SP 24 en

WEC REGIONAL ENERGY FORUM – FOREN 2008
Neptun, 15-19 June 2008
Reference no: Sp-24-en
ON-LINE MONITORING OF THE HYDRO UNITS CONDITION IN IRON

GATES I HPP
POSSIBILITIES OF PREDICTIVE MAINTENANCE IMPLEMENTATION
Ioan Nicolae BLEIER Helmut KECK

Hidroelectrica S.H. Portile de Fier, Romania VA Tech Hydro AG, Switzerland
Dragos Marian NOVAC Viktor Ado MEIENHOFER
Hidroelectrica S.H. Portile de Fier, Romania VA Tech Hydro AG, Switzerland
ABSTRACT
After an operation period of almost 30 years and more than 200.000 operation
hours for the hydro units, in 1997 started the execution of the refurbishment project
for the hydro units in the Iron Gates I HPP. At present the works at the last unit were
finalised.
The aim of the hydro units refurbishment project was that after a long
operation period, with the occasion of some important overhaul works (with complete
dismantling of the hydro units), the components showing moral and physical wear
and tear to be replaced, to have increased the installed capacity and enlarged the
operation domain, taking into account the changes in respect of the hydro-energetic
conditions (increasing the downstream level) and to have implemented the newest
technologies and materials at the moment.
Another task aimed by the employer was the installation, with this occasion, of
an on-line monitoring and diagnostic system for the refurbished hydro units, mainly
in view of creating a new maintenance concept, instead of the planned maintenance
(based on a certain number of operation hours) which was applied until the start of
refurbishment works.
This paper presents the system of on-line monitoring and diagnosis of the
hydrounits, its functionality and the experience got with the target of a new
maintenance philosophy.
1
Overview of the Iron Gates I hydro power plant.
The left part of the plant belongs to Serbia, the right part to Romania
2
1. Introduction
The hydro power plant Portile de Fier I on the Danube was commissioned
between 1970 and 1972 with six 190 MVA hydro units equipped with Kaplan
turbines, each on the Romanian and Serbian side. With these 12 units of 9,5 m runner
diameter, it is the largest river power station in Europe. After 25 years of operation,
site investigations shown that a complete refurbishment of the turbines and the
generators would be necessary, since cracks in important turbine parts and dramatic
decrease of the generators insulation level were increasing operational risk.
The studies carried out have shown that, from technical-commercial point of
view, it was justified to increase the unit output power in the same time with the
refurbishment works, up to 216 MVA, target which has been reached without any
civil works.
In 1997, SULZER Hydro, now Andritz VA Tech Hydro, was awarded by the
Romanian Electricity Company CONEL the refurbishment contract as the main
supplier. The main sub-suppliers were ABB Switzerland, Energomontaj Romania,
Electroputere Romania, UCM Resita Romania. After CONEL restructuring, this
project was managed by S.C. Hidroelectrica S.A. and their subsidiary Iron Gates, as
Employer.
Together with these works the old automation and control system was
completely replaced and a new on-line monitoring and diagnosis system was
additionally implemented. This system has been implemented starting with the
commissioning of the first refurbished unit in the year 2000 and it has been subject to
a continuous process of improvement (“learning”) during the next years, at present
having an almost definitive configuration.
2. Description of SUDIS (SUlzer monitoring and DIagnosis System)

2.1. General
The SUDIS is a computer based system to support condition based maintenance
of machines, plants and processes. The system continuously monitors and diagnoses
the condition of the hydro-units to ensure early detection of potential damages. This
not only increases the availability of the units and reduces the maintenance outages
but also enables optimal operation and service planning.
The system consists of following modules:
- Acquisition and storage of process variables;
- Visualization and supervision of condition;
- Early detection of deviations such as wear, fouling, clogging etc.;
- Planning of maintenance;
- Smart MONITORTM to eliminate the influence of turbine and generator
operating points and the ambient conditions.
The philosophy of the presented system is the overall condition judging with the
implemented diagnose tools for the turbine – generator and therefore the early
recognise of overloaded and worn out components and the indication of the hydro
unit operation condition.
Assessment of these data by the operator or specialists enables preventive
(condition based) maintenance.
3
An overview of the dignostic system is shown in Figure 1 as block diagram, with
its hardware and software modules embedded into the PCS (Power Control System).
Figure 1. Block diagram of the plant diagnostic system with its hardware and software modules embedded into the plant
automation system.
The monitored components include all larger mechanical and generator specific
modules essential for the hydrounits operation. For the detection of wear, clogging
and/or errosion processes, monitoring modules are implemented. Special overall
performance monitoring modules using a priori physical knowledge are also built into
the system. An overview of the monitored components and the supervised parameters
are shown in Figure 2.
4
Figure 2. Overview of monitored components.
2.2. Functionality of SUDIS

