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A1_201_2010

CIGRE 2010

Optical system for hydrogenerator monitoring

J.B. ROSOLEM ; C. FLORIDIA CPqD Brazil

J. SANZ Eletronorte Brazil

SUMMARY Classical systems for monitoring hydro generators normally use the following variables: Turbine: pressure of spiral duct, cover and discharge; Generator: copper, core and cooling water temperature, partial discharges, core vibrations, cooling water pressure; Bearings: axis oscillations, cover vibrations, metal and oil temperatures; Excitation system: slip ring temperature, current, voltage, rotor temperature, electric field. In these systems, electric variables and temperatures are transmitted from the supervisory system by means of communication device. The other variables as oscillations, vibrations, pressures, partial discharges and electric field are available by means of specific sensors, connected directly or through electronic devices to a computer, which condition and organize the data. This structure of monitoring systems, despite its important use to predict failures, has important installation cost and requires periodic calibration of the measurement chains. The development of sensors based on fiber optics technology offers new capabilities for the monitoring systems: the first available sensors are of the direct or intrinsic type, namely that the sensor is inlaid in the fiber, such as temperature, pressure, vibrations sensors. Eletronorte, a Brazilian utility company located in the Amazon region, interested in monitoring systems that are simple, more trustworthy and less onerous, decided to invest in the development of the two more required and not yet available sensors in the market: a sensor for oscillation of shaft and other for partial discharges. As the rotor is a component of the generator without supervision, Eletronorte also developed an optic communication system for the data measured at the rotor (temperature mainly) with optic sensors that transmit the measured data to the part fixed on the stator. The sensor of axis oscillation is of the indirect or extrinsic type, when the transducer acts in the fiber, using the magnetic properties of the sensor to intervene with implanted grid of Bragg in the fiber. The partial discharges sensors are of the hybrid type, when the fiber takes the information of the transducer, an antenna type minder that catches the induced impulses of partial discharges, transforms them into luminous impulses, which are then transmitted by the fiber. The communication system of data measured in the rotor consists of two collimators, one installed at the rotor that receives the measurements carried out by the rotor embarked optic sensors, and the other in the stator, that catches the measured signals each time that the mobile 1

collimator passes in front of it, enabling the direct measurement of the temperature of the polar regions and the wheel deformation. Considering that the current technology allows to place 80 optic sensors in a fiber loop, and that a total monitored hydro generator would need approximately 150 measurement points, two optical-fiber loops can transmit the monitored data; therefore for reliable measurement, the number of loops can be increased decreasing the points distributed in each loop, in a way to get a control system and optoelectronic measurement multipoint and multiloop. Optic measurements are made by an interrogator module and converted into electronic and digital signals, enabling its treatment by a computer. A total optical system in the hydro generator environment guarantees an improved reliability because of its immunity to electromagnetic interferences.

KEYWORDS - monitoring system; - optical direct type sensor; - optical indirect type sensor; - optical hybrid type sensor; - hydrogenerator sensor; - collimator; - interrogator;

OPTICAL SYSTEM FOR HYDROGENERATOR MONITORING 1. Synopsis a. Philosophy of the monitoring systems for Hydrogenerators; b. Currently used system; c. Change for sensors and optic system; d. Commercial and developed optic sensors; e. Projected optic system; 2. Philosophy of the monitoring systems for hydrogenerators The main reason that guided the conception of the applied systems to monitoring Eletronortes hydrogenerators was the importance of the machine components in function of its defect frequency. Thus we classify these components in order of decreasing importance of defects frequency, classification practically identical to the one elaborated by Cigre. Amongst all components, the generator stator shows the highest number of defects, mainly for the loss of its capacity of isolation: the variables that allow to follow this degradation in isolation are the partial discharges, associated with the temperatures (bars, core and cooling water), the core vibrations and the operative and maintenance scheme. In second place, the bearings are also components that must be supervised closely. These equipments are controlled by the temperatures of the metal and the lubricate oil, by the oscillations of the axle and the vibrations of the bearings boxes. We also 2

