21, rue dArtois, F-75008 PARIS http: //www.cigre.

org

A1_203_2010

CIGRE 2010

Komati Unit 9 turbo-generator filter inspections after filtration runs

K.S NAIDOO* Eskom Republic of South Africa

Z.D JIYANE Eskom Republic of South Africa

SUMMARY
It was intended to have the Komati Unit 9 generator returned to service after being decommissioned in 1990. Endoscope inspections in 2006 showed that debris in the generator could not be removed by traditional means such as vacuuming. Five filtration runs (varying durations ranging from 10 minutes to 18 days) were conducted on this generator (off and on load) to remove the debris, which would otherwise cause extensive damage to critical asset such as the generator. This involved installing filters between the cooler discharge and rotor fan suction areas, performing filter inspections following a run, weighing magnetic and non-magnetic particles until such time metal particle content of the vacuumed particles were less than 0,5g with the total weight of the debris less than 10g with the last filter inspection. The objective in performing filtration runs and filter inspections was to achieve efficient and durable operation of the generator as well as minimizing cost in so doing. The first four filter inspections showed acute magnetic and nonmagnetic dust and foreign material in the generator. The final inspection revealed that generator contamination had reduced to a very minute quantity of 0,53g. While performing the filtration runs, the generator parameters mainly stator bar, rotor (calculated), hot and cold gas temperatures and GCM parameters (H2 flow and GCM output) were carefully monitored. These were all within the acceptable limits. Conclusions: The concept and implementation of generator filtration runs with the generator off and on load proved to be very effective. Non-magnetic particles such as insulation were filtered. H2 Coolers also act as filters.

naidookm@eskom.co.za

Prevented catastrophic damage to generator. With filtration runs and filter inspections major damage and downtime of the rotor and stator is avoided, thereby increasing the life span of the machine. The authors are of the belief that: Filtration runs and inspections can be made a norm for new machines. Should there be ingress of small debris and dirt during a refurbishment or repair of a machine filtration runs and inspections can be used by the concerned utility. An international guideline can be drawn up for filtration runs and inspections.

KEYWORDS
Filtration run Filter Generator Magnetic Non-magnetic

INTRODUCTION

Between 1989 and 1990, the Komati Unit 9 generator was shutdown but not properly mothballed in accordance with Eskom procedures and preservation measures at the time. Consequently, foreign material such as dirt, dust, debris, etc. entered the generator frame. In 2006, it was decided to return Komati Unit 9 generator to service with minimum repairs. During the visual (endoscope) inspections, it was noticed that the core vents were contaminated with insulation material, dust, dirt, debris, paint flakes, etc. It proved difficult to remove the contaminants by vacuuming or using other manual means such as magnetic pick ups. It was then strongly recommended by the author to perform filtration runs using refurbishment procedure [1] and commissioning procedure [2] in an attempt to remove foreign material that could prove fatal to Komati Unit 9 generator depending on location of these foreign bodies. The filtration run required filters and filter frames to hold the filters such that they do not enter the gas flow path and cause substantial damage to the generator. This paper aims to extend the concept of filtration runs with the generator on load. The paper commences with filter specification and filter casing design, it discusses the number and duration of filtrations runs on Komati Unit 9 generator, the findings after each filtration run, conclusions and recommendations. The paper closes with three appendices; Appendix 1 contains definitions and abbreviations, Appendix 2 provides cooler data and drawing, Appendix 3 discusses the filter findings (includes photographs) after each filtration run. 2 EFFECTS OF CONTAMINANTS AND CONSEQUENCES ON GENERATOR Magnetic dust can accumulate in rotor vents or inlets; insulation can block rotor vents or inlets starving the coil/s of sufficient cooling. Metal shavings and particles will act as magnetic termites burrowing into insulation of stator, can also end up in rotor. The consequences are stator and rotor earth faults, flash overs, double rotor earth fault, damage to stator and rotor insulation, possible rewind to rotor and stator, etc.

