Search results for: in-pile instrumentation
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 47

Search results for: in-pile instrumentation

17 The Use of the Flat Field Panel for the On-Ground Calibration of Metis Coronagraph on Board of Solar Orbiter

Authors: C. Casini, V. Da Deppo, P. Zuppella, P. Chioetto, A. Slemer, F. Frassetto, M. Romoli, F. Landini, M. Pancrazzi, V. Andretta, E. Antonucci, A. Bemporad, M. Casti, Y. De Leo, M. Fabi, S. Fineschi, F. Frassati, C. Grimani, G. Jerse, P. Heinzel, K. Heerlein, A. Liberatore, E. Magli, G. Naletto, G. Nicolini, M.G. Pelizzo, P. Romano, C. Sasso, D. Spadaro, M. Stangalini, T. Straus, R. Susino, L. Teriaca, M. Uslenghi, A. Volpicelli

Abstract:

Solar Orbiter, launched on February 9th 2020, is an ESA/NASA mission conceived to study the Sun. The payload is composed of 10 instruments, among which there is the Metis coronagraph. A coronagraph aims at taking images of the solar corona: the occulter element simulates a total solar eclipse. This work presents some of the results obtained in the visible light band (580-640 nm) using a flat field panel source. The flat field panel gives a uniform illumination; consequently, it has been used during the on-ground calibration for several purposes: evaluating the response of each pixel of the detector (linearity); and characterizing the Field of View of the coronagraph. As a conclusion, a major result is the verification that the requirement for the Field of View (FoV) of Metis is fulfilled. Some investigations are in progress in order to verify that the performance measured on-ground did not change after launch.

Keywords: Space instrumentation, Metis, solar coronagraph, flat field.

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16 Designing a Motivated Tangible Multimedia System for Preschoolers

Authors: Kien Tsong Chau, Zarina Samsudin, Wan Ahmad Jaafar Wan Yahaya

Abstract:

The paper examined the capability of a prototype of a tangible multimedia system that was augmented with tangible objects in motivating young preschoolers in learning. Preschoolers’ learning behaviour is highly captivated and motivated by external physical stimuli. Hence, conventional multimedia which solely dependent on digital visual and auditory formats for knowledge delivery could potentially place them in inappropriate state of circumstances that are frustrating, boring, or worse, impede overall learning motivations. This paper begins by discussion with the objectives of the research, followed by research questions, hypotheses, ARCS model of motivation adopted in the process of macro-design, and the research instrumentation, Persuasive Multimedia Motivational Scale was deployed for measuring the level of motivation of subjects towards the experimental tangible multimedia. At the close, a succinct description of the findings of a relevant research is provided. In the research, a total of 248 preschoolers recruited from seven Malaysian kindergartens were examined. Analyses revealed that the tangible multimedia system improved preschoolers’ learning motivation significantly more than conventional multimedia. Overall, the findings led to the conclusion that the tangible multimedia system is a motivation conducive multimedia for preschoolers.

Keywords: Tangible multimedia, preschooler, motivation, multimedia.

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15 Forward Speed and Draught Requirement of a Semi-Automatic Cassava Planter under Different Wheel Usage

Authors: M. O. Ale, S. I. Manuwa, O. J. Olukunle, T. Ewetumo

Abstract:

Five varying speeds of 1.5, 1.8, 2.1, 2.3 and 2.6 km/h were used at a constant soil depth of 100 mm to determine the effects of forward speed on the draught requirement of a semi-automatic cassava planter under pneumatic wheel and rigid wheel usage on a well-prepared sandy clay loam soil. The soil draught was electronically measured using an on-the-go soil draught measuring instrumentation system developed for the purpose of this research. The results showed an exponential relationship between forward speed and draught in which draught ranging between 24.91 and 744.44 N increased with an increase in forward speed in the rigid wheel experiment. This is contrary to the polynomial relationship observed in the pneumatic wheel experiment in which the draught varied between 96.09 and 343.53 N. It was observed in the experiments that the optimum speed of 1.5 km/h had the least values of draught in both the pneumatic wheel and rigid wheel experiments with higher values in the pneumatic experiment. It was generally noted that the rigid wheel planter with the less value of draught requires less energy requirement for operation. It is therefore concluded that operating the semi-automatic cassava planter with rigid wheels will be more economical for cassava farmers than operating the planter with pneumatic wheels.

