Int J Syst Assur Eng Manag

https://doi.org/10.1007/s13198-020-00945-4

ORIGINAL ARTICLE

FMECA analysis and condition monitoring of critical equipments

in super thermal power plant
J K. Mohanty1 • P. R. Dash1 • P. K. Pradhan1

Received: 16 July 2019 / Revised: 5 January 2020

 The Society for Reliability Engineering, Quality and Operations Management (SREQOM), India and The Division of Operation and
Maintenance, Lulea University of Technology, Sweden 2020

Abstract In the recent years, there is a trend to build super Keywords Condition monitoring
Thermal power plant

thermal power plants in order to have better economic FMECA
Vibration analysis
FMEA
viability. With the growth of the capacity and size, the
complexities of these plants have also grown multifold.
There is more chance of fault in the system, when it is more 1 Introduction
complex. An early detection of these faults can allow time
for preventive maintenance before a severe failure occurs. Electricity is the only form of energy which is easy to
Condition monitoring is implementation of the advanced generate, transmit, use and control. It is considered as the
diagnostic techniques to reduce downtime and to increase most usual form of energy transmission and distribution.
the efficiency and reliability. The research is for deter- There are various types of power plants from which elec-
mining the usage of advanced techniques like Vibration tricity can be generated in a bulk manner. Thermal power
analysis and Oil analysis and to diagnose ensuing problems plant is one of them.
of the plant and machinery at an early stage and plan to Thermal Power Plants or Steam Power Plants generate
take corrective and preventive actions to eliminate the issue more than 65% of the total electricity produced in the
and enhancing the reliability of the system. Now days, world (Mpoweruk). India is currently the 3rd largest pro-
most of the industries have adopted the condition moni- ducer of electricity in world and production of coal based
toring techniques as a part of support system to the basic thermal power is about 85% of the country’s power gen-
maintenance strategies. Failure Mode, Effect and Critical- eration (Power tech). The thermal power plant basically
ity Analysis (FMECA) is associated with condition moni- works on the principles of a Rankine cycle. The Rankine
toring to determine the criticality of such unit or machines. cycle is a process that is used to convert heat into
It is a design method used to systematically analyze mechanical work. The heat is supplied externally to a
probable component failure modes of product or process, closed loop, which is used to convert water into steam.
assess the risk associated with these failure modes and find That steam runs the turbine, which is coupled with a
out the resultant effects on system operations. In this study, generator and the generator produces the electricity. The
practical approach have been applied for the FMECA to heat sources used in thermal power plants are either com-
determine the critical equipments in a super thermal power bustion of fossil fuels like coal, oil and natural gas or the
plant and condition monitoring of such equipments have nuclear fission (Nag 2008).
been done. There are hundred numbers of units, subunits, compo-
nents, and parts in thermal power plant. The major com-
ponents of a thermal power plant are; Turbine, Boiler,
& P. K. Pradhan Generator, Condenser and Feed pumps.
[email protected] In the recent years, there has been a developed trend to
1 build thermal plants with higher efficiency in order to fulfill
Mechanical Engineering Department, VSSUT, Burla, Odisha,
India the requirements with better economic viability. With the

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growth of the capacity and size, the complexity of the xi. Ultrasonic monitoring
plants is also growing. The more complex a system, the
Before going to implementation of CBM of any indus-
higher are the chances of occurrence of faults in it. These
try, it is essential to do FMECA (Failure Mode, Effect &
faults may lead to cause catastrophic failure and collapse of
Criticality Analysis) to identify the degree of criticality of
the system. The faults which are having slow pace of
various machineries and components of such industry.
growth can be detected by carefully monitoring the chan-
Based on these, application of CBM techniques can be
ges in the process parameters.
decided.
Since its’ genesis, the Maintenance culture has evolved
down, through different types of maintenance techniques
1.2 Failure mode, effect and criticality analysis
(Mohanty 2014; Williams et al. 1994; Jardine et al. 2006;
(FMECA)
Kim et al. 2014) like.
• Unplanned maintenance: Run to failure or breakdown FMECA is an extension of failure mode and effects anal-
maintenance ysis (FMEA). FMEA can be applying to recognize proba-
• Schedule maintenance ble failure modes, conclude their effect (Würtenberger
• Preventive maintenance et al. 2014). FMEA is extended to FMECA (Chen et al.
• Condition monitoring/predictive maintenance 2012; Catelani et al. 2018; Pancholi and Bhatt 2016; Sri-
• Reliability centered maintenance vastava and Mondal 2015; Zhou et al. 2014) to indicate
• Total productive maintenance that criticality analysis is performed too. It is a design
method used to systematically analyze probable component
In earlier days, the main form of maintenance was
failure modes of product or process, assess the risk asso-
corrective maintenance instead of predictive maintenance
ciated with these failure modes and find out the resultant
system, resulting to high downtime with reduced genera-
effects on system operations.
tion, besides safety & environmental issues. These chal-
The basic steps for performing an FMEA/FMECA
lenges gave rise to Condition Based Maintenance (CBM)
analysis include:
that actively manages the health and condition of the
assets; as maintenance work is only done when really (a) Identify the machine(s), item(s) or process (es) to be
needed through use of diagnostic tools. analyzed.
(b) Identify the function(s), failure(s), effect(s),
1.1 Condition monitoring cause(s) and control(s) for each item or process to
be analyzed.
Condition monitoring detect and diagnose of incoming (c) Evaluate the risk associated with the issues identified
defects in any equipment and plan the maintenance based by the analysis.
on machine condition to prevent breakdown for better (d) Prioritize and assign corrective actions.
availability with cost optimization and reduction of sec- (e) Perform corrective actions and re-evaluate risk.
ondary failures. Today condition monitoring is becoming (f) Distribute, review and update the analysis, as
essential for all the machines/equipment in a thermal power appropriate
plant.
Most analysis of this type also includes some method to
Types of condition monitoring techniques
assess the risk associated with the issues identified during
The various condition monitoring techniques are used in
the analysis and to prioritize corrective actions. There are
industries. These are;
two common tools used to determine the degree of criti-
i. Visual, optical, tactile and aural monitoring cality of the machineries. These are;
ii. Performance monitoring i. Risk priority numbers (RPNs)
iii. Temperature monitoring ii. Criticality analysis/score
iv. Vibration monitoring
v. Electrical current monitoring through MCSA
(motor current signature analysis) i. Risk priority numbers (RPNs)
vi. Lubricant monitoring (through oil analysis) The RPN is a result of a multiplication of detectability
vii. Shock pulse monitoring (D) 9 severity (S) 9 occurrence (O). With each on a scale
viii. Leakage monitoring from 1 to 10, the highest RPN is 10 9 10 9 10 = 1000.
ix. Crack monitoring and corrosion monitoring This means that this failure is not detectable by inspection,
through NDT (Non destructive testing) very severe and the occurrence is almost sure. If the
x. Noise monitoring (through acoustic analysis) occurrence is very sparse, this would be 1 and the RPN