For better understanding of the functionality of SUDIS, in this chapter will be
presented how the system works to fulfill the above mentioned targets.
a) Data acquisition
On per unit basis, SUDIS gets vibration, air gap and partial discharge signals via
FTP over Ethernet from an ABB HPM System (Hydro Power Monitoring). All other
signals and events are exchanged via OPC (Ole for Process Control). Out of 1000
signals available per turbine, SUDIS and its modules use about 450 signals for
diagnosis purposes. For better understanding see also Figure 1.
b) User friendly GUI (Guide User Interface)
SUDIS also provides an user-friendly GUI (STR00) for Smart MONITOR
displaying all the required figures, trends and information, as early warnings and
shifted confidence intervals to allow the specialist to do predictive maintenance.
c) Smart MONITOR
SmartMONITOR is the heart of SUDIS, notifying abnormal behaviour of
industrial process components. In very simple terms, smartMONITOR functions in
the following manner: The measured variables of any industrial process are
reproduced by means of mathematical models and compared with the actual values
from the process. The difference, the residuum, is practically zero for the damage-
free conditions, where the model correlates with the process. Since the model follows
all the load and operating point changes exactly like the process, these variations
have no influence on the residuum. If the process shows signs of e.g. wear in the
course of time, this will have an effect on the measured variables. With constant wear
phenomenon, the residuum will exhibit an increasing tendency, which can be
evaluated and an early warning can be triggered
5
(see item “d” for more details)
d) Model based Process Supervision
d1) Introduction to method
Often condition monitoring in an industrial context is still interpreted as
comparing single process variables to the pre-selected alarm thresholds. This
approach is not well suited for condition monitoring purposes because it does not
optimally use the information contained in the measured signals. A much more
efficient approach can be reached by means of models which describe the relations
between the measured process variables. Process models can be obtained by
exclusively using a priori knowledge about the physical relationships between the
variables. Considering the large number of models required for a successful
monitoring of all the components shown in Figure 2, this approach is very time
consuming and expensive. A more promising method used here, is to obtain the
models directly from the measured data through a method called system
identification.
Based on ARX (Auto-Regressive with eXtra inputs) Multi-Input-Single-Output
Models the main concept of smartMONITOR is the evaluation of the difference
between the process and the model output, which is called residuum. As long as it
stays inside the manually or automatically adjusted confidence interval, no wear or
clogging trend is present. When the signal leaves the confidence interval a so-called
“early warning” is triggered
input signals measured signals

process
+ residuals
_ Early warning triggered
model
reconstructed signals
Figure 3. Bearing temperature of a water turbine over a period of almost one year (with seasonal influences). A value which
simulates increased friction is added from Day 120 on. Around Day 160 smartMONITOR would detect the wear trend and trigger an
“early warning”.
ARX model has the advantage that its model parameters can be estimated
online without a large computational effort using the well-known RLS algorithm
(Recursive Least Squares) [LJU99]. Thus given an initial preliminary model
parameter set smartMONITOR can provide a wear indication soon after it has been
installed on site. If at this early stage fixed confidence intervals were used, false wear
trends could be indicated. Therefore, the confidence interval is automatically adjusted
6
in order to reflect the model parameter uncertainty and the computed noise until the
system specialist decides to set them to constant values after the training period.
Figure 4. ARX model parameter estimation with RLS algorithm and condition monitoring with adaptive confidence levels (or
warning threshold), illustrated with one of the performance models, the model for the active power P.
d2) Fingerprint
As already mentioned data driven models need a training phase. During this
phase a fingerprint is taken by collecting all required process signals. This phase has
to include the seasonal influences as different river water and ambient temperatures,
different tail water levels and heads. Therefore a fingerprint phase of one year is
required. This collected data allows the system specialist to fix the model parameters
and to set the confidential intervals to constant values. To support the specialists a
tool named smartTOOL can be used which allows calculating the optimal model
parameters.
d3) Examples of modelled processes
Since commissioning of the first unit in autumn 2000 about 900 models have
been parameterized. The models of the last unit are in training mode until spring
2008. From this set a selection of models will be illustrated in detail in this section
using data collected with a nominal sampling interval of 60 seconds. Note that only
set points with P larger than 40 MW are modelled (minimal P allowed is 60 MW).
This explains partly the gaps in the following figures, other reasons for the gaps are
revision stops and communication interruptions. The plant mainly provides peak
power (see also Figure 4). Therefore the turbine is running in irregular intervals and
with different loads which increases the difficulties to model the different processes.
3. Experience with SUDIS in Iron Gates I HPP

