Posted: April 3rd, 2022

Design and Machinery Vibration Monitoring and Analysis System

Design and Machinery Vibration Monitoring and
Analysis System for Hydroelectric Power
The content of the essay should mainly base on the two notes, so reference should be less than 5. NOTES LINK:https://www.sendspace.com/filegroup/vzfNrBvsuOXMRuDPg60Vlw.
Choice one of the five cases to design which are shown in ‘M04_Major Assignment Brief_Jan 2019.pdf’, and follow the assignment brief and marking allocation guidelines inside. The Assignment Template is also attached

Abstract
The paper examines the design and machinery vibration monitoring and analysis carried out on the hydroelectric power. The process involved a description of the measurement point location, orientation and the frequency of monitoring techniques that guides the vibration process. The paper describes the appropriate instrumentations and software as well as their respective specs for use in the industrial processes. The industrial scenarios such as the variable speed, water speed and the speed of rotation are also examined and applied in evaluating the vibration of the hydropower plant. Moreover, the paper presents the outline of measurement procedures and data processing as well as the monitoring and diagnosis approaches including data display. The conclusion summarizes all the processes undertaken and the appropriate measures for improvement.
Keywords: Hydropower, monitoring and diagnosis, vibration, measurements

Design and Machinery Vibration Monitoring and
Analysis System for Hydroelectric Power
The research discusses the design and vibration monitoring and analysis system for hydroelectric power. The case study for analysis is the Cwm-y-Cawl hydroelectric power station that supplies the steel power plant with a power of 300 MW. The steel power relies on the plant for its operations. Vibration monitoring and design of the system is important for the reduction of the maintenance cases and prevention of failures. Vibration monitoring is a process that should take place on all parts of the machines, whether it is moving or rotational machines. The vibration process is as a result of rubbing and rolling components caused by the roughness in mating surfaces. The vibration process may result in negative impacts such as failures of the equipment. All machines that operate vibrate and the degree of vibration differs due to the condition of the machine (Kougias et al., 2019). The vibration monitoring causes the bearing condition and the lubricant condition. Vibration analysis is considered important during the commissioning stage because it ensures the correct installation and the prevention of early life failures of the hydropower machine. The vibration monitoring establishes the parts to carry out maintenance and ensuring the integrity of the machines to prevent incurring huge costs during failures. The vibration techniques of the machines are performed time-to-time by monitoring the moving parts of the machines. The movement may appear on parts that do not normally move such as rotors on shafts. The analysis of vibration in hydropower stations HPS is done by considering the shaft vibration, turbine over vibration, stator core vibrations, stator bar vibrations and thrust bearing axial vibration among other parts. Therefore the paper discusses the measurements carried out in conducting the vibration analysis for hydropower stations. The techniques presented are the vibration signal processing and fault detection techniques.
Measurement Pont Location, Orientation, Access, and Frequency Monitoring
The transducer machine is used in the measurement by placing it at a specific measurement point location or the part of the hydropower machine that should be checked. It is important to place the transducer on the signal path. The transducer should be placed along the signal path for it to give accurate vibration results. The parts for carrying out the vibration measurements are the turbines, motors, rotor, transformer, and penstock. The vibration by the turbine runner is caused by the mechanical imbalance issues, the hydraulic imbalances, the misalignments, rough zone operations and improper lubrication of the mechanical parts among other effects. On the other hand, the vibration on the rotor is a result of the local overeating of the rotor and the imbalanced pull among other factors. The transformer vibration is a result of the magnetic force which causes vibration in the core and windings. The vibration is caused by factors such as the nose. The point of measurement, in this case, is on the core and windings. The vibration of the transformer results in a decrease in the efficiency of the parts of the machines. Also, the penstock is another part that should be considered as the point of carrying out the measurement. The penstock vibration is caused by the local hydraulic conditions in the penstock outlets and on the dynamic properties. The orientation of the hydropower machine is determined by the location of its parts such as the rotor, transformer, motors, and generators among others. The orientation of the devices is critical because they are sensitive in a single direction which is a contributing factor to the vibration monitoring. The vibration components might also occur in a different direction and the process is affected by the local conditions such as mounting the machine at a given location of the hydropower plant machine. The orientation of the transducer machine is important because of its sensitivities to vibration in a given direction. The device detects the vibration of a device in a different direction but other local factors also determine the process.