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would decrease to 100. So, criticality analysis enables to 2 Methodology and experimentation
focus on the highest risks.
Present study is focused on FMECA analysis and condition
ii. Criticality analysis
monitoring or predictive maintenance of equipments in
Criticality analysis is a systematic approach to identify super thermal power plant, Vedanta Limited.
potential risks and their consequences which can impact
the business. It has well defined criteria that specify the 2.1 FMECA/criticality analysis of vedanta limited
potential consequences, so that they can be evaluated,
categorized & prioritized. Criticality Analysis is done for all individual equipment up
Present study is focused on FMECA analysis and con- to replaceable part and the same is to be reviewed once in a
dition monitoring or predictive maintenance of equipments year in Captive Power Plant of Vedanta Aluminium Lim-
in super thermal power plants. ited (VAL), Jharsuguda, India.
The current study is based on Captive Power Plant In the current study, the criticality score is taken as
(CPP) of Vedanta Limited (VL), Jharsuguda, Odisha. It has multiplication of seven numbers of distinct factors cover-
9 units having capacity of 1215 MW. With the commis- ing the entire functionality of the equipment. These factors
sioning of its first unit in August 2008, the plant has come a are to be rated on a scale of 1 to 3 by considering the
long way with all the nine units commissioned in 2010. guideline briefed as below. The seven factors for calcu-
The plant possesses world class technology supplied by lating the Criticality analysis are:
Shanghai Electric Company, Sanghai. Technologies like
(a) Consequence factors: CF
High Concentration Slurry Disposal &Close-circuit cooling
(b) Redundancy factor: RF
systems are environment friendly technologies and positive
(c) Downtime factor: DF
impact on reduction in water consumption.
(d) Cost of replacement factor: CrF
The plant having capacity of 9 9 135 MW, is a sub
(e) Severity factor: SF
critical, direct pulverized coal fired, corner tangential fir-
(f) Loading factor: LF
ing, natural circulation boiler and single reheat, double
(g) Restoration/service factor: SF
cylinder, double flow, single shaft, extraction and con-
densing steam turbine of ‘Shanghai Electric’ Make. It has Criticality
adopted the state-of-art Digital Distributed Control System, score(CS) = CF 9 RF 9 DF 9 CrF 9 SF 9 LF 9 SF
High Concentration Slurry Disposal (HCSD) of fly ash & The degree of criticality may be defined as
bottom ash, counter-flow forced draft Cooling Towers and
1. Most critical = Criticality score [ = 450
multi-flue Stacks. It sources water from Hirakud Reservoir
2. Critical = 50 \ Criticality score \ 450
over a distance of 33 km. Coal is transported from Maha-
3. Non critical = Criticality score = \ 50
nadi Coal Fields having bottom discharge wagons and also
by road from some of the nearer mines. The following guide lines have been followed for the
The Captive Power Plant supplies power to the power present work;
intensive Pot Lines of the 0.5 mMT Aluminium Smelter The below factors are ranked on a scale of 1 to 3 based
through a 220 kV Switchyard where the AC power is on their conditions as given.
converted to DC power through a set of Transformer
A. Consequence factor (CF)
Rectifiers. The DC power is utilized for Electrolysis of
Alumina in 608 no. of cells in pot lines to produce 1. Impacts production or quality: Neither P nor Q
Aluminum. 2. Impacts production or quality: Either P or Q
The power plant along with Aluminium smelter is cer- 3. Impacts production or quality: Both P & Q
tified by ISO 9001, 14001 and OHSAS 18001 i.e. Inte-
B. Redundancy factor (RF)
grated Management System from IRQS. Also both Captive
Power Plant and Smelter of Vedanta Limited have been 1. Whether it has dedicated stand by
certified by SGS India Pvt. Ltd for ISO 50001 (Energy 2. Whether it has conditional stand by
Management System) and ISO 55001 (Asset Management 3. Whether it has no standby
System).
Dedicated standby means a separate unit, which is not
operating. It is provided beside the working unit and is
ready to start when the working unit stops. Exp: Boiler
Feed Pumps

