Response Planning and Machine Implementation of Emergency - PDF document

1 Response Planning and Machine Implementation of Emergency Diagnostics. Ken Bailey April 2005

Agenda Background to Emergency Response Planning Unit Disaster Recovery and the Concept of Emergency Response Planning Use of generator diagnostics to identify and monitor risks Practical implementation of Emergency Response Planning 2

Agenda Background to Emergency Response Planning Unit Disaster Recovery and the Concept of Emergency Response Planning Use of generator diagnostics to identify and monitor risks Practical implementation of Emergency Response Planning 3

UK thermal capacity by age (by Prime Mover Group) 6,000 NUCLEAR 5,500 STEAM 5,000 Installed Capacity (MW) 4,500 COMB CYC 4,000 COG GAS TURB 3,500 (combustion) 3,000 GAS TURB 2,500 (OCGT) 2,000 1,500 1,000 500 0 2 4 6 8 10 13 16 18 20 22 24 26 28 30 32 34 36 40 42 46 49 54 Years Old (as at Aug 2001) 99% of Steam and 90% of Nuclear Capacity in the UK is 10 years or older 91% of Steam and 42% of Nuclear Capacity in the UK is 20 years or older 69% of Steam and 23% of Nuclear Capacity in the UK is 30 years 4 or older

Generator ages graph Air Cooled <60MW 1794 Units Air Cooled >60MW 1145 Units 1000 1000 900 AIR <60MW 900 AIR <60MW 800 800 >20 year >20 year Volume (Units) Volume (Units) 700 700 10-20 year 10-20 year 600 600 <10 year <10 year 500 500 400 400 300 300 200 200 100 100 0 0 Mannheim Mannheim Baden Charleroi Baden Essen Charleroi Belfort Essen Sesto Belfort Stafford Sesto Stafford Vasteras Wroclaw Vasteras Wroclaw H2/H20 <500MW 845 Units H2/H20 >500MW 309 Units 200 400 180 H2/H2O <500MW H2/H2O >500MW 350 Volume (Units) 160 >20 year Volume (Units) >20 year 300 140 10-20 year 10-20 year 250 120 <10 year <10 year 200 100 80 150 60 100 40 50 20 0 0 Mannheim Baden Belfort Essen Charleroi Sesto Stafford Vasteras Wroclaw Mannheim Baden Essen Charleroi Belfort Stafford Vasteras Sesto Wroclaw 5

6 General cost distribution for Power Industry

7 The Industry Trend

Ageing plant & deregulation - The effects � Aging factor � 55% of coal-fired thermal plant has approached or passed theoretical design life. � Cost cutting factor. � Deregulation, price regulation, demand changes, bottom line profit, has squeezed power plant owners to fixed overheads and maintenance budget cuts. � Change in plant operating demands � Plant flexibility - particularly responsiveness, start-up / shutdown rates and loading curves pushed to design limits and beyond. � Loss in expertise 8 � Engineering gap, reduction of essential staff.

Operational effect � What does this mean? � Running older machines with higher demands and more constraints. � Demands: Reliability, Availability, Higher performance, Efficiency improvement, more flexible running regimes all to increase profit margins. � Constraints: Lower maintenance budgets, Minimum spare holdings, shortages of experienced staff, Shorter outages with longer time between outages. 9

Operational effect How does this affect the Power industry Operator? � To survive in a competitive market the power operator needs to be able to adapt to the constant demands and changes in the market place. � This means taking higher risks more often. � But the key word is risk. Risk can be minimized or reduced but not eliminated. Failures will occur. � Targeted 90 / 7 / 3 concept. – i.e world class stations still have unplanned outages. � To minimize the effect of failure and down time you need to be proactive to handle the situation. THIS LEADS TO ERP (EMERGENCY RESPONSE PLANNING) 10

Agenda Background to Emergency Response Planning Unit Disaster Recovery and the Concept of Emergency Response Planning Use of generator diagnostics to identify and monitor risks Practical implementation of Emergency Response Planning 11

What is Unit Disaster Recovery ? � Loss mitigation of an unplanned outage following a minor/major component failure. – Requiring/causing an unplanned outage, – Potential for significant time duration for repair, with spares supply. – Resulting in high unavailability and substantial loss of revenues. 12

Typical Categorisation of Events � Catastrophic Event – Usually results in the requirement to rebuild, or replace the machine. – Eg Cracked generator rotor shaft. � Major Event – Requires the unit to be dismantled resulting in substantial repair time and loss of revenue. – Eg Stator earth fault, rotor earth fault. � Minor Event – Can be repaired in a short duration but requires the unit to be brought off- line. 13 – Hydrogen leak, gas-into-water leak.

