CONDITION MONITORING PROGRAM IN THERMAL POWER PLANT

CONDITION MONITORING PROGRAM IN THERMAL POWER PLANT :

CONDITION MONITORING PROGRAM IN THERMAL POWER PLANT SHIVAJI CHOUDHURY

OBJECTIVE OF CONDITION MONITORING:

OBJECTIVE OF CONDITION MONITORING TO IDENTIFY CHANGES IN CONDITION OF MACHINE THAT WILL INDICATE SOME POTENTIAL FAILURE. DIAGNOSIS OF FAULT PREDICTION OF FAULT TO AVOID FURTHER DAMAGES TO PLAN BETTER SPARE MANAGEMENT OUTAGE OF EQUIPMENT CAN BE BETTER PLANNED. ENHANCING THE MACHINE EDURANCE LIMIT. LESS DOWN TIME AND MORE PRODUCTIVITY GREATER SAFETY TO WORK FORCE.

MONITORING TECHNIQUE:

MONITORING TECHNIQUE VIBRATION MONITORING. LUBRICANT ANALYSIS. NOISE ANALYSIS. WEAR DEBRIS ANALYSIS. THERMOGRAGHY. D G A. NDT ULTRASONIC

VIBRATION ANALYSIS:

VIBRATION ANALYSIS TURBINE. GENERATOR. PUMP. MOTOR. FAN. COMPRESSOR.

VIBRATION DIAGNOSIS:

VIBRATION DIAGNOSIS SHAFT AND ROTOR- UNBALANCE , BENT, MISALIGNMENTS BEARING –DAMAGES,,DISTORTION,LOSS OF LUBRICANT. GEAR –TOOTH MESHING FAULT,WORN TEETH,MISALIGNMENT MECHANICAL LOOSNESS

VIBRATION ANALYSIS:

VIBRATION ANALYSIS S.N FREQ CAUSE AMPLITUTE PHASE COMMENTS 1 ½ ROTIONAL SPEED OIL WHIP OR OIL WHRIL OFTEN VERY SEVERE ERRATIC HIGH SPEED MACHINES WHERE PRESSURISED BEARING ARE USED 2 1*RPM UNBALANCE PRORRTIONAL IMBALANCE SINGLE 3 2*RPM LOOSENESS ERRATIC TWO MARKS USUALLY HIGH IN VERTICAL DIRECTION 4 2*RPM BENT,SHAFT MISALIGNMENT LARGE IN AXIAL DIRECTION TWO MARKS USE DIAL INDICATOR FOR POSITIVE DIAGNOSIS 5 1,2,3,4*RPM BAD DRIVE BELT ERRATIC 1,2,3,4 UNSTEADY USE STOBE LIGHT TO FREEZE FAULTY BELT 6 MANY *RPM BAD BRG ERRATIC MANY REF MARK 7 RPM* GEAR TEETH GEAR NOISE USUALLY LOW MANY REF MARK 8

LUB OIL ANALYSIS:

LUB OIL ANALYSIS MOISTURE MECHANICAL IMPURIRTIES DENSITY VISCOCITY ACIDITY

LUB OIL DIAGNOSIS:

LUB OIL DIAGNOSIS DEGRADATION OF LUB OIL IMPURITIES IN LUB OIL

WEAR DEBRIS ANALYSIS & DIAGNOSIS :

WEAR DEBRIS ANALYSIS & DIAGNOSIS WEAR DEBRIS CARRIED OUT FOR WEAR PARTICLE CONCENTRATION IN OIL CONDITION OF LUB OIL OUTSIDE CONTENMATION TO DETERMINE TO WEAR CONDITION OF MACHINE NORMAL RUBBING BEARING FAILURE CONDITION OF GEAR CUTTING OF METAL

THERMOVISION MONITORING:

THERMOVISION MONITORING IDENTIFICATION OF HOT SPOT . USED FOR MONITORING OF SWITCHYARD EQUIPMENT. ROUTINE MONITORING OF MOTOR/PUMP. MONITORING OF DRAIN PIPES LINES TO DETECT CHOKING OF PIPE LINES. TO MONITOR OF CONDITION OF INSULATION ON PIPE AND EQUIPMENT.