The risk of leaving the generator with contaminants and not performing the filtration run:

3 FILTER SPECIFICATION AND FILTER CASING DESIGN 3.1 System description The Komati Unit 9 generator has an indirect cooled stator winding and a direct cooled stator core and rotor. Table 1 shows the generator rating data. Table 1: Komati Unit 9 rated generator data Description Serial # Type Year of manufacture Apparent power pf Speed / frequency Generator casing pressure Insulation class (stator / rotor) Stator voltage Value 8117 FKWS 3742p 1964 139 MVA 0,9 3000 rpm / 50Hz 206,84 kPa B/F 10,5 kV 5% Power capability chart

Figure 1 shows the gas flow path in the Komati Unit 9 generator. The filters are located on cold gas side of the coolers. There are 16 filters in the generator casing; 4 between the cooler and the rotor fan. See Appendix 2 for cooler drawing and data sheet.

View X see Figure 3

Figure 1: Gas flow paths in Komati Unit 9 generator and filter locations With regard to filter casing design and filter specification, the design of the casing and choice of filter material was of vital importance as this must ensure sufficient cooling of the generator and simultaneously remove foreign objects and dirt that would cause its own destruction. 3.2 Filter specification 3.2.1 Filter calculations This section is for determining the size of the filter and to ensure that filter will be able to withstand the volume of gas flow expected. This done by working out the volume expected through the coolers in relation to the volume of the generator casing. As the calculation shows below the filters will be able to withstand twice the volume through the coolers. Hydrogen volume required for generator casing: Generator volume = 44 m3 (@ 88 kPa) Calculate volume at 206,8 kPa P1V1 = P2V2 V2 = 44 x 88/206,8 = 103,4 m3 Cross sectional area through the filters (Trapezoidal shape): A= a (b1 + b2) = 0,117 m2 Filter rated capacity = 5400 m3/h/m2

In volume flow rate = 5400 x 0,117 x 16 = 101088 m3/h Hydrogen gas flow in the generator is 24 m3/s Gas flow through the filter 24 x 3600/16 = 5400 m3/h The filters are able to withstand twice the volume that is currently flowing through the coolers. Calculation of interest: Casing Volume = 103,4 m3 Time it takes to fill the casing = 103,4/24 = 4,3 s Total volume being circulated is 24 x 3600 = 86 400 m3/h Of the total only 10 108 m3/h goes through to the filters. By determining the flow experienced by the filter, the correct filter material can be specified. In this case the filter AmerTex R-Series filters labelled: EN 779:G4 R-50 was selected. 3.2.2 Filter selection The filter that is selected should have the following characteristics: Ensure a high number of fibres per square metre for a given weight. Low resistance to airflow. High dust holding capacity. Must be able to withstand the generator maximum hot gas temperatures. Should be fully washable and easy to clean. Should ideally be tested for performance in accordance with BS EN 779:2002 [4].

3.2.3 Filter casing design To design the filter casing, the generator gas flow path, the stator casing (see Figure 3) and sustaining generator clean conditions was scrutinised to enable ease of installation and removal (including minimising downtime), no clean condition breaches during operation and filter replacement. See Figure 4 for filter casing drawing and photographs depicting the front and rear of the casing (non-magnetic stainless steel). Wire mesh (also of non-magnetic stainless steel was tack welded on casing anterior. The wire mesh on the posterior side of the casing was fixed using nylocks and threaded rods, which were welded perpendicular to casing. This drawing was submitted to DB Thermal for manufacture of 16 filter casings for Komati Unit 9 generator. Cutaways (4 for each cooler): Filter casing location

Figure 3: Stator casing showing cutaways for gas flow (cold gas side of coolers)

Front of filter casing

Rear of filter casing

Gas flow direction (OUT)

Gas flow direction (IN)

Rubber and glue installed here

Figure 4: Filter casing drawing and photographs (without wire mesh and filter) 3.2.4 Filter casing rubber lining and glue specifications Natural rubber seals were used on the filter casings to prevent dust and debris from being carried away unfiltered around the perimeter of the filter frame. Glue was used to fasten rubber seals to the filter frame. The glue should be selected so that it bonds properly (without any damage) to rubber seal and frame. 4 Filtration run dates and durations The first filtration run commenced on 13 June 2008 at 03h20 and was complete at 04h04 with only 3 non-consecutive cycles and with generator casing air pressure of about 20 kPag without seal oil. Then all the H2 coolers were removed, filters inspected and replaced with new ones. Silicon grease was applied to one filter in H2 cooler 4 compartments because the filters are permeable to very tiny dust specks. The second filtration run was carried out on 16 June 2008 at 10h08 and was complete at 10h30 with only 2 cycles and with generator air casing pressure of approximately 30 kPag. Five consecutive cycles was not permitted by the OEM because the turbo-generator train has a broad critical speed range from 1200 to 2300 rpm. The filters remained in place until the first outage. However, during the generator drop (or leak) test, it was found that there were major leaks on both the TS and ES H2 seal housing and inner door half joints. The repair of these leaks was imperative with a repair time of 2 days. Therefore, the opportunity to inspect two H2 coolers was taken. The filters in H2 coolers 3 and 4 compartments were inspected.