Keywords: Cassava planter, planting, forward speed, draught, wheel type.

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14 Application of Computer Aided Engineering Tools in Performance Prediction and Fault Detection of Mechanical Equipment of Mining Process Line

Authors: K. Jahani, J. Razavi

Abstract:

Nowadays, to decrease the number of downtimes in the industries such as metal mining, petroleum and chemical industries, predictive maintenance is crucial. In order to have efficient predictive maintenance, knowing the performance of critical equipment of production line such as pumps and hydro-cyclones under variable operating parameters, selecting best indicators of this equipment health situations, best locations for instrumentation, and also measuring of these indicators are very important. In this paper, computer aided engineering (CAE) tools are implemented to study some important elements of copper process line, namely slurry pumps and cyclone to predict the performance of these components under different working conditions. These modeling and simulations can be used in predicting, for example, the damage tolerance of the main shaft of the slurry pump or wear rate and location of cyclone wall or pump case and impeller. Also, the simulations can suggest best-measuring parameters, measuring intervals, and their locations.

Keywords: Computer aided engineering, predictive maintenance, fault detection, mining process line, slurry pump, hydrocyclone.

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13 Settlement Analysis of Axially Loaded Bored Piles: A Case History

Authors: M. Mert, M. T. Ozkan

Abstract:

Pile load tests should be applied to check the bearing capacity calculations and to determine the settlement of the pile corresponding to test load. Strain gauges can be installed into pile in order to determine the shaft resistance of the piles for every soil layer respectively. Detailed results can be obtained by means of strain gauges placed at certain levels into test piles. In the scope of this study, pile load test data obtained from two different projects are examined.  Instrumented static pile load tests were applied on totally 7 test bored piles of different diameters (80 cm, 150 cm, and 200 cm) and different lengths (between 30-76 m) in two different project site. Settlement analysis of test piles is done by using some of load transfer methods and finite element method. Plaxis 3D which is a three-dimensional finite element program is also used for settlement analysis of the test piles. In this study, firstly bearing capacity of test piles are determined and compared with strain gauge data which is required for settlement analysis. Then, settlement values of the test piles are estimated by using load transfer methods developed in recent years and finite element method. The aim of this study is to show similarities and differences between the results obtained from settlement analysis methods and instrumented pile load tests.

Keywords: Failure, finite element method, monitoring and instrumentation, pile, settlement.

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12 Fiber Braggs Grating Sensor Based Instrumentation to Evaluate Postural Balance and Stability on an Unstable Platform

Authors: Chethana K., Guru Prasad A. S., Vikranth H. N., Varun H., Omkar S. N., Asokan S.

Abstract:

This paper describes a novel application of Fiber Braggs Grating (FBG) sensors in the assessment of human postural stability and balance on an unstable platform. In this work, FBG sensor Stability Analyzing Device (FBGSAD) is developed for measurement of plantar strain to assess the postural stability of subjects on unstable platforms during different stances in eyes open and eyes closed conditions on a rocker board. The studies are validated by comparing the Centre of Gravity (CG) variations measured on the lumbar vertebra of subjects using a commercial accelerometer. The results obtained from the developed FBGSAD depict qualitative similarities with the data recorded by commercial accelerometer. The advantage of the FBGSAD is that it measures simultaneously plantar strain distribution and postural stability of the subject along with its inherent benefits like non-requirement of energizing voltage to the sensor, electromagnetic immunity and simple design which suits its applicability in biomechanical applications. The developed FBGSAD can serve as a tool/yardstick to mitigate space motion sickness, identify individuals who are susceptible to falls and to qualify subjects for balance and stability, which are important factors in the selection of certain unique professionals such as aircraft pilots, astronauts, cosmonauts etc.

