TECHNICAL SPECIFICATION OF ON LINE CONDITION

MONITORING SYSTEM

1.0 SCOPE

1.1 This specification covers the Design, Manufacture, Supply

Erection, Testing & Commissioning of latest state of art on line
condition monitoring system comprising of AGMS for
generator, Labyrinth gap monitoring system for Turbines,
vibration monitoring system and complete integrated analyzing
and diagnostic system, software and hardware for turbine
generator units of 6 X 250 MW Nathpa Jhakri Hydro Power
Station.
1.2 The scope of work shall include supply, erection & commissioning
of all the accessories such as sensors,
processors/controllers/transducers, input/output modules,
diagnostic station, peripherals, software, protection units, data
acquisition units, workstation (common), special cables and
junction boxes etc. Any other equipment required for
completeness of the system, and satisfactory performance shall
also be considered as in the scope of supply
1.3 The scope of work shall also include training of at least one
week’s duration at owner site for at least 3 (three) Engineers of
the corporation regarding operation and maintenance of the
system including analysis/interpretation of reports.
1.4 The scope of work shall also include technical support for
analysis/interpretation of data during warranty period of 2 (two)
years for which cost shall be deemed to be included in the prices
given in the bid.
1.5 The system complete in all respect shall be designed by the
supplier, approved by SJVNL and subsequently supplied and
installed by the supplier. Methods of installation of different
components and material/hardware used shall also be mentioned
clearly and shall not in any way compromise the integrity and
safety of the machine.

2.0 EXPERIENCE

The bidder shall have at least of 10 (ten) years of experience

regarding supply, erection, testing, commissioning of on line
Condition Monitoring of hydro turbine generator sets of size and
capacity of 100 MW and above, including installation of labyrinth
gap measurement system in Francis Turbines and
supplied/installed 10 (ten) power houses any where in world

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 including at least 2 (two) No. of similar system in a hydro power
plant any where in India & working satisfactorily for at least one
year as on date of submission of bid. Bidders shall have to
furnish performance certificate from the purchaser. Other
contractual/financial criteria as per CVC guidelines. Th e bidder
shall give a brief detail of at least 2 (two) on line condition
monitoring system of hydro generators along with labyrinth gap
measurement system of Francis Turbine installed by them and
working satisfactorily for period of one year and above.

3.0 BASIC INFORMATION TO BIDDER

3.1 PROJECT LOCATION :Jhakri, Tehsil Rampur Bushahar, Distt.

Shimla, H.P

3.2 TURBINE DATA

1. Manufacturer : M/s GE Hydro, Norway

2. Number of units :6
3. Type of Turbine : Vertical Francis
4. Rated Design Head : 428 M
5. Rated Output : 255 MW
6. Synchronous speed : 300 rpm
7. Run away speed : 545
8. Weight of Turbine rotating parts: 45 Tons
9. Bearing : Shell type
10. Target material of Labyrinth : Stainless stell 165 CrNi,
hard coated with WC based powder
11. Silt ppm : 2000 – 4000
12. Max. Pressure at spiral case : 48 Bar
13 Pressure at draft tube : 2.5 Bar
14. Clearance gap of labyrinth : 0 – 3 mm

3.3 GENERATOR DATA

1. Type : Vertical shaft, water

wheel driven, alternating
current synchronous
generator
2. Rated out put : 278 MVA
3. Power factor : 0.9 lagging
4. Frequency : 50 Hz
5. Direction of rotation : Clockwise when viewed
from top

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 6. Stator winding connection : Star
7. Generator earthing : Star point earthed through
a distribution T/F
8. Inertia constant (H) : 4 MW-Sec/MVA
9. Stator and Rotor winding insulation: F
10. Bearing type : a) 2 (Two) Guide Bearing
pivoted pad located above
and below rotor
b) 1 (One) Thrust
Bearing below rotor, Spring
plate type
11. Air Gap at center of pole : 30 mm
12. Rotor Diameter : 5940 mm
13. Shaft Diameter : 1010 mm
14. Active height of stator :3M

4.0 TECHNICAL REQUIREMENTS

ALREADY EXISTING SYSTEM

Three sets of vibration detectors (Displacement type) are already

installed at each of upper, lower and turbine bearing bracket, at
right angel to each other and wired up to the main processor of
distributed control system vibration cubical. The values are taken
as Smax and are used for trending purpose and alarm and trip of
the unit in abnormal conditions.

