4 GAP

generator assessment process

a solution to life assessment of large generators

1 GAP

2 GAP

* GAP

4 GAP

3 GAP

GAP4 is the inspective approach to assess the residual life of the generator .

Methodology The methodology employed is conducting standard and special electrical tests and inspection on stator and rotor windings and accessories

Unit Condition The machine is in dismantled condition with rotor threaded-out Inspection & tests Performed Physical examination Tests and inspection

Benefits Reveals pending faults in winding Reveals deterioration of coil insulation by corona or end winding vibration Establish a base line for evaluating future inspection Accurately assess life maintenance requirements Record of core tightness Preventive maintenance plan Schedule for GAP2, GAP3 and GAP4 and future

Final Report Standard format provided electronically Photographs of critical areas Dielectric absorption insulation integrity graph of and all analysis test of and

Results and summary measurements taken Plots showing winding basket frequency

Location and levels of corona activity distribution of end

Core tightness record EL CID test record and wedge mapping Establishes a base-line for evaluating future inspections and input for instituting planned major maintenance activities

Expected Downtime 12-15 days Option .

Life Assessment
FEM Approach

Geometrical data of the stator coils is collected to make a model by FEM method for stress analysis

Overhangs

Turbine End

Straight side

Exciter End

Overhangs

Stress/Tensile Strength (MPa)

60 1090 1120 1150 1180 1210 1240 1270 1300 1330 1360 1390 1420 1450 1480 1510 1540 1570 1600 1630 1660 1690 1720 1750 1780 1810 1840
Hundreds

62

64

66

68

70

72

74

76

78

LIFE ESTIMATION BY FEM METHOD

Equivalent Operating Hours

1870 1900

Condition Assessment
Risk Assessment Approach

The following indicators are used separately to evaluate the condition of stator and rotor Operation and maintenance history Physical inspection Insulation test Generator Age

These condition indicators are initially evaluated using inspections, tests, and measurements, which are conducted by utility staff or contractors over the course of time and as a part of routine maintenance activities. Numerical scores are assigned to each stator and rotor condition indicator, which are then weighted and summed to determine the Stator and Rotor Condition Indices. The lower of the two indices is selected to represent the overall Generator Condition Index.

An additional stand-alone indicator is used to reflect the quality of the information available for scoring the generator condition indicators. In some cases, data may be missing, out-of-date, or of questionable integrity. Any of these situations could affect the accuracy of the associated condition indicator scores as well as the validity of the overall Condition Index. Given the potential impact of poor or missing data, the Data Quality Indicator is used as a means of evaluating and recording confidence in the final Generator Condition Index.

Additional information regarding generator condition may be necessary to improve the accuracy and reliability of the Generator Condition index. Therefore, in addition to the Tier 1 condition indicators, this appendix describes a toolbox of Tier 2 inspections, tests, and measurements that may be applied to the Stator and Rotor Condition Indices, depending on the specific issue or problem being addressed. Tier 2 tests are considered non-routine. However, if Tier 2 data is readily available, it may be used to supplement the Tier 1 assessment. Alternatively, Tier 2 tests may be deliberately performed to address Tier 1 findings. Results of the Tier 2 analysis may either increase or decrease the score of the Generator Condition Index. The Data Quality Indicator score may also be revised during the Tier 2 assessment to reflect the availability of additional information or test data.

Condition Assessment
Stator

Operation & Maintenance History

Physical Inspection

Insulation Test

Generator Age

DC Ramped Voltage Test

Partial Discharge Measurement

Dissipation Factor Measurement

Ozone Monitoring

Black Out Test

High Potential Withstand Test

Stator Core Inspection

Wedge Tightness Evaluation

Core Loop Test

ELCID Test

Corona Probe Test

Coupling Resistance Test

Bump test

Capacitance Measurement

Core Bolt Insulation Resistance

Winding Conductor Resistance Measurement

Impedance Measurement

Winding Dissection

Stator Condition Index

2 3 4 5 6 7 8 9 10

Stator Data Quality Index

10

Condition Assessment
Rotor

Operation & Maintenance History

Physical Inspection

Insulation Test

Generator Age

High Potential Withstand Test

Rotor Core Inspection

AC Pole Drop Test

AC Impedance Test

Winding Resistance Measurement

RSO Test

Rotor Condition Index

2 3 4 5 6 7 8 9 10

Rotor Data Quality Index

10

Condition Assessment
Generators

Generator Condition Index

2 3 4 5 6 7 8 9 10

Generator Data Quality Index

10