DIAGNOSTIC TOOLS
FOR
GENERATOR
DIAGNOSTIC TOOLS
INDIVIDUAL BAR TEMP. MONITORING SYSTEM
ROTOR WINDING TEMP. MONITORING SYSTEM
GEN. END WDG. VIBRATION MONITORING
SYSTEM
GROUNDING BRUSH MONITORING SYSTEM
MOISTURE MEASURING SYSTEM
GENERATOR CONDITION MONITORING SYSTEM
ON LINE PD MEASUREMENT SYSTEM
RF MONITORING SYSTEM
SHAFT TORSIONAL MONITORING SYSTEM
GEN EXPERT
MONITORING SYSTEM
INDIVIDUAL BAR TEMPERATURE
MONITORING SYSTEM
WHY?
MACHINES OF HIGHER RATINGS LIKE 500MW
ENVISAGE DIRECT COOLING OF STATOR WINDING
BY DM WATER
TEMP OF STATOR WINDING WHEN MEASURED BY RTDs
IN SOME SLOTS MEASURE ONLY THE BAR SURFACE
TEMP AT LOCATION OF RTDs.
OUTLET TEMP AT HEADER ALSO GIVES AVERAGE TEMP.
SCALE FORMATION OR OTHERWISE WATER FLOW
REDUCTION IN ANY BAR CAN CAUSE INCREASE IN TEMP.
AND MAY LEAD TO WINDING FAILURE
INDIVIDUAL BAR TEMPERATURE
MONITORING SYSTEM
ARRANGEMENT:
SPECIAL OUTLET NIPPLES ARE DESIGNED TO
ACCOMMODATE MINIATURE RTDs
LEADS ARE TAKEN OUT FOR CONNECTION TO
MICROPROCESSOR BASED SYSTEM
CORRECTION FACTORS ARE APPLIED
TEMP IN INDIVIDUAL BAR IS SCANNED CYCLICALLY
ALARMS ARE GENERATED WHEN PRESET LIMITS ARE
CROSSED
INDIVIDUAL BAR TEMPERATURE
MONITORING SYSTEM
INDIVIDUAL BAR TEMPERATURE
MONITORING SYSTEM
L
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:
MOISTURE MEASURING SYSTEM
PURPOSE :
HYDROGEN USED FOR COOLING OF VARIOUS
COMPONENTS OF STATOR AND ROTOR
H2 DURING CIRCULATION PICKS UP MOISTURE
FROM VARIOUS SOURCES
MOISTURE CAUSES DETERIORATION OF
INSULATION SYSTEM , STRESS CORROSION IN
RETAINING RING , COIL SHORTING, ARCING ETC.
MOISTURE MEASURING SYSTEM
MEASURING PRINCIPLE :
BASIC ELECTRODE IS OF ALUMINIUM
COUNTER ELECTRODE OF GOLD FILM THROUGH WHICH WATER
CAN PENETRATE
MOISTURE SENSITIVE ALUMINIUM OXIDE SERVES AS
DIELECTRIC
WATER MOLECULES OF HUMID GAS DIFFUSE THROUGH PORES
OF OXIDE LAYER AND CHANGES IMPEDENCE OF THE CELL
SIGNAL FROM SENSOR IS PASSED ON TO MOISTURE ANALYSER TO
PROVIDE CONTINUOUS MONITORING
MOISTURE MEASURING SYSTEM
SKETCH OF MOISTURE PROBE
MOISTURE MEASURING SYSTEM
PROBE MOUNTING DETAILS
MOISTURE MEASURING SYSTEM
INSTALLATION SCHEME
MOISTURE MEASURING SYSTEM
MULTI CHANNEL CONFIGURATION
MOISTURE MEASURING SYSTEM
TECHNICAL DATA :
A. PROBE :
PLANER GOLD / ALUMINIUM OXIDE , CAPACITANCE PRINCIPLE,
CALIBRATION RANGE : -80 Deg C TO 20 Deg C,
RECALIBRATION AFTER 6 TO 24 MONTHS AS PER REQUIRED ACCURACY
REPEATABILITY : +/- 1Deg C
MAXIMUM GAS VELOCITY : 5 M/S AT 10 BAR
SIGNAL TRANSMISSION : PULSE FREQUENCY MODULATED
PROTECTION : IP 65
B. ANALYSER :
MICROPROCESSOR BASED
FOUR CHARACTER LCD DISPLAY
OUTPUT 4-20 MILLIAMP INTO 500 OHM
SERIAL BUS CONNECTION WITH GATEWAY
PROTECTION : IP 20
DEW POINT MONITOR
ON LINE PD MEASURING SYSTEM
FAULTS AT INCIPIENT STAGE ARE OFTEN REVEALED BY
ELECTRIC DISCHARGE BEFORE CAUSING SERIOUS SHORT
CIRCUITS.
