Life Expectancy Analysis Program: For Electrical Machine Insulation

Cajetan Pinto, Global R&D Manager Machines Service, March 4, 2009
Life Expectancy Analysis Program

for Electrical Machine Insulation
ABB Group
October 29, 2009 | Slide 1
Presentation overview
ABB Group
Life Cycle Management Approach
Reliability and failure statistics
Planning your Strategy
LEAP Methodology & Use
LEAP Standard
Case Studies
Benefits
Life Cycle Concept
Optimized Maintenance Line
Value to
customer
through
maintenance
Continuous
Upgrading/
Replacement
Maintenance
Overhaul
Aging
Repair
Warranty Period
Upgrade and
Modernization Period
Maintenance Period
Customer Project Lifecycle
ABB Group
Replacement & Recycle Period
Time
Total cost of operation (TCO)*

TCO includes:
Purchase price
Specifications
Transportation
Storage
Installation
QA
Reliability
Electricity
Repairs
Administration
Inventory
etc
74 %
17.4 %
1%
2.7 %
4.9 %
Installation Purchase Cost of repair Reliability Electricity
* Information provided by MachineMonitor based on survey of 6000 machines

ABB Group
Basis of Analysis: Stress & Strength v/s Time
Strength
Stress, strength
Premature Failure
Transients
Stress
Residual Life
Time
ABB Group
Failure
Life Expectancy Analysis: Benefits

Strength
Condition assessment and taking

suitable actions at this point.
Adv. 1: No Premature Failure

Transients
Failure
Stress
Residual Life
ABB Group
Adv. 2: Increase in Life
Reliability
&
Failure Statistics
ABB Group
Failure statistics: IEEE Survey 1985-1987
Bearing
Winding
11%
5%
3%
6%
37%
Rotor
Shaft/coupling
5%
Brushes/slipring
33%
Detection during Normal operation
ABB Group
External devices
Not specified
Failure statistics : IEEE Survey 1985-1987
Bearing
4%
10%
Winding
7%
Rotor
Shaft/coupling
8%
2%
Brushes/slipring
8%
61%
Detection during maintenance or test
ABB Group
External devices
Not specified
Failure Statistics: HV Motors Petrochemical Industry

1999
Distribution of Failures for motors below 2000KW
Bearing
Stator Windings
14.60%
1.20%
Rotor- Bars/rings
2.80%
57.40%
Shaft or coupling
5.60%
External device
18.40%
Not Specified
Distribution of Failures for motors equal and above 2000KW

7.89
IEEE
transactions on
industry
applications .
vol. 35. no. 4.
july/august 1999
7.89 0.00
18.42
60.53
ABB Group
5.26
For Machines less than 2000 kW

anti-friction bearings are commonly
used which are more likely to fail
For Machines above 2000 kW

sleeve bearings are often used
which are less likely to fail
Factors affecting Failure rate

Total Failure Rate Vs Age
%wdg Failure Rate
7
6
5
4
%
3
2
1
0
3.5
3
2.5
2
%
1.5
1
0.5
0
0-5
5.1-10
10.1-15
15.1-20
20.1-25
3000-5000
25.1-
Age (Years)
6600-10500 1100013800
Voltage(Volts)
%wdg. Failure Rate
Wdg Failure Rate
1.4
1.2
1
0.8
%
0.6
0.4
0.2
0
2.5
2
Series1
1.5
1
Series1
0.5
0
6
Pole Number
ABB Group
6000
10
1 or less
More than 1
No of Starts/day
Stator winding failures
Other
14%
Persistent
Overloading
7%
High Ambient
Temperature
8%
Normal
deterioration with
age
18%
Abnormal Moisture
18%
Abnormal Voltage
5%
Abnormal
Frequency
1%
Poor Ventilation/
Cooling
8%
Aggressive
Poor Lubrication
chemicals
5%
7%
High Vibration
9%
FAILURE CONTRIBUTORS
ABB Group
Planning your maintenance STRATEGY
Protection
Condition
Monitoring
continuous, on-line,
action taken in real time
on-line, but not

necessarily continuous
to limit the damage or

prevent operation under
abnormal conditions
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
ABB Group
Life-time
Estimation
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
LEAP
LEAP not just a step ahead

