SENT Summary Report TG 500 Run Down 25th JUNE 2010

Contract No.
Preliminary Report
Run Down Vibration Monitoring Service Report
For TG 500
June 25th, 2010
Chevron Geothermal Salak, Ltd
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SKF-Reliability Systems Indonesia

PT. Skefindo Primatama
BRI II Bldg. 8th Fl. Suite 801, Jl. Jend. Sudirman Kav. 44-46, Jakarta 10210, Indonesia
Tel: + 62 21 5793 2244 Fax: + 62 21 5795 3115
E-mail: skefindo.primatama@skf.com Website: www.skfindonesia.com www.skf.com
CONTENT
1. Introduction
2. Scope of Service
2.1 Scope of Work
2.2 Duration of Work
2.3 Technical Vibration Analysis Report
3. Methodology
3.1 Overall Alarm Definition

3.2 Equipment Layout and Measurement Points
3.3 Turbine – Generator Manufacturing Data
4. Executive Summary
4.1 Steam Turbine – Generator Unit 500
5. Vibration Result & Analysis During Run Down
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1. INTRODUCTION
Referred to Turbine Generator Vibration Analysis and Measurement for in
Professional Services Contract No. C693083 between SKEFINDO PRIMATAMA and
CHEVRON GEOTHERMAL SALAK, Ltd, the 4TH of Quarterly Vibration of 3 Set Turbine
and Generator was performed in 6 June 2010 (Run down for overhaul TG unit 500), and
Detailed Vibration Analysis Report submitted in 11 June 2010
The accuracy and exactness of any machinery vibration analysis works depend to a great
extent to the availability of machine’s vibrations related data. This includes but not limited
to Turbine-Generator manufacture data, i.e. vibration severity data, key-phasor, and
vibration sensor. Though with some machines in your plant the data are not yet available,
we still tried to come up with an analysis based on our experiences on similar equipment
with other industries.
2. SCOPE OF SERVICE
Chevron Geothermal Salak, Ltd. (CGS) operates three units of turbine generator, namely
TG Unit 400, TG Unit 500, and TG Unit 600, each has 66 MW installed capacity. These
turbine-generators can be classified as critical equipments, since if any of the equipments
fails, production of CGS power plant can significantly be impaired. Consequently, the
number of unexpected failures must be minimized.
The philosophy behind a Condition Monitoring system is to allow a machine to continue to
operate as long as it runs within its performance parameters. When it doesn’t, the principal
intent of the program is to provide a warning of any conditions that are changing beyond
preset parameters and to initiate investigative or corrective action. This could involve the
process, the machine, or both.
Periodic condition monitoring can identify early failure that appears before a functional
failure occurred.
By having the means to anticipate problems and then plan accordingly, the equipment
reliability can be improved and unnecessary maintenance and production costs will be
reduced. This is a result of taking corrective action only when it needs to be done.
Some various failures mode of Turbine-generator are rotor imbalance, rotor bow,
misalignment, oil whirl, oil whip, mechanical looseness, resonance, electrical problem, soft
foot, rotor rub, and others.
The real time analyzer can give a comprehensive vibration data in real condition of turbine-
generator, can be captured and represented simultaneously in steady state and transient
(run-up & coast down) events.
2.1 Scope of Work

The works that will be performed in this project are the following
a. Provide vibration expert / engineer for vibration measurement complete with PPE at
Chevron Geothermal Salak Ltd.
b. Shall measure and analyze vibration data at agreed schedule to the equipment
below:
i. Turbine T-400 and Generator G-400 (1 Unit)
ii. Turbine T-500 and Generator G-500 (1 Unit)
iii. Turbine T-500 and Generator G-500 (1 Unit)
iv. Other rotating equipment as per Chevron Geothermal Salak, Ltd needed
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c. Carry out quarterly monitoring and analyzing of Turbine and Generator based on
the agreed schedule.
d. Prepare and setup all vibration tools and instrumentation.
e. Measure and analyze Turbine and Generator vibration data at full load.
f. Analyze vibration data and trend to determine the equipment condition. Contractor
shall also detect failure occurred on the equipment and procedure Possible Failure
Root Cause Analysis.
g. Provide engineering suggestion for corrective actions and performance
improvements.
h. Propose preliminary report/field report and final report. The report should contain:
i. Trending of vibration data and complete data, including the limit value for
each parameter shall comply with ISO: 10816 series, 7919 series, API 612,
API 670.
ii. Assessment of machine condition
iii. Fault diagnostic of equipment failure
iv. Suggested corrective actions or performance improvement.
i. Perform presentation (if required), by qualified person from Skefindo Primatama
(SKF)
Skefindo Primatama, PT (SKF) will provide:

