Case Studies On Vibrations

A.K.
SINHA, DGM (TURBINE)
WHAT IS PHASE ANGLE
360 0
BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA
A.K.SINHA, DGM (TURBINE)
USES OF PHASE ANGLE MEASUREMENT

1.
BALANCING
2.
STRUCTURE MOTION STUDY
3.
DETECTION OF RESONANCE FREQUENCY
RUN UP & RUN DOWN BEHAVIOUR
BODE PLOT
4.
HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS
5.
UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT

REAR 245
228
220 FRONT
230
165
FRONT
212
2
170
245 REAR
220
209
127
138
107
101
87
71
3
112
120
96
94
4/5
6
7
LEFT SIDE
53
19
63
10
11
16
12
11
7
16
12
-14
17
17
18
13
13
19
24
15
-23
23
10
15
-9
22
51
56
14
11
21
14
33
20
RIGHT SIDE
20
21
22
-25
18
23
HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS
3
2
1
9
8
7
5
4
GENERATOR SIDE
LEFT
21 C
20
14
15
13
BASE PLATE
B
A
11 12
RIGHT
10
18
17
19
16
SECONDARY GROUT
TURBINE SIDE
UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT
B1
B2
B3
B4
Case Studies
on
Vibration Problems in Steam
Turbine Generators
HIGH VIBRATION IN
500 MW TG SETS
HIGH VIBRATION IN 500 MW TG SETS

PROBLEM
HIGH HP FRONT SHAFT AND BEARING PEDESTAL VIBRATION
OBSERVATIONS
(A) FREQUENCY ANALYSIS CARRIED OUT WHICH INDICATED
PREDOMINANT 1-X VIBRATION COMPONENTS FOR BOTH SHAFT AND
BEARING PEDESTAL VIBRATION
STEADY PHASE ANGLE
(B) BEARING PEDESTAL VIBRATIONS AND SHAFT VIBRATIONS WERE
HAVING RISING TENDENCY AT RATED SPEED HOWEVER, THEIR RATIO
WAS FOUND TO BE ALMOST CONSTANT

ANALYSIS
PREDOMINANT 1-X VIBRATION WITH SLIGHT CHANGE IN PHASE
ANGLE INDICATED THERE WAS UNBALANCE IN THE ROTOR SYSTEM
LEADING TO INITIATION OF MINOR RUB
MAIN SOURCE OF VIBRATION WAS HIGHER DYNAMIC LOADING FROM
THE SHAFT WHICH WAS GETTING TRANSMITTED TO BEARING
ACTION TAKEN
TO REDUCE THE HP FRONT SHAFT VIBRATION LEVEL, INSITU
BALANCING WAS CARRIED OUT USING LP ROTOR BALANCING PLANES

RESULT OF INSITU BALANCING
HP SHAFT VIBRATION BROUGHT DOWN TO STEADY VALUE OF 120
MICRONS, 0-PK FROM EARLIER VALUE OF 150 - 200 MICRONS, 0-PK
HP FRONT BEARING VIBRATION CAME DOWN INITIALLY TO 15
MICRONS, 0-PK AT 3000 RPM FROM EARLIER VALUE OF 25 40
MICRONS, 0-PK
LATER, WITHIN 2-3 HOURS OF OPERATION, HP FRONT BEARING
VIBRATION INCREASED BEYOND ALARM VALUE (35 MICRONS, 0-PK).
DURING THIS PERIOD, NO INCREASE IN SHAFT VIBRATION WAS
OBSERVED

INTREPRETATION OF RESULTS AFTER INSITU BALANCING
AS HP FRONT BEARING PEDESTAL VIBRATION INCREASED, EVEN
WHEN HP FRONT SHAFT VIBRATION WAS CONSTANT, INDICATED THAT
THE CAUSE OF HIGH BEARING PEDESTAL VIBRATION WAS SOME
FACTORS APART FROM UNBALANCE OF THE SHAFT
ANALYSIS DONE
BASED UPON THE VIBRATION BEHAVIOUR OF BEARING PEDESTAL AND
SHAFT VIBRATION, IT WAS DECIDED TO SCAN FRONT BEARING
PEDESTAL BY PORTABLE VIBRATION ANALYSER

