GE Energy

Optimization & Control GE Energy

1631 Bently Parkway South
Minden, NV 89423 USA

P: +1.775.782.3611

Learn more about our Hydro Solutions online at:

www.gepower.com/o&c/hydro

Copyright © 2005 General Electric Company.

All rights reserved.

* Actionable Information, Bently Nevada, Keyphasor,

Proximitor, System 1, and Decision Support are
trademarks of General Electric Company.

HydroTrac is a trademark of Iris Power Engineering Inc.

in Canada and other countries.

Photo on page 11 supplied courtesty of New York Power

Authority. Used by permission.

Condition
Monitoring
Solutions
for Hydro
Bently Nevada™ Asset Condition Monitoring

imagination at work
GEA-13978 REV NC (07/2005)

P: +1.775.782.3611
Minden, NV 89423 USA
1631 Bently Parkway South
Optimization & Control
GE Energy

www.gepower.com/o&c/hydro.
Contact your GE Energy salesperson or visit us online at

For More Information

We Understand Hydro Machinery
Whether Kaplan, Pelton, Francis, bulb, or propeller – vertical or horizontal – generation-only or pump/storage, our hydro
monitoring solutions are effective because we understand the measurements you need to detect the unique malfunctions
that can affect hydro units.

ME ASUREMENT

Generator Temperatures
Guide Bearing Vibration

Head Cover /Draft Tube

Stator Frame Vibration

Wicket Gate Position

Seal Ring /Blade Tip

Oil Film Thickness2

Generator Air Gap

Keyphasor* Pulse

Process Variables

Partial Discharge
Malfunctions and

Thrust Bearing

Thrust Bearing
Guide Bearing
Temperature2

Temperature2

Clearance4
Corresponding

Generator
Vibration
Measurements (Runout)2

See
Note
4

Mechanical Unbalance (Direct,

1X)

Electrical Unbalance (Direct,

1X)

(Direct,
Hydraulic Unbalance Shaft CL,
1X, NX)

Rough Load Zone (NOT 1X)

Shear Pin Failure (Shaft CL,

NX)
MALFUNCTION 1

(Direct,
Misalignment Shaft CL,
1X)

Cavitation
Seal Ring /
Discharge Ring Distortion3
Excessive Turbine Vibration3
Bearing Overload
Bearing Fatigue
Insufficient Bearing Lubrication
Stator Insulation Deterioration
Stator Winding Vibration
Rotor Rim Movement
Stator Core Shifts
Uneven Air Gap
Stator / Rotor Out of Round
Stator / Rotor Concentricity
Stator Flexing
Loose Stator Laminations
Unbalanced Air Gap Forces
Plugged Stator Coolers
Blocked Stator Ventilation Ducts
Overheated Stator Coils
1 Detection of a particular malfunction requires all of the Minimal System – Measurements required for basic safety shutdown when
measurements checked in that row. catastrophic failure occurs, limited condition monitoring and proactive
2 These parameters are recommended for auto-shutdown capabilities.
machinery protection. Basic System – Measurements required for basic protection with moderate
3 Francis, Kaplan, or Propeller-type runners only. condition monitoring and proactive capabilities.
4 This measurement is recommended on a case-by-case basis, Recommended System – Measurements required for optimal protection and
subject to customer condition monitoring needs, equipment condition monitoring, full proactive capabilities.
condition, and turbine construction constraints.

3
The Right Products
From robust sensors, to highly reliable monitoring hardware, to diagnostic software, our Bently Nevada condition monitoring
products are designed to work together, delivering the high quality information you need to manage your assets.

Transducers
• 3300 XL Proximity Transducer System
Relative vibration between the rotating shaft and
stationary bearing components is especially important
for machinery that utilizes fluid film bearings because the
direct shaft measurement provides the highest sensitivity
to vibration issues and the best chance of early fault
diagnosis.
Proximity sensors are typically mounted at each radial
bearing to detect radial vibration and within the thrust
bearing structure to detect oil film thickness. A proximity
sensor is also used to observe a once-per-turn shaft
discontinuity (such as a key or keyway) to provide a
precise phase reference, called a Keyphasor* signal.
Proximity probes are available to cover a wide range of
measurement distances and mounting configurations.

