ENERGI ES

LAVERA
6FA Generator MO and Transformer depolarization
6FA Generator Major Overhaul and Transformer
Depolarization - Lavera Energies
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Equipment :
2 turbines GE frame 6 FA/6B 109 MW elec
2 HSRG with post combustion, output steam flow
power 240t/h at 80 bars
Cogeneration - Lavra Energies
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
6FA Generator identity card
Constructor : Alsthom
Power : 68,9 MVA
Voltage : 11,5 kV,
Speed 3 000 tr/h,
52 300 FFH in 2011
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Generator MO strategy
Diversity in approach and practice in use internationally :
Source : Generator maintenance inspection and test programmes, working group
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Lavera Generator MO strategy
Decision to achieve the MO instead of the good results
of the generator in-service diagnostic testing :
10 years of operation
52,3 kh
Opportunity to shutdown (planned turbine maintenance)
Scope
MO scope is based on the AEW proposal (standard one)
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Extraworks
The bearings generator side and gear box side are damaged :
High temperature impacts, one hole detected
For both bearings clearance out of range
Replacement of the bearings and several bolts
Clearance adjusted to 0,6 mm on the base of the new calculation
Rotor alignment between load gear and the generator on the base of the
new clearance value.
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Extraworks
The slot wedges are moving excessively :
Risks of damages to the rotor windings
Vibration risks during the start up
AEW and Alsthom advice to remove retaining rings and
resize the slot wedges
So the rotor balancing becomes necessary
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Extraworks
High pollution at the windings surface above the
retaining rings :
dry cleaning
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Some global figures
Cost
MO order : 128 k
Scaffolding for the rotor 12 k
Exciter maintenance 18 k
CSF maintenance 8 k
Craning 8 k
Retaining rings removal/balancing 76 k
Miscellaneous 10 k
TOTAL 260 k
Planning
Base : 6 weeks
Extraworks 6 weeks
TOTAL 12 weeks
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Extent of problem transformer depolarization
The report of the working group A2-32, Copper Sulphide in
Transformer Insulation describes the issue
The problem of copper sulphide in transformer insulation is quite
old. However, it is only in the last 15 years that it has gotten very
much attention,
No one has a really good grasp of the extent of the problem.
Estimates vary, but we can estimate the number of sulphide-
related failures are in the range 50 to 100.
Transformers from several different manufacturers have been
involved, and also several different suppliers of oil.
The connection with corrosive sulphur in oils implemented 10-15
years before became evident.
There is a correlation between e.g.high disulphide contents in
general (and DBDS content in particular) and the formation of
copper sulphide. This is complex, and far from well understood
today.
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Extent of problem transformer depolarization
Copper sulphide is a semiconductor. It will normally not be good
to have such a substance in the insulation. But the presence of
copper sulphide will not necessarily lead to failure. It will surely
depend on the amount, as well as the location.
It seems that basically we have 2 main routes:
1 Progressively lowered insulation withstand as copper sulphide
penetrates the insulation. The paper get more or less
impregnated. In the end it is not insulation any more.
2. However, it may not always be necessary to have very large
amounts of sulphide or failures to occur.
There may be other failure modes as well. Failures often destroy
the evidence , leaving the field open for speculation
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Extent of problem transformer depolarization
The approach is to use chemical analysis, to detect the presence
of potentially harmful sulphur species.
Some are known to be relevant, such as DBDS content, or total
disulphide content.
The important thing to know, is that such tests may not in
themselves be enough for assessing if an oil is potentially
harmful or not.
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Mitigation technique
Four techniques exist :
additives
Oil treatment (for example depolarization)
Oil exchange
Modified operating conditions
The selective depolarization process is used in Italy and France
since summer 2005, to remove DDBS and reduce corrosiveness.
We applied this technology to treat the Lavera transformer.
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Depolarization task
Contractual points :
Dalkia started the specific audit / campaign since 2007 for all transformers
The contractual points / warranty are defined via specific global contract
13 days off-load treatment maximum
50 k cost
DDBS concentration at the end < 10 mg/kg
DDBS concentration after 6 months < 10 mg/kg. In case of deviation, the
supplier will achieve the additional treatment free of charge
Historic :
56,7 mg/kg DDBS before and 9 mg/kg after the depolarization
31 mg/kg after 6 months (additional depolarization implemented)
Now its OK since 12 months
Leaks on the transformer seal during the start-up,
Immediate seals replacement
3 months later the preventive thermograph control discovered the hot
point on the transformer connections (154 C instead of 45C)
Decision to stop the machine (5h)
Connection cleaning, bolt replacement
Proper bolt and nut torque process
Start up and new thermograph control => OK
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Thermograph report
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Hot spot on the connections
ENERGI ES
LAVERA
6FA Generator MO and Transformer depolarization
Thank you for your attention