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Equity Services & Solutions Co., Ltd 267/96-97,Mueng Mai Maptaphut Sukhumvit Rd. Maptaphut Mueng-rayong Rayong 21150 Tel : 0 3860 9200 Fax : 0 3860 9201 Tel : 0 2998 7308 Fax : 0 2998 7309 Email : [email protected] [email protected]

บริษัท อีควิต้ี เซอรวิสเซส แอนด โซลูชั่นส จํากัด 267/96-97 มาบตาพุดเมืองใหม ถนนสุขุมวิท ต.มาบตาพุด อ.เมืองระยอง จ.ระยอง 21150 โทร. 0 3860 9200 โทรสาร 0 3860 9201 โทร. 0 2998 7308 โทรสาร 0 2998 7309 อีเมล : [email protected] [email protected]

Vibration Analysis

Equity Services & Solutions Co., Ltd 267/96-97,Mueng Mai Maptaphut Sukhumvit Rd. Maptaphut Mueng-rayong Rayong 21150 Tel : 0 3860 9200 Fax : 0 3860 9201 Tel : 0 2998 7308 Fax : 0 2998 7309 Email : [email protected] [email protected]

บริษัท อีควิต้ี เซอรวิสเซส แอนด โซลูชั่นส จํากัด 267/96-97 มาบตาพุดเมืองใหม ถนนสุขุมวิท ต.มาบตาพุด อ.เมืองระยอง จ.ระยอง 21150 โทร. 0 3860 9200 โทรสาร 0 3860 9201 โทร. 0 2998 7308 โทรสาร 0 2998 7309 อีเมล : [email protected] [email protected]

Vibration Transient Analysis

Equity Services & Solutions Co., Ltd 609/9 M.8 Soi.Ramin-Tra 34, Ramin-Tra Rd. Tharang, Bangkhen, Bangkok 10230Tel : 0 2943 8289-91, Fax : 0 2943 8293 Tel : 0 2998 7308, Fax : 0 2998 7309 Email : [email protected] [email protected]

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Report

Pre-Post shutdown vibration characteristic

Of

Steam turbine power generation

Plant : Padaeng Industry

Rayong

Reported by Manorom Chiewpanich Date : 16 Nov 2009

Confidential


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Sensors position, detection dated 15 Oct 2009 and 08 Nov 2009

Total seismic sensors : 8 detected simultaneously, unit measurement mm/sec (peak)

Sensor : Y-NDE-1-generator, measured value gain = 5 ( reading > actual 5 times ) X-NDE-1-generator, measured value gain = 5 ( reading > actual 5 times ) Y-DE-2-generator, measured value gain = 5 ( reading > actual 5 times ) X-DE-2-generator, measured value gain = 5 ( reading > actual 5 times ) Y-DE-1-turbine, measure value gain =1 X-DE-1-turbine, measure value gain =1 Y-NDE-2-turbine, measured value gain = 5 ( reading > actual 5 times ) X-NDE-2-turbine, measured value gain = 5 ( reading > actual 5 times )

Vibration detection using seismic sensor to measure the bearing housing vibration on item 1,2 . While item 4 detection using In-Situ Eddy current sensors ( without key phaser ) at position DE-1, turbine

X

Y Generator

GearTurbine

NDE-1 DE-2

Generator

DE-1 NDE-2

A

A

A

A


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Summary

1) Generator , Post vibration characteristic is better than Pre-shutdown ( see page 7, 10)

2) Turbine, Pre & Post vibration at NDE –vertical plane is higher than DE, and it is almost reach the unacceptable region according to ISO-10816-3 at arrowed page 4

3) Turbine, Pre & Post vibration characteristic indicates loose of damping properties. Which has the possibility from the excessive bearing clearance. ( see circled page 13,16 )

4) Turbine DE bearing Post shutdown only, 4.1 Found bearing instability at speed range 9000-10092 rpm ( see circled page 13,16 ) 4.2 Found the 1st critical speed is around 7320 rpm see circles page 18 4.3 Found vibration signal from mechanical run out and/or electrical run out at 17,8

microns ( see page 19 )

5) Reduction gear, Post Vibration signature is cleaner , possibly due to better lubrication.

