TURBOVISORY instruments

Anil Kapoor Engr.

TURBOSUPERVISORY INSTRUMENTS VIBRATION PICKUPS THERMAL EXPANSION PICKUPS AXIAL SHIFT PICKUP ECCENTRICITY SPEED PICKUP BEARING TEMPERATURE

NEED FOR TURBOVISORY INSTRUMENTS Heavy mass rotating at high speed Small clearances between moving and stationary blades Ensures turbine healthiness Gives idea of any problem in turbine Helps in increasing turbine operating lifetime by giving timely indications

TURBINE BEARINGS ARRANGEMENT

HPT IPT LPT

GENERATOR

EXCITER

BRG.1

BRG.2

BRG.3

BRG.4 BRG.5

BRG.6 BRG.7

BEARING 1 (HPT FRONT) INSTRUMENTS HALL PROBE FOR SPEED MEASUREMENT HPT ROTOR EXPANSION HP CASING EXPANSION THERMOCOUPLES FOR BEARING TEMP.(4 NO.S) PEDESTAL VIBRATION PICKUP SHAFT VIBRATION PICKUP

BEARING 2 (HPT REAR) INSTRUMENTS AXIAL SHIFT PICKUP THERMOCOUPLES FOR BEARING TEMP.(8 NO.S) PEDESTAL VIBRATION PICKUP SHAFT VIBRATION PICKUP

BEARING 3 (IPT REAR) INSTRUMENTS IP CASING EXPANSION IP ROTOR EXPANSION ECCENTRICITY PICKUP THERMOCOUPLES FOR BEARING TEMP.(2 NO.S) PEDESTAL VIBRATION PICKUP SHAFT VIBRATION PICKUP

BEARING 4 (LPT REAR) INSTRUMENTS IP+LP SHAFT EXPANSION THERMOCOUPLES FOR BEARING TEMP.(2 NO.S) PEDESTAL VIBRATION PICKUP SHAFT VIBRATION PICKUP

BEARING 5(GENERATOR FRONT) INSTRUMENTS THERMOCOUPLES FOR BEARING TEMP.(2 NO.S) PEDESTAL VIBRATION PICKUP

BEARING 6 (GENERATOR REAR) INSTRUMENTS THERMOCOUPLES FOR BEARING TEMP.(2 NO.S) PEDESTAL VIBRATION PICKUP

BEARING 7 (EXCITER) INSTRUMENTS THERMOCOUPLES FOR BEARING TEMP.(2 NO.S) PEDESTAL VIBRATION PICKUP SHAFT VIBRATION PICKUP

VIBRATION MEASUREMENTS

VIBRATION CAUSES
Unbalance forces Internal damages Misalignment Poor lubrication Eccentricity Thermal stresses

VIBRATION TYPES
PEDESTAL VIBRATION SEISMIC MASS TYPE
VELOCITY TYPE ACCELERATION TYPE

ABSOLUTE SHAFT VIBRATION PROXIMITY TYPE(NON CONTACT)

EDDY CURRENT TYPE PICKUP

4 steps in vibration measurement

SENSOR TYPES (SEISMIC MASS) Velocity sensors Velocity of vibration is the speed at which the part is moving at any instant during the vibration cycle Measured in mm/s Rms value of velocity gives vibration Seismic mass type sensors Velocity gives the kinetic energy

SENSOR TYPES (SEISMIC MASS)

Velocity sensors 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. Operates within range of 10hz to 150 hz

CONSTRUCTION
Seismic sensor
spring Terminals
Magnet Coil Magnet

Damper

Aluminum case Output=B*l*V B & l are constant

Output is proportional to velocity, hence the name Velocity sensor

SENSOR TYPES (SEISMIC MASS)

Accelerometer Piezoelectric accelerometer transducers Rate of change of vibration velocity at any instant during vibration cycle Measured in mm/s2 Acceleration gives the force Emf proportional to force Internal amplifier for boosting signal Can measure Acceleration, velocity and displacement

ACCELEROMETER

SHAFT VIBRATION
Proximity (Non contact) type

Shaft vibration measures the radial motion of the rotating shaft relative to the case. This measurement gives the first indication of a fault, such as unbalance, misalignment, cracked shaft, oil whirl or other dynamic instabilities Total distance moved by the vibrating part in a given direction Measured in micrometers

SENSOR TYPES
Proximity (Non contact) type Proximity probe senses the distance between the probe tip and the observed surface. Proximeter generates a radio 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.