• 330425 Accelerometer
The 330425 industrial accelerometer is a proven, reliable
casing-mounted sensor that can detect turbine cavitation
and structural vibrations/resonances.
Typically mounted to the turbine head cover or draft tube
wall, this mounting location provides the best sensitivity to
turbine- and flow-related issues.

• Linear Variable Differential Transformers (LVDTs)

A variety of LVDT configurations are available for
addressing wicket gate and valve position measurements.

• HydroTrac™ Partial Discharge System

One of the leading causes of major outages in hydro
machinery is generator insulation failure. Stops, starts,
thermal and load cycling of generators in today’s flexible
operating environment lead to increased stress on all
components, including generator insulation. Partial
discharge (PD) monitoring is an industry accepted
measurement used to indicate the early onset of stator
insulation problems. The HydroTrac unit, provided by Iris
Power Engineering, a leader in this technology, is designed
to provide continuous on-line measurement of partial
discharge activity. Integration between the HydroTrac
system and System 1* software allows the correlation of
partial discharge measurements to other condition
monitoring parameters.

• Special Applications
Comprehensive custom engineering capabilities
are available to adapt transducers for submerged
applications.

4
• 330505 Low-Frequency Seismic Sensor
Our Low-Frequency Seismic Sensor is designed
specifically to detect vibration of the stator core,
stator frame, and bearing supports on hydro units.
Stator core and frame vibration can cause fretting
and damage to the winding insulation. The seismic
sensor is mounted on the outer diameter of the stator
core and frame to detect such problems before serious
damage occurs.
Bearing housing vibration can cause premature failure of
machine components and be a sign of significant machine
problems. In addition, housing vibration can also distort
levels of vibration observed by relative measurement
proximity probes.
The sensor is mounted to the bearing housing either as a
single measurement or close to the same orientation as
existing proximity sensors. It measures absolute vibration
within the range of 0.5Hz to 1.0kHz and meets the
requirements of International Organization for
Standardization (ISO) Standard 10816-5.

• 4000 Series Air Gap Sensor System

Air gap is a measure of the distance between rotor and
stator in the hydro generator. Both the stator and the
rotor on hydro machines can be quite flexible, and their
shape and location are affected by operating centrifugal,
thermal, and magnetic forces.
Off-center or out-of-round conditions will, at minimum,
reduce operating efficiency. More severe cases can lead
to damage from magnetically induced heating or a rotor-
to-stator rub.
Air gap monitoring utilizes multiple specially designed
Bently Nevada capacitive proximity sensors that are
mounted on the inner bore of the generator stator in one
or more planes. Measurements are made from the stator
bore to each rotor pole as the rotor turns. Minimum air
gap dimension and location along with rotor shape are
directly measured during unit operation. Stator shape is
calculated utilizing multiple air gap transducers.

5
3500 Series Machinery
Protection System
With more than 20,000 systems supplied,
the 3500 platform has proven its value and
dependability with customers everywhere,
year after year. It features the industry’s
most extensive selection of machinery
measurement parameters and utilizes
software configuration for virtually all monitor
options, providing unparalleled flexibility.
Using the 3500 System’s monitoring modules,
vibration, bearing temperatures, thrust
position, speed, air gap, process variables
(electrical load, oil pressure, reservoir
elevation, etc.) and other measurements can
be configured to address the specific needs
for correlation of data and analysis of each
hydro unit in your facility.
Hydroelectric turbine-generators typically
operate at low rotational speeds, usually from
60 to 600 rpm, and are often physically very
large, sometimes with generator rotors that
may be more than 50 feet in diameter and
weigh more than 1,000 tons. Their physical
mass and slow rotational speeds give rise to
large vibration amplitudes and low vibration
frequencies. This requires monitoring
capabilities with special low-frequency
response, filtering, and signal conditioning.
6
The 3500/46M Hydro Monitor module has
been specifically developed to deliver these
capabilities by providing the suite of radial
vibration measurements used for guide
bearing runout, and seal ring position. In
addition, the 3500/46M is used for generator
air gap measurements, providing:
• Overall vibration (direct)
• 1X filtered vibration and phase
• NX filtered vibration and phase
(where N is a user-selectable integer
between 2 and 20)
• NOT 1X vibration amplitude
• Gap voltage (shaft radial position)
• Composite
• Instantaneous air gap
• Average air gap
• Minimum air gap
• Maximum air gap
• Minimum air gap pole number
• Maximum air gap pole number
System 1 Software
System 1* software allows you to analyze, trend, correlate, Hydro-Specific Plot Types in System 1
and display vibration, position, temperature, and any other
process variable of interest, dramatically improving your Overall Hydro Displays an overview of plant condition with
Plant View normal parameters in green and alarm para-
ability to proactively manage your hydro units. It delivers the meters in colors designating severity of the alarm.
real time information you need to make intelligent decisions.
It also links to maintenance management applications, Air Gap Plots Displays the gap for each sensor versus pole
reliability tools, process control, SCADA, historian systems, (Gap versus Pole) number, for one rotor revolution.
diverse documentation resources, and much more. This Air Gap Plots Displays measured rotor shape as observed from
integration of multiple systems is a significant advantage (Rotor Shape) each air gap probe.
for hydro operators, allowing you to monitor and trend
Air Gap Plots Displays stator and rotor roundness and
parameters from the diverse systems in your plant in a (Combined Rotor concentricity by combining measured rotor
single user interface. and Stator Shape) shape with calculated stator shape.

