DIGITAL TOOLS APPROACH FOR GENERATOR

STATOR & ROTOR PERFORMANCE ONLINE

MONITORING

CONFERENCE ON ELECTRICAL POWER EQUIPMENT

DIAGNOSTIC ASIA 2023 (CEPED ASIA 2023)

Ir. M Hamdan B Kamarul Baharaini (Petronas Gas Berhad)

Mohd Helmy Halim (MHH Condition Monitoring Sdn Bhd)
21.11.2023

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

PROJECT BACKGROUND
CASE FOR CHANGE
▪ Gas Turbine Generator units in Plant 1 & 2 located at Terengganu, East Coast of Malaysia experienced premature alternator failure and performance
degradation due to electrical issues and subsequently resulted in power failure and power import.
▪ There is no online monitoring system and digital tools to monitor alternator healthiness, leading to unit failure and cause unplanned outages.
Originally, maintenance program for alternator is based on time-based method.
▪ Since 2017 to 2020, Asset Team spent approximately RM35Mil for alternator corrective action and power import due to the several tripping events.
▪ Subsequently, all GTGs undergone Partial Discharge repair and rewinding activities at local workshop in 2017, 2018, 2019 and 2020. Therefore,
comprehensive solution and modern online monitoring is crucial to be introduce and ensuring alternator reliability for earlier failure detection as
well as facilitate prediction for third level maintenance program to avoid un-planned outages leading to power import penalty.

BUSINESS REQUIREMENT
BUSINESS REQUIREMENT

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

GAS TURBINE GENERATOR OVERVIEW

Hot air from

turbine

Fresh air for

cooling

Generator
Gearbox Compartment

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

Problem Statement / Issues

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

PRE-FAILURE SYMPTOM
Increment in excitation current values against power
produced by generator & Open Circuit Curve (OCC)
Characteristics validation

Increment on NDE bearing vibration value

Generator not able to achieve rated

active power Rotor winding resistance
degradation & increasing partial
discharge

Early Indications of Generator Problem

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Rotor winding experienced Inter-turn short in 2017 and 2018 due to prolong overheating running condition
without online monitoring. The units required four (4) un-planned outage for re-winding process.
Plant 2 GT-B – Rotor winding inter-
turn short due to overheated and
Stator winding failure due to high Plant 1 GT-B – Stator winding Plant 1 GT-B – Stator winding
PD reading. detected high PD and detected high PD and
required PD rectification. required PD rectification

All Generator units found carbon particle generated from PD development during yearly inspection

2017 2018 2019 2020 2020

Plant 2 GT-A – Rotor winding inter- Plant 1 GT-A – Stator winding burn
turn short due to overheated and due to PD high reading and Rotor
Stator winding failure due to high winding inter-turn short due to
PD reading. overheated

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 Problem Statement: Stator winding experienced flashover in 2019 and 2020 due to high Partial Discharge reading
without proper control & monitoring system. The units required un-planned outage for four (4) months for re-
winding process.

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

BUSINESS REQUIREMENT
Generator Rotor Unhealthiness Notification (GERUN) and Partial Discharge Online Monitoring (PD ONLINE) projects were initiated to provide
instantaneous indications of the alternator’s health and PD trending monitoring. The projects are categorized as digital transformation
initiatives (Revolution 4.0) as to enable online monitoring & performing diagnostic and prescriptive.
▪ Diagnostic & prescriptive provides asset owners with insights on alternator’s health, subsequently preventing unforeseen failure in real time
▪ Prescribe operational mitigations to prolong alternator’s life
▪ Recommends targeted test and maintenance (Third level predictive maintenance) addressing the exact health issues of the alternator

FRAMEWORK

Real-time plot of Performance Curve • Live OCC or V-Curve plot

Indexation of operating area • Color coding (Green – Healthy, Yellow – Warning, Red – Danger)

Remnant life • Estimation of remaining life of generator rotor through losses calculation

▪ Tailor-made for each plant’s electrical system

Specific prescriptions
▪ Workshop with operator required for concurrence on proposed prescriptions

Web-based interface • Digital visualization and dashboarding of alternator healthiness index

