VMS

Agenda

1.
1. Introduction-
Introduction- Basic
BasicConcepts
Concepts

2.
2.Components
Componentsof
ofvibration
vibrationmonitoring
monitoringsystem
system

3.
3.Vibration
Vibrationmonitoring
monitoringat
atpower
powerplant
plant

4.Turbine
4.TurbineSupervisory
SupervisoryInstrumentation
InstrumentationSystem
System

5.Vibration
5.VibrationDiagnosis
Diagnosisand
andAnalysis
Analysissystem
system

6.Recent
6.Recent developments
developments

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

Introduction to vibrations

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

What is vibration monitoring ??

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

Definition
 A tool to measure and display
the vibrations in a machinery
which is a form of wasted
energy
 Undesired vibrations may be
the result of one or more of
the below reasons:
– Mass Unbalance
– Mechanical looseness
– Misalignment of couplings or
bearings
– Poor lubrication
– Resonance

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

ed
i r
q u

?
re
i s
it
hy
W

Gyanendra Sharma, NPTI Delhi 3/27/21

FTA 3/27/21 02:13:28 AM
 VMS

Destruction of generator
 Sometimes very high
vibrations can be
catastrophic as shown

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

More benefits
Productivity of unit
Healthiness of
machinery
Predictive and
preventive maintenance
Reducing overall costs

Gyanendra Sharma, NPTI Delhi 3/27/21 FTA 3/27/21 02:13:28 AM

Components of a Vibration Monitoring system

Gyanendra Sharma, NPTI Delhi 3/27/21

Machinery Protection Systems
• Proximity probes
• RTDs
• Thermocouples
Sensor • Accelerometers
• Magnetic speed sensors
Transducer • Sensor leads
system • Extension cables
• Accelerometer cables

Signal
conditioner • Oscillator-Demodulator

(where required)
Gyanendra Sharma, NPTI Delhi Signal cable
•3/27/21
Machinery Protection Systems
• Signal cable

Signal processing • Radial vibration

Alarm/Shutdown/ • Axial position
Integrity logic processing • Casing vibration
• Temperature
Monitor Power supply(ies) • Piston rod drop
system • Speed indication
Display indication • Overspeed
Inputs/Outputs detection

Protective relays
Gyanendra Sharma, NPTI Delhi 3/27/21
Transducer System
Nomenclature

Gyanendra Sharma, NPTI Delhi 3/27/21

Standard Probe

Gyanendra Sharma, NPTI Delhi 3/27/21

Sensor Type and Purpose
Proximity probe
(Non-contact displacement sensor ; Eddy current
type) for Shaft Vibration, Axial Position, Rotational
Speed and Phase Reference

Velocity Transducer or Accelerometer

for Bearing Vibration
Magnetic Speed Sensor
for Rotational Speed

Gyanendra Sharma, NPTI Delhi 3/27/21

Conduit Arrangement

Gyanendra Sharma, NPTI Delhi 3/27/21

Typical System Grounding

Gyanendra Sharma, NPTI Delhi 3/27/21

Standard Axial Probe arrangement

Gyanendra Sharma, NPTI Delhi 3/27/21

Transducer and sensor Arrangement

Gyanendra Sharma, NPTI Delhi 3/27/21

 Example of Sensor

Vibration / Displacement Velocity Transducer /

Transducer (Non-contact Accelerometer
Eddy current type)

Tacho Sensor
Tacho Sensor
Gyanendra Sharma, NPTI Delhi (Magnetic
3/27/21 Pickup)
(Eddy current type)
EXTN CABLE , JUNCTION BOX & MOUNTING PAD

EXT
CABLE

JUNCTION
BOX

MOUNTING
PAD
Gyanendra Sharma, NPTI Delhi 3/27/21
 Primary Functions of Monitor
Conversion to monitoring parameter
Indication of measured value
Output of measured value
Detection of Danger and Alert status
Indication of Danger and Alert status
Output of Danger and Alert status
Buffered output of vibration wave form for analysis

Gyanendra Sharma, NPTI Delhi 3/27/21

 Primary Functions of Monitor

Input Output
Signals from Measured Value
Sensors (4 - 20mA or 1 - 5VDC)