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Conditional standby means a second unit is operating in Scoring is based on the utilization of the equipment
parallel with the primary duty unit and both are sharing the against its rated capacity.
demand. If the primary unit fails, the second unit takes the
1. Less than 80% of rated capacity
full service. Exp: Rectifier Units have conditional standby
2. Between 80 and 100% of rated capacity
C. Downtime factor (DF) 3. More than 100% of the rated capacity
The Scoring is based on the percentage of downtime Based on the type of equipment, its load (average for the
hours as compared to running hours. year) needs to be calculated (equipment wise) and com-
pared against its rated capacity and kept as backup in the
1. Less than 1% of running time
criticality assessment workbook.
2. 1–3% of the running time
3. Greater than 3% of the running time G. Restoration/service factor (SF):
Downtime = (Breakdown hours/Running hours) 9 1. If spares and expertise are available within the
100% plant
In case running hour is equal to calendar hour i.e. no idle 2. If spares and expertise are partly available within
time is there for equipment then calendar hour is to be the plant and external help may be required
considered. The entire calculation is to be done on the basis 3. If availability of spares and/or expertise are
of previous 1 year data. completely dependent on external parties only
D. Cost of replacement factor (CrF) In this factor we need to consider the time required to
repair the equipment in case of major failure. In case of
Scoring is based on the cost of the equipment/assembly/
replaceable part cause wise MTTR (Mean Time to Repair)
spare.
data can be considered.
1. Less than Rs. 1 Lakh After taking care of all parameters, the criticality scores
2. Between Rs. 1 and Rs. 5 Lakh of all important equipments are evaluated and presented in
3. Greater than Rs. 5 Lakh. Table 1.
E. Severity factor (SF) The above criticality analysis has categorized some of
the most important equipments of the Captive Power Plant.
Scoring is based on whether it impacts safety or statu-
In this paper, we have considered three most critical
tory requirements.
equipments for the analysis. These are;
1. Impacts neither safety nor statutory
i. ID fan (induced draft fan)
2. Impacts either safety or statutory
ii. FD fan(forced draft fan)
3. Affects both safety and statutory
iii. APH (air preheater)
F. Loading factor (LF)

Table 1 Equipment criticality analysis for CPP

SN Equipments CF RF SF CrF LF DF SF CS = (CF 9 RF 9 DF 9 Degree of critical
SF 9 CrF 9 LF 9 SF)

1 Turbine 3 3 3 3 3 3 2 1458 Most critical

2 Air pre-heater 3 3 3 3 3 1 2 486 Most critical
3 ID fan 3 3 3 3 3 1 2 486 Most critical
4 FD fan 3 3 3 3 3 1 2 486 Most critical
5 CT fan 2 3 2 2 2 1 1 48 Non critical
6 BFP 2 3 2 2 2 1 1 48 Non critical
7 ESP 3 1 1 3 3 1 2 54 Critical
8 Boiler 3 3 3 3 3 1 2 486 Most critical
9 Generator 3 3 3 3 3 1 2 486 Most critical
10 PA fan 3 3 3 3 3 1 2 486 Most critical
11 Compressor 2 3 2 2 2 1 1 48 Non critical
12 CW pump 2 3 2 2 2 1 1 48 Non critical
13 High pressure heater 2 1 1 3 3 1 2 36 Non critical

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Table 2 FMEA of ID fan

Primary parts Component/sub- Potential failure mode Potential causes
process

Impeller Blade Impeller damage Ash erosion

Impeller jam Cone misalignment
Shaft Shaft runout Shaft misalignment
Overload
Overheating
Bearing failure
Shaft erosion Erosion
Bearing jamming due to oil quality
Bearing housing Cooling water line Bearing damage High temperature
Shaft damage Bearing damage
Housing damage Shaft damage
Locating ring Sudden increase in Wrong operation
RPM
Overheating Rotation of bearing outer race
Oil view glass Oil view glass damage High vibration
Improper fitment of view glass
Poor view glass quality
Variable speed turbo coupling (VOITH Coupling Bearing Oil contamination.
coupling) damage Increase differential pressure on double oil
filter
Abnormal Speed variation
Sudden Increase in oil level
Increase in temperature of Coupling
Variation in output speed
Variation in Lube Oil pressure
Bellow Bellow damage Dust
Increase in pressure
Pricking due to support clamp
Improper bolt tightening
Inlet cone Uneven clearance Increase in fan Improper installation
Vibration

2.2 FMEA analysis the furnace to remove the flue gases from furnace via multi
cyclone and to push the flue gases to chimney. The FMEA
The FMEA of the above most critical equipments have of ID Fan is given as below (in Table 2).
been done and presented as follows
ii. Forced draft fan
i. Induced draft fan
The main functionality of a Forced Draft Fan or FD fan
Induced Draft Fan or ID fan is used to create a vacuum is for providing the required quantity of hot pressurized air
or negative pressure in steam boiler. ID Fan is also used to to the furnace for smooth and uniform combustion of fuel.
identify the combustion process used in large boilers. With In the case of a steam boiler assembly, this fan is of great
mechanical ventilation inside the boilers, the heat transfer importance. As we know, in a Boiler to generate steam,
rate increases. ID fan is always located between dust col- combustion must occur, be it with any fuel i.e. coal, LDO,
lector and chimney. ID fan takes the hot flue gases from Furnace oil etc. and for combustion to exist one of its’
furnace via dust collector (ESP or dust separation system or three main requirements is air. This requirement is com-
Fume Extraction system) and delivers to chimney. It pro- pensated by a Forced Draft Fan. However, the total air
duces the pressure lower than atmospheric in the system or requirement to the boiler is managed by both Primary Air
it may be said that ID fan produces a negative pressure in (PA) Fan & Forced Draft (FD) Fan. PA fan is used to

