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Generator Diagnostics From Failure Modes To Risk Forced Outage PDF
Generator Diagnostics From Failure Modes To Risk Forced Outage PDF
Ageing
Design,
Material
Operation
Stator core
Stator frame
Stator winding
Rotor 35%
Bearings 10%
Exciter 5%
Slip rings and brushes 5%
Electric testing
6 Gabor Csaba IRMC 2018 - Generator diagnostics based on failure modes
Inspection levels for turbogenerator
• Normally there are three inspection levels:
– Major Overhaul (MO) where bearings, coolers and the
rotor are disassembled.
– Limited Inspection (LI) where parts of bearings and some
winding covers are removed.
– Safety Check (SC) where only inspection hatches are
removed / opened.
Penetrant / EC
Failure mode
El-mät basic
El-mät basic
El-mät basic
Anmärkning
PD mätnng
PD mätnng
PD mätnng
Ultraljud
high pot
high pot
high pot
Visuell
Visuell
Visuell
ElCID
RSO
RSO
RSO
which failure mode?
Failure mode
Stator frame
Defect in ancoring details i i i
Defects in guide devices i i i
Crack groving caused by vibration d d
Loose screw joints i i
Touch in contact between fan and cover i i i
High vibration in generator with shield bearings
Stator Core
Degenerated core pressure i
Shortened lamination d i
Shortened lamination from foreign parts d i
Deformed lamination in teeth i
Fatigue cracs in lamination i
and described.
Ageing of main insulation d d i i d i d d i d
Wet insulation i i i
Stator slot
Large area with missed bounding between green bar and insulation d d d
Delaminating in main insulation i- i- i-
Bad contact between slot wall and corona protection i i i
Corona protection on the bar acting as a conductor d d d d
Hole in the main insulation, at the straight part of the bar i d- i d- d d- d
Loose slot wedges i
Increased temperature by a Hot spot in the teeth d- i d- d-
d i-
i
d
d
d
d
d
d
d
d
d
d
d
d
i i
i
i
a
i
i
d
i
d
d
d
Bad insulation d i d i d i
Abnormal wear of brushes i b i i
Abnormal wear of slip ring i i i
Spaking brushes i i i
Ghost mark i i i
Exciter with rectifier
Contamination i d i d
Defect diods i i
Defect contacts to rotor connectors i d i d
Defects i AC winding circuit i i
Defect suppport of the end winding AC i i
Cracks in the of the rectifier ring j
Deformation or lose parts i i
Pedistal or Shield
Oil leakage i i
Insufficient insulation of the bearing i i i i
Bearings
Current through bearing i
Damaged surfaces on the bearing or the shaft i
15 Incorrect clearance bearing/shaft
Missed bonding between babbit and steel
i
i
Incorrect alignment of bearing to the shaft i
Penetrant / EC
El-test basic
El-test basic
El-test basic
PD measure
PD measure
PD measure
Ultra sonic
HV-test
HV-test
HV-test
Visual
Visual
Visual
ElCID
RSO
RSO
RSO
Felmod
Aging of main insulation stator winding d d i i d i d d i d
Contaminated stator end winding i d i d d
Cracks in rotor fans d i d
25% 55%
12
investigated before the restart.
Result of inspection with diagnostics
• We supply You with the present risk situation!
• Analysis of the data results in a risk assessment at component level.
• The risk to the generator is equal to that of the highest-risk component, taking into account
planed operation until next MO
• Results are reported as four risk levels from Base Risk to High Risk.
4 1 Base risk
4 1 2 3
2. Increasing risk
3. Medium high risk
4. High risk
18
15
Life time assessments using failure
mode concept
AOH*) ~= 260’000
– Operation: continuous,
~5000 hours/year
2
– Exciter 2 1 3 4
Fan blades
– Bearings 1
1
2 3 4 Fan blades Retaining ring
– The total risk equals the highest risk for Retaining ring Rotor slots
individual components, here level 4, High Risk.
Potential weak areas ASEA/ABB GTL-type
• Recommendations for further investigations, Phase 2.
22 Gabor Csaba IRMC 2018 - Generator diagnostics based on failure modes
Pressure rings
-1
• Experience say that >=0.1 MPa is Calibration of equipment in lab
acceptable. -3
-4
-6 0,2MPa
bellow and movement detector calibrated -7
0,1MPa
0
• Over all result ‐1
0 5 10 15 20 25 30 Movement detector
gave core ‐2
‐3
pressure ‐4 Pressure bellow
Bad
assessed to be ‐5
Good
<< 0.1 MPa ‐6
‐7
‐8
• To reduce the risk to acceptable level, a new core is needed and a new winding.
• Recommendation was to purchase a new stator.
• Customer decided to replace the complete generator with a new one.
Connection box
27 Gabor Csaba
Analyzer IRMC 2018 - Generator diagnostics based on failure modes
Example of installation for monitoring the stator
Connection box
Installation of PD couplers
Example of PD measurement on-line
Phase connection
Coupler