Keywords: Biomechanics, Fiber Bragg Gratings, Plantar Strain Measurement, Postural Stability Analysis.

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11 Unattended Crowdsensing Method to Monitor the Quality Condition of Dirt Roads

Authors: Matías Micheletto, Rodrigo Santos, Sergio F. Ochoa

Abstract:

In developing countries, most roads in rural areas are dirt road. They require frequent maintenance since they are affected by erosive events, such as rain or wind, and the transit of heavy-weight trucks and machinery. Early detection of damages on the road condition is a key aspect, since it allows to reduce the maintenance time and cost, and also the limitations for other vehicles to travel through. Most proposals that help address this problem require the explicit participation of drivers, a permanent internet connection, or important instrumentation in vehicles or roads. These constraints limit the suitability of these proposals when applied into developing regions, like Latin America. This paper proposes an alternative method, based on unattended crowdsensing, to determine the quality of dirt roads in rural areas. This method involves the use of a mobile application that complements the road condition surveys carried out by organizations in charge of the road network maintenance, giving them early warnings about road areas that could be requiring maintenance. Drivers can also take advantage of the early warnings while they move through these roads. The method was evaluated using information from a public dataset. Although they are preliminary, the results indicate the proposal is potentially suitable to provide awareness about dirt roads condition to drivers, transportation authority and road maintenance companies.

Keywords: Dirt roads automatic quality assessment, collaborative system, unattended crowdsensing method, roads quality awareness provision.

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10 Backcalculation of HMA Stiffness Based On Finite Element Model

Authors: Md Rashadul Islam, Umme Amina Mannan, Rafiqul A. Tarefder

Abstract:

Stiffness of Hot Mix Asphalt (HMA) in flexible pavement is largely dependent of temperature, mode of testing and age of pavement. Accurate measurement of HMA stiffness is thus quite challenging. This study determines HMA stiffness based on Finite Element Model (FEM) and validates the results using field data. As a first step, stiffnesses of different layers of a pavement section on Interstate 40 (I-40) in New Mexico were determined by Falling Weight Deflectometer (FWD) test. Pavement temperature was not measured at that time due to lack of temperature probe. Secondly, a FE model is developed in ABAQUS. Stiffness of the base, subbase and subgrade were taken from the FWD test output obtained from the first step. As HMA stiffness largely varies with temperature it was assigned trial and error approach. Thirdly, horizontal strain and vertical stress at the bottom of the HMA and temperature at different depths of the pavement were measured with installed sensors on the whole day on December 25th, 2012. Fourthly, outputs of FEM were correlated with measured stress-strain responses. After a number of trials a relationship was developed between the trial stiffness of HMA and measured mid-depth HMA temperature. At last, the obtained relationship between stiffness and temperature is verified by further FWD test when pavement temperature was recorded. A promising agreement between them is observed. Therefore, conclusion can be drawn that linear elastic FEM can accurately predict the stiffness and the structural response of flexible pavement.

Keywords: Asphalt pavement, falling weight deflectometer test, field instrumentation, finite element model, horizontal strain, temperature probes.

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9 Design and Development of Optical Sensor Based Ground Reaction Force Measurement Platform for GAIT and Geriatric Studies

Authors: K. Chethana, A. S. Guru Prasad, S. N. Omkar, B. Vadiraj, S. Asokan

Abstract:

This paper describes an ab-initio design, development and calibration results of an Optical Sensor Ground Reaction Force Measurement Platform (OSGRFP) for gait and geriatric studies. The developed system employs an array of FBG sensors to measure the respective ground reaction forces from all three axes (X, Y and Z), which are perpendicular to each other. The novelty of this work is two folded. One is in its uniqueness to resolve the tri axial resultant forces during the stance in to the respective pure axis loads and the other is the applicability of inherently advantageous FBG sensors which are most suitable for biomechanical instrumentation. To validate the response of the FBG sensors installed in OSGRFP and to measure the cross sensitivity of the force applied in other directions, load sensors with indicators are used. Further in this work, relevant mathematical formulations are presented for extracting respective ground reaction forces from wavelength shifts/strain of FBG sensors on the OSGRFP. The result of this device has implications in understanding the foot function, identifying issues in gait cycle and measuring discrepancies between left and right foot. The device also provides a method to quantify and compare relative postural stability of different subjects under test, which has implications in post-surgical rehabilitation, geriatrics and optimizing training protocols for sports personnel.