DISCHARGE PRODUCES CURRENT PULSES OF RF SPECTRUM
AND CAN BE DETECTED AT GENERATOR NEUTRAL AND PHASES
USING RF CURRENT PROBES, HV COUPLING CAPACITORS AND
A SPECTRUM ANALYSER
RF EMISSION DATA GIVES THE HEALTH OF STATOR INSULATION
ON LINE PD MEASURING SYSTEM
SALIENT FEATURES :
RF EMISSION IS DETECTED BY SPECTRUM ANALYSER AND A RF
MULTIPLEXER
RF DATA IS SENT TO PC VIA BUS COMMUNICATION LINK
SOFTWARE DEVELOPED SENDS COMMANDS FROM PC TO
ANALYSER FOR RESET, FREQUENCY , RANGES, SWEEP TIME ,
READING OF DIFF PEAK AMPLITUDES ETC
ON LINE PD MEASURING SYSTEM
MESURING METHODS :
FAULTS IN GENERATORS GET ANNOUNCED BY PD
BRIDGING PART OF HV INSULATION AND ARE DETECTABLE
DUE TO RF SIGNAL COMPONENTS
DISTRIBUTION OF PD wrt PHASE ANGLE OF GEN VOLTAGE
IS CHARACTERISTIC FOR CAUSE OF DISCHARGE AND
ALLOWS FOR CONCLUSION TO FURTHER OPERATION OF
GENERATOR
RF COUPLERS ARE INSTALLED AT BUS DUCT FOR 3 PHASES
OF GENERATOR TO DETECT DISCHARGES
TYPICAL ARRANGEMENT FOR
PARTIAL DISCHARGE MONITORING SYSTEM
PD SYSTEM
COUPLERS MOUNTING ARRANGEMENT
ON LINE PD MEASURING SYSTEM
ISM & GRI
HARDWAR
PARTIAL DISCHARGE TEST AT 11KV ON DIFFERENT SAMPLE BARS
16000
14000
12000
PD in pC
10000 [Link]
8000
6000 [Link]
4000
2000
SAMPLE CATEGORY 1. THRI fresh [Link] fresh with artificial defects [Link] (180 C for 12
weeks) [Link](200 C for 12 weeks) 5. RR(160 C for 12 weeks) [Link] motors(200 C for 12
weeks)
ISM & GRI
HARDWAR
RF MONITORING SYSTEM
DETECTS FAULTS IN HIGH VOLTAGE EQPT OF POWER PLANTS
1. SPARKING OF GROUNDING BRUSHES ON GENERATOR SHAFT
WITH SECONDARY DAMAGES ON BEARINGS
2. BROKEN GROUND CONNECTION ON GEN STATOR WDG
CIRCUIT / BAR
3. DEFECTIVE GENERATOR BUSHING
4. BROKEN LEAD IN VOLTAGE TRANSFORMER WINDING/
PROTECTION EQPT
5. HIGH CORONA DISCHARGE IN A 400 KV GROUNDING SWITCH
6. HV DISCHARGE INSIDE MAIN TRANSFORMER WINDING
7. PD ON PHASE BUS SUPPORTS
8. PD DUE TO DAMAGED PHASE BUS BUSHING
RF MONITORING SYSTEM
TYPICAL SCHEME
RF MONITORING SYSTEM
BLOCK SCHEMATIC DIAGRAM
RF MONITORING SYSTEM
SPECTRUM DATA FOR NEUTRAL AND BASE LEVEL
END WINDING
VIBRATION MONITORING SYSTEM
PURPOSE :
LONG UNSUPPORTED PORTION OF STATOR WINDING
