Approach To Generator CBM

A New Holistic Approach to Generator Diagnostics and Monitoring
Thomas Laird
I&C and Diagnostic Operations ALSTOM Power Inc., Midlothian, Virginia
Michael Drpic
Generator Global Product Management ALSTOM (Switzerland) Ltd, Baden, Switzerland
Keywords:
Condition Based Maintenance (CBM), Turbine Generator Monitoring, Data Mining, AMODIS, Generator Diagnostics, Human Machine Interface (HMI)
Abstract:
A cost effective maintenance strategy that provides high reliability of a plants turbine generator is critical for profitable generation of power. Early warnings concerning potential generator-related issues, effective planning, and extension of the interval between overhauls can reduce maintenance costs. In the past, plant maintenance personnel have used ad hoc methods for transition from the traditional time-based maintenance methodology to a condition-based maintenance strategy for the turbine generators. This paper discusses a new holistic approach that is available for generator diagnostics and monitoring. The equipment used for monitoring the critical components for the generator are integrated into a single comprehensive monitoring system. Generator condition status is available to the plant operator through the units Human Machine Interface - HMI providing early warning of generator issues. Detailed information including trends and the location of a generator problem can be accessed by the plants maintenance engineering resources locally or remote. This new system also incorporates the use of Alstoms large database of fleet design, maintenance records, and operational performance information. Recommendations for corrective action of identified problems can quickly be provided to help ensure maximum availability and reliability of the unit.
Copyright 2007 by ISA -The Instrumentation, Systems and Automation Society. Presented at 17th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference 50th Annual ISA POWID Symposium, Pittsburgh, PA, USA
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Introduction:
The holy grail of a profitable power plant is maximum availability, operational reliability, and reduced maintenance costs of critical equipment. To gain competitive advantage, utilities are mainly interested in how to detect degradation of power equipment at an early stage. Unplanned costly interruption of service and extension of the lifetime without losing reliability is of vital concern. To meet goals, exploration of maintenance concepts based on actual condition of the equipment is replacing traditional time-based preventive maintenance programs. Timebased maintenance strategies applying fixed-interval inspection and repair schedules are far from optimal regarding costs and operational availability of power equipment. The regular schedules for off-line diagnostics and maintenance are usually based on past experience with that specific type of equipment. Even though planning of maintenance can be optimized, utilities are often not able to use their resources in a most efficient and economic way as they like to. Generator components, like stator winding, stator core, rotor winding, rotor-retaining rings, generator bearings and high voltage bushings, are subject to continuous high stresses. Failures will inevitably occur when maintenance is not sufficiently considered. Utilities usually apply different maintenance methodologies depending on the kind of power plant and the specific operation requirements for their turbine generators. Justification for maintenance procedure will be different according to the type of power producer. For example, a nuclear power plant with requirements of fixed outage schedules with critical path of the outage linked to refueling will have much different maintenance requirements compared to an industrial power producer. Major utilities using combinations of time-based maintenance and condition-based maintenance strategies usually have a team of in-house generator experts looking for better ways to improve reliability and reduce maintenance costs.
Basic Requirements For CBM and Real-time Condition Assessment

The most demanding task within modern Condition Based Maintenance - CBM concepts is to obtain objective evidence of need for specific maintenance actions. This requires much more than simple instrument reading. Appropriate sensors, partly embedded into the operating equipment are needed as well as powerful tools for measuring and monitoring specific diagnostic parameters. Extensive knowledge is needed on individual equipment design features, material and critical component characteristics. To understand the actual condition of the equipment and its specific implications on operational reliability, interactions of several physical and chemical processes are required.
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experience physical models of

