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23rd ABCM International Congress of Mechanical Engineering

December 6-11, 2015, Rio de Janeiro, RJ, Brazil

PERFORMANCE ASSESSMENT OF GENERATORS GROUPS WITH


DIESEL ENGINES, AS FROM THE APPLICATION OF TECHNICALS OF
VIBRATION ANALYSIS

Eraldo Cruz dos Santos


Federal University of Par - UFPA, Belm Par
eraldocs@ufpa.br

Marco Antnio Rosa do Nascimento


Federal University of Itajub - UNIFEI, Itajub Minas Gerais
marcoantonio@unifei.edu.br

Lucilene de Oliveira Rodrigues


Federal University of Itajub - UNIFEI, Itajub Minas Gerais
lucilener@unifei.edu.br

Fagner Luis Goulart Dias


Federal University of Itajub - UNIFEI, Itajub Minas Gerais
fagnerunifei@yahoo.com.br

Luiz Fernando Valado Flres


Federal University of Itajub - UNIFEI, Itajub Minas Gerais
valadao@unifei.edu.br

Abstract. In Brazil, with the current energy situation in the country, where according to the National Electric Energy
Agency ANEEL, there are in operation over five hundred thermoelectric power plants TPPs that generate
electricity for many municipalities, in public service or as Independent Power Producers PIE, operating both in the
isolated system SI as the Brazilian grid, the number of outages for breaking equipment is high, which increases the
cost of energy generated by these sources of energy. Specifically the TPP with diesel engines in spite of operating the
same for twenty-four hours a day, over time the components of such engines degradation level tend to deteriorate,
either due to requirement of continuous operation, the type of engine used, the conditions of the facilities, or the
maintenance conditions practiced by generating companies, which often are the maintenance of the corrective type
unplanned, which corroborate the high breaking index of TPPs engines. Motivated by the need to reduce breaks
machines during operation this you study presents a set of mitigating preventive actions, based on standard techniques
of vibration analysis and evaluation of operating conditions of the engine and its facilities. The objective of this paper
is to evaluate engine performance and present an analysis methodology and control based on vibration analysis and
the severity of standard criteria for the displacement, velocity and acceleration of vibration, in order to reduce the
engine breaks. It is hoped that this study reduce breakage of machines of TPPs which consequently, reduce the cost of
maintenance and energy to the final consumer

Keywords: Power Generation, Vibration Analysis, Diesel Engines, Thermoelectric Power Plants, Monitoring and
Control.

1. INTRODUCTION

The realization of vibration tests on generator sets with diesel engines is part of predictive management, proposed
by Santos (2012), which aims at surveying the operating conditions of Units Diesel Generators - UDGs of Thermal
Power Plants - TPPs in order to determine the basic field operation of UDGs and the instant of the intervention for
maintenance, from the condition of generating equipment.
According to the National Electric Energy Agency - ANEEL (2015), there are in operation in Brazil over five
hundred TPPs operating both in public service and in private service.
This study was developed in UDGs Energy Company Potiguar - CEP, which is the company that owns the TPPs
Potiguar and Potiguar III, whose O & M is conducted by Global company Engenharia Ltda. Such TPPs are located in
the municipality of Macaba - RN. The said UTEs began operation in March 2009 and are equipped with 144 UDGs,
830 kW each, resulting in a generation capacity of 119.520 eMW (CEP, 2010).
Santos, E. C., Nascimento, M. A. R.; Rodrigues, L. O.; Dias, F. L. G.; Flres, L. F. V.;
Performance assessment of generators groups with diesel engines, as from the application of technicals of vibration analysis

The TPP Potiguar has 64 UDGs totaling an installed capacity of 53.12 MW, while TPP Potiguar III has 80 UDGs,
resulting in an installed capacity of 66.40 MW. Both have the advantage of being fully operational for emergency
dispatch electricity and operate biodiesel.
This study aims to appraise the impact on the service life of diesel Caterpillar engines, C32 model, depending on the
serial failures in the components of the cooling systems, intake and exhaust mainly in intercooled turbocharger and
exhaust pipe. Its motivated by the need to reduce failures during operation and to present mitigating actions, based on
mitigation techniques for vibration analysis and evaluation of operating conditions UDGs.
The study will take as a starting point to carry out analysis of the historical failures of the engines, which will be
evaluated the results of vibration analysis, lube oil and engine performance, to identify its causes and consequences.

2. OPERATING CONDITIONS

Caterpillar diesel engines, C32 model, have 12 cylinders arranged in "V", with two turbochargers, as shown in
Fig. 1. According to the manufacturer, each engine can produce, on a continuous basis until 937 bkW or 1,257 bhp
nominal mechanical power output, totaling an installed capacity of 134,928 bMW.

