Integrated Condition Monitoring of Large Captive Power Plants and Aluminum Smelters
J.K. Mohanty1, A. Adarsh2, P.R. Dash1, K. Parida1 and P.K. Pradhan1,*
1Department of Mechanical Engineering, VSSUT, Burla, Odisha, India
2Vedanta Limited, Jharsuguda, Odisha, India
*Corresponding Author: P.K. Pradhan. .
Abstract: Condition monitoring is implementation of the advanced diagnostic
techniques to reduce downtime and to increase the efficiency and reliability.
The research is for determining the usage of advanced techniques like Vibration
analysis, Oil analysis and Thermography to diagnose ensuing problems of the
Plant and Machinery at an early stage and plan to take corrective and preventive
actions to eliminate the forthcoming breakdown and enhancing the reliability of
the system. Nowadays, the most of the industries have adopted the condition
monitoring techniques as a part of support system to the basic maintenance strategies. Major condition monitoring technique they follow is Vibration Spectrum
Analysis, which can detect faults at a very early stage. However implementation
of other techniques like Oil analysis or Ferrography, Thermography etc. can
further enhance the data interpretation as they would detect the source of abnormality at much early stage thus providing us with a longer lead time to plan and take
the corrective actions. In Large Captive Power Plants and Aluminium Smelters,
Integrated Condition Monitoring techniques play an important role as stoppage
of primary system and its auxiliaries (boiler, steam turbine, generator, coal and
ash handling plants etc.) results into the stoppage of the entire plant, which in turn
leads to loss of productivity. From economical and operational point of view, it is
desirable to ensure optimum level of system availability.
Keywords: Condition monitoring; thermal power plant; vibration analysis; thermographs; maintenance
Condition based maintenance improves the reliability and capability of the system. It eliminates the
accidents and so-called ‘sudden failures’. Though there are several conditions monitoring techniques,
vibration analysis is considered to be a very sensitive and strong technique to trace the developments of
the defects. However, in some cases, one or more technique should be applied in combination to enhance
the reliability. Like in case study-3, the combination of oil analysis with a detailed vibration analysis was
able to detect the defect in gear box, which might not have been possible to detect by using single
technique. Equipping auxiliary machinery and suitable condition monitoring techniques ensure the
reliable, safe and resource-saving maintenance of power plants.
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