Condition Management System for

Hydro-Turbine Generators
An Application Guide
Bently Nevada Asset Condition Monitoring

Table of Contents
1. Disclaimer��������������������������������������������������������������������������������������������������������������������������������������� 4

2. Abbreviations................................................................................................................................. 4

3. Introduction.................................................................................................................................... 5

4. HTG Asset Management................................................................................................................ 5

4.1 The Problem............................................................................................................................. 5

4.2 The Solution............................................................................................................................. 5

4.3 Transducers.............................................................................................................................. 6

4.4 Monitoring and Protection.................................................................................................... 6

4.5 Asset Management................................................................................................................. 7

5. P-F Curve����������������������������������������������������������������������������������������������������������������������������������������� 8
6. Types of HTG Construction........................................................................................................... 8

6.1 Francis Runner......................................................................................................................... 8

6.1.1 Pump Storage Units in Pump Storage Hydro Power Plants............................ 9

6.2 Kaplan Runner........................................................................................................................10

6.2.1 Bulb Units.....................................................................................................................10

6.3 Pelton Runner........................................................................................................................10

6.4 Synchronous Condensers....................................................................................................11

7. HTG MAINTENANCE PROBLEMS................................................................................................12

8. CMS Measurements for HTG.......................................................................................................12

8.1 Overview.................................................................................................................................12

8.2 Temperature...........................................................................................................................12

8.3 Vibration.................................................................................................................................12

application note
application note
8.4 Position Measurements..............................................................................................................13

8.5 Air Gap..............................................................................................................................13

8.6 Other Specific Measurements for HG.........................................................................14

8.6.1 Partial Discharge...................................................................................................14

8.6.2 Electro-Magnetic Flux...........................................................................................14

8.6.3 Stator Segment Vibration....................................................................................14

8.6.4 Stator End-Winding Vibration.............................................................................14

8.6.5 Stator Bar Vibration..............................................................................................14

8.6.6 Stator Frame Vibration.........................................................................................15

8.6.7 Stator Case Vibration............................................................................................15

8.6.8 Sole Plate Position.................................................................................................15

8.7 Specific Measurements for Various HT Runners.......................................................15

8.7.1 Kaplan Runners......................................................................................................15

8.7.2 Francis Runner........................................................................................................15

8.7.3 Pelton Runner.........................................................................................................16

8.8 Water Dedicated Measurements.................................................................................16

8.8.1 Flow..........................................................................................................................16

8.8.2 Pressure..................................................................................................................16

8.9 Speed and Phase Related..............................................................................................16

8.9.1 Keyphasor* Probe..................................................................................................16

8.9.2 Speed.......................................................................................................................17

8.9.3 Creep........................................................................................................................17

8.10 Other Measurements.....................................................................................................18

8.10.1 Shaft Voltage/Current...........................................................................................18

8.10.2 Torsional Vibrations..............................................................................................18

8.10.3 Wicket Gate Vibration..........................................................................................18

8.10.4 Penstock Pipe Position/Vibrations.....................................................................19

9. Horizontal vs. Vertical Orientation Considerations...............................................................19

10. Monitoring (and Protection) Systems Selection.....................................................................20

10.1 Selection Considerations..............................................................................................20

10.2 Selection Criteria – Malfunctions................................................................................21

10.3 Selection Criteria – Maintenance Approach..............................................................22

10.4 Product Features............................................................................................................22

10.5 Best Practice Recommendations.................................................................................23

10.5.1 HTG Measurement Conventions.........................................................................23

10.5.2 Sensor Low-End Frequency Response...............................................................24

2
 application note
10.6 Rotor Measurements.....................................................................................................24

10.6.1 Keyphasor...............................................................................................................24

10.6.2 Axial Position..........................................................................................................24

10.7 Guide Bearing..................................................................................................................25

10.7.1 Bearing Temperature............................................................................................25

10.7.2 Rotor Relative Vibration (Runout)......................................................................25

10.7.3 Guide Bearing/Support Vibration.......................................................................25

10.8 Thrust Bearing Measurements.....................................................................................26

10.8.1 Thrust Pad Temperature......................................................................................26

10.8.2 Thrust Pad Oil Film Thickness..............................................................................26

10.9 Stator and Windings......................................................................................................27

10.9.1 Air Gap (AG).............................................................................................................27

10.9.2 Stator Temperature...............................................................................................27

10.9.3 Stator Frame Vibration.........................................................................................28

10.9.4 Stator End Winding (SEW)...................................................................................28

10.9.5 Sole Plate Position.................................................................................................29

10.9.6 Partial Discharge...................................................................................................29

10.9.7 Magnetic Flux.........................................................................................................29

10.10 Wicket Gate.....................................................................................................................30

10.10.1 Vibration.................................................................................................................30

10.11 Turbine..............................................................................................................................30

10.11.1 Seal Ring Position/Blade Tip Clearance.............................................................30

10.11.2 Cavitation...............................................................................................................31

10.11.3 Rough Load Zone (Rheingans Influence)............................................................31

10.12 Penstock..........................................................................................................................32
10.12.1 Flow Monitoring.....................................................................................................32

10.12.2 Pressure Monitoring..............................................................................................32

10.12.3 Alarm Management...............................................................................................32

10.12.4 CMS Hardware: multimode functionality.........................................................33

11. LOWER LEVEL OF CMS: S/W build systems..............................................................................34

11.1 Components of a diagnostic system...........................................................................34

11.2 Types of data acquisition..............................................................................................34

11.3 Data acquisition in Alarm Conditions.........................................................................34

11.4 Type of analysis...............................................................................................................34

11.5 AIR GAP analysis.............................................................................................................34

11.6 Multi State Analysis in CMS..........................................................................................35

3
application note
11.6.1 Operating Conditions...........................................................................................35

11.6.2 Logic Rules..............................................................................................................35

11.6.3 State-Based Analysis............................................................................................36

11.6.4 Conclusions for the Multistate Analysis............................................................36

12. UPPER LEVEL OF CMS: S/W build systems The Industrial Internet.....................................36

12.1 Variety of analysis system solutions...........................................................................36

12.2 Anomaly detection systems.........................................................................................37

12.3 An example of anomaly detection in HPP..................................................................37

12.4 Deterministic expert system for HPP.........................................................................39

12.5 Variety of analysis system solutions...........................................................................40

12.6 Final Remarks Regarding the Intelligent Diagnostic................................................40

References...........................................................................................................................................41
APPENDIX TABLES..............................................................................................................................42

Appendix 1: Industry Related Standards and Guidelines............................................................42

APPENDIX 2: Technology Discussion...............................................................................................42

APPENDIX 3: CEATI Tolerances for Air Gap Monitoring................................................................45

1 Disclaimer CM&PS Condition Monitoring and Protection System

CTQ Critical to Quality
This document is intended solely as guidance and should be considered
illustrative only. The recommendations provided herein may not apply ECT Eddy Current Transducer
to specific situations, including government or industry regulations, ESD Emergency Shutdown Device
customer-specific requirements, or public safety laws and regulations. FO Fiber Optic
BHGE assumes no responsibility for errors or omissions that may HG Hydro Generator
appear in this document, and reserves the right to change this
HT Hydro Turbine
document at any time without notice. This document is not to be
construed as conferring by implication, estoppel, or otherwise any HPP Hydro Power Plant
license or right under any copyright or patent, whether the use of any HTG Hydro Turbine Generator
information in this document employs an invention claimed in any LVDT Linear Variable Differential Transformer
existing or later issued patent.
MEMS Micro-Electro-Mechanical System based transducer
NCT Not Contact Transducers
2 Abbreviations ODS Over Speed Detection System
1-D 1 directional vibration transducer PD Partial Discharges
2-D 2 directional vibration transducer PdM Predictive Maintenance
3-D 3 directional vibration transducer PGE Power Generation Enterprise
A, V, H Orientation of seismic transducers: A = axial, and V&H PM Preventive Maintenance
are two mutually orthogonal directions in the plane PSHPP Pump Storage Hydro Power Plant
perpendicular to rotor axis RPM Rotation per Minute
APM Asset Performance Management RTD Temperature sensor: thermo-resistive type
BEP Best Efficiency Point SV/C Shaft Voltage / Current
BN MDS Bently Nevada Machinery Diagnostics Services TBF Time Between Failures
BOM Bill of Materials TC Temperature sensor: thermocouple type
CMS Condition Management System CMSw Condition Monitoring XY Two reciprocally orthogonal directions for NCT
Software
XYXY Four orthogonal directions for NCT

4
 application note
Note 1: Rotor vibration is commonly referred to as “runout” in the operating efficiency and reliability due to mechanical erosion, fatigue,
hydro industry. However, in this Application Guide, and anywhere and damage. Moreover, financial pressures are forcing the reduction
that eddy current noncontacting displacements sensors are applied, or elimination of normally scheduled maintenance outages, which can
runout refers to a measurement error (uncertainty) defined as output lead to the increased likelihood of forced outages.
signal from a noncontacting probe system resulting from nonuniform Additionally, some regions are encountering drought conditions. In these
electrical or mechanical properties of the observed material that is regions, HPP that were designed for a nominal head are now forced to
unrelated to vibration. operate at lower than nominal head, far from BEP. This results in unusual
forces and vibrations, resulting in accelerated fatigue of the HTGs.

3 Introduction Therefore, improving the ability to detect and diagnose the dynamic
forces impacting HTG components helps optimize the operating
This document establishes guidelines for the selection and installation conditions. This increases the time between failures, and, when
of BHGE Bently Nevada* transducers, protection and monitoring deterioration begins to occur, the CMS can help monitor and manage
systems on hydroelectric turbine/generators and pump/storage the asset’s condition.
machines. These recommendations apply to both new machines and
retrofit of existing machines. The management systems described vary
from simple monitoring and protection systems to complete asset
management systems. Applications will range from unattended plants
4.2 The Solution
that are remotely operated to operations that are staffed 24/7 with a Although operators have limited influence in the demands placed
full operations, maintenance, and engineering staff. on their assets, they can mitigate the resulting risk factors by better
condition management of their HTG units. As older units are being
These recommendations apply to small, medium, and large machines increasingly refurbished, rerated, and upgraded to deal with these
and machines in critical and non-critical operational situations. The size new operating realities, CMS are being added to the project to provide
range definitions typically used in the hydro industry list small machines additional protection and information during startup, commissioning,
as less than 10 MW, medium machines as 10 – 100 MW, and large and subsequent ongoing operation.
machines as over 100 MW. Unit size alone is not the only criterion for
selecting a machinery management strategy. Consideration must be HTG asset management can employ two categories of CMS tools.
given to the requirements that are critical to a quality operation (known These are:
as CTQ or Critical to Quality) including unit size, speed, unit history, plant • Hardware:
staffing and the criticality of the unit to the system operation. Although
CMS selection will be discussed later in this document, from the –
transducers
outset it is useful to understand the fundamental distinction between – monitoring and protection system displays and alarms
machinery protection and machinery management.
– embedded intelligence for detecting conditions and
malfunctions

4 HTG Asset Management • Software:

– signal processing and data presentation for more advanced
4.1 The Problem analysis than available in the hardware or control system
Historically, hydro machines have had the lowest cost per MW on the – anomaly detection and predictive analytics of asset condition
grid, so system operators would base load these units and only reduce and performance
load or remove them from service for maintenance, demand, or water
source considerations. In this base loaded mode of operation, a typical – conversion of the data into information useful for asset
large hydro machine could conceivably operate for over 40 years operation and maintenance optimization
with minimal monitoring and protection, and only routine scheduled A typical present-day structure of an online CMS is presented in
maintenance. Figure 1 [1]. This 5-tiered CMS structure has been established over
Today’s world is much different: partially deregulated utilities, hydro many years. However, new developments within each category have
units that share the power grid with highly variable wind and solar increased the effectiveness of today’s systems. The foundation of
sources, and fish and water issues that often dictate power dispatch a CMS is a permanently installed set of transducers to provide the
decisions. In this operating environment, the flexibility of hydro necessary measurements.
machines has forced these same units into load follow operation, with In discussions of modern condition monitoring technologies, “on-line”
continuous load changes and extended run time under partial loading. typically means measurements are taken while the monitored asset is
In some cases, these machines are cycled on and off line multiple running and performing its function. The term “off-line” is often used
times in one day. to indicate measurements taken while the monitored asset is shut
Partial load operation causes some units to operate far from their best down, cooled-down, depressurized, vented, drained, locked-out, etc.
efficiency point (BEP), and introduces hydraulic conditions like rough With such a broad definition, on-line measurements may be taken with
load zone and cavitation. Continuous speed and load cycling introduces portable instruments and temporarily installed transducers as well as
thermal, mechanical, and electrical stresses that may not have been with permanently installed monitoring instruments and transducers.
considered in the original design. Many of these machines have been However, for purposes of this document, we will use on-line specifically
operating for 40 or more years. All these factors tend to reduce a HTG’s to mean continuous monitoring by permanently installed systems.