• International Qualified personnel’s (ASNT LEVEL 2A (ISO CAT.II), LEVEL 2B (ISO
CAT.III) and ASNT LEVEL 3) guidelines stipulated SNT-TC-1A and ISO 18436-2
Standard.
• Real Time Analyzer – SKF Data Acquisition IMx-P, Portable Advance Analyzer –
SKF GX / AX Series, and Any accessories (cables, connectors, any consumable,
etc.)
• SKF Observer ver. 8.3 and SKF @ptitude Analyst Software’s
• Preliminary / Detail report maximum 2 weeks after visit & Print out and soft copy of
report.
• SKF Standard and procedures for Condition Monitoring activities, Transportation
and PPE.
Chevron Geothermal Salak, Ltd will provide:

• Site safety orientation and Permit of Work.
• Power to perform the job and Working place and Lunch / Dinner at Salak Area.
2.2 Duration of Work

This work is planned to be performed within 2 years duration in 8 times visit. There is one
(1) steady state event (normal condition) have been performed of vibration measurement.
2.3 Technical Vibration Analysis Report

This is a 3rd measurement report and the result and analysis resumes referred to the latest
report from SKF and CGS technical information.
This report is based on technical visit dated on 23 April 2010 versus 25 January 2010.
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3. METHODOLOGY
There are two methods of vibration measurement that will be conducted in this project, i.e.
shaft vibration (relative motion) by Proximity Probe and bearing housing vibration
(absolute motion) by Acceleration Probe.
The shaft vibration measurement will be conducted using the existing proximities and the
running speed will be monitored by key-phasor.
On machines with plain bearings (journal bearings), high casing to rotor weight ratios and
high damping, the non-contacting displacement probe measures the actual motion of the
shaft relative to the bearing at the direction as well as the amount (Figure 1).
The bearing housing vibration is measured by acceleration sensor within 2 channel
vibration method in simultaneous condition. Accelerometers are favored over velocity
transducers because of their better frequency response, ruggedness and price and are
preferred by API
(American Petroleum Institute) 678 standards. Bearing housing is a special case of the
high transmissibility system, and accelerometers are useful in detecting small impact of
frequency signals that are often early warning of internal damage (Figure 2).
Figure 2 Figure 1
All data will be acquired using SKF IMx-P & AX / GX Series and be processed further
using analyzer software - Observer SW & Aptitude Analyst SW.
3.1 Overall Alarm Definition
After review of all spectral data on a machine, if no problems are found, the first two
columns
(“Good” and “Fair”) are offered to give the customer a general feel for the overall
condition of each machine being assessed.
Corrective action should be taken on those machines having vibration exceeding
“Warning or ALARM 1” , while those exceeding “Fault or ALARM 2” are felt to be
exposed to such high levels as to render potentially catastrophic failure.
Much work continues today on establishing standards for allowable overall vibration. This
includes the international working on machinery vibration standards, which is now working
to update several criteria.
To acquire vibration data, Two (2) parameters of vibration amplitudes normally are used:
1. Vibration Velocity (by Acc. Sensor) [Horizontal Velocity (HORIZ-Vel), Vertical Velocity
(VERT-Vel), Axial Velocity (AXIAL-Vel)] - Used to represent commonly experienced fatigue
problems like misalignment, imbalances, etc.) In mm/sec or in/sec
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a. ISO 10816-2; 1996 – Mechanical vibration. Evaluation of machine vibration by
measurements on non-rotating parts. Large land based steam turbine generator
sets in excess of 50MW.
b. Overall condition rating of Technical Associates of Charlotte, Inc. Copyright