To further enhance the condition monitoring of the unit,

following systems are required:-

A. Measurement of Air gap.

B. On line vibration monitoring/analysis system.
C. On line measurement in turbine Upper or Lower labyrinth
clearance.
D. Complete hardware and software for analysis and diagnosis.

The following detailed specification shall be considered for

designing on line condition monitoring system.

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4.1 MEASUREMENT OF AIR GAP :

4.1.1 INTRODUCTION

The supplier shall be responsible for design, manufacture,

test, supervision of site installation and commissioning of an
air gap monitoring, diagnostic and analysis system for on line
monitoring of generator air gaps. Inspection of material
before dispatch shall be done by SJVNL. The system shall
provide dynamic air gap measurements as required without
requiring a service outage and permit static measurements
also and randomly monitor the condition of the generator air
gap. Magnetic field, dust, oil and carbon particles found in the
air gap should not alter the system measurement. System
installation shall be done for all units during maintenance of
the generator at site during the month of Nov’08 to March 09.
The installation of the system sensors and cabling must be
possible when rotor is in place. The system provided shall not
compromise the reliability and safety of the Generator. The
supplier must have extensive experience in the supply of air
gap sensor in the field and sensors installed in the past ten
years should still meet original specification and design
requirements. The system must provide software for
complete diagnostic and analysis.

4.1.2. SCOPE OF WORK

The supplier shall design, manufacture, test, supply, install at

site 6 (six) sets plus one spare set of air gap monitoring
system (AGM), vibration monitoring system comprising of all
kind of sensors, controller/processors, cables (including
special cables), conduits, diagnostic unit, protection unit,
display unit including standard furniture and fixture etc. for
online monitoring of the condition of dynamic air gap without
an interruption in the operation of the machine. The AGM
system, vibration monitoring system and labyrinth clearance
measurement system furnished and installed shall not in any
way compromise the integrity and safety of the machine. The
system shall be complete in all respect covering all major
items. Any other item which is not specifically stated, but
essentially required for installation and trouble free operation
of the system shall also deemed to have been included in the
supplier’s scope without any additional cost to purchaser.

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4.1.3 AIR GAP SENSORS AND CABLE LEADS

The air gap sensors must be preferably of capacitive type with

one plate of the capacitor being the air gap sensor and the
other plate being the rotor poles. The capacitive air gap
sensor shall be permanently installed in the air gap on the
stator iron packets of the stator inside wall. The number of
sensors shall correspond to be at 2 (two) planes, one near top
and one at bottom of stator core and shall be minimum 4
(four) sensors at each plane. The sensor frequency response
shall range from 0 to 1000 Hz of static and dynamic air gap
measurement and shall have a linearity better than or +/-
1%. Maximum operating temperature of the sensor shall be
125 degree centigrade. The material used for fabrication of
the sensor shall be compatible with class ‘F’ epoxy insulation
or higher grade , totally immune to the generator magnetic
field. Calibration charges for each sensor shall be included in
the offered price by the supplier. A synchronization probe
used for rotor pole reference purpose shall be installed above
the rotor near the shaft at the upper bracket. The same probe
shall also be used for the keyphasor reference required for
vibration analysis purpose. The synchronization probe shall be
a proximity type that shall detect a small metallic target or
glow sign epoxied to the rotor shaft. The leads for the sensor
shall be of suitable type and size which will be brought out
and be terminated in a wall mounted enclosure. Only one
cable per sensor shall be used. The leads for the
synchronization probe shall be of suitable type and size. The
leads from the synchronization probe to the wall mounted
enclosure shall also be routed in a protective conduit. The
placement of all conduits shall not interfere with normal
operation and maintenance of the generator. The conduit
shall be fastened securely to the stator frame/civil structure
to prevent movement due to vibration.

