Integrated Condition Monitoring of Large Captive Power Plants and Aluminum Smelters

Condition monitoring is implementation of the advanced diagnostic techniques to reduce downtime and to increase the efficiency and reliability. The research is for determining the usage of advanced techniques like Vibration analysis, Oil analysis and Thermography to diagnose ensuing problems of the Plant and Machinery at an early stage and plan to take corrective and preventive actions to eliminate the forthcoming breakdown and enhancing the reliability of the system. Nowadays, the most of the industries have adopted the condition monitoring techniques as a part of support system to the basic maintenance strategies. Major condition monitoring technique they follow is Vibration Spectrum Analysis, which can detect faults at a very early stage. However implementation of other techniques like Oil analysis or Ferrography, Thermography etc. can further enhance the data interpretation as they would detect the source of abnormality at much early stage thus providing us with a longer lead time to plan and take the corrective actions. In Large Captive Power Plants and Aluminium Smelters, Integrated Condition Monitoring techniques play an important role as stoppage of primary system and its auxiliaries (boiler, steam turbine, generator, coal and ash handling plants etc.) results into the stoppage of the entire plant, which in turn leads to loss of productivity. From economical and operational point of view, it is desirable to ensure optimum level of system availability.