PROXIMITY SENSOR
Eddy Current

CONDUCTIVE MATERIAL

PROXIMITOR
Radio Frequency Signal

OBSERVED MATERIAL

EXTENSION CABLE AND PROBE

PROXIMITOR

OSCILLATOR

DETECTOR

VOLTAGE
0 100

VOLTS PROBE GAP

PROXIMITY SENSOR
NON CONTACT TYPE

PROXIMITY SENSOR
Measurin g Amplifier 45O 45O

Proximity Pick-up

SHAFT

2 transducers spaced 90 deg to each other for a 2 dimensional view of

each bearing The 315 and 45 points are used to avoid the half joints of the bearings and to ensure that when bearings are removed the probes are removed along with them. This moves the probes away from possible mechanical damage when the turbine is being worked on.

WHEN TO USE DISPLACEMENT, VELOCITY & ACCELERATION

VIBRATION SENSITIVITY 10 1 0.3 .1 .01 .001 VELOCITY DISPLACEMENT

eduil p m not a b V t a i r i

ACCELERATION

FREQUENCY CPM

60

600

6000

60000

600 000

SHAFT VIBRATION
For no variation in gap we get DC signal which indicates gap or average distance from transducer tip. In case shaft is vibrating there will be both AC & DC components and varying voltage will give vibration signal Sensitivity around 8V/mm

VIBRATION ANALYSES Each machine defect produces a unique set of vibration components that can be used for identification. By identifying different frequency components we can make out the defect in turbine. Spectrum analysis, shaft centerline plots, orbit plots, waterfall plots are some of the techniques used for analysis

PEDESTAL VIBRATION PICKUP SHAFT VIBRATION PICKUP

Thermal expansions

THERMAL EXPANSION MEASUREMENT Differential expansion Overall casing expansion Rotor expansion

HP ROTOR/CASING EXPANSION

IP ROTOR /CASING EXPANSION

IP+LP SHAFT EXPANSION

HPT

IPT

LPT

GENERATOR

EXCITER

BRG.1

BRG.2
ANCHOR POINT

BRG.3

BRG.4 BRG.5

BRG.6 BRG.7

DIFFERENTIAL/ROTOR EXPANSION
Difference between the thermal growth of the rotor compared to the thermal growth of the case. Important during a turbine "cold" start-up. Since the pedestal are of fixed type, differential expansion can not be measured directly. Hence casing expansion & rotor expansion are measured separately and differential expansion between the two rotor expansion is measured at HP front & IP rear brgs Due to the mass of the case it will grow slower than the rotor, so the operator must make sure the case has expanded enough to keep it from making contact with the rotor. If shaft expands more than casing it is positive expansion and if casing expands more than shaft than it is negative expansion

THERMAL EXPANSION/ AXIAL SHIFT PICKUP PROXIMITY TYPE VARIABLE INDUCTANCE TYPE

IP ROTOR EXPANSION (VARIABLE INDUCTANCE)

If a relative movement is occur between turbine shaft and casing ,the air gap changes and, as a result the inductance of sensor coils changes inversely Turbine Shaft Power Supply Unit l1 d1 d2 Turbine Casing L1 L2 d1 d2 Sensor Coils Air gap l2 I Measuring Attachment Small Relative Expansion

ROTOR EXPANSION PICKUP

IP+LP SHAFT EXPANSION

d1

d2

- Power Supply Unit

L1 Turbine Casing L1 L2 d1 d2 Sensor Coils Air gap

L2

Measuring I Attachment

Large Relative Expansion, Shaft with double cone

IP+LP SHAFT EXPANSION PICKUP

CASING/OVERALL EXPANSION
Steam temperature varies greatly between startup, operation, and shutdown. Shell expansion is a measurement of how much the turbine's case expands from its fixed point outward as it is heated. Continuous indication of shell thermal growth allows the operator to manage the amount of shell distortion as the load is increased or decreased. LVDT Type pickup

