INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM

STUDENT PARTICULARS
FIRST NAME LAST NAME MOBILE NO. EMAIL COLLEGE NAME ADDRESS BRANCH SEMESTER TEAM NAME SIGNATURE OF STUDENT 1.GOHEL SANJAY C. 1 9687150092 . Gohel.Sanjay26@gmail.com 2 . PRAJAPATI DHAVAL B. 9033224970

GOVERNMENT ENGINEERING COLLEGE,BHAVNAGAR VIDHYANAGAR, BHAVNAGAR-364002. MECHANICAL ENGINEERING YEA 7TH R SANJAY,DHAVAL

2011

INDUSTRY PARTICULARS
NAME CONTACT ADDRESS MOBILE NO. EMAIL ---------------INDUSTRY COORDINATOR--------------MOHIT B. PATEL C-3464,PATEL PARK,OPP.AYODHYANAGARI, KALVIBID, BHAVNAGAR 7567883107 Mohitb.patel@gmail.com ---------------INDUSTRY--------------2nd Floor, ACPC Building, L. D. College of Engineering Campus, Navrangpura, Ahmedabad,(Gujarat)India-380015.Phone:91-7926300699,Email:gtu_innovation_council@gtu.edu.in M:9909959336

NAME ADDRESS

EXCEL CROP CARE LTD 6/2,RUVAPARI ROAD, BHAVNAGAR MOBI LE BHAVNAGAR

CONTACT OFFIC NO. E NAME OF INDUSTRIAL ESTATE

7567883107

COMPANY LOGO

INDUSTRY DEFINED PROBLEM STATEMENT FORM TITLE OF PROBLEM/PROJECT Problem associate with effect of lubrication on the failure of bearing in turbine and blower.

DISCIPLINARY | INTERDISCIPLINARY

DISCIPL INE

INDUSTRIAL DEFINE PROBLEM (IDP)

Title of problem:
Problem associate with effect of lubrication on the failure of bearing in turbine and blower.

Problem indentificatoin
In EXCEL CROP CARE LTD, there are three turbines installed which are

 one of capacity of 17.35 mw/hr, two of capacity of 16.45 mw/hr, three of capacity of 5.40 mw/hr,

To generate the power of 58.00 mw/hr capacity. The turbine is the set of a generator, a gear box and a rotor. A barring mechanism is provided between the gear box and generator to rotate the shaft at the shutdown time. Bearing description: Bearings are a important component in major industries. Bearing problems can result in costly downtime, equipment damage and breakdowns. In addition, large industrial bearings represent a significant capital investment. This is especially true in industrial applications, where operating conditions tend to be harsh, loads are heavy, and contamination from dirt and scale are common.

Barring gear mechanism: It is the mechanism provided to rotate the turbine generator shaft at a very low speed after unit stoppages. Once the unit is "tripped" (i.e., the steam inlet valve is closed), the turbine coasts down towards standstill. When it stops completely, there is a tendency for the turbine shaft to deflect or bend if allowed to remain in one position too long. This is because the heat inside the turbine casing tends to concentrate in the top half of the casing, making the top half portion of the shaft hotter than the bottom half. The shaft therefore could wrap or bend by millionths of inches. This small shaft deflection, only detectable by eccentricity meters, would be enough to cause damaging vibrations to the entire steam turbine generator unit when it is

restarted. The shaft is therefore automatically turned at low speed (about one revolution per minute) by the barring gear until it has cooled sufficiently to permit a complete stop.

Turbine description:
The turbine to be supplied under this specification shall be installed in an existing turbine bay to complete the three-unit powerhouse. It shall be constructed to suit the existing water passages and powerhouse layout. The dimension and weights of the assembled parts shall be within the capacity and hook approaches of the existing 115-ton powerhouse crane. The turbine shall be designed and constructed to provide a high degree of reliability with minimum maintenance and shall be of rugged construction suitable for the operating environment and resources of the Employer. The equipment shall incorporate features to facilitate inspection and maintenance and to minimize maintenance requirements. Emphasis shall be placed on reliability, minimizing maintenance and protection of equipment rather than on maximizing turbine efficiency. The design shall be tolerant of misalignment and deformation of the concrete structures. The Contractor shall integrate the design of the turbine, generator, governor, inlet valve and pressure regulator to meet all specified requirements without conflict between the characteristics of the individual parts.

