Avikshit Singh 1/30

Know - How Sharing

SWAS (Steam Water Analysis System) High pres. Steam boiler and turbine are under constant attack from erosive and corrosive element such as Silica, Sodium, Dissolved Oxygen (D.O.), Calcium, Chlorides and Phosphates. Without accurate and dependable on line instrumentation the monitoring becomes quite difficult and it leads to serious damage to boiler and turbine. SWAS is combination of 1-Sample conditioning 2-Sample analysis Sample conditioning acts as a protective wall between analyzer and parameter to be analyzed It brings the samples physical parameter as per requirement of analyzer. It comprises of Sample cooling Pressure reduction with safety devices Pressure regulation To flow meter and Analyzer The analyzers, which are normally, are on line 1- Silica 2- Sodium 3- Hydrazine 4- D.O. 5- pH 6- Conductivity 7- Chloride, Phosphate, Chlorine, Dissolved Ozone & Nitrates etc as per operational and conditional requirement. Silica analyzer It is based on optical density of silico molybdenum blue complex which is developed by reacting with ammonium molybadate and H2SO4 in developing yellow silicomolybdic acid complex and then reacting with Ferro ammonium sulphate for developing intensely blue coloured silicomolybdenum blue complex . The streams where this monitoring is done are 1-DM plant for continual monitoring of Anion and Mix bed exchanger and also resin exhaustion 2-Boiler and Steam: Deposition of silica on the super heater tube and turbine blades leads to loss of efficiency and permanent mechanical damage. Silica solubility increases with high temperature Hence continual monitoring is crucial. 3-Condensate: For proper functioning of polishing plant and resin exhaust. Sodium Analyzer NaCl and NaOH in particular are known to be associated with stress corrosion cracking of boiler and super heater tubes. Presence of sodium indicates contamination with potentially corrosive anion (chlorides & sulphates) under high pres. and temperature Measurement of sodium is recognized among other chemical parameter as an effective tell tale to reveal the condition of high purity water/steam circuit
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Avikshit Singh 2/30

The ubiquitous character of sodium in the environment makes it a useful indication to reveal possible leak condition within the circuit and particularly in condenser where sodium detects cooling water leak with much higher sensitivity than conductivity measurement. Sodium sensitive glass electrodes do measurement where in previously conditioned Sample of pH >10 is passed. pH adjusting is done by gaseous Di -isopropylamine . Sample conditioning is essential for limiting interference by other ion and for lowering detection limit. Hydrazine analyzer It is an oxygen scavenger and used as source of feed water alkalinity. It also helps maintain a protective magnetite layer over steel surface. Under dozing hydrazine leads to increased chances of corrosion while over dozing is an expensive waste. At high temperature Hydrazine disintegrate into Ammonia which made process water acidic, therefore to improve pH phosphate dozing is done in Boiler Drum. It also helps in maintaining magnetite layer. Dissolved oxygen analyzer D.O. in feed water causes oxidation (rusting) of components & down stream piping especially at high temperature eventually leading to puncture or failure. Measurement depends upon Clark cell principle. An oxygen permeable membrane isolates the electrodes from sample water. A constant voltage supply powers two electrodes maintaining each at constant potential. Gold working electrode (Cathode) reduces the DO to OH ion O2+2H2O+4 e= 4 OH A large counter electrode (Anode) provides the oxidation reaction 4Ag+4Br=4AgBr+4e pH(Hydrogen ion concentration) pH of water and steam must be maintained at a slightly alkaline level (between8.8 to 9.2) in order to prevent equipment corrosion. Conductivity To detect leakage in heat exchanger conductivity measurement is one of reliable parameter. Conductivity 1-To detect leakage in heat exchanger (Contamination) conductivity measurement is one of reliable parameter. 2-Concentration of simple water 3-Gaging quality of pure water 4- Measuring extent of reaction Flow of electricity through matter is by movement of electric charges, which in metallic conductor are electron and in electrolytic conductor are ions. In electrolytic conductor current is usually introduced and leaves the system through metallic electrode on surface of which chemical reaction occurs. (+ Tive ion or cation moves towards cathode where reduction occurs and negative or anions moves towards anode where oxidation occurs.)The conductivity of a solution depends upon the concentration and mobility of all ions present in the solution. The ions mobility in turn depends upon ion size and charges as well as dielectric constant of the solvent
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Avikshit Singh 3/30

and solution . To avoid polarization, A.C. potential is used in on line monitoring of conductivity measurement. The determination of electrical conductivity (specific electrical conductance) consists basically in measuring the a.c. resistance of a column of solution. With a.c., concentration charges and polarization effects can be reduced to any extent dictated by purpose of measurement. Unit and definition The resistance Rx of the conductivity cell of constant cross section immersed in or filled with solution under test , is proportional to the distance L between electrode and inversely proportional to the cross section area A of the electrolyte and intrinsic constant of the solution. Sc= L/A*1/Rx By dimension Sc= Cm/Cm.Cm*1/Ohm=1/Ohm.Cm= Mho/Cm The term L/A is effective cell constant of the conductivity cell and is denoted by K. K= Rx( measured resistance of the filled system)/ Specific resistance =Ohm/ Ohm CM Range of practical conductivity measurement extends from fraction of micro Mho to 1Mho. Gas analyzers 1-O2 in flue Gas 2-CO in flue Gas 1- H2 purity in Alternator O2 in Flue Gas The aim of a combustion control system is to enable fossil fuels to be burned as efficiently as possible with minimum of pollution emission. In order to guarantee complete combustion, it is usually necessary to feed excess air which is done at a price. Increasing excess air level increases the stack losses. During combustion operation an important natural phenomenon occurs. Oxygen molecules seek to migrate from higher concentration in the outside atmosphere to the lower concentration in the furnace gases. This natural phenomenon is the principle on which on line O2 analysis Zirconia sensor operates. Sensor is made of Yttrium stabilized Zirconia electrolyte which has the ability to conduct oxygen ion at temperature exceeding 650*C. Platinum electrodes on opposite surfaces of the Zirconia electrolyte provides catalytic surfaces for the transformation of Oxygen molecule( O2 ) to Oxygen ions(O-) which moves through the electrolyte and recombine on opposite electrode. The movement of Oxygen ion produces a voltage across the sensor which is the function of the relative difference in Oxygen concentration between its outer surfaces i.e. furnace atmosphere and its inner surface i.e. ambient air and sensor. Emv=0.0496+(log10 p0/p1)+/- C mV p0 is reference air partial pressure P1 is measured O2 partial pressure C is cell constant (initially +/- 1mv) At inner surface (Ambient air) O 2O +4e At outer surface (flue gas) 2O+4e O CO in flue gas If a fossil fuel is burned CO2, H2O, SO2, NOX, CO, O2 and N2 is expected in flue gases. All these gases are present under excess air condition with exception of CO.
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Avikshit Singh 4/30