5
application note
Some maintenance strategies rely on portable data collection with today’s systems (when configured with expert diagnostic capabilities)
temporarily installed transducers. While portable instruments are is the ability to both automatically identify specific problems, and to
appropriate for some assets used in HPP, they are not generally notify relevant personnel, allowing very timely intervention to occur.
acceptable for critical machines (such as HTG) that often require Currently, the expert diagnostics layer can provide significant help to
automatic shutdown protection. They are also not particularly maintenance personnel in multi-unit and unmanned hydro stations.
helpful for failure modes that can progress rapidly – such as thrust Various packages provide specialized modules that can ensure various
bearing failures or runner blade losses – which progress much faster levels of support in malfunction recognition / identification and are
than a portable data collection interval can capture. Further, they dedicated to various assets.
do not provide adequate interval frequency to take advantage of
advancements in data analytics. CMS information can be used to drive other maintenance functions,
such as work orders, MRO materials (inventory and purchasing
Portable systems should therefore be applied in a HPP only for activities), and work scheduling and tracking. This is done by linking
non-critical assets or non-critical failure modes that develop slowly to Maintenance Management Systems such as MAXIMO*, ORACLE*,
enough to be detected within the collection interval (e.g. weakness in and SAP*. Higher-level systems can consume the data from the
a coupling connection, weakness in stator segment connections) – or CMS, maintenance management, and business systems to perform
for supplemental data collection on machines that are already being maintenance optimization. The combination of these systems, and
monitored continuously. the benefits they provide, is described by the term Asset Performance
For useful data to be acquired it is important not only to select the proper Management (APM).
transducers, but also to install them in the proper locations and follow
recommended installation guidelines. These transducers are connected
to a monitoring and protection system, the second layer from the bottom
in Figure 1. Continuous monitoring provides operators with current
information about the mechanical and electrical condition of an asset,
and can protect against serious failure of the asset (via connection with
an ESD) and the consequential interruption of production.
It is often adequate to use a limited number of transducers as a source
of data for a preventive maintenance (PM) program. However, if the
goal is to move to a more effective predictive maintenance (PdM)
program, then a greater number of transducers may be required to
ensure that potential faults can be reliably detected.
Operators require basic information regarding an asset’s condition that
simply tells them whether it can be run safely in its present condition,
but are typically not concerned with how changing process conditions
affect the stresses (mechanical and thermal) imposed on the asset. Figure 1: Condition Management System Components

Maintenance personnel, on the other hand, require more detailed

information so that any required repairs can be planned, and the
root cause of the potential failure eliminated or at least minimized. 4.3 Transducers
Maintenance personnel are also keenly interested in changes in Transducers are the sensors that translate mechanical, electrical,
asset condition, even when still within safe operating limits, as these and hydraulic behavior into signals that can be used to measure
can signify the first signs of early deterioration and establish cause- (quantify) and characterize (diagnose) that behavior. Transducers are
effect relationships between operating conditions and mechanical or the foundation of any system, whether it be a portable device, an
electrical problems. To provide this additional diagnostic functionality, on-line condition monitoring system and/or machinery protection
the third layer of the structure provides specialized plots and data system. Transducers are also the “Achilles Heel” of the entire
presentation formats via appropriate software (e.g. shaft orbits, CMS system; if the sensors are inappropriate, improperly located
spectra of structural or water vibration, various air gap analyses, or mounted, or have signals unduly contaminated by noise, no
rotor and stator mode shape, air gap magnetic flux, etc.). amount of signal processing can make up for it. While there are no
In the early 1990s, automated diagnostic capabilities began to appear measurements that can directly determine all aspects of an asset’s
in some CMSs, allowing not only the automatic collection of condition overall health, there are some widely-used measurements that can
monitoring data, but also the automatic analysis of this data. These be very effective in assessing the physical condition of monitored
embedded intelligence capabilities and expert diagnostics represented assets. Reliable indication of specific conditions or malfunctions
a significant step in the progression of a CMS, and are denoted by layer depends on the proper selection and location of the transducers.
4 in Figure 1. This functionality not only allows users to embed the rules
and logic employed by human diagnosticians, but also to automate the
notification functions that previously depended on the diagnostician 4.4 Monitoring and Protection
who had to inform the various people in the enterprise of the nature of
The purpose of machinery monitoring (protection) is to reliably
the problem and the action(s) required by them. A significant feature of
shut down a machine or return it to a safe or nondestructive

6
 application note
mode of operation without human intervention. Therefore, a
machinery protection system is the last line of defense against
excessive machinery stress, unplanned events, and abnormal
operating conditions that could threaten or damage human life,
the environment, or other plant assets. A protection system is
warranted when the sudden nature of a problem and/or inability
to humanly detect it could allow the problem to progress to a
dangerous condition.
The machinery protection system usually consists of electronic
signal processing hardware that takes the inputs from the
transducer systems, conditions the signals into the desired
measurements, and compares those measurements with alarm
thresholds (i.e., set points). If a set point is exceeded, the system
can communicate the problem to an operator, and/or send a signal
to the control system to automatically shut down the machine.

4.5 Asset Management Figure 3: Three Dimensions of the Asset CMS

The structure of a modern CMS installation at a hydro plant (or There are several proposed taxonomies for plant assets [3]. These
broader enterprise) needs to support the maintenance strategies include production and automation assets, and they are split up
appropriate to each asset criticality. A general correlation between into two categories: electrical, and mechanical. Referring to Figure
the most common maintenance strategies and the tiers of a 4, the next sections will concentrate on tools that can help with the
condition management system is shown in Figure 2. following expert assessments of HPP assets:
• Asset condition (based on mechanical integrity, electrical
integrity, and performance)
• Condition of the instrumentation used to monitor the
production asset
• Condition of the instrumentation used to monitor and control
the production process
The purpose of a CMS is to detect subtle changes in machine
conditions and identify root-cause failure modes for maintenance
work planning. It facilitates asset management and optimization
by utilizing a range of mechanical and electrical conditions, hydro-
turbine operation performance, oil analysis, and other technologies.
A CMS may incorporate and share sensors and signal processing
with the machinery protection system, but it uses them additionally
for more predictive and proactive purposes. The system employs
Figure 2: Maintenance Strategies and Corresponding CMS technologies and methodologies that optimize asset availability
Components while reducing life cycle support costs, and supports corresponding
maintenance strategies. The specific hardware and software
In the case of Preventative Maintenance (PM), only a limited features are as individual as how the plant or enterprise makes
number of transducers are needed for condition monitoring and decisions based on their maintenance strategy for their HTG assets.
asset protection. If Predictive Maintenance (PdM) is used, then the
number of transducers typically increases, and a proper diagnostic A proper CMS can help the hydro operator detect, diagnose, and
data acquisition system should be added. An expert diagnostic avoid (as much as possible) conditions where load, temperature,
system can be used if a PdM strategy is used for highly critical hydraulic conditions, or vibration can cause premature damage and
assets. Various types of expert systems can be used for various a forced outage. The CMS can provide early warning of impending
purposes as described in the next sections. failures, allowing time to schedule maintenance outages and make
repairs before small problems become large ones (or to manage
Figures 1 and 2 represent a model that is dedicated to asset the machine intelligently until an outage can be accommodated).
mechanical and electrical integrity. However, hydraulic and The CMS will also provide the operator with sufficient information
electrical performance (efficiency) evaluations can also be used to make intelligent decisions regarding maintenance planning, thus
to determine asset physical condition. Figure 3 expands the limiting maintenance scope and cost to only those things that need
2-dimensional structure to three dimensions, where the additional to be done.
dimension represents asset performance.

7
application note
5 P-F Curve 6 Types of HTG Construction
Although the concepts of asset management described above apply The categories of HTG construction are a factor in determining the
to electrical, mechanical, hydraulic, and other conditions of the HTG, details of a CMS. These are:
they are typically understood in the context of mechanical integrity. • Function of the HTG:
Therefore, from a reliability approach the PF-curve in Figure 4
below illustrates the methodology and maintenance strategies –
generation only
represented in a CMS. – alternating generation and pumping modes (pump storage)
• Type of turbine runner
• Type of radial bearings
• Number of radial bearings and their location
• Location of the thrust bearing
• Rotating speed
• Unit orientation (horizontal or vertical)
• Type of connection (coupling) between turbine rotor and
generator rotor
The following sections briefly describe the most commonly
encountered turbine runner types, including a few of their
variations.

Figure 4: P-F Curve for Asset Mechanical Integrity 6.1 Francis Runner
Increasingly, anomaly detection methodologies typically applied to Francis turbines are usually found in medium head (25 – 180
the process conditions are included in or incorporated into the CMS. meters) and pump storage applications, and have a relatively low
As illustrated in Figure 5, these technologies are also applicable shaft speed (100 – 300 rpm). Most units are vertical, but smaller
to asset mechanical integrity, and can be considered a part of the units can be horizontal.
concept illustrated in Figure 3. Because anomaly detection may A Francis runner is optimized for one expected head and flow
have a dedicated software application and include signals from condition. Outside of that condition (typically during partial
other process-related. loads), hydraulic inefficiencies result in disturbances at the runner
discharge and in the draft tube at the discharge of the runner.

Figure 5: Application of anomaly detection systems

Figure 6: Example of Vertical Francis HTG

8
 application note
However, a Pump Storage Hydro Power Plant (PSHPP) can operate
using one or more units as HTGs (operating only in generating
mode), and a separate set of motor-driven pumps that function
only in pumping mode. There can also be more complicated units,
which in addition to the turbine and generator, have a coupling and
a pump on the opposite end. These can be vertical or horizontal
orientations.
Pump Storage units take advantage of excess power supply from
other generating sources, such as wind turbines, to buy base load
power at a low cost (typically during night-time periods and/or
when general demands are low). They use this power to pump
water into a reservoir and then run the water back through the
same machine during peak power demand times. The generator
construction of these units is different than a generation-only unit
because it incorporates motor functionality into the conventional
generator design.
The PSHPP fulfills other purposes in the grid system besides
peak-load functionality and the ability to respond quickly to
sudden increases in the electrical system power demand. The
Figure 7: Example of Horizontal Francis HTG
units can additionally be used to improve the quality of power by
providing grid frequency and voltage stability, and operating in a
compensation mode that can improve COS(Ø) (Power Factor).
6.1.1 Pump Storage Units in Pump These modes of operation do not come without an increased
Storage Hydro Power Plants risk to their mechanical integrity. A hydro-unit that is frequently
One variant of the Francis runner units is pumped storage. When brought on and off the grid (on average two times per day) is
run in reverse, the Francis runner functions as a pump, and the significantly more susceptible to certain types of wear and stress
generator switches to electric motor functionality. An example of a due to transient mechanical forces, not unlike thermal generating
reversible runner is presented on Figure 8. units that undergo thermal cycling. Therefore, a CMS used for units
in PSHPP is usually more advanced than a similar system used for
units of similar size, but operating continuously [12].