degradation processes prototype and model investigations data from on-line and off-line measurements extraction of sensitive diagnostic parameters design /system and material know how diagnostic database trend / reference data
reliability requirement
experience
problem identification condition assessment diagnostic decision leads maintenance
experience
assessment of actual risk
Fig. 1: Knowledge infrastructure needed for a diagnostic decision making process within CBM strategies The application of CBM requires various basic elements, to allow reliable diagnostic decision making to be realized. In Fig. 1 main emphasis is given to the knowledge infrastructure needed and to the general process of diagnostic decision-making. The following elements are considered being essential for a CBM process: 1. Measurement data from on-line monitoring of the equipment during service. 2. A set of appropriate diagnostic parameters, derived from the original measured data. This ensures the detection in a high degree of sensitivity and selectivity to the relevant degradation mechanisms. 3. A catalog containing detailed information about typical failure modes for the specific generator. 4. Design, system, and material know-how, for generator assessment since different components react differently to operational long-term stresses and possible shortterm overstresses. 5. A large diagnostic database reflecting expert knowledge on decision-making processes and unit history information. 6. Clear decision rules that provide an unambiguous assessment of equipment condition, based on the information available. When reviewing all theses requirements, it becomes obvious that the application of CBM is a demanding task, which needs much more than just to monitor a machine and make a guess about the meaning of the measured data. An important question is how to proceed efficiently and how to process the huge amount of information, virtually in real time, within advanced CBM strategies. The diagram in Fig. 2 illustrates a basic methodology for the quality of real-time condition assessment. It considers known and unknown weakness identification of the generators major components and monitoring of the stress factors (Temperature, Electrical, Ambient conditions, and Mechanical stresses, also called TEAM factors).
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Quality of real-time condition assessment

Unknown Component Weaknesses
Aging factors Component design weaknesses not monitored Quality of repair / refurbishment Unexpected operational stresses
OEM Information
Nameplate information OEM Maintenance recommendations OEM Technical bulletins
Unit Condition Assessment

Commissioning & inspection reports Off-line diagnostics results Corrective action status Root cause analysis of failures
Assessed Condition Trending

On-line diagnostic results Periodic measurements Continuous monitoring
Unit Design an Component Weakness Identification
Monitoring of Stress Factors
Fig. 2 Quality of Real-time Condition Assessment
Unknown Factors and Diagnostic Limitations

Unexpected failures on generators of similar design in areas that are not typical may occur. This may be attributed to the normal aging process of the unit, unexpected operation excursions or unpredictable short-term overstresses. Maintenance, tests and inspection requirements should be continually re-evaluated for the units age and current assessed condition. Unfortunately, current technology cannot assess the condition of some of the generators critical components during unit operation. Only best guess for operational reliability can be done. For example, rotor retaining ring condition cannot be monitored and thus failures cannot be predicted. It can only be assumed that this critical component is reliable based on the material and results of non-destructive examinations during a major outage. Defects within the generator system may develop during operation, which cannot be detected by the available monitoring methods. For example, on-line partial discharge measurements can only detect insulation problems, which cause local electrical overstressing finally resulting in short duration current pulses. Problems caused by heavy current loading with low voltage, or local failures involving continuous leakage currents due to conductive paths between different insulation elements, are not detectable. Knowing the limitations of on-line and off-line diagnostic tests and inspections should be considered when evaluating risk assessment for reliable operation. It should be noted that in many cases the information provided by diagnostic tests is still rather limited. Actual aging mechanisms and failure modes under multi-stress conditions are not sufficiently known.
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Holistic Approach to Generator Diagnostics and Monitoring

