Ge Mongolia Power Conversion Services

May 2013

Mungunshagai Enkhbold

GE Energy Management Power Conversion Services in Mongolia

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A Global Company

300,000+ employees worldwide

Manufacturing facilities in 40+ countries

Operations in over 100+ countries

Growing in key global markets

Eastern Europe

China Middle East

India

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Outline

• Who is GE

• What GE Energy Management do

• GE Power Conversion – Complete Solution offering

• GE Power Conversion Services

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• Energy

• Oil & Gas

• Power & Water

• Aviation

• Healthcare

• Transportation

• Aviation Financial Services

• Commercial Finance

• Energy Financial Services

• GE Money

• Treasury

• Businesses operating in more than 100 countries … 130 years

• Over 300,000 employees worldwide

• All of GE’s businesses have presence in China with over 50 legal entities and more than

13,000 employees.

GE’s Portfolio

Energy Infrastructure

Technology Infrastructure

GE Capital

• Appliances & Lighting

• Intelligent Platforms

Home & Business Solutions

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New & Refurbished Motors • Repair by Replace Option

Up Rating Motors • Increase HP capacity

Extended Warranty Opportunities • Two Year Warranty on General Service

• Five Year Warranty on Rewinds

• 10 Year Warranty with Maintenance Agreement

EMP or “Mini EMP Programs” • On-Site Full Time Motor Engineer

• Motor Management Program

• Long Term Service Agreements (LTSA)

• DDMS opportunities

On Site Rewinds • Large AC & DC

• GE 600 Applications

Field Services, Balancing, Alignment • On-site trouble shooting

• fan balancing

• laser alignments

• Babbitt bearing scraping

• IR Scanning

• Cryogenic Cleaning

Condition Forecaster • Large critical motors

DC Motors over 20 Tons • All target industries

Specialty Motors • Special applications

• Steel Mills

• Vertical Kingsbury Motors

• Crane M&G Sets

• Dynamometers

GE Specific Applications • GE’s installed base

• Schenectady/Peterborough built

• Parts opportunities

High Voltage Motors • 6.9KV & 13KV

• VPI & GE 600 Hard Coil

• Leverage (3) GE coil manufacturing plants

• Support Engineering

• GE Drawings

Synchronous Motors • Slip Ring Applications

• Pole Rewinding & Manufacturing

Targeted motor services

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Gearboxes • Disassembly and inspection

• Sleeving and boring of bearing fits

• Re-machining shaft fits

• Casing repairs, welding or metal-stitch

• Shaft replacements

• Gear evaluation and upgrades

• New gears

• Reverse engineering

Pumps • Complete tear down and inspection

• Line bore housings and casings

• Complete welding & machining capabilities

• Casing repair, welding or metal stitching

• Impeller wear rings and sleeves

• Stainless or bronze retrofitting

• New shafts, bearings

• Mechanical seal recondition & conversion

• Dynamic balancing

• Complete repair report & documentation

Crushers • Mainframe/bottom shell rebuild

• Top shell rebuild

• Bowl rebuilds

• Eccentric repairs

• Mainshaft repairs

• Head repairs

• Onsite assembly of crushers

Refiners • Inspections of rotors, shafts, bearings, hydraulic systems & housing

• NDT

• Weld repairs

• Re-machining

• Balancing

• Upgrades

• Complete machine rebuilds

• Field Services

Centrifuges • Removal and reinstallation • Disassembly

• Inspection

• Retiling

• Hardfacing Renewal

• Gear Box Repair

• Bowl and scroll repair

• Journal and housing repair

• Repair/replacement of worn areas

• Complete balancing of rotating components

Compressors • Inspection

• Complete overhaul

• Shaft replacement

• Seal replacement

• Component part replacement

• Anti-erosion and anti-corrosion coatings

• Upgrades and modifications (impellers, diaphragms, etc.)

• Balance and alignment of rotating components

• 24-hour emergency service

Targeted mechanical services

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How and why do motors fail?

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Less than 4kV

4kV and above

Failure Modes for Electric Motors

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IR Scanning, Temperature Trending

On-Line MCA

Off-Line MCA

Vibration analysis

Visual inspection

Oil Analysis

Predictive Maintenance Technology Legend

Common Failure Modes and Causes

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Winding Failures

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Major cause of stator winding failure (40%) • Starting and full load currents

produce forces that cause vibration of the coil

• End turns at 2X line frequency (100Hz)

• Movement must be eliminated to ensure motor reliability and extend motor life

Mechanical Motion

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Natural time-temperature aging

process (10°C half life) results in coil looseness causing contamination, stress points, coils to vibrate and wear the insulation • Load/fluctuating Load

• Over voltage/under voltage

• Voltage unbalance

• Voltage harmonics/distortion

• Power factor

• Ambient conditions

• Startup and shutdown procedures

Thermal Degradation

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Rotor Failures

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Cage rotor • Cracked or loose bars

End Rings • High resistance joints and cracks

Solutions

• Borescope inspections

• Current signature analysis

• Infrared scans

Open Rotor Bars & Cracked End Rings

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Rotor failures Wound rotors DC Armatures