Thus it is only one which indicates that incomplete combustion is taking place. Minimum heat loss from a boiler occurs at a point where Co is just starting to be produced .At trace level of CO of typically 100 PPM, there is just sufficient excess air to produce complete combustion irrespective of operational condition, type of fuel and wear/tear of burners / control valves. On line wet analysis type Infrared absorption analyzer are used to monitor CO in flue gases. All hetero atomic gases absorb infrared radiation in distinct band specific to each gas. H2 Purity in Alternator According to Brown molecular movement there is an exchange of kinetic energy among molecules. Te transfer of energy can be measured by the conductivity, which is the property of substance in respect of which gases differ quantitatively. According to kinetic theory of gases: The thermal conductivity is directly proportional to square root of absolute temperature and inversely proportional to square root of molecular wt. nd independent of pressure. H2 being the lighter gas in comparison to CO2 and Air, the thermal conductivity Is 7 times higher than air and it offers best cooling medium for generator winding. Refilling in generator H2 purity meter has three scales for complete refilling sequence monitoring. a) 0 to 100 % by volume CO2 in Air b) 100 to 0 % by volume H2 in CO2 c) 100 to 80 % by volume H2 in Air Sequence 1- CO2 is heavier than air , therefore Generator is gradually filled from bottom and monitoring is done by selecting scale a). Sequence 2-Displacing the CO2 by H2. H2 having lower density than CO2 is filled in from the top until an adequate purity of 96 to 98 %is obtained. Monitoring by Scale b) Sequence 3-H2 is maintained at a pressure.. purity is monitored by selecting scale c). Magnetic flow meter Magnetic Inductive flow meter s measure the volume flow of electrically conductive liquids and slurries. An electrical conductor in this case is the electrically conductive medium passes through a magnetic field. the voltage U induced in this medium is directly proportional to mean flow velocity V, Magnetic Induction B, nd distance between electrodes (nominal pipe diameter) are constant. U=K*B*V (-ve)*D ( K=Inst .constant) V-=U/K*B*D Volume flow rate qv can be calculated according to qv=V-*Dsqr*pi/4 qv=U*D*pi/K*B*4 Induced voltage signal is picked up either by two measuring electrodes in the conductive Contact with the medium. A signal converter process the signal into a pulse of 1Pulse/M3 Measuring tube is made of electrically insulating material.Flow is independent of flow profile of the medium. i.e. pres., temperature, visco., density. Services where magnetic flow meter are installed are Reactivated carbon filter column Anion and Cation column and pressure filters in WTP 2.
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Avikshit Singh 5/30

Radar Gauge Used for level monitoring of up and down stream of TWS What is radar it is acronym for Radio Detection and Ranging. It typically uses an Electromagnetic wave to determine distance and speed. Radar gauges transmit in the frequency range between 3 to 30 G Hz. The most common type of Radar wave or signals used for level measurement are: 1- Pulse wave 2- FMCW (Frequency modulated continuous wave) A basic principle of radar is its capacity to reflects off the surface of material base on material Dielectric constant (D K) which is directly proportional to the amount of Electromagnetic energy reflected from it. Any material that has D K greater than 1.8 will easily reflects radar signal. The higher the DK of the material the more signal that is reflected and available for level measurement. In addition changes in temperature and pressure of the material have minimum effects on the signals. Radar gauge determines the level of a product in a tank by measuring the Ullage or vapour space. It is the distance from Radar gauge location to the surface of the material. Radar electronic is the heart of radar gauge .It produces an EM wave by using an oscillator that Converts direct currents power into a u wave frequency signal . It also receives the return signal Basic components of a Radar gauge includes 1- Gauge housing, 2-Electronics, 3-Mounting flange 4-Wave guide, 5-Antenna
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Radar gauge works well in Tubular, aerated, Solid laden, Viscous, Corrosive, Thick paste or Slurries. Since there is no moving parts maintenance cost is quite minimal

