PROJECT: VIJAYAWADA TPS PROBLEM: VIBRATION ANALYSIS OF UNIT 5, 210 MW SIEMENS TURBINE - SIEMENS GENERATOR

VTPS unit 5 was rolled on 23-05-08 after rectification works carried out for Generator Earth fault. Bently Nevada ADRE Vibration analyzer system was used for vibration measurements and analysis. During coast up of the unit, Generator front and rear vertical vibrations were recorded. The coast up vibration values both amplitude in microns and phase are given in figure 1. The b ode plot shows that the run up of generator rotor is very smooth. Table 1 and 2 gives the bearing pedestal vibration levels for Turbine, Generator and Exciter both in velocity and displacement units. The table gives 1X running speed vibration component , corresponding phase and overall vibration levels which is a sum of all vibration frequency components. The bearing vibrations on all pedestals are satisfactory except for exciter primarily in horizontal direction. The exciter vibrations which were 85 microns peak - peak at 3000 RPM showed a steady increase after synchronization and at rated load were 128 microns peak - peak. Figure 2 shows the velocity and displacement spectrums of exciter bearing in horizontal direction. The spectrum shows that the bearing vibrations are predominantly of running speed component.

Table 3 gives the control room vibration levels at rated load. The Bearing and shaft vibrations are satisfactory except at exciter bearing. The Exciter bearing vibrations are above alarm values . The increase in exciter vibrations with time before stabilization could be because of the following reason. Design diametrical clearance between spigot and recess in Generator Exciter coupling should be 0.03mm to 0.05mm . But the measured clearance at site is 0.12 mm . A 0.05 mm shim has been introduced between recess in Generator rotor and Spigot in exciter rotor . This was not providing a desired solution to the high exciter vibration problem. A permanent solution suggested would be to ream and introduce dowels at 120 degrees apart positions on Generator Exciter couplings as being followed in Hyderabad 120 MW units. Till such time customer was advised to operate the unit with close monitoring of exciter vibration levels.

Fig 1. Generator Front Vertical and Rear vertical Bode Plot

Figure 2. Exciter Pedestal Vibrations Horizontal, Velocity and Displacement spectrums

Table 1. Bearing vibrations in Velocity and Displacement units at 3000 RPM

Velocity in mm/sec 1X Vertical HP Front Axial Vertical Axial Vertical IP Rear LP Rear Axial Vertical Axial Vertical Gen Front Axial Vertical Gen rear Axial Vertical Exciter Axial 1.2 1 1.2 0.4 0.6 0.7 1.8 5.2 4.2 1.5 4.4 1.5 0.4 6.2 Horizontal 1.0 Phase 243? 171? 228? 89? 287 98? 302? --284? 358? 163? 294? 309? 297? 157? 142? 52? 317? 180? 22? 32?
?

Displacement in microns pk-pk Overall 1X Phase Overall 6 2 2.6 3.8 2.1 1.2 1.5 1.2 1.1 2.5 4. 4 5.3 4.2 3.1 1.8 4.9 2.4 1.9 1.3 14 6.6 7 6 6 8 10 3 4 1 4 10 23 33 26 15 10 29 15 9 2 85 38 333? 260? 317? 176? 16
?

10 8 9 10 10 5 5 3 6 12 26 34 28 16 11 30 16 11 5 86 40

Horizontal 1.6 HP Rear

186? 32? --14? 84? 252? 22? 41? 26? 246? 230? 141? 49? 263? 110? 122?

Horizontal 0.1

Horizontal 3.6

Horizontal 2.4

Horizontal 2.3

Horizontal 13

Table 2. Bearing vibrations in Velocity and Displacement units at 215 MW Load Velocity in mm/sec 1X Vertical HP Front Axial Vertical HP Rear Axial Vertical IP Rear LP Rear Axial Vertical Axial Vertical Gen Front Axial Vertical Axial Vertical Exciter Axial 1.0 0.9 0.5 0.8 1.0 0.3 4.0 11 7.0 2.6 3.3 1.3 1.7 7 Horizontal 1.0 Phase ----------?

Overall 3 3.5 3.0 7 4 2 0.3 1.8 1.5 6.2 7.2 11 7.9 3.6 3.9 5.4 3.2 2.3 3.3 21 9

Displacement in microns pk-pk 1X Phase Overall 7 6 5 4 10 2 7 3 1 27 34 70 46 12 17 21 4 9 10 128 47 313? 242? 295? 198 51?
---

8 9 10 10 12 5 11 6 4 29 35 72 48 17 19 27 12 11 15 128 53

Horizontal 1.7

-------330? 177? 161? 319? 300? 156? 128? --------7 33?

120? 257
---

Horizontal 0.5

62? 263? 248? 51? 36? 240? 213? 146? 47? 339? 96? 126?

Horizontal 5.4

Horizontal 2.0

Horizontal 0.3 Gen rear

Horizontal 21

Table 3. Control room vibration values 24-05-08 12.53 hours Load: 215.3 MW Speed : 2954 RPM Vacuum: -0.885 kg/cm2
Bearing Vibrations Shaft Vibrations in microns peak HP Front HP Rear IP Rear LP Rear Gen Front Gen Rear Exciter 1.3 2.5 2.4 2.5 18.4 8.3 43.4 47.3 39.9 38.7 56.0

89.7

Bearing temp
HP front 62.3 67.2 54.1 75.7 Thrust 63.3 61.5 69.0 68.8 HP Rear 61.3 59.3 59.9 57.2 IP Rear 86.3 75.1 LP Rear 83.3 85.6 Gen Front Gen Rear 78.2 78.9 72.4 73.6 Exciter 54.7 59.7