2000 with additional criteria for using these ratings are bellow:
1. Assuming Machine Speed = 500 to 50000 RPM; Assuming Measurement by Accelerometer
or Velocity Pickup securely mounted as Close as Possible to Bearing Housing
2. Assuming Machine Is Not Mounted on Vibration Isolators (for Isolated Machine - Set Alarm
30-50% Higher); Set Motor Alarms the Same as that for the Particular Machine Type unless
Otherwise Noted.
3. Consider Setting Alarms on Individual External Gearbox Positions about 25% Higher than
that for a particular Machine Type
2. Vibration Displacement (by Proximity Sensor) Vertical Displacement (VERT-Displ]

– It is used to measure shaft vibration, radial and axial shaft positioning and
differential expansion between the case and rotor in mils or micron p-p.
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a. Vibration Displacement & Velocity Chart (Entek IRD Internationa, Milford,OH)
101.6 µm p-
50.8 µm p-p
3000 RPM
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b. Vibration Displacement Standard (Manufacturing Standard – Fuji Electric
Co.,Ltd)
TZ
TURBINE 500 GENERATOR 500
T1 T1 T2 T2 G1 G1
G2 G2
MANUFA TURBINE (µm p-p) GENERATOR (µm p-p)

C. STD
AXIA RADIAL RADIAL
L
TZ T1X T1Y T2X T2Y G1X G1Y G2 G2Y
X
ALERT 125 125 125 125 125 125 125 12 125
5
DANGER 250 250 250 250 250 250 250 25 250
0
c. ISO 7919-2 2nd Edition (2001-11-15) - Land-based steam turbines and generators
in excess of 50 MW with normal operating speeds of 1 500 r/min, 1 800 r/min, 3000
r/min and 3500 r/min
Recommended values for maximum relative displacement of the shaft for steam turbines
and generators at the zone boundaries
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The ISO standards classify vibration level I the four zones i.e.:
1. Zone A: The vibration of newly commissioned machine would normally fall
within this zone.
2. Zone B: Machines with vibration within this zone are normally considered
acceptable for unrestricted long-term operation.
3. Zone C: Machines with vibration within this zone are normally considered
unsatisfactory for long-term continuous operation. Generally, the machine
may be operated for a limited period in this condition until a suitable
opportunity arises for remedial action.
4. Zone D: Vibration value with this zone are normally considered to be
sufficient severity to cause damage to the machine
Priority 1 Failure is imminent. Requires immediate attention and repair

FAULT / CRITICAL shutdown should be seriously considered.
(C/D) Closely monitoring of the machine is a must.
Priority 2
WARNING Plan the repair shutdown on the next opportunity.
(B/C)
Priority 3
FAIR Minor problem. Trending only.
(A/B)
Priority 4 NO action is recommended at this level. Data acquisition is as per
GOOD / NORMAL
(A) schedule.
3.2 Equipment Layout and Measurement Points
TZ
TURBINE 500 GENERATOR
500
T1 T1 T2 T2 G1 G1
G2 G2
Bently
Nevada
By Control Panel
IMx-P
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TURBINE 500 GENERATOR
500
T1 - T2 - G1 - G2 -
T1 - X T2 - X X G1 - X G2 -
T1 -
Vertical T2 - G1 - G2 -
Horizontal
Axial
GX Series
By STG Bearing Housing
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3.3 Turbine - Generator Manufacturing Data
TURBINE
Manufacture Fuji Electric Co., Ltd
Type 2 Cylinders, 2 flow, reaction, condensing
Rated Speed 3000 RPM
st
Critical Speed (1 ) 2200 RPM
Rated Output 70 MW gross
Stage 2x9 stages
Rotor Weight 31799 kg
Bearing NDE Thrust bearing and Journal bearing
Bearing DE Journal Bearing
Journal Bearing Base carbon steel and Surface Babbitt – 10.6 mm (thick)
Double wedge (type); 430 µm (design clearance); Kongo (Manufacturer)
Thrust Bearing Base CrMoNiV forged steel and surface babbitt
8 (number of pad); Mitchell (type); 660 mm2 (surface area); Kongo
(manufacturer)
GENERATOR
Manufacture Fuji Electric Co., Ltd
Type Synchronous
Number of Pole 2
Enclosure Totally Enclosed Water / Air Cooled (TEWAC)
Output Capability 70 MVA
Rate Speed 3000 RPM
Critical Speed (1st Speed) 1303 RPM
Efficiency (full load) 98.4%
Rate Voltage 11.8 kVA
Frequency 50 Hz
Current 3166 A
Coolant Temp 46 Deg Celsius (mech. design), 27.2 Deg Celsius (Process design)
Number of Phase 3
Insulation F
Rotor Weight 20400 Kg
Bearing NDE Journal bearing
Bearing DE Journal bearing
Journal Bearing Base carbon steel and surface Babbitt 10.6 mm (thick)
Double wedge (type); 430 µm (design clearance); Kongo (Manufacturer) Page11

