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DESCRIPTION
maintenance of hydro power plant.
Citation preview
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MAINTENANCE PRACTICES
&
FEEDBACK
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COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM
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FEATURES
EQUIPMENT MANAGEMENTWORK MANAGEMENTBREAKDOWN MAINTENANCEPREVENTIVE
MAINTENANCEPREDICTIVE MAINTENANCEOVERALL EQUIPMENT
EFFECTIVENESSDOCUMENT MANAGEMENTMIS REPORTSPROJECT
MANAGEMENTEXECUTIVE INFORMATION SYSTEMCALIBRATION & TOOLS
MANAGEMENT SYSTEMINSPECTION MANAGEMENT SYSTEMKNOWLEDGE BASED
SYSTEMFAILURE ANALYSISMATERIAL MANAGEMENT SYSTEMPROCESS AUTOMATION
INTEGRATIONINTEGRATION WITH MOBILE DEVICES
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DATABASE CREATION
ANNUAL MAINTENANCE DATATEST / MEASUREMENT VALUES
DISSOLVED GAS ANALYSIS
VIBRATION ANALYSIS
TEMPERATURE TRENDING ETC.,
HISTORY SHEETS BREAKDOWNREPORTS RESTORATION & ANALYSIS
REPORTSINVENTORYSPARES SEGREGATION
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REPORTING A FAILURE
ACKNOWLEDGE ALL ALARMSRECORD ALARMS AND RESETANALYZE & LOCATE
FAULTINFORM RLDC ABOUT FAULT & CHANGE SCHEDULETAKE IR VALUE OF
SUSPECTED EQUIPMENT (GEN, MOTOR)SYNCHRONIZE IF NORMALELSE CALL
MAINTENANCE DIVISIONPREPARE TRIP REPORT AFTER RECTIFICATION PREPARE
RESTORATION & ANALYSIS REPORTPREPARE HISTORY REPORT FOR
RECORD
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DISTURBANCE RECORDER
DR IS A TOOL FOR ANALYZING PERFORMANCE OF POWER SYSTEM AND RELATED
EQUIPMENT DURING AND AFTER MAJOR DISTURBANCES.RECORDING OF
MONITORED INPUT IS INITIATED BY A POWER SYSTEM DISTURBANCE E.G. A
RELAY PROTECTION TRIP.
Pre fault recording time=0.02-0.98s in steps of 0.02s
Post fault recording time = 0.1-5s in steps of 0.1 s
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BLOCK TRANSFORMER FAILURE
URI POWER STATION,
U-PH OF UNIT-3 ON 04/06/99
ALARMS:
BLOCK OVERALL DIFFERENTIAL TRIPPEDBUCHHOLTZ TRIPPEDNEGATIVE
SEQUENCE STARTEDREVERSE POWER RELAY START
REASONS:
INTERTURN SHORT CIRCUIT IN HV WINDING
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EVENT LOGGER PRINTOUT
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DISTURBANCE RECORDER PRINT OUT
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DIAGRAM TO HELP ANALYSIS OF INTERTURN FAULT
a2
a1
b2
b1
c2
c1
C1
C2
B1
B2
A1
A2
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ANALYSIS
Ratio test shows 1 or 2 % of turns of HV winding short circuited.No
big change in line current of U-ph as compared to other phasesPeak
value of current before CB trip
U-ph:7273 A
V-ph:7162 A
W-ph:7537 A
shows negative sequence protection start.
