Вы находитесь на странице: 1из 20

IFEA Høstarrangement Borregaard 31.10.

2013, Motors and Generators Services

Maintenance for motors and generators


Why maintenance?

ƒ Maximize availability
ƒ Increase reliability
ƒ Extend lifetime
ƒ Minimize unplanned stops
ƒ Hold the high safety
standard
ƒ Protect the environment
ƒ Save the investment

© ABB Group
November 5, 2013 | Slide 2
Type of maintenance

ƒ Reactive maintenance
ƒ Failure or abnormal operation

ƒ Preventive time based maintenance


ƒ Time based maintenance

ƒ Based on manufacturer’s experience

ƒ Predictive / condition based maintenance


ƒ Maintenance based on actual measurements

© ABB Group
November 5, 2013 | Slide 3
Maintenance program

ƒ Four levels
ƒ L1 – L4

ƒ Interval
ƒ Depending on
motor/generator type
and application
ƒ Always check manual for
instructions and actions
ƒ Maintenance kits:
ƒ Parts to be on site for

the maintenance

L1 L2 L1 L3 L1 L2 L1 L4
Years 1 2 3 4 5 6 7 8
© ABB Group
November 5, 2013 | Slide 4
Maintenance program

Maintenance
levels L1 L2 L3 L4

Time based Per each motor and generator type.


intervals
Defined in user manual of each motor and generator.
0.5-1 year 1-2 year 3-5 year 8-12 year

Expected work 4-8 hours 8-16 hours 5 days 10 days


time

Manpower 1 service 1 service 2 service 2 service


needed engineer engineer engineers + engineers +
1 local 2 local
technicians technicians

© ABB Group
November 5, 2013 | Slide 5
Preventive maintenance
Equivalent operating hours

ƒ Equivalent operating hours = Actual operating hours + Number of


starts x 20h

H Eq. = H Op. + ( Starts × 20h)

ƒ Considers the thermodynamic and mechanical stresses


during starting
ƒ Factor 20h can be altogether too low for starting of
compressors with very high inertia

ƒ For VSD applications:

H Eq. = H Op. ×1.2

© ABB Group
November 5, 2013 | Slide 6
Predictive maintenance
Condition based

ƒ ABB provides services for Condition Based Maintenance (CBM)

ƒ CBM provides information on the time and scope of preventive


maintenance

ƒ Advantage of CBM
ƒ Optimized maintenance schedule and actions

ƒ Increased availability and productivity

ƒ Reduced direct and indirect costs

ƒ Condition monitoring tools used by ABB:


ƒ ABB LEAP

ƒ ABB MACHsense

© ABB Group
November 5, 2013 | Slide 7
Condition Based Maintenance
The tools

ƒ ABB LEAP
ƒ Identifies condition of stator winding insulation

ƒ Uses package of AC and DC measurements

ƒ Analysis of measured data to estimate remaining life of stator


windings
ƒ Applicable for HV motors and generators (above 3.3KV) of
any make

ABB MACHsense
ƒ Identifies condition of rotor, bearings, installation and power
supply
ƒ Makes vibration, current and voltage measurements

ƒ Uses custom made data collector for measurements

ƒ Applicable for any size and make of motor

ƒ MACHsense-R provides web based service

© ABB Group
November 5, 2013 | Slide 8
Maintenance for your motor or generator

ƒ The maintenance program is developed to meet the needs of each


motor and generator
ƒ Content, duration and required customer preparations for
maintenance varies by motor and generator type, size and
application
ƒ Motor and generator specific details described in motor/
generator manual

© ABB Group
November 5, 2013 | Slide 9
L1 Maintenance
Synchronous example

ƒ Visual inspection
ƒ Review and evaluation of
operating parameters
ƒ Voltage, current, load,
temperatures, vibrations
cooling condition
ƒ Check protection, trip and
alarm logs
ƒ Replace required consumables
ƒ Filters, oil, brushes etc.

ƒ Required parts:
ƒ Maintenance kit L1
ƒ Expected downtime:
ƒ Less than one day

© ABB Group
November 5, 2013 | Slide 10
L2 Maintenance
Synchronous example

Same as L1, plus:


ƒ Measurement and evaluation
of stator insulation resistance
ƒ Rotor and exciter if
applicable

ƒ Required parts:
ƒ Maintenance kit L2
ƒ Suggestions from
previous inspection
ƒ Expected downtime:
ƒ Less than two days

© ABB Group
November 5, 2013 | Slide 11
L3 Maintenance
Synchronous example

Same as L2, plus:


ƒ Detailed inspection of
opened bearings
ƒ Cleaning of coolers

ƒ Rotor inspection using fiber


optics

ƒ Required parts:
ƒ Maintenance kit L3
ƒ Suggestions from
previous inspection
ƒ Expected downtime:
ƒ Approx. 5 days

© ABB Group
November 5, 2013 | Slide 12
L4 Maintenance
Synchronous example

Same as L3, plus:


ƒ Rotor removal

ƒ Detailed inspection of stator


and free standing rotor
ƒ Diagnostic measurements

ƒ Required parts:
ƒ Maintenance kit L4
ƒ Suggestion from
previous inspection
ƒ Expected downtime:
ƒ Approx. 10 days

© ABB Group
November 5, 2013 | Slide 13
Maintenance kits

ƒ Consist of parts that should be replaced during the


maintenance
ƒ Based on experience and condition monitoring

ƒ Kits should allways be available on site in time for the


maintenance
ƒ Some parts may have significant delivery time

ƒ Parts available on site minimizes service downtime

© ABB Group
November 5, 2013 | Slide 14
Maintenance kits
Example

Each motor and


generator has
L1 L2 L3 L4
maintenance kits with
a defined content
Sleeve bearings

Bearing temperature sensors x

Bearing shells x

Oil rings x
Bearing seals and gaskets (not x x
aluminum)
Cooling system
Open
Air filters x x x x
Example of Excitation equipment, control and protection
preventive
maintenance kit
AVR unit and board x
content for an air Rectifier diode set x x
cooled AMG Varistor x x
generator with
standard AVR in Transformers
land application Voltage transformer x
Short circuit current transformers x
Actual value current transformer x
Stator current measurement
transformers x
Anti-condensation heater x

© ABB Group
November 5, 2013 | Slide 15
Certified and trained personnel

ƒ ABB maintenance is
performed by certified
engineers
ƒ Fully trained with vast
experience
ƒ Knowing the motors and
generators and knowing
what to look for
ƒ Safe and efficient
working practices
ƒ Minimized down time

© ABB Group
November 5, 2013 | Slide 16
Field service tools

ƒ ABB offers a range of special field service tools


ƒ Safer and more effective working practices

ƒ Enables on-site maintenance with no, or limited, lifting


capacity
ƒ Tailor made to site conditions and motor/generator
specific characteristics

© ABB Group
November 5, 2013 | Slide 17
Preventive maintenance report

Each ABB maintenance includes a comprehensive report


ƒ Summary with customer recommendations

ƒ All checks and measurements with status and


evaluation
ƒ Discovered irregularities and corrective action taken

© ABB Group
November 5, 2013 | Slide 18
Summary

ƒ There are several possible maintenance strategies


ƒ Reactive

ƒ Preventive time based

ƒ Predictive condition based

ƒ ABB offers services for all maintenance strategies

ƒ Maintenance program based on four levels; L1 - L4

© ABB Group
November 5, 2013 | Slide 19