BLOWER:

In the blower ,which is run by the motor, is not working. Because the bearing which is mounted in the shaft, is damaged. The bearing is almost cracked and the hot air is remain in the formulation plant, so it is harmful to the workers which are worked in the plant.

Blower description: Blower having a impeller inside. outside it has a casing to protect the entire mechanism. The hot air is coming in the blower through the heavy pipe which is at the mounted on top of the plant, the impeller is forced this hot sir into the atmosphere. The blower should be designed with high degree of reability with minimum maintenance and constructed should be suitable to resources of the employer.

Literature review

ABSTRACT

Grease lubrication is widely applied to rolling bearings. The consistency of grease prevents it from leaking out of the bearing, makes it easy to use, and will give it good sealing properties.

The same consistency prevents an optimal lubrication performance. Most of the grease is pushed out of the bearing during the initial phase of bearing operation and no longer actively participates in the lubrication process, leaving only a limited quantity available, which is stored inside the bearing geometry and on the bearing shoulders (covers or seals). This stored volume strongly determines the remaining lubrication process in the bearing. The distribution of this volume is determined by the grease flow, which is very complex to understand due to the strong nonlinear rheology. There is no consensus on the next phase in the lubrication process. The grease may bleed and provide oil to the raceway; it may be severely sheared in the raceway releasing oil; or small fresh quantities of grease may be sheared off from the volume stored on the shoulder. In addition, the lubrication process may be dynamic. Grease has self-healing properties where fresh grease is supplied in case of film breakdown and self-induced heat development. This article describes the state-of-the-art knowledge on grease lubrication, including grease flow, film formation, film reduction, dynamic behavior, and grease life. INTRODUCTION The main role of grease in a rolling bearing is to provide the rolling element ring contact with a lubricant to ensure a separation of the two such that the bearing has a long life and low friction. The main advantages of using grease rather than oil lubrication are the ease of use (it will not easily leak out of the bearing due to its consistency), the inherent sealing action, the protection against corrosion, and low friction (provided that the bearing is properly

filled). The main disadvantage of using grease is its limited life. Mechanical work on the grease deteriorates its structure and in cases of high temperature, oxidation takes place (T > 120 C) (Ito, et al.'). Severe lubricant starvation occurs, causing bearing failures. This implies that the service life of the bearing may be determined by the life of the grease. In that case the bearings may need to be relubricated occasionally; i.e., filled with fresh grease. The bearing manufacturers have specified the re-lubrication intervals in their catalogues. These re-lubrication intervals are calculated from the life of the grease. Unfortunately, there is no absolute value for this. Even if bearings are running under very wellcontrolled conditions, such as in a laboratory situation, there is the usual significant spread in life. The relubrication interval is defined as the LOl of grease life; i.e., the time at which 1% of a population of bearings is expected to have failed The challenge in grease research is threefold primarily. The first challenge is to develop greases that will give longer life and/or are able to operate under more severe conditions (extreme low and high temperature and speed). The second challenge is the development of predictive tools, such as numerical models or expert systems. The third challenge is to design bearing systems that would increase grease life by, for example, optimizing the grease flow. All these aspects require a fundamental understanding of the lubrication mechanisms of lubricating greases. The research efforts in grease lubrication have so far been relatively small. The global business for grease does not allow for large research programs. The bearing industry has a particular interest in understanding grease lubrication, though. More than 90% of all rolling element bearings are greased and sealed for life, effectively making grease a bearing component similar to rolling elements and seals. In addition, the internal design of the

