21_krueger_rotmachines intro, design faults.pdf
TRANSCRIPT
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Michael Krger OMICRON
ROTATING ELECTRICAL MACHINES Introduction
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 2
Introduction
Stator Winding Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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Hydro Generator 11MVA
Page 3
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Hydro Generator
Page 4
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Hydro Generator 50MVA
Page 5
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1000 MVA Generator (Steam Power Plant)
Page 6
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90 MVA Generator (Steel Factory)
Page 7
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14 MW Motors in a Steel Factory
Page 8
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Stator of a Hydro Generator 50MVA
Page 9
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Rotor Stator of a Hydro Generator
Page 10
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Rotor of a Hydro Generator
Page 11
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Rotor of a Synchonous Motor
Page 12
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 13
Introduction
Stator Winding Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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Design of a Machine Stator
Page 14
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Stator Slot with Winding
Page 15
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Conductor Design
Page 16
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Stator Winding Insulation
Page 18
A. coating
B. wedge/spacer
C. main insulation (mica tape)
D. end corona protection
E. outer corona protection (OCP)
F. inner corona protection (ICP)
G. partial conductor insulation
H. slot closure
I. stator core
outer corona protection, prevents slot discharges between the exterior surface of the insulation and the slot wall. Graphite paper or graphite coating
end corona protection prevents surface discharges at the exit point of the conductor from the laminated stator core. Made of materials with non-linear conductivity (e.g. silicon carbide)
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Stator Winding Insulation
Page 23
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 24
Introduction
Stator Winding Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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Damage to Hydro Generators
Page 25
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Sources of Insulation Damages
Page 26
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Why do Rotating Machines Fail?
other; 3%
rotor winding; 10%
bearings and vibrations; 50%
stator winding; 37%
Page 27
[IEEE85] Motor Reliability Working Group, Report of large motor reliability, survey of industrial and commercial installations-Part I, IEEE Trans. Ind. Applicat., vol. 21, July- August, 1985
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Why do Rotating Machines Fail? Stator winding
stator core; 3%
partial conductor insulation; 11%
mechanical elements; 22%
main insulation; 64%
Page 28
[IEEE85] Motor Reliability Working Group, Report of large motor reliability, survey of industrial and commercial installations-Part I, IEEE Trans. Ind. Applicat., vol. 21, July- August, 1985
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Why do Rotating Machines Fail?
Page 29
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Cigre Brochure 392 SURVEY OF HYDROGENERATOR FAILURES Working Group A1.10
Page 30
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Electrical Failures
Page 31
Delamination
Mechanical Abrasion Insufficient contacting between corona and end winding protection surface
Insufficient spacing, contamination
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Electrical Failures
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Perfect Mica Insulation
Page 33
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Mica Insulation with Voids
Page 34
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Electrical Treeing
Page: 35
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Winding Insulation with Cracks
Page 36
Copper
Cracks Main Insulation
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Abrasion of the Slot Corona Protection due to Vibration
Page 37
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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New Hydro Generator Bar with Delamination in the Mica Insulation
Page 38
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Hydro Generator Bar after 37 Years of Service
Page: 39
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Hydro Generator Bar after 40 Years of Service
Page 40
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Fault in the End Winding
Page 41
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Faults in the End Winding
Page: 42
Source: VATech Hydro Austria
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PD Fault in the End Winding
Page 43
Source: VATech Hydro Austria
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Discoloration due to Leakage of Cooling Water
Page 44
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS July/August 2008
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 45
Introduction
Stator Winding Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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Insulation Resistance
Page 46
VE: Empfehlungen fr die Zustandserfassung der Aktivteile rotierender elektrischer Maschinen
dry
humid
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Insulation Resistance Measurement
Page 47
Measurement Time Current
U-VWE 60 s 25.9809 nA
Measurement Time Current
U-VWE 600s 3.7637 nA
PI = 25.98 / 3.76 = 6.9
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Time Constant
Page 48
dry
humid
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 49
Introduction
Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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Dielectric Response Combination of PDC and FDS
Page: 50
Cur
rent
[nA]
Zeit [s]
Trans- formation
Frequency [Hz]
Verlu
stfa
ktor
0,001 0,001
1
1000
1000 1
100
1
Frequenz [Hz]
Tan
Del
ta
1000
1
0,001 0,1
1. f > 0,1 Hz Frequency Domain
2. f < 0,1 Hz Time Domain
3. Transformation of the Time Domain Data into the Frequency Domain
Polarisations- und DepolarisationsstromPDC
Frequency Domain Spectroscopy FDS
PresenterPresentation NotesResults in frequency domain are directly displayed.Results from time domain are at first transformed to frequency domain and then displayed.Time domain data (polarization current) can be shown as well.