Figure 1. Side view of a diesel engine of UTE Potiguar.

The working speed of these motors is 1800 rpm with motors of indirect cooling system. Still according to Fig. 1,
each motor is coupled to electrical generators, SR43GD model, also manufactured by Caterpillar, owning 830 kW of
installed power each of 480 V voltage and current of 1247 A. The operating frequency is 60 Hz, power factor 0.8,
insulation class H, three phases and four poles, totaling 119.520 eMW of installed capacity. Finally, the speed
regulation controls and departure are both electric (CATERPILLAR, 2007).

3. ANALYSIS OF VIBRATION

According to Santos (2004) and Caterpillar (2007) upon receipt of a UDG in a power plant realignment and a
balancing these units must be performed after UDG be properly installed in their operation base in order to ensure that
vibration levels are within the expected and acceptable values for the standards and the manufacturer. Most times, the
coupling adjusting the UDG is the most important, due to the movement of the held base generator set during transport.
According to Oliveira (2009) the strength coming from the combustion process in the engine cylinders during
operation, tends to twist the crankshaft. The associated vibration is called a torsional vibration and if this force is too
intense, the crankshaft can be damaged by it.
To avoid or minimize the effects of torsional vibration are used vibration dampers, also known as dumpers, in order
to maintain the vibration of UDG within acceptable values and prevent damage to the crankshaft. In this case, the
occurrence of damage or failure of such dampers, excessive noise may be identified along the gear train for the various
speed ranges (Nascimento et al., 2015).
Is noteworthy that, the monitoring of vibration speeds in UDGs can assist in the maintenance process, thus
preventing premature wear of the various components of the system of engines and generators, failures and even breaks
the components of motors (Santos, 2010).

4. METHODOLOGY .

In accordance Caterpillar (2007) of the TPPs Potiguar and Potiguar III engines have sites for adjustment of
vibration, as shown in Figs. 2 (a) and 2 (b). Vibration adjustments must be made on the following points: Base; Screw
adjustments; Support bases; Connecting screws and shims.
23rd ABCM International Congress of Mechanical Engineering
December 6-11, 2015, Rio de Janeiro, RJ, Brazil

(a) (b)

Figure 2. Places of in UDGs vibrations adjustments: (a) Engine base and (b) Generator.

In general, It's must tighten all screws that secure the supports of the engine and generator, as well as those who
support the generator set at the base, using half the final torque.
It should also ensure visually that the adjustment screws indicated with the number (2) in Fig. 2(b) are centered in
the holes with little clearance. In addition to performing the inspections of the distances in the coupling between the
engine and the generator must also be ensured that the screws are installed and the support bases of the engine and the
generator as well as the attachment screws and shims base, as shown in Figs. 3(a) and 3(b).

(a) (b)

Figure 3. Checkpoints and alignment of UDGs: (a) coupling and (b) in the generator.

In the alignment process is necessary to check the highlighted spots shown in Fig. 4, that correspond to places where
they should install control equipment and vibration monitoring. The points to be monitored are: motor gear train; the
flywheel housing; coupling support of the generator and generator bearing support bearing (Nascimento, 2015).

Figure 4. Vibration measurement points in UDGs. Source: Nascimento, (2015).

4.1 Measuring Points

During the measurements should be obtained offset values, speed and acceleration of vibration in UDGs. Figs. 5(a)
and 5(b) show the vibration measurement points in an electrical generator, Fig. 5(a) and the internal combustion engine,
Fig. 5(b).
Santos, E. C., Nascimento, M. A. R.; Rodrigues, L. O.; Dias, F. L. G.; Flres, L. F. V.;
Performance assessment of generators groups with diesel engines, as from the application of technicals of vibration analysis

(a) (b)

Figure 5. Scheme measurement points: (a) generator and (b) In the engine.

In Figs. 5 (a) and 5 (b) may be measurement points perceived in the vibration generators, which were identified as:
1V and 1A points: vertical and axial positions, located in the upper section of the generator, respectively;
2H point: horizontal position, on the side section of the electric generator;
3V point: vertical position, located in the support of the electric generator base;
4V point: upright support base located in the center of the electric generator;
5A and 5H points: axial and horizontal positions, located on engine rear upper section and the side section left
engine, respectively;
6V point: vertical position, located in the upper section of the motor coupling;
7A and 7H points: axial and horizontal position, located in the upper section of the engine and the side section
left engine below the turbocharger, respectively;
8V point: vertical position, located on the left side of the motor section;
9A and 9H points: axial and horizontal position, located front section and side of the engine water pump.