bearing has an impact on the performance of the grease. This article gives an overview of the existing knowledge on the various aspects of grease lubrication and the stateof-the-art models that exist in the public literature today. The main research on the lubrication mechanisms has been done on single contact configurations where the rolling element ring contact is simulated by a ball on a flat disc. This is generally allowed for studying EHL (elastohydrodynamic lubrication), where the contact geometry can easily be reduced to this configuration. The great advantage o this is the possibility to accurately measure film thickness using optical interferometry methods. The main drawback is the large difference in timescale between successive over-rollings and the impossibility to simulate the true lubricant flow and the feed and loss mechanisms, which will be described later. Moreover, the large centrifugal forces acting on the grease in the bearing cannot be simulated in these instruments. Nevertheless, despite these drawbacks, the observations using these instruments have contributed significantly to understanding the lubrication mechanisms in grease lubrication. Greases are classified primarily on the thickener type. In rolling bearings, lithium/lithium complex soap and polyurea greases are mostly used. A description of the various types can be found in any textbook on lubrication and goes beyond the scope of this article (e.g., Bartz3 or Harris4). GREASE PROPERTIES GrEasE Structure Grease is defined as "a solid to semi-fluid product or dispersion of a thickening agent in a liquid lubricant. Other ingrethents imparting special properties may also be included" (NGLI5). The base oil is kept inside the thickener structure by a combination of Van der Waals and capillary forces (Bauer, et al.6). Interactions between thickener molecules are dipoledipole including hydrogen bonding (Hurley7) or ionic and Van der Waals forces

(Forster, et al.8). The effectiveness of these forces depends on how these fibers contact each other. The thickener fibers vary in length from about 1 to 100 pm and have a length to diameter ratio of 10 to 100 where this ratio has been correlated with the consistency of the grease for a given concentration of thickener (Scarlett11). It is not obvious how to visualize the structure of grease. In general, wet samples cannot be used in a scanning electron microscope.the Since grease contains 80-90% oil, one may argue that the thickener structure may collapse if the oil is washed out and that such a picture may be misleading. Other visualization techniques have been used as well such as a freeze-fracture technique (Magnin and Piau11'; Shuff and Clarke"), where a replica is made of a frozen grease sample, which can be observed in the SEM. Also, atomic force microscopy (AFM) has been used (Hurley and Cann12). Shin, et al.13 visualized the grease flow in a shear field with an optical microscope in phase contrast mode. They observed very long fibers ranging from 50 to 100 ??, which are much longer than those observed with the SEM. An environmental SEM may be used but the low contrast between soap and base oil makes visualization difficult. Salomonsson, et al.H have visualized the grease structure using the cryo-TEM technique and visualized naphthenic lithium grease and paraffinic lithium grease by increasing the contrast between soap and oil through, e.g., replacing lithium by lithium/cesium soap. Additives

The role of additives in grease has not been explored in much detail. At high temperatures, the antioxidant additives will have the greatest effect. These additives are continuously consumed during bearing operation and, according to van den Kommer15, totally consumed after 50% of grease life. Extreme pressure/anti-wear (EP/AW) additives are generally applied for low speed and/or high load. The effect on grease life that these additives have is

not well understood. According to Gow16 some 90% of all lubricant additives destroy the thickener structure of grease since they are often based on surface-active materials and this leads to what is commonly called the mayonnaise effect (softening and discoloring). He also mentions that of the remaining 10%, some 90% do not work. He ascribes this to the fact that the thickener material is almost always very polar (metallic soaps) and that the (also polar) EP additives will adhere to the soap structure rather than to the metal surface (Gow17). This is in contradiction to the results found by McClintock18 who tested a number of greases on lubricant life and found an increase in life. A very promising development is the use of bismuth as an EP/AW additive because it is nontoxic and shows verygood performance (Rohr1"). Kaperick20 shows in an evaluation of the "Timken OK Load Test," in which identical EP additives give a different response to EP action for different formulated greases and ascribes this to a possible impact of mobility towards the surface through chemical interactions or attractive forces. If Gow is right then it is likely that the impact of EP additives on grease performance may be measurable through the mechanical and thermal aging of grease. This direct impact may be primarily on consistency and bleeding rate. Non-Newtonian Rheology A lubricating oil shows non-Newtonian behavior at high shear rates and pressure. Due to the thickener structure and its interaction with the base oil, grease shows this behavior already at very low shear rates and ambient pressure. Measurements from low to high shear rates can be found in Pavlov and Vinogradov21 . The solid-like behavior, or resistance to flow (or leakage), is traditionally characterized through the consistency or penetration, measured using a cone penetrometer (ISO 2137, ASTM D217), which is translated into an NLGl consistency number. An alternative is to measure the yield strength on a

