Vibration Monitoring of C-1 Steam Turbine

(Jan ~ June, 2016)

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Background • In January. 2016 CVCM was asked to investigate the cause of fluctuating vibration levels of bearings # 3. 6 & 7 for trending/fault • Vibration data collection was started in March using state-ofthe-art monitoring equipment. 6 & 7. Analysis report issued in April • Real-time monitoring was then started and results reported on May 05 2/7 . M(E) and CVCM/ DNPER had maintained that there was no need to shutdown C-1 plant since turbine vibrations were well within acceptable limits • This viewpoint was also endorsed by M(P) • CVCM was asked to perform on-line vibration monitoring of turbine structure and bearings # 3. • In the earlier meeting at PAEC HQ.

8s followed by low signal for 4. ‒ Vibration fluctuations at Brg#7 were quite stable 3/7 .2s ‒ Vibrations at Brg#3 & 6 are relatively out of phase. • The vibration signals at bearing# 3. 6 & 7 displayed a periodic fluctuating pattern of bearing vibrations as follows: ‒ Brg#3: Signal remained relatively high for 4. signal high for 0.2 second duration followed by a lower magnitude signal for 0.8s ‒ Brg#6 displays exactly opposite behavior.Initial Findings – Vibration Pattern • The blade pass frequencies of C-1 & C-2 were determined to detect any blade wear.

• There was no change in the vibration amp & frequency of the bearings during the four-month period Feb . • It was observed that the variation in fluctuation pattern decreased with increase in load.Initial Findings – Vibration Magnitudes • For all times the vibration mag levels remained below 1/5 th of alarm level.May. 4/7 . 2016.

Major Significant Results • Max vibration displacement magnitude occurred at running speed of the rotor (3000 rpm). small at blade frequencies] • Time signal recorded with the Proximity Probes appeared relatively stationary than signals from Absolute Sensors. 5/7 . • There was a strong doubt that vibration signals were contaminated with the 50 Hz line-frequency signal (ground loop interference) • This is a serious condition since it may mask true magnitude of turbine vibrations and may lead to turbine damage. [rel. • It was observed that vibration frequency of turbine structure and all bearings always occurred at ~ 50 Hz at all times.

• C-1 informed that the task could not be done due to risk of damage and plant shutdown.) • CVCM asked C-1 to check isolation between Electrical and I&C grounds as well as between signal common and signal ground. • CVCM devised a unique method to check ground loop interference in vibration signals by recording vibration signals during turbi ne coast-down • The data recorded and analyzed during plant shutdown showed that turbine vibration frequency has no interference from line frequency • The cause of fluctuating vibration signals required further investigation 6/7 .Significant Results (contd.

• Since injection of ground loop interference has been ruled out by realtime measurement. which indicates that there is no significant deterioration in turbine performance with time • C-1 may comment on the behaviour of other turbine parameters.Conclusion • No significant change in blade stiffness/wear was observed by blades vibration frequency measurements during six-month monitoring. • Periodic fluctuations in the vibration magnitude at bearing 3 and 6 are continuing. • Possible reason is due to reduced damping of the blades which occurred as a result of blades removal from the turbine. 7/7 . it is therefore possible to monitor true vibrations • Turbine vibrations are very small and stable.

8 . The solution was to put the turbine into full arc operation. the 2¥ vibration disappeared.Forty-Eight Case Histories of Intriguing Machinery Problems Analysis of the problem determined that the vibration was the result of the two gaps in the first-stage blade group going in and out of the active steam arc. and it was possible to run the turbine until the new blades could be installed. This case illustrates why it is necessary to understand how a machine works to diagnose a problem and come up with a solution (see Figure 1). When this was done. where all the valves open evenly and accept the throttling losses at low loads.

Thanks 9 .