Avikshit Singh 7/30

Profit centred maintenance Maintenance Management has a direct impact on Improvement, Prevention and Correction. Maintenance Department is a +tive contributor to the bottom line of the company. The road block to Maintenance profitability is lack of management investment in the procedure, system and equipment Convincing management for making this investment has become the primary challenge of Maintenance professionals because equipment down time is a liability. The equipment merely good enough are not profitable. Machine that are kept running in first rate condition through predictive and preventive Maintenance are more productive than just good enough. When presenting profitability, not only down time cost but also cost benefit of, inventory reduction, improved product quality , reduction in repair and Maintenance cost and improved equipment life all matters .Co-operation and knowledge sharing are key to an efficiently run company. Maintenance leaders have to be innovative in personnel leadership and must be able to gain commitment rather than just consensus. Continuous training is also necessary to +ve profit centred Maintenance dept.100 hrs of training in a year is good enough. Maintenance /Operation that is not investing in continuous Maintenance education and development of its people are in danger. Each Maintenance employee has to understand that a shared commitment for improving the maintenance is a +ve factor. They must have +ve expectation about a change and overcome the ve, normally associated with being resistant to change. Some of the initiative taken at BTPS, C&I dept wrt cost centred Maintenance are 1- Installation of DCS in all the units 2- Replacement of conventional servo drive recorder with paper less recorder 3- Replacement of rota meters with magnetic Flow meters in WTP2 4- Installation of radar gauges in TWS system for level monitoring 5- Installation of level monitoring inst. all the LDO and DMW tanks. 6- Installation of variable frequency drive for monitoring of speed of RCF and PCF in Milling 7- Installation of proximity pick up for speed monitoring of speed of PCF 8- Development of different type of jigs for pre-installation calibration , speedy fault Diagnosis and reclaiming also tool for training and innovative improvement Air drying unit operation and maintenance Service-To supply bone dry clean air to C&I system Make-Chemech air drying unit Supply- M/s Kirlosker pneumatic co in unit 5 M/S KG khosla in unit 4 Inlet- Capacity-18m3/min Pres- 8kg/cm2 Temperature-40degre C Moisture content-100%rh Outlet- Flow rate-16.2m3/min Temp-52 deg.C Pres.-7.65kg/cm2
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Dew pt at atmos.pres-(-)40 deg C Moisture content-80ppm Dryer unit components 1-Duel adsorption towers filled with desiccant (silica gel) and embedded 12 kW Heater (in separate enclosure) for reactivation. While one tower is drying other will be in adsorption mode. 2-Chang over system with 4 way 2 Audco lubricated plug valve. 3-Pneumatic power cylinder operated by two solenoid valve to operate 4 way valve. 4-Control panel for Auto/Manual operation of the system. 5-A Dew pt apparatus Cycle time for adsorption/Reactivation 6 hrs Operation; 1- Exothermic Adsorption 2- Change over of Adsorber 3- Reactivation After 6 hrs of adsorption i.e. drying of inst. air in 1st tower. 2nd tower which has been under reactivation comes in adsorption mode by operation of 4 way valve. The change over takes place automatically by a timer command to operate a power cylinder which in turn operate 4 way valve. Reactivation- Time 6 hrs 1Depressurisation for 5 minutes by a solenoid valve which remain open for 5.30 hrs 2Heating of silica gel for 3 hrs to raise the temperature of purge air to 180 deg Celcius. Heaters cut off is by 6 hrs timer or temp switch contact when temperature rises beyond 180 deg C. which ever is earlier. 3- Cooling and idling for 2hrs 20 minutes by purge air flowing through a orifice connected across both the towers 4- Re-pressurisation takes place in last 30 minutes of 6 hrs cycle when depressurization SV get closing command from the timer. Tower under reactivation comes to line pressure and just after 6 hrs of cycle ends, the tower under reactivation comes in adsorption mode. Fault, possible causes and remedy in drier 1Inter lock has been provided for making heater ON only when depressurization SV is open In both auto and manual mode of operation. 2Faulty change over takes place when limit switch of 4 way valve has not operated due to Mechanical jamming of valve or power cylinder has not operated to full stroke or solenoid valve of power cylinder has not operated or leakage of air is taking place due to puncture of air piping connected with the system. 3When control supply fails, 6-hrs synchronous motor operated timer remains in stay put condition i.e. it will not come to initial position. 4In auto mode heater switch must be kept in off position. 5Faulty change over indication/alarm comes through a electronic timer adjustable to 1 to 25 sec. 6Heater on condition depends on permission from synchronous timer and in series connected temperature switches. 7Periodic dew pt measurement must be carried out to ensure optimized operation of drying unit.
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Avikshit Singh 9/30