rheometer, by means of the computerized evaluation of yield value (CEY; Gow22) or through the "cross-over stress" (Couronn, et al.23; Couronn and Vergne24). A correlation between yield stress and penetration/consistency can be found in Couronn et al.25. Generally, this is only determined at room temperature. It is clear that the grease will be severely worked in the bearing. This applies to the grease that is being churned between the rolling elements but also applies to the fraction that passed the EHL contacts where shear rates are OQO6 S1). This causes a rapid change in rheological properties of the grease during the initial phase of bearing operation. It is therefore relevant to measure the rheology after working the grease. This can be done in a rheometer itself, in a grease worker", or in a Shell roll tester27. The change in consistency loss is quantified by measuring the mechanical stability of the grease before and after working the grease. The yield stress strongly depends on temperature. Measurements for different types of grease can be found in Karis, et al.28 or Czarny29. Karis shows that the yield strength of a lithium grease may drop from 500 Pa at 20 C to 100 Pa at 60C. As shown by Forster and Kolfenbach30, greases show viscoelastic behavior. There are a number of models proposed for low and high shear rates. The best known are the power law, Rhee-Eyring, Bingham and Herschel-Bulkley models. A definition of these models can be found in Yousif31. These models assume solid or very high viscous behavior at low shear rates and viscous (with possible shear thinning) at higher shear rates. An example can be seen in Figure 2. In addition to this nonlinear shear stress-shear rate behavior, grease is thixotropic, meaning that the measured stress also depends on time. Paszkowski32 defined thixotropy as an isothermal decrease in structural (apparent) viscosity during shearing (at both constant and variable shear rates) followed by an increase in the viscosity and the re-solidification of the substance once shearing ends. Pavlov and Vinogradov2' show creep-like behavior at very low shear (1O0 s ,) until the yield strength has been reached. As shown by Hurley and Cann33, grease rheology approaches that of the base oil at high shear rates.

They also show that mechanical work changes the rheological behavior significantly. The grease thickener structure is thus continuously degrading and is transformed irom a Bingham plastic or Herschel-Bulkely materia! towards a more viscous material (Mrieux, et al.34). LUBRICATION MECHANISMS:Lubricating ConditionsThere is no consensus on the lubrication mechanisms in grease lubrication. There is an overall agreement though that grease-lubricated bearings are generally running under starved lubrication conditions. This has been shown by Poon in 1972 on a disc machine (Poon35) and by Wilson in 19793" in full bearings. Wilson measured the film thickness in cylindrical and spherical roller bearings and showed that the lubricant film initially exceeds the value in case of fully flooded oil lubrication by 20-25%. However, already after a few hours the film thickness has decreased below this value. At this point the bearing runs under starved lubrication conditions. Barz37 measured the film thickness in a cylindrical thrust bearing as a function of bearing speed. His measurements show that the film thickness is relatively large at low speed but decreases with speed up to a speed where the film stays constant. Wikstrm and Jacobson38 measured the electrical capacity over the bearing contacts (using a method developed by Heemskerk, et al.w) in a grease lubricated spherical roller bearing and showed that metal-to-nietal contact occurs very regularly, meaning that the films are very thin, certainly smaller than the values that could be expected assuming fully flooded conditions. As a rule of thumb approximately 30% of the free volume of the bearing should be initially filled with grease. It will be clear that this is much more than required to provide the bearing with a (fully flooded) lubricant film. In the beginning, excessive grease churning, or grease flow, takes place, which is responsible for the high temperature peak caused by the churning component of the friction torque. The initially thick lubricant films in the beginning indicate that at least during this initial bearing operation thickener enters the contact. Single contact measurements by Astrm, et. al.40, Williamson, et al.41, and Kaneta, et al.42* using a scoop to ensure fully flooded conditions, have shown that the film thickness is

indeed higher than the fully flooded oil film thickness. The optical setup also made it possible to show that grease thickener lumps were entering the contact. The literature does not reveal if Ulis is really restricted to the initial phase of bearing operation. It might be that this i

DISCUSSION AND CONCLUSION The various hypotheses on the mechanisms of grease lubrication, all based on observations/measurements, indicate that there may be no unique mechanism. As an example, at low temperatures oxidation and evaporation will not give a significant contribution to "grease aging." At high temperatures oxidation will dominate. Some metals catalyze oxidation (brass cages!). This may be one explanation why there is no consensus on the mechanism. It is certain that initial filling plays a major role. Too much grease leads to excessive churning, high temperatures, and severe grease degradation. If the bearing is properly filled, two phases can be distinguished; i.e., a churning phase where excessive grease will be pushed to the shoulders of the bearing onto the seals/ covers. This process is determined by the flow properties of the grease (rheology). Prediction of flow is very complex due to the nonlinear grease rheology and the two/three phases involved (thickener, oil, air).

