2. A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
USES OF PHASE ANGLE MEASUREMENT
1. BALANCING
2. STRUCTURE MOTION STUDY
3. DETECTION OF RESONANCE FREQUENCY
ī RUN UP & RUN DOWN BEHAVIOUR
ī BODE PLOT
4. HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS
5. UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT
5. 10
11 12
4
5
6
7
8
9
13
14
15
GENERATOR SIDE
TURBINE SIDE
3
2
1
C A
B
D
LEFT
RIGHT
16
17
18
19
20
21
BASE PLATE
SECONDARY GROUT
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS
6. A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT
B1 B2 B3 B4
7. Case Studies
on
Vibration Problems in Steam
Turbine Generators
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
8. HIGH VIBRATION IN
500 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
9. HIGH VIBRATION IN 500 MW TG SETS
PROBLEM
HIGH HP FRONT SHAFT AND BEARING PEDESTAL VIBRATION
OBSERVATIONS
(A) FREQUENCY ANALYSIS CARRIED OUT WHICH INDICATED
īPREDOMINANT 1-X VIBRATION COMPONENTS FOR BOTH SHAFT AND
BEARING PEDESTAL VIBRATION
īSTEADY PHASE ANGLE
(B) BEARING PEDESTAL VIBRATIONS AND SHAFT VIBRATIONS WERE
HAVING RISING TENDENCY AT RATED SPEED HOWEVER, THEIR RATIO
WAS FOUND TO BE ALMOST CONSTANT
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
10. ANALYSIS
īPREDOMINANT 1-X VIBRATION WITH SLIGHT CHANGE IN PHASE
ANGLE INDICATED THERE WAS UNBALANCE IN THE ROTOR SYSTEM
LEADING TO INITIATION OF MINOR RUB
īMAIN SOURCE OF VIBRATION WAS HIGHER DYNAMIC LOADING FROM
THE SHAFT WHICH WAS GETTING TRANSMITTED TO BEARING
ACTION TAKEN
âĸ TO REDUCE THE HP FRONT SHAFT VIBRATION LEVEL, INSITU
BALANCING WAS CARRIED OUT USING LP ROTOR BALANCING PLANES
HIGH VIBRATION IN 500 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
11. RESULT OF INSITU BALANCING
īHP SHAFT VIBRATION BROUGHT DOWN TO STEADY VALUE OF 120
MICRONS, 0-PK FROM EARLIER VALUE OF 150 - 200 MICRONS, 0-PK
īHP FRONT BEARING VIBRATION CAME DOWN INITIALLY TO 15
MICRONS, 0-PK AT 3000 RPM FROM EARLIER VALUE OF 25 â 40
MICRONS, 0-PK
īLATER, WITHIN 2-3 HOURS OF OPERATION, HP FRONT BEARING
VIBRATION INCREASED BEYOND ALARM VALUE (35 MICRONS, 0-PK).
DURING THIS PERIOD, NO INCREASE IN SHAFT VIBRATION WAS
OBSERVED
HIGH VIBRATION IN 500 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
12. INTREPRETATION OF RESULTS AFTER INSITU BALANCING
īAS HP FRONT BEARING PEDESTAL VIBRATION INCREASED, EVEN
WHEN HP FRONT SHAFT VIBRATION WAS CONSTANT, INDICATED THAT
THE CAUSE OF HIGH BEARING PEDESTAL VIBRATION WAS SOME
FACTORS APART FROM UNBALANCE OF THE SHAFT
ANALYSIS DONE
âĸ BASED UPON THE VIBRATION BEHAVIOUR OF BEARING PEDESTAL AND
SHAFT VIBRATION, IT WAS DECIDED TO SCAN FRONT BEARING
PEDESTAL BY PORTABLE VIBRATION ANALYSER
HIGH VIBRATION IN 500 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
13. RESULTS OF SCANNING OF FRONT PEDESTAL
īVIBRATION ON LEFT AND RIGHT HAND SIDE OF FRONT BEARING