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FDS Result
Page 51
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PDC Result
Page 52
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 53
Introduction
Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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Measurement of Dielectric Losses
Page 54
Dielectric losses in insulating systems (tan ) conducting losses (tan C) polarization losses (tan P) partial discharge losses (tan PD)
tan = tan C + tan P + tan PD
Dielectric losses: tan = f (U)
Tip-Up Test according to IEEE 286 Tan-Delta Test according to IEC 60894
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Test Equipment
Page 55
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C-Range with 2 CR500
Page 56
LCf
LCCL
2111
===
L = 20H
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Test Current with different Inductors
Page 57
0 H 80 H 40 H 26.6 H = 80 II 40
cap
ind
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Test Setup C-Tan-Delta Measurement
Page 58
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 59
Introduction
Stator Winding Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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PD Limits
Page 60
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Offline Test IEC 60037-27 U (V,W+Stator)
Page 61
IEC 60034-27
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IEEE Std 1434-2000
Page 62
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Cigre Brochure 258
Page 63
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IEC 60034-27
Page 64
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Rotating Electrical Machines Design, Faults and Diagnostic Measurement Methods
Page 65
Introduction
Stator Winding Design
Faults on Generators
Insulation Resistance and the Polarisation Index (PI)
Dielectric Response
Capacitance and Dielectric Dissipation (Power) Factor
Partial Discharge (PD) Measurement
Case Study - Measurements on a Hydro Generator
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Measurement on a 20MVA Generator
Page 66
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C-Tan-Delta-Measurement
Page 67
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C-Tan-Delta-Measurement
1,20
1,30
1,40
1,50
1,60
1,70
1,80
1,90
0,0V 1000,0V 2000,0V 3000,0V 4000,0V 5000,0V 6000,0V 7000,0V
%
Tan Delta [%]RST
Page 68
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C-Tan-Delta-Measurement
-0,20
-0,10
0,00
0,10
0,20
0,0V 1000,0V 2000,0V 3000,0V 4000,0V 5000,0V 6000,0V 7000,0V
%
delta Tan Delta
RST
Page 69
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C-Tan-Delta-Measurement
Page 70
Tan Delta (f) at 2kV
1.001.101.201.301.401.501.60
0.0 Hz 100.0 Hz 200.0 Hz 300.0 Hz 400.0 Hz
%
RST
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FDS / PDC Measurement
Page 71
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FDS Measurement
Page 72
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PDC Measurement
Page 73
Measurement Time Current
U-VWE 60 s 25.9809 nA
Measurement Time Current
U-VWE 600s 3.7637 nA
PI = 25.98 / 3.76 = 6.9
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Synchronous 4-Channel Partial PD Measurement
Page 74
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Channel 1 = U1
Page 75
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Channel 2 = U2
Page 76
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Channels 3 and 4 = V1 and W1
Page 77
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PD Calibration Matrix
Page 78
Cal Input 2nC 1 2 3 4
1 1.00 0.28 0.30 0.272 0.37 1.00 0.30 0.283 0.27 0.09 1.00 0.284 0.27 0.07 0.30 1.00
Channel
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Synchronous 4-Channel PD Measurement
Page 79
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3PARD
Page 80
3PARD = 3 Phase Amplidude Related Diagram
or in this case:
3 Channel Amplitude Related Diagram
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Synchronous 3-Channel PD Measurement with 3PARD Filtering Cluster A
Page 81
A
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Synchronous 3-Channel PD Measurement with 3PARD Filtering Cluster B
Page 82
B
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Questions and Remarks?
ROTATING ELECTRICAL MACHINESIntroductionRotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsHydro Generator 11MVAHydro GeneratorHydro Generator 50MVA1000 MVA Generator (Steam Power Plant)90 MVA Generator (Steel Factory)14 MW Motors in a Steel FactoryStator of a Hydro Generator 50MVARotor Stator of a Hydro GeneratorRotor of a Hydro GeneratorRotor of a Synchonous MotorRotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsDesign of a Machine StatorStator Slot with WindingConductor DesignStator Winding InsulationStator Winding InsulationRotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsDamage to Hydro GeneratorsSources of Insulation DamagesWhy do Rotating Machines Fail?Why do Rotating Machines Fail? Stator windingWhy do Rotating Machines Fail?Cigre Brochure 392SURVEY OF HYDROGENERATOR FAILURESWorking GroupA1.10Electrical FailuresElectrical FailuresPerfect Mica InsulationMica Insulation with VoidsElectrical TreeingWinding Insulation with CracksAbrasion of the Slot Corona Protection due to VibrationNew Hydro Generator Bar with Delamination in the Mica InsulationHydro Generator Bar after 37 Years of ServiceHydro Generator Bar after 40 Years of ServiceFault in the End WindingFaults in the End WindingPD Fault in the End WindingDiscoloration due to Leakage of Cooling WaterRotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsInsulation ResistanceInsulation Resistance MeasurementTime ConstantRotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsDielectric ResponseCombination of PDC and FDSFDS ResultPDC ResultRotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsMeasurement of Dielectric LossesTest EquipmentC-Range with 2 CR500Test Current with different InductorsTest Setup C-Tan-Delta MeasurementRotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsPD LimitsOffline TestIEC 60037-27 U (V,W+Stator)IEEE Std 1434-2000Cigre Brochure 258IEC 60034-27Rotating Electrical Machines Design, Faults and Diagnostic Measurement MethodsMeasurement on a 20MVA GeneratorC-Tan-Delta-MeasurementC-Tan-Delta-MeasurementC-Tan-Delta-MeasurementC-Tan-Delta-MeasurementFDS / PDC MeasurementFDS MeasurementPDC MeasurementSynchronous 4-Channel Partial PD MeasurementChannel 1 = U1Channel 2 = U2Channels 3 and 4 = V1 and W1PD Calibration MatrixSynchronous 4-Channel PD Measurement3PARDSynchronous 3-Channel PD Measurement with 3PARD Filtering Cluster ASynchronous 3-Channel PD Measurement with 3PARD Filtering Cluster BSlide Number 83