8-

Most of the temperature switches are bimetallic type, their functioning must be monitored otherwise they should be replaced with liquid filled system or resistance type temperature detector. Travelling water screen TWS help to provide debris free in take water in suction of Raw water pumps discharge of which is used for various usage in the power station .Travelling Water Screen are installed in a vertical chamber forming a part of intake well.As the water passes through the screens, refuse in the water is retained on the screen trays and as the trays rises the refuse are washed away by flat sprays of water nozzles. Flush water is tapped from cleaned raw water header at a minimum pressure of 0.5 kg/cm2, passes through duplex strainer and pressurized by flush water pump to not less than 5kg/cm2. Two flush water pumps are in use .One in service and other stand by. The pressurized water passes through the butterfly valves BFV1 or 2 into two headers. Header no 1 connected with BFV 1 and no 2 with BFV2 .Flow nozzles are connected to the pressurized header in head section of the screen and in turn high velocity water jets from the nozzles clean the screen. 1st 1 to 4 and then 3 to7 .The flush water along with the debris removed from the screen flows through to refuse trench provided with 7 nos. trench jetting nozzles .first 4 Trench nozzles are connected with header of either BFV1or 2 and rest 3 with header of BFV2. The screens can be cleaned either manually or automatically (OMRON timers) from control panel. Selection by A/M switch (SS-01). Manual operation: Under manual mode entire operation has to be done sequentially meeting the requirement of basic interlocks which are required in both mode of operation. 1) Screen flush water pumps are interlocked with suction pressure. 2) Torque and Travel limit switches for opening and closing of BFVs. 3) Auto circuit of screen drives is interlocked with corresponding Butterfly valve position limit switch and delivery header pressure switch. st nd 4) Under Manual mode, the operation of 1 (1 to 4)and 2 group (5 to 7) of screen can be controlled by group start and stop push button and also individual screen can be controlled by local start/stop push button. 1-Type of screen Flow through 2- No of screen 7 3-Rated capacity of each screen 20,000mcu/hr 4-Speed of screen 2meter/minute 5-No of spray nozzles 18 6-No of screen wash pump 2 (Mather & Platt) 7-Capacity and Head 300Mcu/hr at 60MWC,75KW 8-Setting suction 0.2Kg/cm2 ,Diff 0.6Kg/cm2 9- Discharge 4.5Kg/cm2, Diff.!.0 Kg/cm2 10-Butterfly Valves actuator K30 F10E,BECON ROTORK 0.1KW, 24rpm (geared) 11-Time for opening closing 31.5sec 12-Level Indicator Radar gauge Endress+Hauser Range : upstream 5.65M Down stream 6.35M
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Differential level >200mm Manual Operation for cleaning of screen 1-All mechanical valves are properly opened/closed 2- Selector switch on Manual mode (contactor K-102picked up) 3- Start any flush water pump(Pump selection switch) 4- Open BFV-1 and Start group-1 of screen 5- Open BFV-2 and Start group-2 of screen 6- For stopping the manual operation follow the reverse path i.e.Stop the screen and then close the respective BFV s and then stop the screen flush water pump. Auto operation (Timer TM 101,102,103 &401) contactor K- 101 is picked up. 1-Timer TM 101 is used to set the time interval for auto start of the screen washing system a fresh after one cycle of operation for cleaning of group 1 and 2 is finished. 2-After a set time interval flush wash pump will start and with the start of the pump BFV1 starts opening. When delivery header pressure in header-1 is established the 1st set of screen start automatically. 3-TM-401 sets the time delay from the start of screen flush water pump upto closing of BFV-1 .i.e. desired washing time of 1st set of screen(1 to 4). With the closing of BFV-1, 1st set of screen also stopped automatically. 4-While giving closing command to BFV-1, TM-401 simultaneously gives opening command to BFV-2. 5-Once the BFV-2 has opened and delivery header pressure in header 2 is established, 2nd set of screen (5 to 7) is started. 5- TM-102 set the time delay ( sum total of wash time for group1&2) for giving trip command to running screen flush water pump and with that BFV-2 starts closing which in turn stops the 2nd set of screen. 6-Timer TM-103 (6 sec) receives command from Timer TM-102 after 2nd set of screen are stopped for resetting of Timer TM-101 which starts counting interval after which again washing get started. Initial starting of the system 1- Check that whole system is in zero state i.e.flush water pumps, screen, and both BFVs are in closed position. 2- Set the system in Auto mode (contactor K 101 picked up).and select either of the two flush water pump. 3- Now turn the control switch (S-102) to close position from its neutral position and bring it back to neutral position In doing so control supply is given to timers for starting the sequence of operation in auto mode.1st cycle starts immediately and subsequent cycle after 1st is over. Now no need of further closing of control switch. Timers shall take care of further operation till control supply is available in the system. However if control supply is switched off, starting command for next cycle of operation is available only after set time from Timer TM-01 is over after restoration of supply. In Rest period operation 4- If we require starting an immediate cycle of operation because of large amount of debris then a fresh starting command from the control switch becomes necessary. or timer setting to bring to minimum.
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Avikshit Singh 11/30

1)

2) 3)

In case of control supply fails before 2nd cycle is over, then BFV-2 should be closed after restoration of supply. Only then command for starting of cycle is available 6- If the control switch is brought to trip position then no further screen wash cycle shall come. However if control switch is operated to trip position during screen wash cycle , then the system will stop only after wash cycle is over . 7- Once closing command is given by the control switch (S-102) then the timer TM-101,102 &103 immediately start counting time. Trouble shooting If a group of screen is not starting , the reason is discharge header pressure connecting to that group is not adequate or pressure switch is 1) not making contact 2) impulse line choking ,3) valve closed and 4)BFV not fully open5) problem with electrical/C&I control system. One particular screen is not running; it is due to electrical system problem, ELM to be contacted. Flush pump is not starting: it may be due to 1) low suction pressure, 2) pressure switch problem 3) Timer connected with suction pressure switch is not holding 4) electrical problem
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Turbine supervisory instrumentation in power station Turbine is an active interface between steam and electric power generator, therefore it is called prim mover. The efficient and safe operation demands careful monitoring of all associated parameters which must be ensured as most reliable measurement. The variables which are monitored are: 1) Axial shift of turbine rotor 2) Differential expansions between , a)HP turbine casing and rotor b)IP turbine casing and rotor c)LP turbine casing and rotor 3) 3-Eccentricity of turbine Rotor at barring gear and synchronous speed. 4) 4-RPM of turbine rotor 5) 5-Movement of position of speeder gear of turbine governing system 6) 6-Over all Total expansion of HP& IP turbine 7) 7-Movement of position of control valves servo motor for steam inlet in turbine. 8) Vibration of bearing of turbine of casing and flange of HP and IP turbine. Installation 1-For the measurement of parameter from SL. no 1 to 5, the sensors are mounted inside the turbine casing. 2-From SL no 6 to 9 sensors are mounted at out side. Type of sensor 3-The Eddy current loss based sensors are used for the measurement of parameter from SL no. 1 to 4. 4-Variable resistance of 360-deg rotation is used for monitoring of parameter for SL no. 5,6 &7 . 5- Electromagnetic self generating seismic mass type velocity measuring sensors are used for monitoring of vibration of turbine bearing casing .
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Avikshit Singh 12/30

6- Cr/Al

mineral insulated thermocouple is used for monitoring the temperature of turbine casing and flange..

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Avikshit Singh 13/30

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Avikshit Singh 14/30

location 1- Sensors for Rotor Axial shift and Eccentricity monitoring are mounted in the vicinity of thrust bearing of turbine . 2- Sensors for Diff. Expansions are mounted after flanged coupling of rotors of respective turbine 3- Sensor for Position of speeder gear is mounted near seeder gear motor 4- Sensor for RPM measurement is mounted against MOP (Main oil pump) shaft were in a 30 teethed wheel is inserted. 5-Sensor for control valve servo motor travel position is mounted near the CVSM. 6-Sensors for vibration monitoring are mounted at top of bearing housing in radial directions (vertical and horizontal). 7-All thermocouples are mounted at respective location i.e. front top, front bottom rear, top, rear bottom, inner layer outer layer of flange, studs hole., top flange and bottom flange.

