Protection, Management, and Optimization for Hydro-Power ...
Transcript of Protection, Management, and Optimization for Hydro-Power ...
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Protection, Management, and Optimizationfor Hydro-Power Assets and Operations
Bently Nevada
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Common Malfunctions
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Machinery Problem CategoriesHydro Turbine Generator problems fall into three main categories:
• Electrical
• Mechanical
• Hydraulic
Problems can be detected with condition monitoring systems and corrective action can be taken before the situation worsens.
sensors
monitorssoftware
List of malfunctions
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Failure Modes and Detection
Faults
• Insulation Breakdown/Failure
• Rotor Pole Faults
• Bearing Faults
• Cooling System Faults
• Excitation Fault
• Rotor Stator Misalignment/Contact
Detection
•Temperature/Partial Discharge
•Magnetic Flux and Temperature
•Vibration signature and temperature
•Temperature and process data
•Voltage/Current Monitoring
•Generator Air Gap
Generators
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Failure Modes & Detection
Faults
• Erosion/Material Loss
• Unbalance
• Bearing Failures
• Hydraulic Faults
• Misalignment
Detection
•Relative and Seismic Vibration
•1x Vibration
•Vibration signature and temperature
•Seismic and bearing vibration
•1x and possibly 2x vibration changes. Orbit shape changes
•Correlate Process Data
Turbines
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Maintenance Philosophies
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PROACTIVE
Maintenance {PaM}
MAINTENANCE STRATEGIES
PREDICTIVE
Maintenance
{PdM}
PREVENTIVE
Maintenance
{PM}
Run-to-
Failure
Maintenance
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Understanding the P-F Interval
Point where
failure
starts to
occur
Changes in Vibration
P-F interval 1-9
monthsWear Debris in oil P-
F interval 1-6
months
Audible noise P-F
interval 1-4 weeks
Heat by touch P-
F interval 1-5
days
P1 P2
P5
P6
F
IR Thermography P-F
interval 3-12 weeks
P3
F = Failure
Quantitative PM P-F
Interval 5-8 weeks
P4
P7
Process Performance Data (highly
dependent on tuning of system /
instruments) ~1 week – 6 months
Time (Non-Linear)
Sta
tus
Asset no longer performs it’s intended function
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Hydro Condition Monitoring
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TransducersThe “Big Picture”
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Proximity transducer system
•Radial vibration
•Thrust
•Keyphasor®
•Seal ring clearance
•Turbine blade clearance
(submersible versions available)
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Rotor Phase
Keyphasor
probe
Shaft indentation
or projection
0°
-VONE REVOLUTION
Shaft indentation
produces periodic dip in the signal.
displacement probe
• Keyphasor® provides once per revolution phase reference signal for machine rotor.
• Creates a pulse each time an appropriate feature passes the probe.
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Low frequency velocity sensor for Hydro applications
• Bearing housing vibration
• 0.5 - 1000 Hz sensitivity
• Low signal-to-noise ratio
• Moving coil technology
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Stator Frame / Stator Core Vibration
CoreFrame
StatorRotor
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Air gap sensors
• Stator to Rotor Air gap
• Two Ranges• 50 mm – range 1800 mils (45.7 mm)
• 20 mm – range 720 mils (18.3 mm)
Stator
Rotor
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Protection
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Bently Nevada 3500 System
– Continuous On-line Monitoring and Protection
– Modbus Interface to SCADA and DCS
– 4 Vibration / Position Inputs Per Monitor – up to 56 channels
– 6 or 16 Channel Temperature Monitors
– Rotor Phase (Keyphasor)
– Direct Interface to System 1
– Display Options– LCD (backlit available)– VGA touchscreen– PC-based display
Instrument Rack with bulkhead mount option
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3500/46M Hydro Monitor
• Proximity probes– Direct, Gap, 1X, Not 1X, NX
• Air Gap– Avg., Min., Max gap and pole number
• Velocity– Direct, 1X, 2X
• Embedded Shear Pin Failure Detection
• Multimode Capability– Eight configurable machine states– Distinct alarm set points and time delays– Multimode can be based on Speed, Load,
Direction of Rotation, Environmental Conditions, Process Variable Levels etc.
– Feeds state-based plotting capabilities of System 1®
More
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Other Measurements / Functions
• Temperatures (6 and 16 channel monitors - 3500/60, /61, /65)
• Sole plate position (3500/46 or /42)
• Cavitation (3500/46 or /42)
• Rotor Phase (3500/25)
• Process Variables (3500/62)
• Speed (3500/50)
• Relay Card, 4 0r 16 Channel (3500/32, /33)
• Various Display Options
• Communications Gateway (3500/92 or /91 for Mark VIe)
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Hydro Asset Management
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System1™
Plant Asset Optimization for Hydro-Power Plants
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Typical System Arrangement
Stator End Winding Sensor
More System 1Architecture
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System 1® Software
• Analysis, trending, correlation, and display
• Hydro Turbine Generator specific plots
• Decision SupportSM – Automated data analysis that provides Actionable Information®
• Communication Links to SCADA, Control and Maintenance systems for data correlation
• HydroX RulePaks
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System 1® Platform Development11/17/2014
System 1 – Lubricant Data Analysis Version 6.7
• Import historical data and then import new results over time
•Data is trended•Data evaluated for alarms and notifications
•Data available for rules and rule packs•View Lab recommendations / status
•Lubrication data available in all •Data correlation using plots•Event/analysis documentation with plot sessions
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25 /GE /
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High level Asset Monitoring View
It is all green – Asset is OK!!
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27 /GE /
Under Severity 4
Operation Status Is Red and Flashing
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Hydro-Specific Plot Types in System 1
Spectrums can be
looked at over time in a waterfall plot to view changes in spectral content.
Spectrum waterfall Plot
Rotor/Stator Profile Plot
Overall Hydro Plant View
Air Gap Plots
(Gap Vs Poles)
Air Gap Plots
(Rotor Shape)
Air Gap Plots
(Combined Rotor And Stator Shape)
X Vs Y
Multiparameter Plots
More Plots / Screen shots
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29 /GE /
Summary
• Value: tools to implement a maintenance strategy that supports your company’s business objectives
• Comprehensive measurements to address mechanical, hydraulic and electrical malfunctions
• Integrated hardware and software platform that adjusts data collection and alarm levels to suit the operating conditions
• Dynamic data plots go beyond alarms and trends to enable quick and accurate troubleshooting and analysis
• Open: export & import data to and from 3rd-party devices
• Scalable: grow capabilities to match changing needs
• Optional HydroX RulePak provides Actionable InformationSM
• Full complement of local service and support before, during, and after installation