Figure 8: Example of Reversible Francis Runner

9
application note
6.2 Kaplan Runner
Kaplan (a type of propeller runner) turbines are usually found in low
head (up to 80 meters) “run-of river” applications, and have a relatively
low rotor speed (50 – 300 rpm). Most units are vertical (Figure 10).
Kaplan units have adjustable-angle blading to optimize efficiency over
varying head conditions, something that cannot be achieved by other
propeller runners with constant-pitch (fixed) blades.
Kaplan turbines characteristically experience cavitation at the
blades and throat ring, owing to the fluid dynamics required by
their design. Kaplan unit thrust bearings are subject to relatively
high loads.

Figure 11: Example of Vertical Bulb HTG

6.3 Pelton Runner

Pelton turbines (sometimes called free-jet turbines) are usually
found in high head (200 - 1000 meters) applications and have a
relatively high shaft speed (up to 1500 rpm). Most units are smaller
horizontal units with two bearings (Figure 12), but medium and large
units are typically vertical with two or three bearings (Figure 13).
Pelton turbines can experience imbalance and super synchronous
Figure 9: Example of Vertical Kaplan HTG shaft vibrations due to broken buckets or blocked nozzles.

6.2.1 Bulb Units

Bulb HTG units are a variant of Kaplan turbine, and therefore also
operate at low head. The term “bulb” refers to the feature that
the generator is located inside of a submerged, watertight “bulb.”
They are typically oriented horizontally, although vertical units are
sometimes encountered (Figure 10). Some constructions include a
speed-increasing gearbox between the turbine rotor and generator,
so that a smaller, higher-speed generator can be used to reduce the
diameter of the bulb.

Figure 12: Example of Horizontal Pelton HTG

Figure 10: Example of horizontal bulb HTG

10
 application note
6.4 Synchronous Condensers
Synchronous condensers are like pump storage units and provide
correction of the grid power factor, a synchronous condenser’s
primary role is power factor correction for the grid by running the
generator as a motor. Synchronous Condenser Systems (Figure 14)
are engineered and designed to provide a highly reliable and efficient
solution to address reactive compensation and voltage support
requirements, providing transmission operators an optimized
solution for cost, performance and operational flexibility.
For most styles of hydro turbine, this involves the addition of air
compression equipment to force the water below the level of
the turbine runner. To operate as a synchronous condenser, the
turbine cannot be submerged in water while the generator is run
as a motor. Air compressors are used to depress the water below
the level of the turbine. Pelton wheel machines are ideal for this
application because the turbine wheel is not submerged. Some new
units are being installed as dedicated synchronous condensers.
Figure 13: Example of Vertical Pelton Turbine These units typically have hydrogen cooled generators, which
differs from the air-cooled generator designs traditionally used for
hydro turbines.

Stator Cooling System

• Vacuum pressure impregnation (VP) Multiple options to suit application needs:

• Double layer lapwinding • TEWAC (totally Enclosed Water-to-Air-
• Full lenght slot wedges Cooled)
• Corona resistent • WP (Weather Protected)
• Stress grading • TEPV (Total Enclosed Pressure Wentilation)
• Sealed winding (NEMA, MG 1-20.18) • TEAAC (Totally Enclosed Air-to-Air Cooled)

Exciter

• Brushless or static design

• Eliminates synchronizing module
• Simple speed sensing
• Conservatively rated diodes & SCRs

Rotor with Solid Integral Pole Tips

• Fewer loose components

• Improved mechanical stability
• No pole screw locking
• No differencial thermal expansion problems

Figure 14: Example of Horizontal Synchronous Condenser

11
application note
7 HTG MAINTENANCE PROBLEMS
The following is a list of examples of maintenance problems that
can be encountered in a HTG. Later sections will describe how the
CMS can be applied to detect and monitor these problems.
• Rotor system mechanical unbalance
• Runner system hydraulic unbalance
• Generator rotor electrical unbalance
• Radial bearing mechanical integrity
• Thrust bearing mechanical integrity
• Coupling mechanical integrity
• Turbine runner mechanical integrity
• Generator rotor mechanical integrity and shape Figure 15: Eight pillars of CMS Measurements for HTG
(including spider, poles, …)
• Rotor system voltage/stray currents
• Bearing oil system parameters 8.2 Temperature
• Cooling system (air and [if so] water) operation Temperature measurements are usually the traditional applications
found in other types of rotating machinery, while a few are unique
• Sealing ring mechanical integrity to HTG.
• Hydraulic abnormalities (cavitation, vortices) in various flow Traditional temperature measurements:
sections of the system
• Bearing temperatures (metal and oil)
• Wicket gates mechanical integrity
• Stator winding temperatures
• Control system wicket gates operation (shear pin failure)
• Cooling fluid temperature
• Generator stator mechanical integrity and shape
(including segments, windings/bars, frame, case, etc.) Temperature measurements unique to HTG:

• Head cover and fastening bolts mechanical integrity • Rotor pole temperatures

• Excitation system operation (brush condition) • End-winding temperatures

• Discharge ring mechanical integrity Types of temperature transducers used for temperature
measurements:
• Speed/Overspeed monitoring and protection
• Thermocouple
• Runner chamber mechanical integrity (and shape)
• Resistance Temperature Detector (RTD)
• Fiber-optic (FO)
8 CMS Measurements for HTG • Digital (MEM)
8.1 Overview
As previously mentioned, proper transducer selection is crucial to 8.3 Vibration
the effectiveness of a CMS. Figure 15 shows typical measurement
categories (pillars) that make up a comprehensive CMS for HTG. There are two types of vibration measurements. Relative vibration
Some of these measurements are dedicated exclusively to one measurements are provided mostly for the rotor systems operating
problem in Section 7, but many of them can be used for more with fluid film bearings, and use non-contact proximity transducers.
than one malfunction. This section describes these types of The non-contact transducer is fixed to a stationary element of
measurements to help you understand the applicability of each to HTG, and from this reference position observes another machine
your HTG protection and management needs. element. These typically use eddy-current (inductive) or capacitance
technologies. Applications include:
• Shaft vibration observed by transducers connected to a
bearing element
• Generator rotor vibration observed by transducers connected
to the stator (or vice versa)
• Movement of generator sole plate relative to the foundation

12
 application note
Further information on rotor non-contact vibration transducers for a. Two separate guide bearings; one above and one below the rotor.
HTG can be found in Reference [ 5]. One thrust bearing placed above the rotor.
The other type is seismic vibration measurements. These are b. One separate guide bearing below the rotor. Above the rotor one
performed by transducers that are mounted directly to the HTG thrust and one guide bearing are combined.
component that is vibrating. These typically use piezoelectric, c. One separate guide bearing above the rotor. Below the rotor one
piezo resistive, moving coil, fiber-optic, or MEM technologies. thrust and one guide bearing are combined.
Applications include:
d. Combined guide and thrust bearing located below the rotor,
• Bearing housing and support vibrations “Umbrella type”.
• Bridge (crest) vibrations e. One thrust bearing and one guide bearing; the thrust bearing is
• Stator frame and core vibrations mounted on the turbine casing and the guide beating is located
below the rotor.
• End-winding vibrations
On HTGs with a long shaft, the axial rotor position can provide valuable
• Runner cover vibrations
information when measured at both ends of the rotor system. In this
Further information on the application of seismic vibration case, the second measurement is on the opposite end of the rotor from
transducers on HTG can be found in Reference [ 3]. the primary measurement local to the thrust bearing.
The large mass of the HTG components, in combination with axial
reaction forces of water acting on the runner, produces relatively
8.4 Position Measurements large thrust that can cause changes in thrust bearing itself.
The signal provided by non-contact transducers has a dual-
Therefore, the position of the thrust bearing housing or supports
measurement capability, where the AC characteristic represents
can be measured separately using a transducer that is fixed to the
the vibration and the DC characteristic represents the position
power house structure or similar stable reference point.
of the observed component. This means that while measuring
the relative rotor vibration we can also collect data about rotor The position of the runner within the turbine case is an important
radial position within the bearing clearance, which is valuable for measurement. Maintaining adequate clearance between the
condition monitoring. However, the most important and common rotating runner and the stationary case is crucial in preventing
application of position measurement is rotor system position in the mechanical damage (rubs), and preserving the hydraulic efficiency
thrust bearing. This is just as important (if not more so) in a vertical of the unit (minimizing recirculation from the low pressure back to
HTG as it is in a horizontal HTG. Here also, because of the dual- the high-pressure side of the runner.)
measurement capability of non-contact transducers, the AC signal Further information on axial rotor position measurement
characteristic of an axial position transducer can also be used to applications can be found in [4].
measure axial vibration for condition monitoring purposes.

8.5 Air Gap

Air gap is one of the most important mechanical measurements for
a HTG. The generator rotor typically represents the largest diameter
spinning component of the machine. Its outer circumference is a
relatively complex assembly of electrical current-carrying poles that
are subject to significant centrifugal and electromagnetic forces.
The generator rotor is spinning inside the cylindrical stator, which is
itself subject to the same electromagnetic force that tends to pull it
inward toward the rotor. Rubs can happen between stator and rotor
because of deformation or movement of one or both components.
The causes of the deformations can be different, e.g. stator
deformations due to thermal stabilization which is impacted by a
change of local winding temperature, and rotor pole deformation
due to partial loss of mechanical integrity.
Figure 16: HTG Bearing Configurations [1] The Air Gap measurement typically uses multiple transducers (at
The thrust bearing is most often integral to the generator support least four per measurement plane) evenly positioned around the
structure. Vertical generators have at least one thrust bearing to inside of the stator. The number of transducers increases with
carry the rotor weight and hydraulic thrust, and one guide bearing stator diameter, and for tall stators, air gap sensors are placed in
to restrict the movement in the radial direction. The position more than one plane.
combination of the bearings affects the construction of the rotor However, there can be other transducer configurations, e.g.
and the stator. Referring to Figure 16, there are five different two transducers connected to the rotor, and two to the stator.
combinations of bearing positions: Configurations using rotor-mounted air gap sensors are difficult to

13
application note
apply due to the technical problems associated with getting power system resonance will result in a serious increase in the number
to the rotating transducers and getting the transducer signals off of stress cycles and their amplitude and can lead to mechanical
the rotor to send to the CMS. system damage due to fatigue. There are numerous end- windings,
so the measurement is only provided for a representative number of
carefully selected locations (Figure 17).
8.6 Other Specific Measurements for HG
Below are the most commonly provided measurements for
electrical generators.

8.6.1 Partial Discharge

Partial Discharge measures the condition of the generator stator
windings or bars by using an antenna (called a coupler) to detect
electric noise generated by discharges (sparks). In the same way
that seismic vibration transducers focus on various frequency
bands, different PD solutions are available that either (a) collect
generator discharges in wide frequency bands but are unable to
distinguish generator electrical noise from other components of
the electrical grid (transformers, switchgear), or (b) operate only
on a partial band of the discharge frequencies available, and can
reject noise from the electrical grid. The OEM or end user may
be interested in one or the other PD signal acquisition and post-
processing, so the customer’s preference should be understood Figure 17: Example of a Stator End Winding Transducer
before a solution is chosen. Installation

8.6.2 Electro-Magnetic Flux 8.6.5 Stator Bar Vibration

Magnetic flux is a measurement of the strength of the magnetic This is a measure of how securely the stator windings/bars are held
field between each of the rotor poles and the stator. It aids in the in place in the core iron (Figure 18). As with the stator end-winding
understanding of the electrical condition of generator rotor poles. vibration measurement, only representative measurements can
The flux transducer can be connected to the rotor system as well, be made on a small number of selected bars. However, in this case,
and then it can observe fluctuation of the magnetic field according an effective criterion for identifying the candidates that should be
to the angular change of rotor position. monitored does not exist. Therefore, BHGE Bently Nevada does not
recommend this measurement. If the tightness of bars in the stator
is weak, the PD activity will increase providing a sufficient indicator
8.6.3 Stator Segment Vibration of loosening of windings/bars in the stator.

This is a measure of stator flexibility (in the range of frequency

close to the rotating speed) or stator integrity (in the range of twice
grid electrical frequency). These measurements need at least one
transducer per segment. If the stator starts to lose mechanical
integrity (due to looseness of windings / bars in the iron) or loses
stiffness (due to weakening of the connections between stator
segments), then the corresponding vibration levels can change.