4.1.4 WALL MOUNTED ENCLOSURE (IF ANY)

The wall mounted enclosure shall meet the oil and dust tight
requirement of EEMAC/NEMA standard. Its dimensions shall
be sized to accommodate on line air gap monitoring system
with all cable leads. Protective conduits for sensor leads,
synchronization leads and the AC power line shall be rigidly

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 fixed to the metallic housing. The sensor cable lead shall be
labeled to show the associated sensor. A 14 gauge copper
wire shall be connected between the ground lug on the air
gap monitoring system and the generator ground bus. The
location of the wall mounted enclosure shall not interfere with
normal operation and maintenance of the generator.

4.1.5 AIR GAP MONITORING SYSTEM HARDWARE/SOFTWARE

The supplier shall furnish an air gap monitoring (AGMS) which

is specifically designed for use with the permanently installed
sensors. The system furnished shall operate with an IBM (or
equivalent) type computer and an Hewlett Packard (or
equivalent) type printer. The AGMS shall measure the static
and dynamic air gaps and shall be controlled by a user
friendly software package to display results in a polar,
rectangular and tabular form. The AGMS shall provide
software and/or hardware alarm when the air gap reaches
preset alarm levels and shall store automatically, at least 20
rotations before and after an alarm event occurred in short
term storage. The system shall be capable of storing the
trends in the form of polar plot on continuous and permanent
basis in long term storage. The supplier shall specify the
sampling time, raw data format, hard disk capacity and the
necessary hardware required. The system must be capable of
accepting externally triggered events to be able to take
measurements during machine trips, start and stops of the
unit.

Communications from AGM system to the computer shall

depend on a highly reliable opto-isolated differential EIA 485
or equivalent communication link. The supplier shall provide a
complete installation, testing and operation guide with the
AGMS for operating personnel.

4.1.6 FIELD INSTALLATION

The supplier shall provide sensor, cable leads and

synchronization probes, wall mounted enclosures, opto
isolated RS 485 or equivalent communication links and air
gap monitoring system. Provision for the engineering design
and supervision for the placement and installation of the

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 AGMS on the generator shall be provided by the supplier with
a complete installation report. Semiskilled and unskilled
manpower will be provided by SJVNL. Supplier shall indicate
the no. of persons required in the offer. Highly
skilled/specialist required for field installation will be provided
by the supplier.

Installation criteria:-

• The AGMS applied to all generators for 6X250MW,

15.75 KV, 300 rpm.
• Locate the sensor at 300 mm from top and/or bottom of
the stator laminations – as designed.
• Total number of sensors – Min. four sensors at each
plane.
• The sensor dynamics is proportional to the air gap.
• Installation to be made during the period of annual shut
down of machines tentatively between Nov’08 to
March09.

4.1.7 COMMISSIONING

The supplier’s field engineer shall provide all necessary test

equipment to verify the proper operation of the installed
AGMS. The supplier shall provide a complete diagnostic
procedure guide for the operating personnel.

4.1.8 INTERPRETATION OF AIR GAP & VIBRATION READINGS

The supplier shall provide on site analysis/interpretation and

technical support of initial on line condition monitoring test
readings for all six machines and two subsequent test
readings per machine taken during warranty period of two
years and any other data needed to be analyzed/interpreted
during this period of two years.

4.1.9 WORKING ENVIRONMENT FOR AGMS

AGMS covered in this specification shall be capable of

operating trouble free at an ambient temperature range of 0
degree to 50 degree centigrade (max.), 90% relative

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 humidity and present noise level normally of the order of 90
db and available vibration level of normally 100 to 200
microns and the present disturbances beyond the above limits
in power house. Temperature in the vicinity of sensors will
approx. 125 degree centigrade (max absolute).