RESULTS OF SCANNING OF FRONT PEDESTAL
VIBRATION ON LEFT AND RIGHT HAND SIDE OF FRONT BEARING
PEDESTAL (NEAR HP CASING FRONT PALMS) IN THE VERTICAL
DIRECTION WERE HAVING LARGE VARIATION
(LHS VIBRATION IS ABOUT 5 TIMES MORE THAN RHS VIBRATION)
HP CASING PALM VIBRATION AMPLITUDE IN VERTICAL DIRECTION ON
LEFT AND RIGHT PALM WAS FOUND TO BE OF LOWER MAGNITUDE
AND SAME
SCANNING INDICATED THAT THERE WAS NO PROBLEM WITH BASE
PLATE, SECONDARY GROUT & FOUNDATION MATING SURFACES
HP CASING PAM
(RIGHT HAND
SIDE)
HP FRONT BEARING PEDESTAL

ANALYSIS
SCANNING DATA INDICATED THAT LOAD DISTRIBUTION BETWEEN
PALMS OF HP CASING WAS NOT PROPER
THERE WAS GAP BETWEEN CASING PALM AND PEDESTAL ON LEFT
HAND SIDE
ACTION TAKEN
0.15 MM SHIM WAS ADDED BELOW LEFT HAND SIDE PALM WHEREAS
0.1 MM SHIM WAS REMOVED FROM RIGHT HAND SIDE PALM FOR
IMPROVING THE LOADING PATTERN OF HP CASING ON PEDESTAL

RESULT OF CORRECTION IN SHIMS
VIBRATIONS ON BEARING PEDESTAL REDUCED FROM 35 MICRONS, 0PK TO 15 MICRONS, 0-PK AND NO INCREASING TENDENCY WAS
OBSERVED
HP FRONT SHAFT VIBRATION WAS FOUND TO BE REDUCED FROM 120
MICRONS, 0-PK TO 90 MICRONS, 0-PK AND BEARING VIBRATION
SETTLED DOWN TO 10 MICRONS, 0-PK AT FULL LOAD
RATIO OF LEFT AND RIGHT HAND SIDE VIBRATION ON FRONT
PEDESTAL IN VERTICAL DIRECTION CAME DOWN TO 2:1 FROM
EARLIER VALUE OF 5:1
HENCE, UNBALANCE OF ROTOR SYSTEM & UNLOADING OF

LEFT SIDE PALM WAS FOUND TO BE THE ROOT CAUSE OF THE
HIGH HP FRONT SHAFT AND BEARING PEDESTAL VIBRATION
CONCLUSION
VIBRATION
IMPORTANT
SCANNING
TOOL
FOR
IS
VERY
DIAGNOSTICS
PURPOSES
VIBRATION SCANNING SHOULD BE USED AS
FREQUENTLY AS POSSIBLE
IT HELPS IN RULING OUT OR PIN POINTING
CERTAIN DEFECTS
HIGH VIBRATION IN
210 MW TG SETS

BACKGROUND
MACHINE IS OF KWU DESIGN STEAM TURBINE COUPLED WITH LMW
GENERATOR (LP REAR BEARING AND GENERATOR FRONT BEARING IS
LOCATED IN COMMON PEDESTAL)
VIBRATION BEHAVIOUR WAS FOUND TO BE NORMAL DURING FIRST
COMMISSIONING ON ALL BEARINGS AND LATER ON VIBRATION ON
BEARING NO. 4 / 5 PEDESTAL DETERIORATED GRADUALLY BEYOND
ALARM LEVELS (35 MICRONS, 0-PK)

PROBLEM
HIGH LP REAR BEARING VIBRATION
HIGH GENERATOR FRONT BEARING VIBRATION
OBSERVATIONS
FREQUENCY ANALYSIS CARRIED OUT WHICH INDICATED
PREDOMINANT 1-X VIBRATION COMPONENT FOR BOTH LP REAR AND
GENERATOR FRONT VERTICAL AND AXIAL VIBRATION
VERTICAL VIBRATION AT LP REAR AND GENERATOR FRONT BEARING
WAS OF THE ORDER OF 100 MICRONS, PK-PK
AXIAL VIBRATION WAS ABOUT 200 MICRONS, PK-PK FOR BOTH LP
REAR BEARING AND GENERATOR FRONT BEARING