4.2 Measurement Methodology

The adopted measurement methodology was adapted from Santos (2004), ISO 2372 Standards apud Mechefske
(2010), where from them we conducted a vibration test shall in two previously selected UDGs, whose purpose of this
essay is to monitor the behavior of UDG as the specific fuel consumption and vibration, so the measurements of engine
operating parameters were performed.
For the realization of vibration measurement tests and conditions of the generating units of TPPs Potiguar and
Potiguar III, it used the procedure developed below:
Get all general characteristics of UDG (including the value of the effective engine power and the ambient
temperature);
Open a work order to achieve the vibration measurement tests;
meters (sensors) vibration must be installed to obtain the vibration level on points, horizontal - H, vertical V
and Axial A, simultaneously: the water pump (H, V, A); to engine flywheel holder (H, V, A); coupling
between the engine and generator (M, V, A); the bearing free of the generator side (M, V and A) and at the
base of the generator set.
The generating unit is expected to enter operation by and be heated for 15 minutes;
General checks in the generating unit during heating: lube oil condition; Cooling water conditions and leaks.
Synchronize generating unit. It is recommended that the test be made from highest to lowest power (load);
Perform engine load variation, for at least 30 minutes, as the installed engine nominal power ranges that are:
100 (%) = 830 (kW); 90 (%) = 750 (kW); 80 (%) = 660 (kW); 70 (%) = 580 (kW); 60 (%) = 500 (kW); 50 (%)
= 415 (kW); 25 (%) = 210 (kW).
For each engine power variation record the values of speed, displacement and acceleration to the spots where
meters (sensors) vibration have been installed;
Register to load variation, the generation of parameters such as: Fuel consumption; the gas inlet temperature;
Temperature of exhaust gas; Fuel temperature on admission and fuel temperature in return.
Build graphs and tables;
Remove the synchronism generating unit;
Perform the cooling generating unit after the end of the tests for 30 minutes;
Conduct a complete stop generating unit and remove the meters (sensors) vibration of;
Terminate the order of vibration measurement service;
Perform the necessary comments occurrences during the test.
23rd ABCM International Congress of Mechanical Engineering
December 6-11, 2015, Rio de Janeiro, RJ, Brazil

4.3 Vibration Class

According Mechefske (2010), based ISO 2372 and ISO 3945 standards, the vibration severity criteria for UDGs can
be divided in the classes:
Class I individual components, integrally connected with complete machine (electric motors up 15 kW);
Class II Medium sized machines (15 75 kW electric motors)
Class III Large prime movers on heavy, rigid foundations
Class IV Large prime movers on relatively soft, light- weight foundations

In the face of engine classes listed above for the severity of vibration, the UDGs of TPPs Potiguar and Potiguar III
fall within the class III severity.
Tables 1 and 2 show the vibration severity classes on the basis of RMS speed ranges and speed limits for tracks
according to the class of machines distributed by power and base type.

Table 1. Standards Based on Machinery Type. Table 2. Tracks limit speeds and machine classes.

Source: ISO 2372 Standard apud Mechefske (2010). Source: ISO 2372 Standard apud Mechefske (2010).

5. RESULTS

Fig. 6 shows the results of vibration analysis in UDGs of TPPs Potiguar and Potigar III, with the criteria of ISO
2372 and ISO 3945 (Mechefske, 2010). Note that 56% of UDGs are in vibration condition immediate attention, which
corresponds to 81 UDGs. It is also reported that 08% are on the alert condition, i.e., 11 UDGs, 04% of UDGs are in
good conditions as vibration, that is, 06 UDGs. They also that 32% of UDGs where there is no information on
operating conditions, i.e., 46 UDGs are out of operation.

Vibration Analysis of UDGs


Good Condition Alert No Information Immediate Attention

4% 8%

56% 32%

Figure 6. Vibration analysis based on the criteria of ISO 2372 and 3945 standards.

