GEK 103566.pdf

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GEK 103566h Revised, July 2012

GE Energy

Creating an Effective Maintenance Program

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General Electric Company. © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

GEK 103566h

Creating an Effective Maintenance Program

TABLE OF CONTENTS I. II. III. IV. V. VI.

BACKGROUND......................................................................................................................................... 3 MAINTENANCE FREQUENCY ............................................................................................................. 3 TESTING .................................................................................................................................................... 8 INSPECTION ............................................................................................................................................. 8 MAGIC INSPECTION .............................................................................................................................. 8 MAINTENANCE PLANNING ............................................................................................................... 10

LIST OF TABLES Table 1. Recommended Stator Tests...................................................................................................................... 5 Table 2. Recommended Water Cooled Stator Leak Tests*.................................................................................... 6 Table 3. Recommended Field Tests ....................................................................................................................... 7 Table 4. Visual Inspection Areas ........................................................................................................................... 9

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© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

Creating an Effective Maintenance Program

GEK 103566h

I. BACKGROUND Implementing a thorough maintenance program is the most effective way to retain generator reliability and avoid major failure expenses. However, it must be cost effective in that there are demonstrated savings in improved availability and reliability to offset the cost of implementing the program. The three important elements of a thorough program are maintenance frequency, electrical testing and visual inspection. It is the intent of this instruction to provide information on each of these elements, which will aid the owner/operator to establish a thorough and cost effective maintenance program. II. MAINTENANCE FREQUENCY There are a number of components, which require routine maintenance or inspections between scheduled outages. The operator will find these recommendations in various equipment sections, and should also include additional maintenance tasks as operating experience indicates. Results of this routine maintenance should be retained in well-organized files readily available for reference. These routine maintenance records coupled with the information from the monitored operating data are a good indicator of pending service or operating problems that should be addressed at the next scheduled outage. The monitored information alone is usually not sufficient for tracking or highlighting trends. During the first several months of operation, the stator winding support system and some of the other generator components experience a break-in period with more severe duty/wear than normal. Therefore, the first major maintenance inspection is recommended for one year after it is placed in service. Generator insulation and stator assembly components age at all temperatures, which can cause compression, shrinkage and wear with time. This is not directly related to operation hours and starts/stops. Delaying or omitting the first year inspection can cause increased maintenance outage time, increased maintenance scope, or possibly a forced outage prior to the scheduled maintenance outage. If the unit’s operating experience has been unusual because of disoperation or very limited in-service hours, etc. you may wish to discuss your particular circumstances with your local GE Field Service Office for recommendations specific to your circumstances. Subsequent planned outages must also be performed in a timely fashion. Experience has shown that regularly scheduled maintenance outages are one of the most important steps in retaining unit reliability and reducing major repair/failure expenses. A minor maintenance outage is recommended every 30 months. During these outages the end shields or end plates are removed to permit inspection from of the end winding area, but the field remains in place. A major outage is recommended every 60 months. This includes removing the field from the stator or using MAGIC (Miniature Air Gap Inspection Crawler) to permit a thorough inspection of the core section of the stator and field. To inspect the field and stator using MAGIC requires the removal of a few entrance gap baffles to allow access to the air gap with the field in place. The inspection must include a comprehensive series of electrical tests and a thorough visual inspection. Each has their particular advantage and neither alone is sufficient. See Section V for a brief description of the capabilities of MAGIC and MAGIC Jr. Older generators with asphalt insulated stator windings and core lengths greater than 150 inches [3810 mm] are subject to girth crack failures in the stator bars, and therefore, these generators should be re-inspected twice as often (Minor Outage - 18 months; Major Outage - 36 months). These recommended outage intervals have proven themselves over many years of use. Extending these maintenance intervals could lead to extended maintenance durations and cost. In worst case situations extending the intervals may result in forced outages.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

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GEK 103566h

Creating an Effective Maintenance Program

Potential reasons for forced outages or increased maintenance costs are described in the following tables. One potential way to overcome this limitation is through Condition Based Maintenance (CBM). CBM relies on availability of reliable on-line instrumentation and evaluation techniques. As these evaluation methods become proven and practical, they will be incorporated into recommended operation and maintenance packages such that maintenance outages can be scheduled based on the condition of the unit.