OVERHANGS ARE FIXED WITH THE HELP OF
BRACINGS AND SUPPORT BRACKETS / RINGS
HIGH VIBRATIONS CAN CAUSE INSULATION
FAILURE DUE TO RUBBING OF CONDUCTORS AND
FATIGUE
END WINDING
VIBRATION MONITORING SYSTEM
SENSORS FOR VIBRATION MEASUREMENT
END WINDING
VIBRATION MONITORING SYSTEM
SYSTEM DETAILS :
VIBRATION PICK UPS
ACCELEROMETER TYPE
CHARGE SENSITIVITY : 10 TO 100 pc/g
TRANSVERSE SENSITIVITY : UPTO 5 % OF IN PLANE
OF VIBRATION
TEMP SENSITIVITY : LESS THAN 7% AT 150 DEG C
RESONANT FRQUENCY : NOT LESS THAN 10 KHz
END WINDING
VIBRATION MONITORING SYSTEM
SYSTEM DETAILS :
CHARGE AMPLIFIER :
PROVIDES AMPLIFICATION OF TRANSDUCER SIGNALS
TO AVOID DISTORTION IN SIGNAL TRANSMISSION TO
MONITOR
MEASURING MODE : ACCELERATION
FREQUENCY RANGE : 20 HZ - 1.5 KHz
ACCELERATION SENSITIVITY : 10 TO 1000 pc/g
CABINET MOUNTED
END WINDING
VIBRATION MONITORING SYSTEM
SYSTEM DETAILS :
PROVIDES GRAPHIC DISPLAY OF VIBRATION
ALARM INDICATION
SET POINT INDICATION WITH ADJUSTMENT
FACILITY
OUTPUTS FOR RECORDING
IN BUILT POWER SUPPLY
DATA PROCESSING / TRENDING / STORING
SELF DIAGNOSTIC
END WINDING
VIBRATION MONITORING SYSTEM
12 ACCELEROMETERS
12 NOS. CHARGE 12 PAIR
+ + AMPLIFIERS( PLACED NEAR GEN.) CABLE
+
MONITOR
+ OOOOOOOOOOOO IN
GENERATOR UCB / CER
+
+
+
DAS
IN
ALARM UCB
END WINDING
VIBRATION MONITORING SYSTEM
SYSTEM OVERVIEW :
GENERATOR CONDITION MONITORING
SYSTEM
PRINCIPLE :
INSULATION WHEN HOT BEYOND SAFE LIMITS GENERATES
SMALL PARTICULATES BEFORE ACTUAL BURNING TAKES
PLACE
THESE PARTICULATES ARE MADE TO PASS THROUGH AN ION
CHAMBER OF GCM
UNDER NORMAL CONDITION IONS PASS FROM CATHODE TO
ANODE IN CHAMBER AND FLOW OF IONS IS MEASURED IN
CURRENT AS 100%
PARTICLES WHEN PRESENT REDUCE THE FLOW & HENCE THE
CURRENT
LOW CURRENT BELOW PRESET VALUE GENERATES AN ALARM
ALARM VALIDATION :
ION CHAMBER BYPASSED , IF CURRENT RETURNS TO 100%
VALUE , THE ALARM IS GENUINE . OTHERWISE IGNORE THE
ALARM
GENERATOR CONDITION MONITORING
SYSTEM
INTERPRETATION :
AFTER ALARM VALIDATION PARTICULATES PRESENT IN COOLING
MEDIUM (H2) IS PASSED THRU AN EXTREMELY FINE MESH FILTER
SAMPLE COLLECTED IN FILTER ANALYSED BY GAS
CHROMOTOGRAPH
ANALYSIS IS IN THE FORM OF VERTICAL LINES CALLED FINGER