The remaining grease inside the bearing will be overrolled, where the thickener structure will be broken down, releasing oil, and where the thickener material could form a thin layer (Cann and Spikes45; Cann, et al.46) or a high viscous layer (Scarlett9). After this phase the "bleeding" phase takes place. This phase is characterized by starvation. The lubricant film thickness is initially larger than calculated using the base oil viscosity. Side flow reduces the film thickness. Electrical resistance measurements in full bearings confirm the occurrence of starvation. The grease reservoir may be formed by grease under the cage (Scarlett9) and/or on the bearing shoulders (Cann, et al.49). However, there are also hypotheses that the bearing simply runs on the initial layer throughout its

life-time and will not be replenished at all Scarlett9. Scarlett9 states that the grease on the shoulders plays a major role in providing a long grease life. He ascribes its role to provide an excellent sealing. Such sealing may indeed prevent side flow and reduce starvation. This would also explain why Lansdown and Gupta12 found an increase in oil content of grease close to the raceway. At least for line contact bearings it has been clearly proven that grease located under the cage bars is bleeding oil (Mas and Magnin55). It is not clear, though, to what extent this bleeding contributes really. The 100 h that Scarlett mentions is very short. Prediction of film thickness in grease lubricated bearings is very complex. The film is a result of feed and loss mechanisms where bleeding, or grease creep flow, is the feed mechanism and where side flow (starvation), oxidation, polymerization, and evaporation are the loss mechanisms (Figure 4, Wikstrm and Jacobson38). Side flow may be hindered by the excellent sealing from grease located on the shoulders of the bearing. For some bearing types an additional loss mechanism is formed by pumping, which takes place due to the tangential component of the centrifugal forces on roller and rings (van Zoelen, et al.65 ; van Zoelen, et al.69). At low shear rates grease creeps, so it may be that grease very slowly flows into the track. An additional complexity is the dynamic behavior of grease lubrication. The grease lubricated bearing shows an inherent "self-healing" mechanism where replenishment may happen due to film breakdown resulting in metal-tometal contact, local heat development, and release of grease into the raceways (Mas and Magnin55; Cann and Lubrecht73; Lugt, et al.74). This means that the life of the grease in bearings cannot easily be predicted based on film thickness calculations only. Ultimately, knowledge on multi-phase flow, nonlinear rheology, EHL theory, and chemistry need to be combined to develop predictive models for grease lubrication in rolling bearings.

Objectives: A typical oil system consists of an oil reservoir, pump, piping and filter. A cooler may also be

required. This system sensor an adequate supply of oil for both cooling and lubrication. Contaminants and moisture are removed from the bearing by the flushing action of the oil, and filters trap contaminants. It is relatively easy to direct lubricant to multiple bearings in the deterioration. increasing lubricant life and system efficiency. maintenance will be reduced. In large units, lube oil cools the bearing by carrying off heat to the oil coolers. Lube oil in some turbines also acts as a hydraulic fluid to operate the governor speedcontrol system.

METHODOLOGY: there are mainly two type of lubricatoin oil pump system is required. 1. Main oil pump, 2. Auxiliary oil pump, Than iInn turbine due to the carelessness of the operators, failure of the lubrication system of that turbine occurs, so the friction between the journals bearing and shaft occures. Therefore the failure of jurnal bearing occurs. Proper maintenance is must needed. Failure to follow installation instructions and to maintain proper lubrication can result in equipment failure. To investigate the problems, the engineer must have in depth knowledge about basic of lubrication systems and design of bearing Your lubrication supplier and bearing supplier should have the most current data and be able to recommend the proper lubricant for the application. As in selecting the proper bearing for the application, the