8.6.4 Stator End-Winding Vibration

This is a measure of mechanical aging of the connection between
end-windings and windings/bars. If the end-winding resonance
frequency is higher than twice electrical grid frequency, a result
of the aging will be decreasing stiffness and decreasing of the end
winding resonance. Prolonged excitation close to this mechanical
Figure 18: Stator segment and Components

14
 application note
8.6.6 Stator Frame Vibration Note that the width and angle of blades as they rotate past the
transducer may challenge the monitoring system’s ability to react
This measurement is used in correlation with the stator core iron quickly enough to make an accurate measurement. Note also
vibration and stator frame vibration (Figure 18). This measurement that the metallurgy of the blade material may require a custom
can be of additional value during unit load transient conditions calibration (modification) of the eddy current transducer system
(unloading). Note that the vibration measurements can provide only Proximitor*. Capacitive type sensors cannot be used for this
indirect information about the condition of the frame and other measurement.
connected stator elements. One frame malfunction can be its twist.
Although twist could be easily detected by position transducers
specifically installed for that purpose, in their absence the frame
vibrations can be an indicator of when stator twist is occurring.
8.7.2 Francis Runner
On Francis hydroelectric turbines, the bottom ring seal (Figure 20)
minimizes unwanted leakage of water around the turbine runner
8.6.7 Stator Case Vibration that would lead to a loss of hydraulic efficiency. It performs the
same function as “wearing rings” in pumps. Mounted at the end of
This is a measure of the correlation between stator components the unsupported portion of the rotating shaft system, the seal ring
and the housing vibration. is subject to contact when extreme shaft deflection occurs. This
happens particularly at the point of priming a pump-turbine unit
on startup in the pump mode. Seal rubs have also occurred when
8.6.8 Sole Plate Position the concrete structure around the turbine has moved for various
reasons, or when the stationary bottom ring has deformed.
This is a measure of abnormalities in the connections between the
sole plate and other contacting elements. In the case of vertical The clearance measurement of the bottom ring seal, often referred
generators, temperature stabilization can result in expansion and to as “seal ring clearance,” can be made using four (4) transducers
contraction of the stator. Distortion of the stator shape can occur if in a “XYXY” configuration. These transducers can be helpful in
one or more sole plates do not allow for these movements relative evaluating the sealing ring integrity, as well as determining any
to the foundation. changes in the shape of the chamber. The XYXY set of transducers
can be additionally used for relative vibration measurements of the
runner against of chamber where the they are fixed.
8.7 Specific Measurements for Various
HT Runners 8.7.3 Pelton Runner
Because of its characteristic of running unsubmerged, draft tube
8.7.1 Kaplan Runners accelerometer, seal ring clearance, and draft tube dynamic pressure
measurements are not made on Pelton runner units.
On Kaplan or a propeller type turbine, the clearance between the
blade tip and stationary turbine throat is important for turbine
efficiency and is susceptible to mechanical problems (see Figure
19). The blade tips are subject to contact when extreme shaft
deflection and/or discharge ring deformation occurs. For propeller
runners (including Kaplan runners), this clearance measurement
(“blade tip clearance”) can be made using the same number of
non-contact transducers equivalent to the number of blades on
the runner. This measurement can be a useful indicator of runner
blade integrity, as well as determining any changes in the shape of
the runner chamber.

Figure 20: Example of Bottom Sealing Ring XY Monitoring

(viewed from outside of the turbine chamber)
Further information about seal ring clearance monitoring can be
found in Reference [6].

Figure 19: Kaplan Runner, Showing Gap Between Blades and

Discharge Ring

15
application note
8.8 Water Dedicated Measurements 8.9 Speed and Phase Related

8.8.1 Flow 8.9.1 Keyphasor* Probe

Flow measurements are helpful in monitoring of efficiency of a A Keyphasor signal is a once-per-turn reference on the rotating
HTG operation. Although they are typically part of the process shaft, made by a proximity probe. Figure 22 below presents how the
measurements made by other systems, including flow data Keyphasor probe converts a single notch or projection on the shaft
in the CMS can enable correlation with vibration and other into an electrical reference pulse.
measurements, and provide a more comprehensive understanding
of HTG health.

8.8.2 Pressure
Pressure measurements can help identify the nature and
pinpoint the source of some mechanical vibrations observed in
other measurements. Pressure measurements can be made for
static and/or dynamic (pressure pulsation) characteristics, and
transducers are available that measure both. Pressure transducers
can be installed in various hydraulic components of the hydro
turbine, such as the draft tube, the space between wicket gates and
the runner, penstock.
Pressure transducers can supplement or corroborate with other
vibration or acoustic sensors in the recognition of cavitation.
Dynamic pressure can help with the detection and measurement of
some other anomalies in HTG operation, for example, delamination
of the discharge ring in propeller type machines.
Figure 22: Keyphasor Signal Illustration
Figure 21 illustrates typical locations where measurements of static
and dynamic pressure are made. More than one transducer may The importance of the Keyphasor signal cannot be overstated.
be installed at each location, e.g. on the draft tube, measurements A Keyphasor signal provides speed information that is useful for:
are frequently made at a couple of different elevations, and the • Acquisition of synchronous waveform samples, i.e. sampling a
pressure measurements in wicket gates area can be monitored with defined number of points per shaft revolution
a several transducers measuring at various angular localizations.
• Synchronous (simultaneous) sampling of transient data from
multiple channels during changes in speed, i.e., run-up and
coast-down
A Keyphasor signal also enables vector X-Y probe measurements
(1x, 2x, nx, ...), used for:
• Rotor balancing
• Bode and Polar plots
• (when trended) detecting rotor stiffness changes and cracks
• Direction of precession
• Estimation of rotor mode shape
• Localization of events or elements on the circumference of the
rotating components (such as for flux, air gap, and turbine blades)
Figure 23 illustrates that the best location for a Keyphasor probe
is close to the thrust bearing. This location of the Keyphasor probe
Figure 21: Typical Dynamic Pressure Measurement Locations usually means affixing its mounting bracket is to the bottom part of
thrust bearing tub.
Alternatively, the Keyphasor probe can be located close to turbine
guide bearing. In this situation, the probe is observing a shaft that
can move vertically because of axial flexure of the thrust bearing
and supports under different flow and load conditions. This may

16
 application note
cause the notch or projection on the shaft to move under the probe
viewing area. This type of installation should be carefully evaluated
8.9.3 Creep
to assure that the notch or projection target is of sufficient length Rotor “creep” is the small rotational movement of the rotor system.
to not move out of the probe viewing area. The target length must, One function of a HTG control system is controlling the turbine brakes.
have a safety to account for any increased movement of the shaft The turbine brake consists of pads that can be forced up against a
due to machine deterioration over time. flat ring, typically located underneath the generator (on large vertical
HTG), to hold the rotor in place when it is stopped. Therefore, one of the
permissive signals provided by the control system enables the creep
detector after a fixed time following application of brakes on shutdown.
Various types of transducers are used to detect creep, such as ones
like those used for the speed control system, and air gap sensors.
Creep monitoring detects malfunctions such as improper closure
of the water system (wick gates, the main valve), or improper
operation of the generator
brakes. Figure 24 shows wicket
gates that may allow leakage of
water (top), one of the brakes
of a vertical unit (bottom left),
and a brake of a horizontal HTG
(bottom right).

Figure 24: Wicket Gates (top)

and Brakes (bottom)
Worn wicket gate end clearances
can result in a decline in of unit
performance because the leakage
contributes to loss of power
Figure 23: Keyphasor Probe Location generation. This occurs most often for units with a low service
factor (i.e., the gates are in a closed position for a significant period
of time).
8.9.2 Speed In a new (Kaplan) units, the leakage through properly designed
wicket gates may be markedly less than 1% of full gate discharge,
Speed measurement is necessary for proper mechanical and
however, over years of operation this could double due to eroded
electrical operation of the HTG. Therefore, a dedicated speed
end clearances, worn stem journal bushings, and improperly
sensor is not part of the CMS, but it is important to understand
adjusted toe to heel closures.
the important differences between speed and Keyphasor signal
measurements. Usually a provision is made for some form of creep monitoring in
a HTG. A zero-speed monitor with a probe looking at a multitooth
• Every turbine needs to have a measurement dedicated to
wheel could be used for this application. Figure 25 shows how
speed control.
using proximity transducers, a creep indication can be achieved.
• The turbine speed control system must acquire speed Two separate sets of high resolution creep detectors are installed
information with minimum update time, sufficient resolution on each unit; one dedicated for the Governor PLC and one for the
and accuracy to control the machine speed. Therefore, many Creep PLC. The high-resolution creep detectors are designed to
impulses per revolution of the rotor are required. be immune from normal powerhouse vibrations. Each detector
• Every professional diagnostic system must provide absolute consists of two proximity sensors observing a 360-tooth steel gear
phase measurements. For this reason, an impulse from the connected to the generator shaft. The probes are out of phase with
rotor system is required. This, by definition, is a Keyphasor each other so that when one probe sees a tooth, the other sees a
which provides one (1) impulse per one (1) rotor revolution. valley. In other words, the speed pickups are located so that one
pickup is on the rising of a gear tooth and one is located on the
• A speed control transducer cannot be used as a Keyphasor phase falling of a gear tooth. Consequently, both pickups must show a
reference signal due to the multiple impulses per revolution. change of state before the PLC issues a creep alarm. This feature
• A Keyphasor signal can be used for speed detection. However, prevents the system from reacting to unit vibration or issuing false
it is not suitable to be used for turbine speed control. No speed creep alarms.
detection or control application for a Keyphasor signal should
be agreed to without Bently Nevada Engineering knowledge
and review.

17
application note
the wicket gate control mechanisms showing increasing levels
of vibration. A single vibration transducer in one section of the
controlling system can be helpful in detecting such malfunctions.
Figure 26 shows a possible solution for condition monitoring of
wicket gate condition. The optimal location for a single vibration
transducer is identified by the red arrow as shown of the left.
An example of wicket gate shaft vibration monitoring using two
transducers connected to an on-line CM&PS with a 3rd transducer
magnetically mounted and providing a signal to a PDC is shown on
the right.

Figure 25: Proximity Probes Used for Governor Speed and

Creep Detection
Alternatively, an AIRGAP measurement can be applied.
In the case of more critical machines, a redundant creep detection
system can be installed. Therefore, a separate Creep PLC in parallel
with the Governor PLC can be used. The Creep PLC independently
determines unit speed and confirms slow rotation (creep) of the unit.
For lower criticality units that do not use a Creep PLC, a solution
based on the CMS can be used. Given proper signals (from any
Figure 26: Transducer Locations for Wicket Gate Condition
appropriate type of sensor), appropriate logic (in software or
Monitoring
hardware (could be created to detect rotor creep.)
In the BHGE portfolio, there are several creep detectors. One of which
uses two proximity probes and the Woodward 505 Hydro Governor. 8.10.4 Penstock Pipe Position/Vibrations
Penstock and pipe vibration and position can be helpful for above-
8.10 Other Measurements ground penstock pipes. This measurement is especially useful for
penstocks in Pump Storage Hydro Power Plants. The penstock
vibration monitoring can be extended by use of WATER DYNAMIC
PRESSURE monitoring.
8.10.1 Shaft Voltage/Current
Shaft voltage/current (SVC) can occur in the rotor system which
may lead to bearing, seal and shaft erosion due to electrostatic 9 Horizontal vs. Vertical Orientation
discharge (ESD). For bearings, the occurrence of ESD can
significantly shorten the time between failures (TBF). Considerations
There are significant differences in construction of the vertical
and horizontal machines. Additionally, there can be a significant
8.10.2 Torsional Vibrations difference in power generated by both types of HTGs which directly
impacts the unit’s criticality. Vertical machines can generate much
Rotor system torsional vibration can be a problem for some HTGs
more power than horizontal machines. Therefore, the CMS applied
under certain operating conditions. Generator synchronization, loss
to vertical units is usually more advanced than those applied to
of one phase, out of phase synchronization attempts, a short circuit
horizontal HPP units.
between phases, grid upsets and other abrupt changes in load are
common torsional vibration excitations. Although most of these The CMS provides various measurements that are helpful in
problems are diagnosed by monitoring the electric parameters determining a HTG operational condition. The most popular
of the generator, there are means to directly measure torsional standards for the assessment of HTG operational conditions
vibration. Measurement of the angle of twist over a specified length are dedicated to the evaluation of vibration conditions. Two ISO
of the shaft or measurement of the strain at a selected location on Standards commonly referred to are: ISO 10816-5 which is focused
the shaft are two possible methods. The technique to be applied upon on absolute structural vibration, i.e. vibration measurements
will be specific to the machine train and installation. of the non-rotating parts, and ISO 7919-5 which is dedicated to
rotor relative vibration. Additionally, IEC 60994:1991 Guide for field
measurement of vibrations and pulsations in hydraulic machines
8.10.3 Wicket Gate Vibration (turbines, storage pumps and pump-turbines), with corrections