A key aspect of asset management is the ability to detect X versus Y Plotting any X (such as vibration) versus any Y
asset-related symptoms and events as early as possible and (such as unit load), provides powerful diagnostic
with as much clarity as possible. This is where System 1 tools. Cause-and-effect relationships and
correlation can be easily visualized and
software provides exceptional capabilities through its understood. System 1 has data historian
Decision Support* functionality. Decision Support is System 1 capabilities allowing it to archive virtually any
software’s ability to automatically validate and analyze its data, even if not condition-related. It can also
collected data using user-configurable rules and knowledge; interface to existing historian systems you may
already have installed.
detect mechanical, electrical, or hydrodynamic problems;
and generate informative Actionable Information* advisories. Multi-Parameter Multiple parameters can be displayed on the
In other words, System 1 software can tell you when there is Plots same plot. For example, plotting turbine flow,
a problem with your machinery – via e-mail, pager, cell combined unit load, and bearing vibration
provides the ability to immediately identify
phone, control system screen, desktop annun-ciator, or events associated with rough load zone. Changes
virtually any other notification method your prefer. in the duration and amplitude of these events
can be an indication of excessive wear or
In addition to rules you generate yourself, System 1 impending failure.
software can be augmented with numerous pre-configured
rule collections – RulePaks – for specific machine types.
RulePaks can be loaded directly into the Decision Support
module of System 1, giving you ready-made capabilities to
automatically isolate and identify numerous common
problems for specific machine types or even machine
components, without the need to write your own rules.
RulePaks can also be combined with the rules you have
authored yourself, giving you a system tailored to your
exact needs. Armed with these Decision Support capabilities,
your company’s ability to make faster, more confident
operating and maintenance decisions is easier than ever.

7
Typical System Arrangement

Measurement Monitor Transducer

Guide Bearing Vibration (Runout) 3500/46M 3300 XL Series Proximity
By measuring vibration at generator and turbine guide bearings, a variety of important 4-channel Transducer Targeting the
malfunctions can be detected such as rough load zone, various sources of unbalance, Hydro Monitor Machine Shaft
shear pin failure, bearing problems, and wicket gate problems. Each channel of the X-Y configuration at each
3500/46M module can simultaneously monitor direct, 1X vector, NX vector, NOT 1X, bearing.
shaft radial position (gap voltage), and composite amplitude (gap voltage change
multiplied by NX amplitude). This special signal conditioning and filtering is required
for detecting various malfunctions.

Thrust Bearing Oil Film Thickness 3500/40M or 3300 XL Series

Large vertical hydro units can weigh over one thousand tons, with the unit’s entire 3500/42M 4-channel Proximity Transducer
weight carried by the thrust bearing. An absence or reduction in oil film thickness at Vibration/Position One probe each in two selected
the thrust pads results in rapid breakdown of the bearing babbit and can result in Monitor pads, with approximately 90
rotor/bearing damage if not corrected. On hydro units, the thrust bearing shoes are degrees of radial separation. For
fitted with proximity probes observing the thrust collar, providing a measurement of units larger than 100 MW, four
oil film thickness. probes (one every 90 degrees) are
generally advised.

