Turbovisory Instruments (2) Gyanendra Sharma NPTI Delhi

TURBOVISORY
INSTRUMENT
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 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

CROSS SECTION OF TURBINE
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

7 TURNING GEAR
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
VIBRATION MEASURING
INSTRUMENTATION
SHAFT VIBRATION / ECCENTRICITY
- PROXIMITY PROBE
BEARING VIBRATION
- VELOCITY PICK UP

Why Vibration?
• We can understand the machine

• We can find the weakness
• Thereby we can predict, plan, maintain and
improve
• Improve availability and reduce costs

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

VIBRATION MONITORING
WHAT IS VIBRATION ?
WHAT CAUSES VIBRATION ?
HOW DO WE MEASURE VIBRATION ?
HOW DO WE ANALYSE VIBRATION ?

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

What Is Vibration?
It is the response of a
system to an internal or
external force which causes
the system to oscillate.

2. Measurement direction - Horizontal,
Vertical, Axial.

General rule of direction
• We measure H direction for machines on the
foundation.
• We measure V direction for machines on
structures
• We measure A direction when we suspect
misalignment
• There are advantages, but there are
exceptions to this rule.

Modes of Amplitudes
• DISPLACEMENT
• VELOCITY
• ACCELERATION
• SPIKE ENERGY
Physical Significance Of Vibration
Amplitude
Displacement : Strain Indicator
Velocity : Fatigue Indicator
Acceleration : Force Indicator

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.

UNITS OF MEASUREMENT
DISPLACEMENT - MICRONS
VELOCITY - MM / SEC.
ACCELERATION - MM / SEC2 , G
AMPLITUDE DESCRIPTORS
• RMS - Displacement
Velocity
• PEAK - 1.414 RMS Displacement

Velocity
Acceleration
• PEAK-TO-PEAK - 2 * PEAK Displacement

ISO 2372
Class Class Class Class Class Class
Limits
1 Step

WHEN TO USE DISPLACEMENT, VELOCITY & ACCELERATION
VIBRATION
SENSITIVITY DISPLACEMENT
10
VELOCITY
.1
.01
.001
ACCELERATION
FREQUENCY 60 600 6000 60000 600 000

CPM

Accelerometer

SIMPLE VIBRATION
Time Domain
Amplitude
(mm)
A
Time
(sec)
Period T
Amplitude Frequency Domain

(mm)
A
f=1/T Frequency f
(Hz)
REAL VIBRATION
Time Domain
Amplitude
(mm)
Time
(sec)
Frequency Domain - Vibration Signature

Amplitude
(mm)
Frequency f
(Hz)
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

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

Vibration Sensors
• Acceleration Sensor - Accelerometer

• Velocity sensor – Velocity sensor or
seismic sensor
• Displacement sensor - Non Contact pickup
Accelerometer

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

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 inside
• 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 freq
(600,000 CPM)
• Can measure Acceleration, velocity and displacement
• It is advised to involve suppliers or persons knowledgeable in
this area to choose accelerometers for on line monitoring
applications

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

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

Non contact type

Non contact
sensor
Installation
in a Turbine

ABSOLUTE BEARING VIBRATION
VELOCITY TRANSDUCER
SEISMIC MASS TYPE
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.

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
ABSOLUTE SHAFT VIBRATION
• RELATIVE SHAFT VIBRATION IS BASED ON EDDY CURRENT PRINCIPLE.
• PROXIMOTY PROBE SENSES THE DISTANCE BETWEEN THE 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 GENERATED IN THE SURFACE AND LOSS OF
STRENGTH IN THE RETURN SIGNAL IS DETECTED BY THE
PROXIMETER.