Although real-time condition assessment for generators will not be 100% risk free using modern technology, most generator problems can be identified early enough to prevent in-service failures. The equipment and methods popularly used for generator monitoring is a collection of sensors, acquisition tools, and equipment supplied from different sources. It is the responsibility of the utilitys generator specialist or maintenance engineer to piece together all of these sources. He has to collect the information from the generator manufacturer and previous diagnostic reports, to properly assess the reliability of the unit. Forcing the maintenance engineer to be proactive on a critical component for unit operation invariably causes maintenance problems. For him this is another component just as critical for plant operational availability as many others. An optimized maintenance strategy at the plant level is the key factor for economic plant operation. Measures should be taken to permit the maintenance engineer to be reactive to early warning systems leaving time for attention to other less critical plant components. The holistic approach for generator diagnostics and monitoring will alleviate this proactive responsibility of the maintenance engineer. Technology exists today to electronically combine all of the information provided by the various sensors and monitoring equipment into one display. However, to ensure the actions required from the maintenance engineer are reactive rather than proactive, a simple assessed condition trending display for the generators monitored components can be incorporated into the plants HMI in the control room.
Fig. 3 Notification of Generator Issue Early warning of impeding generator issues will be noted by the control room operator. The operator in turn will notify the plants maintenance engineer for investigation. Using the HMI, the maintenance engineer can investigate the area of concern in more detail,
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isolating the problem. For example, in Fig.4 Turbine Generator Status Page, the Concern flag appears for monitored assessed condition of the stator winding. The flags are in three categories for the assessed condition, OK, Concern, and Critical. The Concern and Critical alarms have associated Recommendation boxes. The Recommendation box shows the next action to take to investigate the concern or critical condition in more detail.
abcd
Fig. 4 Turbine Generator Status Page Fig. 5 shows the monitored trends with generator output. Note that the partial discharge activity level for phase A of the generator stator winding was gradually increasing over time giving an indication of when the deviation from the assessed condition started to occur. The rate of degradation can be calculated thus providing important information for risk assessment for continued reliable operation.
Fig. 5 Turbine generator trends

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Fig. 6 shows the resultant phase resolved partial discharge pattern used for analysis of the concerned generator issue. These patterns can be compared with the stored patterns created when the service provider assessed the units condition (the units signature).
Fig. 6 Phase resolved PD distribution patterns If the risk assessment for operational reliability is not obvious, then help can be provided electronically using the OEMs database and generator design know-how to obtain recommendations for corrective measures.
CONCLUSION
The key to the holistic approach of generator real-time condition assessment is to take advantage of todays technology in diagnostics and monitoring. Combining known OEM design information and the monitored data regardless of the sensor or acquisition equipment provides usable and reliable information for the control room operator and
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maintenance engineer. The integration of the monitoring system within the plant HMI reduces the need to give attention to different screens, including remote operation. Recognizing the quality of information available and eliminating risk of misinterpretation will increase the quality of real-time condition assessment. The holistic approach shall respect the fact, that control room operators in the power plant, have a different function and need, in data information content, than the responsible maintenance engineer. The adaptation of the information content to what the user needs, also reduces the risk of decision taking based on insufficient or incomplete data content. The holistic approach to generator diagnostics and monitoring will maximize reliability through early detection of condition changes, will increase availability through reduction of unplanned outages and reduce maintenance cost through optimized outage planning. The ultimate goal is to use this approach to give power plant operators the ability to react to generator issues in a proactive way.
REFERENCES
Laird, T.; Hoof, M.; A Strategy for Advanced Condition Based Maintenance of Large Generators. Electrical Insulation Conference EIC 2003, Indianapolis, Indiana, September 2003 Maughan, C.V.: Generator Reliability as Influenced by Engineering Design Parameters. Electrical Insulation Conference EIC2001, Cincinnati, USA, (2001), 159-79 Bindert, A.; Hoof, M.; Stephan, C.-E.: Lifetime Assessment A Tool for Improving Generator Availability. POWER-GEN Europe 2002, Milan, Italy, (2002) Hoof, M.; Laird, T.: Assessed Condition Trending System - A Tool for Generator On-Line Diagnostics. Electrical Insulation Conference EIC2001, Cincinnati, USA, (2001), 411-16 Hoof, M.; Lanz, S.: PD Diagnostics on Rotating Machines Possibilities and Limitations. Electrical Insulation Conference, Cincinnati, USA, (1999), 195-200
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Approach To Generator CBM

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Approach To Generator CBM

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A New Holistic Approach to Generator Diagnostics and Monitoring

Basic Requirements For CBM and Real-time Condition Assessment

experience physical models of

Quality of real-time condition assessment

Unit Condition Assessment

Assessed Condition Trending

Unit Design an Component Weakness Identification

Monitoring of Stress Factors

Fig. 2 Quality of Real-time Condition Assessment

Unknown Factors and Diagnostic Limitations

Holistic Approach to Generator Diagnostics and Monitoring

Fig. 5 Turbine generator trends

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