Customer presentation, Motors and Generators Service

ABB Life Expectancy Analysis Program

Condition and lifetime assessment of
stator winding
ABB Life Expectancy Analysis Program (ABB LEAP)
Overview

§ Introduction

§ Motivation to perform ABB LEAP

§ Failures statistic

§ Consequences of stator failure

§ Basic theory

§ Levels and measurements

§ Why is ABB LEAP unique?

§ Value and benefits for customers

§ Report

§ Case studies
© ABB Group
October 25, 2018 | Slide 2
ABB Life Expectancy Analysis Program (ABB LEAP)
Introduction

§ ABB LEAP (Life Expectancy Analysis Program) is

unique diagnostic tool for motors and generators which
§ assesses the condition of the stator winding
insulation,
§ evaluates the remaining life of the stator winding
insulation
§ Site measurements are performed by trained personnel
in the ABB Service Center network and the data
analyzed at the ABB LEAP Center of Excellence at
Mumbai
§ Service is performed by Local ABB Service Providers

Benefits for customers

§ ABB LEAP creates optimized maintenance plans
that helps our customers to
§ minimize unplanned downtime
§ extend motors and generators lifetime
§ boost return on investment
§ reduce operating risks

© ABB Group
October 25, 2018 | Slide 3
Motivation to perform ABB LEAP
Failure Statistics – IEEE and EPRI

70%
Failures observed in
motor during normal 61%
operating condition
60%

Failures identified in
50%
motor when carrying
out activities such as:
§ Preventive 40% 37%
Maintenance 33%
§ Condition
Monitoring 30%

20%
11% 10%
8% 8% 7%
10% 6% 5% 5% 4%
2% 3%

0%

© ABB Group
October 25, 2018 | Slide 4
Motivation to perform ABB LEAP
Stator failures - What might be the consequences?

§ What is the time for repair?

§ What are the costs involved in a

complete stator replacement or
rewinding?

§ What are the losses related to

production due the stator failure?

§ And downtime cost?

© ABB Group
October 25, 2018 | Slide 5
Factors influencing stator winding life
Age, voltage, speed, operation

Total Failure Rate Vs Age

7
6
5
4
%
3
2
1
0
0-5 5.1-10 10.1-15 15.1-20 20.1-25 25.1-
Age (Years)

© ABB Group
October 25, 2018 | Slide 6
Basis of ABB LEAP
Stress and Strength vs Time

Strength

Premature failure
Stress, strength

Failure
Transients

Stress

Residual life
Time
© ABB Group
October 25, 2018 | Slide 7
ABB Life Expectancy Analysis Program (ABB LEAP)
The Benefits

Strength Condition assessment and taking

suitable actions at this point.

Adv. 1: No Premature failure

Transients

Failure
Stress

Residual life
Adv. 2: Increase in life

© ABB Group
October 25, 2018 | Slide 8
ABB Life Expectancy Analysis Program (ABB LEAP)
Levels

Premium
Large synchronous
Advanced motor and generator
Large synchronous above 710 frame size
Standard motor and generator
All AC motors and above 710 frame
generators size

1. Condition assessment 1. Condition assessment and

1. Condition assessment
and life expectancy with life expectancy with 90%
and life expectancy with
85% confidence confidence
80% confidence
2. Machine stopped and 2. Machine stopped and fully
2. Machine stopped but not
partially dismantled (end dismantled (rotor removed
dismantled
covers removed) from stator)
3. During short stoppage
3. During minor overhaul (1 3. During major overhaul (3
(few days)
week stoppage) week stoppage)

© ABB Group
October 25, 2018 | Slide 9
ABB Life Expectancy Analysis Program (ABB LEAP)
Tests carried out in each level

Test Standard Advanced Premium

Polarization Depolarization Current Analysis (PDCA) • • •
Tan Delta and Capacitance Analysis • • •

Non-Linear Insulation Behaviour Analysis • • •

Partial Discharge Analysis • • •
Visual inspection of end winding • •
Visual inspection of stator and rotor •
ELCID •
Endoscopic test •
RSO •
Natural frequency •
Wedge tightness •
FEM •

© ABB Group
October 25, 2018 | Slide 10
ABB LEAP measurements
General information

§ Can be applied on motors and generators from any

manufacturer
§ Time for data collection approximately 4 hours with
motor/generator stopped (off-line tests)
§ Not necessary to open covers/machine for data collection
§ Only need access to the terminal boxes
§ Non destructive tests

© ABB Group
October 25, 2018 | Slide 11
ABB LEAP measurements
Standard package

§ DC
measurements 100
P o la r iz a tio n -D e p o la r iz a tio n C u rr e n ts
U PHASE § DC Measurements
gives more
§ Polarization De-Polarization
Pol-Depol Currents (microAmp)

information on 10

the surface of
the insulation 1
Current Analysis
§ AC 0 .1

measurements 1 10
T im e (s e c)
10 0 1000

gives more C h a rg i n g D i s c h a rg in g
§ AC Measurements
information on
the volume of
§ Non Linear Behavior Analysis
TAN DELTA MEASUREMENTS

insulation 4.00

§ Tan δ and Capacitance Analysis

3.50

3.00
Tan Delta (%)

2.50

2.00
§ Partial Discharge Analysis
1.50

1.00

0.50
1 2 3 4 5 6 7 8
Voltage (kV)

