Success Stories

Generator Exciter Bearing High Vibration

POC
Things aren't always what they seem. Vibration propagation can deceive even the best instrumentation, but experience is hard to mislead, especially when the cause does not produce the expected effect. Read more about how the Power Optimization Center saved a generation facility $1,781,795 in Total Cost Avoidance by downloading our White Paper now.
The Luminant Power Optimization Center identifies, forecasts and advises plant personnel of emergent issues impacting production through the integration of remote monitoring, modeling and diagnostics. In the current market environment of low natural gas and wholesale power prices, and tightening emissions standards, generators need to produce megawatts as profitably as possible. The Power Optimization Center can help reach that goal. Power Optimization Center personnel discovered rapidly rising bearing vibration on a turbine exciter bearing. Immediate action by the Power Optimization Center saved this generation facility $1,781,975 in total cost avoidance. The Problem Things aren’t always what they seem. Vibration propagation can deceive even the best instrumentation, but experience is hard to mislead, especially when the cause does not produce the expected effect. One morning, the Power Optimization Center was actively monitoring a plant startup from hot standby. After the required soak time, the plant began to raise turbine rpm to full speed. Bearing vibration was expected to increase as speed increased, especially as turbine speed enters the critical range where natural harmonics are experienced. After turbine speed passes through this critical range, bearing vibration should return to normal. In this case, generator bearing vibration continued to rise. The Solution The Power Optimization Center contacted the control room and apprised plant operations of the rapidly rising bearing vibration. Turbine speed was lowered to the previous soak speed. Originally, plant personnel believed the problem bearing to be the indicated bearing based solely on overall vibration readings. Power Optimization Center engineers, through intense scrutiny and evaluation, found the problem bearing to be the coupler-opposite bearing. They determined that a bearing rub, which affected the coupler-opposite bearing significantly more than the indicated bearing, was the culprit. Armed with new information, the plant was able to closely monitor the correct bearing. The turbine ultimately returned to full speed, but only after the offending bearing indicated that the rub was no longer present. Without Power Optimization Center assistance, the plant would have based its corrective actions on the wrong bearing, which would have led to additional delays and possible bearing damage. The Savings The Power Optimization Center determines cost avoidance by applying proprietary calculations. This generating facility avoided $1,759,015 in lost revenue and $22,960 in additional maintenance costs, including parts and labor, totaling $1,781,975 in total cost avoidance. Utilizing over a dozen separate software systems that monitor and diagnose just about any issue that may affect plant operations, the Power Optimization Center has a proven history of helping manufacturing and generating facilities realize maximum asset performance. With power markets nationwide under low price pressures, generators more than ever need a way to analyze unit performance in real time to enhance efficiency, prevent shutdowns and save dollars. Whether your equipment resides in the utility industry, manufacturing or any other type of facility, the Power Optimization Center is ready to help your company achieve the highest levels of safety and reliability. Call us today to see how we can bring value to your company and visit www.pocdiagnostics.net to learn more.