Over a long operation period, the wicket gate shafts can develop
significant clearances. These clearances result in components of

18
 application note
“COR1:1997” can be considered. This IEC guide applies to any components, the evaluation should be based on broad-band
reaction or impulse turbine, as well as to any pump-turbine and measurements of both displacement and velocity.
storage pump that are coupled to an electric generator or motor. • For medium- and high-speed machines (300 RPM to 1 800
It covers the field of vibration and pulsation tests referred to as RPM), the preferred measurement quantity is vibration
standard tests. velocity in rms units. If the spectrum contains low-frequency
components, the evaluation should be based on broad-band
Both ISO standards focus upon the two following tasks:
measurements of both velocity and displacement.
• Task A: changes in vibrational behavior;
The location where the absolute vibration measurements are to
• Task B: excessive kinetic load. be taken are shown in figures in the ISO 10816-5 standard. The
There is the additional task of rotor relative vibration ISO standard requires that the measurements span the frequency
measurements: range from 2 Hz to 1 000 Hz when the measurement parameter is
vibration velocity in rms units.
• Task C: the monitoring of radial clearance of the bearings.
Some limitations of the ISO vibration standards dedicated to
vertical turbine or/and pump units are: 10 Monitoring (and Protection) Systems
• they are applicable to machine sets in hydraulic power Selection
generating and pumping plants where the hydraulic machines
have speeds from 60 RPM to 1,800 RPM. 10.1 Selection Considerations
• the use of shell or shoe type sleeve bearings Selection of the appropriate components of a CMS for a project
• and a power output of 1 MW and more will be based on several criteria, but all of them should be tied
to the customer’s Critical to Quality (CTQ’s) needs. The selection
The position of the shaft line can be vertical, horizontal or at an criteria should include the type, size, speed, orientation (vertical
arbitrary angle between these two directions. or horizontal), criticality, and typical or expected malfunctions
The ISO 7919-5 is does not apply to hydraulic machines or machine associated with the unit. Consideration should also be given to the
sets having rolling element bearings or for hydraulic machines intent (protection or management) of each of the measurements
with water-lubricated bearings. The water-lubricated bearings (sensors) to be specified. The sections below provide tables
are mostly used for turbine guide bearings in vertical trains (The summarizing what was presented earlier in this document and
generator guide bearings are typically not water-lubricated). provide information on key features of the monitoring hardware.
These will help guide the selection of the appropriate functionalities
ISO 10816-5 categorizes HTG into the following groups which each for the CMS. The last section gives specific recommendations that
need an individual monitoring approach relative to their seismic will enable the construction of a proper Bill of Materials (BOM) for a
vibrations: given project.
i. Group 1: Horizontal machine sets with pedestal or end-
shield bearings mounted on a rigid foundation, usually with
operational speeds of above 300 RPM. 10.2 Selection Criteria – Malfunctions
ii. Group 2: Horizontal machine sets with bearing housings which Table 1 identifies measurements corresponding to malfunctions.
are only braced against the casing of the hydraulic machine, The blue shaded area indicates essential coverage.
usually with operational speeds of less than 300 RPM.
iii. Group 3: Vertical machine sets with bearing housings which
are all braced against the foundation, usually with operational
speeds of between 60 RPM and 1,800 RPM.
iv. Group 4: Vertical machine sets with lower bearing housings
braced against the foundation and upper bearing housings
braced against the generator stator only, usually with
operational speeds of between 60 RPM and 1,800 RPM.
v. Dependent upon the HTG rotor speed and group, other
consideration for condition monitoring measurements are:
• The preferred measurement parameter for low-speed
machines (below 300 RPM), is vibration displacement
in p–p units. If the spectrum contains high-frequency

1
These ISO standards have some limitations (where they can and where they cannot
to be used as described below). Therefore, it is strongly advised to recognize them
before an application. Additionally, please note that both ISO standards will be
replaced soon by one ISO 20816-05.

19
application note

Head Cover/Draft Tube

Thrust Bearing Oil Film
Vibration (Runout)

Generator Air Gap

Keyphasor Signal
Thrust Bearing
Malfunction & Corresponding
Guide Bearing

Guide Bearing
Temperature

Temperature
Measurements
Thickness

Vibration
Mechanical/Electrical Hydraulic
x x
Unbalance
Rough Load Zone x x
Shear Pin Failure x x x
Misalignment x x
Cavitation x
Rotor Rim Movement x x
Stator Winding Vibration
Stator Core shift x x
Uneven Air Gap x x
Unbalanced Air Gap Forces x x
Insulation faults
Excitation fault
Seal Ring/Discharge Ring
x
Distortion
Excessive Turbine Vibration x
Bearing Overload x x x x
Bearing Fatigue x x x x
Insufficient Bearing Lubrication x x x x
Stator Insulation Deterioration
Stator/Rotor Out of Round x x
Stator/Rotor Concentricity x x
Stator Flexing x x
Loose Stator Laminations
Plugged Stator Coolers
Blocked Stator Ventilation Ducts
Overheated Stator Coils

Table 1: Common HTG Faults and their Corresponding Malfunctions

20
 application note

Rotor Mounted Air Gap

Stator Frame Vibration

Wicket Gate Position

Stator Bar Vibration

Stator End Winding
Seal Ring/Blade Tip
Process Variables

Generator Partial

Brush Monitoring
Malfunction & Corresponding Temperature
Measurements
Generator

Clearance
Discharge
Mechanical/Electrical Hydraulic
x
Unbalance
Rough Load Zone x x
Shear Pin Failure x
Misalignment
Cavitation x x
Rotor Rim Movement
Stator Winding Vibration x x x
Stator Core shift x x
Uneven Air Gap x x
Unbalanced Air Gap Forces x x
Insulation faults x x x
Excitation fault x
Seal Ring/Discharge Ring
x
Distortion
Excessive Turbine Vibration x
Bearing Overload
Bearing Fatigue
Insufficient Bearing Lubrication
Stator Insulation Deterioration x x x
Stator/Rotor Out of Round x x
Stator/Rotor Concentricity x x
Stator Flexing x x
Loose Stator Laminations x
Plugged Stator Coolers x
Blocked Stator Ventilation Ducts x
Overheated Stator Coils x

21
application note
10.3 Selection Criteria – Maintenance Many HTGs monitored by a CM&PS are not interfaced to an
emergency shutdown device (ESD). It is, therefore, the operator’s
Approach responsibility to act when a system measurement exceeds a critical
If the monitoring strategy for a HTG is preventive maintenance, a alarm threshold.
lesser number of measurements can be used to fulfill this strategy.
A predictive or proactive maintenance strategy requires a more
comprehensive set of measurements to enable the condition 10.4 Product Features
monitoring system’s ability to detect developing malfunctions.

Sensor Inputs 3500 3701/46 2300 vbOnline Pro

Proximity Probe Yes Yes Yes Yes1
Accelerometer Yes Yes Yes Yes2
Stator End Winding Accelerometer Yes No No No
Velomitor® Yes Yes Yes No
Low Frequency Velocity Sensor Yes Yes Yes No
Air Gap Yes No No No
Magnetic Flux Yes 3
No No No
Dynamic Pressure Yes4 Yes5 No No
RTD & Thermocouple Yes No Yes6 No
4 to 20 mA Inputs Yes No Yes6 No
Vibration Inputs Per Monitor 4 6 + KØ 2 + Speed 12 + 2 KØ
Max. # of Channels per system ~56 + 4KØ 12 + 2 KØ 37 12 + 2 KØ

Signal Processing 3500 3701/46 2300 vbOnline Pro

Continuous Monitoring Yes Yes Yes No
Min. RPM 1 1 1 1
Min. Vibration Frequency Response (Hz) 0.18 0.0625 0.2 0.2
1X, Not 1X, nX, Not Default + User-
Filtered Measurements (Bandpass filters only) (Refer to Data Sheet)
1X8 defined9
16, 32, 64, 128, 256, 8, 16, 32, 64, 128, 256,
Synchronous Samples/revolution (n/a) (Refer to Data Sheet)
360, 512, 720, 1024X 512, 1024, 2048, 4096
Max. Async. Spectrum Resolution 800 Lines 3200 Lines 3200 Lines 10
12,800

System Interfaces 3500 3701/46 2300 vbOnline Pro

Local Packaged Display Yes No Yes No
4 to 20 mA Outputs Yes No Yes11 No
Modbus Outputs Yes Yes Yes No
Buffered Outputs Yes Yes Yes Yes
Alarm Relay Outputs Yes Yes Yes No
System 1* Classic Compatible Yes No Yes10 No
System 1 Evolution Compatible No Yes Yes Yes

Table 2: Features by Product Type

Notes: 8. 3 500/46M Multimode Hydro Radial Vibration channel type; differs for
1. Keyphasor channels only. other channel types.
2. Supports 2-wire IEPE/ICP constant-current accelerometers only. 9. In addition to the default 1X, 2X, Rough Load Zone, and Cavitation filtered
3. Requires modifications and third-party transducer system. values, 3701/46 channels support multiple additional user-defined nX,
4. Uses Bently Nevada 350300 Dynamic Pressure Sensor, which also Band-pass, Spectral Band, and Peak Extraction filtered values.
provides static pressure measurement. 10. 2300/25 via DSM SPA connection only.
5. When used with third-party dynamic pressure sensors. 11. 2300/20 only.
6. When Auxiliary Inputs used with third-party interface modules.
7. Speed channels have limited functionality when used for temperature
inputs.

22
 application note
10.5 Best Practice Recommendations Table 3 summarizes the transducer selection for hydroelectric
turbine/generators. Specific information regarding the
Figure 27 shows the placement of a standard set of transducers on measurements for each machine component – their corresponding
a hydroelectric turbine/generator. transducers and 3500, 3701, 2300, and vbOnline Pro monitor
modules – are contained the sections following the table.

10.5.1 HTG Measurement Conventions

When defining where a transducer is to be located angularly
around the shaft, the end of the shaft from which the machine is
viewed must be established. The most commonly used transducer
reference convention for vertical hydro machines deviates from that
used for other machines: probe angular locations are referenced
when viewing the shaft from the driven (generator) end of the
machine (from above on vertical machines). Also, the zero-degree
reference of “up” on horizontal machines cannot be used for
vertical hydro turbines, so the most commonly used references
are “upstream” or a compass coordinate (“North”, “South”, etc.).
Measurement conventions are the customer’s preference, but
whatever conventions are chosen, they should be documented,
understood, and used consistently.