U Phase V Phase W Phase UVW Phase

© ABB Group
October 25, 2018 | Slide 12
ABB LEAP measurements
Salient points

DC measurements:
Conventional IR,PI
§ DC measurement § AC measurement
values may be
satisfactory even for § By measuring leakage § Confirm the results
highly contaminated
windings
and absorption current, from DC
PDCA test helps Measurements
AC measurements:
quantify and identify § Assess the condition of
Conventional
measurement
location of charge corona protection
interpretation is storage within the shield
based on trend
motor or generator § Determine the extent of
§ Identifies de-lamination or void
contamination even content in terms of a
when IR, PI values are percentage of
“acceptable” discharging air volume
§ Determines state of to insulation volume
winding insulation, § Assess condition of the
ageing, contamination stress grading system
Q1, Q2
and others at slot ends
Q3

§ Trend ageing effects

© ABB Group
October 25, 2018 | Slide 13
ABB Life Expectancy Analysis Program
Why is ABB LEAP unique?

§ Traditional measurement looks at values such as IR, PI, Tan δ,

whereas ABB LEAP looks from point of strength aspects of
insulation

§ Trend of data required in traditional analysis. With ABB LEAP

finger print can be established with one set measurement

§ 65-72% of failures are related to thermal (aging) 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

§ Can be related to time and shall be integrated into the

maintenance plan

© ABB Group
October 25, 2018 | Slide 14
ABB Life Expectancy Analysis Program
Value and benefits for customer

§ Optimizes maintenance planning of electrical motors and

generators
§ Helps to extend the life of motors or generators by
suggesting correct maintenance at appropriate time leading
to better return of investment
§ Facilitate decision making (short and long run)
§ Provides lifetime inputs to make realistic calculation of
lifetime costs

© ABB Group
October 25, 2018 | Slide 15
ABB Life Expectancy Analysis Program
Reports

Provides condition assessment of stator

winding
§ Helps make short term maintenance
plan

Provides remaining lifetime of stator

winding
§ Helps make long term maintenance
plan

Provides recommendation
§ What maintenance needs to be done
§ When maintenance needs to be done
§ What winding areas to attend
§ When to perform rewinding or buy new
stator

© ABB Group
October 25, 2018 | Slide 16
ABB LEAP case study
Contamination
§ 11 MW, 11KV, 1500 rpm synchronous motor

§ Purpose of test:
§ The motor was in operation for 69,000 hours with no outage.
§ ABB LEAP Standard carried out to determine the need for L3 or Level 4 inspection
§ On-line pd alarm had appeared

§ Results PDCA test:

§ IR- 2310 Meg ohm
§ PI- 2.02 (Limits)
§ Q1(%) – 9.63 (<7%)
§ Q2 (%) – 11.30 (<10%)
§ Q3 (%) – 44.54 (< 20%)

§ Key findings
§ ABB LEAP Standard indicated presence of oil/carbonized contaminants
predominantly on the overhangs

§ Recommendation
§ Open the end covers and clean end windings. No immediate need of overhaul with
rotor removal

§ Benefits
§ Optimized maintenance planning

© ABB Group
October 25, 2018 | Slide 17
ABB LEAP case study
Insulation wear

§ 725 KW, 6.6KV, 990 rpm

§ Sector
§ Petrochemical industry
§ Purpose of test:
§ Routine shutdown checks
§ Results
§ Performed ABB LEAP Standard
§ Evidence of slot PD recorded from PD pattern
§ Key findings
§ Substantial erosion of corona protection field indicated
§ Recommendation
§ Customer advised to open the machine and re-impregnate the
windings with resin
§ Benefits
§ Life extension

© ABB Group
October 25, 2018 | Slide 18
ABB LEAP case study
Lifetime optimization
LIFE ESTIMATION

78

76

74
Equivalent
Operating
Hours at
Intersecting
• 400 MW, 23KV, 2 pole generator
St ress/Tensile Strength (MPa)

Present Points
Equivalent

Sector
72
Operating

70

68
Hours

•
66
Remaining Life (118387 eq. hrs)

64

62
1 60
167413
170 180 190
Stress Developed (9240 psi or 63.66 MPa)

20 0 2 10 220 230 240 25 0 2 60 270

285800
280 29 0 3 00
• Power plant
Equivalent Operat ing Hours ( x 1000 )

• Purpose of test:
• To validate health condition since machine is in operation for 20
years
• Results
• Performed LEAP Premium
• Tests done:
• LEAP Standard
• Wedge deflection
• Bump test
§ Key findings
§ Looseness in wedges and end windings
§ Recommendation
§ Customer advised to do re-wedging and implement new tie ups
between coil and support structure.
§ Benefits
§ Life extension

© ABB Group
October 25, 2018 | Slide 19