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Table 3 FMEA for FD fan

Primary parts Component/Sub-process Potential failure mode Potential causes

Impeller Blade Impeller imbalance High vibration

Shaft Shaft Shaft runout High vibration/Wobbling of shaft
Coupling Coupling Misalignment High vibration
Bearing failure
Shaft undercut Foreign material ingress
Oil seepage
Bearing housing Cooling water line Bearing damage PA fan trip
Shaft damage
Housing damage
Oil view glass Oil view glass damage Oil leakage
DE & NDE Bearing Impeller Imbalance High vibration
shaft runout High vibration
Discharge damper Fan discharge damper Bearing seize Remote operation Not possible
Shaft damage
Bellow Suction bellow Bellow damage Abnormal sound
Bellow damage Reduction in header pressure
Inlet cone Inlet cone Uneven clearance Reduction in discharge pressure

transport the pulverized coal from mills to the furnace for From the above FMEA analysis it is observed that the
the combustion. While primary air is supplied to the burner most of the failures are due to vibration and due to lack of
with the fuel that controls the rate of combustion as well as lubrication. So in this work, some case studies, which are
the amount of fuel that can be burnt, Secondary air is related to vibration analysis and oil analysis for these
supplied to the combustion process that controls combus- ‘‘Most Critical’’ equipments i.e. ID Fan, FD Fan and APH
tion efficiency to ensure complete combustion of the fuel. are studied and analyzed.
FD fan supplies air to the Air-preheater, where it captures
the heat from the flue gases coming from the boiler outlet.
The FMEA for FD Fan is enumerated in Table 3. 3 Case studies and observations
iii. Air preheater
Condition monitoring of the above critical equipments are
An Air Preheater (APH) is any device designed to heat done through vibration analysis and oil analysis, which are
air before another process (for example, combustion in a presented as follows;
boiler) with the primary objective of increasing the thermal
efficiency of boilers. These may be used as a single unit in 3.1 Case study 1: Condition monitoring of ID Fan
small capacity boilers where air is indirectly heated by #4A, VOITH coupling
steam externally and supplied to boilers. However, in
bigger units it is a regenerative one, which is installed in A VOITH Coupling is a hydraulic coupling or fluid cou-
the flue gas path prior to ESP in order to reduce the flue gas pling manufactured by VOITH GmbH, Germany. Fluid
exit temperature, while increasing the air temperature Coupling is a device used for transmitting power from one
required for combustion in furnace. So the purpose of the shaft to another shaft by means of acceleration and decel-
air preheater is to recover the heat from the boiler flue gas eration of a hydraulic fluid. In Fluid couplings, the output
which increases the thermal efficiency of the boilers by speed is always less than the input speed. There are two
reducing the useful heat lost in the flue gas. As a conse- types of fluid coupling namely.
quence, the flue gases are also conveyed to the flue gas
1. Constant fills/fixed speed type:
stack (or chimney) at a lower temperature, allowing sim-
2. Variable speed/Scoop type:
plified design of the conveyance system and the flue gas
stack. It also allows control over the temperature of gases The VOITH Coupling used in ID Fans in this case is a
leaving the stack to meet emissions regulations. It is Scoop control type. VOITH coupling is an important
installed between the economizer and chimney. The FMEA component of ID fan, which is monitored by means of
for APH is enumerated in Table 4. vibration analysis. Also oil analysis or patch test is done for

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Table 4 FMEA for APH

Primary parts Component/sub-process Potential failure mode Potential causes

Guide bearing Guide bearing Bearing seize Oil leakage from guide bearing
Oil contamination
Seal tube damage
Improper oil circulation
Rotor misalignment
Guide bearing cap bolt damaged
Rise in oil temperature
Bearing material quality
Support bearing Support bearing Bearing seize Oil leakage from support bearing
Oil contamination
Seal tube damage
Improper oil circulation
Rotor misalignment
Rise in oil temperature
Bearing material quality
Gear box Gear Gear damage Improper backlash
Poor gear material
Misalignment of main shaft
Misalignment of trunion shaft
Deformation of rotor Oil leakage
Oil contamination
Oil level low
GB and motor misalignment
APH sudden stop
bearing material quality
Lub oil pump Oil cooler APH bearing damage Seal damage
Spider coupling damage
Oil contamination
Pump damage
APH rotor Heating elements Rotor deformation Flow and velocity of flue gases
Radial/axial/bypass/post seals Improper seal setting Ash erosion
Erosion Flue gas erosion of APH internals
Leakages in APH
Chocking in scarph
Diaphragm plates Erosion and corrosion and aging Loose tightening
Improper seal setting
Sector plates Erosion and aging Flue gas
(HE and CE)
Rack and pinion assy Teeth damage Shearing of teeth
Gear box failure Improper lubrication
Bearing failure
overload
Air seal assy(Seal tube) Line chokage Ash
Gland packing failure Ageing
Main shaft and trunion shaft Trunion bolt looseness Improper fitting
Misalignment Support bearing failure
Locking cap looseness Sleeve and shaft clearance
Support grating Erosion and corrosion Ash erosion
Weld looseness Poor welding