What is LEAP?
LEAP is not just a package of

inspections; it is a systematic
approach to managing Machine
Maintenance
ABB Group
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
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
Advanced
When the machine is

stopped and partially
dismantled
Premium
When the machine is

stopped and rotor removed
90
Confidence Level
75
60
45
30
15
0
ABB Group
Basic
Standard
Advanced
Premium
Level Based Inspections

Solution
Levels
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
Standard
Advanced
Level
Condition Based Inspection and Maintenance

Plan
Condition Assessment of Stator Windings for
Standard Data Collection

Visual Inspection on end windings
Partial Discharge Probe measurements & Dynamic
Condition Assessment of Stator Windings with Standard
Stress analysis of End-windings
ABB Group
Life Expectancy Analysis 65% Confidence
Basic Data Collection

Polarization Depolarization Current Analysis PDCA
Tan Delta & capacitance Analysis
Non-Linear Insulation Behaviour Analysis
Partial Discharge Analysis
Mechanical Response of Windings
Premium
Deliverables
Packages
Advanced Data Collection

Wedge Tightness Map & Coupling resistance measurements
Visual inspection, including slot areas
Stress analysis of Windings
Contamination, ageing, looseness,

delamination, stress grading system
Level
Plan
Package + End-winding assessment

Level
Plan
Condition Assessment of Stator Windings with

Advanced Package + slot region assessment
Level
Plan
LEAP Methodology
&
Use of LEAP
ABB Group
LEAP methodology
Collection of Data
Operating data, test measurements and
machine information
Analysis of Data
ABB 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

Maintenance
Lifetime is estimated with different
Confidence levels depending on the LEAP
package
Possible further inspections, maintenance,
replacements or even upgrades are drawn
up
ABB Group
LEAP
Standard
ABB Group
LEAP Standard package

P o la r iz a tio n -D e p o la r iz a tio n C u r r e n ts
U PHASE
Pol-Depol Currents (microAmp)
100
DC Measurements
10
Polarization De-Polarization
Current Analysis
0 .1
1
10
100
1000
T im e (s e c )
C h a r g in g
D is c h a r g in g
TAN DELTA MEASUREMENTS
AC Measurements
4.00
3.50
Non Linear Behavior Analysis
Tan and Capacitance Analysis
Tan Delta (%)
3.00
2.50
2.00
1.50
1.00
0.50
1
Voltage (kV)
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
ABB Group
DC measurements
Polarization-Depolarization Currents
UVW PHASE
Q1, Q2
Q3
Pol-D epol C urrents (m icroA m p)
100
10
0.1
0.01
1
10
100
Time (sec)
Charging
Remark:
Conventional IR
& PI
Measurements
may have
satisfactory
values even
with highly
contaminated
windings
ABB Group
Discharging
1000
Parameters
Derived
Time constants
T1, T2, T3
Charge storage
: Q1, Q2, Q3
Ageing Factor
Dispersion
Ratio
(1+Q1+Q2+Q3)
Volume
Resistivity
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.
AC measurements
CAPACITANCE (Arbitrary Units)
INSTANTANEOUS CAPACITANCE VARIATIONS

@ 5.8 kV
110
65
20
-25
-70
40
42
44
46
48
50
52
54
56
58
TIME (msecs)
U - PHASE
V - PHASE
W - PHASE
UVW - PHASE
Non Linear Behavior Analysis, Tan and Capacitance Analysis,

Remarks:
Conventional
measurement
interpretation
is generally
based on
trends
ABB Group
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
60
LEAP
from the Case Book
ABB Group
Contamination indicated by LEAP
IR >>1000
M
PI >> 2
ABB Group
Contamination indicated by LEAP
ABB Group
Slot discharge / wear detected by LEAP
ABB Group
Surface discharge detected by LEAP
ABB Group
Case study 1: LEAP Maintenance Planning

11MW 11kV 1500 RPM, Synchronous
Motor (Air Separation problem)
Purpose of Testing: The motor was in
operation for 69,000 hours with no outage. LEAP
Standard carried out to determine the need for L3 or
L4 Maintenance. On-line pd alarm had appeared.
Results - PDCA Test

