INTRODUCTION

TO
TURBOVISORY INSTRUMENTS
Surajit Ghosh
Sr. Supdt (C&I), BTPS

Presentation outline
Turbovisory Parameters
Measurement of Turbovisory parameter
Introduction to Vibration Measurement
Type of Vibration Sensors and their
installation
Differential Expansion /Axial Shift and their
Installation
Speed /Brg Metal temp/Valve Position

TURBOVISORY PARAMETERS
VIBRATIONS
- SHAFT VIBRATION / ECCENTRICITY
- BEARING VIBRATION
TURBINE EXPANSION
- OVERALL EXPANSION
- DIFFERENTIAL EXPANSION
- AXIAL SHIFT
SPEED / OVERSPEED
LOAD
BEARING BABBIT METAL TEMPERATURES
MS / HRH PRESSURE / TEMPERATURE
TURBINE METAL TEMPERATURE
VACUUM
LUB OIL PRESSURE / TEMPERATURE
HP / LP EXHAUST TEMPERATURE
GLAND STEAM HEADER TEMPERATURE

CROSS SECTION OF TURBINE

RELATIVE EXPANSION
ABS EXPANSION

RELATIVE SHAFT VIBRATION

REL EXPANSION

ABSOLUTE BRG VIBRATION

REL SHAFT VIBRATION

ABS BRG VIBRATION

REL EXPANSION
ECCENTRICITY
ABS BRG VIBRATION

ABS EXPANSION
AXIAL SHAFT POSITION

ABSOLUTE BRG VIBRATION

REL SHAFT VIBRATION

ABSOLUTE BRG VIBRATION

ABS BRG VIBRATION

VIBRATION MEASURING
INSTRUMENTATION
SHAFT VIBRATION / ECCENTRICITY
- PROXIMITY PROBE
BEARING VIBRATION
- VELOCITY PICK UP

What are the different

ways?

Overall
Time domain
Frequency domain
Envelope analysis
Cepstrum analysis
Wavelet analysis
Etc

Basic Theory Of Vibration

Simple Spring Mass System

Upper Limit
Neutral Position
Lower Position
Max Velocity, Min Acceleration

Displacement

Max Acceleration, Min Velocity

Max Acceleration, Min Velocity

IT FOLLOWS SINE CURVE

VIBRATION MONITORING
WHAT IS VIBRATION ?
WHAT CAUSES VIBRATION ?
HOW DO WE MEASURE VIBRATION ?
HOW DO WE ANALYSE VIBRATION ?

What Is Vibration?

It is the response of a
system to an internal or
external force which
causes the system to
oscillate.

2. Measurement direction Horizontal, Vertical, Axial.

General rule of direction

We measure H direction for machines
on the foundation.
We measure V direction for machines
on structures
We measure A direction when we
suspect misalignment
There are advantages, but there are
exceptions to this rule.

VIBRATION MONITORING
Modes of Amplitudes

DISPLACEMENT

VELOCITY

ACCELERATION

SPIKE ENERGY

Physical Significance Of Vibration

Amplitude

Displacement : Strain Indicator

Velocity

: Fatigue Indicator

Acceleration : Force Indicator

The significance

Displacement gives the strain energy

Velocity gives the kinetic energy
Acceleration gives the force
Spike energy/HFD/gE are special
ways to measure acceleration only.

VIBRATION MONITORING
UNITS OF MEASUREMENT
DISPLACEMENT

- MICRONS

VELOCITY

- MM / SEC.

ACCELERATION

- MM / SEC2 , G

VIBRATION
MONITORING
AMPLITUDE DESCRIPTORS
RMS

Displacement
Velocity

PEAK

1.414 RMS Displacement

Velocity
Acceleration

PEAK-TO-PEAK -

2 * PEAK

Displacement

WHEN TO USE DISPLACEMENT, VELOCITY & ACCELERATION

VIBRATION
SENSITIVITY

DISPLACEMENT

10
1
.1

VELOCITY

.01
.001

ACCELERATION

FREQUENCY
CPM

60

600

6000

60000

600 000

SIMPLE VIBRATION
Time Domain
Amplitude
(mm)