Reverse power start
- DAILY MAINTENANCE SHEETUNIT No. GENERATOR1.Stator & Rotor
ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not
ok)Sound and odour inside barrelVibration LevelCondensation on
pipes and coolers in barrelLeakage from water pipelines ,coolers
etcReverse water flow2.BEARINGSThrust Bearing oil levelUGB oil
levelLGB oil levelCooling water flow to bearings3.EXCITATION
SYSTEMIndicationsExcitor cooling fan operationCarbon brush
-sparking/chattering etc.4.UAT &UCBAbnormal noise and
odourIndications
- DAILY MAINTENANCE SHEETGENERATOR1.Stator & Rotor
ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not
ok)5.TEMPERATURE ANALYSIS (PAST 24 HRS.)Stator windingStator
coreThrust Bearing oil Thrust Bearing metalUpper Guide bearing
oilUpper Guide bearing metalLower Guide bearing oilLower Guide
bearing metalField temperatureExcitation transformer6 BRAKE,
JACK,HP LUBRICATIONIndicationsBrake pressure in the panelOil/air
leakageHP pump operation during start stop
- FORT NIGHTLY MAINTENANCE SHEET ACTIVITYOKNOT OKTYPE OF FAULT
(If not ok)ACTION TAKEN (If not ok)FIRE FIGHTING SYSTEMAIR
COMPRESSOR AUTOMATIC START/STOP AND RUNNING TESTAUTOMATIC DELUGE
VALVES ALARM AND TRIPPING TEST (TRANSFORMERS, CVT ZONES AND, SHUNT
REACTORS)ILLUMINATIONCHECKING OF ILLUMINATION AND REPLACEMENT
WHEREVER NECESSARY
- MONTHLY MAINTENANCE SHEETGENERATORUnit No1.Stator & Rotor
ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not
ok)THE EXTERNAL PARTS-FRAME,JOINTS,RADIAL SUPPORT OF THE
STATORWORKING OF RTD AND TSDCHECK FOR EXCESSIVE AMOUNT OF CARBON
DEBRIS\CONTAINMANTAIR PASSAGE IN STATORCLEAN/REPLACE AIR
FILTERSWORKING OF BARREL HEATERSOVERHANG PORTION OF STATOR
WINDINGSTATOR FOUNDATION AND CRACKS IN CIVIL STRUCTURECONDITION OF
THE WINDINGSTRIPPING& ALARM CONTACTS FOR PROPER FOCTIONINGCLEAN
THE BRAKING RINGVISUAL INSPECTION OF ROTOR FASTENERS & OTHER
PATRSCONDITION OF THE WINDING2.BEARINGSFUCTIONING OF
THERMOSIGNALLING & TEMPERATURE MEASURING DEVICEREPLACEMENT OF
HP OIL FILTEROIL LEVEL
- MONTHLY MAINTENANCE SHEETGENERATOR1.Stator & Rotor
ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not
ok)3.EXCITATION SYSTEMCLEAN EXCITATION
SYSTEM,COMMUTATOR,SLIPRING,BRUSHES,BRUSH BOXCHECK LENGTH OF THE
BRUSHESCHECK AND TIGHT ALL CONECTIONS IN FIELD BREAKER
CUBICLESCHECK THYRISTER RECTIFIER OPERATIONCLEAN INLET AIR
FILTERCHECK OPERATION OF COOLING FAN4 BRAKE, JACK,HP
LUBRICATIONINSPECT BRAKE AND JACK FOR ANY ABNORMALITYOPERATION OF
AC/DC HP LUBRICATION PUMPCLEAN THE BRAKES/LINERS ETC TO REMOVE
TRACES OF OIL ETCCLEAN HP OIL FILTER/STRAINER
- QUARTERLY MAINTENANCE SHEET ACTIVITYOKNOT OKTYPE OF FAULT (If
not ok)ACTION TAKEN (If not ok)GENERATORFILTERATION AND
CENTRIFUGING OF UPPER GUIDE BEARING OILFILTERATION AND CENTRIFUGING
OF COMBINATION BEARING OIL
- HALF YEARLY MAINTENANCE SHEETUNIT-NO-GENERATOR ACTIVITYOKNOT
OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)CHECK COLLECTOR
RING HOUSING AIR FILTERS FOR CLEANLINESSCLEAN THE COLLECTOR AND
COLLECTOR INSULATORCHECK THAT HIGH/LOW LEVEL SWITCHES OF ALL THE
BEARINGS ARE WORKING PROPERLY.CHECK THE STATOR AND FRAME FOR
TIGHTNESS OF BOLTS AND NUTS
- ANNUAL MAINTENANCE SHEETUnit No.GENERATOR ACTIVITYOKNOT OKTYPE
OF FAULT (If not ok)ACTION TAKEN (If not ok)STATOR INSPECT WINDINGS
THOROUGHLY CHECK a)STATOR WINDING BOLTSb) STATOR STAMPINGS HOLDING
DOWN BOLTS c) VENTILATING DUCTSd) SLOTS , SLOT WEDGES & PAINT
CHECK AIR GAP BETWEEN STATOR & ROTOR. CHECK FOR ANY DAMAGED
INSULATION . CLEAN GENERATOR HOUSING. CLEAN OVERHANG PORTION OF
WINDINGS. CHECK STATIC STATOR VIBRATION CHECK FOR
OVERHEATING/TIGHTNESS AND CLEAN a) Y POINTSb) MAIN CT TERMINALS c)
MAIN & NEUTRAL CONNECTIONS OF STATORd) NEUTRAL GROUNDING
TRANSFORMER CHECK IR VALUE OF WINDINGS CHECK DC RESISTANCE OF
WINDINGS CHECK TRIPPING AND ALARM CONTACTS CHECK EARTHING OF STATOR
BODY.