PEDESTAL (NEAR HP CASING FRONT PALMS) IN THE VERTICAL
DIRECTION WERE HAVING LARGE VARIATION
(LHS VIBRATION IS ABOUT 5 TIMES MORE THAN RHS VIBRATION)
īHP CASING PALM VIBRATION AMPLITUDE IN VERTICAL DIRECTION ON
LEFT AND RIGHT PALM WAS FOUND TO BE OF LOWER MAGNITUDE
AND SAME
īSCANNING INDICATED THAT THERE WAS NO PROBLEM WITH BASE
PLATE, SECONDARY GROUT & FOUNDATION MATING SURFACES
HIGH VIBRATION IN 500 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
14. HP CASING PAM
(RIGHT HAND
SIDE)
HP FRONT BEARING PEDESTAL
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
15. ANALYSIS
īSCANNING DATA INDICATED THAT LOAD DISTRIBUTION BETWEEN
PALMS OF HP CASING WAS NOT PROPER
īTHERE WAS GAP BETWEEN CASING PALM AND PEDESTAL ON LEFT
HAND SIDE
ACTION TAKEN
âĸ 0.15 MM SHIM WAS ADDED BELOW LEFT HAND SIDE PALM WHEREAS
0.1 MM SHIM WAS REMOVED FROM RIGHT HAND SIDE PALM FOR
IMPROVING THE LOADING PATTERN OF HP CASING ON PEDESTAL
HIGH VIBRATION IN 500 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
16. RESULT OF CORRECTION IN SHIMS
īVIBRATIONS ON BEARING PEDESTAL REDUCED FROM 35 MICRONS, 0-
PK TO 15 MICRONS, 0-PK AND NO INCREASING TENDENCY WAS
OBSERVED
īHP FRONT SHAFT VIBRATION WAS FOUND TO BE REDUCED FROM 120
MICRONS, 0-PK TO 90 MICRONS, 0-PK AND BEARING VIBRATION
SETTLED DOWN TO 10 MICRONS, 0-PK AT FULL LOAD
īRATIO OF LEFT AND RIGHT HAND SIDE VIBRATION ON FRONT
PEDESTAL IN VERTICAL DIRECTION CAME DOWN TO 2:1 FROM
EARLIER VALUE OF 5:1
HENCE, UNBALANCE OF ROTOR SYSTEM & UNLOADING OF
LEFT SIDE PALM WAS FOUND TO BE THE ROOT CAUSE OF THE
HIGH HP FRONT SHAFT AND BEARING PEDESTAL VIBRATION
HIGH VIBRATION IN 500 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
17. īVIBRATION SCANNING IS A VERY
IMPORTANT TOOL FOR DIAGNOSTICS
PURPOSES
īVIBRATION SCANNING SHOULD BE USED AS
FREQUENTLY AS POSSIBLE
īIT HELPS IN RULING OUT OR PIN POINTING
CERTAIN DEFECTS
CONCLUSION
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
18. HIGH VIBRATION IN
210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
19. HIGH VIBRATION IN 210 MW TG SETS
BACKGROUND
ī MACHINE IS OF KWU DESIGN STEAM TURBINE COUPLED WITH LMW
GENERATOR (LP REAR BEARING AND GENERATOR FRONT BEARING IS
LOCATED IN COMMON PEDESTAL)
ī VIBRATION BEHAVIOUR WAS FOUND TO BE NORMAL DURING FIRST
COMMISSIONING ON ALL BEARINGS AND LATER ON VIBRATION ON
BEARING NO. 4 / 5 PEDESTAL DETERIORATED GRADUALLY BEYOND
ALARM LEVELS (35 MICRONS, 0-PK)
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
20. PROBLEM
ī HIGH LP REAR BEARING VIBRATION
ī HIGH GENERATOR FRONT BEARING VIBRATION
OBSERVATIONS
FREQUENCY ANALYSIS CARRIED OUT WHICH INDICATED
ī PREDOMINANT 1-X VIBRATION COMPONENT FOR BOTH LP REAR AND
GENERATOR FRONT VERTICAL AND AXIAL VIBRATION
ī VERTICAL VIBRATION AT LP REAR AND GENERATOR FRONT BEARING
WAS OF THE ORDER OF 100 MICRONS, PK-PK