Induced Draft Booster Fan Bearing High Vibration

POC
The Power Optimization Center received an induced draft booster fan outboard bearing high vibration alarm on the main alarm system. Plant operations was contacted and apprised of the rapidly rising bearing vibration. Read more about how the Power Optimization Center saved a generation facility $1,291,738 in Total Cost Avoidance by downloading our White Paper now.
INDUCED DRAFT BOOSTER FAN BEARING HIGH VIBRATION The Luminant Power Optimization Center identifies, forecasts and advises plant personnel of emergent issues impacting production through the integration of remote monitoring, modeling and diagnostics. In the current market environment of low natural gas and wholesale power prices and tightening emissions standards, generators need to produce megawatts as profitably as possible. The Power Optimization Center can help reach that goal. For instance, Power Optimization Center personnel discovered rapidly rising bearing vibration on an induced draft booster fan outboard bearing. Speedy action by the Power Optimization Center saved this generation facility $1,291,738 in total cost avoidance and 1.425% negative impact on equivalent forced outage rate. The Problem The Power Optimization Center received an induced draft booster fan outboard bearing high vibration alarm on the main alarm system. The booster fan provides pressure for the induced draft fan, which draws air and gasses from the furnace, helping to maintain a negative pressure in the boiler. Following a swift investigation, Power Optimization Center operators compared bearing vibration parameters for the alarming booster fan to historical values and determined that the increased vibration was not normal and needed immediate attention. Power Optimization Center procedures state that plant control rooms should be contacted directly when emergency situations arise, minimizing the time between emergency and remedy. This allows for proper plant personnel to assess the situation and follow their procedures without delay, minimizing risk and maximizing response time. The Solution The Power Optimization Center contacted the plant and apprised operations of the rapidly rising bearing vibration. Plant maintenance was attempting to reduce fan housing vibration. However, in their attempt, vibration was increased causing a sensing line on a stall probe to fail, which removed plant vibration indication. Plant operations was unaware of the rising vibration. The Power Optimization Center utilizes redundant instrumentation to monitor and diagnose impending failures even when the most relied-upon instrumentation fails. Plant operations was able to stop maintenance activities and return fan vibration to normal, preventing permanent damage, an unplanned outage and possible serious injury to those working on and around the booster fan. The Savings The Power Optimization Center determines cost avoidance by applying proprietary calculations. This generating facility avoided $1,227,613 in lost revenue and $64,125 in maintenance costs, including parts and labor, totaling $1,291,738 in total cost avoidance. They also avoided a 1.425% negative impact on equivalent forced outage rate. Utilizing over a dozen separate software systems that monitor and diagnose just about any issue that may affect plant operations, the Power Optimization Center has a proven history of helping manufacturing and generating facilities realize maximum asset performance. With power markets nationwide under low price pressures, generators more than ever need a way to analyze unit performance in real time to enhance efficiency, prevent shutdowns and save dollars. Whether your equipment resides in the utility industry, manufacturing or any other type of facility, the Power Optimization Center is ready to help your company achieve the highest levels of safety and reliability. Call us today to see how we can bring value to your company and visit www.pocdiagnostics.net to learn more.

Circulating Water Pump Misoperation

POC
The Power Optimization Center performs thermal efficiency reviews based on a number of conditions. In this case, a three-unit power generation facility was experiencing cooler than normal weather. Power Optimization Center engineers initiated a thermal efficiency review and determined all three circulating pumps were needlessly running on each of the three units. Read more about how the Power Optimization Center saved a generation facility over $500,000 in Total Cost Avoidance by downloading our White Paper now.
The Luminant Power Optimization Center identifies, forecasts and advises plant personnel of impending issues impacting production through the integration of remote monitoring, modeling and diagnostics. In the current market environment of low natural gas and wholesale power prices, and tightening emissions standards, generators need to produce megawatts as profitably as possible. The Power Optimization Center can help reach that goal. For example, Power Optimization Center personnel discovered significant heat rate and generation impact due to the misoperation of unit circulating water pumps. Detailed plant modeling and due diligence by the Power Optimization Center saved this generation facility over $500,000 in total cost avoidance. The Problem The Power Optimization Center performs thermal efficiency reviews based on a number of conditions. In this case, a three-unit power generation facility was experiencing cooler than normal weather. Power Optimization Center engineers initiated a thermal efficiency review and determined all three circulating pumps were needlessly running on each of the three units. The third circulating water pump is typically secured as cooling water temperatures decrease during the onset of winter. The third operating pump caused an excessive decrease in condenser backpressure, negatively impacting unit gross generation. None of the three units were turbine limited at the time, resulting in an adverse capacity limit. In an ideal world, the condenser removes only that amount of heat needed to change low-energy steam to water, retaining as much heat as possible. A perfectly balanced Ideal Rankine Cycle would then require the boiler to only add latent heat of vaporization. When excess cooling is applied inside the condenser, the boiler must heat the water back to its boiling point before transforming that water into steam, requiring more fuel and auxiliary power to be consumed than what should be necessary. The Solution The Power Optimization Center contacted plant operations personnel to apprise them of the heat rate impact and recommended securing a single circulating water pump on each unit. Shortly after securing the third circulating water pump, the Power Optimization Center observed optimized condenser backpressure, positive impact on gross generation, optimized total unit auxiliary load, and optimized heat rate for present unit full load condenser operating conditions. Analysis revealed that securing the third circulating water pump resulted in 37 BTU/KWh heat rate improvement for each unit and an additional 3 MWe capacity improvement. The Savings The Power Optimization Center determines cost avoidance by applying proprietary calculations. This generating facility saved $125,626 in heat rate improvement and $374,587 in generation capacity improvement totaling $500,213 in total cost avoidance for the period between the date that plant personnel were advised to secure the third circulating water pump and the date that the third circulating water pump would normally be secured. Utilizing over a dozen separate software systems that monitor and diagnose just about any issue that may affect plant operations, the Power Optimization Center has a proven history of helping manufacturing and generating facilities realize maximum asset performance. With power markets nationwide under low price pressures, generators more than ever need a way to analyze unit performance in real time to enhance efficiency, prevent shutdowns, and save dollars. Whether your equipment resides in the utility industry, manufacturing or any other type of facility, the Power Optimization Center is ready to help your company achieve the highest levels of safety and reliability. Call us today to see how we can bring value to your company and visit www.pocdiagnostics.net to learn more.

