CONDITION MONITORING IN THERMAL POWER PLANT SHIVAJI CHOUDHURY
OBJECTIVE OF CONDITION MONITORING <ul><li>TO IDENTIFY CHANGES IN CONDITION OF MACHINE  THAT WILL INDICATE  SOME POTENTIAL ...
MONITORING TECHNIQUE <ul><li>VIBRATION MONITORING. </li></ul><ul><li>LUBRICANT ANALYSIS. </li></ul><ul><li>NOISE ANALYSIS....
VIBRATION ANALYSIS <ul><li>TURBINE. </li></ul><ul><li>GENERATOR. </li></ul><ul><li>PUMP. </li></ul><ul><li>MOTOR. </li></u...
VIBRATION DIAGNOSIS <ul><li>SHAFT AND ROTOR-   UNBALANCE , BENT, MISALIGNMENTS  </li></ul><ul><li>BEARING  –DAMAGES,,DISTO...
VIBRATION ANALYSIS 8 MANY REF MARK USUALLY LOW GEAR NOISE RPM* GEAR TEETH 7 MANY REF MARK ERRATIC BAD BRG MANY *RPM 6 USE ...
LUB OIL ANALYSIS <ul><li>MOISTURE </li></ul><ul><li>MECHANICAL IMPURIRTIES </li></ul><ul><li>DENSITY </li></ul><ul><li>VIS...
LUB OIL DIAGNOSIS <ul><li>DEGRADATION OF LUB OIL </li></ul><ul><li>IMPURITIES IN LUB OIL </li></ul>
WEAR DEBRIS  ANALYSIS & DIAGNOSIS   <ul><li>WEAR DEBRIS CARRIED OUT FOR WEAR PARTICLE CONCENTRATION IN OIL </li></ul><ul><...
THERMOVISION MONITORING <ul><li>IDENTIFICATION OF HOT SPOT . </li></ul><ul><li>USED FOR MONITORING OF SWITCHYARD EQUIPMENT...
DISSOLVE GAS ANALYSIS <ul><li>FOR ALL TRANSFORMERS. </li></ul><ul><li>DIELECTRIC STRENGTH OF TRANSFORMER OIL. </li></ul><u...
TRANSFORMER OIL DIAGNOSIS <ul><li>CO AND CO2 IN OIL—THERMALCONDITION INVOLVING PAPER </li></ul><ul><li>METHANE,ETHANE,ETHY...
VIBRATION MEASUREMENT  MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS Y OTHER  PUMPS/FANS 9 Y CW PUMPS 8 Y CEP 7 Y BFP 6 Y Y SEA...
OIL ANALYSIS MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS 5 Y BFP LUB OIL 4 Y MILL LUB OIL 3 Y ID FAN LUB OIL 2 Y Y Y Y MOT OI...
DISSOLVED GAS ANALYSIS YEARLY SCHEDULE FOR  CRITICAL TRANSFORMERS Y STATION  AND OTHER TRANSFORMER 3 Y UNIT AUX TRANSFORME...
HOT SPOT SURVEY THROUGH THERMOVISION CAMARA Y SWITCH YARD AND  TRANSFORMER YARD OF STATION 1 SIX MONTHLY EQUIPMENT  S.N
TEMPERATURE MEASUREMENT BY IR PYROMETER  <ul><li>Measure temperature of  all drain valves , to check valves are passing or...
WEAR DEBRIS ANALYSIS Y MILL GEAR BOX OIL 2 Y MOT OIL 1 ANNUALLY ONCE IN FOUR MONTH EQUIPMENT S.N
STANDARDS FOR CONDITIONAL MONITORING CONDITION MONITORING AND DIAGNOSTICS OF MACHINE AND PROGNOSTICS ISO 13381 3 MECHANICA...
