Case Studies on Addressing High Vibration in Steam Turbine Generators

A.K.
SINHA, DGM (TURBINE)
WHAT IS PHASE ANGLE
BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA
360 0
A.K.SINHA, DGM (TURBINE)
USES OF PHASE ANGLE MEASUREMENT

1. 2. BALANCING STRUCTURE MOTION STUDY
3.
DETECTION OF RESONANCE FREQUENCY

RUN UP & RUN DOWN BEHAVIOUR BODE PLOT
4.
5.
HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS

UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT
STRUCTURE MOTION STUDY

REAR 245
220 FRONT 230 170
FRONT
220 212
245 REAR 209 138
228 165
127
3 112 96 LEFT SIDE 120 94 107 4/5 6 7 8 101 71 RIGHT SIDE 56 51 19 14 33 20 15 11 11 10 10 24 20 15
87
53
19 14
63
21
16
-9 12
11
7 16
21
-14 17
12
22
17 -23 13 13 -25
22
23
18
23 18
STRUCTURE MOTION STUDY
HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS

3 2 1 9 8 7 4 5 GENERATOR SIDE BASE PLATE 6
LEFT 21 C 20 19 14
D
15
B A
11 12 10 18 17 16
RIGHT
13
SECONDARY GROUT
TURBINE SIDE
UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT
B1
B2
B3
B4
Case Studies on Vibration Problems in Steam Turbine Generators
HIGH VIBRATION IN
500 MW TG SETS
HIGH VIBRATION IN 500 MW TG SETS

PROBLEM HIGH HP FRONT SHAFT AND BEARING PEDESTAL VIBRATION OBSERVATIONS
(A) FREQUENCY ANALYSIS CARRIED OUT WHICH INDICATED

PREDOMINANT 1-X VIBRATION COMPONENTS FOR BOTH SHAFT AND BEARING PEDESTAL VIBRATION
STEADY 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

ANALYSIS PREDOMINANT 1-X VIBRATION WITH SLIGHT CHANGE IN PHASE ANGLE INDICATED THERE WAS UNBALANCE IN THE ROTOR SYSTEM LEADING TO INITIATION OF MINOR RUB MAIN SOURCE OF VIBRATION WAS HIGHER DYNAMIC LOADING FROM THE SHAFT WHICH WAS GETTING TRANSMITTED TO BEARING
ACTION TAKEN
TO REDUCE THE HP FRONT SHAFT VIBRATION LEVEL, INSITU BALANCING WAS CARRIED OUT USING LP ROTOR BALANCING PLANES

RESULT OF INSITU BALANCING HP SHAFT VIBRATION BROUGHT DOWN TO STEADY VALUE OF 120 MICRONS, 0-PK FROM EARLIER VALUE OF 150 - 200 MICRONS, 0-PK HP FRONT BEARING VIBRATION CAME DOWN INITIALLY TO 15 MICRONS, 0-PK AT 3000 RPM FROM EARLIER VALUE OF 25 40 MICRONS, 0-PK LATER, 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

INTREPRETATION OF RESULTS AFTER INSITU BALANCING AS 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 BASED UPON THE VIBRATION BEHAVIOUR OF BEARING PEDESTAL AND
SHAFT VIBRATION, IT WAS DECIDED TO SCAN FRONT BEARING

PEDESTAL BY PORTABLE VIBRATION ANALYSER

RESULTS OF SCANNING OF FRONT PEDESTAL VIBRATION 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)

HP CASING PALM VIBRATION AMPLITUDE IN VERTICAL DIRECTION ON LEFT AND RIGHT PALM WAS FOUND TO BE OF LOWER MAGNITUDE
AND SAME
SCANNING INDICATED THAT THERE WAS NO PROBLEM WITH BASE PLATE, SECONDARY GROUT & FOUNDATION MATING SURFACES
HP CASING PAM (RIGHT HAND SIDE) HP FRONT BEARING PEDESTAL

ANALYSIS SCANNING DATA INDICATED THAT LOAD DISTRIBUTION BETWEEN PALMS OF HP CASING WAS NOT PROPER
THERE WAS GAP BETWEEN CASING PALM AND PEDESTAL ON LEFT

HAND SIDE ACTION TAKEN
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

RESULT OF CORRECTION IN SHIMS
VIBRATIONS ON BEARING PEDESTAL REDUCED FROM 35 MICRONS, 0PK TO 15 MICRONS, 0-PK AND NO INCREASING TENDENCY WAS OBSERVED HP 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 RATIO 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 BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA
CONCLUSION
VIBRATION IMPORTANT PURPOSES VIBRATION SCANNING SHOULD BE USED AS SCANNING TOOL FOR IS A VERY DIAGNOSTICS
FREQUENTLY AS POSSIBLE
IT HELPS IN RULING OUT OR PIN POINTING CERTAIN DEFECTS
HIGH VIBRATION IN
210 MW TG SETS

