Generator System Testing - and Why! - Frame 6 Users...
Transcript of Generator System Testing - and Why! - Frame 6 Users...
Frame 6 User’s Group MeetingJune 14, 2006Phoenix, Arizona
Recommended Generator System Testing – and Why!
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Routine Maintenance Programfor the Generator System
Reliability of the Generating System
Dodge the costs associated with a Major Breakdown or Failure!
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Routine Maintenance Programfor the Generator System
MUST BE COST
$$$EFFECTIVE
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Routine Maintenance Programfor the Generator System
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Routine Maintenance Programfor the Generator System
1. How Often?
2. What to Test?
3. Visual Exam / Inspection!
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Routine Maintenance Programfor the Generator System
During regularly scheduled Minor Maintenance Outages
(18 – 24 Month Cycle)
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Routine Maintenance Programfor the Generator System
Develop Records as a
Reference File.
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Routine Maintenance Programfor the Generator System
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Record all incidents of mis-operation along with your MaintenanceRecords
40 Relay TripsShort Circuit Faults
Regulator ProblemsFull-Load RejectionLightning Strikes
Unexplained AlarmsOverload / AmpsOvervoltageMajor VAR Swings
Routine Maintenance Programfor the Generator System
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What to include?
Routine Maintenance Programfor the Generator System
64F GAC NGTROTATING DIODE BRIDGE
HV MAIN BUSFIELDSTATOR
HV NEUTRAL BUSLA / SURGE CAPS 52G
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What to include? (cont.)
Routine Maintenance Programfor the Generator System
RTD’S TRANSDUCERSPT PPT
SYNCHRONIZING SYSTEMALARMS
PROTECTIVE RELAYSMETERSCONTROL LOGIC
TRIP TESTS
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What to include? (cont.)
Routine Maintenance Programfor the Generator System
EXCITATION SYSTEMFUSE SIZING
VOLTAGE REGULATORSHAFT GROUNDINGNERC COMPLIANCE
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TESTING EQUIPMENT (calibrated)
VACUUMVACUUM
CLAMPCLAMP--ONONAMMETERSAMMETERS
RELAYRELAYTEST SETTEST SET
DC POWERDC POWERSUPPLYSUPPLY
TORQUETORQUEWRENCHWRENCH
mA / mVmA / mVSOURCESOURCE
CLEANINGCLEANINGSUPPLIESSUPPLIES
DUCTORDUCTOR
TTRTTRMEGGERMEGGER
CAMERACAMERA DVMDVM’’ss
OSCILLOSCOPEOSCILLOSCOPE
OSCILLOGRAPHOSCILLOGRAPH
Routine Maintenance Programfor the Generator System
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VISUAL INSPECTION / ODORS?(eyes, nose, cameras, boroscopes, mirrors, etc.)
LOOSE WIRES
OIL LEAKS
RUST
WATERLEAKS
RACCOONS
SNAKES
EXCESS HEATING
LOOSE COVERS
BRUSHCHATTER
Routine Maintenance Programfor the Generator System
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Generator FieldI. INSULATION TESTING (500 Volt Megger)
To determine the integrity (moisture, contamination, etc.) of the Generator Field Windings.Two factors:
1. Resistance level per megger reading.
2. P.I. Value
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Generator FieldI. INSULATION TESTING (500 Volt Megger) cont.
P.I. = Polarization Index
10 min Reading1 min Reading
P.I. for Field should be 1.25 or higher
= P.I.
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Generator Field
II. FIELD WINDING COPPERRESISTANCE CHECK
DLRO - Digital Low Resistance Ohmeter
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Generator FieldIII. BRUSH RIGGING & COLLECTOR RINGS
a) Clean
b) Surface Inspection
c) Check for Brush Wear & Spring Force
d) Check Clearances
e) Check Tightness
f) Check for brush bounce and sparking during operation
g) Brush Rigging Insulation check
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Generator FieldIV. SHORTED TURNS
High Field Amps to attain rated K.V.
Overexcitation Limiter pickups at low VAR levels.
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Generator FieldIV. SHORTED TURNS cont.
Impedance Testing
“Installed” Flux Probe
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64F Field Ground Detector
Field is Ungrounded!
“Field Ground” can be detected from rotating field back through the excitation system.
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64F Field Ground Detector
A “second” ground on the Generator Field is not a good thing.
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64F Field Ground DetectorMaintenance1. Operational Test –
solid ground at Collector Rings.