DISSOLVE GAS ANALYSIS:

DISSOLVE GAS ANALYSIS FOR ALL TRANSFORMERS. DIELECTRIC STRENGTH OF TRANSFORMER OIL. MOISTURE,DENSITY,COLOUR OF TRANSFORMER OIL. DISSOLVE GAS ANALYSIS IN TRANSFORMER OIL-TO DIAGNOSIS OF FAULT.

TRANSFORMER OIL DIAGNOSIS:

TRANSFORMER OIL DIAGNOSIS CO AND CO2 IN OIL—THERMALCONDITION INVOLVING PAPER METHANE,ETHANE,ETHYLENE AND SMALL AMOUNT OF ACETYLENE IN OIL - THERMAL CONDITION INVOLVING THE OIL HYDROGEN,METHA AND SMALL AMOUNT OF ACETYLENE AND ETHANE IN OIL--PARTIAL DISCHARGE HYDROGEN,ACETYIENE AND ETHELENE IN OIL-SUSTAINED ARCING-SUSTAINED ARCING

VIBRATION MEASUREMENT MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS:

VIBRATION MEASUREMENT MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS S N Equipment 1 ST WEEK 2 ND WEEK 3 RD WEEK 4 TH WEEK 1 ID FANS Y 2 FD FANS Y 3 PA FANS Y Y 4 MILL GEAR BOX Y Y 5 SEAL AIR FANS Y Y 6 BFP Y 7 CEP Y 8 CW PUMPS Y 9 OTHER PUMPS/FANS Y

OIL ANALYSIS MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS:

OIL ANALYSIS MONTHLY SCHEDULE FOR CRITICAL EQUIPMENTS S N EQUIPMENTS 1 ST WEEK 2 ND WEEK 3 RD WEEK 4 TH WEEK 1 MOT OIL Y Y Y Y 2 ID FAN LUB OIL Y 3 MILL LUB OIL Y 4 BFP LUB OIL Y 5

DISSOLVED GAS ANALYSIS SCHEDULE FOR CRITICAL TRANSFORMERS:

DISSOLVED GAS ANALYSIS SCHEDULE FOR CRITICAL TRANSFORMERS S.N EQUIPMENT SIX MONTHLY YEARLY 1 GENERATOR, STATION TRANSFORMER Y 2 UNIT AUX TRANSFORMER Y 3 OTHER TRANSFORMER Y

HOT SPOT SURVEY THROUGH THERMOVISION CAMARA:

HOT SPOT SURVEY THROUGH THERMOVISION CAMARA S.N EQUIPMENT SIX MONTHLY 1 SWITCH YARD AND TRANSFORMER YARD OF STATION Y

TEMPERATURE MEASUREMENT BY IR PYROMETER :

TEMPERATURE MEASUREMENT BY IR PYROMETER Measure temperature of all drain valves , to check valves are passing or not. Measure temperature of all bearing of critical pumps, fans, compressors, motors, turbine . S.N EQUIPMENT MONTHLY IN EVERY THREE MONTH 1 DRAIN VALVE Y 2 BEARING OF FANS,PUMPS, COMPRESSORS, MOTORS,TURBINE. Y

WEAR DEBRIS ANALYSIS:

WEAR DEBRIS ANALYSIS S.N EQUIPMENT ONCE IN FOUR MONTH ANNUALLY 1 MOT OIL Y 2 MILL GEAR BOX OIL Y

STANDARDS FOR CONDITIONAL MONITORING:

STANDARDS FOR CONDITIONAL MONITORING S.N STANDARD NO DESCRIPTION 1 ISO 17359 CONDITION MONITORING AND DIAGNOSTICS OF MACHINES ,GENERAL GUIDELINE 2 ISO 13373 MECHANICAL VIBRATION AND SHOCK –VIBRATION MONITORING OF MACHINE 3 ISO 13381 CONDITION MONITORING AND DIAGNOSTICS OF MACHINE AND PROGNOSTICS

THANKYOU:

THANKYOU