STUDY AND ANALYSIS OF VIBRATION IN POWER PLANT

THE KAVERY ENGINEERING COLLEGE

Submitted by KARTHI.R MATHIVANAN.M MURALI.M PARTHIBAN.G (080111804020) (080111804028) (080111804033) (080111804036)

GUIDE Ms. E.JAMUNA Asst.Professer

CO-GUIDE Mr. S.MANIKANDAN Lecturer

ABSTRACT
To predict the failure of machine in advance and to avoid the quantity and quality loss in the production and generation. Predictive maintenance is implemented in most of the process and power generation industries.

Spectrum and phase analysis of multi sensor arrangements will be followed.

WHY MEASURE VIBRATION?

All machines vibrate. Developing problems are usually accompanied by an increase in vibration. The vibrations unique characteristics will be determined by the nature of the developing fault. Measuring vibration will allow a machines condition to be assessed.

VIBRATION FREQUENCY

The time required to complete one full cycle of vibration is called the period. If one period is completed in one fifth of a second, the vibration frequency would be 5 cycles per second (5 Hz) or 300 cycles per minute (300 cpm).

IDENTIFYING CONSTRAINTS

Velocity , Displacement are the parameters used for analyze the vibration.
The following vibration meters are used for identifying these parameters, Analog meter (IRD 306) Digital meter / Analyser (IRD 880, Data PAC)

DISPLACEMENT
Displacement is a measure of the total travel of the mass - back and forth. Unit of measurement = Microns

VELOCITY
Velocity of the Vibration is a measure of speed at which the mass is moving or vibrating during its oscillation. Unit of Measurement = mm/sec In/sec

ACCELERATION
Acceleration is the rate of change of speed of the mass during its oscillation.

Units of Measurement = gs

PROBLEMS CAUSING HIGH VIBRATIONS

Unbalance Looseness Defective Bearings Electric Problems Misalignment Eccentricity Defective Gear Resonance

Vibration Frequencies & Likely Causes

FREQ 1 X RPM

CAUSES UNBALANCE

OTHERS Eccentric Journals, Gears, Pulleys. Misalignment, Bent Shaft, Resonance, Electrical Misalignment if high axial Resonance, Reciprocating Forces, Bad Belts If 2XRPM of belt Combination of misalignment & excessive clearances. Background Vibration, Beat Vibration

2 X RPM

Mechanical Looseness Misalignment

3 X RPM

Less than 1 x Oil Whirl ( less RPM than X RPM)

Vibration Frequencies & Causes

FREQ Synchronous (AC line frequency) Many times RPM (Harmonically related)

CAUSES Electrical

OTHERS Includes broken rotor bar, eccentric rotor, unequal air gap. Gear teeth times RPM. No of Fan blades times RPM No of impeller vanes times RPM 2,3,4 & higher if severe looseness Cavitation, Rubbing, Improper lubrication of journal brgs.

Bad Gears, Aerodynamic forces, Hydraulic, Looseness

High Bad anti Frequency( friction Not bearings harmonically related)

VIBRATION MEASURING METER

Use Velocity transducer for measurements. The Frequency range is from 300CPM to 240 KCPM ( 5Hz to 4kHz) Displacement in microns (Pk Pk) & Velocity in mm/sec (Pk) Amplitude meter contains 2 different scales 1) bottom scale- 0 to 3 2) top scale - 0 to 1

IRD 306 vibration meter

ACCELEROMETER SENSOR FOR ANALYSERS

Sensor Of IRD 880

Sensor of Data PAC 1500

Vibration Spectrum taken using Datapac 1500

Data histories of all equipments in MTPS

TYPES OF MACHINES

The machines are classified into two types based on machine position. They are,

Horizontal machines Vertical machines

In a horizontal machines, the vibration readings are taken in three positions, Horizontal Vertical Axial In a vertical machines, the vibration readings are taken in two positions, Radial Axial

Vibration measurement locations in vertical machines

Vibration measurement locations in horizontal machines

Measurements in Motor DE

ROLLING ELEMENT BEARING PROBLEMS

Improper lubrication Use of wrong lubrication Lubrication contamination Improper storage Moisture Improper installation Improper application

VIBRATION SPECTRUM SHOWING BEARING FAILURE

Spectrum shows Higher order harmonics indicates bearing failure.

