Availability Improvement by Early Detection of Motor Bearing Failure Using Comprehensive Condition Monitoring Techniques at DTPS

摘要

This paper shares a success story out of the Implementation of Co-ordinated Condition Monitoring techniques at DTPS, wherein imminent Motor bearing failure of one of the most critical HT auxiliary used during coal bunkering system i.e. Belt Conveyor-4B was diagnosed. On 15/01/2014, Motor NDE and DE bearing acceleration value deviated from 1.3 and 1.2 g to 2.2 and 4.9 g (Peak) respectively. Suspecting deterioration in Motor bearings and to confirm the same a Ultrasonic Monitoring carried out and observed that Ultrasonic level also increased from 4 to 8 LEDs. In view of Steep increasing trend of Motor bearings Acceleration value and Ultrasonic level, it was decided to replace the Motor with spare one. During inspection of motor, it was observed that Motor bearing clearances were found increased than the normal value and bearings rollers found damaged. Thorough inspection of Motor winding and Stator Rotor also done and found intact. No Scoring marks observed on both ends of Motor shaft. Vibration Analysis and Ultrasonic Monitoring helped in diagnosing the exact root cause of abnormity of deterioration of Motor bearings at early stage and thus avoided the catastrophic failure. The application saved the plant from huge losses in terms of power generation, down time, associated maintenance and spares costs which could have caused total cost of ￡58,854.3.