Indicator Danger / Alert Status

(Relay Contact Output)

Buffered Output
(Vibration Wave Form)

Gyanendra Sharma, NPTI Delhi 3/27/21

Example of Monitor Display

Measured Value (Digital)

Danger Set Point

Alert Set Point

Gap Voltage

Measured Value (Bar Graph)

Status Lamp (Danger, Alert, OK)

Gyanendra Sharma, NPTI Delhi 3/27/21

Examples of Monitor Arrangement

Gyanendra Sharma, NPTI Delhi 3/27/21

 Multichannel VMS Monitor

Rack with
Monitoring
Module

Display Unit
If required

Gyanendra Sharma, NPTI Delhi 3/27/21

Gyanendra Sharma, NPTI Delhi 3/27/21
 API Std 670
API standard 670 is issued by American Petroleum
Institute, and the standard addresses the
monitoring systems for vibration and other critical
parameters of machines.

Ed. Title Issue

Noncontacting Vibration and Axial
1st 1976/06
Position Monitoring System
2nd Vibration, Axial-Position, and 1986/06
Bearing-Temperature Monitoring
3rd Systems 1993/11
4th Machinery Protection Systems 2000/12
Gyanendra Sharma, NPTI Delhi 3/27/21
 VMS

Vibration monitoring in Power

Plant

Gyanendra Sharma, NPTI Delhi 3/27/21

TYPICAL COAL FIRED POWER PLANT -SCHEMATIC

TSI
VMS

VMS VMS

VMS

VMS

VMS

VMS
VMS VMS

VMS
Gyanendra Sharma, NPTI Delhi 3/27/21
MOTORS

Gyanendra Sharma, NPTI Delhi 3/27/21

CRUSHER
Crushers

Gyanendra Sharma, NPTI Delhi 3/27/21

 FANS

Gyanendra Sharma, NPTI Delhi 3/27/21

GAS TURBINE
Gas Turbines

Gyanendra Sharma, NPTI Delhi 3/27/21

Gyanendra Sharma, NPTI Delhi 3/27/21
Vertical Pumps
Centrifugal Pumps
Gyanendra Sharma, NPTI Delhi 3/27/21
 VMS

Turbine Supervisory Instruments

Gyanendra Sharma, NPTI Delhi 3/27/21

Example of Monitoring System for
Steam Turbine Generator Train
③ ⑥ ⑦ ② ① ⑧ ① ① ① ④ ① ① ①

STEAM
VALVE

HP GENE-
TURBINE LP RATOR
TURBINE

⑤
Bearing

No Monitoring Parameter No Monitoring Parameter

① Shaft Vibration ⑤ Case Expansion
② Axial Position ⑥ Rotating/Zero Speed
③ Eccentricity p-p ⑦ Phase Marker
④ Differential Expansion ⑧ Valve Posotion
Gyanendra Sharma, NPTI Delhi 3/27/21
TYPICAL LAYOUT FOR 500 MW TSI - BHEL

Gyanendra Sharma, NPTI Delhi 3/27/21

 TSI-Monitoring Parameters
Monitoring Parameter Description
Relative vibration (displacement) between
Shaft Vibration shaft and bearing at each bearing.
1 or 2 points par each bearing.
Absolute vibration (velocity or
Bearing Vibration acceleration) of bearing housing/casing.
1 or 2 points par each bearing.
To monitor clearance of thrust bearing.
Critical monitoring parameter during
Axial Position
operating machine, especially at start up
and shut down.
Shaft can be bent because of its own
weight and partial heating. It’s necessary
Eccentricity p-p to monitor bending of rotor as observing
shaft eccentricity during slow speed
turning at non-operating of turbine.
Gyanendra Sharma, NPTI Delhi 3/27/21
 TSI-Monitoring Parameters
Monitoring Parameter Description
Differential Expansion between rotor and
casing because of different thermal
Differential Expansion
expansion of them during start up and
operating of turbine.
Thermal expansion of turbine case.
Case Expansion Contortion of case expansion is also
monitored.
Rotating Speed Rotating speed of turbine shaft (rotor).
Phase reference for vibration analysis.
Phase Marker Detection of one rotation for measuring
eccentricity p-p.
To observe opening position of main
steam inlet valve of steam turbine. This is
Valve Position
used for controlling rotating speed of
turbine.
Gyanendra Sharma, NPTI Delhi 3/27/21
 Radial Shaft Vibration
Oscillator-
Vibration
Demodulator
Extension Monitor
(Driver)
Vertical cable
center