Guide Bearing Temperatures 3500/61 RTD or Thermocouple

Bearing temperature can indicate problems related to fluid-film bearings, including 6-channel One sensor per bearing pad.
overload, bearing fatigue, or insufficient lubrication. Temperature Monitor

8
Measurement Monitor Transducer
Thrust Bearing Temperatures 3500/61 RTD or Thermocouple
Bearing temperature can indicate problems related to fluid-film bearings, including 6-channel One sensor per bearing shoe.
overload, bearing fatigue, or insufficient lubrication. Temperature Monitor

Keyphasor Signal 3500/25 3300 XL Series

A proximity probe observing a once-per-turn notch or protrusion (such as a key or Keyphasor Module Proximity Transducer
keyway) on the machine’s shaft provides a precise reference signal used for indicating Generally mounted near the
rotational speed, filtering vibration to multiples of running speed (such as 1X, NX, and upper guide bearing. The shaft’s
NOT 1X), providing vibration phase information, and allowing air gap profile data. The notch or projection should align
Keyphasor signal is required by the 3500/46M and other monitor modules. with an established reference on
the rotor such as the generator’s
#1 pole.

Head Cover/Draft Tube Vibration 3500/42M 330425 Accelerometer

Certain operating conditions can give rise to cavitation, an implosion of vapor cavities 4-channel
in the liquid. Cavitation can damage the turbine, eroding metal, affecting efficiency, Proximitor*/
and eventually forcing a shutdown and dewatering for repair of affected parts. Seismic Monitor
Cavitation is measured with an accelerometer mounted on the draft tube or the
turbine head cover. By monitoring for draft tube or head cover vibration with an
accelerometer, and filtering appropriately, cavitation can be detected and conditions
can be adjusted to avoid operating the unit in this damaging region.
Generator Air Gap 3500/46M 4000 Series Air Gap Sensors
Special capacitive sensors mounted around the bore of the stator measure the 4-channel AG 20 mm for smaller air gaps
distance between the rotating and stationary parts in the generator. Air gap Hydro Monitor or AG 50 mm for larger air gaps
measurement is important because the stator is a flexible assembly that can become – sets of four to 16 sensors per
distorted or off center. The monitor is able to provide instantaneous, minimum, plane depending on generator
maximum, and average air gap measurements along with the rotor pole to which bore diameter.
min and max measurements coincide. When connected to System 1, the software
can interpolate between sensors, providing calculated stator shape plots.

Stator Frame Vibration 3500/46M 330505 Low-Frequency

Vibration of the stator core and frame can cause fretting and damage to the winding 4-channel Seismic Sensor mounted on the
insulation. Uneven air gap can also cause the stator core to vibrate. By mounting an Hydro Monitor outer diameter of the stator
appropriate seismic vibration transducer on the stator core/frame, such problems can core and frame.
be detected before serious damage occurs.

Generator Temperatures 3500/61 RTD or Thermocouple

Temperature sensors are installed in locations such as in stator slots, air cooler inlet 6-channel
and outlet, water inlet and outlet, etc., providing important information on stator Temperature Monitor
condition. The monitor provides alarming functions, alerting operators when
temperatures are outside of acceptable limits. The monitor can also supply
temperature information to System 1 software where it can be trended and
correlated with other measurements for a more complete picture of unit health.
Process Variables 3500/62 Any sensor with an industry-
Load, reactive load, exciter voltage and current, generator voltage and current, 6-channel Process standard proportional output of
lube oil pressure, wicket gate position, and reservoir elevation are just a few of the Variable Monitor 4-20 mA, 1-5 Vdc, or any
parameters that may be available in the unit’s or plant’s control and automation proportional voltage between
system, and these variables can generally be easily interfaced to System 1 software. –10 and +10 Vdc
However, in some cases a process-related measurement is either not available in the
unit’s control system, or it is simply beneficial to hardwire the signal in parallel to both
the control system and the condition monitoring system.
Generator Partial Discharge Continuous PD Capacitive PD Couplers
Partial discharges are low-level electrical discharges that occur within the voids of monitor (provided
high-voltage insulation systems. By monitoring these partial discharges, a variety of by IRIS Power
winding-related problems can be detected, allowing maintenance to be planned and Engineering).
serious failures to be avoided.
Wicket Gate Position 3500/45 Linear Variable Differential
Monitoring wicket gate position provides an indication of turbine flow. Combined with 4-channel Transformer (LVDT)
other parameters such guide bearing vibration, reservoir elevation, and load, flow- Position Monitor
induced instabilities at the turbine runner can be identified and avoided. Wicket Gate
position is often included in the unit’s control system and can be monitored directly
with System 1. If wicket gate position is not monitored, an LVDT can be used to make
the measurement.
Seal Ring Position/Blade Tip Clearance 3500/46M 3300 XL Series 11 mm
Francis-, Kaplan-, and propeller-type turbines employ seal rings to prevent unwanted 4-channel Proximity Transducer, modified
leakage of water past the runner, influencing efficiency. Francis units have two rings – Hydro Monitor for underwater use and runner
a stationary ring and a rotating ring mounted on the runner. In contrast, Kaplan and target material.
propeller units have only a stationary ring that seals directly against the rotating
blade tips. Mounted at the extremity of the unsupported portion of the shaft, these
sealing surfaces are subject to rubbing when extreme shaft deflection occurs. On
pump/storage units, such deflections can be common during pump-mode startup.