2. Verify minimum resistance-to-ground pickup.
3. Verify Output: Alarm & Trip.
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Generator Stator
AC Partial
Discharge
Dob
lePo
wer
Fac
tor
AC HIPOT
IR / PI Testing
DC HIPOT
EL Cid W
inding
Resistance
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Generator Stator
I. INSULTATION TESTING (5000 Volt Megger)
Two Factors:1. Resistance Level2. P.I. Value (2.5 or higher)
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Generator Stator
II. STATOR WINDING COPPER RESISTANCE CHECK
Use DLRO
Record Stator Temperature at various RTD locations.
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Generator Stator
III. END WINDING INSPECTION
CleanlinessOverheatingDamage, etc.
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Generator StatorIV. OPERATION CHECK OF THE
GENERATOR HEATERS
a) Sequence check by operating 52G Aux. Relay
b) Record Amps / Phase
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HV Neutral Bus
Inspect
Clean
Check Compartment Strip Heaters
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Neutral GroundingInspect
Clean
IR Checks with Megger; (1000 Volts)
H winding – GRDL winding – GRDH winding – L winding
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Neutral GroundingTransformer Turns Ratio CheckCheck Secondary ResistorVerify Proper Circuit Connections
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HV Main Bus
Inspect
Clean
Verify operation of all compartment strip heaters
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Lightning Arrestors / Surge Capacitors
InspectionAre ground connections tight?
Clean
Megger Checks(with Stator Windings)
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Generator Auxiliary Compartment
InspectCheck for water tightness of side walls, doors & roof joints.
CleanVerify all strip heaters are operating.AC Lights and Receptacles & DC Emergency Lights
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52G Generator BreakerMechanical Inspection of Breaker & Racking Mechanism
Binding?Grease as required
Hipot of the Vacuum Bottle**
Electrical Operational Checks
Close & tripSpring charging52GX Aux. Relays
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52G Generator BreakerInspection of the 52G Compartment
Evidence of waterTightness of connections
CleanRecord “Breaker Counter”
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Potential Transformers (PT)
Clean & Inspect the “Drawers”HV & LV Fuse CheckMegger ChecksTTR
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Power Potential Transformer (PPT)(Excitation Power Source)
Clean and inspectMegger Checks
HV Winding – GrdLV Winding – GrdHV – LV Winding
TTR
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Protective Relays
Inspect
Clean
Operational Tests
Settings/Calibration Tests
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Protective Relays
Record of all Relay “Trips”
Actions Taken following “Trip”
Causes Found
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Protective Relays“Settings” Review
System Changes to be accounted for
NERC, following August ‘03 blackout, recommends review of settings as they relate to performance during System Disturbances
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Protective Relays
On Digital Relays, check the set-up of the Oscillography & Events Recorder
Be prepared
Great troubleshooting tool for causes of “trips”.
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Generator RTD’s
Check calibration of all RTD’s at Incoming TB (Generator Control Panel).
Verify operation/calibration of the Generator Temperature Meter.
Verify “pickup” and operation of the 49G Generator Temperature Relay.
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MetersCalibration Check:
WMVARMAMVMFMFAMFVM
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Transducers
Transducer Outputs to:
Turbine ControlSCADA SystemMeters
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Transducers
Calibration Check:Zero & Range4-20mA Output(or 0-1mA)
Verify “Scaling Inputs” utilizing the 4-20mA Transducer Outputs.
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SynchronizingMeter Calibration Check
Incoming VMRunning VM
Monitor Synchroscope at “Closing”
Does it close at 12 o’clock?
Monitor VAR Flow at “Closing”
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Alarms / Annunciators
Gen Field GroundAlarm
Exciter Overvoltage
Alarm
Fault Transfer to Manual Regulator
Alarm
Rectifier Temperature
HI Alarm
Minimum Excitation
Limit Alarm
Bus Undervoltage
Alarm
Volts Per Hertz Alarm
Generator Over-
temperature Alarm
Sequence / Verify all Alarms
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Alarms / Annunciators cont.
Generator Ground Alarm
Generator Lockout
Trip Alarm
Loss of Excitation Trip Alarm
Over-frequency
Alarm
Loss of PT Alarm
Take Time to Re-familiarize YourselfWhat does this mean?Critical or Non-critical?Action required?
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Control SequencingProof Test of all Control Circuitry to verify even “seldom utilized” circuits.Examples:
AVR Setpoint R/L & Runback
MVR Setpoint R/L & Runback
Rectifier B-U Cooling Fan
59E Overvoltage Relay
All System TD Relays
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Control Sequencing cont.
Proof Test of all Control Circuitry to verify even “seldom utilized” circuits.Examples: cont.
Regulator Transfer Logic
Field Flashing / Startup
Power Supply Source Power Transfer
52G Breaker Close / Trip
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Trip Tests
TRIPTRIP52G52G TRIPTRIP
EXC.EXC.