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Avikshit Singh 15/30

Now let us share about sensors working Eddy current Pick up When any metal moves from more flux density magnetic field to less or vice versa, currents are induced in the metal with direction in opposite.i.e. induced current from more to less will be opposite from less to more. These induced currents in the metals are called Eddy current which are perpendicular to the direction of the flux and complete their path through the core of the metal .The loss of power due to the flow of eddy current is called Eddy current loss because core offer resistance to flow of eddy current. Eddy current loss depends on 1- Core thickness 2- Core resistivity 3- Loss increases with square of flux density and frequency Power loss in core =(1.64*1/P*bM2*f2*t2) watt /m2 If we multiply watt with time then energy loss =watt*time joule /volt 1.64 is form factor of the flux wave bm is max value of flux density f is frequency t is thickness of core p is resistivity of core The eddy current loss sensitivity depends upon magnitude of displacement which is monitored . For displacement > 4.0 mm sensitivity will be 2v/mm In between 4v/mm < 2.5 mm sensitivity will be 8v/mm The measurement of axial shift of rotor, and diff. Expansions between casing and rotor is done by eddy current pick-ups. The reference position of turbine rotor for 0 value of measurement is necessary in overhauled turbine, therefore rotor thrust colour is pushed against working pad of thrust bearing up to zero mm of gap. The pick-ups are then mounted at respective locations with pre- determined gaps between pre- fabricated machined colour and pick ups on the rotor .The calibration is done by recording different gaps position in mm vs. eddy current pick-up converter out put .It must be in linear form and deviation if any should be in permissible limits. i.e. +/- 2 .0 % of O/P. The monitoring value for 1- Axial shift =+/-0.5 mm in exceptional cases more than this. Turbine trip value is 1.7 &+1.2 mm 2-HP diff. expansion (-) 1.2 to (+) 4.o mm /+-3.0mm in 100 Mw 3-IP diff. expansion (-) 2.5 to (+) 3.0 mm 4-LP diff. expansion = (-) 2.5 to (+)4.0mm / -2.0 to +5.0 mm in 100 Mw Some interesting observation 1-After overhauling of turbine the oil flushing is carried out at elevated temperature of 50deg C to clean up the bearings, associated housing and piping for cleansing from material impurities. A very alarmingly high values are seen in axial shift and HP diff. Expansion parameters. These extended values are due to the uneven expansion of rotor (soft material) and casing in that particular location. Measurement of speed and eccentricity is also accomplished by eddy current probe.
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Speed measurement. Pickup is mounted against a wheel having 30 teethes . when a protruded teeth passes the tip of the pickup, a pulsed of suitable amplitude is generated and a counter counts the pulse generated in one minutia turbine is rotating at barring gear speed then total pulse will be 30 *No of rotation per minute and indicated value will be in RPM by use of suitable divider. Like wise the system works also on synchronous speed.

Eccentricity measurement It is the monitoring of run out of turbine at barring gear and shaft vibration at synchronous speed. The pickup is mounted after thrust bearing on the coupling of rotor just after HPT steam seals in 2nd stage and at Mop coupling in 1st stage turbine. A slowly varying DC voltage signal proportional to rotor run out is generated at barring gear speed and recorded as band width of minimum to maximum pen movement. The difference between these two values is Eccentricity of rotor before rolling of turbine and it should match with mechanical Dial indicator mounted locally. Some times band width is not recorded on the width of chart of recorder because of gap which becomes < 1.25mm or more than > 1.75 mm between pickup and rotating mass. This is not unusual and in this case minimum and max values diff. should be known through the indicators. With existing system configuration, >300 rpm turbine speed signal is necessary for monitoring of Eccentricity at barring gear, hence speed measurement must be healthy. Permissible run out at barring dear should not be more than 80 um including fundamental Run out. Monitoring of eccentricity at synchronous speed is by the same set up but signal coming out of converter is a super imposed AC mV of frequency as that of rotor and amplitude is mean of varying gap between pick up and rotor. Permissible limit depends upon thermo dynamic behaviour of rotor but should not be more than 200umm.

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Avikshit Singh 17/30

Use of reading as an aid to operation. 1- Temporary deflection of eccentricity: 2- a) stationary rotor lying in a hot cylinder. This Condition applies just prior to starting after as shut down. The temperature in vertical transverse places in the hot cylinder of a turbine at rest is rarely uniform, and consequently the rotor lies in a transverse gradient and bends accordingly, usually convex upward. This state of affairs is immediately shown as high eccentricity when slow turning begins. Machine must be on Barring gear for long enough to allow the rotor to straighten before run-up. Dial indicator with extension rod bearing on the shaft is used to detect the run out in addition to on line eccentricity system. b) Temporary thermal gradients developing in transverse sections of the rotor even when it is rotating. These arise from non uniform heat flow in to the rotor and most general cause is a gland sleeve which is much hotter than the shaft and owing to diff. Expansion making contact only along a line. Heat flow into the shaft
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is most rapid along this line and thus bending is taking place causing high eccentricity. A gland sleeve will become much hotter than the shaft when the steam supply is much hotter than the turbine, and the mass of steam flowing is sufficient for rapid heating to take place. When such temporary rise in eccentricity is detected reduction in stem flow is suggested. Some times splashes of water impinging on the rotor causes non uniform heat flow. Some measurable data for verification of healthiness of system working with eddy current Probes. 1-Gap voltage depends upon sensitivity a) Diff expansion: 2v/mm b) Axial shift: 2v/mm or 4v/mm depending upon the pickup used c) Eccentricity and Speed: 8v/mm d) Eccentricity signal at synchronous speed :1.4 VAc and on barring gear4vDc for 500 um e) In case of open detector or short circuits, o.k. light (green l.e.d.) will go off at module facia. With alarm of detector faulty. In this situation high/low alarm and trip circuit is inhibited. f) Speed module must be healthy for monitoring of Eccentricity. if >300 rpm permission is through SSM. Other wise change over is provided externally, through a toggle switch mounted locally. g) Power supply to eddy current pick up is always 24v DC It gives added advantage of high range of temperature tolerance for the pickups and system and also damage prevention in case of sort circuit. Position measurement 1: Over all turbine traveled on Expansion.( HP& IP) Range: 0 to 50mm 2; Speeder gear travelled position Range: 0 to 36 mm 3: Control valve servo motor travelled position Range: 0 to 300 mm For all the three services remote measurement is accomplished by 360 Deg variable resistance of 1 K ohm powered by 10 Vdc .The variable arm of the servo pot is mechanical coupled with Pinion of rack and pinion arrangement mounted locally for transferring Linear movement of position. Local indication is also available of all the three services.