ī AXIAL VIBRATION WAS ABOUT 200 MICRONS, PK-PK FOR BOTH LP
REAR BEARING AND GENERATOR FRONT BEARING
HIGH VIBRATION IN 210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
21. ANALYSIS
BASED ON VIBRATION SYMPTOMS, FOLLOWING CHECKS WERE
SUGGESTED IN PLANNED OVERHAUL
īLP / GENERATOR ALIGNMENT
īBEARING ASSEMBLY CHECKS
RESULT OF ABOVE WORKS
AFTER CARRYING OUT THE ABOVE MENTIONED CHECKS &
CORRECTIONS DURING PLANNED OVERHAUL, VIBRATION LEVEL DID
NOT IMPROVE
HIGH VIBRATION IN 210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
22. ACTION TAKEN
FOLLOWING WORKS WERE CARRIED OUT
ī VIBRATION ANALYSIS
ī SCANNING OF LP REAR BEARING PEDESTAL AND ITS SECONDARY
GROUT AND BASE PLATE AREA
OBSERVATIONS / ANALYSIS
âĸ FREQUENCY BEHAVIOUR OF BEARING VIBRATION FOUND SIMILAR TO
EARLIER OBSERVATION
âĸ WIDE DIFFERENCE IN PHASE ANGLE IN VERTICAL DIRECTION
ACROSS BASE PLATE OF LP REAR PEDESTAL AND SECONDARY
GROUTING WHICH INDICATED THAT VERTICAL LOAD TRANSFER
FROM BEARING TO FOUNDATION IS NOT AS EXPECTED
HIGH VIBRATION IN 210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
23. 10
11 12
4
5
6
7
8
9
13
14
15
GENERATOR SIDE
TURBINE SIDE
3
2
1
C A
B
D
LEFT
RIGHT
16
17
18
19
20
21
BASE PLATE
SECONDARY GROUT
SCANNING OF PEDESTAL
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
24. ACTION PLAN SUGGESTED
ī REGROUTING OF LP REAR PEDESTAL
ī REPLACEMENT OF FOUNDATION BOLTS OF LP REAR PEDESTAL AND
PROPER MATCHING OF ANCHOR PLATES
ī IN-SITU BALANCING OF GENERATOR ROTOR TO REDUCE EXCITATION
FORCES TO MINIMUM
DUE TO TIME CONSTRAINT AND POWER REQUIREMENT,
FOLLOWING WORKS CARRIED OUT
âĸ EPOXY GROUTING (PRESSURE GROUTING) OF LP REAR PEDESTAL
âĸ RESTRETCHING OF FOUNDATION BOLTS OF LP REAR PEDESTAL
âĸ LP / GENERATOR REALIGNMENT
âĸ BEARING INSPECTION
HIGH VIBRATION IN 210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
25. RESULT OF ABOVE WORKS
AFTER CARRING OUT THE ABOVE MENTIONED CHECKS DURING NEXT
OVERHAUL
īVIBRATION LEVEL FOUND REDUCED TO 25 MICRONS, 0-PK ON
BEARING NO. 4 / 5 PEDESTAL
ī PHASE DIFFERENCE WAS FOUND TO BE MINIMUM BETWEEN BEARING
PEDESTAL BASE PLATE AND SECONDARY GROUTING
BUT AFTER FEW DAYS OF OPERATION,
âĸ VIBRATION LEVEL STARTED INCREASING GRADUALLY AND TOUCHED
ALARM VALUE OF 35 MICRONS, 0-PK
âĸ PHASE ANGLE DIFFERENCE WAS ALSO FOUND TO BE INCREASING
BETWEEN BASE PLATE AND SECONDARY GROUTING
HIGH VIBRATION IN 210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
26. ANALYSIS
īEPOXY GROUTING WAS INSUFFICIENT TO CURE THE VIBRATION
PROBLEM ON PERMANENT BASIS
īAT THIS POINT OF TIME, CIVIL EXPERT ALSO CONDUCTED STUDIES ON
FOUNDATION WHICH CONFIRMED THE BAD CONDITION OF
SECONDARY GROUT
HIGH VIBRATION IN 210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
27. ACTION PLAN SUGGESTED:
ONCE AGAIN THE PREVIOUS ACTION PLAN WAS SUGGESTED, THAT IS,
īREMOVAL OF LP REAR BEARING PEDESTAL AFTER BREAKING
