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GAP *
             generator assessment process
       a solution to life assessment of large generators




anilscoob@gmail.com                          omsaiempl@gmail.com
First Turbo Generator (1884)




                      anilscoob@gmail.com
The deterioration of large generators or for
that matter any electrical equipment is
normal, and this process begins as soon as
generator is installed.


If deterioration is not checked, it can cause
electrical failures and malfunctions.




                               anilscoob@gmail.com
In addition a TEAM of stresses

- Thermal
- Electrical
- Ambient
- Mechanical

further    contributes    to             the
deterioration process.


                         anilscoob@gmail.com
Thermal            Electrical


           Stress


Mechanical          Ambient


                       anilscoob@gmail.com
The purpose of a good maintenance
program shall be
• to discover the potential reasons of
deterioration
• take remedial measures for correction
to avoid catastrophic failures.
                      failures.

The other important purpose of
maintenance program is to maximize
reliability and availability, improve
operational efficiency and productivity.
                           productivity.


                            anilscoob@gmail.com
GAP* is the answer


             anilscoob@gmail.com
GAP* is a proactive action and the solution to
ensure availability and reliability of generators as
   well as improve operational efficiency and
 productivity to ensure smooth and trouble free
               running of the plant.

GAP* is an inspection and maintenance process
during the lifetime of a generator and is planned
     for during either operation or outage.

 GAP* can be linked to the generator planned
outage time thereby ensuring minimum downtime
 of the plant and at the same time assessing the
           healthiness of the generator.
                                     anilscoob@gmail.com
anilscoob@gmail.com
1   GAP 2
GAP

    GAP*


GAP 4   GAP 3


           anilscoob@gmail.com
• During operation of the
          generator
        • Data collection and on-
          line measurement when
          the generator is in


GAP 1     operation
        • Recommended after
          8,000 hours of
          operation
        • Usually takes 1 day




                        anilscoob@gmail.com
GAP 1         deliverables

Thermal Life Assessment by Arrhenius Equation
Thermal Life Assessment by N-Y method
Schedule for GAP2, GAP3 and GAP4




                                 anilscoob@gmail.com
• During outage with
          power cables removed
          from the generator
        • Data collection and off-
          line electrical


GAP 2     measurements
        • Recommended after
          16,000 hours of
          operation
        • Usually takes 2 days




                        anilscoob@gmail.com
GAP 2         deliverables

Condition Assessment based on Diagnostic Tests
Residual Life Assessment by D-map Method
May include GAP1 deliverables
Schedule for GAP3, GAP4 and GAP1




                                 anilscoob@gmail.com
• During outage on
          partially disassembled
          generator (end-covers
          and inspection windows
          removed)


GAP 3   • Inspection and tests to
          the extent possible
        • Recommended after
          32,000 hours of
          operation
        • Usually takes 3-5 days




                        anilscoob@gmail.com
GAP 3          deliverables

Visual Examination and inspection
Residual Life based on Stress Analysis
May include GAP1 & GAP2 deliverables
Schedule for GAP4, GAP1 and GAP2




                                    anilscoob@gmail.com
• During outage on fully
          disassembled generator
          with rotor threaded-out
        • Inspection and
          appropriate testing


GAP 4   • Recommended after
          64,000 hours of
          operation
        • Usually takes 10-12
          days




                        anilscoob@gmail.com
GAP 4          deliverables

Residual Life based on Stress Analysis
Condition Assessment and Index
Risk Assessment and Index
may include GAP1, GAP2 & GAP3 deliverables
Schedule for GAP1, GAP2 and GAP3



                                  anilscoob@gmail.com
GAP Concept
Life Cycle Concept
   anilscoob@gmail.com
Life Cycle Concept
Value to Customer
through Maintenance
                          Optimized Maintenance Line



                                                                               }    Continuous
                                                                                    Upgrading/
                                                                                    Replacement
                                                                              Maintenance

                                                         Overhaul

                               Aging
                                                         Repair

                             Upgrade and                                                Time
     Warranty Period       Modernization Period        Replacement & Recycle Period

                                  Maintenance Period


           Customer Project Lifecycle



                                                                  anilscoob@gmail.com
GAP Concept
Confidence Level
 anilscoob@gmail.com
Strength
    Stress
                 Calculated
    calculated
                 from GAP1
    from GAP1

                           Strength
                           Calculated
Stress
                           from GAP2
calculated
from GAP2


                              Strength
                              Calculated
                              from GAP3
Stress
calculated
from GAP3



                              Strength
Stress                        Calculated
calculated                    from GAP4
from GAP4




                      anilscoob@gmail.com
uncertainty



                                        Strength
Strength/stress




                  Stress




                               Time
                           anilscoob@gmail.com
GAP Concept
Stator Winding Failures
        anilscoob@gmail.com
Failure statistics
            Detection during Normal Operation




               11%
       5%                                                Bearing
  3%                                  37%                Winding
6%
                                                         Rotor
                                                         Shaft/coupling
                                                         Brushes/slipring
5%
                                                         External devices
                                                         Not specified
                     33%




                                       anilscoob@gmail.com
Failure statistics
                    Detection during maintenance or test




                       10%
               4%
                                                               Bearing
     7%
                                                               Winding
                                                               Rotor
                                                               Shaft/coupling
8%                                                             Brushes/slipring
 2%                                                            External devices
          8%                                                   Not specified
                                                61%




                                                 anilscoob@gmail.com
Failure Statistics Conclusion
•   Bearings fail frequently

•   Windings also share a significant failure rate

•   Very few winding failures are detected
    in maintenance (8.3%) as against the
    total failure of 33% in normal operation