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Condition monitoring in thermal power plant

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Condition monitoring in thermal power plant

  1. 1. CONDITION MONITORING IN THERMAL POWER PLANT SHIVAJI CHOUDHURY
  2. 2. OBJECTIVE OF CONDITION MONITORING <ul><li>TO IDENTIFY CHANGES IN CONDITION OF MACHINE THAT WILL INDICATE SOME POTENTIAL FAILURE. </li></ul><ul><li>DIAGNOSIS OF FAULT </li></ul><ul><li>PREDICTION OF FAULT </li></ul><ul><li>TO AVOID FURTHER DAMAGES </li></ul><ul><li>TO PLAN BETTER SPARE MANAGEMENT </li></ul><ul><li>OUTAGE OF EQUIPMENT CAN BE BETTER PLANNED. </li></ul><ul><li>ENHANCING THE MACHINE EDURANCE LIMIT. </li></ul><ul><li>LESS DOWN TIME AND MORE PRODUCTIVITY </li></ul><ul><li>GREATER SAFETY TO WORK FORCE. </li></ul>
  3. 3. MONITORING TECHNIQUE <ul><li>VIBRATION MONITORING. </li></ul><ul><li>LUBRICANT ANALYSIS. </li></ul><ul><li>NOISE ANALYSIS. </li></ul><ul><li>WEAR DEBRIS ANALYSIS. </li></ul><ul><li>THERMOGRAGHY. </li></ul><ul><li>D G A. </li></ul><ul><li>NDT ULTRASONIC </li></ul>
  4. 4. VIBRATION ANALYSIS <ul><li>TURBINE. </li></ul><ul><li>GENERATOR. </li></ul><ul><li>PUMP. </li></ul><ul><li>MOTOR. </li></ul><ul><li>FAN. </li></ul><ul><li>COMPRESSOR. </li></ul>
  5. 5. VIBRATION DIAGNOSIS <ul><li>SHAFT AND ROTOR- UNBALANCE , BENT, MISALIGNMENTS </li></ul><ul><li>BEARING –DAMAGES,,DISTORTION,LOSS OF LUBRICANT. </li></ul><ul><li>GEAR –TOOTH MESHING FAULT,WORN TEETH,MISALIGNMENT </li></ul><ul><li>MECHANICAL LOOSNESS </li></ul>
  6. 6. VIBRATION ANALYSIS 8 MANY REF MARK USUALLY LOW GEAR NOISE RPM* GEAR TEETH 7 MANY REF MARK ERRATIC BAD BRG MANY *RPM 6 USE STOBE LIGHT TO FREEZE FAULTY BELT 1,2,3,4 UNSTEADY ERRATIC BAD DRIVE BELT 1,2,3,4*RPM 5 USE DIAL INDICATOR FOR POSITIVE DIAGNOSIS TWO MARKS LARGE IN AXIAL DIRECTION BENT,SHAFT MISALIGNMENT 2*RPM 4 USUALLY HIGH IN VERTICAL DIRECTION TWO MARKS ERRATIC LOOSENESS 2*RPM 3 SINGLE PRORRTIONAL IMBALANCE UNBALANCE 1*RPM 2 HIGH SPEED MACHINES WHERE PRESSURISED BEARING ARE USED ERRATIC OFTEN VERY SEVERE OIL WHIP OR OIL WHRIL ½ ROTIONAL SPEED 1 COMMENTS PHASE AMPLITUTE CAUSE FREQ S.N
  7. 7. LUB OIL ANALYSIS <ul><li>MOISTURE </li></ul><ul><li>MECHANICAL IMPURIRTIES </li></ul><ul><li>DENSITY </li></ul><ul><li>VISCOCITY </li></ul><ul><li>ACIDITY </li></ul>
  8. 8. LUB OIL DIAGNOSIS <ul><li>DEGRADATION OF LUB OIL </li></ul><ul><li>IMPURITIES IN LUB OIL </li></ul>
  9. 9. WEAR DEBRIS ANALYSIS & DIAGNOSIS <ul><li>WEAR DEBRIS CARRIED OUT FOR WEAR PARTICLE CONCENTRATION IN OIL </li></ul><ul><li>CONDITION OF LUB OIL </li></ul><ul><li>OUTSIDE CONTENMATION </li></ul><ul><li>TO DETERMINE TO WEAR CONDITION OF MACHINE </li></ul><ul><ul><li>NORMAL RUBBING </li></ul></ul><ul><ul><li>BEARING FAILURE </li></ul></ul><ul><ul><li>CONDITION OF GEAR </li></ul></ul><ul><ul><li>CUTTING OF METAL </li></ul></ul>
