© ABB Group February 29, 2012 | Slide 1
Life Expectancy Analysis Programfor Electrical Machine Insulation
Cajetan Pinto, Global R&D Manager,
© ABB Group February 29, 2012 | Slide 2
Presentation overview
Life Cycle Management Approach
Reliability and failure statistics
Planning your Strategy
LEAP Methodology & Use
LEAP Standard
Case Studies
Benefits
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Continuous Upgrading/Replacement
Upgrade and Modernization Period
Warranty Period
Overhaul
Maintenance
AgingRepair
Optimized Maintenance Line
Time
Maintenance Period
Replacement & Recycle Period
Value to customerthrough maintenance
Customer Project Lifecycle
}
Life Cycle Concept
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*Information provided by MachineMonitorTM based on survey of 6000 machines
TCO includes:
•Transportation
•Purchase price• Specifications
•Storage•Installation•QA•Reliability•Electricity•Repairs•Administration•Inventory•etc
Installation
1%
Purchase
2.7%
Cost of
repair
4.9%
Reliability
17.4%
Electricity
74%
Total cost of operation (TCO)*
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Stress
Strength
FailureTransient faults
Residual Life
Premature Failure
Time
Stre
ss, s
treng
thBasis of Analysis: Stress & Strength v/s Time
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Adv. 2: Increase in Life
Stress
Strength
Failure
Transient faults
Residual Life
Adv. 1: No Premature Failure
Condition assessment and taking suitable actions at this point.
Life Expectancy Analysis: Benefits
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Reliability&Failure Statistics
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Failure statistics: IEEE Survey 1985-1987
37%
33%
5%
6%3%
5%11%
Bearing
Winding
Rotor
Shaft/coupling
Brushes/slipring
External devices
Not specifiedDetection during Normal operation
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Failure statistics : IEEE Survey 1985-1987
8%2%
8%
7%4%
10%
61%
Bearing
Winding
Rotor
Shaft/coupling
Brushes/slipring
External devices
Not specified
Detection during maintenance or test
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Out of 33 % failures occurred during normal operation,
only 8 % could be detected during maintenance/inspection.
Out of 37 % failures occurred during normal operation,
61 % could be detected during maintenance/inspection.
BEARING FAILURES STATOR INSULATION FAILURES
Failure statistics: Inference
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Failure Statistics: HT Motors Petrochemical Industry 1999
18.42
60.53
7.89 5.26 7.89 0.00IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS . VOL. 35. NO. 4. JULY/AUGUST 1999
57.40%
18.40%
5.60%
2.80%14.60%
1.20%
Bearing
Stator Windings
Rotor- Bars/rings
Shaft or coupling
External device
Not Specified
Distribution of Failures for motors below 2000KW
Distribution of Failures for motors equal and above 2000KW
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Total Failure rate Vs Age
Total Failure Rate Vs Age
01234567
0-5 5.1-10 10.1-15 15.1-20 20.1-25 25.1-
Age (Years)
%
IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS . VOL. 35. NO. 4. JULY/AUGUST 1999
00.5
11.5
22.5
33.5
%
3000-5000
6000 6600-10500
11000-13800
Voltage(Volts)
%wdg Failure Rate
Series1
00.5
11.5
22.5
%
1 or less More than 1
No of Starts/day
Wdg Failure Rate
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Stator winding failures (link with TEAM)
FAILURE CONTRIBUTORS
Normal deterioration with
age18%
Poor Ventilation/ Cooling
8%
Aggressive chemicals
7%
Poor Lubrication5%
High Vibration9%
Abnormal Frequency
1%
Abnormal Voltage5%
Abnormal Moisture18%
High Ambient Temperature
8%
Persistent Overloading
7%Other14%
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ProtectionCondition Monitoring
Life-time Estimation
• continuous, on-line, action taken in real time
• to limit the damage or prevent operation under abnormal conditions
• on-line, but not necessarily continuous
• analysis and action is subsequent to data collection
• prevents failure by taking steps with short term planning for maintenance
MST, ARGUS, DLI, PD, Telemetry, etc
LEAP
• on-line + off-line
• analysis and action subsequent to data collection
• detects life limiting defects at the incipient stage, useful in both long term planning and short term planning for maintenance
Planning your maintenance STRATEGY
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LEAP is not just a package of inspections; it is a systematic approach to managing Machine Maintenance
LEAP …… not just a step ahead
What is LEAP?Lifetime Expectancy Analysis Program or LEAP is a unique Maintenance Tool for the Stator Winding Insulation of Electric Machines.
