Vibration monitoring systems provide an early warning network for potential issues in power generation plants. This has several important benefits, including the ability to plan predictive maintenance, minimise downtime, reduce operational costs, and enhance productivity. However, even more important is the role that vibration monitoring plays in averting catastrophic failures. In this article, we look at five examples of how an advanced vibration monitoring system can safeguard critical infrastructure in power plants.
At a power plant, misalignment of a turbine pump assembly can lead to a rapid increase in vibration levels. This is a common issue and many turbines and pump assemblies are highly sensitive to even minor shifts in alignment. Left unchecked, these misalignments can cause wear and tear on crucial components and increase the risk of a catastrophic breakdown. Early detection of the issue through monitoring allows operators to make proactive adjustments before damage occurs, maintaining plant output and avoiding downtime. This could involve realigning rotating replacements, for instance, or replacing worn parts. Instead of reacting to an emergency, these repairs can be conducted during scheduled maintenance windows.
At a power plant dependent on recirculation pumps, increased vibration levels can indicate an underlying bearing defect. A failure in these components can trigger a complete operational halt or, at the very least, reduce plant efficiency. A vibration monitoring system helps you detect the early signs of deterioration, such as wear on bearings, cavitation, or an imbalance. It does this by continually monitoring the performance patterns that could indicate the onset of one of these issues. Armed with this information, your maintenance teams can inspect the pumps, replace faulty bearings, or balance components as necessary before a pump failure occurs – potentially avoiding weeks of downtime.
Many power generation facilities rely on cooling tower fans and fin fans, and process cooling fans to manage heat dispersion. Any failure or loss of efficiency in the systems can disrupt critical operations. A system of vibration monitoring sensors can detect early wear conditions, prompting timely replacements before a fan malfunction occurs. By installing sensors on your fans, shafts, and gearboxes, you’ll get critical warning of any loose components, structural imbalances, or other factors that could risk overheating and the chance of cascading failures that impact other equipment downstream.
Predictive maintenance is the ability to plan your maintenance and repair activities around operational schedules, avoiding unnecessary inspections or component replacements, and extending the life of equipment by addressing issues before they escalate. A predictive maintenance schedule of this nature is possible with an accurate vibration monitoring system, which provides a broader perspective on the health and operational conditions of your critical machinery. With access to real-time and historical data, your operators stand at less risk of being surprised by a sudden critical failure and are better equipped to mitigate operational risk within your facility.
This refers to the deviation of the shaft centreline from its true geometric centre during rotation. It can be caused by: bent shafts, uneven thermal growth, rotor bowing, mass imbalance, misalignment, rubs or bearing wear.
| Benefit | Impact |
|---|---|
| Early detection of shaft distortion | Prevents high-speed failures |
| Identifies bearing clearance issues | Reduces bearing damage and lubrication loss |
| Recognises rotor-to-stator contact | Avoids thermal and mechanical damage |
| Enables predictive maintenance | Cuts costs and downtime |
| Improves system reliability & safety | Enhances operational uptime and personnel safety |
Shaft eccentricity monitoring is essential for high-speed, high-value rotating equipment such as turbines, generators, and compressors. By catching subtle changes in shaft behaviour before they lead to failure, it acts as an early-warning system, preventing catastrophic damage and maintaining reliability in power generation plants.
Large steam turbines are typically run on barring motor drive (very slow speed turning mechanism) until up to temperature and the sag (high eccentricity) of the shafts under the heavy weight is naturally corrected by the rotation, only after the eccentricity measurements are below the acceptable level can the barring gear be disconnected from the turbine allowing it to be run up to full speed on steam.
Get in touch with one of the experienced team at Sensonics today to discover the benefits of vibration monitoring systems, and how they can improve safety and performance your facility.