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Avikshit Singh 19/30

Some interesting observation of over all turbine expansion: When Turbine is under shut down for some Maintenance, the come back to original position is never a smooth rather a staircase one. But rotor contraction is always smooth in side the casing. This some times leads to virtual indication of diff. expansion and axial shift against logic. One should never be alarmed for this. The measurement of over all thermal expansion of IP turbine may give indication which is not compatible to HP turbine. It is because of stuck up of rack rod inside the transmitter due to exposure of high temp seal steam leaking over there leading to indication that is not following the behavioural values. It is found that rod is not touching the fixed plate attached with the casing while turbine reverting back . The signal leads coming out of OTE transmitter must be routed through heat insulated sleeve. The pitch gap (play) between gears of pinion and servo resistance may lead to mismatching in local and remote indication. The signal change must be indicated in DPM, if not check for threshold of resolution of indicator in UCB. It should follow the variation in transmitter. Because of signal conditioning, resolution may fall and this will again results in mismatching.

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Turbine bearing vibration: Vibration measurement offers a way of diagnosing the health of power plant machinery to avoid the possibility of catastrophic failure, reducing the frequency of overhaul and predicting the optimum time of overhaul. The key functions are: 1-Periodic vibration monitoring, it is routine measurement of vibration around the power plant .The main purpose is to detect changes in level which indicate onset of problem and if ignored may lead to failure. 2-Continuous vibration monitoring: it is the system of permanently installed sensors on the machinery and permanently installed instrumentation in the control room to warn the operation personnel of change in vibration level. But because of high cost involved, it is only suitable for critical machines like turbines and generators. Periodic monitoring however meticulously performed, cant take the place of installed instrumentation, because some conditions developed inside the turbine require immediate shut down of turbine .on the other hand flexibility in periodic monitoring offers added advantages. 3-Trending: The aim of trending is to estimate from rate of change of vibration level, how much longer a machine can safely run before being shut down. But some times rate of change increases suddenly as a bearing approaches failure. 4-Diagnosis: It is to find fault which is causing unusual vibration. Million rupees worth of equipment will tell you nothing if you dont understand the machine you are working with. It is therefore important to know the machine dynamics than taking lot of readings. When analyzing a machines vibrations signature, the first step is to look for forcing frequencies which are caused by any mechanical problem. Serious problems occur when one of these forcing frequencies coincides with or is close to natural frequencies of vibration. This condition is known as resonance and it amplifies the effects of forcing frequencies. Therefore 1st step is to look for forcing frequencies which may be the results of the following 1-Unbalance; It is sinusoidal vibration at the m./c running speed.(1x).and is caused when the centre of mass of a component does not coincide with its center of vibration. Unbalance may be in single plane (static) or in multiple planes (dynamic). It is single frequency vibration whose amplitude is same in all radial direction and increases with speed. It does not contain harmonics. It has single reference mark. Unbalance depending upon severity causes bearing failure and even can shear the shaft. 1- Misalignment between shaft of connected machines, bent shaft, and improper seated bearings are cases of misalignment. The principal frequency of vibration is at twice the running speed (2x) and has single, double or triple reference mark. Magnitude of vibration is max at axial direction. 3-Uneven loading, such as belt drive of an eccentric pulley generate vibration at running speed. Distinguished feature is that vibration is unidirectional and varies with load.
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4-Mechanical looseness, it generates 1x and 2x frequencies vibration but almost always contains higher harmonics. Mechanical looseness can often be located by taking velocity readings at several points on the machine. Measured vibration will be highest in the vicinity and direction of looseness. Its easier to detect the mechanical looseness by going around machines and looking for loose or broken support. Mechanical looseness is easily mistaken for other causes of vibration. 5-Oil whirls caused by instability of rotor supported in the fluid film because oil film is partially carried around with the rotating shaft. This produces a self- exited vibration that draws energy into the vibratory motion that is independent of rotational frequency. Changes in oil viscosity change in pressure from design values or external preloads on the shaft can produce conditions that reduce the ability of fluid film to support the shaft. The result is that the journal precesses around the bearing at slightly less than half of running speed. In the extreme cases , the fluid film is no longer able to support the shaft, and bearing wipe occurs.

