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generator assessment process generator assessment process generator assessment process generator assessment process
a solution to life assessment of large generators
omsaiempl@gmail.com anilscoob@gmail.com
GAP GAP GAP GAP
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GAP GAP GAP GAP
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GAP GAP GAP GAP
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GAP GAP GAP GAP
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GAP GAP GAP GAP
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GAP GAP GAP GAP
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GAP GAP GAP GAP
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is the diagnostic approach to
assess the residual life of the generator
Methodology Methodology Methodology Methodology
The methodology employed is
conducting standard and special
electrical tests on stator and rotor
windings and accessories
Unit Unit Unit Unit Condition Condition Condition Condition
The generator is in assembled condition
with power cables disconnected
Inspection Inspection Inspection Inspection & && & tests tests tests tests Performed Performed Performed Performed
Diagnostic test
Insulation test
Polarization index
Capacitance and tan delta test
AC current test
Partial discharge test
Benefits Benefits Benefits Benefits
Reveals pending faults in winding
Reveals deterioration of coil insulation by corona or end
winding vibration
Access life and future maintenance requirements
Preventive maintenance plan
Schedule for GAP
1 11 1
, GAP
3 33 3
and GAP
4 44 4
Schedule for GAP
1 11 1
, GAP
3 33 3
and GAP
4 44 4
Final Final Final Final Report Report Report Report
Standardized format in electronic form
Photographs of critical areas
Residual breakdown strength
Remaining life
Analysis and recommendation
Expected Expected Expected Expected Downtime Downtime Downtime Downtime
1-2 days
Option Option Option Option
Life Assessment
Diagnostic Tests
Consumed Life
Insulation Deterioration
Thermal Stress
Electrical Stress
Thermal Cycle Stress
Operational
History
Establishment
of Residual
BDV
Life Estimation
with Operational
History
Life Estimation
with Diagnostic
Tests
Residual Life
Insulation deterioration
Residual Years to 2E+1 KV
Deduced Assessment
Preventive Maintenance
Program
BDV
Future
Operation
Pattern
Visual
Inspection
Overhaul or
Rewind
Diagnostic
Tests
Life Assessment
D-map Method
Based on the results of Diagnostic Test, the residual
life of stator winding insulation system is derived.
The international standard IEC 60216-2 defines the
end point to be 50% voltage value of the initial
breakdown voltage. The reason why 50% is defined
as the end point Is that the insulation deterioration
accelerates at the final stage of life as shown in the
classic Bathtub Curve. classic Bathtub Curve.
Based on experiments and experiences, the end
point is defined to be 40% of the breakdown voltage.
However, it is recommended to plan for stator
winding when the estimated breakdown voltage is
4050 % of initial breakdown voltage.
Diagnostic Tests
V
r
f (tan, I, Q
max
)
V
r
= Residual breakdown strength (%)
tan = Deviation of tan from lower to higher
voltage
I = Rate of increase of ac current
Q
max
= Maximum partial discharge
50
60
70
80
90
100
R
e
s
i
d
u
a
l

B
r
e
a
k
d
o
w
n

s
t
r
e
n
g
t
h

(
%
)
Life Estimation by D-Map Method
Residual Breakdown Strength
IEC Breakdown Strength
Breakdown Strength
Present Life
Life Estimation
0
10
20
30
40
50
0 5 10 15 20 25 30 35 40 45
R
e
s
i
d
u
a
l

B
r
e
a
k
d
o
w
n

s
t
r
e
n
g
t
h

(
%
)
Operating Years
10 9 8 7 6
5
4 3 2
1
Life Index
10 9 8 7 6
5
4 3 2
1
Life Assessment
B-map Method
Life Assessment by B-method is derived from the breakdown
voltage of the insulation system.
The insulation voltage level that is required for safe operation
of the generator in the case that a surge arrester is equipped
for suppressing lightening surges is [2E+1] KV
The insulation voltage level that is required when the ground
fault is happened around the generator terminals is [1.5E] KV fault is happened around the generator terminals is [1.5E] KV
30
40
50
60
70
B
r
e
a
k
d
o
w
n

V
o
l
t
a
g
e

(
K
V
)
Life Estimation by B-Method
Voltage Level
(2E+1 KV)
required for
safety
operation in
considering
the incoming
lightening
surges
Voltage Level
(1.5E KV)
required for
safety
operation in
considering
the ground
fault on line
0
10
20
30
0 5 10 15 20 25 30 35 40
B
r
e
a
k
d
o
w
n

V
o
l
t
a
g
e

(
K
V
)
Operational years
Residual Breakdown Voltage 2E+1 KV
Residual Breakdowb Voltage 1.5E KV
present breakdown voltage
Breakdown Voltage Level 2E+1 KV
Breakdown Voltage Level 1.5E KV
10
12
14
16
18
20
D
i
s
c
h
a
r
g
e

P
a
r
a
m
e
t
e
r
s
Breakdown Voltage by D-Map Method
90%
80%
70%
60%
50%
40%
30%
Series8
0
2
4
6
8
10
1000 10000 100000 1000000
D
i
s
c
h
a
r
g
e

P
a
r
a
m
e
t
e
r
s
Maximum Discharge Magnitude
10 9 8 7 6
5
4 3 2
1
Life Index
10 9 8 7 6
5
4 3 2
1
Condition Assessment
Diagnostic Tests
Diagnostic Tests
Diagnostic Tests Assessment
IR > 2E+1 M
PI > 1.5
tan < 5.0%, 8.5%, 12.5% tan < 5.0%, 8.5%, 12.5%
I < 5.0%, 8.5%, 12.5%
Q
max
< 10,000 pC
Diagnostic Tests Assessment
IR 100 M
PI 1.5
tan 2.0% tan 2.0%
I 2.0%
Q
max
< 10,000 pC
Diagnostic Tests Assessment
IR 100 M
PI 1.5
tan 0.7%, 6.5% tan 0.7%, 6.5%
I 4.0%, 8.5%, 12.5%
Q
max
< 10,000 pC
Diagnostic Tests Assessment
IR 100 M @ 40
o
C
PI 2.00
tan 1.0 tan 1.0
I 1.0%
Q
max
< 10,000 pC
10 9 8 7 6
5
4 3 2
1
Health Index
10 9 8 7 6
5
4 3 2
1

THANK YOU
W^4I(4 4\4I5

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