Case Studies : Coordinated Condition Monitoring at DTPS

Ashish Upadhyaya Dy. Manager, Reliance Energy

Dahanu Thermal Power Station

102 100 (%) 98 96 94

100.34

101.35 100.00 98.70

96.84 03-04 PLF (%)

96.88 04-05 Year Availability(%) 05-06

DTPS Performance Glimpses

5000 4000 3000 2000

0.6 0.5 0.4 0.3 0.2 0.1 0

0.57

0.42

Breakdown Work orders %

0.14

4407

4439

4323

1000 0

2.12

1.33

0.29

03-04

04-05 Year

05-06

03-04

04-05 Year

05-06

Generation (Mus)

Generation (Loss)

MAINTENANCE STRATEGY
E X C E L L E N C E
Prevention Proactive Predictive Preventive Corrective

Analysis
DETECTION DIAGNOSIS PROGNOSIS ACTION - something is wrong - what is wrong? - what can it lead to ? - what is to be done?

EXPLANATION - why so?

Coordinated Condition Monitoring Program

Objectives Condition monitoring Techniques. Applications Schedules Techniques & Diagnosis Benefits Case Studies

Objectives
Early detection of potential abnormality. Secondary damages are avoided. Likely source of abnormality without stoppage of equipment. Maintenance activities can be well planned. Reduction in quantum of maintenance activities and man- power. Outage of equipment can be very well planned Better spare part management

CO-ORDINATED CONDITION MONITORING TECHNIQUES AT DTPS

NOISE ANALYSIS LUBRICANT ANALYSIS WEAR DEBRIS ANALYSIS THERMOVISION ANALYSIS MOTOR CURRENT SIGNATURE ANALYSIS ELCID TEST VIBRATION MONITORING NDT ULTRASONIC DISOLVED GAS ANALYSIS MAGNATIC PARTICLE INSPECTION

Applications
Applications
Press. Vessels Elect. Motors Compressors Transformers Switchyard Generator Turbine Pumps

Technologies Vibration Monitoring Lubricant Analysis Wear Debris Analysis

Motor Current Analysis Thermography DGA Noise Magnatic Particle Insp. ELCID Test NDT Ultasonic

Fans

Condition monitoring schedule

Sr No 1 2 3 4 5 6 7 Monitoring technique Multi-parameter vibration monitoring Chemical analysis of lube oil Wear debris analysis of lube/gear oil Noise monitoring Motor current analysis Thermography Dissolved Gas Analysis Frequency Daily/Weekly/Fortnightly/Mont hly Quarterly Quarterly Monthly Monthly Monthly Quarterly

Benefits
Major Failures Diagnosed

30 25 20 15 10 5 0 03-04 04-05 Year 05-06 20 20 22

60 50 40 30 20 10 0

Rs. In Lacs
15.54

45.67

49.48

Cost Savings Achieved

03-04 04-05 Year 05-06

Vibration Monitoring
On-line Monitoring: Carried out on Boyce make DATM 4 condition monitoring system. 22 critical equipments covered. Off-line Monitoring Carried out as per the schedule using portable Microlog data collector CMVA 40 Equipment with motor capacity > 5kw (60 HT /95 LT)

Vibration Diagnosis
Abnormal Wear Misalignment Belt flaws Flow Turbulence Structural Resonance Imbalance Mechanical looseness Bearing damages Gear damages Cavitations Fatigue.

Sheave and pulley flaws

Chemical analysis of lube oil

Acidity Density Moisture Mechanical Impurities Viscosity NAS Level

Chemical analysis Diagnosis

Degradation of lubricants Physical status of lubrication Contamination of lubricants

Wear Debris Analysis

Wear debris analysis Carried out for wear particle concentration Oil sample is subjected to magnate field Relative amount of contamination assessed Instrument particle quantifier gives amount of wear debris present in oil.

Wear Debris Diagnosis

Determine the machine mechanical wear condition, Normal rubbing Sever sliding Cutting Gear Bearing failure Lubricant Degradation Outside contamination of lubricants

Noise Monitoring
RAYTHEON make RT 5001 sound level meter Frequency of monitoring: monthly Limit of noise level at manned location: 75 db Quantitative trend analysis.

Motor Current Signature Analysis

Mechanical defects of electric motor are detected Tongue tester or current coil captures current spectrum Sidebands around line frequency indicate severity of faults Frequency Monthly.

