IEEE PES Meeting · IEEE PES MEETING – JAN 2013 . Practical Engineering Methods for Generator...
Transcript of IEEE PES Meeting · IEEE PES MEETING – JAN 2013 . Practical Engineering Methods for Generator...
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Eric See-Toh, B.Sc. EE, P.Eng
IEEE PES MEETING – JAN 2013 Practical Engineering Methods
for Generator Maintenance & Repair
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Introduction
• 11 Year Career, Manitoba Hydro – Commissioning
– Compliancy & Control Testing
– Design & Maintenance Engineering
• Interest Areas – Machine HV Repair & Operation
– Hydro Governor Control
– Abnormal Machine Operation
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Outline
Thought Process
Stator Examples
Air Gap Analysis
Temperature Case Study
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INNOVATION ALREADY EXISTS
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Thought Process
DATA ACQUISITION
PROBLEM
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The Real Tools
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Why Process Trend Data?
Record ANALOG data in DIGITAL so fast that it is piecewise ANALOG, interpret ANALOG data
in DIGITAL for an ANALOG answer
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0 deg 180 deg
A B C’ A’
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Stator Coil Bypass Analysis and Dissection
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Coil Phasor Angle Analysis
T4 Downstream T3 Downstream Pole Group Slot # Slot # Angle Slot # Slot # Angle Slot # Slot # Angle Pole Group Slot # Slot # Angle Slot # Slot # Angle Slot # Slot # Angle
1 3 94 b 88 t 236 93 b 87 t 215 92 b 86 t 193 1 3 335 b 329 t 58 334 b 328 t 36 333 b 327 t 15 2 3 78 b 72 t 250 77 b 71 t 228 76 b 70 t 206 Install new pole jumper from 71t to 61b 2 3 352 b 346 t 66 351 b 345 t 45 350 b 344 t 23 3 3 61 b 55 t 241 60 b 54 t 220 59 b 53 t 198 3 2 368 b 362 t 53 367 b 361 t 31 4 2 44 b 38 t 233 43 b 37 t 211 4 3 385 b 379 t 61 384 b 378 t 40 383 b 377 t 18 5 3 28 b 22 t 246 27 b 21 t 225 26 b 20 t 203 5 3 402 b 396 t 70 401 b 395 t 48 400 b 394 t 26 6 3 11 b 5 t 238 10 b 4 t 216 9 b 3 t 195 6 3 418 b 412 t 56 417 b 411 t 35 416 b 410 t 13 7 2 426 b 420 t 230 425 b 419 t 208 7 3 3 b 429 t 65 2 b 428 t 43 1 b -5 t 21 8 3 410 b 404 t 243 409 b 403 t 221 408 b 402 t 200 8 2 19 b 13 t 51 18 b 12 t 30 9 3 393 b 387 t 235 392 b 386 t 213 391 b 385 t 191 9 3 36 b 30 t 60 35 b 29 t 38 34 b 28 t 16
10 3 377 b 371 t 248 376 b 370 t 226 375 b 369 t 204 10 3 53 b 47 t 68 52 b 46 t 46 51 b 45 t 25 11 3 360 b 354 t 240 359 b 353 t 218 358 b 352 t 196 11 3 69 b 63 t 55 68 b 62 t 33 67 b 61 t 11 12 2 343 b 337 t 231 342 b 336 t 210 12 3 86 b 80 t 63 85 b 79 t 41 84 b 78 t 20 13 3 327 b 321 t 245 326 b 320 t 223 325 b 319 t 201 13 2 102 b 96 t 50 101 b 95 t 28
Total Coils 36 Total Coils 36 T4 Upstream Pole Group Slot # Slot # Angle Slot # Slot # Angle Slot # Slot # Angle T3 Upstream
1 3 119 b 113 t 58 118 b 112 t 36 117 b 111 t 15 Pole Group Slot # Slot # Angle Slot # Slot # Angle Slot # Slot # Angle 2 3 136 b 130 t 66 135 b 129 t 45 134 b 128 t 23 1 3 310 b 304 t 236 309 b 303 t 215 308 b 302 t 193 3 2 152 b 146 t 53 151 b 145 t 31 2 3 294 b 288 t 249 293 b 287 t 228 292 b 286 t 206 4 3 169 b 163 t 61 168 b 162 t 40 167 b 161 t 18 3 3 277 b 271 t 241 276 b 270 t 220 275 b 269 t 198 5 3 186 b 180 t 70 185 b 179 t 48 184 b 178 t 26 4 2 260 b 254 t 233 259 b 253 t 211 6 3 202 b 196 t 56 201 b 195 t 35 200 b 194 t 13 5 3 244 b 238 t 246 243 b 237 t 225 242 b 236 t 203 7 3 219 b 213 t 65 218 b 212 t 43 217 b 211 t 21 6 3 227 b 221 t 238 226 b 220 t 216 225 b 219 t 195 8 2 235 b 229 t 51 234 b 228 t 30 7 2 210 b 204 t 230 209 b 203 t 208 9 3 252 b 246 t 60 251 b 245 t 38 250 b 244 t 16 8 3 194 b 188 t 243 193 b 187 t 221 192 b 186 t 200
10 3 269 b 263 t 68 268 b 262 t 46 267 b 261 t 24 9 3 177 b 171 t 235 176 b 170 t 213 175 b 169 t 191 11 3 285 b 279 t 55 284 b 278 t 33 283 b 277 t 11 10 3 161 b 155 t 248 160 b 154 t 226 159 b 153 t 205 12 3 302 b 296 t 63 301 b 295 t 41 300 b 294 t 20 11 3 144 b 138 t 240 143 b 137 t 218 142 b 136 t 196 13 2 318 b 312 t 50 317 b 311 t 28 12 2 127 b 121 t 231 126 b 120 t 210
Total Coils 36 13 3 111 b 105 t 245 110 b 104 t 223 109 b 103 t 201 Total Coils 36
0.00
20.00
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60.00
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120.00
140.00
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Phas
e An
gle
(deg
rees
)
Coil Number
T3U - Phasor Phase Angles
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Stator Phase Vectors
T1
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Stator Split Phase Analysis
0 0.5 1 1.5 2 2.5 3 3.50
10
