Ge Mongolia Power Conversion Services
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  • 1. GE Energy Management Power Conversion Services in Mongolia Mungunshagai Enkhbold May 2013
  • 2. A Global Company 300,000+ employees worldwide Eastern Europe Operations in over 100+ countries China Middle East India Manufacturing facilities in 40+ countries Growing in key global markets .
  • 3. Outline • Who is GE • What GE Energy Management do • GE Power Conversion – Complete Solution offering • GE Power Conversion Services .
  • 4. GE’s Portfolio • 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. Energy Infrastructure • Energy • Oil & Gas • Power & Water Technology Infrastructure • Aviation • Healthcare • Transportation GE Capital • Aviation Financial Services • Commercial Finance • Energy Financial Services • GE Money • Treasury . Home & Business Solutions • Appliances & Lighting • Intelligent Platforms
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  • 11. Targeted motor services DC Motors over 20 Tons New & Refurbished Motors • All target industries • Repair by Replace Option Specialty Motors Up Rating Motors • Special applications • Steel Mills • Vertical Kingsbury Motors • Crane M&G Sets • Dynamometers Extended Warranty Opportunities 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 • Increase HP capacity • 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 .
  • 12. Targeted mechanical services Gearboxes Refiners • 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 • Inspections of rotors, shafts, bearings, hydraulic systems & housing • NDT • Weld repairs • Re-machining • Balancing • Upgrades • Complete machine rebuilds • Field Services Pumps Centrifuges • 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 • Removal Crushers Compressors • Mainframe/bottom shell rebuild • Top shell rebuild • Bowl rebuilds • Eccentric repairs • Mainshaft repairs • Head repairs • Onsite assembly of crushers 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 • 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 .
  • 13. How and why do motors fail? .
  • 14. Failure Modes for Electric Motors Less than 4kV . 4kV and above
  • 15. Common Failure Modes and Causes Predictive Maintenance Technology Legend IR Scanning, Temperature Trending Vibration analysis On-Line MCA . Visual inspection Off-Line MCA Oil Analysis
  • 16. Winding Failures .
  • 17. Mechanical Motion 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 .
  • 18. Thermal Degradation 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 .
  • 19. Rotor Failures .
  • 20. Open Rotor Bars & Cracked End Rings Cage rotor • Cracked or loose bars End Rings • High resistance joints and cracks Solutions • Borescope inspections • Current signature analysis • Infrared scans .
  • 21. Rotor failures Wound rotors DC Armatures .
  • 22. Bearing Failures .
  • 23. Bearing Failures Inadequate lubrication • too much • too little • contaminated Excessive load • misalignment • imbalance • bent shaft • other Electrical fluting • improper handling • installation • age spall on outer race .
  • 24. Roller Bearing Fluting and One Solution .
  • 25. Sleeve Bearing Wiped and Insulated Sleeve Bearing .
  • 26. Destroyed Sleeve Bearing and Rotor .
  • 27. Benefits of predictive maintenance . 27
  • 28. Classifying Maintenance Methods Maintenance Costs Reactive Preventive Predictive Productivity Run equipment to failure… Time based… Maintenance based on equipment “condition” “Break and Fix” Typically based on OEM specs 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
  • 29. DDMS What testing technologies should you have as part of your PdM toolkit? 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 .
  • 30. Motor Design Overview Identifying the appropriate tests for your motors requires that you understand their design, both electrically and mechanically Things to know: • Insulation system design – – – • Bearing system design – – – – • Low voltage, medium and high voltage Vacuum Pressure Impregnation (VPI) Dip and bake insulation system Rolling element Babbitt fluid film Insulated bearing Grease lubricated, oil bath, forced fed lubrication Rotor design – – – Copper bar Aluminium Magnesium .
  • 31. Vibration Monitoring The single most powerful tool for diagnosing and predicting the health of rotating equipment. 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 .
