31 October 2013

Monitoring in Rotating Machines

Maik Koch, Omicron Berlin
1. Motivation
2. Source separation
3. System design
4. Measurement results
Failure Statistics
Source: Brtsch et al. "Insulation
Failure Mechanisms of Power
Generators", DEIS J uly/August 2008
Dielectric;
56%
Mechanical
; 27%
Thermal;
17%
Temperature
Electrical field
Ageing, moisture, aggressive substances
Mechanical vibrations
Reasons for Partial Discharges
31 October 2013
Monitoring of Rotating Machines

Maik Koch, Omicron Berlin
1. Motivation
2. Source separation
3. System design
4. Measurement results
surface endwinding
discharge - M
End winding surface -
contamination - M
Slot discharge, semicon.
paint abrasion - H
Insufficient Spacing,
Sparking, Contact, Corona,
- M
Micro voids - L
Delamination from
conductor
- H
Delamination of
tape layers
- H
S3
E1 & E2
PD Sources in
Stator Insulation
E1 & E3
S1 & S2 & S4
A)Covering Tape
B) Spacer, Coil-End Bracin
C) Mica Tapes
D) Grading/ Coating
E) Semiconductive Coating
F) Inner Semicon. coating
G) Turn Insulation
H) Slot Wedge / Seal
I) Stator Core
Clas
s
Name Symmetry Shape Phase angle Magnitude Description
Degree of
hazard for
insulation
S1
Delamination winding -
main Insulation from
conductor
Asymmetric, higher density
and magnitude in positive
half wave of AC voltage.
distinct triangular shape
with a sharp rise around the
positive voltage zero.
Start 300- 360
>S4
decrease with load/
temperature:
insulation expands
closing of
delaminations
void between inner
conductor and insulation,
better measurement in
lower freq. range
HIGH
Peak 0-60
>S4

Increase with load
wedge loosens,
overhangs loose, bar
vibration
Stop 90- 150
S2 Delamination of tape layers Symetric
sickle shaped
(shape depends on y-Axis
scaling) mostly mixed with G
Start
120- 210
300- 30
>S4
bigger symmetrical inner
micro void, start of
delamination
HIGH
Peak /
Stop /
S3
Slot discharge, semicon
paint abrasion
Asymmetric, higher
density and magnitude in
negative half wave of AC
voltage.
distinct triangular shape
with a sharp rise around the
negative voltage zero.
Start 120- 180
can increase with load
>S4 (about 10 nC)
void between stator/ slot
iron and insulation caused
by vibration of the bar/
coil in the slot
HIGH

Peak 180 - 240
Stop 270 - 330
S4 Micro voids
Symmetric ,
large amount of impulses
Large amount of impulses,
lower amplitude, shape follows
the gradient of the voltage,
also wave like pattern
Start 270-0 90- 180
normal small air pockets,
healthy insulation system
LOW
Peak
30-90
210- 270
Stop
90 - 180
270 - 360
E1
End winding surface
discharge - contamination
Symmetric
Pattern looks like rabbit ears,
mostly mixed with S4, high
amplitude
Start
~30
~210
>>S4

Surface discharge/ tracking
in enwinding section
MEDIUM

Peak /
Stop /
E2
Insufficient Spacing,
Tracking, Sparking, Contact,
Corona, Floating Potential
Corona Asymmetric:
higher amplitude in one
or another AC cycle
horizontal patterns, also
multiple levels, higher
amplitude
center
Corona
90
270
>>S4 (>50 nC)
all kind of corona, floating
potential, sparking. can be
between the winding but
also from contact or sharp
edges, difficult to
distinguish
MEDIUM
center
Sparking /
contact
30
210
Sparking - Symmetric
E3
Connection area between
slot corona protection and
end winding corona
protection, surface
endwinding discharge
Asymmetric, higher
density and magnitude in
negative half wave of AC
voltage.
compared to slot discharges the
triangular shape is
more oriented to the voltage
maximum also can be similar
like E1one rabbit ear in
negative AC cycle
Start 120- 180
>S4 (10 50 nC)
Discharge in enwinding
section due to bad contact
between AGS and EGS
MEDIUM