OUTPUT VOLTAGE = DIFFERENCE OF VOLTAGE BETWEEN 2 SECONDARY COILS

RANGES
HP Rotor Expansion: 0-25mm IP Rotor expansion:0-21mm HP Casing Expansion:0-30mm IP Casing Expansion: 0-20mm IP+LP Shaft Expansion; (-)15-48mm

SPEED PICKUP
HALL PROBE

ECCENTRICITY
PROXIMITY PICKUP

BEARING TEMPERATURE
THERMOCOUPLES

ECCENTRICITY
Eccentricity is measured as the deviation of mass centre from the geometrical centre of the bearing journal. Eccentricity is the measurement of Rotor Bow at rotor slow roll which may be caused by any or a combination of reasons Fixed mechanical bow Temporary thermal bow Gravity bow

ECCENTRICITY
Eccentricity is measured while the turbine is on slow roll (1 to 240 RPM below the speed at which the rotor becomes dynamic and rises in the bearing on the oil wedge) and requires special circuitry to detect the peak- to-peak motion of the shaft. For eccentricity measurements it is recommended that the transducer be mounted vertically . Slow roll and heating can help reduce the eccentricity to the point where the turbine can safely be brought up to speed without damage from excessive vibration or rotor to stator contact.

ECCENTRICITY
Eccentricity

Eccentricity is normally measured P/P (Peak to Peak) The actual excursion from shaft centerline caused by bow would be one half that measurement or the 0/P (Zero to Peak) measurement

Special consideration for using eddy current probes

RUNOUT Error signal generated by mechanical, electrical or metallurgical irregularities of the shaft MECHANICAL RUNOUT A smooth (64 micro-inch) area approximately 3 times the diameter of the probe tip must be provided for a viewing area. ELECTRICAL RUNOUT Eddy Probes are sensitive to the permeability and resistivity of the target material and the field of the transducer extends into the surface area of the shaft by approximately 15 mils (0.015"), care must be taken to avoid non homogeneous viewing area materials such as Chrome.

System Cable Length

Eddy Probe Systems are a "tuned" length, and several system lengths are available. System length is measured from the probe tip to the Oscillator/Demodulator, and is measured electrically which can be slightly different than the physical length.

Transducer (Probe) side clearances The RF Field emitted from the probe tip of the transducer is approximately a 45 conical shape. Clearance must be provided on all sides of the Probe tip to prevent interference of the RF Field.

Common Point Grounding To prevent Ground Loops from creating system noise, system common, ground and instrument wire shield must be connected to ground at one location only.

GAP VOLTAGE
Gapping the transducer to the center of the linear range is adequate

TURBINE SPEED MEASUREMENT

BASIC ARRANGEMENT OF HALL PROBES AT BEARING 1

DISK

PERMANENT MAGNETS

N-POLE S-POLE
SENSOR BRACKET WIRE

SPEED MEASUREMENT
Allows the operator to increase speed quickly through shaft critical frequencies Hold the speed stable during heat soak plateaus For electric generators, to accurately match the synchronous frequency before connecting the generator to the power grid. Used for tripping turbine in case of overspeed (2/3 logic)

Bearing temperature
Measure of the how hot a bearing is operating. May be due to overloading, mis- alignment, improper lubricant pressure and/or flow. Thermocouples used to measure temperature. Each thermocouple has 3 elements

AXIAL SHIFT
Shifting of rotor due to unbalanced forces in the turbine Positive towards generator, negative towards front pedestal. Very critical measurement as very small gap between stationary and rotating blades Three probes mounted and used in 2/3 protection logic. Total range from (-)1.5mm to + 1.5mm Protection at (-)1.0mm & +1.0mm Proximity probes or relative inductance type probes can be used for measurement

PORTABLE VIBRATION MEASUREMENT

Vibration measurement close to machinery avoids error introduced due to cable problems. Used to check vibration of machinery located at remote location. Easy to carry Evaluate machine condition and bearing problems associated with pumps whose signal is not available in control room

PHASE MEASUREMENT Phase measurement is required for accurate balancing of any rotor. It also provides an indication of shaft cracks, misalignment, mass loss (such as throwing a blade), and other faults.