  • 32. Predictive/Condition Monitoring Step 1 - collection of critical parameter data • Vibration Step 2 - analysis of data • Trending changes indicate the asset’s health is beginning to degrade • Temperature • Oil, moisture • Contamination • Electrical parameters changes over time .
  • 33. Field Visual Inspections 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 .
  • 34. Infrared Scanning What can we detect? Heat rise from misalignment •Heat generated by friction – faulty bearings – Misalignment – Inadequate lubrication issues •Circuit breaker connections •MCC’s •Loose / corroded electrical connections .
  • 35. Alignment Problem: misalignment Solution: laser (shaft) alignment • Incorrect alignment of two coupled machines • Using laser-based equipment, we try to make the center lines of the two shafts collinear – Example: a motor and a pump • Thermal growth needs to be calculated in to the equation • One of the most common sources of excessive vibration Driver Driven power plane .
  • 36. Case Study Capturing Mechanical Losses Symptoms Before alignment • High vibration readings indicative of misalignment Corrective action • Laser aligned motor/pump and corrected loose mounting 008 1.8 No va - Co ol in g T o wer Pu mp -M1H Mo tor O utb oard Ho rizon tal Ro ute Sp ectru m 20-No v-02 08:30:50 1.6 OVERALL = . 1601 V-DG PK = .1599 L OAD = 100. 0 RPM = 3572. RPS = 59. 53 Results • Current draw reduced from 235.7A to 227.9A (-7.8A) • Annual cost of energy = $300 PK Velocity in In/Sec 1.4 1.2 1.0 After alignment 0.8 0.6 0.4 0.2 • Net annual energy savings $2,340 0 0 30 60 90 F req u en cy i n kCPM . 120 150
  • 37. Standardized Reporting .
  • 38. Our Powerful Network of Support • GE M&G forum Downloading the on-site data • Network of 400 + engineers • Instant accessibility • Global support • Connect with the factories • Central server database .
  • 39. How RM&D Works… Identify motor failure before it occurs .
  • 40. Advanced Motor Current Signature Analysis Broken rotor bars faults Stator inter-turn faults Bearing faults Advanced MCSA Broken rotor end-ring faults Rotor eccentricity related faults . Drive-Train Related
  • 41. Remote Monitoring & Diagnostics • Quick installation with 369, 469 & M60 GE Multilin Relays • Can be daisy chained together • Prompt responses with any trend variations .
  • 42. Remote Monitoring & Diagnostics .
  • 43. Global Footprint North America: Europe : Middle East : Asia: Dartford MEELSA Saudi Arabia Perth Bunbury Edmonton, AB, CAN Mechanical Motors Switchgear Langley, BC, CAN Mechanical Motors Switchgear Burlington, ON, CAN San Sebastian Mechanical Motors Switchgear GEK Sydney Stoney Creek, ON, CAN Transformers Dartford MEELSA Saudi GEK - Singapore Motors Motors Switchgear Mechanical Motors Salt Lake City, UT Mechanical Motors Switchgear Transformers Mechanical Motors Philadelphia, PA Mechanical Motors Switchgear Transformers Denver, CO Mechanical Motors Switchgear Transformers Los Angeles, CA Buffalo, NY Mechanical Motors Switchgear Transformers San Sebastian (Fierro) Mechanical Motors Switchgear Transformer Evansville, IN Mechanical Motors Switchgear Mechanical Motors Switchgear Transformers TGE – Sydney, AUS Mechanical Motors Switchgear Charlotte, NC Tucson, AZ Charleston, WV Mechanical Motors Switchgear Monterrey, NL, MEX Motors Mechanical Motors Switchgear TGE – Bunbury, AUS Mechanical Motors Switchgear Mechanical Motors Switchgear New Orleans, LA Mechanical Motors Switchgear Houston, TX Transformers TGE – Perth, AUS .
  • 44. GE Synchronous Motors for Ball Mill Oyu Tolgoi Site .
  • 45. Questions .
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