HOW TO IMPLEMENT PREDICTIVE

MAINTENANCE ON HYDROGENERATORS

Laurent BUSSON
Lima - November 18th, 2022
Technical expert and speaker
Laurent Busson
• Dipl. Ing. of Ecole Nationale Supérieure d’Electricité et de
Mécanique – Nancy – France
• Started to work at ALSTOM Hydro France in 1997
• Different positions held in ALSTOM / GE : calculation
engineer, project design engineer, head of design office and
engineering
• Independant expert at HYDRHOM since 2020
• Different fields of experience : generators, bearings, shaft
line, vibrations, …
Overview

1. Hydro generators failures

2. Instrumentation and monitoring
3. 5 points to implement predictive maintenance
4. Some examples
5. Conclusion
How to implement predictive maintenance on hydrogenerators

Maintenance strategies Predictive maintenance will :

• Detect abnormal behaviour at the earliest posible time
• Provide early warnings before protection limits are reached
• Enable optimized maintenance program

 Availability & reliability of the unit

Source : ABS-USA
Hydro generators failures

Robust machines, with some critical areas :

• Stator winding and core

• Rotor winding and core and …

Hydro generators failures

Some other critical areas :

• Bearing and shafts
• Ventilation / cooling
• Auxiliaries
• Structure and frames
Instrumentation and monitoring

In hydro business, some units are rather old, from the 70s down to the 30s !

Only analogic sensors (0-12 V or 4-20 mA) can be used for

preventive maintenance.

 Instrumentation upgrade may be required

Instrumentation and monitoring

Many information can be extracted during operation from:

• Temperature sensors (Pt100 RTDs)
• Vibration sensors (accelerometers and proximity probes)
• Flowmeters, pressure gauges
• Electrical measurements (U, I)
• Partial discharges
• Airgap
• Magnetic flux
Instrumentation and monitoring

Additionnal information can be obtained during off-line maintenance phases:

• Insulation values
• Oil or grease analysis

 Data are key to perform a predictive maintenance program

Step 1 : Review history of the unit

Provide relevant operation and maintenance history :

Start after maintenance

• Operation time, starts & stops per day/per year
• Key events : overspeed, runaway speed, …
• Incidents & repairs
• Overhauls and associated reports
• Spare parts : used and available

 Historical data are the initial driver for the predictive maintenance program
Step 2 : Audit the machine condition

The on-site audit will be issued by an expert at running conditions and at standstill.
The program will be defined on a case by case basis depending on the characteristics of the unit :
power, speed, voltage, shaft line arrangement, …
Step 1 initial data are also key to organize step 2.
An exchange session with the operation & maintenance staff is a must !

 A deep-dive into the machine

 A unique opportunity to get information that are not referenced
Step 3 : Correct the critical issues

Following the on-site audit, the expert will define some corrective actions, if necessary, to :
• Enhance the operation of the machine and the stability of parameters
• Strengthen the maintenance process
• Align the team with the predictive maintenance objectives

 Start the predictive program with a stable operation and good maintenance practices
Step 4 : Analyze the data

The machine can now deliver collected data to be analyzed by the expert at a defined frequency:
• Definition of acceptable variations around the average value.
• Analysis of the data with corrections on the operating factors
• Recommendations for actions, if any

 The predictive maintenance program is now delivering !

Step 5 : Follow the program

• Maintenance activities as per the program.

• Check operation of sensors
• Actions for identified corrections

 Do the right actions at the right time !

Example 1 : Roller bearing vibrations

Vibration analysis indicate the degradation stage :

• Stage 1 : High frequency signal.
• Stage 2 : Non-synchronous peaks
• Stage 3 : Bearing frequencies BPFO, BPFI, BSF
• Stage 4 : Noise level increase

 Powerful tool for predictive maintenance

Example 2 : Shaft displacements at journal bearing

The shaft displacement analysis is a strong method to detect :

• Unbalance issue
• Alignment issue
• Radial gap issue
• Centering issue

 ISO 20816-5 for hydro machines defines protection limits.

 An expert can perform a deeper analysis to provide early warnings.
Example 3 : Journal bearing oil analysis

Oil analysis to detect abnormal value :

• Appearance
• Water concentration
• Viscosity
• Acidity
• Elemental analysis
• Foaming

 Sampling every 6-12 months is relevant for hydro units

Example 4 : Vibrations of Kaplan turbine oil pipes

Customer was suffering from recurent bronze ring damages.

• Site expertise
• Vibration analysis
• Thermal analysis
Conclusion : oil pipes not aligned with shaft line axis

 Predictive tool to determine wearing of bronze rings

 Next major overhaul will correct the root cause
Conclusion

Implementing predictive maintenance on hydro units requires:

• A strong maintenance process
• A long term vision
• Adequate instrumentation
• A site team trained to predictive maintenance
• One Expert to analyze trends
• And flexibility : in Hydro business, all powerplants are different !
 HYDRHOM Sarl
Belfort- FRANCE
Contact :
laurent.busson@hydrhom.fr
Tél. : +33 6 63 54 18 79

EXPERTISE & ENGINEERING