The problems identified in generator groups were:


20 UDGs are out of operation in the block condition of the broken out engine;
20 UDGs overall maintenance;
02 UDGs are out of operation with damaged motor shaft;
01 UDG is not operational with locked crankshaft;
01 UDG is out of operation with water contamination in the lubricant oil;
Santos, E. C., Nascimento, M. A. R.; Rodrigues, L. O.; Dias, F. L. G.; Flres, L. F. V.;
Performance assessment of generators groups with diesel engines, as from the application of technicals of vibration analysis

01 UDG is not operational to change base;


01 UDG is not operational with lube oil contamination with diesel oil.

Thus, it has been 46 UDGs out of operation for problems arising from excessive vibration in operation.
Due to the large amount of data we attempted to perform vibration analysis only on UDG 53, where we used a
Collector vibration analyzer SKF brand and model CMVA60.
In the graphs of Figs. 7 to 11 were introduced to the variation ranges of the speed, according to ISO 2372 standard
for class II groups, rigid base with power above 75 kW, with the following characteristics:
In cyan color: limit range for vibration speeds considered to be good;
In green color: limit range for the vibration velocity considered to be satisfactory, requiring monitoring;
In gray: limit range for the vibration velocity considered to be unsatisfactory - Alert, with intervention need the
equipment in short time;
In red: threshold range for the vibration velocity, where above this, it has an unsatisfactory condition - risk, in
this case there is a need immediate intervention on UDG.

In the graphs of Figs. 7(a) and 7(b) were also placed in red, as a reference point, the lines corresponding to the
recommended maximum power for operation of components of the generator unit.

(a) (b)

Figure 7. Vibration speeds the electric generator of the UDG 53: (a) Top section and (b) lateral section.

The results of the measurements carried on the electric generator of the UDG 53 in terms of vibration velocity in the
axial, vertical and horizontal directions and the analyzes using the vibration severity criteria of the ISO 2372 standard,
and they are as follows:
UDG was 53 at the time of testing on 7789 hours of operation, which is, compared to similar equipment 1789 hours
after partial revision of the equipment.
It is noted Fig. 7 (a) for point 1A, the axial position, the load increases there is a significant increase in vibration
velocity exceeding before the equipment operation range, the unsatisfactory - Danger limit to the vibration velocity, that
is, this equipment is the need for immediate intervention. However, to the point 1V, the vertical position is observed a
tendency of variation of the vibration velocity between satisfactory and unsatisfactory - Alert tracks. Indicating a need
for vibration monitoring this equipment.
The operation of the equipment to excessive vibration in the axial direction, over time, will exacerbate the level of
vibration which can cause effects such as unbalancing of the generator assembly and the consequent stopping of the
generating equipment.
In Fig. 7(b) it can be seen that the electric generator has an acceptable performance, i.e., good to vibration and speed
in the operating range even with the load increases, the vibration speed is remains in satisfactory condition.
In FIG. 8(a) it can be seen that the electrical generator has a tendency to increase the vibration speed with increasing
load, and that for the operating range and the recommended maximum power with a strong increasing trend vibration,
reaching out to beyond the threshold of dangerous condition.
In FIG. 8 (b) it can be seen that the electrical generator has a tendency to increase the vibration speed with
increasing load, and that for the operating range and the recommended maximum power, presenting an increasing trend
of vibration, not reaching out to beyond the threshold of dangerous condition.
Using the same methodology used in the electrical generator, analyzes the values of the measurements taken at the
motor measuring points were carried out. Although the generator has a larger installed nominal power than the motor it
is noted that for the recommended operating range, the trend of strong increase in vibration levels, which can cause
severe equipment damage.
23rd ABCM International Congress of Mechanical Engineering
December 6-11, 2015, Rio de Janeiro, RJ, Brazil

(a) (b)

Figure 8. Vibration speeds of the electric generator UDG 53: (a) base and (b) side Section.

In Figs. 9 (a) and 9 (b) shows the results of measurements of the vibration speed at the motor measuring points of
UDG 53 UTE Potiguar III.

(a) (b)

Figure 9. Vibration of the engine speeds UDG 53: (a) in the lateral and in the coupling and (b) coupling.

In Fig. 9 (a) it is observed that nearby the coupling vibration speeds have increased with the increase in load, but
remained in the range below the unsatisfactory condition - Alert.
Fig. 9 (b) shows that the axial vibration velocity has a strong growth trend exceeding the limit vibration speed at the
beginning of recommended operating range, being classified as unsatisfactory - Danger. This is necessary intervention
as balancing and alignment of the generating unit, in order to reduce such effects.