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

SOLUTION

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Solution: Development of digital tools and online monitoring system (Revolution 4.0)
(1) GERUN - Generator Rotor Unhealthiness Notification
(2) PD ONLINE - Partial Discharge Online Monitoring
• Tags development & availability/readiness in PI server.
• Algorithms and Dashboard development
• Analytics and visualization development commence when both algorithm and PI tags are ready
• Health Status
• Rotor Remaining Life
• Summary of equipment
healthiness
GERUN • V Curve
• Parameter Trending
Equipment ENMC/IMCS Regional/Plant PGB PI AF • Bearing & Winding
Server PI Server Temp
Generator Generator • Prescriptive on
• Generator • Calculation deviation
Data Data Analysis
Voltage, V (kV)
• Power Factor (pF) • Limit Setting PD ONLINE
• Reactive Power • Notification • PD trending
(Mvar) Setting • Prescriptive on deviation
• Active Power Digital Dashboard • Online report
(MW) LEVEL 4.0
• Generator
Current, I (A)
• Excitation
Current, Iex (A)
PGB – LEVEL 2, 3, 3.5
• Running Hour

PI TAGS READINESS + PI SERVER

FUNCTIONAL
ACCESS
DESIGN SPEC
ANALYTIC
KICK VIZ DEV GO
DEV UAT
OFF! (PI Vision) LIVE!
(PI AF)
DATA ALGORITHM
FIXES
GATHERING DEVELOPMENT

Data Engineering Data Analytics Deployment

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

GERUN: Generator Rotor Unhealthiness Notification

GERUN will provide the healthiness of Alternator which integrate to Digital Dashboard and provide remote monitoring from any location with VPN
connection to local network. The system able to monitor, notify and provide prescription as a guideline for operator interventions if there is any
deviation or anomaly. GERUN is design to monitor generator performance through V-Curve, bearing & winding temperature trending, rotor remaining
life and others critical parameter. Analysis & diagnostic can be performed online, and digital reporting will be generated in real time.

SAMPLE PAGE

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

PD ONLINE: Generator Partial Discharge Online Monitoring System

▪ PD ONLINE will provide Partial

Discharge Online Monitoring meeting
revolution 4.0 which also integration to
Digital Dashboard will provide remote
monitoring from any location with VPN
connection to local network.
▪ PD OLINE system able to monitor, notify
and performing online analysis &
diagnostic on PD pattern, generate real
time reporting and provide
recommendation to operator for 3rd
level maintenance planning.

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

GERUN and PD ONLINE Development Milestone

The project required 14 months to complete starting from technical & specification development till GO-Live. Budget approval and
procurement process are the significant milestone need to be monitored. UAT also one of bigger challenge to ensure all data, design,
development process and algorithms are working as per intent and meeting system requirement
Timeline/
Q1 Q2 Q3 Q4 Q5
milestone

Develop Technical
Specification &
SOW

Tendering &
Procurement

Kick off

Data Gathering

PI Tag Readiness

Algorithm
Development

Analytics
Development

UAT

Functional Design
Spec
Development

GO Live

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PROJECT STEERING COMMITTEE : PROJECT REGISTRATION SUMMARY

VIDEO SIMULATION ON PD ONLINE

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RESULT & CONCLUSION

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RESULT & FINDINGS
• On 27th of June 2023, one of the units experience high values of PD charges. The OMICRON PD online devices indicate micro voids/cavities
embedded within the main insulation.
Years of Uo = 6.6kV
Unit Operation/ Measurement
Operation U(Red) V(Yellow) W(Blue)
2018 4.414nC (2MHz) 16.37nC (2MHz) 26.71nC (2MHz) Offline PD measurement
2019 25.43nC (2MHz) 4.790nC (2MHz) 2.135nC (2MHz) Offline PD measurement
GTA 2020 1.286nC (2MHz) 1.396nC (2MHz) 1.388nC (2MHz) Offline PD measurement
2022 22nC (4MHz) 17nC (4MHz) 6nC(4MHz) Online PD measurement
2023 23nC (4MHz) 21nC(4MHz) 43nC(4MHz) Online PD Measurement

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 CONCLUSION

• The system provide remote monitoring, analysis and diagnostic makes available data
for engineer and expert accelerates productivity. The system provide remote
connectivity advancements in security and data reliability.
• Prediction diagnostics can elevate operation experiences and make operations more
efficient improve design flaws and enable smarter decisions. Viewed as strategic goals
to minimize downtime and reduce costs
• Continuous monitoring promotes reliability and solves maintenance issues before they
become problems. Able to see seasonal or other variations in levels caused by certain
dynamic such as temperature, vibration, PD energy & pattern and loading. Enable
earlier failure detection and to facilitate 3rd level maintenance program resulted no
other un-planned outages after implementation in 2021.
• More sensors located throughout a monitored object allow for earlier detection of
partial discharge activity and can provide additional information on problem location.

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Thank You for Your Passion

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