Professional Documents
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100.34
0.57
0.42
4407
4439
4323
1000 0
2.12
1.33
0.29
03-04
04-05 Year
05-06
03-04
04-05 Year
05-06
Generation (Mus)
Generation (Loss)
MAINTENANCE STRATEGY
E X C E L L E N C E
Prevention Proactive Predictive Preventive Corrective
Analysis
DETECTION DIAGNOSIS PROGNOSIS ACTION - something is wrong - what is wrong? - what can it lead to ? - what is to be done?
Objectives
Early detection of potential abnormality. Secondary damages are avoided. Likely source of abnormality without stoppage of equipment. Maintenance activities can be well planned. Reduction in quantum of maintenance activities and man- power. Outage of equipment can be very well planned Better spare part management
Applications
Applications
Press. Vessels Elect. Motors Compressors Transformers Switchyard Generator Turbine Pumps
Motor Current Analysis Thermography DGA Noise Magnatic Particle Insp. ELCID Test NDT Ultasonic
Fans
Benefits
Major Failures Diagnosed
60 50 40 30 20 10 0
Rs. In Lacs
15.54
45.67
49.48
Vibration Monitoring
On-line Monitoring: Carried out on Boyce make DATM 4 condition monitoring system. 22 critical equipments covered. Off-line Monitoring Carried out as per the schedule using portable Microlog data collector CMVA 40 Equipment with motor capacity > 5kw (60 HT /95 LT)
Vibration Diagnosis
Abnormal Wear Misalignment Belt flaws Flow Turbulence Structural Resonance Imbalance Mechanical looseness Bearing damages Gear damages Cavitations Fatigue.
Noise Monitoring
RAYTHEON make RT 5001 sound level meter Frequency of monitoring: monthly Limit of noise level at manned location: 75 db Quantitative trend analysis.
Thermo-vision Scanning
Hot spots monitored by Infrared Camera Used for switchyard Equipments Monitoring Frequency Monthly. Routine monitoring of Pump, Motors etc by infrared gun
Thermo-vision Diagnosis
Degrading conditions of transformers, motor control centers, switchgear, substations, switchyards, or power lines. In mechanical systems, it can identify blocked flow conditions in heat exchanges, condensers, transformer cooling radiators, and pipes.
DGA Diagnosis
Large amounts of CO and CO2 indicates overheating in the windings. CO, CO2, and CH4 show the possibility of hot spots in the insulation. H2, C2H6, and CH4 are indicative of corona discharge. C2H2 is a sign of internal arcing.
ELCID Test
Carried out for generator during unit overhaul. Stator is excited by a winding that produces a circumferential magnetic flux around the core Test equipment analyses the resultant in-phase and quadrature magnetic potential difference values between adjacent stator teeth.
HYDRAULIC COUPLING
MOTOR
ID Fan Specification
Two ID fan / unit each of 50 % capacity (capacity 258 m3/sec ) Speed of fan-: 701 rpm Fan drive Hydraulic coupling -: Make: Voith Oil: Servotorqe 10 (IOC make ) Bearings: I/p end 7326 BTY PUA O/p end 7320 BMPUA Motor -: Make: BHEL 3ph,6.6kv ,1850kw,745 rpm Bearings: NDE NU232 DE NU 238/6238
Chemical Analysis Contains metallic particles of oil Noise Motor current Rise of 2 dB , Abnormal hissing sound Normal
WDA Report
Date 12 Sept
WPC: 18.8; Severe sliding wear particles of copper alloy of size 126 microns in large quantities. Copper alloy cutting wear particles of size 96 microns in marginal quantities
WDA Report
Date 16 Sept
WPC: 42.9; Severe sliding wear particles of copper alloy of size 400 microns in large quantities.
Motor DE axial vibration rose to 3mm/sec from 1 mm/sec. As per OEM alarm limit is 4.5 mm/sec & danger limit is 11 mm/sec
WDA Report
Date 18 Dec
WPC 78.6 ; severe sliding wear particles of copper alloy of size 90 microns in large quantities & bearing wear particles of size 50 microns in marginal quantities
VIBRATION MONITORING
On 4 Jan axial vibrations reached to 10 mm/sec Amplitude of 4-6 mm/sec at bearing defect frequencies Rise in the radial vibration of motor DE brg Slight rise in the trend of hydraulic coupling axial vibration.
Findings
Bearing cage of output bearing of Hydraulic Coupling found severely worn-out. Motor DE bearing failed due to fatigue failure. Avoided catastrophic failure of ID Fan. Avoided unplanned maintenance loss.
Failed bearing
New bearing
Mill specification
Make BHEL Capacity 84.8 T/Hr Drive motor - 2350 KW, 1488 RPM, 3 ph, 6.6 KV Pinion Bearing - Spherical Roller (23248)
First Symptom
On 20.02.2003, bolts of seal retaining plate of Pinion Coupling (Pinion side half) found sheared. Inspection of gear coupling observed no abnormalities in the gear coupling and all the teeth found intact. After thorough inspection all the bolts were replaced with new bolts.
Sequence of Events
5 6
3 4 2 7
1
On 10.8.2003, Main Reducer of mill 1CD replaced as the axial vibrations at intermediate and output shaft were having increasing trend. No abnormality was noticed in the existing gear box.
2
On 10.10.2003, explosion occurred in the mill while it was being taken out of service. Due to explosion both side hot air ducts got heavily damaged. After rectification work mill was taken in service and found normal.
3
Increasing trend observed in axial vibrations of pinion DE bearing.
4
On 19.04.2004, inspection of Girth gear and Pinion was carried out No abnormality was observed. Alignment between main reducer and pinion checked and found disturbed. Re-alignment of all the couplings was carried out.
5
The amplitude of vibration signal found increasing Spectrum analysis indicated abnormality in bearing.
OVERALL= 1.47 V-DG PK = 1.47 LOAD = 100.0 RPM = 1461. (24.34 Hz)
OVERALL= 2.78 V-DG PK = 2.76 LOAD = 100.0 RPM = 1500. (25.00 Hz)
PK Velocity in mm/Sec
1.6
1.2
0.8
0.4
0 0 50 100 150 Frequency in kCPM 200 250 300 Freq: Ordr: Spec: 6.750 4.500 1.798
6
Bearings of both DE and NDE sides replaced Re-alignment of Girth gear and Pinion carried out.
Pinion Vibration
Before Correction Vibration in mm/Sec
H
2.0 1.2
V
3.3 3.0
A
7.0 1.5
DE NDE
Vibration in mm/Sec
H
1.5 1.1
V
2.5 1.8
A
1.7 1.5
DE NDE
Observations
Findings
The bearing clearances observed to be 0.60 mm. The normal clearances allowed are 0.20 mm. The bearing taper sleeve found cracked. The heavy scoring marks were observed on NDE side of the shaft. Bearing sleeves on both the sides (NDE & DE) observed to be shifted by 20 mm.
CONCLUSION
Condition monitoring pays back the investment : By improving Equipment Reliability By minimizing downtime By maximizing equipment performance and plant availability By maximizing component life
Thank You