TURBOVISORY I

NSTRUMENT

12 January 2018 1
 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

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12 January 2018 3
 CROSS SECTION OF TURBINE
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 LOCATION OF DETECTORS
4 8 2 2 2
5 5 5 5 2 2 5
6 6 6 6 6 6 6
MAA MAB MAC MKA MKC
1 2 7 3
2 4 3
3
1 HALL PROBE NUMBER OF THERMOCOUPLE

2 CASING EXPANSION
3 DIFFERENTIAL EXPANSION
4 AXIAL SHIFT
5 RELATIVE SHAFT VIBRATION

6 ABSOLUTE CASING VIBRATION

TURNING GEAR
7 2018
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 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
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VIBRATION MEASURING INSTRUMENT
ATION
SHAFT VIBRATION / ECCENTRICITY
- PROXIMITY PROBE

BEARING VIBRATION
- VELOCITY PICK UP

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 Why Vibration?
• We can understand the machine
• We can find the weakness
• Thereby we can predict, plan, maintain and im
prove
• Improve availability and reduce costs

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 What are the different ways?
• Overall
• Time domain
• Frequency domain
• Envelope analysis
• Cepstrum analysis
• Wavelet analysis
• Etc

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 VIBRATION MONITORING

WHAT IS VIBRATION ?

WHAT CAUSES VIBRATION ?

HOW DO WE MEASURE VIBRATION ?

HOW DO WE ANALYSE VIBRATION ?

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 Basic Theory Of Vibration
Simple Spring Mass System

Max Acceleration, Min Velocity

Displacement
Upper Limit

Neutral Position

Lower Position

Max Velocity, Min Acceleration Max Acceleration, Min Velocity

IT FOLLOWS SINE CURVE

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 What Is Vibration?

It is the response of a
system to an internal or
external force which cau
ses the system to oscilla
te.
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2. Measurement direction - Horizonta
l, Vertical, Axial.

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12 January 2018 14
 General rule of direction
• We measure H direction for machines on the found
ation.
• We measure V direction for machines on structures
• We measure A direction when we suspect misalign
ment
• There are advantages, but there are exceptions to t
his rule.

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 VIBRATION MONITORING
Modes of Amplitudes

• DISPLACEMENT

• VELOCITY

• ACCELERATION

• SPIKE ENERGY
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 Physical Significance Of Vi
bration Amplitude

Displacement : Strain Indicator

Velocity : Fatigue Indicator

Acceleration : Force Indicator

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 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.

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 VIBRATION MONITORING
UNITS OF MEASUREMENT

DISPLACEMENT - MICRONS

VELOCITY - MM / SEC.

ACCELERATION - MM / SEC2 , G
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 VIBRATION MONITORING
AMPLITUDE DESCRIPTORS

• RMS - Displacement
Velocity

• PEAK - 1.414 RMS Displacement

Velocity
Acceleration

• PEAK-TO-PEAK - 2 * PEAK Displacement

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 ISO 2372
Class Class Class Class Class Class
Limits

1 Step

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 WHEN TO USE DISPLACEMENT, VELOCITY & ACCELERATION
VIBRATION
SENSITIVITY DISPLACEMENT

10

VELOCITY
.1

.01

.001
ACCELERATION

FREQUENCY 60 600 6000 60000 600 000

CPM
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 Accelerometer

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 SIMPLE VIBRATION
Time Domain
Amplitude
(mm)
A

Time
(sec)
Period T

Amplitude Frequency Domain

(mm)
A

f=1/T Frequency f
(Hz)
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 REAL VIBRATION
Time Domain
Amplitude
(mm)

Time
(sec)

Frequency Domain - Vibration Signature

Amplitude
(mm)

Frequency f
(Hz)
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 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

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 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

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 Vibration Sensors
• Acceleration Sensor - Accelerometer
• Velocity sensor – Velocity sensor or seism
ic sensor
• Displacement sensor - Non Contact picku
p

Accelerometer

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

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 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 i
nside
• 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 fre
q (600,000 CPM)
• Can measure Acceleration, velocity and displacement
• It is advised to involve suppliers or persons knowledgea
ble in this area to choose accelerometers for on line mo
nitoring applications
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 Velocity sensor
Output=B*l*V B & l are constant
Output is proportional to velocity, hence the name Velocity sensor

Spring

Magnet
Terminals Damper

Coil

Magnet

Aluminum case

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 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 neede
d
• The temperature rating is higher up to 250 degree C
(no electronics inside)
• Sensitive to 60,000 CPM
• Can check velocity and displacement only

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 Non contact type

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 Non contact
sensor
Installation
in a Turbine

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ABSOLUTE BEARING VIBRATI
ON
VELOCITY TRANSDUCER
SEISMIC MASS TYPE
Works on PLUNGER COIL PRINCIPLE.
Two permanent magnets rigidly fixed to the casing wit
h coils arranged as seismic mass.
The Relative motion between the coil and magnet gen
erates voltage proportional to vibration velocity.