Keywords: Balance, stability, Gait analysis, FBG applications, optical sensor ground reaction force platform.

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8 Wireless Sensor Networks for Swiftlet Farms Monitoring

Authors: Al-Khalid Othman, Wan A. Wan Zainal Abidin, Kee M. Lee, Hushairi Zen, Tengku. M. A. Zulcaffle, Kuryati Kipli

Abstract:

This paper provides an in-depth study of Wireless Sensor Network (WSN) application to monitor and control the swiftlet habitat. A set of system design is designed and developed that includes the hardware design of the nodes, Graphical User Interface (GUI) software, sensor network, and interconnectivity for remote data access and management. System architecture is proposed to address the requirements for habitat monitoring. Such applicationdriven design provides and identify important areas of further work in data sampling, communications and networking. For this monitoring system, a sensor node (MTS400), IRIS and Micaz radio transceivers, and a USB interfaced gateway base station of Crossbow (Xbow) Technology WSN are employed. The GUI of this monitoring system is written using a Laboratory Virtual Instrumentation Engineering Workbench (LabVIEW) along with Xbow Technology drivers provided by National Instrument. As a result, this monitoring system is capable of collecting data and presents it in both tables and waveform charts for further analysis. This system is also able to send notification message by email provided Internet connectivity is available whenever changes on habitat at remote sites (swiftlet farms) occur. Other functions that have been implemented in this system are the database system for record and management purposes; remote access through the internet using LogMeIn software. Finally, this research draws a conclusion that a WSN for monitoring swiftlet habitat can be effectively used to monitor and manage swiftlet farming industry in Sarawak.

Keywords: Swiftlet, WSN, Habitat Monitoring, Networking.

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7 Foot Anthropometry of Primary School Children in the South of Thailand

Authors: S. Rawangwong, J. Chatthong, W. Boonchouytan

Abstract:

The objective of the research was to study of foot anthropometry of children aged 7-12 years in the South of Thailand Thirty-three dimensions were measured on 305 male and 295 female subjects with 3 age ranges (7-12 years old). The instrumentation consists of four types of anthropometer, digital vernier caliper, digital height gauge and measuring tape. The mean values and standard deviations of average age, height, and weight of the male subjects were 9.52(±1.70) years, 137.80(±11.55) cm, and 37.57(±11.65) kg. Female average age, height, and weight subjects were 9.53(±1.70) years, 137.88(±11.55) cm, and 34.90(±11.57) kg respectively. The comparison of the 33 comparison measured anthropometric. Between male and female subjects were sexual differences in size on women in almost all areas of significance (p<0.05). The comparison of size and proportion elementary school students 11-12 years old men in Southern of Thailand with Thai boys aged 11-12 years of industrial standards at stage 4 year A.D. 2000-2001 Number nine ratio. Concluded that students male in Southern of Thailand has a size different from the proportions of research Industrial Standards. Ministry of Industry, Phase 4, when every year from A.D. 2000-2001 ratio was significantly (p<0.05).All of the feet studied were classified into 4 categories according to the ratios of diagonal foot breadth to the maximum foot length and heel breadth to the foot breadth. They were short but thick, small but long, small, and large. The numbers of the males feet classified in these categories were 86, 64, 40, and 115 persons or 28.20, 20.98, 13.11, and 37.70% respectively. For the female feet, the same values were 46, 59, 81, and 109 persons or 15.59, 20.00, 27.46, and 36.95% respectively.