4.2 ON LINE VIBRATION MONITORING SYSTEM

4.2.1 INTRODUCTION

The machine has three horizontal guide bearings i.e Upper

Guide Bearing (UGB), Lower Guide Bearing (LGB) and Turbine
Guide Bearing (TGB) and one vertical load sharing bearing i.e
Lower Thrust Bearing.

Existing system for vibration monitoring is of VIBRO-METER

make having two proximity probes of 4 mV/micron sensitivity
at each Upper, Lower and Thrust Guide Bearing. UVV 697,
Version 02 and PLD 772, Version 21 cards are used.

PLD772 Level detector and display module is used to

measure, monitor and display the analog voltages output by
other modules in a system.

The UVV 697 is a dual channel (X and Y) relative vibration

processor matching two non contacting proximity
transducers/conditioners.

Present vibration monitoring system is used to display relative

shaft vibration at three location in terms of Smax value and
the same are used for trending the overall vibration levels at
each bearing position and also for alarm and trip purpose.
Buffered output is available through BNC adaptors
corresponding to each vibration sensor.

To enhance the capability of present vibration monitoring

system, on line vibration analysis system is proposed to be
installed for the following information to be monitored and
stored in data base for diagnostic purpose :

Historic Plots Transient Plots Real time plots

• Waveform • Trend • Bar graph
• Spectrum • Cascade • Trend

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 • Orbit • Shaft • Waveform
Centerline
• Shaft • Bode • Spectrum
centerline
• Polar • Polar • Orbit
• Trend • Multi Polar • Polar
• Waterfall • Long waveform

Installing this system will assist us to decide when machinery

should be shut down and repaired before costly damage or
mechanical malfunction occurs. Also with accurate diagnostic
information we can isolate potential machinery problem,
reducing maintenance time, reduce forced outages by
trending vibration and process the information to planned
outages.

4.2.2 SCOPE OF WORK

On line vibration monitoring system comprising of relative

and absolute shaft vibration (radial) using proximity
transducers as required, transducers for velocity/acceleration
monitoring sensors, axial shift proximity sensors for axial
vibration measurement, different types of cables,
monitoring/analysis system, software etc. for all 6(six) units
shall be in the scope of supply.

The target/focus components for vibration measurement

(radial and axial) shall necessarily include the following:

• All three guide bearing i.e UGB,LGB cum thurst

bearing and TGB & rotor/thrust bearing.
• Turbine cover i.e Upper turbine cover and spiral
casing.

Any other item which is not specifically stated, but essentially

required for installation and trouble free operation of the
system shall also deemed to have been included in the
supplier’s scope without any additional cost to the purchaser.
The proximity probes which are already installed shall be used
form the buffered output.

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 The details of scope shall be as follows:

Basic transducer system:

• For relative shaft vibration the existing system can be

used, if so desired by supplier.
• For axial shift proximity transducer system comprising
standard mount probe, proximity sensor and extension
cable etc. The supplier shall identify the place of
mounting and the required surface on the rotor/thrust
bearing, design and do the needful.
• Keyphasor used for air gap monitoring should also be
used for vibration monitoring system.

For monitoring/analysis system:

Monitoring/analysis system shall be comprising input

module/cards, proximity monitor, output modules/cards,
hardware parts and accessories, cables and junction boxes
etc.

Software:

Software packages for configuring data acquisition and

monitoring, for achieving/accessing the data and for
analyzing and interpreting the data shall be provided under
the package or as part of complete package.

4.2.3 WORKING ENVIRONMENT FOR VIBRATION

MONITORING SYSTEM

Vibration monitoring/analysis system covered in this

specification shall be capable of operating trouble free at an
ambient temperature range of 0 degree to 50 degree
centigrade (max.), 90% relative humidity and present noise
level normally of the order of 90 db and available vibration
level of normally 100 to 200 microns and the present
disturbances in power house. Temperature in the vicinity of
sensors will approx. 90 degree centigrade (max absolute).