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Air Preheater Hot End Bearing Temperature High

POC
Sometimes, even the best intentions do not yield the greatest results. The Power Optimization Center received a high temperature alarm on an air preheater hot end bearing. Read more about how the Power Optimization Center saved a generation facility $1,781,795 in Total Cost Avoidance by downloading our White Paper now.
The Luminant Power Optimization Center identifies, forecasts and advises plant personnel of emergent issues impacting production through the integration of remote monitoring, modeling and diagnostics. In the current market environment of low natural gas and wholesale power prices, and tightening emissions standards, generators need to produce megawatts as profitably as possible. The Power Optimization Center can help reach that goal. Power Optimization Center personnel discovered rapidly rising bearing temperature on an air preheater hot end bearing. Immediate action by the Power Optimization Center saved this generation facility $1,582,748 in total cost avoidance. The Problem Sometimes, even the best intentions do not yield the greatest results. When a plant was experiencing higher-than-normal bearing temperatures on one of its air preheaters, the Power Optimization Center correspondingly increased their monitoring efforts. Auxiliary cooling was used at the time to help achieve normal bearing temperatures. One morning, the Power Optimization Center received a high temperature alarm on an air preheater hot end bearing. The air preheater utilizes excess heat from exhaust gasses to warm cold air coming in from the forced draft fans. If the rotating heat transfer element cannot rotate, the unit must shut down in order to prevent damage to the rotating element. The Solution The Power Optimization Center contacted the control room and apprised plant operations of the rapidly rising bearing temperature. Plant personnel investigated and found decreased bearing system lube oil pressure, causing higher bearing temperatures. Upon further investigation, the plant found the inline lube oil filter to be partially obstructed. They changed the lube oil filters and bearing temperatures returned to normal. Without advanced notification by the Power Optimization Center, plant personnel would have received air preheater bearing temperature alarms when temperatures reached engineering limits. Bearing temperatures were rising rapidly and immediate action by plant personnel would have resulted in tripping the air preheater and thereby tripping the unit offline. Power Optimization Center intervention prevented a unit trip and potential equipment damage. The Savings The Power Optimization Center determines cost avoidance by applying proprietary calculations. This generating facility avoided $1,530,748 in lost revenue and $52,000 in additional maintenance costs, including parts and labor, totaling $1,582,748 in total cost avoidance. Utilizing over a dozen separate software systems that monitor and diagnose just about any issue that may affect plant operations, the Power Optimization Center has a proven history of helping manufacturing and generating facilities realize maximum asset performance. With power markets nationwide under low price pressures, generators more than ever need a way to analyze unit performance in real time to enhance efficiency, prevent shutdowns and save dollars. Whether your equipment resides in the utility industry, manufacturing or any other type of facility, the Power Optimization Center is ready to help your company achieve the highest levels of safety and reliability. Call us today to see how we can bring value to your company and visit www.pocdiagnostics.net to learn more.