use as an additional source of information the parts of metal which are in suspension in the lubricate oil. The third critical component to be assessed is the slip ring, whose wear is directly linked with the quality of brushes commutation, which depends on the current and the voltage of excitation; we add a control of the temperature of the slip ring by an infra red measurement, a bad commutation causing an increase of the temperature. The fourth critical component is the rotor, whose control is made today by a transducer of thermal image, an indirect and inaccurate measurement linked by a mathematical model to the current and tension excitation. The optic technology allowed to develop a highly reliable system that we will describe below, which enables to efficiently measure temperature and other variables as deformations.. 3. System currently used. On the capture of the variables described above we use the following classification: Process variables, namely temperature, voltages and currents and excitement, power and reactive: normally part of the supervision system of the plant and captured by specific computer interface. Rapid mechanical variables such as vibration, oscillation shaft, pressure: measured using specific sensors and inserted appropriate data acquisition. The partial discharges are captured by capacitive couplers and measured in a direct manner after being filtered, multiplexed and collected by acquisition boards for high frequency, using a system developed in collaboration with the Research Center of Eletrobras, CEPEL. Mechanical and process data are acquired and processed by a computer for each machine; in the case of partial discharge, a computer processes the signals from two machines. All signals are stored in open database, available to feed a system of diagnosis and prognosis, actually on end of development. 4 Moving to sensors and optical systems. The monitoring system involves data acquisition, to processing rules for the diagnosis and prognosis systems, and to modeling in order to analyze the conformity of change of the signal with the possible defect pointed. The acquisition of the signals is the key element, as these are the basis for diagnosis, prognosis and model systems. Therefore, measurements reliability is the key for diagnosis and prognosis functions. Measuring through traditional sensors requires periodic calibrations of the chain of acquisition, and that is not always possible, due to the need of stopping machines. Besides, some sensors have a high cost, increasing the price of the overall system, and making it difficult to convince the investment. Aiming to simplify the monitoring system, lower its cost and increase its reliability, we have studied the alternative of optical sensing, as applied in robotics and aeronautics, with sensors used as direct type, with Bragg grating incorporated. These sensors, when compared to their conventional counterparts, have the following advantages: Are passive; Are immune to electromagnetic interference; They are capable of multiplexing signals from several sensors on one fiber, avoiding multiple and bulky network cables, multi-point connection, which may introduce defects due to bad contact; 3

Are more resistant to corrosion and high temperatures; They are capable of transmitting signals of high frequency and high bandwidth; Allow a few invasive measurements, due to its small size. Dispense most of the calibrations, due to the high degree of reliability of optical sensors. With this type of sensors, type Bragg grating, we can measure all parameters related to mechanical deformation, that is, beyond temperature, pressure and vibration, mainly. Lacked commercial sensors to measure the oscillations of the shaft and the partial discharges, variables widely used by monitoring systems, are set out as part of a specific research program , as explained in the following paragraph. In relation to the rotor, there is no direct measurement of its main features available today in the market, such as temperatures and deformations. All measurements offered, such as measurement of flow and air gap can be regarded as indirect. The optical technology allows the installation on the rotor of a network of sensors direct type with embedded fiber Bragg grating, deployed in a single loop of optical fiber, which enables fitting up to 100 measuring points. The signals are transmitted to a fixed base by a paired optical gun, called collimators. 5. Optical sensors a. Optical sensors commercially available. Type sensors are direct or intrinsic when a Bragg grating is incorporated into the fiber and reproduces the deformation of the body with which the fiber is solidary. These sensors are used to measure deformations, vibrations, forces, temperatures and pressures. Its small size allows easy incorporation with the components where the quantities mentioned above will be measured. Figure 1 shows the difference between a classic sensor temperature (RTD) and the same in optical fiber.

(a) (b) Fig. 1: difference between a classic sensor (a) of temperature and the same optical fiber (b). b. Optical sensors developed for monitoring systems.


