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1 . INTRODUCTION
preventive
This paper presents a successful
maintenance program which can plan preventive
maintenance (pM) using diagnostic techniques of
remaining life for each equipment.
The need for development of a comprehensive
preventive maintenance program is shown in Fig. 1
(Ref.
l).
PLANYIhlG SYSTEM
0149-144)(/93/$3.00
8 1993 IEEE
146
Failure
Rate
(XI
\IL
/'
Bilm-in
ReZion
'
e
/,
S
Useful L i f e
Reqion
Year-ocr
Repion
R e l i a b l e 0pera:ion
I
I
Plants
'
(Plant]
I RK P/an:Short/Long
I
Team
Maintenance Work
Diagnosis o f Deterioration
and Remainina L i f e
I
I Maintenance
-LJ-
Records
I
-
1 Actual
147
3.1.1
3.1.2
Table 1 Diagnostic Systems of Remaining Life
for Equipment
Equipnent
Turbine
Generator
Motor
h p
Conponent
Rotor.
Blade.
Cas i ny.
Main Stop
Va I ve
Stator Coil
Shaft
-+ CREEP
FAT I GL!
D Map nethod
sys lem
Fan
Electric
Va I ve
Packing
Beat
Exchanger
Tube
Pipe
Tube
Control
carbon seal
0 ring
Hardness measurement
3.1.4
Temper embrittlement
-~
Uestructive
Electric
Res istance
Test
Hardness
Test
Sampling
Test
Test
Test
I
Potent i a 1
Difference
Decrease
in Electric
es is tance
Decrease
in
Hardness
E l
Temp.
FATT
SP Energy
Maintenance Records
Fig. 3 The Diagnostic Process of Remaining Life Evaluation for Turbine Rotor
149
Part i a 1 d i scharge
test ; Maximum
Fig. 4
16
14
162217 hr
=5611
Tiaa
VR = 73.54 I
12
A 10
Stw
U
tb!%
a
6
4
2
00
Klm
150
Measured
BDF
(3
Ol
Fig. 6
IA
IB
IC
ID
IE
IF
Estimated BDV of Actual Used Generators
3.2.2
D Map method
The another estimation technique is the "D map"
method. This method evaluates the voids that aere
produced and measures discharge electrical Fig. 7 D Map
magnitude by nondestructive tests, such as tan 6
and partial discharge tests.
Values that are useful in detecting void
discharge i n the electrical diagnoses, are AC
lzn
current change ratio ( A I ) and tan 6 change ratio
( A 2 ) , which represent the extent of average Sln0
deterioration, and &ax, which represents the
extent of local deterioration. The relationship >
between
the
values
was
obtained
from 2''
nondestructive tests, and BDV has been studied by
40
examining many used coils and is obtained using ;
a
:
10
the following eq. (2) :
r
al
VS=lOO
-l.s(A -0.8)
Estimated value:Vs(%)
(2)
Fig.
8 Comparison between Estimated BDV by N-Y
Map and Measured BDV
.....
_ _ N-Y
-D Map Min.
value
-+
~~
151
3.2.3
4. RESULUTS
The
comprehensive preventive maintenance
planning system has been actually applied to
maintenance plans of thermal and nuclear power
plants. Vie obtained good results by its
application. For example, a reduction of the
forced outage rate of nuclear power plants
(Boi 1 ing Water Reactor type plants by Hitachi Ltd.
as main contractor) improved from 0.3 times
/plant-year to 0.16 t imes/plant-year. The failure
rate in a thermal power plants also improved from
1.4 times / 6 months to 1.0 time/ 6 months.
Failure 'of a boiler tube after inspection ,
diagnosis and repair, has not occurred.
II
3.2.4
152
REFEREMES
BIOGRAPHIES
Katsushige Onodera, PhD.
Hitachi Works, Hitachi. Ltd.
Operating Plant Services Center
1-1, Saiwai-cho 3-chome. Hitachi-shi, Ibaralii-Ken, 317 JAPAN
Katsushige Onodera is a mannger in the operating plant
services center. Since joining Hitachi horks in 1961, he has
been involved in re1 iabi I ity analysis and qual i ty assurance
activity in a nuclear power plant.
His PhD in engineering is from Tokyo University in 1990:
his B.S. in Electrical Engineering is from Yamagata
University in 1961.
He is a member of International Electrotechnical
Commission(1EC)- Dependability (IC-56),and a director of
Reliability Engineering Association of Japan(REAJ).
153