Pulverizer Mill Lube Oil Pressure Low

POC
Power Optimization Center operators are always on alert. Complacency is not accepted. Read more about how the Power Optimization Center saved a generation facility $688,435 in Total Cost Avoidance by downloading our White Paper now.
The Luminant Power Optimization Center identifies, forecasts and advises plant personnel of emergent issues impacting production through the integration of remote monitoring, modeling and diagnostics. In the current market environment of low natural gas and wholesale power prices, and tightening emissions standards, generators need to produce megawatts as profitably as possible. The Power Optimization Center can help reach that goal. Upon discovering low lube oil pressure on a bowl mill lube oil system, Power Optimization Center personnel took immediate action, ultimately saving this generation facility $688,435 in total cost avoidance. The Problem Power Optimization Center operators are always on alert. Complacency is not accepted. At 8:30 a.m., the Power Optimization Center received a pulverizer mill lube oil low-pressure alarm. Plant operations was contacted and lube oil pressure was immediately, but temporarily, corrected and the alarm cleared. Then again at 3:50 p.m., the Power Optimization Center received the same alarm. Complacency would dictate that the issue had been remedied and the alarm was a nuisance alarm; however, Power Optimization Center operators are trained to trust their indications unless an instrumentation failure has been proven. The lube oil trend for that bank of pulverizers, along with associated trends, quickly revealed that the plant’s adjustment had the opposite effect. Lubrication is essential to any rotating machinery. The journal bearings installed in this type of pulverizer utilize a forced-oil system that relies on lube oil pressure and temperature to be within a specific band. When lube oil pressure lowers out of specification, bearing damage is likely to occur. The Solution The Power Optimization Center contacted the control room again and apprised plant operations of the decrease in pulverizer lube oil pressure for that bank of pulverizers, especially the ‘G’ pulverizer. Plant operations made another set of adjustments and ‘G’ pulverizer lube oil pressure returned to normal. If pulverizer lube oil pressure remained low with its slow continuous trend downward, then significant bearing damage would be expected. Replacing the affected bearings would have required a 30-day outage with a 9% power derate for the entire duration of repairs. The Savings The Power Optimization Center determines cost avoidance by applying proprietary calculations. This generating facility avoided $563,435 in lost revenue and $125,000 in additional maintenance costs, including parts and labor, totaling $688,435 in total cost avoidance. Utilizing over a dozen separate software systems that monitor and diagnose just about any issue that may affect plant operations, the Power Optimization Center has a proven history of helping manufacturing and generating facilities realize maximum asset performance. With power markets nationwide under low-price pressures, generators more than ever need a way to analyze unit performance in real time to enhance efficiency, prevent shutdowns and save dollars. Whether your equipment resides in the utility industry, manufacturing or any other type of facility, the Power Optimization Center is ready to help your company achieve the highest levels of safety and reliability. Call us today to see how we can bring value to your company and visit www.pocdiagnostics.net to learn more.

Primary Air Fan Bearing High Temperature

POC
Winter can be unpredictable and ambient temperatures can change in the blink of an eye, no matter how well the weather is forecast. One afternoon, temperatures plummeted and the wind strengthened, creating challenging conditions for any power plant. Power Optimization Center personnel received a primary air fan bearing temperature high alarm. Read more about how the Power Optimization Center saved a generation facility over $360,000 in Total Cost Avoidance by downloading our White Paper now.
PRIMARY AIR FAN BEARING TEMPERATURE HIGH The Luminant Power Optimization Center identifies, forecasts, and advises plant personnel of emergent issues impacting production through the integration of remote monitoring, modeling, and diagnostics. In the current market environment of low natural gas and wholesale power prices, and tightening emissions standards, generators need produce megawatts as profitably as possible. The Power Optimization Center can help reach that goal. For example, Power Optimization Center personnel discovered rapidly rising bearing temperature on a primary air fan Bearing. Swift action by the Power Optimization Center saved this generation facility over $360,000 in total cost avoidance. The Problem Winter can be unpredictable and ambient temperatures can change in the blink of an eye, no matter how well the weather is forecast. One afternoon, temperatures plummeted and the wind strengthened, creating challenging conditions for any power plant. Power Optimization Center personnel received a primary air fan bearing temperature high alarm. The operator recognized this temperature signature as an emergency requiring immediate action. Primary air fans provide the required air to carry crushed coal from the coal pulverizers into the boiler furnace. Without these fans, fuel could not be fed into the furnace and the plant would trip. Power Optimization Center Procedures state that plant control rooms should be contacted directly when emergency situations arise, minimizing the time between emergency and remedy. This allows for proper plant personnel to assess the situation and follow their procedures without delay, minimizing risk and maximizing response time. The Solution The Power Optimization Center contacted the control room and apprised plant operations of the rapidly rising bearing temperature. Oil flow to one of the primary air fan bearings was stopped due to freezing weather, causing the bearing to quickly overheat. Due to the timely notification by the Power Optimization Center, plant operations was able to restore oil flow before significant bearing damage occurred, avoiding a fan trip and a subsequent plant trip. Grid conditions are critical during significant weather events and even a single plant trip can be disastrous. The primary air fan was added to the Power Optimization Center Watchlist for additional scrutiny until the fan bearings could be inspected for damage. Not only did the Power Optimization Center help avert potential failure, but plant outage planning personnel also scheduled this asset for bearing inspection during the next available opportunity. They were able to replace the affected bearings during a scheduled outage rather than taking a forced outage during a time when much-needed generation was required to maintain grid reliability. The Savings The Power Optimization Center determines cost avoidance by applying proprietary calculations. This generating facility avoided $350,193 in lost revenue and $13,640 in additional maintenance costs, including parts and labor, totaling $363,833 in total cost avoidance. Utilizing over a dozen separate software systems that monitor and diagnose just about any issue that may affect plant operations, the Power Optimization Center has a proven history of helping manufacturing and generating facilities realize maximum asset performance. With power markets nationwide under low price pressures, generators more than ever need a way to analyze unit performance in real time to enhance efficiency, prevent shutdowns, and save dollars. Whether your equipment resides in the utility industry, manufacturing or any other type of facility, the Power Optimization Center is ready to help your company achieve the highest levels of safety and reliability. Call us today to see how we can bring value to your company and visit www.pocdiagnostics.net to learn more.