Keywords: Ergonomics, foot anthropometry, male and female, primary school children

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6 Developments for ''Virtual'' Monitoring and Process Simulation of the Cryogenic Pilot Plant

Authors: Carmen Maria Moraru, Iuliana Stefan, Ovidiu Balteanu, Ciprian Bucur, Liviu Stefan, Anisia Bornea, Ioan Stefanescu

Abstract:

The implementation of the new software and hardware-s technologies for tritium processing nuclear plants, and especially those with an experimental character or of new technology developments shows a coefficient of complexity due to issues raised by the implementation of the performing instrumentation and equipment into a unitary monitoring system of the nuclear technological process of tritium removal. Keeping the system-s flexibility is a demand of the nuclear experimental plants for which the change of configuration, process and parameters is something usual. The big amount of data that needs to be processed stored and accessed for real time simulation and optimization demands the achievement of the virtual technologic platform where the data acquiring, control and analysis systems of the technological process can be integrated with a developed technological monitoring system. Thus, integrated computing and monitoring systems needed for the supervising of the technological process will be executed, to be continued with the execution of optimization system, by choosing new and performed methods corresponding to the technological processes within the tritium removal processing nuclear plants. The developing software applications is executed with the support of the program packages dedicated to industrial processes and they will include acquisition and monitoring sub-modules, named “virtually" as well as the storage sub-module of the process data later required for the software of optimization and simulation of the technological process for tritium removal. The system plays and important role in the environment protection and durable development through new technologies, that is – the reduction of and fight against industrial accidents in the case of tritium processing nuclear plants. Research for monitoring optimisation of nuclear processes is also a major driving force for economic and social development.

Keywords: Monitoring system, process simulation.

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5 Advantages of Neural Network Based Air Data Estimation for Unmanned Aerial Vehicles

Authors: Angelo Lerro, Manuela Battipede, Piero Gili, Alberto Brandl

Abstract:

Redundancy requirements for UAV (Unmanned Aerial Vehicle) are hardly faced due to the generally restricted amount of available space and allowable weight for the aircraft systems, limiting their exploitation. Essential equipment as the Air Data, Attitude and Heading Reference Systems (ADAHRS) require several external probes to measure significant data as the Angle of Attack or the Sideslip Angle. Previous research focused on the analysis of a patented technology named Smart-ADAHRS (Smart Air Data, Attitude and Heading Reference System) as an alternative method to obtain reliable and accurate estimates of the aerodynamic angles. This solution is based on an innovative sensor fusion algorithm implementing soft computing techniques and it allows to obtain a simplified inertial and air data system reducing external devices. In fact, only one external source of dynamic and static pressures is needed. This paper focuses on the benefits which would be gained by the implementation of this system in UAV applications. A simplification of the entire ADAHRS architecture will bring to reduce the overall cost together with improved safety performance. Smart-ADAHRS has currently reached Technology Readiness Level (TRL) 6. Real flight tests took place on ultralight aircraft equipped with a suitable Flight Test Instrumentation (FTI). The output of the algorithm using the flight test measurements demonstrates the capability for this fusion algorithm to embed in a single device multiple physical and virtual sensors. Any source of dynamic and static pressure can be integrated with this system gaining a significant improvement in terms of versatility.

Keywords: Neural network, aerodynamic angles, virtual sensor, unmanned aerial vehicle, air data system, flight test.

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4 Verification and Validation of Simulated Process Models of KALBR-SIM Training Simulator

Authors: T. Jayanthi, K. Velusamy, H. Seetha, S. A. V. Satya Murty

Abstract:

