A long-standing illustration of probability modeling, the bathtub curve highlights how- as rotating equipment like a generator reaches late life cycle stages- the risks of failure can not only increase, but can do so almost exponentially.
Water-cooled generators in fossil plants typically experience an operating life of 30-40 years, depending on the site’s operating profile. At this late life cycle stage, one of the risks for an aging unit is hydrogen leakage into the generator’s stator winding. Specifically, once a generator reaches 25 years of age, the probability of experiencing this issue within the next six years is 65%.* Such leaks can lead to a forced shutdown of your operation… and all of the associated impacts.
If left undetected, a hydrogen leak can lead to windings running hotter than normal which can deteriorate the unit’s insulation. If not addressed, this anomaly can ultimately lead to the electrical failure of stator bars, possible damage to the generator core and contamination of the rotating field.
Expectedly, the greater the damage extent the bigger the impact to your bottom line, both in repair costs and lost revenue from downtime. Stator-related damage alone could result in millions of dollars in repairs, with incremental costs likely if the generator’s core or field are impacted. In tandem with downtime, an undetected failure of this nature can total tens of millions of dollars. This is where the power of software comes in.
Once a generator reaches 25 years of age, the probability of experiencing hydrogen leakage within the next six years is 65%*.
By applying sensors and associated components to your generator, you can monitor the unit- in real time- and benefit from an early detection warning of hydrogen leaks. Beyond detection, SLMS enables you to monitor the rate of leakage, which informs operating adjustments that can be made to mitigate damage progression until service can be performed. In parallel, the technology helps maintain the cooling water oxygen level… also delaying further damage and allowing for more planning time to resolve the issue.
Additionally, your unit’s data can be fed to our Monitoring & Diagnostics team to assist you in assessing the status of your generator and, if a leak is detected, help you monitor its progression. If you prefer to keep your operating data private, your team has the option to monitor generator activity on site, independently.
SLMS technology can typically be installed in a matter of days. This makes integrating the process into an overall planned outage schedule fairly straightforward. In fact, such insights may even compress your outage timeline by alleviating the need for on-site testing of stator components.** And, if the issue can’t wait for planned maintenance, your downtime is minimal to reap the benefits of evading potentially significant operating and financial impacts.
It's a no-brainer for late life cycle fossil operators.
Learn more about our stator leak monitoring, and other generator health monitoring capabilities, or contact us for more information.
*Source: GE Vernova engineering
**Requires having Phos-Free stator bars & cx-rings.
On-site Services Specialist, GE Vernova
With 12 years of experience in the energy sector—including a decade with GE Vernova—John Deyette is a specialist in electro-mechanical testing and software technologies. In this role, he manages on site activities including the installation, commissioning, testing and repairs of digital technologies including stator leak monitoring (SLMS). Additionally, he trains plant operators on how to use the SLMS system, and coordinates with engineering specialists to develop enhancements to infuse the latest technologies and address evolving customer needs.
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