ANALYSIS
BASED ON VIBRATION SYMPTOMS, FOLLOWING CHECKS WERE
SUGGESTED IN PLANNED OVERHAUL
LP / GENERATOR ALIGNMENT
BEARING ASSEMBLY CHECKS
RESULT OF ABOVE WORKS
AFTER CARRYING OUT THE ABOVE MENTIONED CHECKS &
CORRECTIONS DURING PLANNED OVERHAUL, VIBRATION LEVEL DID
NOT IMPROVE

ACTION TAKEN
FOLLOWING WORKS WERE CARRIED OUT
VIBRATION ANALYSIS
SCANNING OF LP REAR BEARING PEDESTAL AND ITS SECONDARY
GROUT AND BASE PLATE AREA
OBSERVATIONS / ANALYSIS
FREQUENCY BEHAVIOUR OF BEARING VIBRATION FOUND SIMILAR TO
EARLIER OBSERVATION
WIDE DIFFERENCE IN PHASE ANGLE IN VERTICAL DIRECTION ACROSS
BASE PLATE OF LP REAR PEDESTAL AND SECONDARY GROUTING
WHICH INDICATED THAT VERTICAL LOAD TRANSFER FROM BEARING
TO FOUNDATION IS NOT AS EXPECTED
SCANNING OF PEDESTAL
3
2
1
9
8
7
5
4
GENERATOR SIDE
LEFT
21 C
20
14
15
13
BASE PLATE
B
A
11 12
RIGHT
10
18
17
19
16
SECONDARY GROUT
TURBINE SIDE

ACTION PLAN SUGGESTED
REGROUTING OF LP REAR PEDESTAL
REPLACEMENT OF FOUNDATION BOLTS OF LP REAR PEDESTAL AND
PROPER MATCHING OF ANCHOR PLATES
IN-SITU BALANCING OF GENERATOR ROTOR TO REDUCE EXCITATION
FORCES TO MINIMUM
DUE TO TIME CONSTRAINT AND POWER REQUIREMENT,
FOLLOWING WORKS CARRIED OUT
EPOXY GROUTING (PRESSURE GROUTING) OF LP REAR PEDESTAL
RESTRETCHING OF FOUNDATION BOLTS OF LP REAR PEDESTAL
LP / GENERATOR REALIGNMENT
BEARING INSPECTION

AFTER CARRING OUT THE ABOVE MENTIONED CHECKS DURING NEXT
OVERHAUL
VIBRATION LEVEL FOUND REDUCED TO 25 MICRONS, 0-PK ON
BEARING NO. 4 / 5 PEDESTAL
PHASE DIFFERENCE WAS FOUND TO BE MINIMUM BETWEEN BEARING
PEDESTAL BASE PLATE AND SECONDARY GROUTING
BUT AFTER FEW DAYS OF OPERATION,
VIBRATION LEVEL STARTED INCREASING GRADUALLY AND TOUCHED
ALARM VALUE OF 35 MICRONS, 0-PK
PHASE ANGLE DIFFERENCE WAS ALSO FOUND TO BE INCREASING
BETWEEN BASE PLATE AND SECONDARY GROUTING

ANALYSIS
EPOXY GROUTING WAS INSUFFICIENT TO CURE THE VIBRATION
PROBLEM ON PERMANENT BASIS
AT THIS POINT OF TIME, CIVIL EXPERT ALSO CONDUCTED STUDIES ON
FOUNDATION
WHICH
CONFIRMED
THE
BAD
CONDITION
SECONDARY GROUT
OF

ACTION PLAN SUGGESTED:
ONCE AGAIN THE PREVIOUS ACTION PLAN WAS SUGGESTED, THAT IS,
REMOVAL OF LP REAR BEARING PEDESTAL AFTER BREAKING
SECONDARY GROUTING COMPLETELY
REPLACEMENT OF FOUNDATION BOLTS
IN-SITU BALACNING OF GENERATOR ROTOR
DISMANTLING OBSERVATION
DURING REMOVAL OF LP REAR PEDESTAL, SECONDARY GROUT
MATERIAL WAS FOUND IN PIECES
OIL SEEPAGE WAS OBSERVED UNDER PEDESTAL