BACKGROUND
MACHINE IS OF KWU DESIGN STEAM TURBINE COUPLED WITH LMW

GENERATOR (LP REAR BEARING AND GENERATOR FRONT BEARING IS LOCATED IN COMMON PEDESTAL) 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)

PROBLEM HIGH LP REAR BEARING VIBRATION HIGH GENERATOR FRONT BEARING VIBRATION
OBSERVATIONS
FREQUENCY ANALYSIS CARRIED OUT WHICH INDICATED PREDOMINANT 1-X VIBRATION COMPONENT FOR BOTH LP REAR AND GENERATOR FRONT VERTICAL AND AXIAL VIBRATION VERTICAL VIBRATION AT LP REAR AND GENERATOR FRONT BEARING WAS OF THE ORDER OF 100 MICRONS, PK-PK AXIAL VIBRATION WAS ABOUT 200 MICRONS, PK-PK FOR BOTH LP REAR BEARING AND GENERATOR FRONT BEARING

ANALYSIS BASED ON VIBRATION SYMPTOMS, FOLLOWING CHECKS WERE SUGGESTED IN PLANNED OVERHAUL LP / GENERATOR ALIGNMENT BEARING ASSEMBLY CHECKS RESULT OF ABOVE WORKS AFTER CARRYING OUT THE ABOVE MENTIONED CHECKS & CORRECTIONS DURING PLANNED OVERHAUL, VIBRATION LEVEL DID NOT IMPROVE

ACTION TAKEN FOLLOWING WORKS WERE CARRIED OUT VIBRATION ANALYSIS SCANNING OF LP REAR BEARING PEDESTAL AND ITS SECONDARY GROUT AND BASE PLATE AREA OBSERVATIONS / ANALYSIS FREQUENCY BEHAVIOUR OF BEARING VIBRATION FOUND SIMILAR TO EARLIER OBSERVATION
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
SCANNING OF PEDESTAL
3 2 1 9 8 7 4 5 GENERATOR SIDE BASE PLATE 6
LEFT 21 C 20 19 14
D
15
B A
11 12 10 18 17 16
RIGHT
13
SECONDARY GROUT
TURBINE SIDE

ACTION PLAN SUGGESTED REGROUTING OF LP REAR PEDESTAL REPLACEMENT OF FOUNDATION BOLTS OF LP REAR PEDESTAL AND PROPER MATCHING OF ANCHOR PLATES IN-SITU BALANCING OF GENERATOR ROTOR TO REDUCE EXCITATION FORCES TO MINIMUM DUE TO TIME CONSTRAINT AND POWER REQUIREMENT, FOLLOWING WORKS CARRIED OUT EPOXY GROUTING (PRESSURE GROUTING) OF LP REAR PEDESTAL
RESTRETCHING OF FOUNDATION BOLTS OF LP REAR PEDESTAL

LP / GENERATOR REALIGNMENT BEARING INSPECTION

RESULT OF ABOVE WORKS AFTER CARRING OUT THE ABOVE MENTIONED CHECKS DURING NEXT OVERHAUL VIBRATION LEVEL FOUND REDUCED TO 25 MICRONS, 0-PK ON BEARING NO. 4 / 5 PEDESTAL PHASE DIFFERENCE WAS FOUND TO BE MINIMUM BETWEEN BEARING PEDESTAL BASE PLATE AND SECONDARY GROUTING BUT AFTER FEW DAYS OF OPERATION, VIBRATION LEVEL STARTED INCREASING GRADUALLY AND TOUCHED
ALARM VALUE OF 35 MICRONS, 0-PK

PHASE ANGLE DIFFERENCE WAS ALSO FOUND TO BE INCREASING BETWEEN BASE PLATE AND SECONDARY GROUTING

ANALYSIS EPOXY GROUTING WAS INSUFFICIENT TO CURE THE VIBRATION PROBLEM ON PERMANENT BASIS AT THIS POINT OF TIME, CIVIL EXPERT ALSO CONDUCTED STUDIES ON FOUNDATION WHICH CONFIRMED THE BAD CONDITION OF SECONDARY GROUT

ACTION PLAN SUGGESTED: ONCE AGAIN THE PREVIOUS ACTION PLAN WAS SUGGESTED, THAT IS, REMOVAL OF LP REAR BEARING PEDESTAL AFTER BREAKING SECONDARY GROUTING COMPLETELY REPLACEMENT OF FOUNDATION BOLTS IN-SITU BALACNING OF GENERATOR ROTOR DISMANTLING OBSERVATION
DURING REMOVAL OF LP REAR PEDESTAL, SECONDARY GROUT