9
Comprehensive Services
No two customers are alike. Some prefer to monitor their machines themselves and install the systems themselves. Others
want help with installation, but not with the actual use of the system to perform machinery diagnostics. Still others may
require occasional help with balancing or alignment, but little else. Whatever your needs, GE Energy offers a comprehensive
portfolio of condition monitoring-related services for hydro units, including:
• Monitoring system design, site installation, site project
management, and full system documentation (both new
machines and retrofits)
• System integration to ensure your condition monitoring
system can interchange data and information with
process control, SCADA, maintenance management,
reliability management, and other pertinent systems
• Balancing and alignment
• Training – for both machinery diagnostic fundamentals
and operation/maintenance of monitoring system
instrumentation
• Reliability Services including
Opportunity/Risk Assessment
• Lubrication consulting/management
• Foundation/footing problems
• Remote machinery diagnostics
• On-site machinery diagnostics
• Condition monitoring program management
• Monitoring system calibration and repair
In addition, GE Energy provides complete solutions
to optimize and control throughout your plant. From
mechanical systems and unit controls to river management
across multiple dams, consider us your partner in the
hydro industry.

10
The Case For Monitoring
Hydro machines have historically had the lowest cost per
MW on the grid. System operators would base load these Benefits
units, only reducing load or removing the units from service
when maintenance was required, the power was not needed, • Lower life-cycle costs
or stream flow conditions dictated. In this base-load mode, a
• Improved efficiency
typical hydro machine could operate successfully for over 40
years with only routine scheduled maintenance and minimal • Avoidance of load zones with damaging vibration
condition monitoring. or cavitation conditions
But that was then. In today’s world of partially deregulated • Early warning of impending failures
utilities and grid systems where fish and water issues often
eclipse energy issues, the operating flexibility of hydro • Proactive maintenance planning and intervention
machines has often led them to be the load-follow units with • Reduced maintenance costs
continuous load changes and partial-load operation. Running
a unit at partial load brings into play considerations like • Increased availability and reliability
rough load zone and cavitation, along with operation that is
• Longer intervals between outages
far from the unit’s peak efficiency. Further, continuous load
cycling introduces thermal, mechanical, and electrical • Lower insurance premiums
stresses on the machinery that may not have even been
considered in the original design. In some cases, such
machines are cycled on- and off-line multiple times per day.
And pump/storage applications can experience even more
starts and stops, often representing the most extreme
operating conditions of all hydro units. At the same time,
normal scheduled maintenance outages are being reduced
or eliminated. The circumstances that once resulted in
virtually trouble-free operation for decades simply don’t
apply any more. Clearly, the need for condition monitoring
on hydro units has never been more important.
You can confidently turn to GE Energy for the solution. For
over four decades, our Bently Nevada* condition monitoring
portfolio has been synonymous with the highest quality,
most reliable choice available for critical machinery. It’s the
world’s most trusted name for machinery protection with
over two million transducers and monitoring channels
installed globally. Our comprehensive selection of hydro-
specific transducers, monitors, diagnostic software, and of
course, services, has been designed with the unique needs
of hydro operators in mind.