Motor Current Signature Diagnosis

Rotor damage Motor Current Index Rating : 54-60dB Excellent 48-54 dB Good 42-48 dB Moderate 36-42 dB Cracked rotor bar or other source of high resistance. < 30 dB Severe damage Interturn insulation degradation

Thermo-vision Scanning
Hot spots monitored by Infrared Camera Used for switchyard Equipments Monitoring Frequency Monthly. Routine monitoring of Pump, Motors etc by infrared gun

Thermo-vision Diagnosis
Degrading conditions of transformers, motor control centers, switchgear, substations, switchyards, or power lines. In mechanical systems, it can identify blocked flow conditions in heat exchanges, condensers, transformer cooling radiators, and pipes.

Dissolved Gas Analysis (DGA)

For All transformers Frequency Six monthly GT, ST & UAT. Yearly for rest of transformers Break down voltage : For Dielectric strength of the oil. Chemical analysis : For Moisture, Acidity, Appearance, Density etc. Dissolved Gas Analysis : For diagnosis of faults like discharge, partial discharge, thermal fault, insulation degrading etc . Interpretation of fault by IEC599 & ROGERS method

DGA Diagnosis
Large amounts of CO and CO2 indicates overheating in the windings. CO, CO2, and CH4 show the possibility of hot spots in the insulation. H2, C2H6, and CH4 are indicative of corona discharge. C2H2 is a sign of internal arcing.

Magnetic Particle Inspection

Carried out for turbine blades during unit overhaul. Used to find surface & near surface flaws in ferromagnetic materials (steel, iron) The magnetic lines of flux distorted by the presence of a flaw The flaw is located from the "flux leakage", following the application of fine iron particles, to the area under examination.

Magnetic Particle Diagnosis

Detection of shallow sub-surface defects. Welding defects Detection of specific areas of high stress or fatigue loading.

ELCID Test
Carried out for generator during unit overhaul. Stator is excited by a winding that produces a circumferential magnetic flux around the core Test equipment analyses the resultant in-phase and quadrature magnetic potential difference values between adjacent stator teeth.

ELCID Test Diagnosis

Determine the integrity of the inter-lamination insulation in large stator cores.

Case Study-1 ID FAN

FAN

HYDRAULIC COUPLING

MOTOR

ID Fan Specification
Two ID fan / unit each of 50 % capacity (capacity 258 m3/sec ) Speed of fan-: 701 rpm Fan drive Hydraulic coupling -: Make: Voith Oil: Servotorqe 10 (IOC make ) Bearings: I/p end 7326 BTY PUA O/p end 7320 BMPUA Motor -: Make: BHEL 3ph,6.6kv ,1850kw,745 rpm Bearings: NDE NU232 DE NU 238/6238

CONDITION MONITORING OF ID FAN

VIBRATION ANALYSIS CHEMICAL ANALYSIS WEAR DEBRIS ANALYSIS NOISE MOTOR CURRENT ANALYSIS

Routine Condition Monitoring Result of ID Fan

Date 10 Sept
Sr no 1 2 3 4 Technique Vibration Results Within limits,no change in absolute vibration(velocity) & spectrum

Chemical Analysis Contains metallic particles of oil Noise Motor current Rise of 2 dB , Abnormal hissing sound Normal

Oil sample sent for wear debris analysis

WDA Report

Date 12 Sept

WPC: 18.8; Severe sliding wear particles of copper alloy of size 126 microns in large quantities. Copper alloy cutting wear particles of size 96 microns in marginal quantities

WDA Report

Date 16 Sept

WPC: 42.9; Severe sliding wear particles of copper alloy of size 400 microns in large quantities.

Future Course of Action

Wear of bearing cage Inspection of bearing requires outage of Id fan for two days Close watch on Hydraulic Coupling Vibration : Daily Chemical analysis : Weekly Wear debris : Monthly Noise monitoring : Weekly

Vibration Trend (Motor DE: Axial)

Date 18 Dec

Motor DE axial vibration rose to 3mm/sec from 1 mm/sec. As per OEM alarm limit is 4.5 mm/sec & danger limit is 11 mm/sec

Vibration Spectrum Analysis 21 Sept 18 Dec

Peak - 2.6 mm/sec Order - 24.76 X

Motor DE bearing deterioration

WDA Report

Date 18 Dec

WPC 78.6 ; severe sliding wear particles of copper alloy of size 90 microns in large quantities & bearing wear particles of size 50 microns in marginal quantities

VIBRATION MONITORING

On 4 Jan axial vibrations reached to 10 mm/sec Amplitude of 4-6 mm/sec at bearing defect frequencies Rise in the radial vibration of motor DE brg Slight rise in the trend of hydraulic coupling axial vibration.

