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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
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
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
CONSTRUCTION
Seismic sensor
spring Terminals
Magnet Coil Magnet
Damper
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
PROXIMITOR
OSCILLATOR
DETECTOR
VOLTAGE
0 100
PROXIMITY SENSOR
NON CONTACT TYPE
PROXIMITY SENSOR
Measurin g Amplifier 45O 45O
Proximity Pick-up
SHAFT
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.
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
Thermal expansions
THERMAL EXPANSION MEASUREMENT Differential expansion Overall casing expansion Rotor expansion
HP ROTOR/CASING 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
d1
d2
L2
Measuring I Attachment
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
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
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
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
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.