3.1. General concept to implement condition based maintenance using SUDIS
As presented in this paper, the first aim of the SUDIS system is to assure input
data for a new maintenance concept. Our experience shown us that in order to prepare
this new concept, the steps specified below have been done.
A. Colect the relevant input data for a condition based maintenance applicable for
Iron Gates I Hydro Power Plant as follows:
7
i) Identification of the systems, subsystems of the hydro units which lead
to a improper behavior, having in mind the specific aspect of losses in
the production of electrical energy caused by:
- not using all the hydraulic potential of the Danube
- non fulfillment of the contracted ancillary services
- disturbance in the offered hourly production
ii) Settlement of the causes that may lead to the non-functionality or to the
bad functionality of the systems, subsystems identified at item 1.1
above.
iii) Identification of the predictive maintenance which can prevent the
occurrence of the causes listed at item 2.1 above, together with the
necessary spare parts, special tools and devices, as well as the necessary
financial support for the works.
iv) Creating a functional system for data acquisition and analysis of the data
that arise from the activities of the condition based maintenance. This
system need to be treated statistically, the data being compared with the
analysis of the existing trends validated by experts, at the end being used
as reliability figures (markers).
B. Colect information about the essential conditions for the application of a condition
based maintenance means the knowledge of the following:
i) initial status of the systems, subsystems - component installations of the
hydro units;
ii) wear and tear tendency of the above mentioned systems, subsystems
related to the operating conditions (e.g. secondary regulation, primary
regulation, discharge, temperatures, oil quality, cooling water quality
etc.);
iii) basic information from the equipment suppliers, comprised in the
Operation and Maintenance manuals;
iv) operation and maintenance experience of the employer got during 30
years of activity.
The management of Iron Gates I Hydro Power Plant decided to follow the
above mentioned steps and to create, as an intermediate stage, conditions for
predictive maintenance.
In the actual stage, Iron Gates I Hydro Power Plant started the preparation of
the predictive maintenance, using data from the installed SUDIS system, taking the
advantages of knowing very well the initial conditions for all the equipment after the
performance of the refurbishment works.
In this chapter the actual stage of the above mentioned concept implementation
using SUDIS is presented.
SUDIS Model Status SUDIS Model Status