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© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

Creating an Effective Maintenance Program

GEK 103566h

Table 1. Recommended Stator Tests (a). STATOR AIR

HYD

LCSW

MAGI Minor C/RAC Major

Test

Component

Inspection Objectives and Assessment

RTD Element Res.

Gas and Winding RTD’s

Checks for calibration and poor connections.

X

X

X

X

X

RTD Ground Insulation Stator Winding RTD’s

Insulation condition of RTD.

X

X

X

X

X

Winding Copper Res.

Stator Winding

Checks for poor connections and breaks.

X

X

X

X

X

Insulation Resistance (aka Megger)

CE Bearing

Contamination and/or deterioration of insulation.

X

X

X

X

X

Hydrogen Seal Casing

Contamination and/or deterioration of insulation.

X

X

X

X

Polarization Index

Stator Winding

Contamination and/or deterioration of insulation.

X

X

X

X

X

DC Leakage Current

Stator Winding

Contamination and/or deterioration of insulation.

X

X

X

X

X

Stator Winding

Ground wall insulation integrity

X

X

X

X

X

Over Potential/Hipot Wedge Tightness Map

1

Visual Inspections

Stator Wedges

Detect wedge tightness deterioration

X

X

X

X

X

Core Laminations

Foreign Object Damage

X

X

X

X

X

Space Blocks

Migration, cooling passage blockage

X

X

X

X

X

Gas Gap Baffles

Cracked welds, looseness

X

X

X

X

X

Stator Wedges

Evidence of abrasion or looseness

X

X

X

X

X

Stator Bars

Evidence of abrasion or looseness

X

X

X

X

X

End Windings and connection rings

Evidence of relative motion, dusting and/or greasing, loose/broken ties, loose hardware, corona activity

X

X

X

X

X

Copper Flux Shield

Overheating, hardware looseness

X

X

X

X

X

Overall cleanliness

Oil or other contamination

X

X

X

X

X

X

X

X

X

OPTIONAL TESTS Partial Discharge Analysis

Stator Winding Insulation Localized deterioration

Water Flow Verification

Water Cooled Stator Winding

Restrictions in hydraulic circuit

Magnetic Scalar Potential (EL CID)

Stator Core Insulation

Weak or damaged core enamel.

X

X

X

Core Ring Test

Stator Core Insulation

Weak or damaged core enamel

X

X

X

O

Dynamic Freq. Response

Stator End Winding

Potentially damaging resonance.

X

X

X

O

Bar Jacking

Slot Support System

X

X

X

O

Check slot clearance

R

R

X

O

O

O

Air – Air Cooled Generator

HYD – Hydrogen Cooled Generator

LCSW – Hydrogen Cooled Generator with Liquid Cooled Winding

O - Optional Test

X - Pertains only to type of unit selected

R - These tests are performed while the unit is running.

Note: Gas cooled bars use the hydrogen column. During high voltage testing the hollow conductors should be shorted to copper strand

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Wedge Tightness Map – This test may take the form of either a person performing the test with a 2 ounce hammer or piece of equipment used to mechanically evaluate if the wedge is tight. The most critical wedges to test are the last 36 inches each end of the generator. If only the last 36 inches of each end of the slot are tested then the rest of the wedges should be visually inspected for any indications that they are loose. This test does not apply to units with asphalt stator windings or units with the camelback wedge system. © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

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GEK 103566h

Creating an Effective Maintenance Program

Table 2. Recommended Water Cooled Stator Leak Tests*

STATOR

Clip-Strand Braze: Phos Containing Orig SLMS, Bagged Vent, or No Monitoring

Global Epoxy Injection or Clip-Strand Braze: Phos-Free Orig SLMS, Bagged Vent, or No SLMS HP Monitoring Installed