SHAFT & BEARING
VIBRATION PICK UP

BEARING / SHAFT VIBRATION PICK UP
MOUNTED
Saturday, March 27, 2021 ON BEARING NO.
Gyanendra Sharma, NPTI Delhi 4 PEDESTAL 39
Saturday, March 27, 2021 PROXIMITY PROBE
Gyanendra Sharma, NPTI Delhi 40
RECOMMENDED LOCATIONS OF VIBRATION
MEASUREMENTS FOR PEDESTAL BEARINGS
(AS PER ISO)
RECOMMENDED LOCATIONS OF VIBRATION
MEASUREMENTS FOR HOUSING TYPE BEARINGS (AS
PER ISO)
Measuring
Amplifier
Proximity
Pick-up
45O 45O
L R
SHAFT
RECOMMENDED LOCATIONS OF SHAFT VIBRATION

MEASUREMENTS ASGyanendra
Saturday, March 27, 2021
PERSharma,
ISONPTI Delhi 43
Measuring
Amplifier
Proximity
Pick-up
L R
SHAFT
RECOMMENDED LOCATIONS OF SHAFT VIBRATION

MEASUREMENTS ASGyanendra
PERSharma,
ISONPTI Delhi 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 COIL DUE TO
VARIATION IN PROXIMITY OF TARGET MATERIAL
INDUCTIVE TRANSDUCER
PROXIMITY(EDDY CURRENT) TRANSDUCER

INDUCTIVE TRANSDUCER
• TWO MAGNETICALLY RELUCTANCE TYPE TRANSDUCERS 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 ROTOR SPEED
• DEMODULATOR, FILTER,AMPLIFIER & AMPLITUDE DETECTOR

PROXIMITY TRANSDUCER
• SENSES THE DISTANCE BETWEEN THE PROBE TIP AND
OBSRVED SURFACE
• PROXIMETER GENERATES RF SIGNAL, RADIATED THROUGH
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.

PROXIMITY SENSOR :
Eddy Current
CONDUCTIVE
MATERIAL
PROXIMITOR
Radio Frequency
Signal
OBSERVED
EXTENSION CABLE
MATERIAL
AND PROBE
PROXIMITOR
VOLTS
OSCILLATOR
DETECTOR VOLTAGE
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 0 48 100

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 the
object and the power is absorbed thus alternating the voltage across the coil.The
alternating voltage is proportional to the distance between the measured Object
and the sensor.the output amplifier forms a load independent D.C. Voltage signal.

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 2 Power Supply
~~~
3
-
~~~ 3
Output
-
1 Oscillator
2 Demodulator
3 Output Amplifier
EXPANSION MEASURING INSTRUMENTS
OVERALL EXPANSION
- POSITION TRANSMITTER
DIFFERENTIAL EXPANSION MEASUREMENT

- PROXIMITY PROBE
AXIAL SHIFT MEASUREMENT

- PROXIMITY PROBE

OVERALL EXPANSION PICK UP
OVERALL EXPANSION MOUNTED
Saturday, March 27, 2021ON BEARING NO.
Gyanendra 1 PEDESTAL
Sharma, NPTI Delhi 53
DIFFERENTIAL EXPANSION (FOR SMALL
Saturday, March 27,EXPANSION)
2021 & AXIAL
Gyanendra SHIFT
Sharma, NPTI Delhi PICK UP 54
RELATIVE EXPANSION
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 l2
d1 d 2
I
Turbine Casing Measuring Attachment
L1 L2 Sensor Coils
d1 d2 Air gap
Small relative Expansion,Shaft with Collar

DIFFERENTIAL EXPANSION (FOR SMALL
2021 & AXIAL
Gyanendra SHIFT
Sharma, NPTI Delhi PICK UP 56
IP DIFFERENTIAL EXPANSION PICK UP
MOUNTED
Saturday, March 27, 2021 ON BEARING
Gyanendra Sharma, NO. 3 PEDESTAL
NPTI Delhi 57
AXIAL SHIFT MEASUREMENT AT IP COLLAR
DIFFERENTIAL EXPANSION (FOR LARGE
2021 PICKSharma,
Gyanendra UP NPTI Delhi 59
RELATIVE EXPANSION :
d1 d2
- Power Supply Unit
L1 L2 Measuring
I Attachment
Turbine Casing
L1 L2 Sensor Coils
d1 d2 Air gap
Large Relative Expansion, Shaft with double cone