SECONDARY GROUTING COMPLETELY
īREPLACEMENT OF FOUNDATION BOLTS
īIN-SITU BALACNING OF GENERATOR ROTOR
DISMANTLING OBSERVATION
âĸ DURING REMOVAL OF LP REAR PEDESTAL, SECONDARY GROUT
MATERIAL WAS FOUND IN PIECES
âĸ OIL SEEPAGE WAS OBSERVED UNDER PEDESTAL
HIGH VIBRATION IN 210 MW TG SETS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
28. HIGH VIBRATION IN 210 MW TG SETS
RESULT OF ABOVE WORKS
ī AFTER THE ABOVE MENTIONED WORKS CARRIED OUT (INCLUDING
IN-SITU BALANCING OF GENERATOR ROTOR) IN THE NEXT PLANNED
OVERHAUL, VIBRATION LEVEL OF LP REAR AND GENERATOR FRONT
IMPROVED IN BOTH VERTICALAND AXIAL DIRECTION
ī MACHINE IS RUNNING SATISFACTORILY SINCE THEN
HENCE, LOOSENESS / VOID BETWEEN LP REAR PEDESTALAND
SECONDARY GROUTING WAS FOUND TO BE THE ROOT CAUSE
OF HIGH LP REAR PEDESTALAND GENERATOR FRONT
VIBRATION
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
29. īHISTORY OF THE PROBLEM SHOULD BE GIVEN DUE
WEIGHTAGE FOR ANALYSING THE PROBLEM
īATTENTION SHOULD BE PAID TO INTERFACE AREAS BETWEEN
MACHINE AND SUPPORTING SYSTEM / STRUCTURE IN
ADDITION TO MAIN MACHINE
CONCLUSION
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
30. īHISTORY OF MACHINE WITH RESPECT TO ITS DYNAMIC
BEHAVIOUR SHOULD BE STUDIED
īREGULAR VIBRATION READING ON BEARING PEDESTAL AT
PRESCRIBED LOCATIONS SHOULD BE TAKEN FOR ASSESSING
THE TREND OF VIBRATION BEHAVIOUR ACCURATELY
īSHAFT VIBRATION IN TWO ORTHOGONAL DIRECTIONS
SHOULD BE MEASURED FOR ORBIT ANALYSIS
TIPS FOR BETTER DIAGNOSTICS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
31. RECOMMENDED LOCATIONS OF VIBRATION MEASUREMENTS ON
BEARINGS AS PER ISO
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
33. īEVERY UNIT SHOULD HAVE KEY PHASOR ARRANGEMENT FOR
VIBRATION ANALYSIS.
īSCANNING OF VIBRATION PRONE AREAS INCLUDING SYSTEM /
FOUNDATION AROUND THE PROBLEMATIC AREA SHOULD BE
CONDUCTED
īDEVIATION IN OPERATING PARAMETERS SHOULD BE
RECORDED AND ANALYSED FOR THEIR EFFECT ON VIBRATION
BEHAVIOUR
TIPS FOR BETTER DIAGNOSTICS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
34. īRUN UP & RUN DOWN VIBRATION BEHAVIOUR SHOULD BE
RECORDED FOR ALL BEARINGS AND SHAFT POSITIONS FOR
REFERENCE WHICH CAN BE USED DURING TROUBLESHOOTING
īPRE-OUTAGE SURVEY SHOULD BE CONDUCTED PRIOR TO
OVERHAUL FOR BETTER PLANNING OF ADDITIONAL
ACTIVITIES / SPARES, IF REQUIRED
īRECORD OF PREVIOUS BALANCING AT SITE SHOULD BE
MAINTAINED FOR REFERENCE PURPOSES
TIPS FOR BETTER DIAGNOSTICS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA
35. LAST BUT NOT THE LEAST, DURING TROUBLESHOOTING,
EVERY FEEDBACK / OBSERVATION NEEDS TO BE CONFIRMED.
IF EVERYTHING IS ALRIGHT, VIBRATION PROBLEM WOULD
NOT HAVE BEEN THERE. SO VERIFY EACH & EVERY
POSSIBILITY AND CONFIRM FROM WRITTEN DOCUMENTS
TIPS FOR BETTER DIAGNOSTICS
A.K.SINHA, DGM (TURBINE)
BHEL, POWER SECTOR â TECHNICAL SERVICES (HQ), NOIDA