MATERIAL WAS FOUND IN PIECES OIL SEEPAGE WAS OBSERVED UNDER PEDESTAL

RESULT OF ABOVE WORKS 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 VERTICAL AND AXIAL DIRECTION MACHINE IS RUNNING SATISFACTORILY SINCE THEN
HENCE, LOOSENESS / VOID BETWEEN LP REAR PEDESTAL AND SECONDARY GROUTING WAS FOUND TO BE THE ROOT CAUSE
OF HIGH LP REAR PEDESTAL AND GENERATOR FRONT

VIBRATION
CONCLUSION
HISTORY OF THE PROBLEM SHOULD BE GIVEN DUE
WEIGHTAGE FOR ANALYSING THE PROBLEM

ATTENTION SHOULD BE PAID TO INTERFACE AREAS BETWEEN
MACHINE
AND
SUPPORTING
SYSTEM
STRUCTURE
IN
ADDITION TO MAIN MACHINE
TIPS FOR BETTER DIAGNOSTICS

HISTORY OF MACHINE WITH RESPECT TO ITS DYNAMIC BEHAVIOUR SHOULD BE STUDIED REGULAR VIBRATION READING ON BEARING PEDESTAL AT
PRESCRIBED LOCATIONS SHOULD BE TAKEN FOR ASSESSING

THE TREND OF VIBRATION BEHAVIOUR ACCURATELY SHAFT VIBRATION IN TWO ORTHOGONAL DIRECTIONS
SHOULD BE MEASURED FOR ORBIT ANALYSIS
RECOMMENDED LOCATIONS OF VIBRATION MEASUREMENTS ON
BEARINGS AS PER ISO
RECOMMENDED LOCATIONS OF SHAFT VIBRATION MEASUREMENTS AS PER ISO

Measuring Amplifier Measuring Amplifier
45O
45O
PROXIMITY PICK-UP
VERTICAL
SHAFT
OR
SHAFT
R
HORIZONTAL

EVERY UNIT SHOULD HAVE KEY PHASOR ARRANGEMENT FOR VIBRATION ANALYSIS. SCANNING OF VIBRATION PRONE AREAS INCLUDING SYSTEM / FOUNDATION AROUND THE PROBLEMATIC AREA SHOULD BE CONDUCTED DEVIATION IN OPERATING PARAMETERS SHOULD BE
RECORDED AND ANALYSED FOR THEIR EFFECT ON VIBRATION
BEHAVIOUR

RUN UP & RUN DOWN VIBRATION BEHAVIOUR SHOULD BE RECORDED FOR ALL BEARINGS AND SHAFT POSITIONS FOR REFERENCE WHICH CAN BE USED DURING TROUBLESHOOTING PRE-OUTAGE SURVEY SHOULD OVERHAUL FOR BETTER ACTIVITIES / SPARES, IF REQUIRED RECORD OF PREVIOUS BALANCING AT SITE SHOULD BE BE CONDUCTED PRIOR TO OF ADDITIONAL
PLANNING
MAINTAINED FOR REFERENCE PURPOSES

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
Thank you

Case Studies on Addressing High Vibration in Steam Turbine Generators

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Case Studies on Addressing High Vibration in Steam Turbine Generators

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A.K.

SINHA, DGM (TURBINE)

WHAT IS PHASE ANGLE

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

USES OF PHASE ANGLE MEASUREMENT

DETECTION OF RESONANCE FREQUENCY

HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

STRUCTURE MOTION STUDY

220 FRONT 230 170

245 REAR 209 138

3 112 96 LEFT SIDE 120 94 107 4/5 6 7 8 101 71 RIGHT SIDE 56 51 19 14 33 20 15 11 11 10 10 24 20 15

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

STRUCTURE MOTION STUDY

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HEALHINESS OF MATING SURFACES OF TWO VIBRATING MASSESS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

UNDERSTANDING THE DEFLECTION MODE OF THE SHAFT

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

Case Studies on Vibration Problems in Steam Turbine Generators

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

(A) FREQUENCY ANALYSIS CARRIED OUT WHICH INDICATED

STEADY PHASE ANGLE

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

FACTORS APART FROM UNBALANCE OF THE SHAFT

SHAFT VIBRATION, IT WAS DECIDED TO SCAN FRONT BEARING

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

(LHS VIBRATION IS ABOUT 5 TIMES MORE THAN RHS VIBRATION)

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HP CASING PAM (RIGHT HAND SIDE) HP FRONT BEARING PEDESTAL

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

THERE WAS GAP BETWEEN CASING PALM AND PEDESTAL ON LEFT

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA

A.K.SINHA, DGM (TURBINE)

HIGH VIBRATION IN 500 MW TG SETS

EARLIER VALUE OF 5:1

A.K.SINHA, DGM (TURBINE)

A.K.SINHA, DGM (TURBINE)

BHEL, POWER SECTOR TECHNICAL SERVICES (HQ), NOIDA