LEAP provides information on Machine winding and expected life, and will optimize the Machine Maintenance Plans
LEAP developed by ABB Machines Service, India, is in use for over 12 years, with a database of measurements and analysis in excess of 4000 machines worldwide
Measurements are performed by Local or Global ABB Service centers and data analyzed at the LEAP Center of Excellence
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Level Based Inspections
Opportunities for Inspections
Inspection Schedule
Basic When the machine is operating
Every 5% of the estimated lifetime
Standard When the machine is stopped but assembled
Every 10% of the estimated lifetime
Advanced When the machine is stopped and partially dismantled
Every 25% of the estimated lifetime
Premium When the machine is stopped and rotor removed
Every 50% of the estimated lifetime
45
60
75
90
Con
fiden
ce L
evel
Basic Standard Advanced Premium
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Level Based Inspections
Solution Levels
Packages Deliverables
Basic Data collection (on site or remote):
Operational hours, voltage, current, power, slip, Starts/Stops, Temperature (Winding, Coolant and Ambient), Duty cycle & loading pattern, Failure and Maintenance history, Information on power supply, breaker-cable configuration, etc
Life Expectancy Analysis 65% Confidence LevelCondition Based Inspection and Maintenance Plan
Standard Basic Data Collection Polarization Depolarization Current Analysis PDCA Tan Delta & capacitance Analysis Non-Linear Insulation Behaviour Analysis Partial Discharge Analysis
Condition Assessment of Stator Windings for Contamination, ageing, looseness,delamination, stress grading system Life Expectancy Analysis 80% Confidence LevelCondition Based Inspection and Maintenance Plan
Advanced Standard Data Collection Visual Inspection on end windings Partial Discharge Probe measurements & Dynamic Mechanical Response of Windings Stress analysis of End-windings
Condition Assessment of Stator Windings with Standard Package + End-winding assessmentLife Expectancy Analysis 85% Confidence LevelCondition Based Inspection and Maintenance Plan
Premium Advanced Data Collection Wedge Tightness Map & Coupling resistance measurements Visual inspection, including slot areas Stress analysis of Windings
Condition Assessment of Stator Windings withAdvanced Package + slot region assessmentLife Expectancy Analysis 90% Confidence LevelCondition Based Inspection and Maintenance Plan
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LEAP Methodology&Use of LEAP
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Collection of DataOperating data, test measurements andmachine information
Analysis of DataABB has developed UNIQUE analytical tools aimed at life assessment
Calculation of Stresses Life Expectancy Analysis is performed and factors and conditions that affect lifetime are identified
Estimating Life & Condition Based MaintenanceLifetime is estimated with different Confidence levels depending on the LEAP package
Possible further inspections, maintenance, replacements or even upgrades are drawn up
LEAP methodology
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LEAP Standard
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DC Measurements
Polarization De-Polarization Current Analysis
AC Measurements
Non Linear Behavior Analysis
Tan and Capacitance Analysis
Partial Discharge Analysis
P o la riz at io n -D e p o lar iza t io n C u rre n tsU P H A S E
0 .1
1
1 0
10 0
1 1 0 10 0 1 0 0 0T im e (s e c)
Pol-D
epol
Cur
rent
s (m
icro
Am
p)
C h arg ing D isch arg in g
TAN DELTA MEASUREMENTS
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
1 2 3 4 5 6 7 8
Voltage (kV)
Tan
Del
ta (%
)
U Phase V Phase W Phase UVW Phase
Remark: DC tests are sensitive to the surface condition, and AC tests give more information on the insulation volume
LEAP Standard package
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DC measurements
Polarization - De-polarization Current Analysis
Besides leakage and absorption current, PDCA test gives an idea of quantity and location of charge storage within the machine
Identifies contamination even when IR, PI values are “acceptable”.
Determines state of the winding insulation, ageing, looseness, etc.
Polarization-Depolarization CurrentsUVW PHASE
0.01
0.1
1
10
100
1 10 100 1000Time (sec)
Pol-D
epol
Cur
rent
s (m
icro
Am
p)
Charging Discharging
Parameters DerivedTime constants T1, T2, T3Charge storage : Q1, Q2, Q3Ageing FactorDispersion Ratio (1+Q1+Q2+Q3) < 1.25Volume Resistivity
Q3
Q1, Q2
Remark:Conventional IR & PI Measurements may have satisfactory values even with highly contaminated windings
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AC measurements
Non Linear Behavior Analysis, Tan and Capacitance Analysis, Partial Discharge Analysis
Confirm the results from DC Measurements
Assess the condition of Corona protection shield
Determine the extent of de-lamination or void content in terms of a percentage of discharging Air Volume to Insulation Volume
Assess condition of the Stress Grading system at slot ends
Trend Ageing effects
INSTANTANEOUS CAPACITANCE VARIATIONS@ 5.8 kV
-70
-25
20
65
110
40 42 44 46 48 50 52 54 56 58 60
TIME (msecs)
CAP
AC
ITA
NC
E (A
rbitr
ary
Uni
ts)
U - PHASE V - PHASE W - PHASE UVW - PHASE
Remarks:Conventional measurement interpretation is generally based on trends
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LEAP – How is it different?
Methodology is not dependent on old records of measurements performed. Single occasion of measurements will suffice for making decisions. Parameters are derived from measurements to quantify problems such as contamination, ageing and looseness.
65-72% of failures are related to Thermal and Ambient reasons which may not be detected by measurements that rely only on partial discharges. ABB’s measurements and analysis focuses also on detection non-partial discharge related problems.
Analysis software is UNIQUE and parameters derived from analysis can be utilized in Life Expectancy Calculations
Sophisticated FEM analysis can be deployed in Level III and IV inspections.
Can be related to time and integrated into a Maintenance Plan
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Towards a New Dimension
We change the units !
Machinery status is typically expressed in vague units (green, yellow, red)
We change that into a measurable dimension: time that can be easily interpreted by othercomputerized systems and related to scheduling actions
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Optimizes Maintenance Planning of Electrical Machines by moving from Scheduled Maintenance to Condition Based Maintenance
Life Extension of machines would lead to increased earnings capability and thereby greater return on investment.
Facilitate decision making (short and long term maintenance planning)
Focus mainly on essential maintenance, and machines that are vulnerable, thereby reducing downtime at lower risk levels
Provides important “lifetime ” inputs for more realistic estimates of Life Cycle Costing
LEAP - Value for the Customer
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