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Web Site: www.ijettcs.org Email: editor@ijettcs.org, editorijettcs@gmail.com Volume 2, Issue 6, November December 2013 ISSN 2278-6856
Implementation of a Vibration monitoring system of a steam turbine for optimization of the maintenance
Hassane Elmaati1, Abdelkader Benbouaza2, Bachir Elkihel3, Fabienne Delaunois4
1,2,3
Department Mathematic and Mechanic, National School of Applied Sciences, Oujda, Morocco
4
of defective components in case of any anomaly. This monitoring, which is done without disruption of electricity production [3], constitutes the pivotal role of a conditional predictive maintenance policy on this vital equipment.
Keywords: Conditional Preventive Maintenance, Diagnosis, Optimization of the Maintenance, Vibration Monitoring.
1. INTRODUCTION
A steam turbine is classified as vital machinery [1] whose failure will lead an immediate cessation of electricity production. Otherwise, any incident or accident at this installation threatens directly the safe operation of equipment and personal security. In other words, direct and indirect maintenance costs of this strategic machine are very important. In fact, its rehabilitation requires special spare parts and involves experts with extended shutdown. Thus, adopt adequate preventive maintenance at this turbine is indispensable in the objective to [2]: - Increase productivity, - Improve substantially decision support tools based on on the reliability, by providing capacity the optimization near-real time, - Ensure safe operation of the machine and personal security, - Reduce the risk of failure and increase the availability, - Plan maintenance, - Optimize maintenance resources, - Optimize the stock of spare parts. In this context, a vibration monitoring system has been implemented at the turbines of the power plant study site to replace comparative measurements of the vibration which the irregular use increases more and more the risk of unavailability or incident and they give no indication Volume 2, Issue 6 November December 2013
Figure 4 Rotor of generator 2.3 Technical characteristics of the exciter The technical characteristics of the exciter (see fig n5) are as following: - Continuous Power : 470 KW - Short-term Power : 1380 KW - Long Term Voltage : 280 V - Short-term loads : 480 V - Current walk long : 1680 A - Current walk short : 2880 A - Speed of rotation : 3000rpm - Oil consumption for two bearings : 24 l/mn - Flow of cooling water : 15 m3/h - Weight of exciter with chassis : 6700 Kg - Weight of the exciter armature : 1460 Kg
Figure 2 Rotor of steam turbine 2.2 Technical characteristics of the generator The generator is a rotating machine comprises two cylindrical and coaxial plates, moving relative to each other (see fig n3&4): - The fixed armature (stator) is constituted by a ring of magnetic sheet held by the frame. The stator carries a three-phase armature winding distributed on the inner periphery of the ring and housed in notches, - The moving armature (rotor) turns within the stator. The rotor carries a field winding traversed by a direct current. The generator used in thermal power plant has the following characteristics: - Nominal Power : P=55MW. - Stator voltage : V=10.5 KV. - Frequency : F=50 Hz. - Speed : N=3000 rpm.
(b) View of rear of the exciter Figure 5 Exciter Figure 3 Rotor of generator in the stator Volume 2, Issue 6 November December 2013 Page 241
There is no predictive maintenance without a minimum diagnosis of the defects and their severity. For this reason, the first step of a monitoring action is to ask what the potential defects of the monitored machine are. The second concern the manifestation of these defects. What information, what descriptor parameters of the defect must be elaborated up and be measured to require solid information which will allow us to tell if the situation is normal or not (detecting abnormality), but also those that will allow us to found subsequently their origin (diagnosis of the origin and the severity of abnormalities) [2]. The main vibration manifestations of malfunctions of steam turbine are as follows: 4.1 Massic unbalance The mass unbalance is eccentricity or excess of material (bad machining shaft, etc...), Thus creating a mass imbalance in the rotor. [5] This imbalance creates a centrifugal force thus increasing the amplitudes of vibrations at a frequency equal to the frequency of rotation (1xRPM) in the spectral domain. The unbalance is distinguished from other defects by a phase shift of 90 between two radial sensors orthogonal because it is synchronized with the rotation of the mobile. Volume 2, Issue 6 November December 2013
5. DEVELOPMENT OF A VIBRATION
MONITORING SYSTEM AT THE TURBINE
Vibration analysis at the steam turbine will no longer stop at the observation of the phenomenon, it will also indicate the type of deterioration and which organ is concerned. Thus, to have a complete and accurate view of the vibrations at different bearings of the turbine, a vibration monitoring system has been established to monitor vibration evolution and make a diagnosis when monitoring detects an anomaly or a dangerous evolution of the vibration signal [1]. To establish this system, supply, installation and implementation of on-line vibration monitoring of the group (turbine, generator and exciter) were performed with a quantitative of supplies as follows: 12 accelerometers: 2 accelerometers per bearing mounted on two perpendicular axes. The accelerometer provides a signal at 100mV / g be transmitted over a long distance without attenuation. Its frequency range is high at 2 to 10 000Hz (+/3dB). The sensor is supplied by a constant current at 4mA, Shielded cables, The junction boxes, 6 proximity sensors for contact-free measurement of relative displacement of moving