Ge Mongolia Power Conversion Services
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Transcript of Ge Mongolia Power Conversion Services
May 2013
Mungunshagai Enkhbold
GE Energy Management Power Conversion Services in Mongolia
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A Global Company
300,000+ employees worldwide
Manufacturing facilities in 40+ countries
Operations in over 100+ countries
Growing in key global markets
Eastern Europe
China Middle East
India
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Outline
• Who is GE
• What GE Energy Management do
• GE Power Conversion – Complete Solution offering
• GE Power Conversion Services
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• Energy
• Oil & Gas
• Power & Water
• Aviation
• Healthcare
• Transportation
• Aviation Financial Services
• Commercial Finance
• Energy Financial Services
• GE Money
• Treasury
• Businesses operating in more than 100 countries … 130 years
• Over 300,000 employees worldwide
• All of GE’s businesses have presence in China with over 50 legal entities and more than
13,000 employees.
GE’s Portfolio
Energy Infrastructure
Technology Infrastructure
GE Capital
• Appliances & Lighting
• Intelligent Platforms
Home & Business Solutions
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New & Refurbished Motors • Repair by Replace Option
Up Rating Motors • Increase HP capacity
Extended Warranty Opportunities • Two Year Warranty on General Service
• Five Year Warranty on Rewinds
• 10 Year Warranty with Maintenance Agreement
EMP or “Mini EMP Programs” • On-Site Full Time Motor Engineer
• Motor Management Program
• Long Term Service Agreements (LTSA)
• DDMS opportunities
On Site Rewinds • Large AC & DC
• GE 600 Applications
Field Services, Balancing, Alignment • On-site trouble shooting
• fan balancing
• laser alignments
• Babbitt bearing scraping
• IR Scanning
• Cryogenic Cleaning
Condition Forecaster • Large critical motors
DC Motors over 20 Tons • All target industries
Specialty Motors • Special applications
• Steel Mills
• Vertical Kingsbury Motors
• Crane M&G Sets
• Dynamometers
GE Specific Applications • GE’s installed base
• Schenectady/Peterborough built
• Parts opportunities
High Voltage Motors • 6.9KV & 13KV
• VPI & GE 600 Hard Coil
• Leverage (3) GE coil manufacturing plants
• Support Engineering
• GE Drawings
Synchronous Motors • Slip Ring Applications
• Pole Rewinding & Manufacturing
Targeted motor services
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Gearboxes • Disassembly and inspection
• Sleeving and boring of bearing fits
• Re-machining shaft fits
• Casing repairs, welding or metal-stitch
• Shaft replacements
• Gear evaluation and upgrades
• New gears
• Reverse engineering
Pumps • Complete tear down and inspection
• Line bore housings and casings
• Complete welding & machining capabilities
• Casing repair, welding or metal stitching
• Impeller wear rings and sleeves
• Stainless or bronze retrofitting
• New shafts, bearings
• Mechanical seal recondition & conversion
• Dynamic balancing
• Complete repair report & documentation
Crushers • Mainframe/bottom shell rebuild
• Top shell rebuild
• Bowl rebuilds
• Eccentric repairs
• Mainshaft repairs
• Head repairs
• Onsite assembly of crushers
Refiners • Inspections of rotors, shafts, bearings, hydraulic systems & housing
• NDT
• Weld repairs
• Re-machining
• Balancing
• Upgrades
• Complete machine rebuilds
• Field Services
Centrifuges • Removal and reinstallation • Disassembly
• Inspection
• Retiling
• Hardfacing Renewal
• Gear Box Repair
• Bowl and scroll repair
• Journal and housing repair
• Repair/replacement of worn areas
• Complete balancing of rotating components
Compressors • Inspection
• Complete overhaul
• Shaft replacement
• Seal replacement
• Component part replacement
• Anti-erosion and anti-corrosion coatings
• Upgrades and modifications (impellers, diaphragms, etc.)
• Balance and alignment of rotating components
• 24-hour emergency service
Targeted mechanical services
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How and why do motors fail?
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Less than 4kV
4kV and above
Failure Modes for Electric Motors
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IR Scanning, Temperature Trending
On-Line MCA
Off-Line MCA
Vibration analysis
Visual inspection
Oil Analysis
Predictive Maintenance Technology Legend
Common Failure Modes and Causes
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Winding Failures
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Major cause of stator winding failure (40%) • Starting and full load currents
produce forces that cause vibration of the coil
• End turns at 2X line frequency (100Hz)
• Movement must be eliminated to ensure motor reliability and extend motor life
Mechanical Motion
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Natural time-temperature aging
process (10°C half life) results in coil looseness causing contamination, stress points, coils to vibrate and wear the insulation • Load/fluctuating Load
• Over voltage/under voltage
• Voltage unbalance
• Voltage harmonics/distortion
• Power factor
• Ambient conditions
• Startup and shutdown procedures
Thermal Degradation
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Rotor Failures
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Cage rotor • Cracked or loose bars
End Rings • High resistance joints and cracks
Solutions
• Borescope inspections
• Current signature analysis
• Infrared scans
Open Rotor Bars & Cracked End Rings
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Rotor failures Wound rotors DC Armatures
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Bearing Failures
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Inadequate lubrication • too much
• too little
• contaminated
Excessive load • misalignment
• imbalance
• bent shaft
• other
Electrical fluting • improper handling
• installation
• age
spall on outer race
Bearing Failures
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Roller Bearing Fluting and One Solution
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Sleeve Bearing Wiped and Insulated Sleeve Bearing
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Destroyed Sleeve Bearing and Rotor
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Benefits of predictive
maintenance
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Maintenance Costs
Productivity
Reactive Preventive Predictive
Run equipment to failure… “Break and Fix”
Time based… Typically based on OEM specs
Maintenance based on equipment “condition” Level 1 Condition Monitoring … anomaly detection Level 2 Forecast of future performance… predict and prevent capabilities
Don’t forget safety! 28% more likely to have a safety incident when maintenance work is reactive
versus planned and scheduled.
