Preliminary Report
Run Down Vibration Monitoring Service Report
For TG 500
June 25th, 2010
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1. Introduction
2. Scope of Service
2.1 Scope of Work
2.2 Duration of Work
2.3 Technical Vibration Analysis Report
3. Methodology
4. Executive Summary
4.1 Steam Turbine – Generator Unit 500
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The accuracy and exactness of any machinery vibration analysis works depend to a great
extent to the availability of machine’s vibrations related data. This includes but not limited
to Turbine-Generator manufacture data, i.e. vibration severity data, key-phasor, and
vibration sensor. Though with some machines in your plant the data are not yet available,
we still tried to come up with an analysis based on our experiences on similar equipment
with other industries.
2. SCOPE OF SERVICE
Chevron Geothermal Salak, Ltd. (CGS) operates three units of turbine generator, namely
TG Unit 400, TG Unit 500, and TG Unit 600, each has 66 MW installed capacity. These
turbine-generators can be classified as critical equipments, since if any of the equipments
fails, production of CGS power plant can significantly be impaired. Consequently, the
number of unexpected failures must be minimized.
The philosophy behind a Condition Monitoring system is to allow a machine to continue to
operate as long as it runs within its performance parameters. When it doesn’t, the principal
intent of the program is to provide a warning of any conditions that are changing beyond
preset parameters and to initiate investigative or corrective action. This could involve the
process, the machine, or both.
Periodic condition monitoring can identify early failure that appears before a functional
failure occurred.
By having the means to anticipate problems and then plan accordingly, the equipment
reliability can be improved and unnecessary maintenance and production costs will be
reduced. This is a result of taking corrective action only when it needs to be done.
Some various failures mode of Turbine-generator are rotor imbalance, rotor bow,
misalignment, oil whirl, oil whip, mechanical looseness, resonance, electrical problem, soft
foot, rotor rub, and others.
The real time analyzer can give a comprehensive vibration data in real condition of turbine-
generator, can be captured and represented simultaneously in steady state and transient
(run-up & coast down) events.
Figure 2 Figure 1
All data will be acquired using SKF IMx-P & AX / GX Series and be processed further
using analyzer software - Observer SW & Aptitude Analyst SW.
3.1 Overall Alarm Definition
After review of all spectral data on a machine, if no problems are found, the first two
columns
(“Good” and “Fair”) are offered to give the customer a general feel for the overall
condition of each machine being assessed.
Corrective action should be taken on those machines having vibration exceeding
“Warning or ALARM 1” , while those exceeding “Fault or ALARM 2” are felt to be
exposed to such high levels as to render potentially catastrophic failure.
Much work continues today on establishing standards for allowable overall vibration. This
includes the international working on machinery vibration standards, which is now working
to update several criteria.
To acquire vibration data, Two (2) parameters of vibration amplitudes normally are used:
1. Vibration Velocity (by Acc. Sensor) [Horizontal Velocity (HORIZ-Vel), Vertical Velocity
(VERT-Vel), Axial Velocity (AXIAL-Vel)] - Used to represent commonly experienced fatigue
problems like misalignment, imbalances, etc.) In mm/sec or in/sec
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101.6 µm p-
50.8 µm p-p
3000 RPM
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TZ
TURBINE 500 GENERATOR 500
T1 T1 T2 T2 G1 G1
G2 G2
c. ISO 7919-2 2nd Edition (2001-11-15) - Land-based steam turbines and generators
in excess of 50 MW with normal operating speeds of 1 500 r/min, 1 800 r/min, 3000
r/min and 3500 r/min
Recommended values for maximum relative displacement of the shaft for steam turbines
and generators at the zone boundaries
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Priority 2
WARNING Plan the repair shutdown on the next opportunity.
(B/C)
Priority 3
FAIR Minor problem. Trending only.
(A/B)
Priority 4 NO action is recommended at this level. Data acquisition is as per
GOOD / NORMAL
(A) schedule.