A
Time
(sec)
Period T
Amplitude
(mm)

Frequency Domain

f=1/T

Frequency f
(Hz)

REAL VIBRATION
Time Domain
Amplitude
(mm)

Time
(sec)

Amplitude
(mm)

Frequency Domain - Vibration Signature

Frequency f
(Hz)

Amplitude & Frequency

Amplitude:
It is the magnitude of Vibration signal.
Units: Micron, MM/Sec, M/Sec2
Frequency:
How many times oscillation is occurring
for a given time period?
Units: CPS(Hz), CPM

VIBRATION MEASURING
INSTRUMENTS
Analyser : Measures all the three
characteristics viz. Amplitude, Freq. and Phase
Meter
: Measures only Amplitude
Thus we can have METERS of various types
Displ. And Velocity- Normally uses velocity
pickup
Displ., Velocity, Acceleration and Bearing
Condition- Normally uses Accelerometer
The heart of the instrument is the sensor

Vibration Sensors
Acceleration Sensor Accelerometer
Velocity sensor Velocity
sensor or seismic sensor
Displacement sensor - Non
Contact pickup
Accelerometer

Accelerometer
Piezoelectricity
Emf proportional
to force
Emf proportional
to acceleration
(Mass constant)
Hence called
accelerometer

Accelerometer

Accelerometer cont..

Uses piezoelectric crystal

Normally uses internal amplifier for boosting signal
It will have low temp application up to 150 degree C
For high temperature application amplifier is not given
inside
This causes low signal strength and we use gold plated
contacts and small cable lengths (output rated in pc
per g). The amplification is done outside
Normal accelerometer (amplifier inside) will have
strong signal output and can sustain cable lengths of
300 meter
Available in several design, can go from DC to 10k Hz
freq (600,000 CPM)
Can measure Acceleration, velocity and displacement
It is advised to involve suppliers or persons
knowledgeable in this area to choose accelerometers
for on line monitoring applications

Velocity sensor
Output=B*l*V

B & l are constant

Output is proportional to velocity, hence the name Velocity sensor

Spring
Terminals

Magn
et
Coil
Magnet

Aluminum case

Damper

Velocity sensor cont.

This is self generating (764 mv per mm/sec)
Can sustain cable length of 1000 feet easily
For longer length intermediate amplification
is needed
The temperature rating is higher up to 250
degree C (no electronics inside)
Sensitive to 60,000 CPM
Can check velocity and displacement only

Non contact type

Non contact
sensor
Installation
in a Turbine

ABSOLUTE BEARING
VIBRATION

VELOCITY TRANSDUCER
SEISMIC MASS TYPE
Works on PLUNGER COIL PRINCIPLE.
Two permanent magnets rigidly fixed to
the casing with coils arranged as seismic
mass.
The Relative motion between the coil and
magnet generates voltage proportional to
vibration velocity.

ABSOLUTE SHAFT
VIBRATION
RELATIVE SHAFT VIBRATION IS BASED ON EDDY
CURRENT PRINCIPLE.
PROXIMOTY PROBE SENSES THE DISTANCE
BETWEEN THE PROBE TIP AND THE OBSERVED
SURFACE.
PROXIMETER GENERATES A FREQUENCY
SIGNAL, WHICH IS RADIATED THROUGH THE
PROBE TIP INTO THE OBSERVED SURFACE. EDDY
CURRENTS ARE GENERATED IN THE SURFACE
AND LOSS OF STRENGTH IN THE RETURN
SIGNAL IS DETECTED BY THE PROXIMETER.