Decision on Outage at Right time

Motor DE bearing and Hydraulic Coupling bearing had reached critical stage. All required man & materials were available Decided to take maintenance outage on 5 Jan, during an Off-Peak period.

Findings
Bearing cage of output bearing of Hydraulic Coupling found severely worn-out. Motor DE bearing failed due to fatigue failure. Avoided catastrophic failure of ID Fan. Avoided unplanned maintenance loss.

HYDRAULIC COUPLING BRG - 1

Failed bearing

New bearing

Case Study-2 Coal Mill

Mill specification
Make BHEL Capacity 84.8 T/Hr Drive motor - 2350 KW, 1488 RPM, 3 ph, 6.6 KV Pinion Bearing - Spherical Roller (23248)

First Symptom
On 20.02.2003, bolts of seal retaining plate of Pinion Coupling (Pinion side half) found sheared. Inspection of gear coupling observed no abnormalities in the gear coupling and all the teeth found intact. After thorough inspection all the bolts were replaced with new bolts.

Sequence of Events
5 6

3 4 2 7

1
On 10.8.2003, Main Reducer of mill 1CD replaced as the axial vibrations at intermediate and output shaft were having increasing trend. No abnormality was noticed in the existing gear box.

2
On 10.10.2003, explosion occurred in the mill while it was being taken out of service. Due to explosion both side hot air ducts got heavily damaged. After rectification work mill was taken in service and found normal.

3
Increasing trend observed in axial vibrations of pinion DE bearing.

4
On 19.04.2004, inspection of Girth gear and Pinion was carried out No abnormality was observed. Alignment between main reducer and pinion checked and found disturbed. Re-alignment of all the couplings was carried out.

5
The amplitude of vibration signal found increasing Spectrum analysis indicated abnormality in bearing.

Spectrum Pinion NDE Axial

0.9 0.8 0.7 PK Velocity in mm/Sec 0.6 0.5 0.4 0.3 0.2 0.1 0 0 50 100 150 Frequency in kCPM 200 250 300 mill - coal mill1CD mill1CD -G7H Shaft 01 Inboard Horizontal Route Spectrum 01-Jun-03 15:32:06

Total Magnitude 1.3649 mm/sec

OVERALL= 1.47 V-DG PK = 1.47 LOAD = 100.0 RPM = 1461. (24.34 Hz)

Non-synchronous - 1.2779 (88 %) Synchronous - 0.4704 (12 %) Sub- synchronous - 0.0925 (0 %)

Spectrum Pinion DE Axial

2.4 mill - coal mill1CD mill1CD -G6H Shaft 03 Outboard Horizontal Route Spectrum 01-Jun-03 15:31:12 2.0

Total Magnitude 2.6429 mm/sec

OVERALL= 2.78 V-DG PK = 2.76 LOAD = 100.0 RPM = 1500. (25.00 Hz)

PK Velocity in mm/Sec

1.6

1.2

0.8

0.4

0 0 50 100 150 Frequency in kCPM 200 250 300 Freq: Ordr: Spec: 6.750 4.500 1.798

Non-synchronous - 2.5156 (91 %) Synchronous - 0.8103 (07 %) Sub- synchronous - 0.0000 (0 %)

6
Bearings of both DE and NDE sides replaced Re-alignment of Girth gear and Pinion carried out.

Pinion Vibration
Before Correction Vibration in mm/Sec

H
2.0 1.2

V
3.3 3.0

A
7.0 1.5

DE NDE
Vibration in mm/Sec

After Bearing Replacement

H
1.5 1.1

V
2.5 1.8

A
1.7 1.5

DE NDE

Deep Crack in the Bearing Sleeve

Observations

Bearing Sleeve Shifted

Scoring Marks On the Pinion Shaft

Findings
The bearing clearances observed to be 0.60 mm. The normal clearances allowed are 0.20 mm. The bearing taper sleeve found cracked. The heavy scoring marks were observed on NDE side of the shaft. Bearing sleeves on both the sides (NDE & DE) observed to be shifted by 20 mm.

CONCLUSION
Condition monitoring pays back the investment : By improving Equipment Reliability By minimizing downtime By maximizing equipment performance and plant availability By maximizing component life

Thank You