Power Plant Condition Monitoring

Modern power plants depend heavily on rotating machines such as steam turbines, gas turbines, generators and so on. To maximize power plant profit, rotating machines of power generation trains should be operated with maximum reliability, maximum capacity, maximum efficiency and minimum operating and maintenance costs.

Effective monitoring and high reliability starts with basic-design phase, particularly with rotating machine specification and power generation train basic design.

Inadequate specification impacts extensively power generation train reliability. Proper bidding phase clarification (particularly extensive bid evaluation prior to vendor selection and purchase order placement) establishes an effective machine reliability basis. A proper development strategy is necessary for successful condition monitoring and predictive maintenance.


Power generation companies maximize profits by operating the un-spared (critical) power generation trains without shutdown. They are investing heavily on identifying and eliminating potential reliability issues through effective condition monitoring and predictive maintenance to meet continuous and efficient operation.

Power generation train manufacturers maximize profit by manufacturing the machinery to meet project specifications and applicable codes at the lowest cost to assure the equipment will be reliable for the warranty period. Rotating machine manufacturers usually do not initiate improvements to extend reliability and trouble-free operation beyond the manufacturer warranty period.

Many manufacturers believe they cannot stay competitive and in business if they design and produce equipment beyond code and client specification requirements for a long-term (let's say 20 years) of trouble-free operation. This is key to understanding power generation train reliability and required actions to increase reliability.

For effective reliability analysis as well as failure analysis and trouble-shooting, all facts-- particularly operating condition changes, piping and foundation changes and ambient condition changes--must be considered. Power generation trains should be considered as a complete system including transmission system and coupling and involving auxiliaries such as gear unit (if applicable), lube oil system, cooling system (if any), seal system and so on.

The power generation packages regardless of type always become customized because of the environment (such as network, site conditions, unique battery limits, unique piping arrangement, specific foundation and so on). Each machine has its own unique signature.

To be continue to:
http://mechanic-info.blogspot.com/2013/06/condition-monitoring.html

http://mechanic-info.blogspot.com/2013/06/failure-analysis-and-trouble-shooting.html

http://mechanic-info.blogspot.com/2013/06/bearing-monitoring.html

http://mechanic-info.blogspot.com/2013/06/bearing-predictive-maintenace.html


http://mechanic-info.blogspot.com/2013/06/bearing-case-sudies.html

http://mechanic-info.blogspot.com/2013/06/bearing-other-practical-notes.html

Author: Amin Almasi is lead rotating equipment engineer at WorleyParsons, Brisbane, Australia. He holds chartered engineer certificate from Engineers Australia and IMechE in addition to a M.Sc. and B.Sc. in mechanical engineering. He specializes in rotating machines. Mr Almasi is active member of Engineers Australia, IMechE, ASME, IEEE, Vibration Institute and others. He has authored more than 50 papers and articles dealing with rotating equipment, condition monitoring, offshore, subsea and reliability.