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4.3 ON LINE LABYRINTH CLEARANCE MONITORING

The top or bottom labyrinth clearances of the turbine shall be

continuously measured at 2(two) suitable locations. Bidder may
indicate options/possibilities for number, type and location of
sensors with Francis runner for which documents shall be
provided for reference of SJVNL. The hard coating layer and
parent material of the labyrinth seal ring is subjected to erosion/
cavitation damages due to which the clearances may increase
and seating/holding area of the probes may get damaged. The
labyrinth seals are required to be repaired/replaced after
erosion. The probes shall be designed that they can be easily
fitted/installed on the labyrinth. Even the probes shall have to be
erosion resistant for the silt levels mentioned in turbine data
clause 3.2. Bidder shall have to include all necessary sensors,
necessary modifications in turbine, hardware, software etc. for
the complete system for all 6 (six) units.

The bidder shall give details of any preparatory work including

machining etc. of turbine/generator part of NJHPS to be done by
the owner in presence of supervisor/expert of the contractor.
Para regarding details of installation of sensor of labyrinth in
technical bid.

5.0 MONITORING OF AGMS, VIBRATION, LABYRINTH GAP

a) monitoring hardware: Monitoring hardware shall

comprise of online multi channel data acquisition units
which simultaneously monitor and synchronize high and
low speed parameters for processing monitoring software.
The hardware shall be capable of operation in an ambient
temperature up to 50 degree centigrade. The monitoring
hardware shall:
• Accept input from air gap, vibration, labyrinth clearance
and other sensors.
• Provides synchronize measurements of air gap and all
connected parameters under condition from stand still to
run away.
• A system shall be suitable for mains operation (240V+/-
10%) 50 Hz AC., 48/220 VDC available with owner.
• Also shall have provision of UPS with 30 (thirty) minutes
back up.

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• Permit continuous alarm monitoring capability with user
defined dual level threshold input.
• Accepts analogue signal sources as required.

b) Monitoring software: the online Monitoring software shall

be capable of the following:
• Co-relation of all required electromechanical parameters
for reliable and quick machine diagnostic.
• Should be user friendly and capable of trending analysis,
alarm monitoring etc. and should be Window based.
• Monitoring in entire transit zone from machine stand still
to over speed.
• Position for networking facility.
• Automatic data storage to provide tracking of pre and post
alarm measurements for at least one year in long term
storage, possibility of interfacing with existing IMS/Control
system of NJHPS having facility of long term storage shall
also be mentioned by the bidder.
• The software shall be capable of providing following
minimum out puts for diagnostic:-

i) Polar view of the rotor and stator providing

information about roundness and eccentricity of both
stator and rotor.
ii) A signature display of the minimum air gap of each
rotor pole over one revolution.
iii) An average air gap function providing a programmable
and automatic air gap trending measurement.
iv) Simultaneous display of multiple parameters for
data/event co-relation.
v) Centering and run out features.
vi) Password protection to prevent unauthorized access.
vii) Polar view of turbine labyrinth clearance.
viii) Any other measurement necessary for complete
diagnostic of generating unit.
ix) Waveform display.
x) Frequency spectrum of vibration data.
xi) Bode plot and polar plot during run up, run down and
over speed.
xii) Orbit of vibration.

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6.0 DOCUMENTS TO BE SUBMITTED ALONG WITH QUOTATION

Following documents shall be submitted along with quotation in

triplicate:

• Clause by clause confirmation regarding compliance of this

specification and deviation, if any, shall be stated clearly
w.r.t specification.
• Latest detail list and technical literature/specification for all
the component of the total system.
• Single line block diagram for the total specification for all
the complete monitoring system.
• Location of sensors duly marked on the generator/turbine
section.

6.1 Integration With Present Operator Station

(OS)/Information Management System (IMS)

ADVANT Control system AC 410 ABB make OS and AC 450

ALSTOM make IMS are operational in the power house. The
bidder shall also include in his offer a proposal along with
additional cost involved if any for integration of AGMS, labyrinth
gap measurement system and vibration monitoring system with
the existing OS/IMS . Overview of IMS system is given in
drawing section.