PRINTS OR SIGNATURES
FINGER PRINT MATCHING DONE WITH LIBRARY BUT IS TEDIOUS,
COSTLY AND TIME CONSUMING
TAGGING COMPOUNDS ARE APPLIED ON VARIOUS PARTS OF
GENERATOR TO IDENTIFY WHICH PART IS ACTUALLY HOT
ANALYSIS OF SAMPLES IN FILTER NOT POSIBLE IN INDIA
SHAFT GROUNDING SYSTEM
SHAFT VOLTAGE GETS DEVELOPED DUE TO :
STATIC CHARGES
CAPACITIVE COUPLED EXCITATION VOLTAGE
UNBALANCE/DIS-DYMMETRY IN ROTOR SHAFT
SYSTEM CONTAINS :
MAIN UNIT
DISPLAY UNIT
LOCAL JUNCTION BOX
SHAFT GROUNDING SYSTEM
FEATURES :
MEASURES SUPERIMPOSED VOLTAGE
MEASURES GROUND LOOP CURRENT
MEASURES RESULTANT OR ACTUAL SHAFT VOLTAGE
ALARM FOR:
a. FUNCTION FAILURE
b. BRUSH DEGRADATION / LOSS OF CONTROL
c. BRUSH BOUNCE CONDITION
d. BEARING PEDESTAL INSULATION FAILURE
GROUNDING BUSH MONITOR
MOUNTING ARRANGEMENT IN
KWU / RUSSIAN MACHINES
MOP GEN EXCITER
MOP GEN EXCITER
TORSIONAL STRESS ANALYSING
SYSTEM
CALCULATES SHAFT FATIGUE AND EXPENDED
LIFE OF TG SHAFT FOR EACH SHAFT SECTION
PROVIDES ALARM TO WARN THE OPERATOR WHEN
SHAFT TORQUE EXCEEDS A LOW LEVEL GROWING
OSCILLATIONS.
PROVIDES CHART OUTPUTS FOR RECORDING
VARIOUS INPUT PARAMETERS SHAFT OSCILLATIONS
WITH FACILITY FOR EXTERNAL CONNECTIONS
TORSIONAL STRESS ANALYSING
SYSTEM
SYSTEM DETAILS :
TOOTHED WHEELS
MAGNETIC PICK UPS
DIGITAL TRANSDUCER
CONTROL ASSEMBLY
DIGITAL FAULT RECORDER WITH 16 ANALOG
AND 32 DIGITAL CHANNELS
TSA EVENT ANALYSIS WORKSTATION
PRINTER
TORSIONAL STRESS RELAY
DECODER
TORSIONAL STRESS ANALYSING
SYSTEM
STANDARD PLANT CONNECTIONS :
THREE PT INPUTS FOR GENERATOR VOLTAGE
THREE CT INPUTS FOR GENERATOR CURRENT
SIGNAL INPUT FROM DEDICATED MAGNETIC PICK
UPS AT TURBINE END
SIGNAL INPUT FROM DEDICATED MAGNETIC PICK
UPS AT EXCITER END
STATUS / ALARM OUTPUT CONTACTS FOR PLANT
ANNUNCIATOR AND SEQUENCE OF EVENT RECORDER
UPS SUPPLY
TORSIONAL STRESS ANALYSING
SYSTEM
SYSTEM OVERVIEW
ROTOR WINDING TEMP. MONITORING
SYSTEM
INDIRECT & APPROXIMATE METHOD
QUADRATURE AXIS V/S CURRENT
CHARACTERISTICS
SHOP TEST RESULTS FOR FIELD CURRENT V/S
ROTOR WINDING TEMP
EXTRAPOLATION OF DATA
REALISATION IN DCS BY CURVE FITTING FOR
QUAD. VOLTAGE V/S TEMP RISE OVER COLD GAS