6-Steam whirls; load restriction due to steam- exited rotor vibration because of gland sleeve is a world wide problem. The vibration usually occurs on HP turbine shaft, with a frequency very close to one of the shafts own natural resonances. Above some critical output level, amplitude can increase suddenly so that a rapid load reduction become necessary. Now what is vibration analysis? Vibration can be either a cause of trouble or the result of a trouble. Vibrations are in the wave form originating from a source and travel to be indicated some where else and may not directly point out the source. By the study of wave pattern, the source can be identified and the cause rectified, this study is called vibration analysis.
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What is vibration, mechanical vibration is caused by the motion of a m/c or its part, back and forth from its position of rest and is a periodic dynamic phenomena. By plotting movement against time is frequency, total distance of movement from peck peak is displacement, and maximum speed of movement is velocity of vibration. The position of the m/c or its part at any given instant with reference to some fixed point is the phase of vibration known by stroboscope light focussed on the m/c rotating part If the vibration has the form of pure sinusoidal curve along a axis, the instantaneous displacement from reference position can be represented as x= x peak sin wt. (w is angular velocity, x peak is max displacement position from reference point, t is time). Velocity is the time rate of change of displacement, it is represented as V=dx/dt=2pif cos. 2pift, the acceleration which is time rate of change of velocity is given as A= dv/dt= - 4pi fsq sin 2pift peak velocity V, displacement D, and acceleration A are therefore given by V=D/2pif; A= V/2pif; D=A/(2pif)sq. Vibration velocity is measure of speed with which a m/c part is vibrating as compared to the displacement which indicates how much the part is vibrating. The energy generated by vibration is dissipated as heat and impact between components of m/c parts, and causes internal wear failure. This energy is proportional to mean velocity and as such velocity data are of great interest for knowing the over all m/c condition but would not be able to pinpoint the cause of vibration. Displacements reading are useful for detecting an increase or decrease in vibration at specific frequency. Vibration acceleration is an indication of force acting on a part. The max acceleration that occurs during a vibration cycle is expressed in terms of g peak. Most of the signals from a rotating m/c are complex and may contain spikes or some departure from periodic form in this case accelerometer only gives correct picture of the vibration. Velocity pickup is seismic velocity pickup. It consists of a coil of fine wire supported by springs with low stiffness. A permanent magnet is firmly attached to the case of the pickup and provides a strong magnetic field around the suspended coil. When the case of the velocity pickup is attached to or held against a vibrating part, the permanent magnet (being firmly attached to the case) follows the motion of vibration. The coil of wire supported by springs with low stiffness remains stationary in space. Under these conditions the relative motion between the magnetic field and the coiled conductor is the same as the motion of the part relative to the fixed point in space and voltage generated is directly proportional to this relative motion. Hence, the name Velocity pickup. The voltage output of a velocity pickup is normally expressed in millivolts pre inch per second. This is also referred as sensitivity of the pickup. It is 1080 millivolt peak pre inch per second for velocity pickup being used on line at BTPS. The sensitivity of velocity pickup is only constant over a specific frequency range. Below 600cpm output drops exponentially.

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Accelerometer pickup An accelerometer is a self generating device with an output proportional to vibration Acceleration. Since accelerometer is a function of displacement and frequency squared, they are especially sensitive to vibration occurring at high frequencies and are much less sensitive to stray magnetic field. In accelerometer the output is electrical charge produced by a material when it is compressed. Such an material is said to be piezoelectric and may be natural, synthetic or a ceramic material. The sensitivity is expressed in Pico coulombs per g. The o/p of
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accelerometer is usually v. small as compared to the vel. Pickup. therefore preamplification is required before a usable signal is obtained. The transducing element of accelerometer consists of two piezoelectric discs on which is resting a heavy mass. The mass is preloaded by a stiff spring and whole assembly is mounted in a metal housing with a thick base. When accelerometer is subjected to vibration, the heavy mass will exert a variable force on the piezoelectric discs. Due to the piezoelectric effects a variable potential will be developed across the two discs which is proportional to the force of acceleration of vibration. The sensitivity is depends upon Piezoelectric properties of material and wt of the mass . Non contact pickup Many high speed machines such as turbines consists of relatively light Wt rotor mounted in heavy ,massive cases and rigid bearing. Due to the stiffness of these heavy Stationary objects, there is often little outward evidence of rotor or shaft vibration even though they may be vibrating excessively within the clearances of the bearing. On this type of machine It becomes necessary to measure shaft vibration relative to the bearing housing in order to know when seal and bearing clearances are in danger. Also measurement of radial and axial displacement of m/c shaft within the sleeve bearing. Non contact type is not a self-generating device but requires power from a signal sensor or converter which generate a very high frequency A.C. carrier signal .This signal is applied to a small coil encapsulated in the tip of the NCP, producing a magnetic field at the pickup tip. Any metallic conductor, such as steel shaft, in close proximity, absorbs energy from the magnetic field which in turn produces a proportional reduction in the amplitude of the carrier signal. When the distance between the pickup tip and metal object changes, carrier signal amplitude also changes. The instantaneous amplitude change or modulations of the carrier signal detected as A.C. signal which is proportional to the pk-pk vibrations of the shaft. Non contact type pickup are normally installed in holes drilled and tapped in the m/c case or Bearing cap with the pickup tip in close proximity to the rotating shaft. Gap voltage is monitored to assure that pickup gap is properly adjusted at all time.

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How vibration is characterized: In practice, no m/c vibration is purely sinusoidal at a single frequency. The vibration is caused by several different frequencies interacting with one or more natural resonant frequencies. Another complication is that not all vibration mechanism are linear. In a linear system, the restoring force on the m/c component is proportional to its displacement from mean position. In a non linear system, the response is limited by some overriding influence like seal rubbing ,mechanical looseness etc. therefore any vibration signal is expressed as sum of large no of sinusoidal vibration at different frequencies. The vibration analyzer uses Fast Fourier Transform (FFT) analysis technique to differentiate deferent sinusoidal frequencies and corresponding amplitudes and this is known as vibration signature of m/c. To day with availability of digital electronic, the analysis is performed in a fraction of second. The same instrument can tell vibration amplitude in displacement, velocity, or acceleration and display the results on screen as a function of frequency which is known as signature of vibration or frequency spectrum. Frequency is often displayed in cycle per minute rather than hertz because of the close relationship between vibration frequencies and running speed in revolution per minute.