6) Vibration trip during start up.6.1 It was found the electrical signal interference. Remedy was made by apply 0,000035

microfarad capacitor to cross over the signal cable terminal. 6.2 Operating speed was reached the 1st critical speed, and was not passed over quickly.

Resulted high vibration trip due to amplification phenomenon.

7) Vibration trip at 3200 MW load. As per recent information from Padaeng Industry on high vibration trip when increasing load to 3200 MW.

From all vibration data that were detected during 8,12,13 Nov 2009 at load < 3200 MW, there is no sign of high vibration. However, there is possibility on the high vibration which may relate to item 3, and item 4.1 , 4.3

Vibration analysis during increasing load to 3200 MW will be carried out soonest.


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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Pre-shutdown

Post-shutdown


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1st critical speed


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Slow roll data at 312 rpm indicates mechanical/electrical run out at 12 and 17,8 microns


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Sensors position, detection dated 10 Oct 2009 and 8 Nov 2009

Total sensors :

First detection, 5 detected simultaneously, unit measurement Gs (peak)

Sensor : Y-NDE-1-gear, measured value gain = 1 X-NDE-1-gear, measured value gain = 1 Y-DE-2-gear, measured value gain = 1 X-DE-2-gear, measured value gain = 1 Y-DE-1-case, measure value gain =1

Gear mesh frequency = 253 200-253 500 cpm

Generator

Gear

Turbine NDE-1 DE-2

case

A

X

Y

X

YNDE-1DE-2

A

A

A


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Pre-shutdown ( full scale 1.2 Gs )

Post-shutdown ( full scale 4.8 Gs )


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Pre-shutdown ( full scale 1.2 Gs)

Post-shutdown ( full scale 3.8 Gs )


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Pre-shutdown

Post-shutdown


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Pre-shutdown ( full scale 1.2 Gs )

Post-shutdown ( full scale 10 Gs )


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Pre-shutdown ( scale 0.2 G/division )

Post-shutdown ( different scale, 1 G /division )


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Report

High vibration after shutdown

Of

Steam turbine power generation

Plant : Padaeng Industry

Rayong

Reported by Manorom Chiewpanich Date : 21 Nov 2009

Confidential,customer name


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Executive summary

1) , rotor residual unbalance2) shutdown “free rotor position” alignment

, 1 rotor residual unbalance 3) shutdown bearing clearance , damping

factor Log decrement , 2 (sensitive)4) shutdown misalignment. Bearing radial offset

misalignment ( ) rotor damping factor . misalignment bearing rotor shaft journal turbine .

1) , bearing2 ( ESS bearing).

shutdown 8-12 , cool down

2) Short term, bearing shutdown reconditionrotor shaft journal bearing .

bearing bearing (bearing pad-shoes)geometric mismatch. ( ESS 150,000 ).

shutdown 12-16 , cool down

2.1 modify Bearing pad 3-4

3) Intermediate term, . complete bearing set ( pad housing ). ESS modify complete bearing set rotor shaft journal .

2 (ESS 120,000 ). shutdown 12-16 , cool down

3.1 modify Bearing pad 2-3

4) Long term-permanent basis, recondition spare rotor bearing3( ESS rotor . rotor

modify bearing 3, ESS 320,000 ).shutdown 3

.

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4.1 recondition Rotor 3-4 - rotor run out 14,000 , rotor run out rotor 40,000

- UT scan fluorescent PT 80,000 - Balancing 80,000

4.2 Rotor shaft recondition ( blade recondition ) - rotor , .

- , grinding , 80,000- .