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4. EXECUTIVE SUMMARY
4.1 Steam Turbine – Generator Unit 500

4.1.1 Regarding captured online vibration monitoring TG unit #500 for run-down condition
on 25 June 2010, found OA vibration amplitudes at normal speed (steady state) and
turning gear condition below in range/standard, but still found slightly run-out on
turbine and generator side, also still in below range/standard. Turbine Generator
Unit #500. Generally is in normal condition
4.1.2 Captured vibration monitoring by using SKF GX-S handheld data collector device to
take bearing housing vibration (body measurement) to monitor run-down condition
of such of 1X and 2XRPM frequencies especially at power transmission – Coupling
side and combine with take shaft on line vibration data by BN-3300 no significant
vibration amplitude and specific frequencies, they are in normal condition
4.1.3 Check for rotor run-out (mechanical and electrical) on Turbine & Generator’s rotor
at next TA
5. VIBRATION RESULT & ANALYSIS

5.1 OVERALL VIBRATION RATING ISO 7919-2 – TG UNIT 500 AT STEADY STATE
AND TURNING GEAR
OVERALL DATA TURBINE GENERATOR FOR RELATIVE MOTION MEASUREMENT
T/G Unit 500 – Steady State (variable load) and Turning Gear
Amplitude Standardization
Steady Steady Steady Turning
ASSET POSITIO POINT state 100% state state 8 % Gear
NAME N NAME ISO 7919-2 Manuf.
50%
(µm p-p)
T1-X 16.73 16.86 16.13 7.45 80 / 165 125 / 250
T-NDE
TURBINE T1-Y 23.93 23.96 23.57 10.22 80 / 165 125 / 250
SIDE T2-X 17.16 16.91 14.75 11.47 80 / 165 125 / 250
T-DE
T2-Y 9.99 11.25 9.67 13.83 80 / 165 125 / 250
G1-X 16.40 16.78 16.18 9.42 80 / 165 125 / 250
G-DE
G1-Y 24.54 22.77 22.77 9.82 80 / 165 125 / 250
GEN. SIDE
G2-X 14.62 15.36 15.36 6.07 80 / 165 125 / 250
G-NDE
G2-Y 36.00 30.49 30.49 7.07 80 / 165 125 / 250
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ORBIT AND TIME WAVEFORM TURBINE GENERATOR FOR RELATIVE MOTION
MEASUREMENT
Steady State Condition Turbine Side T1XY
Turning Gear Condition Turbine Side T1XY
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Turning Gear Condition Generator Side T3XY
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Steady State Condition Generator Side T4XY
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Asset Name Status Vibration Analysis – Shaft Vibration (relative motion)
Appeared 1X and 2X RPM in orbit and spectrum plots although overall vibration
TURBINE is in normal level referred to ISO and Manufacturer standards.
T-NDE OA decreased at TG (turning gear) condition. Slightly spike signal at time
waveform appeared. Check run out shaft at first time.
Appeared normal impact signals (1XRPM and 2XRPM) with normal shaft
TURBINE vibration amplitude. Overall vibration is in normal condition, slightly spike signal
T-DE at time waveform appeared. The overall vibration is in stable condition. Check
run out shaft at first time.
Appeared spike signal in orbit (time waveform) as suspected the rotor surface
GENERATOR
has run out (electrical and mechanical). The OA vibration is in below range. OA
G-DE decreased at Turning Gear (TG) condition. Check run out shaft at first time.
Slightly similar with DE generator appeared spike signal in orbit (time waveform)
GENERATOR as suspected the rotor surface has run out (electrical and mechanical). The OA
vibration is in below range. OA decreased at Turning Gear (TG) condition. Check
G-NDE
run out shaft at first time.
5.2 OVERALL VIBRATION RATING ISO 10816-2 – TG UNIT 500 S