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the cross verification. A patch test is oil analysis, which Measurement of vibration readings are done at horizontal,
enables to identify abnormal levels of contamination and vertical and axial directions, over the VOITH Chamber,
wear debris present in the working fluid. The term ‘4A’ just above the inside bearing of VOITH chamber. A typical
stands for Unit-4, A-side Fan. The schematic diagram of an case study, which was carried out during November,
ID fan is shown in Fig. 1. 2018-January, 2019, has been taken for consideration. The
time-domain data as well as spectra of vibration signal
3.1.1 Specification and equipment details have been captured and analyzed. The RMS value of
vibration and spike energy (gSE) are presented on Table 5.
Motor KW-1700, RPM-991, Motor NDE (Non Drive End) The vibration spectra are presented in Figs. 2 and 3.
Bearing: NU240ECM, Motor DE (Drive End) Bearing: After the inspection and analyzing the time-domain data
23044CC/C3W33. Driving end bearing of VOITH Cou- and vibration spectra, it is observed that
pling: NU 1040, Bearings inside VOITH Chamber:
1. The vibration spectra of VOITH chamber bearing show
7322 = Two nos., NU 230 = One no., Output bearing of
the peak at 387.7 Hz, which is a non-synchronous
VOITH Coupling: 7230 = Two nos. Fan DE & NDE
bearing frequency i.e. 38.15 9 RPM. The harmonics
Bearings: 22232EASMC3. Class: IV Machine (i.e. 300
of this frequency are also observed. Those indicate
KW and no rigid foundation).
there is impact in bearing.
Vibration velocity limit (as per ISO-2372/ISO-10816):
2. Spike energy (gSE) is 1.9 m/s2 at VOITH coupling
Normal: 7.1 mm/s, Marginal: Above 7.1 mm/s, Critical:
Non drive end side.
11.2 mm/s & Above
3. Little abnormal noise observed from the VOITH
Vibration gravitational spike energy (gSE) Limit ISO
coupling.
standards: Max. 1.0 m/s2 for a good bearing.
4. Metallic particles (of smaller sizes) are found during
oil analysis.
3.1.2 Machine diagnosis symptoms during operation
After analyzing the abnormal vibration spectrum, it is
The condition monitoring of VOITH coupling is done confirmed that there is defect in the internal bearings of
through vibration analysis. The vibration data are taken and VOITH coupling. As per the recommendation, the VOITH
analyzed using Emerson make- CSI-2140 Vibration Data coupling was replaced on 25th December 2018. After
Logger with accelerometer and AMS Suite Software. replacing the Voith coupling, following spectra (i.e. Figs. 4
and 5) were taken.
After corrective action i.e. replacing the VOITH cou-
pling, following things are observed
1. RMS value of vibration is reduced.
2. Vibration amplitude at non synchronous frequency (i.e.
387.7 Hz) decreased significantly from 0.5 to 0.1 mm/
sec.
3. Spike energy value reduced from 1.9 to 0.8 g.
4. No such abnormal noise observed from the VOITH
coupling.
5. In patch test for oil analysis, no particle was found
Fig. 1 Schematic diagram of an ID fan

Table 5 RMS of vibration (in mm/s) and spike energy, gSE’ (in m/s2) of VOITH Coupling
16th Nov. 2018 06th Dec. 2018 13th Dec. 2018 25th Dec. 2018 25th Dec. 2018 04th Jan. 2019

Voith DE H (gSE) 1.12 0.90 1.14 Coupling replaced 0.8 1.01

(gSE = 1.2) (gSE = 1.3) (gSE = 1.3) (gSE = 0.8) (gSE = 0.7)
V 1.48 1.58 1.18 0.9 1.38
A 2.73 2.93 2.10 2.0 1.94
Voith NDE H (gSE) 1.42 1.59 1.77 1.0 1.40
(gSE = 1.2) (gSE = 1.4) (gSE = 1.9) (gSE = 0.9) (gSE = 0.8)
V 1.85 1.95 1.37 1.6 1.49
A 1.91 1.97 1.89 2.2 2.30

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BID - ID FAN -4A

4A -G1H Shaft 01 Inboard Horizontal
0.7
Route Spectrum
I I I I I I I I I I I I I I I 13-Dec-18 15:26:50

0.6 OVERALL= 1.18 V-DG

387.51
RMS = 1.19
LOAD = 100.0
RPM = 619. (10.32 Hz)
0.5 20.53
>FAG 7322B
RMS Velocity in mm/Sec

I=BPFO -IB

0.4
16.68

0.3

1595.9
433.38

1983.4
0.2
177.27

774.98
10.39

106.91
109.64

204.42
180.04
201.82
171.14

0.1

0
0 600 1200 1800 2400
Frequency in Hz

Fig. 2 Vibration spectrum of VOITH Input (Horizontal direction)

BID - ID FAN -4A

4A -G1A Shaft 01 Inboard Axial
0.8
Route Spectrum
J J J J J J J J J J J J J J J 13-Dec-18 15:27:12
0.7 OVERALL= 1.77 V-DG
RMS = 1.88
LOAD = 100.0
76.18

0.6 RPM = 992. (16.53 Hz)

77.55

775.08

>FAG 7322B
RMS Velocity in mm/Sec

1983.6
J=BPFO -IB
0.5
106.01

1596.0

0.4
433.45
86.32
96.92
81.41

0.3
91.62

820.88
387.53

1208.5
20.28

0.2

0.1

0
0 600 1200 1800 2400
Frequency in Hz

Fig. 3 Vibration spectrum of VOITH Input (Axial direction)

3.2 Case study 2: Condition monitoring of FD fan Vibration velocity limit ISO standards
#7A Normal: 7.1 mm/s, Marginal: Above 7.1 mm/s, Critical:
11.2 mm/s & Above
FD Fan health monitoring is done by means of vibration Vibration gravitational spike energy (gSE) Limit ISO
analysis. Also oil analysis or patch test is done for the cross standards: Max. 1.0 m/s2 for a good bearing.
verification. The term ‘7A’ stands for Unit-7, A-side Fan.
The schematic diagram of a FD fan set up is shown in 3.2.2 Machine diagnosis symptom during operation
Fig. 6.
The condition monitoring of FD Fan is done through
3.2.1 Specification and equipment details vibration analysis. The vibration data were taken and
analyzed. Measurements of vibrations are done in hori-
Motor: KW-400, RPM-992, Motor Non Drive end (NDE) zontal, vertical and axial directions of both DE and NDE of
bearing:6326; Motor Drive end(DE) bearing: NU 228EC3; the Fan as well as of the Motor. A typical case study, which
Fan Drive end(DE) bearing:6232MC3, Fan Non Drive was done during June–September, 2018, has been taken for
end(NDE) bearing:6238 considerations. The time-domain data as well as spectra of

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BID - ID FAN -4A

4A -G1H Shaft 01 Inboard Horizontal
0.5
Route Spectrum
02-Jan-19 11:13:09

OVERALL= 1.01 V-DG

RMS = 1.01
0.4 LOAD = 100.0
RPM = 992. (16.53 Hz)