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Bearing Failures

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Inadequate lubrication • too much

• too little

• contaminated

Excessive load • misalignment

• imbalance

• bent shaft

• other

Electrical fluting • improper handling

• installation

• age

spall on outer race

Bearing Failures

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Roller Bearing Fluting and One Solution

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Sleeve Bearing Wiped and Insulated Sleeve Bearing

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Destroyed Sleeve Bearing and Rotor

. 27

Benefits of predictive

maintenance

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Maintenance Costs

Productivity

Reactive Preventive Predictive

Run equipment to failure… “Break and Fix”

Time based… Typically based on OEM specs

Maintenance based on equipment “condition” Level 1 Condition Monitoring … anomaly detection Level 2 Forecast of future performance… predict and prevent capabilities

Don’t forget safety! 28% more likely to have a safety incident when maintenance work is reactive

versus planned and scheduled.

Source: Paper Industry Management Association, 2003

Classifying Maintenance Methods

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On-line testing: testing with no interruption of motor operation • Vibration monitoring and testing

• On-line motor circuit analysis (MCA)

• Infa-red scanning

• Temperature analysis

• Oil analysis

• Visual inspections

Off-line testing: testing that requires motor to be taken out of service • Off-line motor circuit analysis (MCA)

Experienced analysts • Interpret the technical and inspection data

• Precisely and accurately report the findings

• Make credible recommendations for improvements

• Commitment and investment towards PdM program

What testing technologies should you have as part of your PdM toolkit?

DDMS

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Identifying the appropriate tests for your motors requires that you understand their design, both electrically and mechanically

Things to know: • Insulation system design

– Low voltage, medium and high voltage – Vacuum Pressure Impregnation (VPI) – Dip and bake insulation system

• Bearing system design – Rolling element – Babbitt fluid film – Insulated bearing – Grease lubricated, oil bath, forced fed lubrication

• Rotor design – Copper bar – Aluminium – Magnesium

Motor Design Overview

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Vibration can degrade a motor both mechanically and electrically

What can we detect?

• Bearing issues

• Lubrication issues

• Alignment issues

• Soft foot conditions

• Imbalance issues

• Rotor issues

Important notes

• Vibration data must be trended per motor with alarm points identified

• The most recommended frequency is monthly – However, each motor should be evaluated to determined the appropriate frequency

The single most powerful tool for diagnosing and predicting the health of rotating equipment.

Vibration Monitoring

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changes over time

Step 1 - collection of critical parameter data

• Vibration

• Temperature

• Oil, moisture

• Contamination

• Electrical parameters

Step 2 - analysis of data

• Trending changes indicate the asset’s

health is beginning to degrade

Predictive/Condition Monitoring

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No matter how advanced technology gets, the trained eyes and ears of skilled experts will always be a key component of predictive maintenance

Low oil level

Loose/Missing bolts

Damaged/Leaking fittings

Bad grouting

Faulty seals

Field Visual Inspections

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What can we detect?

•Heat generated by friction

– faulty bearings

– Misalignment

– Inadequate lubrication issues

•Circuit breaker connections

•MCC’s

•Loose / corroded electrical connections

Heat rise from misalignment

Infrared Scanning

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Problem: misalignment

• Incorrect alignment of two coupled machines

– Example: a motor and a pump

• One of the most common sources of excessive vibration

Solution: laser (shaft) alignment

• Using laser-based equipment, we try to make the center lines of the two shafts collinear

• Thermal growth needs to be calculated in to the equation

Driver Driven

power plane

Alignment

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Symptoms

• High vibration readings indicative of misalignment

Corrective action

• Laser aligned motor/pump and corrected loose mounting

Results

• Current draw reduced from 235.7A to 227.9A (-7.8A)

• Annual cost of energy = $300

• Net annual energy savings $2,340

Before alignment

Capturing Mechanical Losses

Nova - Cool ing Tower Pump

008 -M1H Motor O utboard Horizontal

Route Spectrum

20-Nov-02 08:30:50

OVERALL= .1601 V-DG

PK = .1599

LOAD = 100.0

RPM = 3572.

RPS = 59.53

0 30 60 90 120 150

0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

Frequency in kCPM

PK

Velo

cit

y i

n I

n/S

ec

After alignment

Case Study

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Standardized Reporting

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Our Powerful Network of Support

• GE M&G forum

• Network of 400 + engineers

• Instant accessibility

• Global support

• Connect with the factories

• Central server database

Downloading the on-site data

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How RM&D Works…

Identify motor failure before it occurs

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Advanced Motor Current Signature Analysis

Advanced

MCSA

Rotor eccentricity

related faults

Bearing faults

Stator inter-turn faults

Drive-Train Related

Broken rotor bars faults

Broken rotor end-ring faults

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Remote Monitoring & Diagnostics

• Quick installation with 369, 469 & M60 GE Multilin Relays

• Can be daisy chained together

• Prompt responses with any trend variations

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Remote Monitoring & Diagnostics

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Questions

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