45° 45° Sensor

Sensor
Rotor

Gyanendra Sharma, NPTI Delhi 3/27/21

Radial Shaft Vibration

Gyanendra Sharma, NPTI Delhi 3/27/21

Radial Shaft Vibration

Gyanendra Sharma, NPTI Delhi 3/27/21

Casing Vibration
Vibration
Monitor

Accelerometer

Double-Helical
Gyanendra Sharma, NPTI Delhi3/27/21
Gear
Casing Vibration

Gyanendra Sharma, NPTI Delhi 3/27/21

Casing Vibration

Gyanendra Sharma, NPTI Delhi 3/27/21

Casing Vibration

Gyanendra Sharma, NPTI Delhi 3/27/21

 Axial Position
Oscillator-
Demodulator
Extension (Driver)
cable Thrust
Monitor

Rotor

Sensor
Gyanendra Sharma, NPTI Delhi 3/27/21
Axial Position

Gyanendra Sharma, NPTI Delhi 3/27/21

Shaft rotational speed
Oscillator-
Extension Demodulator Speed Monitor
cable (Driver) (Tachometer)

Sensor

Rotor

Gyanendra Sharma, NPTI Delhi 3/27/21

Phase Marker

Gyanendra Sharma, NPTI Delhi 3/27/21

 Piston rod drop
Oscillator-
Demodulator
(Driver)
Extension Rod Dop Monitor
cable
Phase reference
Sensor
sensor

Piston

Piston rod
Cylinder Crankshaft
Reciprocating Compressor

Gyanendra Sharma, NPTI Delhi 3/27/21

 Differential Expansion

Driver
Differential Ramp target
Expansion type
Monitor

Rotor

Sensor
Rotor
Ramp target
type
Rotor
Complementary input type Gyanendra Sharma, NPTI Delhi 3/27/21
Case Expansion
Case Expansion
Monitor

LVDT
Transmitter

T
LVD LVDT (Linear Variable
Gyanendra Sharma, NPTI Delhi 3/27/21Differential Transformer)
 VMS

Vibration Analysis and Diagnosis

Systems

Gyanendra Sharma, NPTI Delhi 3/27/21

 Typical System Configuration
Host PC
Host Network Comm.
Modbus, Ethernet, OPC
(Redundant Comm.)

Panel PC

View
Ethernet
Station
Local Comm.

Contact Input Buffered Output

・ Alarm Reset Front BNC & Rear
・ Alarm Multiply Panel Connector
・ Filter Enable
Recorder Output
4 - 20mA or 1 - 5VDC
Notebook
PC USB Relay Output
Each Monitor Module
Local Comm.
DAN, ALT, CH-OK
Rack Common
SYS-OK, PWR-OK,
DAN-BYPASS

Power Supply Transducer x 24ch

AC or DC VK, FK, CV, CA, RD, MS
Gyanendra Sharma, NPTI Delhi 3/27/21
Power Supply for Transducer x 24ch
Phase Marker x 2ch (RD, FK)
Analysis and Diagnosis

Gyanendra Sharma, NPTI Delhi 3/27/21

 Diagnosis
Root Cause to be observed as a result
Unbalance, Misalignment, Critical speed, Permanent bow
Lost rotor parts, Rotor Crack, Nonsymmetrical rotor,
Gear inaccuracy,
Seal rub, Seal whirl
Oil whirl,
Oil whip,
Steam whirl,
Cavitations, Vane vibration 、
Draft core, Surging