conditions to which the lubricant will be subjected must be considered. How grease waiting for future use is treated and stored will be a key factor in the life expectancy of equipment. Lubricants should be stored in moisture- and temperature-controlled environments, free of dust and chemical exposure. Contamination entering grease will likely happen during transfer from one point to another. Failure to exercise care in this process will nullify the attention given previously. There are a number of ways to properly refill grease guns. Using a scoop or paddle from a container is the oldest technique. It involves spooning grease from a storage container and tamping it into the grease gun to remove air bubbles. This method is most likely to introduce contaminants into the grease, especially when performed in the field. It is not a recommended method except in the most dire of circumstances. Using tube refills is the most common method of refilling a grease gun. It involves removing the empty tube and installing a new, compatible tube of grease into the grease gun. Take care to clean dirt and old grease from the canister and handle assembly before installing a clean, new tube of grease. Perform this task in as clean and dry an environment as possible. When refilling from a storage container using mechanical or hydraulic pumps, grease is pumped mechanically from the storage container directly into the portable grease gun. When care is taken to clean off the port on the grease gun and delivery hook up from the pump, this is the fastest and safest method of grease transfer. Assuring that the correct grease is introduced into bearings may involve coding systems. Labels, numbers, tags, or color-coding on bearing housings that indicate what type of grease is being used can be very helpful

to the lubrication technician. Ensure that grease guns are matched up with the coding system on equipment. New employees should be trained on the matching system before any lubrication task is performed. This is an easy system to implement and minimizes the chances of introducing noncompatible greases into the bearing. When it becomes necessary to switch delivery tubes from one grease gun to another, make certain to clean dirt and grime from the tube and then purge all the grease from the tube to prevent mixing of incompatible grease types. Clean and purge grease zerk fitting connectors as well. Different grease gun manufacturers allow varying amounts of grease to be applied by a pump or shot of grease. (A pump or shot of grease is one full stroke of the grease gun lever or trigger.) The amount of pressure each grease gun or grease delivery system contains also may vary dramatically. This lack of an industry standard has made it difficult to determine the amount of grease actually being delivered and therefore creates problems using a time- and amount-based lubrication schedule. It is important to calibrate each grease gun and note the volume of grease each gun delivers with one full pump. To properly relubricate a bearing, certain information must be obtained. To help determine the correct timeand amount-based schedule of relubrication, data from the manufacturers recommendations on relubrication intervals must be combined with reliability knowledge and experience. Traditionally, the job function of lubrication is an entry-level position in maintenance. Much was required of these important individuals with little or no specific training provided. Fortunately, this is changing. Companies have invested in maintenance technologies and training to prevent and predict machinery

failure. Companies are learning to invest in standardized training for lubrication practices and in the tools necessary to perform the job in a skilled and efficient manner. While the importance of performing lubrication tasks has not changed, awareness of the importance of the individual performing these tasks is changing. As skill and training criteria standards evolve, the oiler becomes a skilled lubrication technician and analyst. Also called lubrication engineers, these individuals are being provided with the necessary resources to perform their job function. Reliability and predictive maintenance groups are increasingly relying upon the lubrication technicians knowledge and skills. Acoustic analysis or sonic analysis is a rapidly growing method in preventing overlubricated and underlubricated bearings. This equipment uses sonic sound technology and listens to the noise generated by the vibration of the bearing in the sonic range (20 Hz-20 kHz) to decipher when and if a bearing requires greasing. By listening to the voice of the bearing, the lubrication technician is able to make a direct determination of the grease requirements of the bearing. As grease is slowly injected into a bearing, the change in sound or lack of sound change informs the technician when sufficient grease is present. This eliminates the need to calibrate a grease gun as the amount of grease the bearing requires is determined as it is being lubricated. By implementing this proactive method of greasing, lubrication technicians are able to customize existing time/amount-based lubrication schedules. For example, a bearing that had a previous schedule of two shots of grease every two weeks may require only one shot every two weeks. The extra shot of grease every two weeks was overgreasing the bearing. Customizing or adjusting the lubrication schedule to fit the actual bearing requirements slashes bearing failures.

REFERENCES:
The text book of Power plant engineering by aroradomkundwar. The text book of Fluid power engineering by R.K bansal www.google.com