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NHA 2010 Annual Conference Governor Maintenance Roger Clarke-Johnson and Scott Ginesin American Governor Company 28 April 2010

NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

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Page 1: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

NHA 2010 Annual ConferenceGovernor Maintenance

Roger Clarke-Johnson and Scott Ginesin

American Governor Company

28 April 2010

Page 2: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Overview• Governor 101• O&M Goals• NERC / Grid Stability• Preventative Maintenance• Oils• Pumps & PMGs• Training

Page 3: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Governor 101What is a governor?

• A governor is a mechanism that responds to deviations from equilibrium and seeks to restore the system back to equilibrium.

Why do we need them?• The governor is used to start the turbine, control the

speed of the turbine to permit the generator to be synchronized to the grid in a stable and safe manner, and then allows the generator to produce generation and automatically share load with the other units on the grid during frequency excursions.

Page 4: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Governor Interaction at Hydro Plants

Page 5: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Not a good day: Ocoee #2 Runaway 4/14/49

Page 6: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

O&M Goals:Reduce Frequency & Duration of Forced Outages

Increase MTBF

Preventative Maintenance during Planned Outages

Redundancy in Field Devices, Hydraulics, Controllers

Decrease MTTR

Quick TroubleshootingCritical Spare Parts On-SiteQuick Access to Other SparesFast Repairs, Local or FactoryAccess to Emergency SupportIdentification of Long Lead ItemsTraining of PersonnelTechnical SupportField Service

Page 7: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

NERC – Grid Stability

• The role of hydro in supporting grid stability

• Proper governor maintenance is important

• Digital conversion not required to pass NERC tests!

Page 8: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Eastern Frequency Response

27282930313233343536373839

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Decline = 0.62 MW / yearaverage value for calendar year

Beta

M

W p

er 1

mHz

cha

nge

Frequency Response Declined 24%While Load and Generation Increased 20%

Page 9: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Woodward Mechanical Cabinet

Before Maintenance and Tuning After Maintenance and Tuning

Page 10: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Mechanical Cabinet Passes NERC

92

93

94

95

Gate (%)

59.96

59.98

60.00

60.02

60.04

freq (Hz)

04/27/2006 17:03:03

-0.04

-0.02

0

0.02

0.04

0 500 1000 1500 2000 2500 3000 3500

Time (seconds)

Deadb

and(Hz

)

Page 11: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Poor Preventative Maintenance

Page 12: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

12

Mechanical GovernorsThe two enemies of “classic” governors:

• Friction• Lost Motion

How to find and eliminate them: Lubrication Monthly inspection Annual governor testing Overhaul as required

Page 13: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Time-Based MaintenanceWeekly

Add oil to all pivot points.Monthly

Check oil filtersCheck dashpot oil level – add dashpot oil if needed

12 MonthsAdd dashpot oil to strap suspended ballheadCheck ballhead bearings

24-36 MonthsDisassemble, clean, inspect, replace worn parts:Governor pilot valveDashpotBallheadLinkagesLubricate and check movement of governor restoring cableCheck distributing and relay plunger for freedom of movement.

Page 14: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Alternate Approach

TBM ignores actual governor performance:- Governor wear is not uniform- Good, useable parts may be discarded- Annual outage may be unnecessary

TBM widely replaced by Run-To-Failure due to focus on cost reduction: - Governor maintenance may be neglected

- Poor governor performance exposed only during grid disruption

Governor Health Monitoring provides:- Simple, quick governor performance verification

- Identification of poor-performing governors

- Lead time to schedule outage, purchase needed parts

Page 15: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Governor Health Monitoring• An annual test using simple on-line method.

• Allows comparison against past performance.

• Provides tools to tune for peak performance

• Enables scheduling of maintenance or overhaul, as needed. Avoids unnecessary outages.

Page 16: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Digital Governor Maintenance

• Oil Cleanliness / Oil Filters / Oil Sample Analysis

• Calibration of Feedback Sensors

• Hydraulic Solenoids - Exercise to minimize silt build-up

• Control Relays - Exercise to verify contacts and wiring

• Servomotors - Check full travel for binding or abnormal operation.

• Fastener Security - Check the torque on all accessible fasteners.

• Corrosion – Inspect electrical terminations, connectors, components.

• Battery Replacement

• Auxiliary Systems: Pumps and SSGs

Page 17: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Oils• Contaminated Oil is the #1 Cause of Governor Problems

• Oil Should be Free of Dirt, Air & Water

• When to Change or Clean Oil• Appearance

• Smell

• Water or other contaminants

• Viscosity changes

• Excessive wear

• Kidney Loop Filtration Systems

• Incompatible Oils / Choosing the Proper Oil• Filter maintenance schedule with Inspection• Oil sample analysis

Page 18: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Pumps - Preventative Maintenance

Page 19: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Pump Maintenance Postponed

Page 20: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Pumps - Gear Damage

Page 21: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Pumps - Wear Plate Damage

Page 22: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Pumps – Gear Pocket Damage

Page 23: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

PMGs

• Verify PMG voltage

• Remagnetize as needed

• Overhaul auxiliary speed switches

Page 24: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

PMG Remagnetization

• Woodward• Pelton

Page 25: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Training

Staff training is critical to reducing downtime and keep governors running at peak performance.

• On-site Training

• Factory Training

Page 26: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

On-Site Training• Comprehensive on-site training classes include governor basics,

operations, maintenance, and troubleshooting. Available for all types of governors.

• On-site classes focus on your specific governor installation. Hands-on sessions take place at an existing unit.

• Duration is typically 3 to 5 days, depending on the number of students and the amount of hands-on time desired.

• AGC staff have taught more than 200 training classes worldwide.

Page 27: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Factory Training

Page 28: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Factory Training

Page 29: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Governor School

Page 30: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Thank you for your attention!Any questions?

•Roger Clarke-Johnson [email protected]

•Scott Ginesin [email protected]

Page 31: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Overhaul or Upgrade?

Reasons to Maintain …

•Legacy Governor Parts and Service ARE Available

•Legacy Governor Training Classes ARE Available

•Retrofit Kits that Enhance Performance ARE Available

Page 32: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Overhaul or Upgrade?

Reasons to Upgrade …

•Relicensing-Driven Control Upgrades

•Market-Driven Enhancements

•New vs. Old: Technology and O&M Staffs

Page 33: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Digital Conversions

5860-5255860-525

Page 34: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Digital Governor Primer Governor School

Digital Conversions

Page 35: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

PG&E - Chili Bar Dam, CA

Page 36: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Governor School

Operator Interface

Page 37: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Color Touchscreen HMI

Color Touchscreen Human Machine Interface (HMI) provides easy access to:

– Start/Stop Controls– Control Mode Selection– Unit Overview Data– Trending– Alarm Event Log– Status of All Inputs and Outputs– Tunable Parameters

Page 38: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Governor Parts

Page 39: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Shop Repairs

Page 40: NHA 2010 Annual Conference Governor Maintenance 2010 Annual Conference Governor Maintenance. ... • The governor is used to start the turbine, ... • The role of hydro in supporting

Field Service