ABNORMAL CONDITION OF ID FAN

Bearing End MNDE MDE VPY VSY FDE FNDE

Horizontal
m 6-12 8.0 12 10-18 12 18 mm/s 1.0 1.0 1.6 1.4 0.6 0.8

Vertical
m 8-16 10 12 5-18 12 10 mm/s 1.2 2.2 2.2 1.4 0.6 0.4

Axial
m 30-90 30-50 10-18 30-90 18 20 mm/s 3.6-5 3.0 6.6 3-4.6 0.9 0.8

Observation: The spectrum taken shows that multiple higher order frequencies in motor and voith primary and secondary.

DECOUPLED CONDITION OF MOTOR

Bearing End MNDE

Horizontal

Vertical

Axial

m
21

mm/s
1.6

m
20

mm/s
1.8

m
220

mm/s
14

MDE

0.8

1.6

64

4.2

Report given:1. 2. 3. The voith coupling and its alignment may be checked. The motor bearings may also be checked. The motor may also be tested for electrical compliances.

Action taken:-

The voith bearings are replaced , the vibration readings were reduce into normal limits.

ID FAN VOITH

AFTER REPLACEMENT OF VOITH

Horizontal
m 5 6 6 10 12 16 mm/s 1.0 0.8 2.4 1.2 0.6 0.7

Bearing End MNDE MDE VPY VSY FDE FNDE

Vertical
m 3 6 7 10 11 10 mm/s 1.2 1.4 0.8 0.6 0.5 0.4

Axial
m 18 26 10 20 18 20 mm/s 2.2 2.2 3.2 2.0 0.8 0.8

VIBRATION SPECTRUM TAKEN AFTER RECTIFICATION OF ID FAN

GRAPHICAL ANALYSIS OF VIBRATION IN ID FAN

ABNORMAL CONDITION OF ACWP

Position MNDE m 84 84 86 82 56 52 54 60 7 7 8 7 Radial mm/s 6.8 6.6 7.0 6.4 4.6 4.2 4.4 5.0 1.2 1.8 1.6 1.8 m 22 22 18 22 8 6 6 8 5 3 6 6 Axial mm/s 2.2 2.2 1.9 2.2 1.4 1.1 1.4 1.2 0.9 0.8 0.9 1.0

MDE

PUMP

 Observation:The vibration spectrum taken shows that 1X rpm dominant frequency in radial direction.

VIBRATION READING OF MOTOR IN DE-COUPLED CONDITION

Radial Position m MNDE 66 64 66 66 MDE 44 44 44 44 mm/s 5.6 5.0 5.6 5.4 3.6 3.4 3.8 3.6 m 14 14 14 10 6 6 5 6 mm/s 1.4 1.4 1.5 1.4 1.0 0.8 1.0 1.2 Axial

 Report given:The rotor may be checked for its unbalance.

Action taken:Balancing weight of 39.7gms was added

VIBRATION READINGS AFTER RECTIFICATION OF ACWP

Position MNDE m 20 26 20 28 12 16 12 16 6 6 6 6 Radial mm/s 2.0 2.4 2.0 2.4 1.8 1.6 1.4 1.6 0.7 0.7 0.9 0.8 m 6 5 6 7 4 4 4 5 3 3 3 5 Axial mm/s 1.4 0.9 1.6 1.0 1.2 1.2 1.6 0.9 0.4 0.5 0.6 1.0

MDE

PUMP

AFTER BALANCING

VIBRATION SPECTRUM AFTER RECTIFICATION OF ACWP

GRAPHICAL ANALYSIS OF VIBRATION IN ACWP

CONCLUSION
By selecting this project in METTUR THERMAL POWER STATION we have studied the vibration monitoring techniques and analysis carried out in power plant.

In our project we studied about the vibration measurements and causes of vibration that occurred in power plant machines.
There are other vibration problems occurred in thermal power plant are studied, in our project we analyzed the bearing failure in induced draught fan and unbalance in auxiliary cooling water pump.

THANK YOU