20
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50
60
70
IaSPH
IbSPHIcSPH
0 100 200 3000
2
4
6
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10
12
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18
20
Frequency (Hz)
FFT Magnitude - Pine Falls U4 - Slot 89/197 Bypass
IaSPHIbSPH
IcSPH
InVabVcb
0 1 2 3 4 50
2
4
6
8
10
12
14
16
18
20
Harmonics (94.7RPM base)
FFT Magnitude - Pine Falls U4 - Slot 89/197 Bypass
IaSPHIbSPH
IcSPH
InVab
Vcb
ROTATIONAL FREQ CURRENTS (1Xn, 2Xn)
FUNDAMENTAL CURRENTS
FFT SPECTRUM
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Air Gap – Manual Analysis
KEY PHASOR
AIR GAP SENSOR
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AIR GAP RAW DATA
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Manual Air Gap Algorithm
VARIABLE WIDTH PULSE fx(rotation speed)
PROCESSED KEY PHASOR
ROTATIONAL SPEED
VARIABLE WINDOW VECTOR Fx(speed)
Xn INDICATOR
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AIR GAPCOMPRESSED DATA
COMPRESSED DATA VECTOR
POLE NUMBER
ROTA
TIO
N
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Control System - Tuning and Testing -
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Performance =fx(Machine Health) REDUCTION OF HEAD COVER PRESSURE
IMPROVED RESPONSE
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Brake Track Monitoring (Non-Contact Measurement Systems)
ENVELOPE
THRUST PROFILE
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Case Study: Stator Rub Post Event Monitoring
00103-42100-U4 Cover Testing (Nov 9 - 2009)
40
45
50
55
60
65
70
75
801
23
4
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2021
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3435
36
Nov9On - MiddleNov9On - BottomNov9Off - MiddleNov9Off - Bottom
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Stator Wipe - Definition
ROTOR
STATOR
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Measurements
0 2 4 6 8 10 12-20
-10
0
10
20
30
40
50
Tem
p (C
)
Month
Ambient Powerhouse Temperature
Powerhouse Ambient - raw data °CPowerhouse Ambient - Mean Temp °CPine Falls Historical - Mean Temp °CPowerhouse Temperature Rise - Calculated °C
1YR TREND DATA
HISTORICAL CLIMATE
PROCESSED VECTOR
0 200 400 600 800 1000 1200 1400 1600 1800 2000-10
0
10
20
30
40
50
60
70
Data - x 4 hour interval
Tota
l Tem
pera
ture
( °C
)
Back Iron Temperature vs Time (1 Year Data)
Mean Back Iron Temp - BottomMean Back Iron Temp - CentreMean Center-Bottom Back Iron Temp Differential
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SIGNAL PROCESSING FOR ANALYSIS
TIME
LARGE TREND DATA (MB/YRS)
MEASUREMENT PID
HISTOGRAM VECTOR
COMPRESSED PROCESSED DATA (KB)
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Example Filter Implementation (Head Cover Uplift)
120 140 160 180 200 220
80
100
120
140
160
180
200
220
Uplift - filteredUplift - raw
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EXAMPLE SIGNAL PROCESSING TECHNIQUES
CO-EF DIFFERENCE FORMULAS
XN XN+1 XN-1
CENTRAL MOVING MEAN
XN XN+Y XN-Y
THRESHOLD/QUALIFIER FILTRATION N-ORDER FREQUENCY FILTER
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Adapting Vibration Mathematics
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Photographing Plots
50
100
30
210
60
240
90
270
120
300
150
330
180 0
GFU4 - Bottom Back Iron Temp Rise
50
100
30
210
60
240
90
270
120
300
150
330
180 0
GFU4 - Center Back Iron Temp Rise
50
100
30
210
60
240
90
270
120
300
150
330
180 0
Bottom Total Temp - Photographing Plot
50
100
30
210
60
240
90
270
120
300
150
330
180 0
Center Total Temp - Photographing Plot
25
50
30
210
60
240
90
270
120
300
150
330
180 0
Bottom Temp Rise - Photographing Plot
25
50
30
210
60
240
90
270
120
300
150
330
180 0
Center Temp Rise - Photographing Plot
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Measuring Non-Uniform Data
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Cartesian Component Conversion
0 100 200 300 400-40
-30
-20
-10
0
10
20
30
40Component Temp Rise - Bottom - Photographing
Physical Degrees
Tem
pera
ture
Ris
e °C
0 100 200 300 400-40
-30
-20
-10
0
10
20
30
40Component Temp Rise - Center - Photographing
Physical Degrees
Tem
pera
ture
Ris
e °C
X-Compenent Temp RiseY-Component Temp RiseX-Component IdealY-Component Ideal
X-Compenent Temp RiseY-Component Temp RiseX-Component IdealY-Component Ideal
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Spectrum Waterfall
0 5 10 15 20 25 30 350
20
40
60
80
100
Frequency (Hz)
X-Component FFT - Bottom
0 5 10 15 20 25 30 350
20
40
60
80
100
Frequency (Hz)
X-Component FFT - Center
0 5 10 15 20 25 30 350
20
40
60
80
100
Frequency (Hz)
Y-Component FFT - Bottom
0 5 10 15 20 25 30 350
20
40
60
80
100
Frequency (Hz)
Y-Component FFT - Center
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THE END