SHAFT & BEARING

VIBRATION PICK UP

BEARING / SHAFT VIBRATION PICK UP

MOUNTED ON BEARING NO. 4 PEDESTAL

RECOMMENDED LOCATIONS OF VIBRATION

MEASUREMENTS FOR PEDESTAL BEARINGS

RECOMMENDED LOCATIONS OF VIBRATION

MEASUREMENTS FOR HOUSING TYPE
BEARINGS (

Measurin
g
Amplifier
Proximity
Pick-up

45O

45O

SHAFT

RECOMMENDED LOCATIONS OF SHAFT

VIBRATION MEASUREMENTS

Measurin
g
Amplifier
Proximity
Pick-up

SHAFT

RECOMMENDED LOCATIONS OF SHAFT

VIBRATION MEASUREMENTS

ECCENTRICITY
DEVIATION OF MASS CENTER FROM THE
GEOMETRICAL CENTRE OF THE BEARING
JOURNAL.
PROPORTIONAL TO MAX ROTOR DEFLECTION
OCCURING AT THE MIDDLE OF SHAFT
MEASURED BY VARIATIONS OF AN A.C.
CURRENT IN A COIL DUE TO VARIATION IN
PROXIMITY OF TARGET MATERIAL
INDUCTIVE TRANSDUCER
PROXIMITY(EDDY CURRENT) TRANSDUCER

INDUCTIVE TRANSDUCER
TWO MAGNETICALLY RELUCTANCE TYPE
TRANSDUCERS IN BRIDGE
CONFIGURATION, EXCITED BY 10V AC
(1953 HZ)
BRIDGE OUTPUT IS MODULATED BY A
PERCENTAGE PROPORTIONAL TO AMOUNT
OF ECCENTRICITY WITH A MODULATING
FREQUENCY PROPORTIONAL TO ROTOR
SPEED
DEMODULATOR, FILTER,AMPLIFIER &
AMPLITUDE DETECTOR

PROXIMITY TRANSDUCER
SENSES THE DISTANCE BETWEEN THE
PROBE TIP AND OBSRVED SURFACE
PROXIMETER GENERATES RF SIGNAL,
RADIATED THROUGH PROBE TIP INTO
OBSERVED SURFACE.
EDDY CURRENTS ARE GENERATED IN THE
SURFACE AND THE LOSS OF STRENGTH IN
THE RETURN SIGNAL IS DETECTED.
LOSS OF POWER PROPORTIONAL TO GAP
BETWEEN PROXIMETER & CONDUCTIVE
BODY.

EXPANSION MEASURING
INSTRUMENTS
OVERALL EXPANSION
- POSITION TRANSMITTER
DIFFERENTIAL EXPANSION MEASUREMENT
- PROXIMITY PROBE
AXIAL SHIFT MEASUREMENT
- PROXIMITY PROBE

DIFFERENTIAL EXPANSION
THE DIFFERENCE OF AXIAL EXPANSION
BETWEEN THE ROTOR AND THE CASING
POSITIVE IF SHAFT EXPANDS MORE THAN
CASING,NEGATIVE IF CASING EXPANDS MORE
THAN SHAFT
CASING EXPANSION & ROTOR EXPANSION
MEASURED SEPARATELY AND DIFF EXPANSION
IS CALCULATED
ROTOR EXPANSION MEASURED AT HP FRONT &
IP REAR, LP REAR .
MEASURING COLLAR IS IN THE FORM OF
DOUBLE CONE.

DIFFERENTIAL EXPANSION (FOR SMALL

EXPANSION) & AXIAL SHIFT PICK UP

IP DIFFERENTIAL EXPANSION PICK UP

MOUNTED ON BEARING NO. 3 PEDESTAL

LP DIFFERENTIAL EXPANSION PICK UP

MOUNTED ON BEARING NO. 4 PEDESTAL

CASING EXPANSION

MEASUREMENT CARRIED OUT AT HP CASING

FRONT & IP CASING ON THE REAR SIDE.
DISPLACEMENT SENSOR MOUNTED ON THE
PEDESTAL COVER AND CONNECTED TO THE
CASING VIA A ROPE. THE OTHER END OF THE
ROPE IS CONNECTED TO A ROTABLE
MEASURING DEVICE.
ROTABLE MEASURING DEVICE ROTATES
ECCENTRIC TO THE TWO SENSOR COILS WHICH
CREATE DIFFERENT AIR GAPS BETWEEN THE
MEASURING DEVICE AND THE COILS .

