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Condition Monitoring for Steam Turbines and Sleeve Bearing Diagnostics and Failure Analysis. Presented by: Timothy S. Irwin, P.E. Senior Mechanical Engineer M&B Engineered Solutions, Inc. 13 Aberdeen Way Elgin, SC 29045 Email: tsi@mbesi.com 17 February, 2006.
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Presented by:
Timothy S. Irwin, P.E.
Senior Mechanical Engineer
M&B Engineered Solutions, Inc.
13 Aberdeen Way
Elgin, SC 29045
Email: tsi@mbesi.com
17 February, 2006
M&B ESI
Timothy S Irwin
January 2006
M&B ESI
Timothy S Irwin
January 2006
Just for a quick view, here is a decent description of a steam flow path in a multi-stage turbine:
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January 2006
Courtesy of Power Magazine
Here is one small mechanical drive turbine.
This one was actually used to drive a positive displacement oil pump.
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Timothy S Irwin
January 2006
Here is another small drive turbine
This one is also used to drive a positive displacement oil pump.
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January 2006
Here is a small industrial power generation turbine.
Note the mechanical layout of this machine
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January 2006
Here is a big multi-casing utility class machine
Courtesy of Power Magazine
Note that a lot of the mechanical details from the smallest to the largest machines are very similar
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January 2006
What kind of monitoring can we do on a turbine?
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What kind of failures typically occur to turbines?
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Lets look a little closer at some of the failure modes.
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Timothy S Irwin
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Lets look a little closer at some of the failure modes.
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My recommendation was not to defer the overhaul.
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The steam admission valve or stop valve or emergency
stop valve is part of the equipment protection!
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January 2006
Definition – What does alignment mean to ‘coupled’ rotating machines?
In short – we are looking for the two (or more) shaft centerlines to be
concentric to each other. If the shaft centerlines are not concentric
to each other, then the shafts through the coupling try to force themselves
together. Depending on the coupling type, this ‘aligning’ force may show
Itself as various ‘vibration signature changes or indications’, or if severe
enough bearing temperatures or conditions may be affected.
What can cause misalignment?
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Timothy S Irwin
January 2006
Definition – What does alignment internal to a single machine mean?
In short – We want to have the shaft/rotor within a certain position
relative to the casing. Some machines behave better with the rotor not
centered in the casing. Some machines behave better with the rotor
centered. A very typical indication is a ‘rub’ condition in the vibration data.
What can cause misalignment?
Basically the same conditions apply to internal and external misalignment.
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January 2006
Remaining failure modes:
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Failure modes and monitoring methods:
We have to perform the following:
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What kind of monitoring can we do on a turbine?
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January 2006
Steam Conditions – What kind of readings do we want to take? Depends on the machine, what kind of readings do we have available or can we take?
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Steam Tables
Mechanical
Engineering
Reference
Manual –
Michael R.
Lindeburg
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Vibration – What kind of readings do we want to take? Depends on the machine.
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What data do I want?
Also include a speed reading if at all possible.
What are we looking for?
Has the speed changed?
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For larger machines with installed shaft vibration monitors:
Compare the shaft data to casing data.
Remember, we are looking for changes. Having absolute limits for
operation and equipment protection is one thing, but all the monitoring
instruments calculate vibration levels slightly differently. In the field, it
is hard to have an absolute anything.
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January 2006
Again, what kind of machine do we have? Large or small?
Lubrication /lubricant conditions
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Lubrication /lubricant conditions
What are we looking for in an oil analysis?
There are three major condition groups that oil analysis can monitor:
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Rotor speed/load or power.
These items become even more critical for a variable load process!
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Auxiliary System Operation.
On larger machines, there are considerable auxiliary systems that may also indicate development of a significant issue.
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Auxiliary System Operation.
On larger machines, there are considerable auxiliary systems that may also indicate development of a significant issue.
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Noise/Sound levels.
With modern ultrasound technologies, it should be possible to monitor and trend changing conditions within these machines.
We should be able to monitor the following:
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Summary
There are considerable technologies that are available for use
However, the tools we have discussed today are only several pieces of an overall reliability program.
Preventive, Predictive, and Proactive or Reliability Centered components are all necessary to improve reliability and minimize overall operational cost.
Basically, the more we know about the machine, the better we can diagnose a changing condition.
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January 2006
THE END
ANY QUESTIONS?
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Timothy S Irwin
January 2006