Gyanendra Sharma, NPTI Delhi 3/27/21

Especially For
Turbine Generator System Configuration
• High Speed Data Analysis & Diagnosis System
Transmission Remote
• Trend Maintenance
• Spectrum Station
• Shaft Centerline
• Bode/Polar Plot Inter Net
• Orbit
VIEW
• Vector STATION
Max. Vibration
Web Server
Web Server
• Waveform Inputs : 576 Points Ethernet

PROCESSOR

VM-5/ 7 TSI
MONITOR

LP HP Gas
Initial GEN
Turbine Turbine Turbine
Motor

Gyanendra Sharma, NPTI Delhi 3/27/21

 A Typical Plant wide Architecture
Remote
Maintenance
Station
Factory

VIEW
STATION

Inter Net
Ethernet Web Server
Web Server
Ethernet

TSI TSI
MONITOR MONITOR
A
P

Initial LP HP Gas
GEN Turbine Turbine
Motor T

Gas Turbine
Pump
&
Gyanendra Sharma, NPTI
PumpDelhi 3/27/21
FAN Compressor Cooling
Compressors
Towers
 Analysis Data
Transient
Steady State Data Alarm Data Common Data
Data
Machine Train Trend Trend Current Values

Measuring Points Bode Plot Spectrum Alarm Setpoints

Trend Polar Plot Waveform System History

Bar Graph Orbit Alarm History

Vector Spectrum

Spectrum Waveform

Waveform

Gyanendra Sharma, NPTI Delhi 3/27/21

Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Diagnostic Result

Gyanendra Sharma, NPTI Delhi 3/27/21

RV-100 LARGE ROTATING MACHINERY ONLINE
ANALYSIS SYSTEM
VIEW STATION SOFTWARE DIGEST

SHINKAWA ELECTRIC CO. LTD

SHINKAWA SENSOR TECHNOLOGY, INC.

Gyanendra Sharma, NPTI Delhi 3/27/21

 System Configuration
For Metal of
Bearings Model RV-100 Remote
Analysis & Diagnosis System Maintenance
Station
Especially For
Turbine Generator
Inter Net
• High Speed Data
VIEW
Transmission STATION
Max. Vibration
Web Server
Web Server
• Trend Inputs : 576 Points Ethernet
• Spectrum
• Shaft Centerline AP AP AP
• Bode/Polar Plot PROCESSOR

• Orbit
• Vector
• Waveform
VM-5/ 7 TSI
MONITOR

LP HP Gas
Initial GEN
Turbine Turbine Turbine
Motor

Gyanendra Sharma, NPTI Delhi 3/27/21

 Plant wide Architecture for VMS---RIGHT SIZE
SOLUTIONS…
Remote
Maintenance
Station
Factory

VIEW
STATION

Inter Net
Ethernet Web Server
Web Server
Ethernet

VM-7/5 VM-7/5
TSI TSI
A
MONITO P MONITO
R R

Initial LP HP Gas
GEN Turbine
Motor Turbine Turbine

Gas
Pump
Gyanendra Sharma, NPTI Delhi 3/27/21
Turbine Pump FAN Compress Cooling
Analysis Data
Transient
Steady State Data Alarm Data Common Data
Data
Machine Train Trend Trend Current Values