AXIAL SHIFT OF ROTOR

MEASUREMENT YIELDS INFORMATION ON
THE POSITION OF THE SHAFT IN THE
THRUST BEARING AND ON WEAR OF THE
BEARING.
AXIAL SHIFT BEYOND PERMISSIBLE LIMIT
WOULD LEAD MECHANICAL
INTERFERENCE & SURFACE RUBBING.
MEASURED BY EDDY CURRENT PRINCIPLE.
MASUREMENT RANGE IS -1.5 TO 1.5 MM

OVERALL EXPANSION PICK UP

OVERALL EXPANSION MOUNTED

ON BEARING NO. 1 PEDESTAL

DIFFERENTIAL EXPANSION (FOR SMALL

EXPANSION) & AXIAL SHIFT PICK UP

DIFFERENTIAL EXPANSION (FOR SMALL

EXPANSION) & AXIAL SHIFT PICK UP

IP DIFFERENTIAL EXPANSION PICK UP

MOUNTED ON BEARING NO. 3 PEDESTAL

AXIAL SHIFT MEASUREMENT AT IP COLLAR

DIFFERENTIAL EXPANSION (FOR LARGE

EXPANSION) PICK UP

LP DIFFERENTIAL EXPANSION PICK UP

MOUNTED ON BEARING NO. 4 PEDESTAL

SPEED, LOAD MEASURING

INSTRUMENTS
SPEED / OVERSPEED
- KEY PHASOR
- HALL PROBE
LOAD MEASUREMENT
- CURRENT TRANSFORMERS
- POTENTIAL TRANSFORMERS

SPEED SENSOR
Mechanical governor :Radius of flywheel
changes due to change in speed (effect of
centrifugal forces)
Hydraulic Governor: Hydarulic pressure
developed by the primary oil pump
changes due to change in speed
Electrical governor: Three no hall probe
supply voltage pulse each time
permanent magnet pass them.

SPEED MEASUREMENT
CONSISTS OF SLOTTED DISC(FITTED AT
THE TURBINE SHAFT) WITH 60 RADIAL
SLOTS AND MAGNETIC PROBE(HALL
PROBE) MOUNTED FACING THE SLOTS.
4 NO OF HALL PROBES, 3 USED, 1 SPARE
PULSE CONVERTER WITH 3 ISOLATED
OUTPUTS (2 ARE USED)
2 CHANNEL MEASUREMENTS

4 : HYDRAULIC SPEED TRANSDUCER

5 : ELECTRIC SPEED TRANSDUCER

SPEED MEASUREMENT INSTRUEMENT MOUNTED

IN HP FRONT BEARING PEDESTAL

HALL PROBE

HALL PROBE IN BEARING NO. 1 PEDESTAL

OVERSPEED TRIP BOLTS IN BEARING NO. 1 PEDESTAL

PRESSURE, TEMPERATURE, FLOW

MEASURING INSTRUMENTS
PRESSURE MEASUREMENT
- PRESSURE TRANSMITTER
VACUUM MEASUREMENT
- KENETOMETER
- MERCURY MANOMETER
TEMPERATURE MEASUREMENT
- TEMPERATURE TRANSMITTER, THERMOCOUPLE, RTD
FLOW MEASUREMENT
- FLOW NOZZLES, ORIFICES

THERMOCOUPLE
IN JOURNAL BEARING

THERMOCOUPLE

BABBIT METAL TEMPERATURE MEASUREMENT

IN COMBINED JOURNAL & THRUST BEARING

THERMOCOUPLE

THRUST PAD ARRANGEMENT AND THERMOCOUPLE

LOCATION IN COMBINED THRUST AND JOURNAL BEARING

VALVE POSITION
NON CONTACT DISPLACEMENT MEASURING
EQUIPMENT
CONSISTS OF A SENSOR WITH TWO PRIMARY
& SECONDARY COILS AND A SHORTING RING.
THE SHORTING RING IS ATTACHED TO THE
VALVE STEM AND MOVES OVER THE
MAGNETIC CORE.
MOVEMENT OF SHORTING RING CAUSES
GENERATION OF POSITION DEPENDENT
OUTPUT VOLTAGE IN THE SECONDARY COILS.

THANK YOU