Pulverizer Mill Pinion High Bearing Temperature

POC
One hot summer day, the Power Optimization Center received a pulverizer mill outboard bearing high-temperature alarm. Power Optimization Center operators completed a swift investigation, comparing bearing temperatures for the alarming pulverizer mill to historical values, and they determined that the rising temperatures were not normal and needed immediate attention. Read more about how the Power Optimization Center saved a generation facility over $34,000 in Total Cost Avoidance by downloading our White Paper now.
PULVERIZER MILL PINION HIGH BEARING TEMPERATURE The Luminant Power Optimization Center identifies, forecasts and advises plant personnel of emergent issues impacting production through the integration of remote monitoring, modeling and diagnostics. In the current market environment of low natural gas and wholesale power prices and tightening emissions standards, generators need to produce megawatts as profitably as possible. The Power Optimization Center can help reach that goal. In particular, Power Optimization Center personnel discovered rapidly rising bearing temperature on a pulverizer mill outboard bearing. Quick action by the Power Optimization Center saved this generation facility $34,693 in total cost avoidance. The Problem On a hot summer day, the Power Optimization Center received a pulverizer mill outboard bearing high-temperature alarm on the main alarming system. The pulverizer mill crushes coal into a fine powder, allowing for rapid and complete combustion inside the boiler furnace. The mill pinion bearings are essential to mill operation, transferring rotational energy from the mill motor to the mill itself. Large steel balls move loosely inside this style of pulverizer housing, crushing the coal and allowing air from the primary air fans to carry fine coal dust from the pulverizer into the furnace. Power Optimization Center operators completed a swift investigation, comparing bearing temperatures for the alarming pulverizer mill to historical values, and they determined that the rising temperatures were not normal and needed immediate attention. Power Optimization Center procedures state that plant control rooms should be contacted directly when emergency situations arise, minimizing the time between emergency and remedy. This allows for proper plant personnel to assess the situation and follow their procedures without delay, minimizing risk and maximizing response time. The Solution The Power Optimization Center contacted the plant and apprised operations of the rapidly rising bearing temperature. Upon further investigation, they determined the pulverizer mill had been recently started and the plant duty shift supervisor found the auxiliary cooling fan breaker tripped. The auxiliary cooling fan indirectly cools the pulverizer mill bearings. If the pulverizer mill bearing became overheated, it would have experienced permanent damage, possibly causing extensive damage to the pulverizer mill itself, resulting in lost generation revenue and maintenance costs for repairs. The plant duty shift supervisor reset the auxiliary cooling fan breaker, which reset the cooling fans, and all pulverizer mill bearing temperatures returned to normal. The Savings The Power Optimization Center determines cost avoidance by applying proprietary calculations. This generating facility avoided $9,963 in lost revenue and $24,730 in maintenance costs, including parts and labor, totaling $34,693 in total cost avoidance. Utilizing over a dozen separate software systems that monitor and diagnose just about any issue that may affect plant operations, the Power Optimization Center has a proven history of helping manufacturing and generating facilities realize maximum asset performance. With power markets nationwide under low price pressures, generators more than ever need a way to analyze unit performance in real time to enhance efficiency, prevent shutdowns and save dollars. Whether your equipment resides in the utility industry, manufacturing or any other type of facility, the Power Optimization Center is ready to help your company achieve the highest levels of safety and reliability. Call us today to see how we can bring value to your company and visit www.pocdiagnostics.net to learn more. Typical Wiped Journal Bearing

 

Contact us today to see how we can help your facility!
Power Optimization Center
1601 Bryan St.
Dallas, TX 75201
214.875.8130
POCInfo@luminant.com