A New Dual-Channel Analyzer for Vibration of Rotary Machine

A new simultaneous sampling and analyzer for dual-channel signal of vibration for rotating machine is developed based on the C8051F060, which is a high-speed SoC system and has two ADCs embedded with high sampling frequency. The signal condition circuits for various vibration sensors are designed, such as charge amplifier, integral transform and rotating speed detector. A colorful TFT LCD used can display all kinds of vibration analysis plots that are friendly in human-machine interface. The large capability non-volatile memory is used to restore up to one hundred of group of vibration waves. With many typical functions of vibration analysis, including waveform analysis, spectrum, orbit and balancing, this instrument is widely applied to vibration measurement and fault diagnosis of machine and equipment, especially for field balancing of rotary machine.

Greenhouse Gas Emissions Calculation Methodology in Thermal Power Plants: Case Study of Iran and Comparison With Canada

Nowadays, the global climate change has been a worldwide concern and the greenhouse gases (GHG) emissions are considered as the primary cause of that. The United Nations Conference on Environment and Development (UNCED) divided countries into two groups: Annex I Parties and Non-Annex I Parties. Since Iran and all other countries in the Middle East are among Non-Annex I Parties, they are not required to submit annual GHG inventory report. However, the global climate change is a worldwide phenomenon so Middle Eastern countries should be involved and it is necessary to prepare such a report at least unofficially. In this paper the terminology and the methods to calculate GHG emissions will first be explained and then GHG emissions estimates for the Iranian power plants will be presented. Finally the results will be compared with GHG emissions from the Canadian electricity generation sector. The results for the Iranian power plants show that in 2005 greenhouse gas intensity for steam power plants, gas turbines and combined cycle power plants were 617, 773, and 462 g CO2eq/kWh, respectively with the overall intensity of 610 g CO2eq/kWh for all thermal power plants. This GHG intensity is directly depend on efficiency of power plants. Whereas, in 2004 GHG intensity for electricity generation sector in Canada for different fuels were as follows: Coal 1010, refined petroleum products 640, and natural gas 523 g CO2eq/kWh, which are comparable with same data for Iran. For average GHG intensity in the whole electricity generation sector the difference is much higher: Canada 222 vs. Iran 610g CO2eq/kWh. The reason is that in Canada a considerable portion of electricity is generated by hydro-electric and nuclear power plants in which they do not emit significant amount of GHG emissions. The average GHG intensity in electricity generation sector in Iran between 1995 and 2005 experienced 13% reduction. While in Canada at the same period of time there was 21% increase. However, the results demonstrate that still there are great potentials for GHG emissions reduction in Iran’s electricity generation sector.

The Case for Combining Pump Maintenance and Systematic Upgrading

Virtually, all industrial machinery requires periodic maintenance for dependable long-term operation. In fact, the very term “maintenance” is defined as keeping machines in the as-designed or as-purchased and manufactured condition. At issue is whether the equipment owner’s profitability objectives are best served by “maintaining only”, or by judiciously combining maintenance and upgrading tasks. Assuming the answer favors combining maintenance and upgrading, the question arises whether an intelligent and well thought-out combination of maintenance and upgrading should be entrusted only to the original equipment manufacturer (OEM), or if qualified non-OEMs should be considered also. The co-authors would like to offer their answer to the question. Experience shows that a highly qualified independent rebuild shop with demonstrated capabilities and experienced personnel can offer high-quality upgrades that improve both uptime and efficiency. Such a shop can do so consistent with current system performance requirements. With the considerable consolidations in the pump industry, the distinct possibility exists that the OEM is not able to offer the same engineering competence he previously had and that independent shops should be considered. This presentation deals with a case study and details where such upgrading was being planned, implemented, and verified to have had the desired results. It further explains the role played by competent pump rebuild shops (we chose to call them “CPRS”) in these important endeavors. Our work supports the premise that rebuilding a vintage process pump to original OEM specifications makes no sense, given current pump rebuilding technology and changes to the system performance that occur over time. We find compelling reasons to systematically upgrade the efficiency and potential run length of large centrifugal pumps. Of course, this upgrading must be pre-planned and then carried out during a future maintenance outage.

Gas Turbine Efficiency (GTE) Benefits of GTE Water Wash Systems

The desire to maintain power plant profitability, combined with current market fuel gas pricing is forcing power generation companies to constantly look for ways to keep their industrial gas turbine units operating at the highest possible efficiency. Gas Turbines Operation requires the compression of very large quantities of air that is mixed with fuel, ignited and directed into a turbine to produce torque for purposes ranging from power generation to mechanical drive of pumping systems to thrust for air craft propulsion. The compression of the air for this process typically uses 60% of the required base energy. Therefore management of the compression process efficiency is very important to maintain overall cycle efficiency. Since fouling of turbine compressors is almost unavoidable, even with modern air filter treatment, and over time results in lower efficiency and output, compressor cleaning is required to maintain gas turbine efficiency.

Fouling of Heat Exchanger Tubes in Pulverized-Coal-Fired Combustion Chambers

Fouling is a major concern in coal-fired power plants caused by fly ash deposit on the heat exchanger tubes that decreases the overall heat transfer coefficient to water-steam mixture. Fouling has been characterized by weakly bound-loose form, which may be removed by various methods, such as soot-blowing, blast, and sand blowing. We have carried out experimental and modeling work on fouling to develop a methodology by which the thermal conductivity of the ash deposit would be determined in a way similar to the fouling process prevailing in real systems. For that we used tubes identical in material, diameter and temperature to those used in many utility boilers. In the experimental work we placed a tube in an axially symmetric 50 kW furnace, and tested fouling from three coals, bituminous and sub-bituminous. We also developed a dynamic model for the prediction of the ash deposition growth and its heat resistance. Comparison of the model prediction and experimental results yielded satisfactory fit. Consequently, thermal resistance of heat exchanger tuber with ash deposit of those coals was determined.