Performance Generator cooler cold Cooler 1-18
monitoring air outlet
Thrust bearing 20 inner and 20 outer Average air gap 8 measurements
segment temperature
8
Thrust bearing water 4 temperatures Minimal air-gap 8 measurements
outlet
Thrust bearing oil 2 temperatures Overall core vibration 6 measurements
tank temperature
TUGB segment Segment temperatu- Gap wear 1 measurement
res: 2, 5, 8, 11
TUGB oil tank 1 temperature Overall wear 1 measurement
GNCB water outlet 1 temperature Overall of TB Z abs 1 measurement
GNCB segment Segment temperatu- Overall turbine cover 1 measurement
res: 1, 2, 3, 7, 10 vibration z abs
GNCB oil tank 1 temperature GNCB vibration Residual in x and y
direction
Auxiliary generator 12 temperatures (4 TB vibration Residual in x and y
winding temperatures temp. for each phase) direction
Generator core 9 temperatures TUGB vibration Residual in x and y
temperatures direction
Generator main 9 temperatures (3 Vibration orders 1 and 2 order
winding temperatures temp. for each phase) amplitude at GNCB,
TB, TUGB in x and y
direction
Generator temperatu- 3 measurements Partial discharge 4 apparent charge and
res at low-end teeth 4 discharge measure-
ments
Generator temperatu- 3 measurements Shaft seal Gradient supervision
res at up-end teeth
Note: All models at hydro-units 2-6 are “active” and only for hydro-unit 1 they are in “learning”
stage.
From the list above it can be seen that not all signals measured (about 400) have
been modelled. This is because some signals are not a direct system parameter output
suited for model diagnose purposes or are redundant with other signals. Below are
presented two examples of parameter modelling in SUDIS.
3.2 Examples of parameters modelling in SUDIS
3.2.1 Thrust bearing:
The thrust bearing consists of 20 inner and outer segments that according to
Figure 3 are completely immersed in oil. The oil tank temperature which is modelled
separately must therefore be chosen as model input. After an initial lift using pressure
oil, the vertical position of the shaft is maintained by fluid dynamic forces in the axial
bearing only. The bearing clearance decreases with the turbine load, leading to higher
friction forces and therefore to higher temperatures. To add the influence of the
turbine load to the model, the active power P was included as model input. To
improve the model quality higher order of oil tank temperature and power were also
selected as inputs.
9
Figure 5. Measured and modelled inner thrust bearing segment temperature with computed residuum. As a response to a step from P
= 0 to P = 190 MW the steady state temperature is reached only after two hours.
3.2.2 Generator Air Cooler
Figure 6. Measured and modelled cold air cooler outlet temperature with residuum. The long-term temperature trend is
mainly influenced by the river water temperature.
The air used to cool the windings on the rotor and the stator is driven through a
water-cooler by centrifugal forces. The cooler is fed by river water. To monitor the
condition of the cooler, its cold air outlet is modelled as a function of the warm air
inlet and the river water temperature. Additionally, to include the small influence of
the case temperature, also the ambient air temperature measured near the thrust
bearing was selected as model input.
Figure 6 shows that the cold air temperature long-term trend is mainly dominated
by a seasonal effect, namely the variation of the river water temperature. Short-term
trends are influenced by turbine load variations.
3.3 Examples showing the use of SUDIS for maintenance purposes
The supplier together with the employer have implemented in SUDIS a “Maintenance
info files for Iron Gates I HPP” that is used as shown in the following examples.
Example 1 - Generator cooler cold outlet air temperature alert
Possible reasons of increased temperature
- air in the water cooler
- sensor problem
10
- improper function of inlet or outlet valves
- clogging of the cooler
Actions according to the Operation & Maintenance manuals:
- check the water inlet valve position
- check the water outlet valve position
- check the discharge on inlet pipes (water supply)
- check the functionality and the number of filters in operation
- aeration of the cooler
- check and clean the sensor
- shortcut (close) the water entrance in the cooler
Figure 7.1 Modelled signals for generator cooler (marked with red boxes)
Example 2 - Vibration level alert (without increasing of the hydrounit noise level)
Possible reasons of increased values:
- unbalance
- changing in shaft alignment
- loosen parts
- changing the shape of the generator stator or rotor
- self-excitation vibration etc.
Actions according to the Operation & Maintenance manuals:
- use HPM to go into details:
o spectral analyse to define the frequency component with increased
value
o connect the software to separate the original shaft alignment
component from the overall vibration level
o announce the expert
11
Figure 7.2 Modelled signals for vibration (marked with red boxes)
Example 1 shows the procedure when the chief operator may perform by himself
further investigations (with the supprt of the shift working operating team) to clarify
the reason of the alert and to decide the immediately necessary actions.
Example 2 shows the procedure when the chief operator needs the support of some
experts to perform further investigations to clarify the reason of the alert and the
necessary further actions.
These info files were mainly structured so: at the moment when an alert signal is
arising in SUDIS and any other alerts from the Automation & Control system of each
hydrounit are not activated, the chief operator is enabled to operate safely the
hydrounit, until the hydrounit will be stopped without losing energy and the
maintenance / repair works are well prepared.
These information collected from SUDIS models and the results of further
investigations are stored and, together with the requirements from the Operation &
Maintenance Manuals refering to the necessary maintenance works after certain
operation hours for different components (hours counted also in the SUDIS), will
allow the management to decide when the unit will be stopped for the required works
performance.
3.4 Experience with the OPM (Operating Point Monitoring) in Iron Gates I HPP
Into the SUDIS has been implemented a function for hydro-units cavitational
behaviour analysis, using the phenomenon of conversion of the acoustic emission
produced by cavitation into vibrations, that have to be correlated with the cavitation
errosion.
Because this function needs a long learning period, it has been additionally
implemented the OPM function based on the model tests and on the experience got
during the inspections performed after 8’000 hours of operation related to the
monitoring of the cavitational behaviour.
12
Figure 8. OPM display
13
4. Conclusions
SUDIS is a monitoring and diagnosis system adequate for the monitoring and
interpreting the hydro-unit operation, which allows the hydro-unit operation in the
conditions imposed by the designer and the early detection of the defects that arise
during operation.
SUDIS is a system adequate for the data acquisition in view of developing and
implementing the concept of condition based maintenance. This process needs a
learning period during which, according to the authors opinion, the stages presented
in this article must be followed (went through).
The monitoring and diagnosis system SUDIS may be used also to the hydro-units
in operation (not in process of modernisation) on the condition of mounting the
necessary instruments to get the system data and to achieve the communication
interfaces. These works can be performed during a planned stoppage for maintenance
works.
In case it is wanted to use within the SUDIS the information from the already
installed instruments (e.g. air gap, vibrations, partial discharges, temperatures etc.),
there have to be designed and realised the interfaces by means of which these on-line
and off-line monitoring systems should communicate with the SUDIS.
Curricula vitae
Ioan Nicolae Bleier