DIFFERENTIAL EXPANSION (FOR LARGE
EXPANSION) PICK UP

LP DIFFERENTIAL EXPANSION PICK UP
MOUNTED
Saturday, March 27, 2021 ON BEARING
Gyanendra Sharma, NO. 4 PEDESTAL
NPTI Delhi 62
SHAFT POSITION MEASURING
Saturday, March 27, 2021 DEVICE
SHAFT POSITION MEASURING DEVICE
SPEED, LOAD MEASURING
INSTRUMENTS
SPEED / OVERSPEED
- KEY PHASOR
- HALL PROBE
LOAD MEASUREMENT
- CURRENT TRANSFORMERS
- POTENTIAL TRANSFORMERS

4 : HYDRAULIC SPEED TRANSDUCER
5 : ELECTRIC SPEED TRANSDUCER
SPEED MEASUREMENT INSTRUEMENT MOUNTED

IN27,HP
Saturday, March 2021FRONT BEARING PEDESTAL
STARTING AND LOAD
LIMITING DEVICE
PRIMARY OIL
PRESSURE
HALL PROBE
BASIC ARRANGEMENT OF HALL PROBES AT BEARING 1
DISK
PERMANENT MAGNETS
N-POLE
S-POLE
SENSOR
BRACKET

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 = V x B z Ey
Ey = Hall Effect
Ex
HALL VOLTAGE
VAB = EY W w
Ix
HALL PROBE IN BEARING NO. 1 PEDESTAL
Saturday, March 27, 2021 MAIN OILNPTI
Gyanendra Sharma, PUMP
Delhi 73
OVERSPEED TRIP
BOLTS IN
TURBINE ROTOR

OVERSPEED TRIP BOLTS IN BEARING NO. 1 PEDESTAL
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
THERMOCOUPLE
BABBIT METAL TEMPERATURE

MEASUREMENT
Saturday, March 27, 2021 IN JOURNAL
Gyanendra Sharma, NPTI Delhi BEARING 77
THERMOCOUPLE
IN JOURNAL BEARING

THERMOCOUPLE
BABBIT METAL TEMPERATURE MEASUREMENT IN

COMBINED
Saturday, March 27, 2021 JOURNAL & Sharma,
Gyanendra THRUSTNPTI Delhi BEARING 79
THERMOCOUPLE
THRUST PAD ARRANGEMENT AND THERMOCOUPLE

LOCATION IN COMBINED THRUST AND JOURNAL BEARING
THANK YOU

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TURBOVISORY

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 1

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 2

6 ABSOLUTE CASING VIBRATION

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• We can understand the machine

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 8

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 9

WHAT CAUSES VIBRATION ?

HOW DO WE MEASURE VIBRATION ?

HOW DO WE ANALYSE VIBRATION ?

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 10

Max Velocity, Min Acceleration Max Acceleration, Min Velocity

IT FOLLOWS SINE CURVE

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 11

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 12

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 13

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Displacement : Strain Indicator

Velocity : Fatigue Indicator

Acceleration : Force Indicator

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Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 18

• PEAK - 1.414 RMS Displacement

• PEAK-TO-PEAK - 2 * PEAK Displacement

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 21

FREQUENCY 60 600 6000 60000 600 000

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Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 23

Amplitude Frequency Domain

Frequency Domain - Vibration Signature

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Thus we can have METERS of various types

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 27

• Acceleration Sensor - Accelerometer

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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 37

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 38

RECOMMENDED LOCATIONS OF SHAFT VIBRATION

RECOMMENDED LOCATIONS OF SHAFT VIBRATION

• DEVIATION OF MASS CENTER FROM THE GEOMETRICAL CENTRE OF

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 45

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 46

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 47

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 0 48 100

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DIFFERENTIAL EXPANSION MEASUREMENT

AXIAL SHIFT MEASUREMENT

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Power Supply Unit

Turbine Casing Measuring Attachment

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Large Relative Expansion, Shaft with double cone

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