parts on machines. They are particularly well adapted to measure relative vibrations and axial position of the shafts of steam turbines. The characteristics of these sensors are as follows: o Contact-free measurement, o Principle of the eddy current, o Measuring range: 2mm, 4mm or 12mm, o Sensitivity: 1.33 m V / m, 4m V / m or 8m V / m, o Frequency Response: DC to 20 kHz (-3dB). These proximity sensors have been implemented as follows: A proximity sensor with integral cable mounted at the end of radial shaft and measures the variation in radial position due to its eccentricity, o Two proximity sensors for monitoring of speed of rotation and measures phase reference, o A proximity sensor with integral cable mounted parallel to the axis of rotation for the monitoring of the differential dilatation, o Two proximity sensors mounted parallel to the axis of rotation in opposition to 180 relative to the other for monitoring the axial displacement. 1 Electronic monitoring system composed of 2 racks with data loggers memo graph (see fig n6&7): o 1 rack for vibration monitoring,
(c) View of rear of the Electronic monitoring system Figure 6 Electronic monitoring system
(b) Registration of Differential Dilatation, Axial displacement, Eccentricity and Speed of rotation Figure 7 Data loggers of measured values The figures (n8, n9 and n10) below show the location of measurement points and the type of measurement for monitoring the turbo generator. - VA6 to VA1: measuring absolute vibration by accelerometers, radial vibrations in two perpendicular axes X and Y, o Bearings of steam turbine (10-1000Hz frequency, full-scale 0-100m peak), o Generator Bearings (10-1000Hz frequency, fullscale 0-100m peak), o Exciter bearings (10-1000Hz frequency, full-scale 0-100m peak). It is also expected to be able to measure axial vibration on exciter. - DD: measuring Differential Dilatation of the shaft by proximity sensor: o The turbine shaft (full-scale + /-6mm). - DA: measuring Axial displacement (wear thrust) by two proximity sensors: o Thrust bearing (full scale + /-2mm). - EX: measuring Eccentricity by a proximity sensor: o End of the turbine shaft (full scale 500 m peak to peak). - VP1 and VP2: measuring Speed of rotation and reference phase by proximity sensors (full scale 4000 rpm).
(b) Accelerometers vibration sensors implemented on the bearing n2 of the turbine Figure 8 Accelerometers vibration sensors implemented on the bearings of the turbine
(b) Accelerometers vibration sensors implemented on the bearing n2 of the generator Figure 9 Accelerometers vibration sensors implemented on the bearings of the generator
(a) Accelerometers vibration sensors implemented on the bearing n1 of the turbine Volume 2, Issue 6 November December 2013
(a) Accelerometers vibration sensors implemented on the bearing n1 of the exciter Page 244
References
[1] D. AUGEIX, " Analyse vibratoire des machines tournantes" Techniques de lIngnieur, trait Gnie mcanique BM 5 145 [2] J. MOREL, "Vibration monitoring and predictive maintenance", Technique de lingnieur, trait measures et contrle, R 6 100. [3] H.P. RAMELLA, "Maintenance des turbines vapeur ", Technique de lingnieur, trait Gnie mcanique, BM 4 186. [4] H.ELMAATI, A.BENBOUAZA, B.ELKIHEL, F.DELAUNOIS, "Development of a Vibration Monitoring System for Optimization of the Electrical Energy Production ", International Journal of Emerging Technology and Advanced Engineering, Volume 3, Issue 6, June 2013. [5] E. BENEVISE, "Etude de la corrlation entre les mesures vibratoires et ltat rel des groupes de production hydro-lectriques", INSA Strasbourg, Septembre 2011. [6] A. Benbouaza, B. Elkihel, and F. Delaunois, "Analysis and diagnosis of the different defects of asynchronous machines by vibration analysis ", International Journal on Computer Science and Engineering vol. 5, issue 4, April 2013.
(b) Accelerometers vibration sensors implemented on the bearing n2 of the exciter Figure 10 Accelerometers vibration sensors implemented on the bearings of the exciter The Table below shows the alert and danger thresholds of different parameters monitored (absolute vibration, differential dilatation, axial displacement, eccentricity and speed). Table 1: Alert and Danger thresholds
AUTHORS
This current method of vibration monitoring at the group of turbine-generator-exciter constitutes a detecting tool and diagnostic of malfunctions and contributes to reduce overall costs for an optimal maintenance of this installation [2]. Indeed, it ensures: - Visualize in real-time the state of the group, - Monitor and manage alarm levels, - Increase the availability and productivity, - Establish a precise diagnosis by identifying the defective component, - Reduce the risk of failure and incident, - Plan maintenance interventions and limit the level of preventive. Hassane ELMAATI received his engineer degree in Materials engineering in 1997 at the National School of Mineral Industry (ENIM), Rabat, Morocco. Since 1998 until today, Hes an engineer of maintenance in a thermal power plant in Morocco. Head of technical division. He is presently pursuing his PhD program in industrial engineering Department, National School of Applied Sciences University Mohammed I, Oujda, Morocco, on the theme Optimization of the production by an intelligent maintenance. Abdelkader Benbouaza Research engineer in industrial engineering on the theme maintenance of the complex installations industrial by vibration analysis. Bachir El Kihel Professor of Higher Education Grade: C, head of department math and mechanical. PhD status in Structural Design. PhD University of Compiegne engineering school France in Vibration and control non destructive. Fabienne DELAUNOIS Associate Professor- Head of Service Metallurgy University of Mons Belgium.
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