7.0 INSTRUCTION MANUALS

The contractor shall furnish 6 (six) copy of instruction manuals

along with hard copy for the testing, installation, operation and
maintenance of the entire system before the dispatch of the
equipment. All instruction data etc. shall pertain only to the
equipment supplied. The bidder shall furnish catalog/leaflets of
all the equipment software offered along with the bid. The bidder
shall also provide the soft copy of the manuals.

8.0 SPARES

Complete one set of all components required for one machine.

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9.0 WARRANTY

Two years after successful commissioning during which the

supplier will rectify any hardware/software related fault with in a
period of one month at site from the date of notification of such
fault. However if the period taken for rectification is more than
one month, the total period of warranty for that particular unit
shall be extended by total period of faulty condition.

10.0 TRAINING

Supplier to impart training of at least one week’s duration at

owner site for customer operating and maintenance engineers on
the fundamental of the system (as installed) and the use of the
monitoring instrumentation package and software with suitable
recommendation, test procedures, data/result interpretation,
test file management etc. for implementation by end user.
Therefore, training charge, if any, shall be considered as
included in the main offer.

11.0 QUALITY ASSURANCE PROGRAMME

11.1 The supplier shall supply to the purchaser the following

documents:
11.1.1 Literature/catalogues of goods if any.
11.1.2 Instruction manual for erection, testing and putting the
goods in use if any, documentation on design,
drawings, other important information of the goods,
manufacturing process, commissioning, operation,
maintenance, properties etc.

11.2 The owner or his representative shall have the right to witness
inspection and/or testing of the goods to confirm their
conformity to the contract and relevant standards. The supplier
shall inform the testing programme to the purchaser with at
least 15 days prior notice. The Owner may notify the Supplier in
writing, in a timely manner, the identity of any representative(s)
deputed for these purposes.

11.3 The inspection and tests and witnessing (if done) by purchaser,
may be conducted on the premises of the Supplier or at point of
delivery and/or at the goods’ final destination. If the inspection
and/or tests to be conducted on the premises of the Supplier are

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 to be carried out in the presence of SJVNL’s representative, all
reasonable facilities and assistance, including access to drawings
and production data, shall be furnished to the inspector. For the
cost of traveling, boarding, lodging and local traveling on
account of SJVNL’s representative shall be borne by SJVNL.

11.4 Should any inspected or tested Goods fail to conform to the

specifications irrespective of the inspection/tests having been
witnesses or not by SJVNL’s representative, the Owner may
reject the Goods, and the Supplier shall either replace the
rejected Goods or make all alterations necessary to meet
specification requirements free of cost to the Owner.

11.5 The Owner’s right to inspect, test and where necessary, reject
the Goods after the Good’s arrival in India, shall in no way be
limited or waived by reason of the Goods having previously been
inspected, tested and passed by the Owner or its representative
prior to the Goods’ shipment from the country of origin.

11.6 The supplier will furnish the test/compliance certificates for the
goods to be supplied to the Owner as per the Contract. The
test/compliance certificate shall be sent by the Supplier for
approval along with the request to issue MDCC required for
shipment/invoicing. MDCC will be issued by SJVNL within 14
days after receipt of such request from the Supplier provided the
test/compliance certificates are in order. However, if inspection
at manufacturer’s work is required by SJVNL, the Supplier shall
give 3 weeks notice for attending the same. The Supplier shall
dispatch the material only after receipt of MDCC from Purchaser
unless the requirement of MDCC has been explicitly waived off in
writing by the Owner.

11.7 General quality assurance plan is attached as annexure-A.

However, Bidder shall prepare a detailed shop and site ‘Quality
Assurance Programme to meet the requirements of these
specifications for Owner’s approval.

12.0 Drawings

1. Generator Cross Section

2. Francis Turbine Cross Section
3. Overview IMS

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