  10. 10. THERMOVISION MONITORING <ul><li>IDENTIFICATION OF HOT SPOT . </li></ul><ul><li>USED FOR MONITORING OF SWITCHYARD EQUIPMENT. </li></ul><ul><li>ROUTINE MONITORING OF MOTOR/PUMP. </li></ul><ul><li>MONITORING OF DRAIN PIPES LINES TO DETECT CHOKING OF PIPE LINES. </li></ul><ul><li>TO MONITOR OF CONDITION OF INSULATION ON PIPE AND EQUIPMENT. </li></ul>
  11. 11. DISSOLVE GAS ANALYSIS <ul><li>FOR ALL TRANSFORMERS. </li></ul><ul><li>DIELECTRIC STRENGTH OF TRANSFORMER OIL. </li></ul><ul><li>MOISTURE,DENSITY,COLOUR OF TRANSFORMER OIL. </li></ul><ul><li>DISSOLVE GAS ANALYSIS IN TRANSFORMER OIL-TO DIAGNOSIS OF FAULT. </li></ul>
  12. 12. TRANSFORMER OIL DIAGNOSIS <ul><li>CO AND CO2 IN OIL—THERMALCONDITION INVOLVING PAPER </li></ul><ul><li>METHANE,ETHANE,ETHYLENE AND SMALL AMOUNT OF ACETYLENE IN OIL - THERMAL CONDITION INVOLVING THE OIL </li></ul><ul><li>HYDROGEN,METHA AND SMALL AMOUNT OF ACETYLENE AND ETHANE IN OIL--PARTIAL DISCHARGE </li></ul><ul><li>HYDROGEN,ACETYIENE AND ETHELENE IN OIL-SUSTAINED ARCING-SUSTAINED ARCING </li></ul>
  13. 13. VIBRATION MEASUREMENT MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS Y OTHER PUMPS/FANS 9 Y CW PUMPS 8 Y CEP 7 Y BFP 6 Y Y SEAL AIR FANS 5 Y Y MILL GEAR BOX 4 Y Y PA FANS 3 Y FD FANS 2 Y ID FANS 1 4 TH WEEK 3 RD WEEK 2 ND WEEK 1 ST WEEK Equipment S N
  14. 14. OIL ANALYSIS MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS 5 Y BFP LUB OIL 4 Y MILL LUB OIL 3 Y ID FAN LUB OIL 2 Y Y Y Y MOT OIL 1 4 TH WEEK 3 RD WEEK 2 ND WEEK 1 ST WEEK EQUIPMENTS S N
  15. 15. DISSOLVED GAS ANALYSIS YEARLY SCHEDULE FOR CRITICAL TRANSFORMERS Y STATION AND OTHER TRANSFORMER 3 Y UNIT AUX TRANSFORMER 2 Y GENERATOR TRANSFORMER 1 YEARLY SIX MONTHLY EQUIPMENT S.N
  16. 16. HOT SPOT SURVEY THROUGH THERMOVISION CAMARA Y SWITCH YARD AND TRANSFORMER YARD OF STATION 1 SIX MONTHLY EQUIPMENT S.N
  17. 17. TEMPERATURE MEASUREMENT BY IR PYROMETER <ul><li>Measure temperature of all drain valves , to check valves are passing or not. </li></ul><ul><li>Measure temperature of all bearing of critical pumps, fans, compressors, motors, turbine . </li></ul>Y BEARING OF FANS,PUMPS, COMPRESSORS, MOTORS,TURBINE. 2 Y DRAIN VALVE 1 IN EVERY THREE MONTH MONTHLY EQUIPMENT S.N
  18. 18. WEAR DEBRIS ANALYSIS Y MILL GEAR BOX OIL 2 Y MOT OIL 1 ANNUALLY ONCE IN FOUR MONTH EQUIPMENT S.N
  19. 19. STANDARDS FOR CONDITIONAL MONITORING CONDITION MONITORING AND DIAGNOSTICS OF MACHINE AND PROGNOSTICS ISO 13381 3 MECHANICAL VIBRATION AND SHOCK –VIBRATION MONITORING OF MACHINE ISO 13373 2 CONDITION MONITORING AND DIAGNOSTICS OF MACHINES ,GENERAL GUIDELINE ISO 17359 1 DESCRIPTION STANDARD NO S.N
  20. 20. THANKYOU

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