The points of measurement should be accessible to facilitate in vibration analysis and monitoring. The orientation process determines the nature or type of the transducer to be used depending on economic reasons. For instance, the single portable transducer saves on costs as compared to the fixed transducers. Therefore it is economical to limit the number of inaccessible to the hydropower plant and run the cables from the terminal box. The access is also important for carrying out measurements and adjustments on the equipment. The frequency of carrying out the measurements should be minimized and practical enough not to halt the operations of the hydropower plant. The process helps in the reduction of the operation cost of the hydropower plant. The frequency of measurements is set to provide sufficient warning regarding the failure on the machine. The interval of the measurement should not exceed one hour to enhance the accuracy of the measurements and ensure the process does not exceed the cost of operation.
Instrumentation, Software Requirements and Specs
The most critical instrument for use in vibration analysis and monitoring is the vibration transducer. The different types of transducers can measure the velocity, displacement and acceleration. The typical transducer for use, in this case, is the piezoelectric accelerometer because it has dynamic wide frequency ranges. The transducers will be employed in measuring wide ranges of frequencies on the components of the hydropower plant. The thermometer is another instrument for measuring the temperatures in the components of hydropower. The thermometer is used in measuring temperature which is an important factor in providing diagnostic information. Temperature is a function of the heat transfer between the devices and a critical aspect of the vibration monitoring process. The rate of power transmissions can also be determined by the power meters. The power meters are installed to monitor power transmission and ensure it does not go below 300 MW which is the recommended power supply to the steel plant. The power meter is utilized in measuring power and the frequencies by taking into consideration a number of variables such as the speed drives, loads and pumps. Additionally, other technologies such as the use of the infra-red devices that provide accurate information on the variables that determine the vibration measurements. Examples of the devices that can be used in this approach are the spot devices and IR cameras for detecting regions of abnormal changes in temperatures such as high temperatures or low temperatures. On the other hand, online monitoring of parts such as shafts and vibration of the turbines, generators and bearings can help in the determination of the conditions such as unbalance, looseness among others. The appropriate software for vibration monitoring is the Veski CoDis which is a computerized diagnostic system (Zoby & Yanagihara, 2009). The system helps in the monitoring of the status of the machine during the operations. The system can also be utilized in monitoring the rotor magnetic flux and air gaps. Software such as LabVIEW and MATLAB can be utilized in the design process and the analysis of data collected. The MATLAB code can be developed specifically for the hydropower generations and used in monitoring turbine vibration analysis
The CoDis System contains the excitation voltage sensor of 1 % accuracy, maximum voltage of 600 V, the excitation current sensor which contains the transducer type of model LEMHAX 500 TO 2500-S. The excitation current sensor has an accuracy of 1%, the frequency bandwidth of -3dB and the operating temperature of the -25 degrees Celsius to 85 degrees Celsius. The specifications for measuring temperature range are -200°C to 600°C for the standard model. The piezoelectric accelerometers are the most appropriate in vibration monitoring (Kougias et al., 2019). The device has the following specifications: -250 V to +1000 V as the operating voltage. 61 MM L x 35 mm W transducer size and the measurements of 0.4 mm to 0.8 mm thickness. The software used has specifications such as the version and the requirements for the operations.

Industrial Scenarios
The variable speed hydropower generation is an important approach in the operation of hydropower plants. Variations in the operating conditions contribute to the reduction of the plant’s global efficiency. The rotational speed of the power plants in relation to the synchronous speed is used in the determination of the hydrological patterns of the river which is a determinant factor in increasing global efficiency. The use of the electronic converters does the speed variation of hydropower. The converters ensure better active and reactive power control because the variable speed can control both reactive and active pump mode of the equipment. The rotational speed is also another critical scenario in the operation of hydropower plants (Kougias et al., 2019). The rotational speeds determine the measurement of the operation of the turbine and it is an important factor for monitoring the efficiency and operation of the plant. The rotational speed is applied in the determination of the efficiency of the hydropower plant. The water speed is also another industrial scenario that determines the quantity of electricity generated or supplied to the steel power. The other factors are the speed sensors, controller and actuator which control the hydraulic supply system. The function of the control system is to maintain angular speed constant and ensuring that it is equal to the normal value. The factors also contribute to changing the position of the distributor and the variation of the load or the operation conditions (Sritram & Suntivarakorn, 2017). Each of the operation condition contains the requirements for the parameters which are specific for one condition and may/may not be adequate for one condition. The other industrial scenarios are the frequency and the load which contributes in determining the operation of the power plant.