86G86G
86T86T
86RE86RE
9494
5050
50/5150/5187T87T
52G52GTT
51V51V 4646
5959
64G64G
64B64B 40402424
64F64F
59E59E87G87G
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Fuse Sizing
Are they all in the correct location?
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Excitation / Voltage Regulators
“Pre-Excitation” System Checks(with Unit down)
“Off-Line” / FSNL System Checks
“On-Line” System Checks
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Excitation / Voltage RegulatorsPre-Excitation Checks:
PCB inspection
“Flashing” circuit check (resistor & diode)
Field OvervoltageProtection Calibration & Function check
Power Supply check
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Excitation / Voltage RegulatorsPre-Excitation Checks:
Verify all Potentiometer SetpointsVerify “Gain” SettingsTransducer (DCPT) Calibration checksFunctional Check of AVR
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Excitation / Voltage Regulators
Pre-Excitation Checks:
Functional Check of MVR
Inspection / tests of Power Rectifier Bridge(s)
Check integrity of the Shaft Voltage Suppression Circuit
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Excitation / Voltage Regulators
Verify “Flashing”Timing/Amps
Monitor MVR to AVR transfer
Verify VFNL Setpoint of AVR (Runback)
Off-Line Checks: (FSNL)
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Excitation / Voltage RegulatorsOff-Line Checks: (FSNL)
Record VFNL data for future reference:
KV, PT Volts, PPT Volts, PPT Amps, PCB Test Points, Field Amps, Field Volts, etc.
Check Field Voltage Waveshape & recordVerify ”Firing Circuit” Data
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Excitation / Voltage Regulators
Check/record all system gain, lead, lag, loop gain, etc.
Verify operation of all limiters (overexcitation, V/Hz, etc.)
Off-Line Checks: (FSNL)
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Excitation / Voltage Regulators
On-Line Checks: Monitor MVAR “bump”Verify operation and Proof Test of ALL limiters (URAL, overexcitation, etc.)Record operating data at varying load points (for future reference)
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Shaft Grounding Brush
Helps prevent damage to bearings via electrical discharge through the oil films.
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Shaft Grounding Brush
Provides a low impedance path to ground so current flow due to the 360 Hz ripple goes to ground, bypassing the bearings.
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Shaft Grounding BrushInspectionCleanRemove surface glaze on brushCheck spring force & brush holder gapUsing oscilloscope, check shaft-to-ground voltage (6 volts, 0-to-peak)
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NERC Compliance TestingNORTH AMERICAN ELECTRIC
RELIABILITY COUNCIL
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NERC Compliance Testing
Actual Reactive Capability Range
Excitation System Models (data validated by tests)
Generator characteristics (verified by tests)
Governor Droop / Deadband Proof Tests
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NERC Compliance TestingModel & Proof Test of Excitation Limiters
Generator Protective Relay Testing & verification that settings are coordinated with the Excitation Limiters
Operation in AVR only (Performance Proof Test)
Power System Stabilizer operating and verify Model (WECC)
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NERC Compliance Testing
An actual power swing test of a Power System Stabilizer. The voltage setpoint was given a 2% step up then 5 seconds later returned to normal. The red chart above shows the KW swing with the Power System Stabilizer turned off and the green chart shows the KW swing with the Power System Stabilizer enabled. Of note is the much faster damping of the stabilized wave form.
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Questions?
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Rotating Diode Bridge
Rectifies the AC output of the Rotating Exciter for direct input to the generator field.
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Rotating Diode Bridge
Stud Mounted
Press Pack (hockey puck)
Single or Dual Diode Modules
Fig 3: Westinghouse Mark III Exciter Diode Assembly
Variety of Packages & Configurations:
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Rotating Diode Bridge
Common Reasons for Failures
Transients on the Electrical Power Feed.
Faulty or wrong replacement component installed.
Surface leakage due to dirt & moisture.
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Rotating Diode Bridge
Common Reasons for Failures (cont.)
dV / dT
Low Resistance Short in Generator Field windings or leads.
Improper installation.
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Rotating Diode Bridge
One of the most important conditions for
testing the diodes is that the rated voltage
MUST NEVER
be exceeded.
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Rotating Diode Bridge
Meggers & Hi-Pot Test set should not
be used – they can easily damage
the components.
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Rotating Diode Bridge
Ohm meters are only reliable to detect a “Short”, since they do not have
enough voltage to properly energize the silicon wafer in a
Power Semiconductor.
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Rotating Diode Bridge
Test Diodes
Clean Components!!Dirt & moisture can cause surface leakage
Check ConnectionsVerify Assembly Components (Varisters, Resistors, Filtering Circuits, etc.)