Figure 27: Well-Instrumented Hydro Turbine/Generator

Francis

Kaplan

Pelton
Component Monitoring Point Transducer

Keyphasor Probe 3300XL Proximity Probe X X X

Rotor
Axial Vibration & Position 3300XL Proximity Probe X X X
Bearing Temperature RTD or Thermocouple X X X
Guide Bearing Rotor Relative Vibration (Runout) 3300XL Proximity Probes X X X
Bearing Housing Absolute Vibration 330505 Low Frequency Velocity Sensor X X X
Pad Oil Film Thickness 3300XL Proximity Probe X X X
Thrust Bearing
Pad Temperature RTD or Thermocouple X X X
Generator Air Gap Air Gap Sensor X X X
Temperature RTD or Thermocouple X X X
Stator Core/Frame Vibration 190501 Velomitor CT
Generator Stator 330505 Low Frequency Velocity Sensor X X X
and Windings 330500 Velomitor
Partial Discharge (Third-Party System) X X X
Stator End Winding Vibration 330447 SEW Accelerometer X X X
Sole Plate Position 3300XL Proximity Probe or LVDT X X X
Generator poles Pole Temperature (Third-Party System) X X X
Position SCADA interface or LVDT X X X
Wicket Gate
Vibration 190501 Velomitor CT X X X
Cavitation 330400 Accelerometer
350300 Dynamic Pressure Sensor X X
Turbine Hydrophones
Seal Ring Position/Blade Clearance 3300XL Proximity Probes (Underwater version) X X
Dynamic/Static Pressure 350300 (or third-party) Dynamic Pressure Sensor X X
Flow Ultrasonic Flow Monitor X X X
Penstock
Dynamic/Static Pressure 350300 (or third-party) Dynamic Pressure Sensor X X X

Table 3: Monitoring Transducers

23
application note
10.5.2 Sensor Low-End Frequency 10.6.2 Axial Position
Response
For HTG applications, the transducer system’s frequency range System Monitor Transducer Measurements
must be confirmed prior to selection to assure that it extends low
enough to measure the frequencies of interest (Reference 16). The 3500 3500/46M 3300XL Vibration, Position
low running speeds of hydro turbine generators challenge the low- 3701/46 PAV, PAS 3300XL Vibration, Position
end frequency response of many casing vibration sensors, and some
malfunctions manifest themselves at sub-synchronous (below Unlike horizontal high-speed turbine/generators, hydroelectric
running speed) frequencies. The objective is to use (if possible) generators have a large range of freedom in the axial direction.
seismic transducers that operate down to 25% of nominal speed. During full load rejection, some rotors can move over an inch (25.4
Application of seismic transducers that operate below of 0.5 HZ is mm) in the axial direction. Also, axial direction clearances are not as
not practical. critical as axial clearances in steam and gas turbines. Axial position
measurements (rotor position relative to the machine case) are
required to provide information about wear of the thrust bearing
10.6 Rotor Measurements segments, and this measurement can give an earlier indication
than the wear indication provided by the thrust bearing segment
temperatures However, on machines where axial movement is
10.6.1 Keyphasor not excessive and if axial position and vibration measurements
are beneficial, a proximity probe with sufficient linear range can
be used. The mounting location will typically require that the
System Monitor Transducer Measurements measurement be relative to a structural member of the unit. The
range and initial gapping of the probe must take into consideration
Speed; supports the expected or known movement of the shaft due to operating
filtered conditions and flexibility of the thrust bearing pad supports.
vibration vector
measurements in The 3500/46M Hydro Monitor has position measurements
3500/50M or Proximity
3500 other monitors; available in both the thrust and radial vibration channel types.
3500/25 probe
provides Radial vibration channel types provide both thrust and vibration
indexing for Air measurements because the gap voltage full-scale range selection
Gap and Flux includes scale ranges corresponding to thrust position units.
measurements
In the 3701/46 ADAPT Hydro Monitor, Bently Nevada Monitor
Speed; supports Configuration (BNMC) software allows the user to add band-pass
filtered and other vibration trended variables to a Thrust channel.
PAV, PAS, or Proximity
3701/46 vibration vector
PoV probe Alarm and Shutdown setpoints should follow generator
measurements in
other channels manufacturer recommendations. In the absence of specific
generator recommendations, contact an BN MDS engineer with
Speed; supports
Proximity hydro experience for recommendations.
filtered
2300/20 or probe,
2300 vibration vector Rotor Axial Position #2 (Vibration)
2300/25 Proximity
measurements in
switch High speed vertical units operating close to or over the 1st rotor
other channels
resonance frequency may benefit from a 2nd measurement of rotor
Speed; supports axial position (axial vibration). These units can develop problems
filtered with the mechanical integrity of the rotor system coupling(s). Under
Proximity
vbOnline Pro vbOnline Pro vibration vector
probe these conditions, the dynamic component (vibration) will grow
measurements in
other channels measurably.
This measurement can also be useful in locations that are subject to
seismic activity (earthquakes) while the static component (position)
can measure any permanent dislocation of the runner versus its
chamber.
The same monitors described above are applicable for these
measurements

24
 application note
10.7 Guide Bearing 10.7.2 Rotor Relative Vibration (Runout1)

10.7.1 Bearing Temperature System Monitor Transducer Measurements

Direct, Gap, Not
3500 3500/46M 3300XL 1X, 1X+Ø, NX,
System Monitor Transducer Measurements Composite
Thermocouple, Temperature Direct, Gap, 1X+Ø,
3500/60,
RTD, or 3701/46 PAV, PAS 3300XL (other user-
3500 /61, /65 or
temperature configurable)
3500/62
transmitter
2300 2300/20, /25 3300XL Direct, Gap, Bandpass
Thermocouple, Temperature
vbOnline Direct, Gap, (other
RTD, with vbOnline Pro 3300XL
2300 2300/20, /25 Pro user-configurable)
appropriate third-
party interface.
Bearing vibration can indicate problems related to fluid-film
Bearing temperature can indicate problems related to fluid-film bearings, including overload, misalignment, or operating in the rough
bearings, including overload, rubs, or insufficient lubrication. load zone (Not 1X, typically approximately 0.25X); shear pin failure
Measuring temperatures at the bearing and correlating them with and faults with or debris in wicket gates (nX where n is the number
other symptoms of technical condition and process variables can of wicket gates); stator faults, and various sources of unbalance (1X).
assist in determining the overall condition of hydroelectric turbine/ Proximity probes are usually mounted on brackets just above or
generators. below each guide bearing. Two proximity probes are mounted
For a bearing temperature measurement to be effective, the per bearing with 90° separation. NOTE: For the proximity probe
temperature sensing element must be as close to the bearing system to perform well, a suitable probe viewing area, relatively
working surface as possible. The OEM may include temperature free of glitch (scratches, out-of-roundness, residual magnetism,
elements in the pads from the factory, or drill and tap the pads metallurgical discontinuities), needs to be selected. For more
for temperature sensors during the manufacturing process. If information, please see Reference 17.
installation locations are not originally provided, the bearings Alarm and Shutdown setpoints should follow generator
can be removed and drilled to accept the temperature sensors. manufacturer recommendations. In the absence of specific generator
In the absence of OEM installation recommendations, four (4) recommendations, contact a BN MDS engineer with hydro experience
temperature sensors should be installed in each guide bearing of for recommendations. (Note: The owner/end user is ultimately
a vertical HTG: one upstream with respect to flow in the turbine, responsible for setting the alarm and shutdown levels.) Alarm and trip
one 90 degrees to the right of upstream, one 90 degrees to the left setpoints should be adjusted based on actual operating conditions
of upstream and one downstream for sleeve bearings. Tilting pad once sufficient experience is obtained. Note that operating conditions
bearings should have one temperature probe in each pad. vary greatly on hydro machines, so sufficient operating experience
The 3500 System offers six- or 16-channel monitors for use with should be obtained before setting trip points. Rotor relative vibration
either thermocouples or resistance temperature detectors (RTD). (runout) is recommended as a shutdown parameter.
When a temperature transmitter is used, the 4-20 mA signal
proportional to temperature can be brought into a 3500/62 Process
Variable Monitor. Bearing temperature is recommended as a 10.7.3 Guide Bearing/Support Vibration
shutdown parameter.

System Monitor Transducer Measurements

Direct, Bias Volts, 1X
330505 Low vibration amplitude
3500 3500/46M Frequency Velocity and phase (Ø), 2X
Sensor vibration amplitude
and phase (Ø)
330505 Low Direct, Bias Volts,
2300/20,
2300 Frequency Velocity Bandpass
/25
Sensor
Direct, Bias Volts, 1X
vibration amplitude
330505 Low
and phase (Ø), 2X
1
Rotor vibration is commonly referred to as “runout” in the hydro industry. 3701/46 PAV Frequency Velocity
vibration amplitude
In the Oil and Gas industry, runout refers to an output signal from a Sensor
and phase (Ø), (other
noncontacting probe system resulting from nonuniform electrical or
user-configurable)
mechanical properties of the observed material that is unrelated to vibration.

25
application note
Where the rotor mass is large and/or the bearing supports are The 3500 System offers six- or 16-channel monitors for use with
compliant, additional machine condition monitoring information either thermocouples or resistance temperature detectors (RTD).
can be obtained by mounting a low frequency velocity sensor on the When a temperature transmitter is used, the 4-20 mA signal
bearing housing or supports. The signals can be band pass filtered proportional to temperature can be brought into a 3500/62
to help isolate the signals corresponding to the sub-synchronous Process Variable Monitor These should be adjusted based on actual
hydraulic vibration frequencies and extend up to the wicket gates or operating conditions. Bearing temperature is recommended as a
runner vanes frequencies, etc. shutdown parameter.
The shaft (rotor) absolute vibration measurement that is available
in the 3500/42M Proximitor/Seismic Monitor Module is not available
in the 3500/46M. This measurement is not technically feasible at 10.8.2 Thrust Pad Oil Film Thickness
the lower frequency vibrations of hydroturbine generators. This is
because of the phase shift and measurement limitations of velocity
transducers at the lower end of their frequency response curve. System Monitor Transducer Measurements
Alarm and Danger setpoints should follow generator manufacturer 3500 3500/45 3300XL Position, Gap
recommendations. In the absence of specific generator 2300 2300/20, /25 3300XL Position, Gap
recommendations, contact an MDS engineer with hydro experience
3701/46 PAV, PAS 3300XL Position, Gap
for recommendations. Alarm and trip setpoints should be adjusted
based on actual operating conditions once sufficient experience
is obtained. Note that operating conditions vary greatly on hydro Most large hydroelectric generators are vertical machines. The
machines, so sufficient operating experience should be obtained thrust pads must carry the static weight of the machine and any
before setting trip points. Bently Nevada does not recommend the downward load generated by the water flow through turbine. An
use of the 330505 Low Frequency Velocity Sensor for automatic absence or reduction in oil film thickness at the thrust pads results
shutdown (machine protection). in rapid breakdown of the bearing babbitt and can result in rotor/
bearing damage if not corrected. Thrust pad oil film thickness
measurements can indicate problems related to fluid-film thrust
10.8 Thrust Bearing Measurements bearings, including improper tilt angle, insufficient lubrication or lift,
overload, or bearing fatigue.
Two probes per pad are recommended: one on the leading and
10.8.1 Thrust Pad Temperature one on the trailing edge. If the machine is large (more than 100
MW) it may be advisable to place probes at each corner of the
instrumented thrust pads because pads on large machines can
System Monitor Transducer Measurements “saddle” under load. For retrofit installations, the pad can be
removed and drilled to accept the sensor mounting hardware and
Thermocouple, Temperature cable tie downs. Where drilling of the thrust pad is not practical,
3500/60,
RTD, or sensors can be mounted on brackets in the space between pads.
3500 /61, /65 or
temperature
3500/62 Sensors on two pads separated by approximately 90 degrees is
transmitter
the minimum application while four instrumented pads 90 degrees
2300/20, /25 Temperature apart is recommended.
Thermocouple,
RTD, with Alarm and Shutdown setpoints should follow generator
2300 2300/20, /25 manufacturer recommendations. In the absence of specific
appropriate
third-party generator recommendations, contact an BN MDS engineer
interface. with hydro experience for recommendations. Thrust pad oil film
thickness is recommended as a shutdown parameter.
Bearing temperature can indicate problems related to thrust
bearings, including overload, bearing fatigue or insufficient
lubrication. Measuring temperatures at the bearing and correlating
them with other process variables can assist in determining the
overall condition of hydroelectric turbine/generators.
For bearing temperature measurement to be effective, the
temperature sensing element must be as close to the bearing
babbitt as possible. The OEM may include temperature elements in
the pads from the factory, or drill and tap the pads for temperature
sensors during the manufacturing process. If not provided, the
bearings can be removed and drilled to accept the temperature
sensors. In the absence of OEM installation recommendations,
install one temperature sensor per thrust pad.