(a) (b)

Figure 10. Vibration of the engine speeds of UDG 53: (a) Top section and (b) On the left side.
Santos, E. C., Nascimento, M. A. R.; Rodrigues, L. O.; Dias, F. L. G.; Flres, L. F. V.;
Performance assessment of generators groups with diesel engines, as from the application of technicals of vibration analysis

In Fig. 10 (a) shows an increasing trend with stabilization of vibration on UDG 53 for the recommended operating
range, remaining below the limit values of vibration velocity condition unsatisfactory - Alert.
Fig. 10 (b) shows strong increase of 53 UDG vibration speed at the recommended operating range, which exceeds
the vibration speed limit provided unsatisfactory Danger with the need for verification of vibration of the base of the
generator set and its crankshaft, it points possible wear and engine unbalancing.
In Fig. 11 is presented strong vibration velocity in the pump of the engine cooling water system vibration velocity
levels considered to be Unsatisfactory - danger with the potential to cause severe damage over time to the cooling
system components, and radiators (water and oil), hoses, fittings, fans, etc.

Figure 11. Vibration of the engine speeds of UDG 53 in the front section.

6. CONCLUSION

Starting from characteristics of predictive management proposed by SANTOS (2014 and 2012), it is understood
that the engines used in TPPs Potiguar and Potiguar III are not suitable for power generation, i.e., they are not stationary
engines, this can also be found in other TPPs in Brazil.
Was proven in tests and analyzes of the engines, the speeds of vibration values have not remained within the
vibration speed ranges acceptable in any of the points of the engine front section, which characterize mounting error or
cooling system design UDG 53, is recommended to review the conditions of the facility, mounting, balancing with the
fan and inspection of cooling system components.
Thus it can be concluded that the engine is operating with an effective power delivered over the rated power motor
design, which is 708 bkW. Therefore recommends the effective power reduction UDGs released from the TPP Potiguar
and Potiguar III to a value of 680 kW, as shown in the graphs raised vibration of speed x engine load percentage.
Therefore, it is concluded that the engine is operating with overload 229 bkW. Furthermore, the vibration analysis
emphasizes that in the maximum load condition, the engine is working above the vibration limits which reduces the
lifetime of components increase the cost of operation and maintenance, which involves availability and operational
reliability lower.
This behavior replicates itself for other power plant engines and can be evidenced in the analysis of occurrences,
where most failures, with opening service order, analyzed report to excessive vibration on the motor front section.
Then it can be stated that in the power plants of the CEP were installed marine engines adapted for generating
electricity.

7. REFERENCES

ANEEL Agncia Nacional de Energia Eltrica, 2015. Banco de Informaes de Gerao: www.aneel.gov.br,
acessado em 05/05/2015.
BRUNETTI, F., 2012. Motores de Combusto Interna Vol. 1, Editora: Blucher, ISBN 9788521207085.
CATERPILLAR, 2007. Manual de Operao e Manuteno SPBU8083-04.
CEP Companhia Energtica Potiguar S. A., 2010. Relatrio Tcnico do Sistema de Arrefecimento dos GMG 32C
CAT.
GOIS Geradores Service, 2011. Diagnstico dos Servios Executados pela Cat/Marcosa no Recall e outros
Servios em Garantia dos Motores Cat-C32 da Companhia Energtica Potiguar, Relatrio Tcnico.
MECHEFSKE, C. K., 2010. Machine Condition Monitoring and Fault Diagnostics, Mechanical Engineering,
Queens University.
NASCIMENTO, M. A. R.; FLRES, L. F. V.; SANTOS, E. C.; RODRIGUES, L. O., 2015. Estudo do Impacto na
Vida til de Motores Diesel, Modelo CAT C32, em Decorrncia das Falhas no Intercooler, no Sistema de
Resfriamento e na Tubulao de Exausto, Relatrio Tcnico.
23rd ABCM International Congress of Mechanical Engineering
December 6-11, 2015, Rio de Janeiro, RJ, Brazil

OLIVEIRA, M. S., 2009. Caterpillar Engines, Centro de Treinamento.


SANTOS, Eraldo C., 2004. Curso de Operao de Unidades Geradoras com Motores de Mdio Porte
Departamento de Manuteno da Gerao, Engenharia da Manuteno da Gerao DEMAG / Engenharia,
Centrais Eltricas do Par S. A. CELPA, Belm PA, 169 p.
SANTOS, Eraldo C.; NASCIMENTO, M. A. R., 2010. Anlise de Criticidades e Falhas nos Componentes dos
Sistemas de Gerao de Energia Eltrica, CONEM 2010, VI Congresso Nacional de Engenharia Mecnica,
Campina Grande, Paraba PB, Brasil.
SANTOS, Eraldo C., 2012. Ciclo de Rotinas para Melhoria da Manuteno em Unidades Diesel de Gerao de
Energia Eltrica, Tese de Doutorado, Universidade Federal de Itajub - UNIFEI, Itajub - MG, 183 p.

8. RESPONSIBILITY NOTICE

The authors are the only responsible for the printed material included in this paper.

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