- ANNUAL MAINTENANCE SHEETUnit No.GENERATOR ACTIVITYOKNOT OKTYPE
OF FAULT (If not ok)ACTION TAKEN (If not ok)ROTORCHECK/CLEAN/PAINT(
WITH WELDING TACKS)a) POLE CONNECTIONS b) JOINTS/FIXING OF ROTOR
ARMS,PINS,BOLTS,NUTSc) SPIDER RIM KEYSd) TOP AND BOTTOM FAN
BLADESe) TOP AND BOTTOM POLE DAMPERSf) BRAKE TRACKg) ROTOR STAMPING
HOLDING DOWN BOLTS/DOWELSh) VENTILATING SPACE AND COIL SURFACESi)
FIXING AND LOCATION OF JOINTS OF AIR BAFFLES.j) POLE WINDINGS FOR
TIGHTNESS.k) ROTOR & ROTOR POLES l) POLE WEDGES, POLE KEYS
& KEY RETAINER.CHECK IR OF ROTOR WINDING INCLUDING CURRENT
CARRYING LEADSCHECK DC RESISTANCE CHECK CONNECTIONS FROM ROTOR TO
SLIP RINGS.CHECK SPLASH GUARD CLEARANCESMEASURE VOLTAGE DROP PER
POLE.MEASURE THE HEIGHT OF WEDGES AT BOTH ENDS OF UGB & LGB
PADS.CHECK & TIGHTEN/LOCKING OF BOLTS OF ALL BEARINGS. CHECK
DAMPER WINDING FOR LOOSE,BROKEN BARSCHECK ROTOR LEVEL
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THANKS
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EQUIPMENT MANAGEMENT
Hierarchical structure of equipmentGraphical representation of
entire facilityAttachment of OEM & Safety doc. With
equipmentDefining specifications, properties, technical
requirement, failure code & characteristics of equipmentEasy
retrieval of equipment informationDefines spare part of the
equipmentDefine measurement point & parameter for condition
monitoring
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WORK MANAGEMENT
Generate work order for maintenance jobStandardise work
procedureMaintain resource required for taskTrack claims &
warrantiesProvides technical doc, drawing with work order
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OVERALL EQUIPMENT EFFECTIVENESS
ANALYSIS OF SYSTEM WITH THE FOLLOWING PARAMETER:
AVAILABILITY
PERFORMANCE
TOTAL RUNNING TIME
INTERNAL & EXTERNAL STOPPAGE TIME
FAILURE TIME
TOTAL PRODUCTION
MTTR & MTBF
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PROJECT MANAGEMENT
Organize project, subproject, and work order structure with
unlimited complexityEstimate labor costsReserve and requisition
materials, tools, equipment, and other resourcesCreate a master
work order templateGenerate purchase orders based on projectsPlan
for shutdown
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EXECUTIVE INFORMATION SYSTEM
THE BUILT IN KEY PERFORMANCE INDICATORS FOR ASSESSMENT OF
PERFORMANCE OF THE MAINTENANCE SYSTEM. FUNCTIONALITY OF BALANCE
SCORECARD TO ANALYZE THE PERFORMANCE OF OPERATION AND MAINTENANCE
SYSTEM BOTH FROM FINANCIAL AND NON-FINANCIAL PERSPECTIVE.