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 SIESMIC MASS : Plunger Coil principle
Natural frequency of spring mass system ω = 2πf = √c/m
m = mass of plunger coil with spring
C = spring constant
Above ω,coil stands still due to its mass inertia

When coupling the siesmic sensor to vibrating structure,a relative movement is

generated between permanent magnet & plunger coil.a voltage is induced in the coil
Which is proportional to the vibration velocity :

e=B.l.V 6 5
l= Length of conductors
1. Exciter of vibration
B= magnetic induction
2. Permanent Magnet
v =speed of vib. 3 3. Plunger Coil
N 4 4. Magnetic Return Path
5. Spring
6. Sensor Case
2 S

1
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 ABSOLUTE SHAFT VIBRATION
• RELATIVE SHAFT VIBRATION IS BASED ON EDDY CURRE
NT PRINCIPLE.
• PROXIMOTY PROBE SENSES THE DISTANCE BETWEEN T
HE PROBE TIP AND THE OBSERVED SURFACE.
• PROXIMETER GENERATES A RADO FREQUENCY SIGNAL,
WHICH IS RADIATED THROUGH THE PROBE TIP INTO THE
OBSERVED SURFACE. EDDY CURRENTS ARE GENERATE
D IN THE SURFACE AND LOSS OF STRENGTH IN THE RET
URN SIGNAL IS DETECTED BY THE PROXIMETER.

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 SHAFT & BEARING VIBR
ATION PICK UP

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 BEARING / SHAFT VIBRATION PICK UP
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MOUNTED ON BEARING NO. 4 PEDESTAL
12 January 2018 PROXIMITY PROBE 40
 RECOMMENDED LOCATIONS OF VIBRATION MEAS
UREMENTS FOR PEDESTAL BEARINGS
12 January 2018 (AS PER ISO) 41
 RECOMMENDED LOCATIONS OF VIBRATION MEAS
UREMENTS FOR HOUSING TYPE BEARINGS (AS PER
ISO)
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 Measuring
Amplifier

Proximity
Pick-up
45O 45O

L R
SHAFT

RECOMMENDED LOCATIONS OF SHAFT VIBRATIO

12 January 2018 N MEASUREMENTS AS PER ISO 43
 Measuring
Amplifier

Proximity
Pick-up

L R
SHAFT

RECOMMENDED LOCATIONS OF SHAFT VIBRATIO

12 January 2018 N MEASUREMENTS AS PER ISO 44
 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 C
OIL DUE TO VARIATION IN PROXIMITY OF TARGET MATER
IAL
INDUCTIVE TRANSDUCER
PROXIMITY(EDDY CURRENT) TRANSDUCER

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 INDUCTIVE TRANSDUCER
• TWO MAGNETICALLY RELUCTANCE TYPE TRANSDUC
ERS 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 ROT
OR SPEED
• DEMODULATOR, FILTER,AMPLIFIER & AMPLITUDE DET
ECTOR

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 PROXIMITY TRANSDUCER
• SENSES THE DISTANCE BETWEEN THE PROBE TIP AN
D OBSRVED SURFACE
• PROXIMETER GENERATES RF SIGNAL, RADIATED THR
OUGH 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.

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 PROXIMITY SENSOR :
Eddy Current

CONDUCTIVE
MATERIAL
PROXIMITOR

Radio Frequency
Signal

OBSERVED EXTENSION CABLE

MATERIAL AND PROBE
PROXIMITOR

VOLTS
OSCILLATOR

DETECTOR VOLTAGE

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100
PROBE GAP
 THE PROXIMITY PRINCIPLE:
Eddy Current

CONDUCTIVE
MATERIAL
PROXIMITOR
Radio Frequency
Signal

The oscillator in the matching unit supplies(RF signal) the coil in the sensor
with a load Independent,high frequency alternating current.if the sensor is
brought near to a metal object,the eddy currents are induced in surface of t
he object and the power is absorbed thus alternating the voltage across the
coil.The alternating voltage is proportional to the distance between the mea
sured Object and the sensor.the output amplifier forms a load independent
D.C. Voltage signal.
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 PROXIMITY SENSOR – Matching Unit
The matching unit converts the sensor signal into a voltage signal which is
proportional to the distance between measuring object and the sensor.

