Potential Generator Failure at a European Hydropower Plant
Project Generators As part of Monitra’s flexible hydro testing solution, we facilitated partial discharge (PD) testing across several hydroelectric generation sites for our client. The data was collected and managed in Atlas by Monitra™, providing asset condition information and recommendations. Europe
Testing Solution Non-intrusive PD testing was conducted across several sites using High Voltage Coupling Capacitors (HVCCs) and a Kronos Spot Tester unit via an external connection box.
Figure 1 HVCC and POA Termination Box Installation
Data across various generators was collected and reviewed in Atlas, which provided effective classification of different PD conditions across the machines. Monitra Data Analysts used this information to identify Generator A as an asset requiring further investigation.
Figure 2 Generator Summary in Atlas (Demarked for Case Study)
Case Study
Targeted Intervention Prevents a
Potential Generator Failure at a European Hydropower Plant
Results Data analysis revealed significantly elevated PD levels within Generator A, a 9.3kV, 36.5MVA Hydro Generator manufactured in 1995. The PD type was slot discharges which occur between the surface of a bar and the stator core as per the IEC 60034-27-2:2012 standard. This localised insulation deterioration within the generator signifies a heightened risk of failure during operation.
Based on this evidence, our customer opted for a targeted intervention – overhauling Generator A to address the root cause of the PD activity. Subsequent retesting validated the success of the remedial works, with PD levels reduced to within the acceptable range.
Figure 3 Phase-resolved Partial Discharge Patterns for Generator A before (left) and after overhaul (right)
Conclusions and Recommendations
Had this issue not been detected and addressed proactively, the consequence could have been a catastrophic in-service generator fault. A typical hydro generator full overhaul can take around 12 months including new bar/coil lead time and associated works, costing in excess of £1M. With this in mind, such non-intrusive testing as detailed herein allows prioritisation of tailored remedial works which not only saved a potential costly unplanned outage, but also extended the life of this generator.
The positive outcome reinforced the value of proactive PD testing and targeted maintenance. As a result, the customer has broadened their implementation of this program to include additional hydropower sites across their network. A number of other generators were identified with elevated levels of PD, with Monitra’s recommendation to increase the frequency of testing and/or conduct monitoring, to identify and track any trends which may indicate potential rise to insulation system failures prior to occurrence.
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