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

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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 3
 CROSS SECTION OF TURBINE
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 4
 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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 5
 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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 6
VIBRATION MEASURING
INSTRUMENTATION
SHAFT VIBRATION / ECCENTRICITY
- PROXIMITY PROBE

BEARING VIBRATION
- VELOCITY PICK UP

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 7

 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

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

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

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

 VIBRATION MONITORING

WHAT IS VIBRATION ?

WHAT CAUSES VIBRATION ?

HOW DO WE MEASURE VIBRATION ?

HOW DO WE ANALYSE VIBRATION ?

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

 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

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

 What Is Vibration?

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

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

2. Measurement direction - Horizontal,
Vertical, Axial.

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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 14
 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.

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 15

 VIBRATION MONITORING
Modes of Amplitudes
• DISPLACEMENT

• VELOCITY

• ACCELERATION

• SPIKE ENERGY
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 16
 Physical Significance Of Vibration
Amplitude

Displacement : Strain Indicator

Velocity : Fatigue Indicator

Acceleration : Force Indicator

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 17

 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.

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

 VIBRATION MONITORING
UNITS OF MEASUREMENT

DISPLACEMENT - MICRONS

VELOCITY - MM / SEC.

ACCELERATION - MM / SEC2 , G
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 19
 VIBRATION MONITORING
AMPLITUDE DESCRIPTORS
• RMS - Displacement
Velocity

• PEAK - 1.414 RMS Displacement

Velocity
Acceleration

• PEAK-TO-PEAK - 2 * PEAK Displacement

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 20
 ISO 2372
Class Class Class Class Class Class
Limits

1 Step

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

 WHEN TO USE DISPLACEMENT, VELOCITY & ACCELERATION
VIBRATION
SENSITIVITY DISPLACEMENT

10

VELOCITY
.1

.01

.001
ACCELERATION

FREQUENCY 60 600 6000 60000 600 000

CPM

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 22

 Accelerometer

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

 SIMPLE VIBRATION
Time Domain
Amplitude
(mm)
A

Time
(sec)
Period T

Amplitude Frequency Domain

(mm)
A

f=1/T Frequency f
(Hz)
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 24
 REAL VIBRATION
Time Domain
Amplitude
(mm)

Time
(sec)

Frequency Domain - Vibration Signature

Amplitude
(mm)

Frequency f
(Hz)
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 25
 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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 26

 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

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

 Vibration Sensors

• Acceleration Sensor - Accelerometer

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

Accelerometer

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 28

 Accelerometer

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

Accelerometer

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 29

 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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 30

 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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 31

 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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 32

 Non contact type

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 33

 Non contact
sensor
Installation
in a Turbine

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 34

 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.

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 35

 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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 36
 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.

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

 SHAFT & BEARING
VIBRATION PICK UP

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

 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)
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 41
 RECOMMENDED LOCATIONS OF VIBRATION
MEASUREMENTS FOR HOUSING TYPE BEARINGS (AS
PER ISO)
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 42
 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
Saturday, March 27, 2021
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

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

 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

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

 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.

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

 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.

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 49

 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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 50
EXPANSION MEASURING INSTRUMENTS

OVERALL EXPANSION
- POSITION TRANSMITTER

DIFFERENTIAL EXPANSION MEASUREMENT

- PROXIMITY PROBE

AXIAL SHIFT MEASUREMENT

- PROXIMITY PROBE

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 51

 OVERALL EXPANSION PICK UP
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 52
 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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 55

 DIFFERENTIAL EXPANSION (FOR SMALL
Saturday, March 27,EXPANSION)
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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 58
 DIFFERENTIAL EXPANSION (FOR LARGE
Saturday, March 27,EXPANSION)
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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 60

 DIFFERENTIAL EXPANSION (FOR LARGE
EXPANSION) PICK UP

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 61

 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
Gyanendra Sharma, NPTI Delhi 63
SHAFT POSITION MEASURING DEVICE
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 64
SPEED, LOAD MEASURING
INSTRUMENTS
SPEED / OVERSPEED
- KEY PHASOR
- HALL PROBE

LOAD MEASUREMENT
- CURRENT TRANSFORMERS
- POTENTIAL TRANSFORMERS

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 65

4 : HYDRAULIC SPEED TRANSDUCER
5 : ELECTRIC SPEED TRANSDUCER

SPEED MEASUREMENT INSTRUEMENT MOUNTED

IN27,HP
Saturday, March 2021FRONT BEARING PEDESTAL
Gyanendra Sharma, NPTI Delhi 66
 STARTING AND LOAD
LIMITING DEVICE

PRIMARY OIL
Saturday, March 27, 2021
PRESSURE
Gyanendra Sharma, NPTI Delhi 67
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 68
 HALL PROBE
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 69
 BASIC ARRANGEMENT OF HALL PROBES AT BEARING 1

DISK

PERMANENT MAGNETS
N-POLE
S-POLE
SENSOR

BRACKET

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 70

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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 71
 HALL PROBE IN BEARING NO. 1 PEDESTAL
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 72
Saturday, March 27, 2021 MAIN OILNPTI
Gyanendra Sharma, PUMP
Delhi 73
 OVERSPEED TRIP
BOLTS IN
TURBINE ROTOR

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 74

 OVERSPEED TRIP BOLTS IN BEARING NO. 1 PEDESTAL
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 75
 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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 76
 THERMOCOUPLE

BABBIT METAL TEMPERATURE

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

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 78

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
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 80
 THANK YOU

Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 81