Xu Xiao Ming, AP Services, March 2010 Machine services Life expectance analysis program (LEAP)

Transcription

1 Xu Xiao Ming, AP Services, March 2010 Machine services Life expectance analysis program (LEAP) April 12, 2010 Slide 1 Content MV Machine Winding Insulation Stress LEAP Methodology LEAP Standard LEAP from the Case book LEAP Usage and Uniqueness April 12, 2010 Slide 2 1

2 Basis of analysis Stress & strength v/s time Stress, strength Strength Transient faults Premature Failure Failure Stress (T.E.A.M) Residual Life Time April 12, 2010 Slide 3 Life expectancy analysis Benefits Strength Condition assessment and taking suitable actions at this point. Transient faults Adv. 1: No Premature Failure Stress Residual Life Failure Adv. 2: Increase in Life April 12, 2010 Slide 4 2

3 LEAP not just a step ahead What is LEAP? Lifetime Expectancy Analysis Program or LEAP is a unique Predicative Maintenance Tool for the Stator Winding Insulation of Electric Machines. LEAP provides information on Machine winding and expected residual life, and will optimize the Machine Maintenance Plans LEAP developed by ABB Machines Service, India, is in use for over 12 years, with a database of measurements and analysis in excess of 4000 machines worldwide Measurements are performed by Local or Global ABB Service centers and data analyzed at the LEAP Center of Excellence LEAP is not just a package of inspections; it is a systematic approach to managing Machine Maintenance April 12, 2010 Slide 5 Level based inspections Solution Levels Basic Standard LEAP Levels Packages Data collection (on site or remote): Operational hours, voltage, current, power, slip, Starts/Stops, Temperature (Winding, Coolant and Ambient), Duty cycle & loading pattern, Failure and Maintenance history, Information on power supply, breaker-cable configuration, etc Basic Data Collection Polarization Depolarization Current Analysis PDCA Tan Delta & capacitance Analysis Non-Linear Insulation Behavior Analysis Partial Discharge Analysis Deliverables Life Expectancy Analysis 80% Confidence Level Condition Based Inspection and Maintenance Plan Condition Assessment of Stator Windings for Contamination, ageing, looseness, delamination, stress grading system Life Expectancy Analysis 80% Confidence Level Condition Based Inspection and Maintenance Plan Advanced Premium Standard Data Collection Visual Inspection on end windings Partial Discharge Probe measurements & Dynamic Mechanical Response of Windings Stress analysis of End-windings Advanced Data Collection Wedge Tightness Map & Coupling resistance measurements Visual inspection, including slot areas Stress analysis of Windings Condition Assessment of Stator Windings with Standard Package + End-winding assessment Life Expectancy Analysis 85% Confidence Level Condition Based Inspection and Maintenance Plan Condition Assessment of Stator Windings with Advanced Package + slot region assessment Life Expectancy Analysis 90% Confidence Level Condition Based Inspection and Maintenance Plan April 12, 2010 Slide 6 3

4 Time (sec) Charging Discharging TIME (msecs) U - PHASE V - PHASE W - PHASE UVW - PHASE Voltage (kv) U Phase V Phase W Phase UVW Phase LEAP methodology Collection of Data Operating data, test measurements and machine information is collected using a package of measurements Analysis of Data Data collected is analyzed to identify the process of insulation degradation ABB has developed UNIQUE analytical tools to identify, characterize and quantify defects that could be present within the insulation system Calculation of Stresses Life Expectancy Analysis is performed and factors and conditions that affect lifetime are identified Estimating Life & Condition Based Maintenance Lifetime is estimated with different Confidence levels depending on the LEAP package Clear plans for possible further inspections, maintenance, replacements or even upgrades are drawn up April 12, 2010 Slide 8 LEAP standard package Pol-Depol Currents (microamp) Polarization-Depolarization Currents U PHASE DC Measurements Polarization De-Polarization Current Analysis CAPACITANCE (Arbitrary Units) INSTANTANEOUS CAPACITANCE 5.8 kv TAN DELTA MEASUREMENTS AC Measurements Non Linear Behavior Analysis Tan and Capacitance Analysis Partial Discharge Analysis Tan Delta (%) Remark: DC tests are sensitive to the surface condition, and AC tests give more information on the insulation volume April 12, 2010 Slide 9 4

5 DC measurements Polarization - De-polarization Current Analysis Besides leakage and absorption current, PDCA test gives an idea of quantity and location of charge storage within the machine Identifies contamination even when IR, PI values are acceptable. Determines state of the winding insulation, ageing, looseness, etc. Q3 Q1, Q2 Pol-Depol Currents (microamp) Polarization-Depolarization Currents UVW PHASE Time (sec) Parameters Derived Time constants T1, T2, T3 Charge storage : Q1, Q2, Q3 Ageing Factor Dispersion Ratio (1+Q1+Q2+Q3) Volume Resistivity Charging Discharging April 12, 2010 Slide 10 AC measurements Non Linear Behavior Analysis, Tan and Capacitance Analysis, Partial Discharge Analysis Confirm the results from DC Measurements Assess the condition of Corona protection shield Determine the extent of de-lamination or void content in terms of a percentage of discharging Air Volume to Insulation Volume Assess condition of the Stress Grading system at slot ends Trend Ageing effects INSTANTANEOUS CAPACITANCE 5.8 kv CAPACITANCE (Arbitrary Units) TIME (msecs) U - PHASE V - PHASE W - PHASE UVW - PHASE Remarks: Conventional measurement interpretation is generally based on trends April 12, 2010 Slide 11 5

6 Case study LEAP findings April 12, 2010 Slide 12 Case study LEAP findings April 12, 2010 Slide 13 6

7 Case study LEAP findings April 12, 2010 Slide 14 Case study LEAP Standard 6034 HP, 6 kv, 502A, 1481rpm Purpose of Testing: Routine Outage Inspection RESULTS - PDCA TEST Before Overhauling After Overhauling IR Mohm (> 100) PI (> 2) Q % (7%) Q % (10%) Q % (20%) DR 3.73 (1.25) IR Mohm (> 100) PI 5.63 (> 2) Q % (7%) Q % (10%) Q % (20%) DR 1.25 (1.25) Q3 Key findings: Contamination of windings Recommendation: Cleaning Benefits: Life Extension and improve reliability April 12, 2010 Slide 15 7

8 Case Study Generator - Premium Generator re wound after 18 months Extensive damage recorded on the coil sides in the slots Benefits: Catastrophic Failure Avoided! April 12, 2010 Slide 16 LEAP usage LEAP for Maintenance Planning L1, L2, L3, L4 LEAP for Run/Replace/Retrofit Decisions Measurements and Analysis are to be done at a single occasion (L4) with additional assessment of other components besides the stator windings LEAP for Life Extension/ Upgrade Decisions Measurements and Analysis are to be done at a single occasion (L4) with additional assessment of other components besides the stator windings April 12, 2010 Slide 17 8

9 LEAP How is it different? Methodology is not dependent on old records of measurements performed. Single occasion of measurements will suffice for making decisions. Analysis software is UNIQUE and parameters derived from analysis can be utilized in Life Expectancy Calculations. Can be related to time and integrated into a Maintenance Plan April 12, 2010 Slide 18 April 12, 2010 Slide 19 9