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Structural Health Monitoring with VibroFibre: Vibration & Temperature Measurement in Stator End Windings

Learn about VibroFibre™ Technology for vibration and temperature monitoring in stator end windings, its benefits, design structure, and installation process. Discover how it can prevent generator failures and detect hidden faults. Presented by Peter Kung, QPS Photronics Inc.

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Structural Health Monitoring with VibroFibre: Vibration & Temperature Measurement in Stator End Windings

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  1. The application of VibroFibre TM Technology to measure Vibration and Temperature in the Stator End Windings (SEW) A presentation By Peter Kung QPS Photronics Inc Structural Health monitoring with VibroFibre

  2. Objectives • Why you should know about the Static End winding (SEW) vibration problem • Failure mechanism in the generator • PD measurement • Invention of VibroFibre TM and how it can eliminate such risks Structural Health monitoring with VibroFibre

  3. Fire damage on the end windingcan be quite sudden Structural Health monitoring with VibroFibre

  4. End winding Overhangs Vibrate at 2 x Synchronous Frequency Structural Health monitoring with VibroFibre

  5. Relationship between Vibration amplitudes & looseness inside the generator • Vibration comes from rotor/stator interaction • Any looseness will increase the amplitude of this electro-magnetic force induced vibration • Wedges that are not tight • Windings are not tied down • Cracks in any stator bar • The end winding serves as a mechanical amplifier making it easier to measure Structural Health monitoring with VibroFibre

  6. Structural Health monitoring with VibroFibre

  7. Detecting these loose wedges used to require lengthy visual inspection Structural Health monitoring with VibroFibre

  8. Other options • You can pay GE $300K to perform an automatic robotic inspection • Good news is , it will help you locate looseness • Bad news is it might not find any, but your money would already be spent! Structural Health monitoring with VibroFibre

  9. QPS Photronics and Peter Kung Structural Health monitoring with VibroFibre

  10. Company Expertise and history • Invented The phase mask Technology • Pioneered in Fiber gratings technology , product and process development • Providing OEM products and solutions using fiber Bragg gratings technology • In 2006 Peter Kung invented and patented a Fibre Bragg Grating structure VibroFibre™ to measure vibration Structural Health monitoring with VibroFibre

  11. Fiber L Core Period, Λ Fiber Bragg Gratings Ir Measurand Induced Shift It Ii Transmitted Signal Reflected Signal λ λ λb λb λ What is a Fiber Bragg Grating? Structural Health monitoring with VibroFibre

  12. Benefits • FBG is small in size and light in weight • Long operating life of >25 years • Ideal for remote and distributed sensing • FBG sensor is passive, draws 0 power • Immune to RFI and EMI • Can work in hostile environment, like extreme temperature and high voltages Structural Health monitoring with VibroFibre

  13. Design Structure • By placing 2 such FBGs separated by a distance inside an optical fiber ,we will form a cavity, giving rise to interference fringes • Vibration signal would modify these interference fringes shifting them back and forth, intersecting a stationary laser , producing an intensity profile • Sensitivity can be controlled by a mechanical amplifier structure and by electrical gain circuit • Together they can calibrate the output to a standard sensitivity of 10mV per micron Structural Health monitoring with VibroFibre

  14. Twin gratings Cavity Structural Health monitoring with VibroFibre

  15. FBG Cavity Reflection Spectrum showing all the fringes Structural Health monitoring with VibroFibre

  16. These fringes have a bandwidth of 48 pm • These fringes are much narrower and give rise to higher sensitivities and also convert wavelength changes to voltages signal we can understand Structural Health monitoring with VibroFibre

  17. How we measure low frequencies Structural Health monitoring with VibroFibre

  18. Packaged to protect against dust oil and humidity Structural Health monitoring with VibroFibre

  19. Packaged SEW vibration sensor Structural Health monitoring with VibroFibre

  20. Opened Vibrofibre showing the vibrating platform acting like a mechanical amplifier Structural Health monitoring with VibroFibre

  21. In Y direction Structural Health monitoring with VibroFibre

  22. In X direction Structural Health monitoring with VibroFibre

  23. In Z direction Structural Health monitoring with VibroFibre

  24. Best place to install these sensors • For each phase, place the SEW sensor at the winding with the highest induced voltage • Place other sensors at locations 120, 240 degrees apart • Attaching VibroFibre sensor is easily done using epoxy on the end cap • For hydrogen cooled generator, we will use added tapes to secure the sensors Structural Health monitoring with VibroFibre

  25. Example of where we install Structural Health monitoring with VibroFibre

  26. On the other end Structural Health monitoring with VibroFibre

  27. First you clean the End Windings before you mount the sensors Structural Health monitoring with VibroFibre

  28. Installing Vibro Fibre sensor at the end cap at Radial and Tangential positions Tangential Position Radial Position Structural Health monitoring with VibroFibre

  29. VibroFibre™ Installed on Generator Structural Health monitoring with VibroFibre

  30. The vibration sensor can actually measure temperature • Fiber gratings are sensitive to temperature • The fringes would move left and right of the stationary center wavelength of the laser • We have developed an algorithm to track the peak of the selected fringe , and use laser current to track all the changes • These counter measures form the indirect temperature measurement Structural Health monitoring with VibroFibre

  31. Bearing Vibration Signals SERVER 4-20mA RS485- MODBUS NDE VibroFibre Signals DE Analysis & Trending Relays MIL - QPS SEW Generic Architecture Protection Monitor API670 QPS Data Logger Bearing Vibration & SEW Integrated Monitoring Structural Health monitoring with VibroFibre

  32. Prior to installation: Sensor Calibration Traceable to National Standards Structural Health monitoring with VibroFibre

  33. Sensor spectral characteristics Structural Health monitoring with VibroFibre

  34. Sensor Linearity Structural Health monitoring with VibroFibre

  35. Measures the fast temperature rise and vibration at the same time Structural Health monitoring with VibroFibre

  36. TG GUARD software can help you examine time domain signal Structural Health monitoring with VibroFibre

  37. TG EYE trending and long term FFT Structural Health monitoring with VibroFibre

  38. Showing the benefit Structural Health monitoring with VibroFibre

  39. Water Fall plot Structural Health monitoring with VibroFibre

  40. Hydrogen cooled generators at another customer site Structural Health monitoring with VibroFibre

  41. Hermetic sealed junction plate isolates the Hydrogen rich atmosphere Structural Health monitoring with VibroFibre

  42. Return on your investment • A small fraction of what you would pay for GE robotic tightness inspection (300K US) • 24/7 condition monitoring for LIVE! • Keep you from unplanned shut down and total assets loss • Savings can be Multi-million dollars • Cost of solution returned in 2 years Structural Health monitoring with VibroFibre

  43. Thank you for your attention contact Peter Kung Email peter@qpscom.com for your local distributor vibration measurement with fiber gratings 43 Structural Health monitoring with VibroFibre

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