IR- 2310 Meg ohm
PI- 2.02
Q1(%) 9.63
Q2 (%) 11.30
Key Findings:
LEAP Standard indicated presence
of oil/carbonized contaminants
predominantly on the overhangs
Q3 (%) 44.54
DR 1.65
AgF 60.12
Vol Res 1013.78 Ohm-m
Recommendation:
Open the end covers and clean end windings (L3). No immediate need of
overhaul with rotor removal (L4)
Benefits: Optimized Maintenance Planning

ABB Group
Case Study 3: LEAP Maintenance Verification

6034 HP, 6 kV, 502A, 1481rpm
RESULTS - PDCA TEST

Before Overhauling
IR - 2205 Mohm
PI - 4.79
Q1 78.68 %
Q1, Q2
Q2 65.49 %
Q3 128.56 %
Q3
DR 3.73
After Overhauling
IR - 32464 Mohm
PI 5.63
Q1 7.84 %
Q2 8.84 %
Q3 8.86 %
DR 1.25
ABB Group
LEAP Usage
ABB Group
LEAP for Maintenance Planning
LEAP for L1, L2, L3, L4 inspection
LEAP for Run/Replace/Retrofit

Decisions
Measurements and Analysis are to be

done at a single occasion (L4) with
additional assessment of other
components besides the stator windings
LEAP for Life Extension/ Upgrade

Decisions
Stress/Strength
Life Improvement
Strength
Developed Stress
Years
Improvement in
life by restoring
strength droop
Improvement in life by
upgrading machine
ABB Group
Stress/Strength
Life Improvement
Strength
Developed Stress
restoring original stress
developed
LEAP for
Life Extension
ABB Group
Years
reducing stress through
redesign
LEAP How is it different?
ABB Group
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. ABBs 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 during L3 and L4

maintenance.
Can be related to time and integrated into a Maintenance Plan
Towards a New Dimension
ABB Group
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 other
computerized systems and
related to scheduling
actions
LEAP - Value for the Customer
ABB Group
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
ABB Group

Life Expectancy Analysis Program: For Electrical Machine Insulation

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Cajetan Pinto, Global R&D Manager Machines Service, March 4, 2009

Life Expectancy Analysis Program

Life Cycle Management Approach

Reliability and failure statistics

Planning your Strategy

LEAP Methodology & Use

Life Cycle Concept

Optimized Maintenance Line

Customer Project Lifecycle

Replacement & Recycle Period

Total cost of operation (TCO)*

Installation Purchase Cost of repair Reliability Electricity

* Information provided by MachineMonitor based on survey of 6000 machines

Basis of Analysis: Stress & Strength v/s Time

Life Expectancy Analysis: Benefits

Condition assessment and taking

Adv. 1: No Premature Failure

Adv. 2: Increase in Life

Failure statistics: IEEE Survey 1985-1987

Detection during Normal operation

Failure statistics : IEEE Survey 1985-1987

Detection during maintenance or test

Failure Statistics: HV Motors Petrochemical Industry

Distribution of Failures for motors equal and above 2000KW

For Machines less than 2000 kW

For Machines above 2000 kW

Factors affecting Failure rate

%wdg Failure Rate

%wdg. Failure Rate

Wdg Failure Rate

Stator winding failures

Planning your maintenance STRATEGY

on-line, but not

to limit the damage or

analysis and action is

MST, ARGUS, DLI, PD,

LEAP not just a step ahead

LEAP is not just a package of

Lifetime Expectancy Analysis Program or

LEAP provides information on Machine

LEAP developed by ABB Machines Service,

Measurements are performed by Local or

Level Based Inspections

When the machine is

Every 5% of the estimated lifetime

When the machine is

Every 10% of the estimated lifetime

When the machine is

Every 25% of the estimated lifetime

When the machine is

Every 50% of the estimated lifetime

Level Based Inspections

Data collection (on site or remote):

Starts/Stops, Temperature (Winding, Coolant and Ambient),

Condition Based Inspection and Maintenance

Condition Assessment of Stator Windings for

Standard Data Collection

Condition Assessment of Stator Windings with Standard

Stress analysis of End-windings

Life Expectancy Analysis 65% Confidence

Basic Data Collection

Mechanical Response of Windings

Advanced Data Collection