26
 application note
10.9 Stator and Windings A frequent question is whether it is possible to affix the transducers
without removing the rotor. If it is possible to remove one or two
poles, the increased clearance in front of the stator can be used to
mount the transducers by rotating the rotor to each position where
10.9.1 Air Gap (AG) a sensor needs to be installed.
Air gap measurement requires the installation of a Keyphasor
System Monitor Transducer Measurements probe. For more information, reference Section 8.9.

4000 Series Average AG, Min & Air gap is generally not used as a protection function, so most air
3500 3500/45 Air Gap Max. AG & Poles, gap monitoring systems will be set to alarm only on minimum
System Instantaneous AG air gap. Alarm set points should follow the manufacturer’s
recommendations. Refer to the guidelines from the Center for
The Air Gap Monitoring System measures the distance between Energy Advancement through Technological Innovation (CEATI) in
the rotating and stationary parts in the generator using proximity Appendix 3.
sensor secured to the inside diameter of the generator stator. This
measurement is important because the hydro generator stator is
a flexible assembly (large units can be over 50 feet or 15 meters in 10.9.2 Stator Temperature
diameter) where concentric integrity is critical.
Measuring the distance from the air gap sensor to each rotor pole
as the rotor turns provides direct indications of rotor shape. Using System Monitor Transducer Measurements
multiple air gap sensors located around the stator and interpolating Thermocouple, Temperature
3500/60,
between these measurements provides a calculated stator shape. RTD, or
3500 /61, /65 or
temperature
Air gap monitoring can indicate problems related to uneven 3500/62
transmitter
or insufficient air gap, including off center rotor or stator
(concentricity), stator out-of-roundness (circularity), rotor pole Thermocouple, Temperature
movement, and rotor rim movement. At a minimum, a non-circular RTD, with
2300 2300/20, /25 appropriate
or non-concentric rotor and stator reduces the efficiency of the
third-party
hydro machine. If left unchecked, air gap anomalies can lead to interface.
rotor-stator rubs that can result in catastrophic failures.
Bently Nevada 4000 Series air gap sensors are available in two Stator temperature measurements (for example RTDs in stator
ranges, so the sensor must be selected based upon the design slots and at the air cooler inlet and air cooler outlet) can be used
(nominal) air gap information provided by the customer. The probe to detect changes in stator condition including plugged coolers,
assembly is secured to the inside diameter of the stator with epoxy. grossly overheated coils, blocked ventilation ducts and other forms
Be aware that when applying an air gap sensor, the thickness of of degradation. Including generator temperature data, either by
the sensor, approximately 1/8 inch (3.2 mm), will take up part of the means of the monitoring system or through the System 1 interface,
air gap. In addition, the flat sensor will protrude from the circular will allow a more thorough diagnosis of generator events.
stator on small diameter stators reducing overall air gap. The sensor
A 3500 monitoring system with System 1 provides a potential cost
cables are routed through the stator to the signal conditioner
savings to hydro operators a by replacing existing independent
located on the outside of the stator housing. A minimum of four
systems, typically chart recorders, with a single system accessing
sensors in a single plane is recommended for stators with bore
all the HTG monitoring data. Many aging plants are seeking to
diameter less than 7.5 meters. Larger stators can be more flexible
replace their existing temperature monitoring systems, and new
and therefore susceptible to more localized movement, so a larger
plants wish to install a single system capable of tracking, alarming,
number of sensors will increase the resolution of the stator shape
and tripping on critical temperature conditions. This function
measurement. Number of sensors recommended for various
can easily be accomplished within a Bently Nevada machinery
generator stator sizes are shown in the following table.
management solution.
Diameter (meters) Sensors The 3500 System offers six- or 16-channel monitors for use with
<7.5 4 either thermocouples or resistance temperature detectors (RTD).
When a temperature transmitter is used, the 4-20 mA signal
7.5 - 12 8 proportional to temperature can be brought into a 3500/62 Process
12 - 16 12 Variable Monitor. Temperature information can also be acquired
>16 16 directly by System 1 with a SCADA or unit control system interface.
Measuring temperatures at the stator and correlating them with
The minimum recommendation is for monitoring in a single plane other process variables, including megawatts and megavars (active
near the top of the generator stator. On stators with height of and inactive power) can assist in determining the overall condition
1.8 meter (6 feet), air gap monitoring in both the upper and lower of hydroelectric generators.
planes of the generator is recommended.

27
application note
Local temperature transducers may be mounted between stator frame. Other measurements, including stator frame vibration
coils in a slot. Bulk stator temperature transducers may be mounted relative to the soleplates and stator core vibration relative to
in the inlet and outlet cooler air stream. Generally, each cooler will the stator frame, can be made using proximity probes. Where
have a temperature transducer at air inlet and outlet and water possible, proximity probes should be applied for all low frequency
inlet and outlet. applications.
Alarm and Shutdown setpoints should follow generator Alert and Danger set-points should follow generator
manufacturer recommendations. In the absence of specific manufacturer recommendations. In the absence of specific
generator recommendations, contact a BN MDS engineer with generator recommendations, contact a BN MDS engineer with
hydro experience for recommendations. hydro experience for recommendations. Stator frame vibration
measurement is not recommended for automatic shutdown
(machine protection).
10.9.3 Stator Frame Vibration
10.9.4 Stator End Winding (SEW)
System Monitor Transducer Measurements
330505 Low Direct Amplitude,
Frequency 1X Amplitude System Monitor Transducer Measurements
Velocity and Phase, Overall Vibration
3500/46M
Sensor; Line Frequency Amplitude,
3500 with mod.
330500 Amplitude*, 330447 Stator Bias Voltage,
181253
Velomitor; Pole Passing 3500 3500/46M End Winding Pole Passing
190501 Amplitude* Accelerometer Amplitude, Direct
Velomitor CT Resultant, Pole
330505 Low Direct, Bias Volts, Passing Resultant
Frequency 1X+Ø, 2X+Ø,
3701/46 PAV Velocity (other user- Winding insulation within hydro generators can be damaged by
Sensor; configurable) excessive vibration over time. The vibration is induced as the rotor
Velomitor CT magnetic poles exact a continuous force on the stator frame where
330505 Low Direct, Bias Volts, the windings are located. The frequency of this dynamic force is
Frequency Bandpass filtered at two times the machine’s line frequency. Thus, if a generator is
Velocity values producing 60 Hz power, the machine’s windings will experience a
Sensor; mechanical vibration at 120 Hz.
2300 2300/20, /25
330500
Velomitor; Typically, the highest vibration will be measured on the generator
190501 end windings, which protrude out the top and bottom of the stator
Velomitor CT core. End winding vibration can be severe if the natural resonance of
the end winding structure coincides with the two times frequency of
* 3500/01 modification 181253-01 is required for these measurements.
the mechanical vibration induced by the rotor magnetic field. Proper
Stator cores are built from insulated steel laminations stacked on trending of end winding vibration using accelerometers can provide
top of one another. Some (especially older design) stators consist valuable insight into the rigidity of the winding structure over time.
of several arc sections connected by vertical joints (in the case of Plant managers can use this information to plan for retrofits during
vertical machines). Movement of the stator core relative to the outages if necessary. Bently Nevada’s Hydro Stator End Winding
windings can cause fretting and damage to the winding insulation. (SEW) Accelerometer system provides a means of monitoring
Vibrations from loose stator core and frame are measured at 2X selected end windings around the circumference hydro generators.
line frequency. Uneven air gap forces will cause stator core and The Bently Nevada Hydro SEW acceleration system provides a dual-
frame vibrations at 2X operating speed. A modification (see table axis transducer suited for the electrically harsh hydro
above) is recommended so that (twice) line frequency and pole
generator environment. The system’s dual axis capability offers an
passing amplitudes are included in the measurements made by the
efficient approach to monitoring hydro generator’s end windings.
3500/46M monitor.
The installation of the Bently Nevada Hydro SEW Accelerometer
Stator frame vibration can indicate problems related to the relative system involves permanently affixing the mounting base directly to
motion between the frame and stator core, including loose laminations carefully selected end windings in several locations around
and unbalanced air gap forces. Early detection of this vibration can
the circumference of the generator. This transducer interfaces
allow for corrective action before serious damage occurs.
with the Bently Nevada 3500/46M Hydro Monitor. The monitor’s
Stator core and frame vibration can be measured with a seismic measurements include a “resultant” value, which is the maximum
transducer mounted mechanically or with epoxy to the core and peak level of vibration geometrically derived from both the X and Y
axis of the dual axis SEW accelerometer.

28
 application note
Alert and Danger set-points should follow generator manufacturer Trending of the PD data over time is used to predict long- term
recommendations. In the absence of specific generator insulation degradation. Unlike temperature or vibration measurements,
recommendations, contact a BN MDS engineer with hydro experience there is no established good or bad level of PD. Essentially identical new
for recommendations. Stator end winding vibration measurement is machines by the same manufacturer can have significantly different PD
not recommended for automatic shutdown (machine protection). levels and still be acceptable for operation. Increasing levels of PD with
time is the primary indicator of degrading insulation. PD instruments
that take data automatically can be interfaced with System 1 for data
10.9.5 Sole Plate Position analysis, trending, and storage.
HydroX RulePak covers PD measurements. It is possible to use the
PD dedicated RulePak when 80 pF couplers are used.
System Monitor Transducer Measurements
3500/42M Or 3300XL Probe Position, Gap
3500
3500/45 or LVDT*
*If LVDT sensors are used, only the 3500/45 Position Monitor, and as standard
only Channels 3 & 4 of that monitor, can be used with LVDT transducers.

Position measurement and trending of the sole plates supporting

the stator of the generator can provide useful information regarding
the movement and deformation of the stator core and frame. This
measurement can be made with extended range proximity probes
(3300XL 25mm) or LVDT sensors.
Alert and Danger set-points should follow generator manufacturer
recommendations. In the absence of specific generator
recommendations, contact a BN MDS engineer with hydro
experience for recommendations. Sole plate position measurement
is not recommended for automatic shutdown (machine protection).

10.9.6 Partial Discharge Figure 28: - EMC PDA Coupler Installation (by IRIS Power
Engineering)

System Monitor Transducer Measurements

Third Party (IRIS

(OPC or Summary 10.9.7 Magnetic Flux
Modbus numbers (NQN,
HydroTracII™ or PDA Couplers
import to Qm), 2D Data,
HydroGuard™)
System 1) Alarms
System Monitor Transducer Measurements

Partial Discharge (PD) is a radio frequency noise measured in the 3500/46M

MHz range that is generated by low level arcing and sparking in with mod.
183432-01 Third Party Avg flux, Max.
generator stator insulation. There are three basic types of PD of 3500
and I/O of (SENIS)* flux, Min. flux
concern in medium voltage generators (5-20kV range): internal 3500/42 with
discharges, slot discharges, and end winding discharges. mod. 162572
Partial discharge measurements are made with third-party PD *The items below from SENIS are required.
Couplers (see Fig. 28) and signal processing electronics.
Couplers of various capacity (typically between 80 pF to ~9 nF) are Description Part Number
available on the market. Partial discharge couplers are connected Magnetic Field Transducer Single-Axis F1A-0YC10F-
directly into the high voltage side of the generator winding. PD C02T2K5M-E
couplers come in two types: Cable-type and Epoxy Mica Capacitors Power Supply, for Senis S12-5
(EMC). The performance of both couplers is similar, but cost and Transducers, 90-264VAC
installation is the primary difference. EMCs cost more but usually
Output Signal Cable, COS30-A-HG
require 3 to 4 days per machine to install, while the cable type
unterminated one end, 5m
couplers require about 5 to 6 days per machine. Two 80 pF couplers length.
per phase are required when used to measure the noise from the
transformer side (typically six (6) couplers for a generator rated less Differential-to-Single-Ended 1DSA-05
than 100 MW). One coupler per circuit per phase is required when Signals Adapter
the couplers are of ~1nF or larger. Probe Head Support PSB PSB-R04**