Peak 210 - 270
Stop 270 - 330
PD Sources and Their Criticality
Excitation Tyristor 6 Peaks also 12
and 24 peaks
Disturbances
Background Noise and Disturbances -
asynchronous with AC
Disturbances
Delamination winding - main Insulation
from conductor void between inner
conductor and insulation
S1
high
Slot discharge, semicon paint abrasion -
void between stator/ slot iron and
insulation
S3
high
Delamination of tape layers - bigger
symmetrical inner micro void
S2
high
Connection area between slot corona
protection and end winding corona
protection, surface endwinding discharge
E3
medium
Inner PD +Endwinding surface discharge
- contamination
E1
medium
Insufficient Spacing, Tracking, Sparking,
Contact, Corona, Floating Potential
E2
medium
Inner PD +End winding surface
discharge - contamination
E1
medium
Micro void - different scaling
S4
low
Micro void different scaling
S4
low

Micro void
S4
low
Insufficient Spacing, Tracking, Sparking,
Contact, Corona, Floating Potential
E2
E3
medium
Connection area between slot corona protection
and end winding corona protection, surface
endwinding discharge
Slot discharge, semicon paint abrasion -
void between stator/ slot iron and
insulation
S3 high
Inner PD +End winding surface
discharge - contamination
medium
E1
medium
The Challenge: Source Separation
Background Noise and Disturbances -
asynchronous with AC
Disturbances
200 pC
Inner PD +End winding surface
discharge - contamination
E1
medium
900 pC
Delamination of tape layers - bigger
symmetrical inner micro void
S2
high
500 pC
1,4 nC
Q
time
Alarm
CORE
L1
L2
L3
neutral
3 2 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 36 35 34 33 32
E
E
H
TE
Coupling between Phases
> 2013-10-31
10/31/2013 Page: 10 OMICRON
Separation with 3PARD
> 2013-10-31
cluster 4
cluster 9
cluster 6
3PARD
10/31/2013 Page: 11 OMICRON
Back Transformermation to PRPD
Supervised
Learning
Feature
Selection
Classification
Classification
Class
(PD source/no PD source)
Classifier
Training
Learning
informa-
tion
Feature
Extraction
Feature
Selection
PRPD
Reference
Database
Probability based
Decision Tree Generation
Decision making
Rule bases
Feature Choice
Feature
Extraction
Feature
Extraction
Categorization of
feature values
Tree Adjustment
CART Framework
Feature Choice
Feature
Extraction
Categorization of
feature values
Tree Descent
Decision Rules
Combination of classification results
- PD experts work

PRPD Data
Collection

Manual
Feature
Definition
Page 12 OMICRON
Pattern Recognition
Page 13 OMICRON
PRPD Pattern Classification Report (example)
31 October 2013
Monitoring of Rotating Machines

Maik Koch, Omicron Berlin
1. Motivation
2. Source separation
3. System design
4. Measurement results
PDM 600-3 Module
Monitoring Server
Controller MCU 502 with Relais
19FO Patchpanel


FO < 1000 m

Triaxial cable < 20m
Coupling capacitor
MCC 124 / 112
Monitoring System OMS600
Page: 16 10/31/2013
Coupling Capacitors MCC 124 / MCC112
> 10/31/2013
System Configuration Multiple Generators
Temporary Monitoring
>One case for easy transport
>Plug and Play (pre-wired)
>IP65 (NEMA 4)


Fixed monitoring vs. Portable monitoring
OMS 600 OMS 605
Browser based Monitoring Software
All measurement systems System per Asset
Configuration User-Settings
Live Trend
20
Historical Data
21
31 October 2013
Monitoring of Rotating Machines

Maik Koch, Omicron Berlin
1. Motivation
2. Source separation
3. System design
4. Measurement results
Customer Project BASF Power Plant Ludwigsburg
First contact BASF-OMICRON: April 2011
Offer, negotiations: 18. Mai 2011
Installation, commissioning Generator 1: 25./26. Mai 2011
Training: 05. J uli 2011
Installation, commissioning Generator 2: 8./9. August 2011

Weekly reports
+ARGOS
Monitoring System Hardware
24
Material & Components

2 OMS 600
1 Monitoring Server, Monitoring Software
1 UMTS Router
Use of existing PD couplers




Commissioning Generator Nr.1

Surface discharge, Phase U_>9,4 kV
25
Monitoring Generator Nr.1
Surface Discharge Phase U
Phase U Phase V Phase W
26
Monitoring of Generator 2

27
28
Reports by Omicron Experts
Summary
On-line monitoring provides results under real operating conditions
Source separation
System design
Diagnosis SW
Monitoring SW
Until now about 50 Installations