Introduction:

Bently Nevada was invited to record transient vibration data of unit 4, and analyze the vibration
response that is causing the high amplitudes on generator bearing #5. A couple of tests were
accomplished to see if the vibration response was of an electrical or mechanical malfunction.
For this the following was done:

-Unit at FSNL (Full Speed no Load) with excitation for 15 minutes

-Unit at FSNL without excitation for 15 minutes
-Unit was shutdown and rolled out to 78 rpm
-Recording data of the startup

Conclusions:

 Recorded data at FSNL and without excitation showed that the modulating vibration
experienced at the entire shaft of unit 4 disappeared from bearings #5 and #6. However it
still was present at bearings #1,2,3 and 4. Bearing #4 showed the highest amplitude for
about 40 minutes.

 After the shut down the unit was started up again on 03 April 2007 at 10:05, and the
recorded data showed that the amplitude at bearing #5 increased immediately. After the
startup, the amplitude at generator NDE starts increasing. Without load and excitation at the
generator during this period indicates that the malfunction that is causing this phenomenon
at unit 4 is a (soft) rub.

 The modulating vibration response at the unit appears to be a soft rub, at generator NDE
near bearing #5. The most likely place for this rub to occur is at the seal near generator NDE
(most likely in the upper half of the seal). The soft rub is causing a moving hot spot and bow
the generator each time at a slight different place. This changes the unbalance vector of the
rotor and causes the 1X phase to shift.

Recommendations:

The vibration amplitudes of the unit at base load show responses about 200 micron pp,
which is considered high. Therefore it is advise to schedule maintenance operation at the
nearest opportunity.

 Prepare an overhaul of the seal at generator NDE

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  Check the clearance of the seal and make sure the minimal clearance limit does not
exceed the bearing clearance.

Trend Bearing 3#, #4,#5 and #6 showing red arrows showing phase change during FSNL

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Polar plot Generator NDE showing the rotation in the leading phase

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Polar plot Exciter bearing #6

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Trend plot generator NDE prior before shutdown

A more detailed report on the findings of the measurement of unit 4 will follow.

Tanju Cakir
MDS Engineer
Netherlands

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