1730.0
RMS Velocity in mm/Sec

81.05

0.3
22.23
11.21

2117.7
16.73

99.02 109.38

0.2
66.62

215.73
161.06

387.77
170.64

1342.2
129.91

0.1

0
0 400 800 1200 1600 2000 2400
Freque n cy in H z

Fig. 4 Vibration spectrum of VOITH Input, (Horizontal direction)

BID - ID FAN -4A

4A -G2A Shaft 01 Outboard Axial
1.2
Route Spectrum
02-Jan-19 11:15:09

OVERALL= 1.77 V-DG

34.04

RMS = 2.01
LOAD = 100.0
0.9 RPM = 668. (11.13 Hz)
RMS Velocity in mm/Sec

0.6
122.82
191.63
202.78
178.05
79.44
127.15
172.25
162.34
197.45
50.15

208.87

775.32
63.72

0.3
45.73

0
Freq: 36.56
0 400 800 1200 1600 2000 2400 Ordr: 3.284
Frequency in Hz Spec: .412

Fig. 5 Vibration spectrum of VOITH input (Axial direction)

Fig. 6 Schematic diagram of a

FD fan

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Table 6 RMS value of vibration (in mm/s)

Position 12th June 2018 26th June 2018 24th July 2018 04th Aug. 2018 18th Aug. 2018 10th Sept. 2018

Motor NDE H 0.80 0.80 0.50 0.50 0.50 0.60

V 0.60 0.60 0.20 0.40 0.30 0.70
A 0.60 0.70 0.20 0.30 0.40 0.30
Motor DE H 0.70 0.70 0.50 0.50 0.50 0.60
V 0.60 0.50 0.20 0.30 0.20 0.30
A 0.50 0.60 0.30 0.40 0.30 0.40
Fan DE H 1.00 1.20 1.60 1.60 1.30 2.40
V 1.40 1.30 0.90 1.40 1.40 2.10
A 1.10 1.20 1.10 1.10 0.90 1.30
Fan NDE H 1.20 1.00 1.30 1.40 1.30 1.50
V 1.20 1.10 1.00 1.00 1.20 1.40
A 0.90 0.80 1.00 1.20 1.30 1.40
26th Sept. 2018 05th Oct. 2018 10th Oct. 2018 01st Nov. 2018 12th Nov. 2018 19th Nov. 2018

Motor NDE H 1.60 1.70 1.70 Fan bearing replaced 0.55 0.68
V 0.40 0.60 0.50 0.50 0.65
A 0.60 0.70 0.70 0.46 0.40
Motor DE H 0.40 0.50 0.60 0.60 0.63
V 0.80 0.90 0.40 0.49 0.21
A 0.30 0.40 0.60 0.40 0.38
Fan DE H 2.50 2.60 2.70 0.90 0.81
V 2.10 2.20 3.30 0.60 0.44
A 2.50 2.60 2.00 0.46 0.20
Fan NDE H 1.70 1.80 2.20 0.90 1.07
V 1.50 1.60 2.80 0.30 0.34
A 1.80 1.90 1.90 0.46 0.50

vibration signal have been captured and analyzed. These 1. The RMS value of vibration was reduced.
are described as follows. The RMS values of vibration are 2. Vibration amplitude at 2 9 BPFO was drastically
presented in Table 6. The vibration spectra are presented in reduced.
Figs. 7, 8, 9 and 10. 3. Vibration amplitude at non-synchronous frequency was
After analyzing the time-domain data and vibration also reduced significantly.
spectra, the following are the observations: 4. There were no metal particles have been detected
during oil analysis.
1. The vibration spectra depict a peak at 170 Hz, which
5. No abnormal noise is felt.
was dominant and is 2 9 BPFO (Fan DE bearing).
Also, the peaks at BPFO and its harmonics were
observed. 3.3 Case study: 3: Condition monitoring of air
2. Peaks at non-synchronous frequency, i.e. 936 Hz were preheater, # 5B
observed.
3. Abnormal noise observed at fan bearings. Air pre-heater (APH) absorbs waste heat from flue gas and
4. Metal particles (of small size) were found during oil transfers this heat to the incoming cold air by means of
analysis. continuously rotating heat transfer element of specially
formed metal plates. Thousands of these high efficiency
As per the recommendation, both the bearings of the Fan
elements are spaced and compactly arranged within sector-
are e replaced on 01st November 2018. After replacing the
shaped compartments of radially divided cylindrical shell,
bearings, following spectra (i. e Figs. 11, 12, 13 and 14)
called the rotor. The housing surrounding the rotor is
were taken.
provided with duct connections at both ends, and is ade-
After replacement of bearing, the follwing points are
quately sealed by radial, axial and circumferential sealing
observed:

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 Int J Syst Assur Eng Manag

Fig. 7 Vibration spectrum of fan DE, (Horizontal direction)

Equipment1-ID1
1.4
170.30

Analyze Spectrum
26-Sep-18 11:16:48

1.2 OVERALL= 2.07 V-DG

RMS = 2.06
LOAD = 100.0
RPM = 992. (16.53 Hz)
1.0
936.63
RMS Velocity in mm/Sec

0.8
931.08

0.6
182.80

0.4
766.29
16.62

851.50
440.59

702.43

783.50

1062.0

1277.2
1.56

1106.9
30.88

0.2
85.11

0
Freq: 85.00
0 400 800 1200 1600 Ordr: 5.141
Frequency in Hz Spec: .04399

Fig. 8 Vibration spectrum of fan DE, (Axial direction)

members—forming an air passage through one half of the 3.3.1 Specification and equipment details
preheater and a flue gas passage though the other. As the
rotor slowly revolves, the mass of elements passes alter- Heating element
nately through the gas and air passages. Heat is absorbed
(a) Hot end layer depth: 1000 mm element configuration
by the element surface passing through the hot gas stream;
0.5 mm thick DU3(Double Undulated) COR-TEN
then, these same surface are carried through the air stream,
Steel
where they release the stored up heat, thus increasing the
(b) Hot intermediate layer depth: 880 mm element
temperature of the incoming cold air. The Air Pre-heater is
configuration 0.5 mm thick DU3 COR-TEN Steel
supported by a support bearing at the bottom and a guide
(c) Cold end layer depth: 305 mm element configuration
bearing on the top. The schematic diagram of an APH set
1.0 mm thick NF6(Notched Flat)corrosion resistance
up is shown in Fig. 15.
steel