Outline of an Emergency Response Plan � Due to aging,demands and constrains. – It is highly likely that some machines will fail during their remaining life. � ERP in its simplest form is a “what if” scenario that considers failure conditions tailored to individual machines & their condition – Team approach to developing effective and detailed plans covering a variety of scenarios. � Generator stator, rotor & exciter failure scenarios proposed based on ALSTOM’s fleet experience – Each failure condition pre-planned and risk assessment performed. – Programmes agreed jointly between OEM and customer. – OEM & Customer resources identified. 14

Emergency Response Plan – The “what if” programme, tailored to individual machine ranges and generic maintenance issues generates all repair requirements . • Specialist equipment and tooling identified – QA planning, process specifications and risk assessments are produced • Identified from the detailed planning process. – Contract and consumable spares for failures with high risk are held on site. • List of local suppliers identified & maintained – Drawing packs are identified and available within the local centre for every volume of the ERP. • With each set of drawings a full set of parts lists. 15

Stages of Emergency Response Planning � Consultation phase – To execute an ERP properly, it is essential to understand the operating regime, and condition of the existing plant. � Risk assessment of plant – Identifies through analysis of operating history, the major risk areas of the machine. � Failure scenario identification – From the risk assessment the key failure scenarios can be tailored to suit individual machines � Assessment of operator’s spares holdings – Identifies which spares are held in order to support the execution of the ERP process. 16

Structure of ERP Documentation Part 1 � Consists of tailored flow charts, decision points, communication channels & commercial arrangements – Simple but effective procedure to allow rapid identification of fault type, who to contact, & support arrangements in place. � Typical ERP contains seven sections – Section 1. Master Process Flow Diagram – Section 2. First Actions in Customer – Section 3. First Actions in ALSTOM – Section 4. ERP Project Organisation – Section 5. Communication Channels – Section 6. Commercial Arrangements – Section 7. Further Issues 17

Structure of ERP Documentation Part 2 � Consists of several volumes representing individual failure scenarios. � Typical volume is split into ten sections – Section 1. Failure Identification – Section 2. Failure Recovery Location – Section 3. Failure Recovery Process – Section 4. Recovery Programme – Section 5. Documentation – Section 6. Parts List – Section 7. Consumables – Section 8. Tooling – Section 9. Resource Schedule – Section 10. Recommendations 18

Structure of ERP Documentation Part 2 Part 2 Stator Failure Modes 1.1.01 Earth Fault Bottom Coil Slot Section 1.1.02 Earth Fault Bottom Coil Overhang Section 1.1.03 Earth Fault Top Coil Slot Section 1.1.04 Earth Fault Top Coil Overhang Section 1.1.05 Flash Over Between Phases 1.1.06 Core Damage Object Going Through Air Gap 1.1.07 Severe Fretting of Overhang Insulation 1.1.08 Gas \ Water Leak through Water Box Joint 1.1.09 Gas \ Water Leak through "Worm Hole“ 1.1.10 Gas \ Water Leak through PTFE Fitting 1.1.11 Gas \ Water Leak through Ring or Ferrule 1.1.12 Coil Damage through Blocked Tubes 1.1.13 Phase Ring Insulation Failure 1.1.14 Phase Connection to Terminal Failure 1.1.15 Manifold Support or Bellows Failure 1.1.16 Cooler Leaks 1.1.17 H2 Seal Failure 1.1.18 Damaged Windings during Removal/Assembly 1.1.19 Line and Neutral Bushings Failure 1.1.20 Large Number Wedges Loose Typical Generator Stator Failure Scenarios 19

ERP Documentation Part 2 Part 2 Rotor Failure Modes 1.2.01 Earth Fault in the Rotor Slot 1.2.02 Earth Fault to the Retaining Rings 1.2.03 Inter Turn Fault in the Slot Section 1.2.04 Inter Turn Fault in the Overhang Section 1.2.05 Damaged Cross Overs & Pole to Pole Conn 1.2.06 Cracked Retaining Rings 1.2.07 Stalk, FL Wedge or Flex Conn Failure 1.2.08 Damaged Shaft Comp, Fan Blade Failure 1.2.09 Damper Wedges Damage Exciter Failure Modes 1.3.01 Rotor Winding Earth Fault 1.3.02 Rotor Winding Connection Failures 1.3.03 Diode Failures 1.3.04 Stalk Connection Failures 1.3.05 Main Stator Pole Winding Earth Fault 1.3.06 Main Stator Pole Inter Turn Failures 1.3.07 PMG Stator/Rotor Damage Failure 1.3.08 Air Cooler Damage 20