Flux Conference 2012

Verification of fault condition behaviour of a synchronous 2-pole generator using Flux 2-D finite element analysis software

Date : 18 October 2012

W. Doorsamy University of the Witwatersrand

Overview
Introduction Background Methodology Experimental Setup Flux Model Fault Conditioning Measurement Results Conclusion
Verification of fault condition behaviour of a synchronous 2-pole generator
2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Introduction
Increased load demands Alternative methods of energy generation/ sources as a solution Integrity of current generation systems have to be increased Need for simple, reliable and cost effective condition monitoring

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Introduction

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Background
Online and offline methods of conditioning monitoring Fault diagnosis accomplished through various methods:
Chemical Mechanical Electrical

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Background
Diagnosis of incipient faults is essential prevention of extended downtime and even catastrophic failure Current methods utilise symptoms of damage/deterioration Unacceptable Previous work conducted on use of shaft signals for fault diagnosis

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Methodology
Consolidation of previous work conducted on fault diagnosis Identification of exact effects of faults on shaft and flux probe
Simulation of fault conditions

Experimental testing Validation

Extend to use in multiple fault diagnosis

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Experimental Setup
Miniature Generator designed to mimic large turbo-generators

Some Capabilities of Generator

20 kVA, 2 Pole, 340 V (line) Cylindrical Rotor Core Insulated Bearings Open stator slots

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Experimental Setup
Mini-Gen designed with additional features
Access to stator and rotor windings Outboard slip rings for static excitation Finished landings on shaft for use of specialised brushes Stator position relative to rotor may be manipulated Flux probes/search coils at various angular positions
Verification of fault condition behaviour of a synchronous 2-pole generator
2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Experimental Setup

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Experimental Setup
Three Phase Rectifier Mini-Gen Shaft Brushes Induction Motor (Prime Mover)
Verification of fault condition behaviour of a synchronous 2-pole generator
2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Flux Model
Casing Stator Slots Air Gap Rotor Core Rotor Slots

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Flux Model

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012

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Fault Conditioning
Incipient faults to analyse

3 Rectifier

Excitation winding short-circuit Static Eccentricity

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Fault Conditioning Rectifier Fault

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Fault Conditioning Rectifier Fault

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Fault Conditioning Rotor Short

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012

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Fault Conditioning Rotor Short

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012

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Fault Conditioning Rotor Short

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Fault Conditioning Eccentricity

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Fault Conditioning Eccentricity

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Measurement
Brushes Probe

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Measurement

Flux probe connector

Shaft brush insert

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Results

% Change tends to infinity due to normal condition 6th harmonic 0

Verification of fault condition behaviour of a synchronous 2-pole generator
2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Results Rectifier Fault

Flux Probe

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Results Rectifier Fault

Shaft Brushes
Harmonic (Hz) 200 250 200 250 Simulation 657.10 43.99 95.04 51.83 Measurement 94.00 38.24 140.11 124.17

Condition No Load With Load

Percentage Change (%)

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Results Eccentricity
Reasons for large harmonic change (Simulation)
Simulation baseline (without fault) value at 300 Hz 0, therefore % change Real machine baseline (without fault) value has asymmetries (imperfections) Presence of noise Sensitivity of simulation i.e. no observation effects unlike with real setup
Verification of fault condition behaviour of a synchronous 2-pole generator
2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Results Fault Diagnosis System

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012
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Conclusion
Reasons for large harmonic change (expected) Simulation predict behaviour and optimise experiment Experimental results validate simulation predictions Algorithm -> viable

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012

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Acknowledgements
EIE - University of the Witwatersrand Professor W. A. Cronje National Research Foundation Cedrat

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012

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Thank you

Verification of fault condition behaviour of a synchronous 2-pole generator

2012 Flux Conference - Rome, Italy, October 17-18, 2012

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