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Int J Syst Assur Eng Manag

Equipment1-ID1
1.4
Analyze Spectrum
26-Sep-18 11:16:09

1.2 OVERALL= 1.86 V-DG

RMS = 1.85
LOAD = 100.0
2 X BPFO RPM = 992. (16.53 Hz)
1.0

170.26
RMS Velocity in mm/Sec

1532.2
1518.7
0.8

0.6

799.36
1 X BPFO Non-synch peak
255.37

0.4

783.27

1338.0
936.35
816.52

1276.8

1362.0
359.43

440.46

1566.5
182.73
85.11

0.2

0
Freq: 85.00
0 400 800 1200 1600 Ordr: 5.141
Frequency in Hz Spec: .143

Fig. 9 Vibration spectrum of fan NDE, (Horizontal direction)

Equipment1-ID1
1.4
Analyze Spectrum
26-Sep-18 11:16:18

1.2 OVERALL= 1.27 V-DG

RMS = 1.27
LOAD = 100.0
RPM = 60. (1.00 Hz)
1.0
RMS Velocity in mm/Sec

0.8
170.29

0.6
3.312.73

766.20

0.4
799.43
510.80

936.67
596.03
16.63

255.42

931.12
851.69
35.84

897.76
816.50

0.2
85.13

0
Freq: 85.00
0 400 800 1200 1600 Ordr: 85.00
Frequency in Hz Spec: .01773

Fig. 10 Vibration spectrum of fan NDE, (Axial direction)

Rotor seals Rotor support bearing: Spherical roller thrust bearing

Radial Seal, Rotor Post Seal, Axial Seal & By-Pass 90394/500
Seal(The forms are of seal leaves on both hot and cold end) Rotor guide bearing: Two-way spherical roller bearing
Rotor drive type 3153160
Main motor: Type Y160M-6B3 7.5KW, 970 rpm Oil capacity: Support bearing housing about 105 L,
(415VAC, 50 Hz), Auxiliary Air Motor: Type Z2-62 Guide bearing housing about 25 L, Oil grade: Servo mesh
Double output shafts 7.5KW 1000 rpm, 415VAC, 50 Hz., SP 680
Speed Reducer: SGW90A, Main Speed Ratio: 96.04, Output RPM of APH: 1.5 RPM
Auxiliary Speed Ratio: 0 * 99.01, Output R.P.M. of Main Bearing outer race diameter: 870 mm
motor: 10.1 rpm, auxiliary motor: 0 * 10.1 rmp, output Problem description: In running condition, the Air Pre-
torque: 7000 N.m heater Unit was tripped suddenly during August-2018.

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BFD - FD FAN 7A
7A -F1H Fan Inboard Horizontal
1.4
Route Spectrum
26-Nov-18 12:29:03

1.2 OVERALL= .7221 V-DG

RMS = .7313
LOAD = 100.0
RPM = 992. (16.53 Hz)
1.0
RMS Velocity in mm/Sec

0.8
16.64

0.6

0.4
174.21 182.88
76.12
100.12

301.89

383.56

0.2
180.33
192.97
197.18
200.80

303.73
62.99
10.47
30.46

0
0 400 800 1200 1600
Frequency in Hz

Fig. 11 Vibration spectrum of fan DE, (Horizontal direction)

BFD - FD FAN 7A
7A -F1A Fan Inboard Axial
1.4
Route Spectrum
26-Nov-18 12:29:29

1.2 OVERALL= .3212 V-DG

RMS = .3103
LOAD = 100.0
RPM = 992. (16.53 Hz)
1.0
RMS Velocity in mm/Sec

0.8

0.6

0.4
963.84
182.80
24.8616.65

0.2
169.20

993.01
942.72
76.06

175.82

945.42
11.28
62.05
31.04
32.73
63.52

0
0 400 800 1200 1600
Frequency in Hz

Fig. 12 Vibration spectrum of fan DE, (Axial direction)

3.3.2 Machine condition report After dismantling we found visually that the oil quality
is in poor condition, which was completely black & thick
On inspection, it is found that the bearing has failed with with lot of sludge deposition inside the chamber, although
roller & cage which have completely displaced out of the entire oil had been changed during the annual over-
position. Outer race was completely broken. Oil was hauling just 6 months before. For oil replacement this
completely black in color and lot of sludge deposition was degraded oil was required to be completely drained off and
found in chamber of bearing housing. Also minor dents the oil chamber was needed to be cleaned with low vis-
have been found on the surface of Roller and lower race. cosity flushing oil. However, complete draining was not
No indication of high current & noise observed from the possible and still a good amount of sludge was remaining
APH prior to failure. The breakdown has happened inside the oil chamber which could not be removed by
abruptly. gravity because of unusual position of drain point at end of

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Int J Syst Assur Eng Manag

BFD - FD FAN 7A
7A -F2H Fan Outboard Horizontal
1.4
Route Spectrum
26-Nov-18 12:29:40

1.2 OVERALL= 1.03 V-DG

RMS = 1.01
LOAD = 100.0
RPM = 992. (16.53 Hz)
1.0
RMS Velocity in mm/Sec

16.64

0.8 182.80

0.6

0.4
76.10
30.61
52.57

193.42
100.09

383.46

0.2
178.89
230.06
176.64
200.11
10.68
60.47
2.62

0
0 400 800 1200 1600
Frequency in Hz

Fig. 13 Vibration spectrum of fan NDE, (Horizontal direction)