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Phase angle of vibration is an important parameter because it helps to distinguish among different causes of vibration. The vibratory motion may be in phase with the m/c defect which caused it or it may lag by 90deg, 180deg or some other angle. Phase angle changes as m/c speed changes. Phase angle is the angle in degrees between the instantaneous positions of the vibrating part and a reference position. Phase difference is angular diff. in degree between two vibrating parts. For balancing it is necessary to know the amplitude and phase of unbalance vibration. Due to unbalance m/c will vibrate at a frequency equal to its rotating speed and amplitude will be directly proportional to the unbalance force present. To add in finding the angular location of rotor unbalance, use is made of a strobe light which is triggered by vibration signal. Due to equal frequency of vibration and rotor speed, strobe light will flash once for each revolution of the shaft and the rotor will appear to be stationary. In m/c balancing, we observe two fundamental principles: a) Amount of vibration is proportional to the amount of unbalance. b) The reference mark observed with stroboscopic light will shift in a direction opposite to the shift of heavy spot and angle that reference mark shifts is equal to angle heavy spot shifted. Balancing of m/c: when a unbalance rotor is taken for balancing, it is required to know how large the heavy spot is and where on the rotor it is located. With the vibration pickup attached to the m/c bearing housing, m/c is rotated at synchronous speed, and unbalance data i.e. amplitude and reference angle (by the help of strobe light) is recorded. Now suppose in a particular situation, it was 125 microns at an angle of 90deg. Now a trial wt of say 100 gm is added at a suitable location and m/c is again rotated at original speed. By doing so we may observe any of three to happen. 1-Vibration amplitude may increase and reference mark remains unchanged. It indicates that trial wt is placed directly on the heavy spot. The correct position of adding wt for removing the unbalance will be directly opposite to the present one.
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2-If the trial wt, by chance is added at exactly the right location i.e. opposite to the heavy spot a decrease in vibration will be seen with reference (phase) mark position remaining unchanged. The balancing will be done by simply increasing the value of trial wt. 3-The most usual case that can happen is that vibration magnitude and phase changed to a new Value and position. In this case by vector analysis correct wt position is determined. In the above example the new vibration data recorded is 75 microns and phase angle shift of 120deg. By these two data vector diagram is made (As shown in the diagram).O, represents original vibrations amplitude, 0 + Tnew found vibrations Amplitude and phase angle after putting wt. Difference of vector O and O+T , gives the effect of trial wt alone and as such marked as T on the vector. By measuring T correct balancing wt can be determined by the formula Correct wt = Trial wt *0mm/Tmm.In this example T=70microns Therefore Correct wt = 100*125/70=178.5 gram. From the vector diagram angle between O and T is 45deg, therefore trial wt is required to be moved by 45deg. From the diagram phase shift is from O to O+T i.e. clockwise hence correct wt should be moved 45deg counter clock wise from the initial trial wt position.
VECTOR REPRESENTATION OF UNBALANCE

3600

2700 O+T

O T

900

1800
Phase Analysis and Mechanical defects 11/10/11 Phase analysis not only helps unbalance correction but can be very useful in diagnosing specific machine defects. In any rotating machine when high amplitude
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vibration at rotating speed in axial direction is observed, it can be due to any of the following, 1- Imbalance of the rotor 2- Coupling misalignment 3-Bearing misalignment 4- Bend shaft By phase analysis, the actual defect can be pin pointed. For example vibration were measured on motor driven fan and revealed high axial vibrations at rotating speed. To diagnose the problem, the phase measurements are taken on two motor and fan bearing in axial direction. If the two motor bearing have a large phase difference between them, it indicates a bend shaft or misaligned bearing. If the two motor bearing and two fan bearing are also in phase with each other but there is large phase difference between motor and fan bearing then coupling is the cause of defects. If the phase on all the bearing is same it indicates static unbalance. If large phase difference (180deg) are seen on different position of bearing housing, it indicates severely bend shaft badly damaged anti friction bearing. Phase stability is indication of machine problem. Characteristics source 1- Unstable unless synchronous speed Electrical 2-Stable, unless caused by uneven loading Imbalance or cavitations. Phase follows transducer location 3-Unstable, may be highly directional Looseness 4-Stable, relation between axial phase at shaft Misalignment ends should be approximately 180deg 5-Unstable Oil whirl 6-unstable, large phase change with change Resonance in rpm Frequency of vibrations gives a clue to machine problem Frequency Most likely other possible causes and remark cause 1*rpm Unbalance 1-Eccentric journals 2-Misalignment or bent shaft if high axial vibration 3-Reosnance 4-Reciprocatinfg forces 5-Electrical problem 2*rpm Mechanical 1- Misalignment if high axial vibrations looseness 2-Reciprocating forces 3-Resonance 2*rpm Misalignment Usually a combination of misalignment and excess axial clearances (looseness) Less than Oil whirl (less 1- Background vibrations 1*rpm than1/2rpm) 2-Sub harmonic resonance Ac line frequency Electrical problem Many (Harmonically times rpm related freq.)
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Mechanical looseness

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Avikshit Singh 30/30

Modal analysis It is a technique for identifying the natural or resonant frequencies of a machines structure. It is also valuable in finding out why a machine is excessively vibrating at a particular frequency. Many cases of excessive vibration occur when a forcing frequency coincides with a natural frequency of vibration. The only solution is to alter or damp the natural resonant frequency of the structure to separate it from stimulus. The 1st step is to find out the resonant frequency and 2nd is to lookout for possible forcing frequencies. When a structure is struck by a hammer (mallet), this is equivalent to imposing a wide range of different forcing frequencies. If those input frequencies include a resonant frequency of the structure, then it will vibrate in resonance for a transient period and the frequency of its vibration can be seen on an FFT analyzer.

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