The third filtration run was conducted from 9 to 11 July 2008 during the hot commissioning of the generator (generator off load and with seal oil system in service). The generator was then synchronised and loaded to 20MW with air at 12kPag and with seal oil system in service for a period of between 3 to 4 hours. The unit was then shut down and placed on outage. The fourth filtration run was performed from 27 July to 15 August 2008 with generator at 3000 rpm for 17 hours and with the generator loaded for 47 hours with H2. The final filtration run was performed from 31 August to 13 October 2008 with generator at 3000 rpm and loaded for 535 hours. While performing the filtration runs, the generator parameters mainly stator bar, rotor (calculated), hot and cold gas temperatures, and generator core monitor parameters (H2 flow and GCM output) were carefully monitored. The rotor body, bushings (gas side only), stator TS and ES end windings have special paint tags on them. 5 FILTRATION RUN AND FILTER INSPECTION FINDINGS The first 4 filter inspections showed that the generator contained excessive contaminants both of a magnetic and non-magnetic nature. Many non-magnetic particles such as insulation were filtered. All generator parameters were within acceptable limits. The coolers act as a first filter and the filters themselves act as a second filter. The final inspection revealed that generator contamination had reduced to a very minute quantity (see graphs below in Figure 5). Acceptance criteria: Metallic particle content of the vacuumed particles are less than 0,5g with the total weight of the debris less than 10g with the last filter inspection. The average metallic particle content measured was 0,53g. A PB Power consultant mentioned that this is a General Electric acceptance criterion when particles are vacuumed from generator during outages. Eskom decided to use this criterion to validate the necessity of further filter inspections.

Figure 5: Example of decrease contaminants in cooler 4 and 2 See Appendix 3 for details of filter inspections (includes photographs and comments for filter inspections corresponding to a particular filtration run). 6 CONCLUSIONS

The concept and implementation of generator filtration runs proved to be very effective as the quantity of magnetic contaminants (dust and pieces of metal) did decrease as observed from the graphs obtained for the amount of particles vs. filtration run dates. Filtration runs are possible with the generator both off and on load by carefully selecting the filter and designing the filter casings.

Owing to the generator not being suitably mothballed and the fact that these dangerous contaminants could not be removed during refurbishment using manual methods, these contaminants would have catastrophically damaged the generator stator and rotor. For the filtration run on the 14 June 2008, it was decided to apply silicon grease to one filter in the H2 cooler 4 compartment because it seemed that the filter was permeable to tiny dust specks. These tiny specks could accumulate and block the tiny cooling vents in rotor and accumulate on cooler tubes. Thus the grease application was significant. Filtration runs must be performed over several hours to days to obtain significant findings especially where the generator casing has been subjected to dirt, debris ingress (which may be a result of improper storage or clean condition breach/es). The risk of leaving the generator as is and not performing the filtration run: Magnetic dust can accumulate in rotor vents or inlets; insulation can block rotor vents or inlets starving the coil/s of sufficient cooling. Metal shavings and particles will act as magnetic termites burrowing into insulation of stator, can also end up in rotor. The consequences are stator and rotor earth faults, flash overs, double rotor earth fault, damage to stator and rotor insulation, possible rewind to rotor and stator, etc.

In addition, It is very difficult to monitor the rotor for exact temperature because this is a derived value and not a direct temperature measurement on rotor body and coils. There are limited temperature sensors on stator bars. There are no core temperature sensors. The generator monitor and electrical protection will prevent catastrophic damage only but will not in any way prevent damage to the machine. The magnetic and non-magnetic dust accumulation on cooler tubes will cause the cooler efficiency to decrease thus affecting and preventing proper cooling of significant generator components such as rotor and stator. Note: A 10 increase in temperature K will halve the insulation life. Thus the integrity of rotor and stator insulation would be dramatically affected and consequently the long term plant health of the generator.