SLMS HP H2 Leak Monitoring Method Installed Inspection Objectives and Minor Major Minor Major Minor Major Minor Major (i). Test Assessment Checks the hydraulic Vacuum Decay integrity of the entire X X X X winding. Checks the hydraulic Pressure Decay integrity of the entire X X X X winding. Helium Tracer Detects minute leaks in the X X X Gas hydraulic circuit. Capacitance Wet ground wall bar X X X Mapping insulation WIM – Wet Wet ground wall bar Insulation insulation X X X Measurement Ensure the electrical Electrical Testing X X X X X X X X insulation integrity of the system * These tests are required to detect hydrogen leaks in water cooled stator windings only and should be performed in conjunction with the recommended tests in Table 1

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© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

Creating an Effective Maintenance Program

GEK 103566h

Table 3. Recommended Field Tests (b). FIELD

LCS W

Minor

X

X

X

X

X

X

X

X

X

Turn shorts and speed sensitive turn shorts

X

X

X

X

X

Heating, arcing, foreign object damage

X

X

X

X

X

Body Weights

Looseness, staking

X

X

X

X

X

Field Wedges

Arcing, migration, cracking

X

X

X

X

X

Retaining Ring “Nose”

Wedge contact, arcing, foreign object damage

X

X

X

X

X

Coil End Turns

Blocked ventilation, damaged insulation, coil distortion

X

X

X

X

X

Overall cleanliness

Oil or other contamination

X

X

X

X

X

X

Ground wall insulation integrity.

X

X

X

O

O

Air Gap Flux Probe

Field Inter-Turn Insulation Shorted turns at operating speed.

X

X

X

R

R

Bore Pressure Test

Chevron Seals

X

X

O

O

AIR HYD

Test

Component

Inspection Objectives and Assessment

Winding Copper Res.

Field Winding

Checks for poor connections and breaks.

X

Contamination and/or deterioration of insulation.

Polarization Index Field Winding AC Impedance

Field Inter-Turn Insulation

Visual Inspection Field Surface

MAGIC/ RAC

Major

OPTIONAL TESTS Over Potential/Hipot Field Winding

Sealing capability of the Chevron seals.

Air – Air Cooled Generator

HYD – Hydrogen Cooled Generator

LCSW – Hydrogen Cooled Generator with Liquid Cooled Winding

O - Optional Test

X - Pertains only to type of unit selected

R - These tests are performed while the unit is running.

Note: Gas cooled bars use the hydrogen column. During high voltage testing the hollow conductors should be shorted to copper strand

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

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GEK 103566h

Creating an Effective Maintenance Program

III. TESTING Generator electrical testing is focused on the insulation systems. However, there are other tests used to monitor for degradation in other components. A list of the typical tests recommended and the test purpose is shown in Tables 1, 2 and 3. Historical records of test results should be maintained and compared to the new test results. Changes between outage test results may point to needed repairs/rework that may not be evident from the absolute test values themselves. Many of the tests require special equipment. Test results may be misleading and useless if the right equipment is not used, or it has not been properly maintained and calibrated to assure accurate results. IV. INSPECTION A visual inspection performed by an experienced individual can disclose unit conditions not detected by monitoring equipment or indicated by tests. In some instances electrical testing will only detect issues when the stator and field insulation systems have been significantly. Also, for example, there is no definitive test for contamination, rust or oil, and water leaks; yet the presence of any of these could significantly adversely affect reliability and operation. A typical inspection should include those items listed in Table 4. As important as it is, visual inspection is limited to areas that can be accessed for view either directly or with mirrors, borescopes, cameras, etc., and therefore, it must be combined with testing to give a complete picture of generator condition. V. MAGIC INSPECTION GE’s MAGIC and MAGIC Jr. robots provide a thorough visual inspection of the stator and field using the robot’s on-board high-resolution video cameras. Additionally, it is capable of providing quantitative wedge tightness and Electromagnetic Core Imperfection Detection (ELCID) assessments. Coupled with the Remote Access Camera (RAC), the MAGIC or MAGIC Jr inspection can provide a comprehensive stator and field inspection. The customer may opt to utilize the MAGIC robot to perform the recommended inspection tasks that normally require the removal of the rotor. As a result, the customer may substitute a MAGIC for a major inspection providing the major inspection tasks outlined in Tables 1, 2, and 3 that don’t require the removal of the rotor are performed during the outage as well. In order to use MAGIC and MAGIC Jr., the generator must meet the following minimum entrance gap dimensions: MAGIC • Retaining ring to core minimum gap 1.13 inches [28.7 mm] • Field to core minimum gap of 2.0 inches [50.8 mm]