A. TURBINE GENERATOR FOR ABSOLUTE MOTION MEAS. (BEARING HOUSING
VIBRATION)
Measurement Type Standardization
ISO Proven
OA DERIVED PEAK
ASSET 10816-2 Method
Point
NAME Steady Steady Turning
Steady
State State Gear Mm/s peak
State 8%
100% 50%
T1-Z 1.63 1.87 1.86 0.15 5.4/10.6 6.9/10.2
T1-X 1.71 1.30 2.33 0.10 5.4/10.6 6.9/10.2
TURBINE T1-Y 1.25 2.65 2.11 0.09 5.4/10.6 6.9/10.2
SIDE T2-Z 2.03 1.94 1.35 0.13 5.4/10.6 6.9/10.2
T2-X 0.76 1.64 1.17 0.06 5.4/10.6 6.9/10.2
T2-Y 1.63 0.97 1.08 0.05 5.4/10.6 6.9/10.2
G1-Z 1.90 1.34 1.55 0.11 5.4/10.6 6.9/10.2
G1-X 2.48 2.73 1.21 0.19 5.4/10.6 6.9/10.2
GENERA
G1-Y 1.47 1.18 1.09 0.05 5.4/10.6 6.9/10.2
TOR
G2-Z 3.94 4.25 3.48 0.17 5.4/10.6 6.9/10.2
SIDE
G2-X 2.64 2.09 2.48 0.13 5.4/10.6 6.9/10.2
G2-Y 3.02 1.64 1.91 0.10 5.4/10.6 6.9/10.2
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5.3 TURBINE GENERATOR UNIT 500 (TIME WAVEFORM PATTERN)
T1Z
T1X
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T1Y
T2Z
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T2X
T2Y
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T3Z
T3X
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T3Y
T4Z
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T4X
T4Y
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5.4 VIBRATION ANALYSIS TG UNIT 500 AT HOUSING BEARING
Asset Name Status Vibration Analysis through STG Bearing Housing
Dominant frequency still at 1X and 2X RPM in spectrum also random

frequency. Characteristic spectrum at steady state to run down the spectrum
TURBINE
most similarly and OA very minor when TG condition stage. Overall
T-NDE Vibration is still in normal level referred to ISO and Manufacturer standards.
NO SIGNIFICANT Found.
DE Turbine side 1XRPM minor 2XRPM and mix with random frequency.
TURBINE The overall vibration value was very minor at this point. Characteristic the
T-DE spectrum most similarly. Vibration is in normal level referred to ISO and
Manufacturer standards. NO SIGNIFICANT Found.
Steady state condition to run down frequency still dominant at 1X and 2X

GENERATOR RPM mix with the slightly harmonic frequency characteristic spectrum
G-DE relative similar, vibration relative stable at steady state and very less at TG.
The overall vibration is in normal condition. NO SIGNIFICANT Found.
The axial direction dominant frequency at 1X and 2X RPM (for 2XRPM