•   This indicates poor        insulation        problems
    detection technique
                                     anilscoob@gmail.com
anilscoob@gmail.com
anilscoob@gmail.com
THANK YOU



ध यवाद




               ‫ا‬
‫ﮨﮯ‬    ‫ﯾہ ادا‬



ந    றி

ಧನ ಾದಗಳ

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Generator Assessment Process - An Overview

  • 1. GAP * generator assessment process a solution to life assessment of large generators anilscoob@gmail.com omsaiempl@gmail.com
  • 2. First Turbo Generator (1884) anilscoob@gmail.com
  • 3. The deterioration of large generators or for that matter any electrical equipment is normal, and this process begins as soon as generator is installed. If deterioration is not checked, it can cause electrical failures and malfunctions. anilscoob@gmail.com
  • 4. In addition a TEAM of stresses - Thermal - Electrical - Ambient - Mechanical further contributes to the deterioration process. anilscoob@gmail.com
  • 5. Thermal Electrical Stress Mechanical Ambient anilscoob@gmail.com
  • 6. The purpose of a good maintenance program shall be • to discover the potential reasons of deterioration • take remedial measures for correction to avoid catastrophic failures. failures. The other important purpose of maintenance program is to maximize reliability and availability, improve operational efficiency and productivity. productivity. anilscoob@gmail.com
  • 7. GAP* is the answer anilscoob@gmail.com
  • 8. GAP* is a proactive action and the solution to ensure availability and reliability of generators as well as improve operational efficiency and productivity to ensure smooth and trouble free running of the plant. GAP* is an inspection and maintenance process during the lifetime of a generator and is planned for during either operation or outage. GAP* can be linked to the generator planned outage time thereby ensuring minimum downtime of the plant and at the same time assessing the healthiness of the generator. anilscoob@gmail.com
  • 10. 1 GAP 2 GAP GAP* GAP 4 GAP 3 anilscoob@gmail.com
  • 11. • During operation of the generator • Data collection and on- line measurement when the generator is in GAP 1 operation • Recommended after 8,000 hours of operation • Usually takes 1 day anilscoob@gmail.com
  • 12. GAP 1 deliverables Thermal Life Assessment by Arrhenius Equation Thermal Life Assessment by N-Y method Schedule for GAP2, GAP3 and GAP4 anilscoob@gmail.com
  • 13. • During outage with power cables removed from the generator • Data collection and off- line electrical GAP 2 measurements • Recommended after 16,000 hours of operation • Usually takes 2 days anilscoob@gmail.com
  • 14. GAP 2 deliverables Condition Assessment based on Diagnostic Tests Residual Life Assessment by D-map Method May include GAP1 deliverables Schedule for GAP3, GAP4 and GAP1 anilscoob@gmail.com
  • 15. • During outage on partially disassembled generator (end-covers and inspection windows removed) GAP 3 • Inspection and tests to the extent possible • Recommended after 32,000 hours of operation • Usually takes 3-5 days anilscoob@gmail.com
  • 16. GAP 3 deliverables Visual Examination and inspection Residual Life based on Stress Analysis May include GAP1 & GAP2 deliverables Schedule for GAP4, GAP1 and GAP2 anilscoob@gmail.com
  • 17. • During outage on fully disassembled generator with rotor threaded-out • Inspection and appropriate testing GAP 4 • Recommended after 64,000 hours of operation • Usually takes 10-12 days anilscoob@gmail.com
  • 18. GAP 4 deliverables Residual Life based on Stress Analysis Condition Assessment and Index Risk Assessment and Index may include GAP1, GAP2 & GAP3 deliverables Schedule for GAP1, GAP2 and GAP3 anilscoob@gmail.com
  • 19. GAP Concept Life Cycle Concept anilscoob@gmail.com
  • 20. Life Cycle Concept Value to Customer through Maintenance Optimized Maintenance Line } Continuous Upgrading/ Replacement Maintenance Overhaul Aging Repair Upgrade and Time Warranty Period Modernization Period Replacement & Recycle Period Maintenance Period Customer Project Lifecycle anilscoob@gmail.com
  • 21. GAP Concept Confidence Level anilscoob@gmail.com
  • 22. Strength Stress Calculated calculated from GAP1 from GAP1 Strength Calculated Stress from GAP2 calculated from GAP2 Strength Calculated from GAP3 Stress calculated from GAP3 Strength Stress Calculated calculated from GAP4 from GAP4 anilscoob@gmail.com
  • 23. uncertainty Strength Strength/stress Stress Time anilscoob@gmail.com
  • 24. GAP Concept Stator Winding Failures anilscoob@gmail.com
  • 25. Failure statistics Detection during Normal Operation 11% 5% Bearing 3% 37% Winding 6% Rotor Shaft/coupling Brushes/slipring 5% External devices Not specified 33% anilscoob@gmail.com
  • 26. Failure statistics Detection during maintenance or test 10% 4% Bearing 7% Winding Rotor Shaft/coupling 8% Brushes/slipring 2% External devices 8% Not specified 61% anilscoob@gmail.com
  • 27. Failure Statistics Conclusion • Bearings fail frequently • Windings also share a significant failure rate • Very few winding failures are detected in maintenance (8.3%) as against the total failure of 33% in normal operation • This indicates poor insulation problems detection technique anilscoob@gmail.com
  • 30. THANK YOU ध यवाद ‫ا‬ ‫ﮨﮯ‬ ‫ﯾہ ادا‬ ந றி ಧನ ಾದಗಳ