However, after the final filtration run and inspection, it was seen that the magnetic and nonmagnetic particles diminished to such an extent that further filtration run/s was deemed unnecessary. Therefore, this shows the importance of these filtration runs as major damage (at least 3 million for 139MVA generator rotor rewind) is avoided, thereby increasing the life span, availability and reliability of the machine. 7 RECOMMENDATIONS After the final filtration run and inspection, it was seen that the magnetic and non-magnetic particles diminished to such an extent that further filtration run/s was deemed unnecessary. On the next generator opening, ensure that following is carried out: Perform visual inspection (including endoscope) of entire stator and rotor. All coolers must be to be visually inspected and vacuumed. The back of the stator core must be visually inspected and vacuumed. The rotor vents must be inspected and vacuumed. In the event of any contamination being found, its cause/s should be determined and removed so that a recurrence of such condition is prohibited by further filtration run/s. For further filtration runs on all Komati H2 cooled generators, increase surface area of filter media by applying 2 filters in filter frame. Put silicon grease or oil between the 2 filters.

However, ensure that minimum differential pressure across rotors fans and the minimum flow through the GCM is maintained. Should filters be operated for long term (greater than 21 days) with generator on load, maintenance and inspection philosophies must be in place. Install delta pressure and indication transmitters to measure the pressure drop across the rotor fan and cooler (already a delta pressure measurement across discharge and suction side of rotor fan). The pressure drop (including the flow) across filter can then be calculated and compared to calculation in section 3.1.6. Ensure that the GCM is fully functional and commissioned correctly before the generator is synchronised. Investigate whether the specified filter can be installed and removed with machine in service until the next planned outage. Together with this install instrumentation such as delta pressure transmitters to monitor blocked filters. Filtration runs and inspections can be made a norm for new machines. In this way the OEM can be very certain that there are no foreign objects that can cause blockages of stator and rotor ventilation holes. Should an incident (such as ingress of small debris and dirt during a process of refurbishing or repairing a machine) occur on a unit during an outage, such a filtration run and inspection can be used by the concerned utility. An international guideline can be drawn up for such filtration runs and inspections to assist utilities and OEMs to perform such filtration runs and inspection the filters accordingly with the machine both off and on load. 8 Appendices Appendix 1: Definitions and abbreviations Appendix 2: Vertical cooler drawing and data Appendix 3: Filter inspections after filtration runs

BIBLIOGRAPHY
[1] [2] [3] K.S. Naidoo Filtration runs on Komati H2 cooled generators M Bezuidenhout Generator 9 filtration run OEM manual Operating and maintenance instructions three phase synchronous generador with hydrogen cooling Type FKWS 3742p Komati Power Station Set 8 and 9 BS EN779:2002, Particulate air filters for general ventilation. Determination of filtration performance

[4]

Appendix 1: Definitions and abbreviations Definitions (1) Contaminant/s Contaminants consist of debris such as dust and dirt, other non-metallic objects such as pieces of insulation material, and metallic (magnetic and non-magnetic) objects. (2) Filtration run The filtration run is a means of removing contaminants from hard to clean places in the generator casing by inserting correctly specified filters on the discharge side of the generator H2 coolers. (3) Endoscope inspection An endoscope is a small flexible tube with light and a camera on the end. It is a means to make a visual inspection in hard-to-reach places such as stator core vents, rotor sub slots, etc. Abbreviations Abbreviation ES GCM H2 OEM TS Description Exciter (or slip ring) side of generator Generator core monitor Hydrogen Original equipment manufacturer Turbine side of generator

Appendix 2: Vertical H2 cooler drawing and data [3]

Vertical H2 cooler drawing Table: Cooler data

APPENDIX 1: Some photographs and all findings on filter inspections FILTRATION RUN AND INSPECTION FILTRATION RUN DATES 13 June 2008 16 June 2008 9 to 11 July 2008 FILTER INSPECTION DATES 13 June 2008
FINDINGS Dust particles were found which are much heavier than in all other coolers. Also metallic/magnetic dust were found after vacuum

27 July to 15 August 2008

31 August to 13 October 2008

17 June 2008

FINDINGS

15 July 2008

FINDINGS Filters: Metalic shavings of 0,7mm long found. Magnetic dust and particles.Cooler chamber: Magnetic dust, large insulation pice 10x0,5mm. Cooler: Paper insulation 2 pieces. Behind stator core (from cooler chamber): excessive magnetic particles and dust, weld flux pieces, insulation pieces, paint flakes, coal dust

