MACHINERY DIAGNOSTIC SERVICES REPORT

CUSTOMER NAME : M/S. GREENKO GROUP

SITE : BUDHIL, HIMACHAL PRADESH
DATE OF VISIT : 23.04.2023 – 27.04.2023
MACHINE : UNIT#1 HYDRO TURBINE

CUSTOMER CONTACT COMPANY NAME

M/S. Greenko Group M/S Aswartha Condition Monitoring Engineers
Hyderabad Plot No-830, Bhagat Singh Nagar,
Kukatpally, Hyderabad – 500 085
Telangana.
ABOUT COMPANY: SERVICES OFFERED BY US:
At ACME, the focus is on Optimum Satisfaction of our Customers 1. Vibration Analysis Services
through World-Class Services in Condition Monitoring Services
2. In-situ Dynamic Balancing
meeting an international quality standard relentlessly.
3. Laser Alignment
Our team commitment & strength in solving several critical
machinery issues in improving the Reliability had made us the most 4. Infrared Thermography
preferred and leading organization in the field of Condition 5. Lube Oil Analysis
Monitoring Integrated Reliability Maintenance (IRM). Our
dedication to work has set Industry benchmarks in effectively 6. Ferrography
responding and deploying the analyst during emergency and 7. Ultrasonic Services
otherwise, in no time under 24*7 Policy of the organization. We
have proven time and again in rendering sophisticated cutting- 8. Non-Destructive Testing
edge technology, professional ethics, effectively and efficiently 9. Acoustic Analysis
honoring the job which has garnered us some of the most
10. Motor current signature analysis
cherished and reliable relationship with our esteemed clients
across the GLOBE. 11. Turbo Machinery Trouble Shooting

DETAILS OF SERVICE MODEL PROPOSED BY US 12. Root Cause Failure Analysis

▪ Service call, per day basis with our Experts and Equipment. 13. Finite Element Analysis
▪ Service call, at a fixed annual rate with our Expert and 14. Model Analysis & ODS
Equipment.
▪ Annual Maintenance Contracts with 24 x 7 concepts with 15. Web-Based Monitoring
our Expert and Equipment. 16. Energy Auditing
▪ Supply of Expert on call if Customer is having
17. Training
appropriate equipment.
▪ Supply of skilled Expert for 24x7 AMC services for above said 18. Asset Management
services if the customer is having appropriate Equipment. 19. Positive Material Identification (PMI)

TABLE OF CONTENTS

1. INTRODUCTION AND PROJECT SCOPE : 01

2. VIBRATION STANDARDS : 02
3. TURBINE DETAILS, OBSERVATIONS & ANALYSIS : 03 - 04
4. SUGGESTED ACTION PLANS : 04
5. FFT SPECTRUM PLOTS : 05 – 07
6. ORBIT PLOTS : 08 – 09
7. BALANCING WEIGHT POSITIONS FROM KEY PHASHER : 09 – 10

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INTRODUCTION
ACME's Machinery Diagnostic Services team was contacted by M/s. Greenko Global, Hyderabad, India,
to perform vibration analysis and dynamic balancing on the UNIT#1 Hydro Turbine installed at the Budhil
Hydro Plant in Himachal Pradesh, India.

M/s. ACME's representative visited the site on April 23 to 27, 2023. During the current visit, "Shaft
Vibration data" in displacement (PK-PK in microns) was collected from the Online Monitoring Panel using
an NADA 16-Channel Analyzer.

The scope of the job is defined by the following objectives:

1. Collect steady state & transient data.

2. Analyze the vibration data and assess the machine’s condition.
3. Performing in-situ dynamic balancing on generator rotor, if required.
4. Provide recommendations on further action as and if necessary.

INSTRUMENT USED FOR ANALYSIS

The following equipment were used to carry out the Vibration analysis:

ON-LINE SHAFT VIBRATION

Hardware : NADA portable data acquisition & machinery diagnostics system for measurement
of “Shaft Vibration” from online Vibration Monitor.

Software : Portable TSI2

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ISO 7919 – 5 VIBRATION STANDARDS

Recommended evaluation ranges for the vibration peak-to-peak displacement in the direction of
measurement, Sp-p, of hydraulic machines or machine sets, valid for turbine operation within the
contractually permissible steady - state flow range

REPORT PREPARED BY: REPORT VERIFIED BY:

Mr. Sasi Vardhan Reddy Mr. K. V Srinivasa Rao
Vibration Analyst – ISO Category II Sr. Vibration Analyst – ISO Category III
General Manager – Technical Services

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TURBINE DETAILS
Machine : UNIT#1 HYDRO TURBINE
Turbine RPM : 500 RPM
Critical Speed : 845 RPM

The current vibration analysis was performed in a steady state with various loads. The following
observations have been made:

OBSERVATION & ANALYSIS:

▪ The vibration values of UNIT#1 were collected from Upper, Lower, and Turbine guide
bearings. Maximum vibration 292 / 206 microns at No load condition and 237 / 144 microns
from X and Y probes at turbine guide bearing was recorded at 35MW load condition.

▪ FFT Spectrum shows 1X RPM vibration component as dominant peak, which indicates
unbalance in the turbine rotor.

▪ The phase analysis shows that the turbine guide bearing horizontal and vertical bearing
vertical directions are 79 degrees out of phase, indicating an unbalance problem.

▪ To compensate for the unbalance force added mass of 5.7 Kg at Upper guide bearing and 10.9
Kg at lower guide bearing, vibration levels reduced from 237 / 144 Microns to 118 / 50
Microns at turbine guide bearing at 35MW load condition.

▪ Multiple harmonics of the running frequency of the generator shaft were observed at the
lower guide and upper guide bearings, indicating a bearing looseness and surface glitches.

▪ The FFT spectrum shows a prominent 1X RPM vibration component as well as multiple
harmonics at the turbine guide bearing.

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▪ Before and After balancing, the vibration values at 38 MW load are shown below.

▪ We attempted to reduce the turbine guide bearing's 1X amplitude by balancing it further, but
when we attempted to reduce the turbine guide bearing vibrations further, the UGB and LGB
vibrations increased at the same time.

SUGGESTED ACTION PLAN:

▪ Multiple harmonics of the generator shaft running frequency were observed at the lower and
upper guide bearings, which indicates minor bearing looseness / clearance and surface
glitches. Hence it is recommended to inspect the lower and upper guide bearings fitment &
clearances, and shaft surface probe viewing area shall be thoroughly examined during major
shut down opportunity.

▪ The current turbine runner has been running for the last four seasons, so it is advised that it
be inspected for wear and replaced if necessary.

▪ As per client earlier observations, if Unit#1 is overloaded beyond 36MW, the vibration trend
begins to increase and does not retaining back as it was at 36MW or less. This is due to
thermal growth. As the load increases, the air gap between the generator rotor and stator
expands owing to thermal expansion. During my visit, we went on several trails to do balance
the rotor and recorded vibration data at various loads, but the vibration levels remained
constant.

▪ At the present shaft relative vibration levels within the satisfactory zone as per ISO limits.

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FFT SPECTRUMS
Upper Guide Bearing -X:

Upper Guide Bearing -Y:

5
Lower Guide Bearing -X:

Lower Guide Bearing -Y:

6
Turbine Guide Bearing -X:

Turbine Guide Bearing -Y:

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ORBITS

Upper Guide Bearing:

Lower Guide Bearing:

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Turbine Guide Bearing:

Balancing Weight Positions from Key Phaser:

Upper Guide Bearing:

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Lower Guide Bearing:

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