Gas Turbine Part Load Performance Testing: Comparison of Test Methodologies

Current trends in usage patterns of gas turbines in combined cycle applications indicate a substantial proportion of part load operation. Commensurate with the change in operating profile, there has been an increase in the propensity for part load performance guarantees. When a project is structured such that gas turbines are procured as equipment-only from the manufacturer, there is occasionally a gas turbine part load performance guarantee that coincides with the net plant combined cycle part load performance guarantee. There are several methods by which to accomplish part load gas turbine performance testing. One of the more common methods is to operate the gas turbine at the specified load value and construct correction curves at constant load. Another common method is to operate the gas turbine at a specified load percentage and construct correction curves at constant percent load. A third method is to operate the gas turbine at a selected load level that corresponds to a predetermined compressor inlet guide vane (IGV) angle. The IGV angle for this third method is the IGV angle that is needed to achieve the guaranteed load at the guaranteed boundary conditions. The third method requires correction curves constructed at constant IGV, just like base load correction curves. Each method of test and correction embodies a particular set of advantages and disadvantages. The results of an exploration into the advantages and disadvantages of the various performance testing and correction methods for part load performance testing of gas turbines are presented. Particular attention is given to estimates of the relative uncertainty for each method.

Study on Unsteady Aerodynamic Force of Turbine Blade With Different Mass Flow

The traditional turbomachinery design systems are always based on the assumption of steady or quasi-steady flows. However, unsteady flows such as wake flow, separated flow and shedding vortices are the main factors inducing the excitation force on turbine blade which leads to high cycle fatigue failure of blade. In this paper, the three-dimensional, time dependent, Reynolds-Averaged Navier-Stokes (RANS) equations were resolved using a commercial program CFX based on finite volume method. The unsteady flow fields of three mass flow cases (design case, 110% design mass flow and 85% design mass flow) in a one-and-a-half stage axial turbine (stator/rotor/stator) were investigated in detail and then the unsteady aerodynamic force on the rotational blade was obtained. Frequencies of unsteady disturbances and excitation force factors were obtained by spectrum analysis. It can be seen clearly that the excitation factors at 110% mass flow case are larger than that at the design case. On the other side, the unsteady aerodynamic force on the rotational blade at 85% mass flow case is quite different from the design case. There are two peaks during a stator passing period and the dominate frequency of the tangential blade force is 6000Hz due to large amount of negative incidence angle. The 6000Hz component tangential aerodynamic force amplitude is 6.533N, which is 5.93 times of that at design case and 2.92 times of that at 110% mass flow case. Because of the large amplitude, the unsteady aerodynamic force at small mass flow case is necessary to be taken into account in the forced vibration analysis of blade.

Benefits of Conducting Periodic Critical Pump Hydraulic and Mechanical Performance Audits

The operability and efficiency of critical pumping equipment is essential. A cost-effective tool that has proven valuable in predictive and preventive maintenance and in the avoidance of unscheduled pumping equipment outages is a comprehensive program of periodic hydraulic and mechanical performance audits. This paper explains how hydraulic and mechanical field testing can be conducted without interrupting plant operations using non-intrusive measurement equipment including: ultrasonic flow measurements, vibration signature analysis, and for electric motor driven pumps, power and dielectric condition analysis. Methods and requirements to conduct the audits will be discussed and a case study with cost benefit analysis is presented. Pumps are basically energy transfer devices. The energy of the pump driver, e.g. electric motor, steam or gas turbine, reciprocating engine, is transferred into the pumpage to move it through the system at sufficient pressure to overcome system losses and meet process requirements. It is the efficient transference of the applied energy that is a critical consideration in pump design and operation. Efficiency of operation is of interest to everyone. The pump designer is motivated to maximize pump efficiency to remain competitive given the increasing cost of energy. However, the designer must not get overly zealous in the quest for pumping efficiency sacrificing reliability and durability. The end-user wants the most efficient pump with longest mean time between repair (MTBR) intervals to both reduce operating cost and minimizing production losses. With the reasons for maximizing pumping efficiencies and longer MTBR intervals established, the value of periodic in situ performance testing or auditing becomes an increasingly valuable and cost effective predictive and preventative maintenance tool.

Improving Plant Efficiency While Optimizing Water Use in Simple and Combined Cycle Power Plants

Closed-loop, evaporative cooling systems (Wet Surface Air Coolers) are a cost-effective heat transfer technology (for cooling and condensing) in simple and combined cycle power plants that also optimize use of scarce water resources. In addition to providing lower outlet temperatures and requiring less space and horsepower (HP), the WSAC can use poor quality water as spray makeup.

Degradation in Turbo Machinery

Gas turbines and steam turbines start to degrade in performance when they first start running. This paper lists the causes of degradation, describes how to monitor degradation, and suggests techniques for minimizing degradation. This paper also suggests how degradation can be handled in contract language for acceptance testing. Lastly, this paper explores a special case, often misunderstood, namely how boiler operation needs to be accounted for when evaluating the effect of degradation (the loss factor) of an HP turbine in a reheat cycle.