TZ
TURBINE 500 GENERATOR
500
T1 T1 T2 T2 G1 G1
G2 G2
Bently
Nevada
By Control Panel
IMx-P
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T1 - T2 - G1 - G2 -
T1 - X T2 - X X G1 - X G2 -
T1 -
Vertical T2 - G1 - G2 -
Horizontal
Axial
GX Series
By STG Bearing Housing
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TURBINE
Manufacture Fuji Electric Co., Ltd
Type 2 Cylinders, 2 flow, reaction, condensing
Rated Speed 3000 RPM
st
Critical Speed (1 ) 2200 RPM
Rated Output 70 MW gross
Stage 2x9 stages
Rotor Weight 31799 kg
Bearing NDE Thrust bearing and Journal bearing
Bearing DE Journal Bearing
Journal Bearing Base carbon steel and Surface Babbitt – 10.6 mm (thick)
Double wedge (type); 430 µm (design clearance); Kongo (Manufacturer)
Thrust Bearing Base CrMoNiV forged steel and surface babbitt
8 (number of pad); Mitchell (type); 660 mm2 (surface area); Kongo
(manufacturer)
GENERATOR
Manufacture Fuji Electric Co., Ltd
Type Synchronous
Number of Pole 2
Enclosure Totally Enclosed Water / Air Cooled (TEWAC)
Output Capability 70 MVA
Rate Speed 3000 RPM
Critical Speed (1st Speed) 1303 RPM
Efficiency (full load) 98.4%
Rate Voltage 11.8 kVA
Frequency 50 Hz
Current 3166 A
Coolant Temp 46 Deg Celsius (mech. design), 27.2 Deg Celsius (Process design)
Number of Phase 3
Insulation F
Rotor Weight 20400 Kg
Bearing NDE Journal bearing
Bearing DE Journal bearing
Journal Bearing Base carbon steel and surface Babbitt 10.6 mm (thick)
Double wedge (type); 430 µm (design clearance); Kongo (Manufacturer) Page11
T/G Unit 500 – Steady State (variable load) and Turning Gear
Amplitude Standardization
Steady Steady Steady Turning
ASSET POSITIO POINT state 100% state state 8 % Gear
NAME N NAME ISO 7919-2 Manuf.
50%
(µm p-p)
T1-X 16.73 16.86 16.13 7.45 80 / 165 125 / 250
T-NDE
TURBINE T1-Y 23.93 23.96 23.57 10.22 80 / 165 125 / 250
SIDE T2-X 17.16 16.91 14.75 11.47 80 / 165 125 / 250
T-DE
T2-Y 9.99 11.25 9.67 13.83 80 / 165 125 / 250
G1-X 16.40 16.78 16.18 9.42 80 / 165 125 / 250
G-DE
G1-Y 24.54 22.77 22.77 9.82 80 / 165 125 / 250
GEN. SIDE
G2-X 14.62 15.36 15.36 6.07 80 / 165 125 / 250
G-NDE
G2-Y 36.00 30.49 30.49 7.07 80 / 165 125 / 250
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Appeared 1X and 2X RPM in orbit and spectrum plots although overall vibration
TURBINE is in normal level referred to ISO and Manufacturer standards.
T-NDE OA decreased at TG (turning gear) condition. Slightly spike signal at time
waveform appeared. Check run out shaft at first time.
Appeared normal impact signals (1XRPM and 2XRPM) with normal shaft
TURBINE vibration amplitude. Overall vibration is in normal condition, slightly spike signal
T-DE at time waveform appeared. The overall vibration is in stable condition. Check
run out shaft at first time.
Appeared spike signal in orbit (time waveform) as suspected the rotor surface
GENERATOR
has run out (electrical and mechanical). The OA vibration is in below range. OA
G-DE decreased at Turning Gear (TG) condition. Check run out shaft at first time.
Slightly similar with DE generator appeared spike signal in orbit (time waveform)
GENERATOR as suspected the rotor surface has run out (electrical and mechanical). The OA
vibration is in below range. OA decreased at Turning Gear (TG) condition. Check
G-NDE
run out shaft at first time.
T1Z
T1X
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T2Z
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T2Y
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T3X
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T4Z
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T4Y
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DE Turbine side 1XRPM minor 2XRPM and mix with random frequency.
TURBINE The overall vibration value was very minor at this point. Characteristic the
T-DE spectrum most similarly. Vibration is in normal level referred to ISO and
Manufacturer standards. NO SIGNIFICANT Found.
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The full spectrum cascade of shaft vibration measured on turbine non drive
st
and bode plot depicted those figures are indicated that the 1 critical speed
is approximately 1002 rpm
TURBINE The plot of average shaft centre line during run-down condition measured at
SIDE turbine side shown that the average turbine shaft centre line migrates in the
down-right direction when the turbine speed reduce and the range of
migration in acceptable range. This average shaft migration confirms that
bearing were working under considerably good operation condition
The full spectrum cascade of shaft vibration measured on turbine non drive
and bode plot depicted these figures are indicated that the 1st critical speed
is approximately 1436 rpm
GENERATOR The plot of average shaft centre line during run-down condition measured at
SIDE generator side that the average generator shaft centre line migrates in the
down-right direction when the turbine speed reduce and the range of
migration in acceptable range. This average shaft migration confirms that
bearing were working under considerably good operation condition
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