BFD - FD FAN 7A
7A -F2A Fan Outboard Axial
1.4
Route Spectrum
26-Nov-18 12:30:00

1.2 OVERALL= .2878 V-DG

RMS = .2727
LOAD = 100.0
RPM = 992. (16.53 Hz)
1.0
RMS Velocity in mm/Sec

0.8

0.6

0.4
182.80
30.63

0.2
16.65

168.52

963.90
171.52
173.61

707.07
383.45
76.08

175.20

301.73
177.21
32.83
3.45

0
0 400 800 1200 1600
Frequency in Hz

Fig. 14 Vibration spectrum of fan DE, (Axial direction)

housing instead of at centre position and also at a height of With the prolonged running of bearing with high con-
10 mm from bottom of the housing. This resulted into the centration of carbonized sludge led to erosion of the
deposition and accumulation of sludge during the 6 years weakest part of bearing assembly i.e. cage and race ways,
of operation. resulting to failure of cage, inner race and outer race
It is worthwhile to note that the sludge is mainly the causing bearing failure. The gap between upper race of
oxidized form of the oil settled at the bottom and was not bearing and adopter plate should be zero during loading
able to drain out completely. Topping up of new oil in the condition. This is shown in Fig. 16. The damaged bearing
system during every overhauling was leading to further (inner race) is shown in Fig. 17.
carbonization of new oil too, which resulted into increase From the analysis the reasons for the damage may be
in oil temperature further and oil pump found running enumerated as follows
intermittently till temperature subside below the alarm • Poor oil quality: Carbonized Sludge in the oil that can
value. lead to damage of bearing resulting to sudden stoppage
of APH due to jamming.

123
 Int J Syst Assur Eng Manag

was done with respect to both support and guide

bearing to make their axes are collinear.
4. Oil sump and the bearing housing were filled up with
fresh oil.
5. New Gland rope was put just above the support bearing
housing (between cover plate & rotor) to prevent any
dust ingress.
6. The bearing base is perfectly leveled and its own axis is
perfectly centered with axis of rotor. So that, the
bearing and rotor are co-axial.

3.3.3 Future recommendation and horizontal

implementation

Fig. 15 Schematic diagram of an air preheater During annual overhauling, both support and guide
bearing housings along with the oil circulating system
• Fatigue failure: Wear out of outer race and inner race are to be cleaned with low viscosity flushing oil. Sludge
may damage the bearing due to prolonged running with deposit has to be completely removed by a
higher load on it. portable vacuum pump. The inaccessible oil drain points
• Ingress of foreign particles from the APH rotor to of other units of the Power station have to be extended
bearing housing. outside with installation of an oil gauge for easy oil
The following corrective and preventive actions were filling and level monitoring. Both Support and guide
taken to make it normal. bearings are to be inspected in every annual overhauling
and are to be replaced with new one in case of any
1. Contaminated oil was drained completely. Housing defect. Alignment of rotor shaft to be done along with
with the oil circulating system flushed with a low guide bearing and support bearing in every overhauling
viscosity flushing oil. Few quantity of sludge which and proper sealing on the rotor shaft to prevent ash dust
could not be drained was removed through a ingress to the bearing housing is to be ensured. Patch test
portable vacuum pump. along with microscopic examination is to be done every
2. The oil drain point was extended outside through month to find out oil quality degradation/contamination
proper tubing and a level gauge was installed. due to carbonization and/or metallic particles. In case of
3. Support bearing was replaced with a new one with change in oil colour and contamination, oil has to be
proper leveling and gap setting. Centering of the rotor

Fig. 16 On load condition,

there is gap between bearing
upper race & adapter plate,
which should be zero

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Int J Syst Assur Eng Manag

Fig. 17 Cracked bearing inner

race a with one roller broken
b with broken cage

drained from the oil sump & the bearing housing and Kim H, Na MG, Heo G (2014) Application of monitoring, diagnosis,
replaced with fresh oil proactively. and prognosis in thermal performance analysis for nuclear power
plants. Nucl Eng Technol 46(6):737–752
Mohanty AR (2014) Machinery condition monitoring: principles and
practices. CRC Press, London
4 Summary Mpoweruk. https://www.mpoweruk.com/fossil_fuels.htm. Accessed
on 20 May 2019
Nag PK (2008) Power plant engineering. Tata Mc Hill Publishing Co.
These examples of equipment diagnostics indicate the Ltd, New Delhi
vibration analysis is a very sensitive and strong technique Pancholi N, Bhatt MG (2016) Multi criteria FMECA based decision-
to trace the developments of the defects. Condition moni- making for aluminium wire process rolling mill through
toring of plant and machineries not only decrease the COPRAS-G. J Qual Reliab Eng. Article ID 8421916
Power tech. https://www.power-technology.com/features/feature-the-
downtime but also improve the efficiency and reliability of top-10-biggest-thermal-power-plants-in-india/. Accessed on 20
the system. It decreases the probability of sudden failure May 2019
and accident. FMECA is an important tool to implement Srivastava NK, Mondal S (2015) Predictive maintenance using
the condition monitoring technique. Equipping auxiliary modified FMECA Method. Int J Prod Qual Manag
16(3):267–280
machinery of power plants and suitable condition moni- Williams JH, Davies A, Drake PR (1994) Condition-based Mainte-
toring, ensure reliable, safe resource-saving maintenance of nance and Machine Diagnostics. Springer, New York
power plants. Würtenberger J, Kloberdanz H, Lotz J, Von Ahsen A (2014)
Application of the FMEA during the product development
process—dependencies between level of information and quality
of Result. International design conference, Dubrovnik, Croatia,
May 19–22, 2014
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