Verification and Validation of Simulated Process Model is the most important phase of the simulator life cycle. Evaluation of simulated process models based on Verification and Validation techniques checks the closeness of each component model (in a simulated network) with the real system/process with respect to dynamic behaviour under steady state and transient conditions. The process of Verification and Validation helps in qualifying the process simulator for the intended purpose whether it is for providing comprehensive training or design verification. In general, model verification is carried out by comparison of simulated component characteristics with the original requirement to ensure that each step in the model development process completely incorporates all the design requirements. Validation testing is performed by comparing the simulated process parameters to the actual plant process parameters either in standalone mode or integrated mode. A Full Scope Replica Operator Training Simulator for PFBR - Prototype Fast Breeder Reactor has been developed at IGCAR, Kalpakkam, INDIA named KALBR-SIM (Kalpakkam Breeder Reactor Simulator) where in the main participants are engineers/experts belonging to Modeling Team, Process Design and Instrumentation & Control design team. This paper discusses about the Verification and Validation process in general, the evaluation procedure adopted for PFBR operator training Simulator, the methodology followed for verifying the models, the reference documents and standards used etc. It details out the importance of internal validation by design experts, subsequent validation by external agency consisting of experts from various fields, model improvement by tuning based on expert’s comments, final qualification of the simulator for the intended purpose and the difficulties faced while co-coordinating various activities.

Keywords: Verification and Validation (V&V), Prototype Fast Breeder Reactor (PFBR), Kalpakkam Breeder Reactor Simulator (KALBR-SIM), Steady State, Transient State.

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3 Artificial Neural Network Model Based Setup Period Estimation for Polymer Cutting

Authors: Zsolt János Viharos, Krisztián Balázs Kis, Imre Paniti, Gábor Belső, Péter Németh, János Farkas

Abstract:

The paper presents the results and industrial applications in the production setup period estimation based on industrial data inherited from the field of polymer cutting. The literature of polymer cutting is very limited considering the number of publications. The first polymer cutting machine is known since the second half of the 20th century; however, the production of polymer parts with this kind of technology is still a challenging research topic. The products of the applying industrial partner must met high technical requirements, as they are used in medical, measurement instrumentation and painting industry branches. Typically, 20% of these parts are new work, which means every five years almost the entire product portfolio is replaced in their low series manufacturing environment. Consequently, it requires a flexible production system, where the estimation of the frequent setup periods' lengths is one of the key success factors. In the investigation, several (input) parameters have been studied and grouped to create an adequate training information set for an artificial neural network as a base for the estimation of the individual setup periods. In the first group, product information is collected such as the product name and number of items. The second group contains material data like material type and colour. In the third group, surface quality and tolerance information are collected including the finest surface and tightest (or narrowest) tolerance. The fourth group contains the setup data like machine type and work shift. One source of these parameters is the Manufacturing Execution System (MES) but some data were also collected from Computer Aided Design (CAD) drawings. The number of the applied tools is one of the key factors on which the industrial partners’ estimations were based previously. The artificial neural network model was trained on several thousands of real industrial data. The mean estimation accuracy of the setup periods' lengths was improved by 30%, and in the same time the deviation of the prognosis was also improved by 50%. Furthermore, an investigation on the mentioned parameter groups considering the manufacturing order was also researched. The paper also highlights the manufacturing introduction experiences and further improvements of the proposed methods, both on the shop floor and on the quotation preparation fields. Every week more than 100 real industrial setup events are given and the related data are collected.

Keywords: Artificial neural network, low series manufacturing, polymer cutting, setup period estimation.

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2 Optimization of the Characteristic Straight Line Method by a “Best Estimate“ of Observed, Normal Orthometric Elevation Differences

Authors: Mahmoud M. S. Albattah

Abstract:

In this paper, to optimize the “Characteristic Straight Line Method" which is used in the soil displacement analysis, a “best estimate" of the geodetic leveling observations has been achieved by taking in account the concept of 'Height systems'. This concept has been discussed in detail and consequently the concept of “height". In landslides dynamic analysis, the soil is considered as a mosaic of rigid blocks. The soil displacement has been monitored and analyzed by using the “Characteristic Straight Line Method". Its characteristic components have been defined constructed from a “best estimate" of the topometric observations. In the measurement of elevation differences, we have used the most modern leveling equipment available. Observational procedures have also been designed to provide the most effective method to acquire data. In addition systematic errors which cannot be sufficiently controlled by instrumentation or observational techniques are minimized by applying appropriate corrections to the observed data: the level collimation correction minimizes the error caused by nonhorizontality of the leveling instrument's line of sight for unequal sight lengths, the refraction correction is modeled to minimize the refraction error caused by temperature (density) variation of air strata, the rod temperature correction accounts for variation in the length of the leveling rod' s Invar/LO-VAR® strip which results from temperature changes, the rod scale correction ensures a uniform scale which conforms to the international length standard and the introduction of the concept of the 'Height systems' where all types of height (orthometric, dynamic, normal, gravity correction, and equipotential surface) have been investigated. The “Characteristic Straight Line Method" is slightly more convenient than the “Characteristic Circle Method". It permits to evaluate a displacement of very small magnitude even when the displacement is of an infinitesimal quantity. The inclination of the landslide is given by the inverse of the distance reference point O to the “Characteristic Straight Line". Its direction is given by the bearing of the normal directed from point O to the Characteristic Straight Line (Fig..6). A “best estimate" of the topometric observations was used to measure the elevation of points carefully selected, before and after the deformation. Gross errors have been eliminated by statistical analyses and by comparing the heights within local neighborhoods. The results of a test using an area where very interesting land surface deformation occurs are reported. Monitoring with different options and qualitative comparison of results based on a sufficient number of check points are presented.

Keywords: Characteristic straight line method, dynamic height, landslides, orthometric height, systematic errors.

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1 Diagnosis of Intermittent High Vibration Peaks in Industrial Gas Turbine Using Advanced Vibrations Analysis

Authors: Abubakar Rashid, Muhammad Saad, Faheem Ahmed

Abstract:

This paper provides a comprehensive study pertaining to diagnosis of intermittent high vibrations on an industrial gas turbine using detailed vibrations analysis, followed by its rectification. Engro Polymer & Chemicals Limited, a Chlor-Vinyl complex located in Pakistan has a captive combined cycle power plant having two 28 MW gas turbines (make Hitachi) & one 15 MW steam turbine. In 2018, the organization faced an issue of high vibrations on one of the gas turbines. These high vibration peaks appeared intermittently on both compressor’s drive end (DE) & turbine’s non-drive end (NDE) bearing. The amplitude of high vibration peaks was between 150-170% on the DE bearing & 200-300% on the NDE bearing from baseline values. In one of these episodes, the gas turbine got tripped on “High Vibrations Trip” logic actuated at 155µm. Limited instrumentation is available on the machine, which is monitored with GE Bently Nevada 3300 system having two proximity probes installed at Turbine NDE, Compressor DE &at Generator DE & NDE bearings. Machine’s transient ramp-up & steady state data was collected using ADRE SXP & DSPI 408. Since only 01 key phasor is installed at Turbine high speed shaft, a derived drive key phasor was configured in ADRE to obtain low speed shaft rpm required for data analysis. By analyzing the Bode plots, Shaft center line plot, Polar plot & orbit plots; rubbing was evident on Turbine’s NDE along with increased bearing clearance of Turbine’s NDE radial bearing. The subject bearing was then inspected & heavy deposition of carbonized coke was found on the labyrinth seals of bearing housing with clear rubbing marks on shaft & housing covering at 20-25 degrees on the inner radius of labyrinth seals. The collected coke sample was tested in laboratory & found to be the residue of lube oil in the bearing housing. After detailed inspection & cleaning of shaft journal area & bearing housing, new radial bearing was installed. Before assembling the bearing housing, cleaning of bearing cooling & sealing air lines was also carried out as inadequate flow of cooling & sealing air can accelerate coke formation in bearing housing. The machine was then taken back online & data was collected again using ADRE SXP & DSPI 408 for health analysis. The vibrations were found in acceptable zone as per ISO standard 7919-3 while all other parameters were also within vendor defined range. As a learning from subject case, revised operating & maintenance regime has also been proposed to enhance machine’s reliability.

Keywords: ADRE, bearing, gas turbine, GE Bently Nevada, Hitachi, vibration.

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