Source: Paper Industry Management Association, 2003
Classifying Maintenance Methods
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On-line testing: testing with no interruption of motor operation • Vibration monitoring and testing
• On-line motor circuit analysis (MCA)
• Infa-red scanning
• Temperature analysis
• Oil analysis
• Visual inspections
Off-line testing: testing that requires motor to be taken out of service • Off-line motor circuit analysis (MCA)
Experienced analysts • Interpret the technical and inspection data
• Precisely and accurately report the findings
• Make credible recommendations for improvements
• Commitment and investment towards PdM program
What testing technologies should you have as part of your PdM toolkit?
DDMS
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Identifying the appropriate tests for your motors requires that you understand their design, both electrically and mechanically
Things to know: • Insulation system design
– Low voltage, medium and high voltage – Vacuum Pressure Impregnation (VPI) – Dip and bake insulation system
• Bearing system design – Rolling element – Babbitt fluid film – Insulated bearing – Grease lubricated, oil bath, forced fed lubrication
• Rotor design – Copper bar – Aluminium – Magnesium
Motor Design Overview
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Vibration can degrade a motor both mechanically and electrically
What can we detect?
• Bearing issues
• Lubrication issues
• Alignment issues
• Soft foot conditions
• Imbalance issues
• Rotor issues
Important notes
• Vibration data must be trended per motor with alarm points identified
• The most recommended frequency is monthly – However, each motor should be evaluated to determined the appropriate frequency
The single most powerful tool for diagnosing and predicting the health of rotating equipment.
Vibration Monitoring
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changes over time
Step 1 - collection of critical parameter data
• Vibration
• Temperature
• Oil, moisture
• Contamination
• Electrical parameters
Step 2 - analysis of data
• Trending changes indicate the asset’s
health is beginning to degrade
Predictive/Condition Monitoring
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No matter how advanced technology gets, the trained eyes and ears of skilled experts will always be a key component of predictive maintenance
Low oil level
Loose/Missing bolts
Damaged/Leaking fittings
Bad grouting
Faulty seals
Field Visual Inspections
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What can we detect?
•Heat generated by friction
– faulty bearings
– Misalignment
– Inadequate lubrication issues
•Circuit breaker connections
•MCC’s
•Loose / corroded electrical connections
Heat rise from misalignment
Infrared Scanning
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Problem: misalignment
• Incorrect alignment of two coupled machines
– Example: a motor and a pump
• One of the most common sources of excessive vibration
Solution: laser (shaft) alignment
• Using laser-based equipment, we try to make the center lines of the two shafts collinear
• Thermal growth needs to be calculated in to the equation
Driver Driven
power plane
Alignment
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Symptoms
• High vibration readings indicative of misalignment
Corrective action
• Laser aligned motor/pump and corrected loose mounting
Results
• Current draw reduced from 235.7A to 227.9A (-7.8A)
• Annual cost of energy = $300
• Net annual energy savings $2,340
Before alignment
Capturing Mechanical Losses
Nova - Cool ing Tower Pump
008 -M1H Motor O utboard Horizontal
Route Spectrum
20-Nov-02 08:30:50
OVERALL= .1601 V-DG
PK = .1599
LOAD = 100.0
RPM = 3572.
RPS = 59.53
0 30 60 90 120 150
0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
Frequency in kCPM
PK
Velo
cit
y i
n I
n/S
ec
After alignment
Case Study
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Standardized Reporting
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Our Powerful Network of Support
• GE M&G forum
• Network of 400 + engineers
• Instant accessibility
• Global support
• Connect with the factories
• Central server database
Downloading the on-site data
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How RM&D Works…
Identify motor failure before it occurs
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Advanced Motor Current Signature Analysis
Advanced
MCSA
Rotor eccentricity
related faults
Bearing faults
Stator inter-turn faults
Drive-Train Related
Broken rotor bars faults
Broken rotor end-ring faults
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Remote Monitoring & Diagnostics
• Quick installation with 369, 469 & M60 GE Multilin Relays
• Can be daisy chained together
• Prompt responses with any trend variations
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Remote Monitoring & Diagnostics
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GEK
Europe: Middle East : Asia:
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Global Footprint
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Questions
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