GENERATOR suspected 2XElectric line Freq.) mixed with the slightly harmonic frequency,
G-NDE characteristic spectrum relative similar vibration relative stable at steady
state and very less at TG, at radial measurement still appeared harmonic
spectrum The overall vibration is in normal condition NO SIGNIFICANT
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CASCADE
BEARING #1 TURBINE SIDE HORIZONTAL
BEARING #1 TURBINE SIDE VERTICAL
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BEARING #2 TURBINE SIDE HORIZONTAL
BEARING #2 TURBINE SIDE VERTICAL
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BEARING #3 GENERATOR SIDE HORIZONTAL
BEARING #3 GENERATOR SIDE VERTICAL
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BEARING #4 GENERATOR SIDE HORIZONTAL
BEARING #4 GENERATOR SIDE VERTICAL
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BODE PLOT
TURBINE SIDE BEARING #1 & #2
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GENERATOR SIDE BEARING #3 & #4
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SCL BEARING #1
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SCL BEARING #2
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SCL BEARING #3
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SCL BEARING #4
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5.5 CASCADE,BODE PLOT AND SCL ANALYSIS TG UNIT 500 AT RUN DOWN
Asset Name Status Analysis of cascade,bode plot,shaft centre line TG 600
The full spectrum cascade of shaft vibration measured on turbine non drive
st
and bode plot depicted those figures are indicated that the 1 critical speed
is approximately 1002 rpm
TURBINE The plot of average shaft centre line during run-down condition measured at
SIDE turbine side shown that the average turbine shaft centre line migrates in the
down-right direction when the turbine speed reduce and the range of
migration in acceptable range. This average shaft migration confirms that
bearing were working under considerably good operation condition
The full spectrum cascade of shaft vibration measured on turbine non drive
and bode plot depicted these figures are indicated that the 1st critical speed
is approximately 1436 rpm
GENERATOR The plot of average shaft centre line during run-down condition measured at
SIDE generator side that the average generator shaft centre line migrates in the
down-right direction when the turbine speed reduce and the range of
migration in acceptable range. This average shaft migration confirms that
bearing were working under considerably good operation condition
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SENT Summary Report TG 500 Run Down 25th JUNE 2010

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Contract No.

Chevron Geothermal Salak, Ltd

SKF-Reliability Systems Indonesia

3.1 Overall Alarm Definition

5. Vibration Result & Analysis During Run Down

SKF-Reliability Systems Indonesia

2.1 Scope of Work

SKF-Reliability Systems Indonesia

Skefindo Primatama, PT (SKF) will provide:

Chevron Geothermal Salak, Ltd will provide:

2.2 Duration of Work

2.3 Technical Vibration Analysis Report

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

b. Overall condition rating of Technical Associates of Charlotte, Inc. Copyright

2. Vibration Displacement (by Proximity Sensor) Vertical Displacement (VERT-Displ]

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

MANUFA TURBINE (µm p-p) GENERATOR (µm p-p)

SKF-Reliability Systems Indonesia

Priority 1 Failure is imminent. Requires immediate attention and repair

3.2 Equipment Layout and Measurement Points

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

4.1 Steam Turbine – Generator Unit 500

5. VIBRATION RESULT & ANALYSIS

OVERALL DATA TURBINE GENERATOR FOR RELATIVE MOTION MEASUREMENT

SKF-Reliability Systems Indonesia

Steady State Condition Turbine Side T1XY

Turning Gear Condition Turbine Side T1XY

SKF-Reliability Systems Indonesia

Turning Gear Condition Turbine Side T2XY

SKF-Reliability Systems Indonesia

Turning Gear Condition Generator Side T3XY

SKF-Reliability Systems Indonesia

Turning Gear Condition Turbine Side T4XY

SKF-Reliability Systems Indonesia

5.2 OVERALL VIBRATION RATING ISO 10816-2 – TG UNIT 500 S

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

Asset Name Status Vibration Analysis through STG Bearing Housing

Dominant frequency still at 1X and 2X RPM in spectrum also random

Steady state condition to run down frequency still dominant at 1X and 2X

The axial direction dominant frequency at 1X and 2X RPM (for 2XRPM

SKF-Reliability Systems Indonesia

BEARING #1 TURBINE SIDE HORIZONTAL

BEARING #1 TURBINE SIDE VERTICAL

SKF-Reliability Systems Indonesia

BEARING #2 TURBINE SIDE VERTICAL

SKF-Reliability Systems Indonesia

BEARING #3 GENERATOR SIDE VERTICAL

SKF-Reliability Systems Indonesia

BEARING #4 GENERATOR SIDE VERTICAL

SKF-Reliability Systems Indonesia

TURBINE SIDE BEARING #1 & #2

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia

SKF-Reliability Systems Indonesia