18 August 2008

FINDINGS Contaminants found at the back of the core

15 October 2008

FINDINGS It was found that there was hardly any contaminants on the filters. The only contaminants found was obtained from vacuming. The filtration proved to be effective as compared to previous runs.

cooler 1

CONCLUSIONS The filtration runs for cooler 1 proved to be effective as the amount of magnetic contaminants did reduce as observed from looking at the filter after the filtration run on the 15 October and from the graphs obtained for the amount of particles vs. filtration run dates. We note a large amount of mag. particles obtained in the first few filtrations.Therefore, major damage of the rotor is avoided.

RECOMMENDATIONS Keep replacing filters during filtration runs period, therafter remove all filters. By the last filtration run, the amount of contaminants found reduced greatly.

Very fine magnetic shavings obtained within cooler. Magnetic dust obtained after vacuum. Cooler was removed and vacuumed cooler 2

Filters: Magnetic dust and particles, 5mm metal shaving found. Cooler chamber: Magnetic dust and paint flakes. Cooler: Paper insulation 7 pieces of which 2 pices 15x0,5mm. Behind stator core: Large insuulation pieces (used for sttaor slot wedging), iron filings, other insulation pieces, metal shavings, coal dust

Contaminants found at the back of the core (magnetic and non-magnetic). Also obtained here are some insulation particles, pieces of wood, etc.

It was found that there was hardly any contaminants on the filters. The only contaminants found was obtained from vacuming. The filtration proved to be effective as compared to previous runs.

The filtration runs for cooler 2 proved to be effective as the amount of magnetic contaminants did reduce as observed from looking at the filter after the filtration run on the 15 October and from the graphs obtained for the amount of particles vs. filtration run dates. on the 18 August, we obtained large amount of contaminants found at the back of the core (magnetic and non-magnetic). Also obtained here are some insulation particles, pieces of wood, etc. Metallic and magnetic objects that are too heavy too be moved will be affected by the magnetic field in the generator casing. These magnetic fields can carry these objects into areas that can cause damage to the generator.

Always vacuum behind the generator core where a large amount of different contaminants were found.Keep replacing filters during filtration runs period, therafter remove all filters. By the last filtration run, the amount of contaminants found reduced greatly.

Fine metal shavings were obtaind in all filters.

Very fine magnetic shavings obtained within cooler. Magnetic dust obtained after vacuum. Cooler was removed and vacuumed

Very similar findings to that on cooler 1 and 2

fine magnetic shavings

It was found that there was hardly any contaminants on the filters. The only contaminants found was obtained from vacuming. The filtration proved to be effective as compared to previous runs.

cooler 3

The filtration runs for cooler 3 also proved to be effective as the amount of magnetic contaminants did reduce as observed from looking at the filter after the filtration run on the 15 October and from the graphs obtained for the amount of particles vs. filtration run dates. We note a large amount of mag. particles obtained in the first few filtrations.Therefore, major damage of the rotor is avoided.

Keep replacing filters during filtration runs period, therafter remove all filters. By the last filtration run, the amount of contaminants found reduced greatly.

contaminants obtained from vacuum

cooler 4

the filter is designed to allow the air and gas to pass throug it, however it was discovered that the tiny metallic particles were passing through also, so the filter was applied with grease to absorb these particles. This proved to be successful.

Very similar findings to that on cooler 1 and 2

vacuum chamber: fine magnetic particles

It was found that there was hardly any contaminants on the filters. The only contaminants found was obtained from vacuming. The filtration proved to be effective as compared to previous runs.

For the filtration run on the 14 June, after some thought, it was decided to apply silicon grease to one filter in H2 cooler 4 compartment because it seemed that the filter was permeable to tiny dust specks. Source of magnetic dust could be from steel grids, laminations, etc. the grease absorbs these tiny metallic particles, thereby preventing the particles from entering the rotor. By 2008 15 October, there were hardly no contaminants present on the filters.

filters are always to be pre-oiled before use preventing the fine paticles from entering the rotor.Keep replacing filters during filtration runs period, therafter remove all filters. By the last filtration run, the amount of contaminants found reduced greatly.