Measurement Procedure and Data Processing
The measurement approach is based on the data collection and analysis of vibration monitoring of the hydropower plant. The measurement procedure involves the boundary measurement of the plant, the measurement of the frequency and thermal measurements. The boundary measurement is critical in the hydropower plant case study because of its determination of the location of the equipment and the number of measurements that should be carried out on the hydropower plant. The procedure of the measurement involves the consideration of the narrow boundary of measurement and the wide boundary of measurement. The narrow boundary of measurements is crucial in the simplification of data while the wide boundary technique is employed in ensuring the accuracy of the results and minimizing the possible errors while carrying out the measurements.
The transducer device is employed in the measurement of the frequency of the vibration signals. The frequency measurements are also carried out to assess the nature of the load of the hydropower plant. The frequency of the measurement is categorized into spot measurement, short-term measurement as well as continuous measurement. The continuous measurements involve the continuous measurement of data at appropriate intervals. The continuous measurement of data aids in improving the accuracy of the measurements or the data obtained. The spot measurement is carried out for the constant load of the hydropower. For instance, the measurement of the constant speed of the turbines is considered as one of the approaches of the spot measurement. The next step of the measurement is done by the use of the power meters to determine the amount of power generation/transmitted to the steel power plant. The devices are fixed on the specified locations on the machinery and set to record power.
The procedure of vibration measurement is specific because it employs the use of transducer in carrying out the measurements at a particular location. The measurements can be carried out in two ways, which involves the measurement due to natural excitation which is determined during the operation of the machine. The other type is force measurement and responses as a result of external excitation. The type of measurement to be carried out depends on the type of transducer used in measuring the vibration. The common types of transducers include the response measuring, displacement, velocity and acceleration transducers. The procedure of measurements entails the understanding of the specifications of the hydropower plant and the appropriate use of the measuring devices.
The data processing of the signals is done by the use of appropriate software by utilizing the data collected in the process. The data processing technique for signals is commonly applied in deriving accurate results for users in the vibration analysis. The process of signal processing is implemented by the identification of the necessary parameters and conducting spectral analysis than the use of computer algorithms in the processing of data. The data is processed and presented for analysis and decision making in reducing the failures of the equipment. Additionally, software such as MATLAB and LabVIEW can be used for analysis (Griscenko & Kulikovskis, 2014). The data collected from the diagnosis should be used in solving the problems that might exist on the hydropower plant.
Monitoring and Diagnosis Approach
The process of monitoring and diagnosis of the hydropower plant is accomplished by the use of the data collected and the results obtained from the analysis. The most important part for carrying out monitoring and diagnosis includes hydroelectric turbines, contamination control, and turbine governor, bearing lube oil system, penstock, runner, inlet valve and thrust bearing among other components (Mohanta et al., 2017). The process that is carried out is known as the controlled based monitoring approach (CBM) which is employed in Assessment to determine the working condition of the hydropower plant. The variables used in the data processing area also utilized in the diagnostic measurement for alerting on any warning that might exist. The information for diagnosis and monitoring process is derived from the monitoring systems and the machines. The data is then processed to give reliable information on the type of diagnosis to be conducted. The vibration monitoring is also carried out and involves the analysis of parameters such as acceleration, velocities and displacement of the hydropower plant.
In monitoring processes, several parameters are considered such as the rotational speed of the turbine, the rate of the load, speed of water and rate of power transmission. Monitoring of the temperature of the various parts of the hydropower plant such as the transformer is critical in identify possible failures. The temperature monitoring is aimed at identifying abnormal changes in temperatures and heat generation due to mechanical components. The utilization of technologies such as the infrared analysis is also used in the determination of temperature changes on the hydropower plant. The infrared technology is preferred because it is more effective in providing real-time information on the condition of the hydropower plant. The most effective diagnosis is carried out by analyzing the different parts of the signal by focusing on a wide range of frequency bands or examination of high-resolution impulses. The instruments, such as computing devices that are fitted with appropriate software, are used in performing the analysis. The instruments for conducting diagnosis may be fixed or may transfer the data to computer systems for analysis. Conducting a vibration test is also the most effective way of carrying out the diagnosis and the best results are obtained by comparing it with the other machines.
The noise from the machines can also be a factor for diagnosis. Noise is a sub-group vibration and can be interpreted by the human ear. The abnormal generation of noise is an indication of the failure of the machine. Noise is generated as a result of the vibration of the components of the hydropower plant. Noise is a component that can be measured easily and provide more critical information for the diagnosis and monitoring of the hydropower plant.
However, in comparing the techniques for diagnosis, the spectrum is useful but is not commonly applied under normal trending scenarios. The process of conducting the analysis can be done by splitting the spectrum into several components for compression.
Monitoring data display for different personnel in the plant
The monitoring and diagnosis are carried out by the plant maintenance engineers who ensure the safety of the hydropower plant. The engineers are required to possess skills in conducting the vibration-based analysis and able to analyze the trends on observation for a period of time. The personnel should possess the skills in problem solving and identification and propose the means of solving. The data display for different personnel who control the power plant is done by the use of software and computer systems. The data are correctly displayed to the personnel by the use of computer devices for them to perform their functions effectively. The data provided to be personnel should be monitored to provide a solution to the devices. In ensuring the effectiveness of the data, it is essential to consider the strategies such as the maintenance, monitoring and diagnosis approaches among others. The appropriate problem-solving approach is done by having the correct data in place. A large amount of data from the signal processing in combination with the appropriate skills and expertise provides the best diagnosis for solving the problems. Training is also important in equipping engineers with the skills of solving the problems. The engineers are able to understand the data displayed to them and utilize it in solving problems.

