Atul Deshpande

Dy. Manager, Reliance Energy

Dahanu Thermal Power Station
 Dahanu TPS (2 x 250 MW) of
Reliance Energy is one of the best
operating coal based power
stations in the country, in terms of
all the major key performance
parameters such as availability,
plant load factor, specific oil
consumption, heat rate etc
Condition monitoring techniques applied to pumps
Vibration monitoring
It helps to determine the condition of pump and structural stability in a system. On-
line vibration monitoring is carried out on DATM 4 condition monitoring system. The
off- line vibration monitoring is being carried out as per schedule by portable
Microlog data collector CMVA 65

Lubricant analysis
Chemical analysis of lub oil is carried out for appearance, density, viscosity, moisture
content, mechanical impurities and NAS level.

Wear debris analysis

It is carried out for wear particle concentration. A lub oil sample is subjected to
magnetic field and by optical density, relative amount of contamination can be
assessed.

Noise monitoring
Noise level are taken every month at designated locations. The limit of noise level at
manned location shall be 75 dB.
YEARWISE PREDICTED FAILURES
Steps for implementation of Condition
Monitoring Technique for Pumps
•Selection of equipment
•Selection of parameters / probe
•Selection of monitoring frequency
•Preparation of schedule
•Preparation of database.
•Actual monitoring and analysis

Selection of monitoring frequency

•Daily (for critical equipments)

•Fortnightly (for sub critical equipments.)
Preparation of database
•Collection of equipment data
•Shaft speed
•No of vanes / blades
•Gear teeth
•Brg. type / no
•Pressure, Temperature, Current, flow

Actual Monitoring & Analysis

•Data collection as per schedule
•Trend / spectrum analysis on day to day basis
•Root cause analysis
•Post maintenance observations
 Case study - 1

High current consumption of BFP

Noticed that current drawn by BFP-2B had gradually increased from

690 to 760 Amps.
Marginal increase in vibration level.
Motor Current Trend

Pump DE Vibration Trend

 DATA
SUMMARY
* Voltage = 6.59 KV
* BFP Current = 760 Amps
* BP Suction Pr. = 8.68 Kg/Cm2
* BFP Suction Pr. = 26.93 Kg/Cm2
* BFP Discharge Pr. = 188.08 Kg/Cm2
* BP Suction Temp. = 167.24 0C
* BP Speed = 1502 Rpm
* BFP Speed = 5492 Rpm
* Suction Flow = 800 T/Hr.
* Vibration DE (H / V / A) = 3.5 / 1.9 / 2.1 mm/sec.
 ANALYSIS
Identified high power consumption and rising
in vibrations.

• Suspected wear & tear of pump internals due to ageing of the pump.
• Possible damage to internal gasket.
• Suspected short-circuiting of suction and discharge chambers.
• Suspected floating seal damaged.
• Suspected pitting in pump suction. chamber.
 Action Taken

• Pump stopped and dismantled.

• Floating seal was replaced.

• Eroded area was gouged properly, welding and grinding done to

achieve smooth surface area.

• In-situ lapping done by in-house developed fixture to avoid further

20 more days delay/downtime.
BFP Cartridge Withdrawal

WEAROUT
OBSERVED
ON THE
CARTRIDGE
Repairing of Pump casing:

Severe erosion in
BFP casing
(Radial surface).

Size of eroded
portion was 100
(L) X 50 (W) X 30
mm.(D)
Repairing of Pump casing:

Erosion observed
in gasket seating
area.
Water was
passing through
this area and
further damaged
radial surface.
Repairing of Pump casing:

Erosion also
observed near
discharge pipe.
It was rectified by
welding.
Repairing of Pump casing:

Eroded area was

welded.

(Radial surface)
Repairing of Pump casing:

Gasket seating
area was welded, BLUE MATCHING OF SEAL
rectified by blue FACE AREA AFTER
matching & lapped. WELDING &
100% blue RECTIFICATION
impression was
obtained.
This work was
carried out in 0.02
mm accuracy.
Repairing of Pump casing:

Rectified radial
surface of BFP
casing.
Bore reading was
obtained within
the accuracy of.
0.02 mm.
 Post-Maintenance
* Voltage Survey: = 6.6 KV
* BFP Current = 685 Amps
* BP Suction Pr. = 8.66 Kg/Cm2
* BFP Suction Pr. = 26.52 Kg/Cm2
* BFP Discharge Pr. = 187.97 Kg/Cm2
* BP Suction Temp. = 167.73 Deg.C
* BP Speed = 1488 RPM
* BFP Speed = 5329 RPM
* Suction Flow = 803 T/Hr.
* Suction Flow = 803 T/Hr.
* Vibration DE (H / V / A) = 2.0 / 1.8 / 1.6 mm/sec.
 Cost Saving
Current drawn before cartridge replacement: 760 amps
& casing repairs (hourly average)
Current drawn after cartridge replacement &: 685 amps
casing repairs (hourly average)
Net current reduction: 75 amps
(hourly average)
Power saving = √3 x V x I x cosφ
= √3 x 6.6 x 75 x 0.85
= 729 kWh

Net cost saving per annum = 729 x 24 x 3.5 x (365/2)

@ Rs. 3.50 per unit = Rs.1,11,75,570/-
(Cr. running hours of one BFP
for six months in a year)
 BASIC ANALYSIS OUT LINE
1. Was the problem always there. How the problem first appeared?

2. Find points of worst vibrations and compare with bearing and foundation vibration.

3. Determine frequency of worst vibration.

4. Cross check what can cause vibration of that frequency to identify most possible
vibration cause.

5. Eliminate causes, which cannot cause this frequency vibration in the machine in
questions.

6. Check for other symptoms.

7. Determine cause.

8. Double check for possible resonance.

9. When you think you have the answer ask yourself what cause the same symptoms.

10. Finalise your decision and go for correction.