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ABSTRACT
To predict the failure of machine in advance and to avoid the quantity and quality loss in the production and generation. Predictive maintenance is implemented in most of the process and power generation industries.
All machines vibrate. Developing problems are usually accompanied by an increase in vibration. The vibrations unique characteristics will be determined by the nature of the developing fault. Measuring vibration will allow a machines condition to be assessed.
VIBRATION FREQUENCY
The time required to complete one full cycle of vibration is called the period. If one period is completed in one fifth of a second, the vibration frequency would be 5 cycles per second (5 Hz) or 300 cycles per minute (300 cpm).
IDENTIFYING CONSTRAINTS
Velocity , Displacement are the parameters used for analyze the vibration.
The following vibration meters are used for identifying these parameters, Analog meter (IRD 306) Digital meter / Analyser (IRD 880, Data PAC)
DISPLACEMENT
Displacement is a measure of the total travel of the mass - back and forth. Unit of measurement = Microns
VELOCITY
Velocity of the Vibration is a measure of speed at which the mass is moving or vibrating during its oscillation. Unit of Measurement = mm/sec In/sec
ACCELERATION
Acceleration is the rate of change of speed of the mass during its oscillation.
Units of Measurement = gs
FREQ 1 X RPM
CAUSES UNBALANCE
OTHERS Eccentric Journals, Gears, Pulleys. Misalignment, Bent Shaft, Resonance, Electrical Misalignment if high axial Resonance, Reciprocating Forces, Bad Belts If 2XRPM of belt Combination of misalignment & excessive clearances. Background Vibration, Beat Vibration
2 X RPM
3 X RPM
FREQ Synchronous (AC line frequency) Many times RPM (Harmonically related)
CAUSES Electrical
OTHERS Includes broken rotor bar, eccentric rotor, unequal air gap. Gear teeth times RPM. No of Fan blades times RPM No of impeller vanes times RPM 2,3,4 & higher if severe looseness Cavitation, Rubbing, Improper lubrication of journal brgs.
TYPES OF MACHINES
The machines are classified into two types based on machine position. They are,
In a horizontal machines, the vibration readings are taken in three positions, Horizontal Vertical Axial In a vertical machines, the vibration readings are taken in two positions, Radial Axial
Measurements in Motor DE
Improper lubrication Use of wrong lubrication Lubrication contamination Improper storage Moisture Improper installation Improper application
Horizontal
m 6-12 8.0 12 10-18 12 18 mm/s 1.0 1.0 1.6 1.4 0.6 0.8
Vertical
m 8-16 10 12 5-18 12 10 mm/s 1.2 2.2 2.2 1.4 0.6 0.4
Axial
m 30-90 30-50 10-18 30-90 18 20 mm/s 3.6-5 3.0 6.6 3-4.6 0.9 0.8
Observation: The spectrum taken shows that multiple higher order frequencies in motor and voith primary and secondary.
Horizontal
Vertical
Axial
m
21
mm/s
1.6
m
20
mm/s
1.8
m
220
mm/s
14
MDE
0.8
1.6
64
4.2
Report given:1. 2. 3. The voith coupling and its alignment may be checked. The motor bearings may also be checked. The motor may also be tested for electrical compliances.
Action taken:-
The voith bearings are replaced , the vibration readings were reduce into normal limits.
ID FAN VOITH
Vertical
m 3 6 7 10 11 10 mm/s 1.2 1.4 0.8 0.6 0.5 0.4
Axial
m 18 26 10 20 18 20 mm/s 2.2 2.2 3.2 2.0 0.8 0.8
MDE
PUMP
Observation:The vibration spectrum taken shows that 1X rpm dominant frequency in radial direction.
MDE
PUMP
AFTER BALANCING
CONCLUSION
By selecting this project in METTUR THERMAL POWER STATION we have studied the vibration monitoring techniques and analysis carried out in power plant.
In our project we studied about the vibration measurements and causes of vibration that occurred in power plant machines.
There are other vibration problems occurred in thermal power plant are studied, in our project we analyzed the bearing failure in induced draught fan and unbalance in auxiliary cooling water pump.
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