adjustments from the Tier 1 Turbine Condition Index:
Tier 1 Turbine Condition Index
__________
__________
________________
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E6-19
E6-20
E6-21
E6-22
E6-23