Born on 6th of December 1944 in Timisoara, Romania. He graduated in 1967 the
Electrotechnical Faculty in Timisoara, afterwards being employed as engineer at the
“Vehicle repair enterprise” between 1968 – 1969 and as design engineer at the
“Regional electricity supply enterprise” Timisoara between 1970 – 1973. Then he
became the head of maintenance department Iron Gates I HPP between 1973 – 1995.
When the refurbishment project started he has been named deputy technical and
refurbishment director in RENEL, Iron Gates subsidiary in the period 1995 – 1998, at
present being deputy Iron Gates I refurbishment director, in Hidroelectrica, Iron
Gates subsidiary and Project manager for Iron Gates I refurbishment project.
Dragos Marian Novac

Born on 25th of May 1965 in Drobeta Tr-Severin, Romania. He graduated the
Electrotechnical Faculty in Bucharest in 1989, being afterwards employed as
engineer in the maintenance department Iron Gates I HPP between 1990 – 1995 when
he became the head of maintenance department Iron Gates I HPP being employed as
such until 1998. When the refurbishment project started he has been named the head
of refurbishment department Iron Gates subsidiary between 1998 – 2001. When the
second refurbishment project started, he has been named deputy Iron Gates II
refurbishment director in Hidroelectrica, Iron Gates subsidiary and Project manager
for Iron Gates II refurbishment project until 2004. At present he is the deputy
technical director in Hidroelectrica Iron Gates subsidiary.
Helmut Keck
14
th
Born on 5 April 1951 in Vienna, Austria. He graduated the Mech. Eng. at Techn.
University, Vienna in 1974, being employed as research assistant prof. at Techn.
University, Vienna between 1974 – 1977. Afterwards he has been employed on
various positions in Escher Wyss / Sulzer Hydro, Zürich
Between 1978 – 1999. From 2000 until now he is Vice President of VA TECH
HYDRO AG, Head of Technology and R&D of the ANDRITZ VA TECH HYDRO
Group, including R&D for Turbines, Pumps, Generators and Automation Systems.
Viktor Ado Meienhofer

Born on 31st of January 1949 in Hefenhofen, Switzerland. He graduated as a Dipl.-
Ing. (M. Sc Electrical Engineer) the ETH (Swiss Federal Institute of Technology,
Zürich) in 1973. From 1974 to 2004 he was employee of SULZER Ltd. Winterthur,
Switzerland, with different positions: between 1974 – 1978 as an engineer for water
treating system; between 1978 – 1990 as the Head of implementation of data
acquisition systems for weaving machines; between 1981 – 1990 as the Project
Manager for development of data acquisition systems for jet engine test beds;
between 1990 – 1997 as the Head of development of building automation system;
between 1997 – 2004 as the Project manager for SUDIS (Sulzer Diagnostic System)
and governors for hydraulic machines. From 2004 until now he is employee of VA
TECH HYDRO LTD, Kriens, Switzerland working as Project manager for SUDIS
(Sulzer Diagnostic System) and governors for hydraulic machines.
15

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WEC REGIONAL ENERGY FORUM – FOREN 2008

Neptun, 15-19 June 2008

Reference no: Sp-24-en

ON-LINE MONITORING OF THE HYDRO UNITS CONDITION IN IRON

Ioan Nicolae BLEIER Helmut KECK

2. Description of SUDIS (SUlzer monitoring and DIagnosis System)

Figure 2. Overview of monitored components.

2.2. Functionality of SUDIS

input signals measured signals

_ Early warning triggered

3. Experience with SUDIS in Iron Gates I HPP

SUDIS Model Status SUDIS Model Status

3.2.2 Generator Air Cooler

Figure 8. OPM display

Ioan Nicolae Bleier

Dragos Marian Novac

Viktor Ado Meienhofer

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