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MAGIC Jr. • Retaining ring to core minimum gap 0.5 inches [12.7 mm] • Field to core minimum gap 0.75 inches [19.05 mm]

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

Creating an Effective Maintenance Program

GEK 103566h

X

X

Stator

X

X

Slot Support System Conn. Rgs and Lower Lds.

X

X

High Voltage Bushings

X

X

All components

X

X

X

X

X

X

X X

X

X

Ventilation Ducts

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

Body and Wedges

X

X

Retaining Rings

X

X

Fans

X

Spindles

X

Winding

X

X

Collectors Journals

X X

Key Bars

Field

X

X

Laminations

All Components

X X

X

Core End Core

X

X

Dusting and/or Greasing

X

EW Support System

X

Core Tightness

X

Shorted Core Punchings

X

Broken Ties

X

Tape Migration

X

Bar Sparking

Bars

Blocked Ventilation

X

Burning

X

Worn Parts

Deterioration (General)

X

Cracks

Mechanical Damage

X

Water Leaks (Water-Cooled Winding

Movement

X

Surface Condition and Wear

Loose or Displaced Parts

X

Corrosion

Cleanliness

All Components

Foreign Material/Contamination

Table 4. Visual Inspection Areas

X X

X

X

X

X

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

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GEK 103566h

Creating an Effective Maintenance Program

VI. MAINTENANCE PLANNING Major maintenance outages are usually scheduled well in advance of the actual outage date, and preparation for the outage should begin early. An important part of that is to review operational logs, previous inspection reports for any indication of work needed, and review recommendations from GE communicated by Technical Information Letters, Engineering Change Notices, etc. to integrate those items into your plans. Materials you expect to need should be ordered to have available at the start of the outage to avoid the risk of costly delays waiting for material. The operational log should include the type of duty, any known incidents of disoperation. Operational events which should be carefully noted are: a.

Errors in synchronizing

b.

Under or over frequency operation

c.

Lightning surges or other transients

d.

Faults (such as short circuits) on system or adjacent machines

e.

Unbalanced load, including single phase operation (Negative Sequences and Motoring)

f.

Overload

g.

Over voltage or under voltage

h.

Loss of field

i.

Loss of cooling water without load run-back

j.

Out of synchronism operation.

Each of these events would have a different impact on the necessary planning for maintenance and inspection. Depending on the circumstances, some of them might dictate that the machine is shut down for immediate inspection, whereas with other events it would be reasonable to wait until the next schedule inspection. Your maintenance program should reflect the level of acceptable risk for the unit. That will probably vary from unit to unit and plant to plant, and will change over time as the importance of the unit to the power system changes. In addition, new technologies are constantly being developed to improve unit reliability, performance, monitoring and inspection equipment, and otherwise provide more cost–effective means for maintaining the generator. The MAGIC Robot In-Situ Generator Inspection System is one example of a new technology developed by GE to provide a more cost-effective means of inspecting your generator. The owner/operator should be aware of these developments and modify the maintenance program accordingly. While this should be a continuous process, the “maintenance outage planning review” is an appropriate checkpoint. Your local GE Field Service Office can assist you in your maintenance planning, and review of your overall maintenance program, incorporating any appropriate new maintenance and upgrade technologies available.

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Creating an Effective Maintenance Program

GEK 103566h

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GEK 103566h

Creating an Effective Maintenance Program

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© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.