, 300,000 500,000


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shutdown “RPO-Padaeng post-shutdown”, “ ”. steam turbine

3,2 MW.

generator , shutdown function generator reduction gear. , shutdown

steam turbine :

Description Pre-shutdown Post shutdown 1) Overall vibration2) Alignment Bearing misalignment

turbine gear. , Appendix I

Alignment turbine gear 0,14

mm ( alignment , Appendix II)

3) Rotor shaft journal

, Appendix III ( rotor shaft ) 4) Rotor high vibration “Pre-shutdown

report”5) Bearing clearance Bearings 2

5.1 Misalignment 2 5.2 Fretting corrosion bearing (bearing pad saddle) rotor

bearing pads ,

bearing clearance Appendix III

6) Turbine vibration ( high vibration trip) (

)7) Vibration signal Mechanical run out 17,8

microns ( Appendix IV )

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?shutdown ,

shutdown

4, rotor high vibration ,

Ref-1. residual unbalance. Rotor term displacement :

Displacement = A sin t ( turbine measurement in “microns”)

Ref-2. trip 50 microns ( increase to 80 microns to compensate mechanical run out Ref-10 )

Ref-3. bearing , displacement bearing (damp) bearing rotor shaft journal .

2, misalignment Ref-4. radial offset misalignment ( ) rotor 1 degree of freedom (damp) degree of freedom

mass eccentric


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Ref-5. shutdown bearing offset- misalignment, rotor shaft journal bearing turbine. ( Appendix I )

Ref-6. alignment shutdown rotor shaft high speed gear pinion rotor

turbine gear pinion 0,14 m.m. ( AppendixII)

5, bearing clearance Ref-7. bearing clearance 0,53 m.m.(~ 500 microns). clearance

rotor 1 degree of freedom degree of freedom ( Appendix III)

, bearing clearance damping factor , log decrement . log decrement rotor (sensitive)

.

turbine shutdown


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Ref-8. misalignment shutdown vibration spectrum , vibration signature order 2

Ref-9. Rotor bearing clearance

12 . . 17 . .

7 , vibration signal Ref-10, Appendix IV rotor ,

( only 312 rpm ) run out mechanical / electrical ( Set point increase to 80 micron to compensate this run

out value )

High vibration


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shutdown (post-shutdown ). , bearing

misalignment

minute of meeting ( Appendix V ) :

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Appendix I , bearings misalignment (scratch),

Scratch at the same orientation

Scratch at the same orientation

View from turbine NDE

View from turbine NDE

Rotor

Rotor


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Appendix II

This high offset value restrained shaft vibration with good damping factor. But destroy rotor shaft and bearing directly. See evidence Appendix I


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Appendix III


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Appendix III


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Appendix IV, vibration mechanical run out.

312 rpm mechanical/electrical run out 12 17,8 microns.

,


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Appendix V,

Cover sheet

Minutes of meeting

Equity Services & Solutions Co., Ltd 609/9 M.8 Soi.Ramin-Tra 34, Ramin-Tra Rd. Tharang, Bangkhen, Bangkok 10230Tel : 0 2943 8289-91, Fax : 0 2943 8293 Tel : 0 2998 7308, Fax : 0 2998 7309 Email : [email protected]

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Minute Of Meeting : 20 2552: 09.00 – 11.30

: .: . ESS Turbine:

. .ESS1. 1. 2. 2. 3. 3. 4. 4.

Action1 ESS Turbine ESS

2 1 41. ( short term) modify bearing clearance

(bearing

dimension bearing )

2. ( intermediate term) bearing modifyclearance ( modify 1

)

3. ( long term) rotor . inspectionbalance rotor

bearing 2

4. ( short term) rotor grinding journalmodify bearing

1. . ESS bearing

modify bearing

2 .

3. . ESS

Equity Services & Solutions Co., Ltd 609/9 M.8 Soi.Ramin-Tra 34, Ramin-Tra Rd. Tharang, Bangkhen, Bangkok 10230Tel : 0 2943 8289-91, Fax : 0 2943 8293 Tel : 0 2998 7308, Fax : 0 2998 7309 Email : [email protected]

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3 . plant 3-7 52 21-25 52

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