Ligth source

Proximeter (fig. 2)

FBGs

l Schaft
Magnet Optical receiver

Optical power l

Fig. 2: Optical proximeter

Indirect or extrinsic sensor: where an element acts on the Bragg grad embedded in the optic fiber and indirectly reproduces the measured variable. When the proximeter is considered, a magnet is attracted by the shaft, and this attraction is proportional to the distance between the mobile shaft and the fixed sensor. The attraction force acts on the Bragg grad, and the consequent light variation is proportional to the force and indirectly to the distance between the shaft and the sensor. Optical partial discharges sensing system (fig. 3).
Optical Source and Optical Receiver 1300 nm RF/Optical sensor

STD Optical Fibers ~ 200 m 1480 nm


200 150 100 50 0 -50

Stator

-100

-150

-200 -1.0E-07 -8.0E-08 -6. 0E-08 -4. 0E-08 -2. 0E-08 0.0E+00 2.0E-08 4.0E-08 6.0E-08 8. 0E-08 1. 0E-07

Rotor

Data Acquisition

Meander antenna PV resistor converter Optical source Optical receiver laser

Optical fiber RF choke

Hydrogenerator

Fig. 3: Partial discharges sensing system. This sensor is hybrid type: the electromagnetic pulses generated by the partial discharges are captured by an antenna minder type, and converted in optical pulses by a converter based on a powered laser diode. Two types of antenna were 5

developed, one installed near the stator bars (fig.4), the other one fixed on the winding (fig.5).

Fig. 4

Fig. 5

Temperature and strain rotor sensing system (fig. 6).

Fig. 6:

Temperature and strain rotor sensing system.

This system is made by an optical fiber loop where are embedded direct type sensors for measurement of the poles temperature and the strain wheel. The light is sent from an interrogator, unit for powered the fiber sensors and converted the optical signals in electronics signals, and is returned to it across a pair of collimators, on mobile installed on the rotor, and the other fixed on the stator. The signals transmission occurs when the two collimators are aligned. The low frequency of the measurement has no influence on its quality because the variables change slowly. 6

6. Design of optical system. The control and acquisition unit, called interrogator (fig. 7), provide optical supply for the sensors and acquire their optical signals. It is designed for 19 rack installation, with 35 cm deep and 9 cm height, electrical supply in 110V or 220V, 50W consumption. Optical supply outputs are made with FC/APC connectors and the optical input use SC/PC connectors. Two electrical outputs are available by BNC connectors, two potentiometers adjust the laser power level, and two keys turn in/off the power supply and the optical power supply for the sensors.

Fig. 7 Interrogator Optical signals are converted into electronic normalized signals and then acquired by a computer, where they are processed and stored in a data bank. The designed system will be made by several fiber loops collecting optical signals, to increase the reliability of the system, and these signals will be treated by the interrogator. When more measured point must be considered, the number of interrogators can be increased, to ensure a higher reliability. An overview of the monitoring system for hydrogenerator is showed on the fig.8 below:

Fig. 8: General System

BIBLIOGRAPHY [1] Kersey, A.D, A Review of Recent Developments in Fiber Optic Sensor Technology, Fiber Optic Smart Structures, U.S.Naval Research Laboratory,,Washington, February 13,1996. [2] Valente, L. G; Silva, L. C. N; Ribeiro, A. S; Triques, A; Regazzi, R. D; Braga, A.M. B, Tcnicas de leitura para sensores a fibra ptica baseados em redes de Bragg, conferncia sobre tecnologia de equipamentos, Salvador, agosto de 2002. [3] A. G. Sellars, 0. Farish, B. F. Hampton Using the UHF Technique to Investigate PD Produced by Defects in Solid Insulation, IEEE Transactions on Dielectrics and Electrical Insulation Vol. 2 No. 3, June 1995. [4] J. B. Rosolem, Sistema de alimentao eltrica de baixa potncia via fibra ptica - Power Fiber", Documento CPqD, PD.30.11.72A.0012A/RT-07-AA, 2003. [5] J. Dymond, R. Ong, N. Stranges, Instrumentation, testing and analysis of electric machine rotor steady-state heating, Paper No. PCIC-01-32, IEEE, 2001. [6] R. L. Leite, J. B. Rosolem, D. C. Dini, H. S. A. Prata, J. E. Urso, E. H. M. Sarmento, Tcnicas de Tele-Comando e Tele-Alimentao via Fibra para Sistemas de Superviso ptica, MOMAG 2004, So Paulo, 2004. 8

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