AFTER THE ABOVE MENTIONED WORKS CARRIED OUT (INCLUDING
IN-SITU BALANCING OF GENERATOR ROTOR) IN THE NEXT PLANNED
OVERHAUL, VIBRATION LEVEL OF LP REAR AND GENERATOR FRONT
IMPROVED IN BOTH VERTICAL AND AXIAL DIRECTION
MACHINE IS RUNNING SATISFACTORILY SINCE THEN
HENCE, LOOSENESS / VOID BETWEEN LP REAR PEDESTAL AND

SECONDARY GROUTING WAS FOUND TO BE THE ROOT CAUSE
OF HIGH LP REAR PEDESTAL AND GENERATOR FRONT
VIBRATION
CONCLUSION
HISTORY
OF
THE
PROBLEM
SHOULD
BE
GIVEN
DUE
WEIGHTAGE FOR ANALYSING THE PROBLEM

ATTENTION SHOULD BE PAID TO INTERFACE AREAS BETWEEN
MACHINE
AND
SUPPORTING
SYSTEM
STRUCTURE
ADDITION TO MAIN MACHINE
IN
TIPS FOR BETTER DIAGNOSTICS

HISTORY OF MACHINE WITH RESPECT TO ITS DYNAMIC
BEHAVIOUR SHOULD BE STUDIED
REGULAR VIBRATION READING ON BEARING PEDESTAL AT
PRESCRIBED LOCATIONS SHOULD BE TAKEN FOR ASSESSING
THE TREND OF VIBRATION BEHAVIOUR ACCURATELY
SHAFT VIBRATION IN TWO ORTHOGONAL DIRECTIONS
SHOULD BE MEASURED FOR ORBIT ANALYSIS
RECOMMENDED LOCATIONS OF VIBRATION MEASUREMENTS ON

BEARINGS AS PER ISO
RECOMMENDED LOCATIONS OF SHAFT VIBRATION

MEASUREMENTS AS PER ISO
Measurin
g
Amplifier
Measurin
g
Amplifier
45O
PROXIMITY
PICK-UP
45O
SHAFT
VERTICAL
OR
SHAFT
R
HORIZONTAL

EVERY UNIT SHOULD HAVE KEY PHASOR ARRANGEMENT FOR
VIBRATION ANALYSIS.
SCANNING OF VIBRATION PRONE AREAS INCLUDING SYSTEM /
FOUNDATION AROUND THE PROBLEMATIC AREA SHOULD BE
CONDUCTED
DEVIATION
IN
OPERATING
PARAMETERS
SHOULD
BE
RECORDED AND ANALYSED FOR THEIR EFFECT ON VIBRATION

BEHAVIOUR

RUN UP & RUN DOWN VIBRATION BEHAVIOUR SHOULD BE
RECORDED FOR ALL BEARINGS AND SHAFT POSITIONS FOR
REFERENCE WHICH CAN BE USED DURING TROUBLESHOOTING
PRE-OUTAGE SURVEY SHOULD
OVERHAUL
FOR
BETTER
BE CONDUCTED PRIOR TO
PLANNING
OF
ADDITIONAL
ACTIVITIES / SPARES, IF REQUIRED

RECORD OF PREVIOUS BALANCING AT SITE SHOULD BE
MAINTAINED FOR REFERENCE PURPOSES

LAST BUT NOT THE LEAST, DURING TROUBLESHOOTING,
EVERY FEEDBACK / OBSERVATION NEEDS TO BE CONFIRMED.
IF EVERYTHING IS ALRIGHT, VIBRATION PROBLEM WOULD
NOT
HAVE
BEEN
THERE.
SO
VERIFY
EACH
&
EVERY
POSSIBILITY AND CONFIRM FROM WRITTEN DOCUMENTS
Thank you

Case Studies On Vibrations

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A.K.

SINHA, DGM (TURBINE)

WHAT IS PHASE ANGLE

A.K.SINHA, DGM (TURBINE)

USES OF PHASE ANGLE MEASUREMENT

STRUCTURE MOTION STUDY

DETECTION OF RESONANCE FREQUENCY

RUN UP & RUN DOWN BEHAVIOUR

HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS

UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

STRUCTURE MOTION STUDY

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

STRUCTURE MOTION STUDY

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

HENCE, UNBALANCE OF ROTOR SYSTEM & UNLOADING OF

A.K.SINHA, DGM (TURBINE)

A.K.SINHA, DGM (TURBINE)

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 210 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 210 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 210 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)