Measuring Points Bode Plot Spectrum Alarm Setpoints

Trend Polar Plot Waveform System History

Bar Graph Orbit Alarm History

Vector Spectrum

Spectrum Waveform

Waveform

Gyanendra Sharma, NPTI Delhi 3/27/21

Trend

Gyanendra Sharma, NPTI Delhi 3/27/21

Long Term Trend

Gyanendra Sharma, NPTI Delhi 3/27/21

Bar Graph

Gyanendra Sharma, NPTI Delhi 3/27/21

 Max Point Bar Graph

Gyanendra Sharma, NPTI Delhi 3/27/21

 S/V Graph

Gyanendra Sharma, NPTI Delhi 3/27/21

X-Y Graph

Gyanendra Sharma, NPTI Delhi 3/27/21

Vector Plot

Gyanendra Sharma, NPTI Delhi 3/27/21

Lissajous

Gyanendra Sharma, NPTI Delhi 3/27/21

 Lissajous & Waveform

Gyanendra Sharma, NPTI Delhi 3/27/21

Shaft Centerline

Gyanendra Sharma, NPTI Delhi 3/27/21

Waveform

Gyanendra Sharma, NPTI Delhi 3/27/21

Spectrum

Gyanendra Sharma, NPTI Delhi 3/27/21

 Multi Spectrum

Gyanendra Sharma, NPTI Delhi 3/27/21

Transient Trend for Shut Down Data

Gyanendra Sharma, NPTI Delhi 3/27/21

Transient Bode Plot

Gyanendra Sharma, NPTI Delhi 3/27/21

Transient Polar Plot for Shut Down

Gyanendra Sharma, NPTI Delhi 3/27/21

 Transient Lissajous

Gyanendra Sharma, NPTI Delhi 3/27/21

Transient Lissajous & Waveform

Gyanendra Sharma, NPTI Delhi 3/27/21

 Transient Waveform

Gyanendra Sharma, NPTI Delhi 3/27/21

Transient Spectrum for Shut Down

Gyanendra Sharma, NPTI Delhi 3/27/21

Transient Spectrum for Shut Down with Order Analysis

Gyanendra Sharma, NPTI Delhi 3/27/21

Transient Shaft Centerline for Shut Down

Gyanendra Sharma, NPTI Delhi 3/27/21

Gyanendra Sharma, NPTI Delhi 3/27/21
Example of Diagnosis
for Unbalance
Gyanendra Sharma, NPTI Delhi 3/27/21
Example of Diagnosis
for Rub

Gyanendra Sharma, NPTI Delhi 3/27/21

Example of Diagnosis
for Oil Whirl

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

Recent Developments in Vibration monitoring systems

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

Recent developments
1) SMART sensors
Inbuilt memory
Provide signal conditioning
Transmits the processed information ready to use via the
Ethernet to the system monitoring point
Reduce the complexity of linking the outputs to Process
control systems
Accurate and reliable
Cost effective

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

Instatel –web based monitoring

Safe and secure 24/7 access to your vibration data
Using internet, transfer of data to a secured web site
for its users
Ideal for sites with large no. of monitoring points
Monitor remote sites without having staff on hand
Faster cost effective service

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

Transducer embedded bearings

• Smart bearings
• Instrumented with sensors
• Data like speed, direction,
• temperature, vibration, load etc
• Data is feed it to a control unit that is used
to monitor bearing operation
• Printing industries, paper converting, food
processing

Gyanendra Sharma, NPTI Delhi 3/27/21

 VMS

WIRELESS TECHNOLOGY – for vibration monitoring

Hazardous areas
Traversing/moving machines where fixed cabling is
not possible.
Eliminates the need for hardwiring for
communications
Reduces sensor cable lengths.
Reduced installation cost

Gyanendra Sharma, NPTI Delhi 3/27/21

Example of Diagnosis
Start procedure

Gyanendra Sharma, NPTI Delhi 3/27/21

Example of Diagnosis
Confirming Message

Gyanendra Sharma, NPTI Delhi 3/27/21

Alarm Level Setting Menu

Gyanendra Sharma, NPTI Delhi 3/27/21

Bearing Temperature
Temperature
Monitor

Rotor

Thermo couple or RTD

Gyanendra Sharma, NPTI Delhi 3/27/21
 Significant Aspects of API-670
 The standard covers the minimum requirements for
a machinery protection system measuring
 Radial Shaft Vibration
 Casing Vibration
 Shaft axial position
 Shaft rotational speed
 Piston rod drop
 Phase reference
 Over speed
 Critical machinery temperatures
 Bearing metal
 Motor winding

 The standard covers requirements for hardware

(Transducer and monitoring systems) installation,
documentation, and testing.

Gyanendra Sharma, NPTI Delhi 3/27/21

SCOPE of API 670 4th Ed.
It covers requirements for hardware
(transducer and monitor systems),
installation, documentation, and
testing.

Gyanendra Sharma, NPTI Delhi 3/27/21

Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21
Gyanendra Sharma, NPTI Delhi 3/27/21