Conclusion
The design and vibration monitoring process for the hydropower machines involves examining the components of the power plant by carrying out the appropriate measurements. The appropriate instruments are used in the collection of data regarding the condition of the power plant followed by the processing of the data by the use of software installed in computer devices. Early detection and identification of the issues or problems in the machine are critical in solving the problems and reducing the cost of maintenance of the machine. The process of carrying out measurements involves signal processing and thermal examination of the components of the hydropower plant. The monitoring and diagnosis techniques have proven effective in detecting problems on the power plant and initiating the appropriate measures. Appropriate hardware is used in the storage of information while the software is used in the signal processing and processioning of other types of data collected. The vibration monitoring process can be enhanced by the use of modern equipment which can display real-time results for timely problem-solving. The hydropower plant machines can be improved to conserve energy and other resources such as water.

References
Griscenko, M., & Kulikovskis, G. (2014). Vibration monitoring of power generation systems, using built-in MATLAB functions for data analysis. In Proceedings of LLU EFRD conference: May.
Kougias, I., Aggidis, G., Avellan, F., Deniz, S., Lundin, U., Moro, A., … Theodossiou, N. (2019). Analysis of emerging technologies in the hydropower sector. Renewable and Sustainable Energy Reviews, 113, 109257. doi: 10.1016/j.rser.2019.109257
Mohanta, R. K., Chelliah, T. R., Allamsetty, S., Akula, A., & Ghosh, R. (2017). Sources of vibration and their treatment in hydro power stations-A review. Engineering Science and Technology, an International Journal, 20(2), 637–648. doi: 10.1016/j.jestch.2016.11.004
Sritram, P., & Suntivarakorn, R. (2017). Comparative Study of Small Hydropower Turbine Efficiency at Low Head Water. Energy Procedia, 138, 646–650. doi: 10.1016/j.egypro.2017.10.181
Zoby, M. R. G., & Yanagihara, J. I. (2009). Analysis of the primary control system of a hydropower plant in isolated model. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 31(1). doi: 10.1590/s1678-58782009000100002

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