1
+
1 2 3 2 Power Supply
~
-
~ ~
~ 3
~
~ Output
-

1 Oscillator
2 Demodulator
3 Output Amplifier
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EXPANSION MEASURING INSTRUMENT
S
OVERALL EXPANSION
- POSITION TRANSMITTER

DIFFERENTIAL EXPANSION MEASUREMENT

- PROXIMITY PROBE

AXIAL SHIFT MEASUREMENT

- PROXIMITY PROBE

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12 January 2018
OVERALL EXPANSION PICK UP 52
 OVERALL EXPANSION MOUNTED
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ON BEARING NO. 1 PEDESTAL
 DIFFERENTIAL EXPANSION (FOR SMALL
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EXPANSION) & AXIAL SHIFT PICK UP
 RELATIVE EXPANSION
If a relative movement is occur between turbine shaft and ca
sing ,the air gap changes and, as a result the inductance of
sensor coils changes inversely
Turbine Shaft

Power Supply Unit

l1 l2

d1 d2
I

Turbine Casing Measuring Attachment

L1 L 2 Sensor Coils
d1 d 2 Air gap
Small relative Expansion,Shaft with Collar
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 DIFFERENTIAL EXPANSION (FOR SMALL
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EXPANSION) & AXIAL SHIFT PICK UP
 IP DIFFERENTIAL EXPANSION PICK UP
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MOUNTED ON BEARING NO. 3 PEDESTAL
 AXIAL SHIFT MEASUREMENT AT IP COLLAR
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 DIFFERENTIAL EXPANSION (FOR LARG
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E EXPANSION) PICK UP
 RELATIVE EXPANSION :

d1 d2
- Power Supply Unit

L1 L2 Measuring
I Attachment
Turbine Casing

L1 L 2 Sensor Coils
d1 d 2 Air gap

Large Relative Expansion, Shaft with double cone

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 DIFFERENTIAL EXPANSION (FOR LARG
E EXPANSION) PICK UP

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 LP DIFFERENTIAL EXPANSION PICK UP
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MOUNTED ON BEARING NO. 4 PEDESTAL
12 January 2018 SHAFT POSITION MEASURING DEVICE 63
 SHAFT POSITION MEASURING DEVICE
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SPEED, LOAD MEASURING INSTRUMEN
TS
SPEED / OVERSPEED
- KEY PHASOR
- HALL PROBE

LOAD MEASUREMENT
- CURRENT TRANSFORMERS
- POTENTIAL TRANSFORMERS

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4 : HYDRAULIC SPEED TRANSDUCER
5 : ELECTRIC SPEED TRANSDUCER

SPEED MEASUREMENT INSTRUEMENT MOUNTED

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IN HP FRONT BEARING PEDESTAL
 STARTING AND LOAD
LIMITING DEVICE

PRIMARY OIL PRESS

12 January 2018 URE 67
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 HALL PROBE
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 BASIC ARRANGEMENT OF HALL PROBES AT BEARING 1

DISK

PERMANENT MAGNETS
N-POLE
S-POLE
SENSOR

BRACKET
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WIRE
 HALL PROBE (USED FOR SPEED MEASUREMENT)

PRINCIPLE : Magnetic Field Applied Perpendicular To The Direction Of Drift

F = q (E + V*B) Bz Ix

In Y direction the force is

Fy = q( Ey – Vx Bz )
(+) (-)
A B
Ey = Vx Bz Ey

Ey = Hall Effect
Ex
HALL VOLTAGE
VAB = EY W w
Ix
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 HALL PROBE IN BEARING NO. 1 PEDESTAL
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12 January 2018 MAIN OIL PUMP 73
 OVERSPEED TRI
P BOLTS IN TUR
BINE ROTOR

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 OVERSPEED TRIP BOLTS IN BEARING NO. 1 PEDESTAL
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 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
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 THERMOCOUPLE

BABBIT METAL TEMPERATURE MEASURE

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MENT IN JOURNAL BEARING
 THERMOCOUPLE
IN JOURNAL BEARING

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THERMOCOUPLE

BABBIT METAL TEMPERATURE MEASUREMENT

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IN COMBINED JOURNAL & THRUST BEARING
 THERMOCOUPLE

THRUST PAD ARRANGEMENT AND THERMOCOUPLE

LOCATION IN COMBINED THRUST AND JOURNAL BEARING
12 January 2018 80
 THANK YOU

12 January 2018 81