29
application note
** Ask SENIS for the customized holder for hydro-generator applications; and runner blade interaction) can be an important issue in the
it has a narrower profile and therefore less impact on cooling of the stator design of these machines. Particularly in high head Francis runners,
than the universal one they typically provide. the presence of vibration from the rotor-stator interaction between
wicket gates and runner blades is a known phenomenon. This
Rotor flux monitoring involves measuring the magnetic flux in the
phenomenon results in high vibrations because pressure waves
generator air gap to determine correct operation of rotor poles. It
generated by the interaction between individual blades and wicket
is the most commonly used method of online rotor pole electrical
gates propagate circumferentially in the radial spaces of the turbine.
condition measurement. In a salient pole machine, the radial
If these waves are in phase, they amplify and can cause problematic
magnetic flux profile across each pole depends on the MW and Mvar levels of vibration. More recently, the hydrodynamic wicket gate-
loading of the machine. Any change in the flux profile within a pole runner blade interaction has been found to be directly responsible
at a given load is a strong indication of shorted turns. To make these for blade cracking.
measurements, a single flux sensor is installed within the air gap to
A Velomitor CT mounted horizontally to the wicket gate stem
measure the pole flux.
support or bearing head can detect vibrations due to the wicket
During machine operation, the magnetic flux from each pole will gate-runner blade interactions. Two or more wicket gates should
induce a current in the flux sensor as the poles rotate past it. The be instrumented, and typically ones closest to where the hydraulic
peaks in the current measure for each pole can be recorded, with servomotors connect to the control ring.
each peak of the waveform representing the “average” flux across
Alert and Danger set-points should follow generator
one rotor pole. Any fault in a pole reduces the effective ampere
manufacturer recommendations. In the absence of specific
turns of that pole, and therefore the measured peak associated
generator recommendations, contact a BN MDS engineer with
with that pole. The recorded waveform data can then be analyzed
hydro experience for recommendations. Wicket gate vibration
to locate the pole containing the fault.
measurement is not recommended for automatic shutdown
If a generator rotor is in good electrical condition, then the flux (machine protection).
measurements for each pole should provide similar (peak) results.
If the peaks for one (or more) of the poles start to vary from others,
then this indicates a reduction in flux. The CM&PS continuously 10.11 Turbine
tracks flux for all poles, and calculates the average value of the flux
from all poles, and determines:
• Maximum flux and associated pole number. 10.11.1 Seal Ring Position/Blade Tip
• Minimum flux and associated pole number. Clearance
Magnetic flux is not recommended as a shutdown parameter.

System Monitor Transducer Measurements

10.10 Wicket Gate 3300XL Seal Ring
3500 3500/46M Underwater Clearance
The wicket gate system of most large hydroelectric generators Probe
consists of a series of axial louvers that control water flow through
the turbine. As load on the turbine increases, the wicket gates open 3500/46M 3300XL Blade Tip
3500 with mod. Underwater Clearance
to allow more water to flow through the turbine.
183410 Probe
Note: Wicket Gate Position is a process measurement that is
3300XL Seal Ring
usually imported from the control system when needed for 3701/46 PAV, PAS Underwater Clearance
condition monitoring. Probe
The number and location of probes for the measurement of a
10.10.1 Vibration Francis turbine’s runner seal ring clearance is a function of unit’s
design and accessibility. Since the seal ring is located inside the
concrete surrounding the steel turbine casing, the probes can
only be installed where there is access to the casing. For wear ring
System Monitor Transducer Measurements condition measurement, a single probe can be positioned in the
Process Variable bottom ring observing the rotating surface of the seal. Turbine
3500 3500/46M Velomitor CT
Display runner movement within the case is measured with two probes
Process Variable installed at 90 degrees apart and in the same radial locations as
3701/46 PAV Velomitor CT
Display the guide bearing radial vibration probes. Turbine case deformation
at the seal ring location is measured by installation of four probes.
The push towards flexible hydroelectric power output has led to These probes can be connected to a 3500 or 3701 monitor, and the
the demand for more compact machines and a larger required signals are processed and viewed in System 1 to the extent that
operating range for new and upgraded turbines. As a result, standard dynamic vibration plot formats permit.
hydrodynamic effects in turbines (such as caused by wicket gate

30
 application note
Blade tip clearance measurement for a Kaplan and propeller turbine penstock and scroll case, whereas more severe cavitation may
is preformed using 4 or 8 sensors installed symmetrically around sound as though gravel were being passed. Extremely severe
the circumference of the discharge ring. The sensors should be cavitation may sound like rocks are being passed through the case.
mounted such that the tip is as close to flush as possible with the Forces from the cavitation are not sufficient to cause measurable
inner wall of the discharge ring. A counter bore around the sensor vibrations on the rotor system.
tip should be provided to eliminate sensor side loading. On many Cavitation is most often measured as a vibration or noise on
of these turbines, the blades of the propeller can change pitch to the draft tube. Draft tube acceleration can provide an indication
accommodate different flow rates and head levels and provide of cavitation stress on the turbine and draft tube, while
optimum efficiency. This requires that the measurement is typically accelerometers on the head cover can detect cavitation if it occurs
made at an elevation in the throat ring as close as possible to the there. Accelerometers can also be mounted on a representative
pivot of the blades. number of wicket gate stems if cavitation occurs on the wicket
In any case, underwater proximity probes are required. Target gates. Bandpass filters are typically adjusted in the monitor to
material can vary from stainless steel, 4140 steel or, in some cases, measure the broadband vibration level caused by cavitation.
carbon steel, so a special material modification may be required. The 330400 Accelerometer or acoustic sensors are typically
Alarm settings are typically not specified for seal rings by the installed on the draft tube just below the seal ring, or on the
OEM. Settings must be based on past experience with each head cover, and connected to a 3500/46M, 3701/46, or 3500/62
particular unit. Contact a BN MDS engineer with hydro experience monitor. A dynamic pressure sensor at these locations, connected
for recommendations. Seal ring and blade tip clearance are not to a 3500/46M or 3701/46 monitor, can provide a corroborating
recommended for automatic shutdown (machine protection). measurement. Cavitation measurements are typically used for
condition monitoring purposes only, and are not recommended for
automatic shutdown (machine protection).
10.11.2 Cavitation
10.11.3 Rough Load Zone
System Monitor Transducer Measurements (W. J. Rheingans Influence)
3500/46M or 330400 Bandpass filtered
3500
/42M Accelerometer Direct vibration
350300 Dynamic System Monitor Transducer Measurements
3500 3500/46M pressure pressure, static 350300 Dynamic
sensor pressure 3500 3500/46M Pressure pressure, static
Bandpass Sensor pressure
Hydrophone
3500 3500/62 filtered sound Shaft relative
(third party)
levels 3500 3500/46M 3300XL Probe guide bearing
Bandpass vibration
330400
3701/46 PAV filtered Direct Shaft relative
Accelerometer
vibration 3701/46 PAV 3300XL Probe guide bearing
Third party Dynamic vibration
dynamic pressure Third party Dynamic
3701/46 PAV
pressure dynamic pressure
sensor* 3701/46 PAV
pressure
* Suggested sensors are PCB Models 121A21, 121A22, or 121A44 sensor*
(depending on pressure range) * Suggested sensors are PCB Models 121A21, 121A22, or 121A44
(depending on pressure range)
Cavitation occurs whenever the local static pressure falls below the
vapor pressure of the liquid. When this occurs, some of the liquid Rheingans influence is a hydraulic phenomenon that occurs on
will flash to vapor and form a vapor cavity. When the liquid reaches Francis turbines when vortices form at the exit of the runner and/
an area of increased local pressure, the vapor cavity will collapse. or in the draft tube past the runner. Rheingans influence typically
These implosions excite the natural frequencies of the spiral case, occurs at low to medium electrical load conditions, where the
runner, and other related parts, resulting in vibrations of random turbine is operating off its best efficiency point, and this load range
amplitude and frequency. As cavitation begins downstream of the is often referred to as “rough load zone” (RLZ).
lowest pressure areas, the most likely spot on the machine to pick
The unequal pressure forces resulting from the swirling vortex
up the cavitation is in the draft tube where flow exits the runner.
“rope” can cause high subsynchronous radial vibrations that can
Cavitation can be destructive, and a visual inspection of affected be detected using proximity probes at the turbine guide bearing.
areas will often reveal metal loss similar to erosion. Eventually, A dynamic pressure measurement can also be used to directly
the turbine loses efficiency, forcing a shutdown and dewatering measure the pressure pulsations caused by the vortex flow, which
for repair. A distinctive noise often accompanies cavitation; could also be manifested in the head cover and scroll case areas.
mild cavitation may have the sound of sand passing through the

31
application note
Kaplan and propeller type turbines can experience vortex flow
after flow disturbances in the scroll case or downstream of the
10.12.2 Pressure Monitoring
guide vanes. These flow phenomena can be measured by dynamic
pressure sensors in those areas.
System Monitor Transducer Measurements
The dynamic pressure sensor is ideally connected to an existing
350300 Dynamic
pressure port using as little tubing length and elbows as possible, 3500 3500/46M Pressure pressure, static
since these would attenuate the dynamic pressure. The Bently Sensor pressure
Nevada 350300 pressure sensor can be connected to a 3500/46M
monitor. The dynamic pressure signal characteristics, together Shaft relative
3500 3500/46M 3300XL Probe guide bearing
with the turbine guide bearing radial vibration probe signals
vibration
can be analyzed in System 1. This allows the identification of
the characteristically high subsynchronous vibration frequency Shaft relative
associated with Rheingans influence. When the 3701/46 ADAPT 3701/46 PAV 3300XL Probe guide bearing
Hydro monitoring system is used, a compatible third-party vibration
sensor can be used. Standard, as well as user-configured monitor Third party
measurements, can be established for the pressure and shaft radial dynamic Dynamic
3701/46 PAV
vibration channels to identify the Rheingans influence frequency of pressure pressure
interest. These measurements are typically used for operational and sensor*
condition monitoring purposes only, and are not recommended for
automatic shutdown (machine protection). Dynamic pressure measurements in the penstock can be used to
detect pulsations from “water hammer” or transmitted from vortex
formation downstream in the turbine. Static pressure can be useful
10.12 Penstock for monitoring hydraulic efficiency of the unit, or identifying inlet
pressures that cause other hydraulic and mechanical conditions in
the unit.
10.12.1 Flow Monitoring The dynamic pressure sensor is ideally connected to an existing
pressure port with as little tubing length and elbows as possible
to avoid attenuation of the dynamic pressure signal. The Bently
System Monitor Transducer Measurements Nevada 350300 pressure sensor can be connected to a 3500/46M
monitor. When the 3701/46 ADAPT Hydro monitoring system
Third-party
Process Variable is used, a compatible third-party sensor can be used. These
3500 3500/62 Acoustic Flow
Display measurements are typically used for operational and condition
Meter*
monitoring purposes only, and are not recommended for automatic
* GE Sensing offers wetted and clamp-on ultrasonic flowmeters for hydro shutdown (machine protection).
applications.

Multipath acoustic flow meter systems are utilized to measure

penstock flow in hydro turbines. The systems are used to determine 10.12.3 Alarm Management
individual unit and plant performance. On-line unit and plant The most important features of an CM&PS are:
efficiency can be determined by monitoring turbine flow, power
A. Provision for redundant power supplies
output, inlet and tail water pressure. These systems are used for
continuous permanent monitoring, and acceptance test programs B. Continuous self-checking (auto-diagnostics) of transducer
for new and refurbished units. Accurate determination of turbine sensors and measurement channels.
efficiency (performance) curves can lead to increased plant C. A variety of alarm configurations used with the auto-diagnostic
efficiency in multi-unit plants. results, NOT OK conditions, etc.
When acoustic flow meters are installed at both the upper (intake) D. Variety of relay outputs.
end and lower (powerhouse) end, penstock leakage or rupture can
be detected by automated monitoring of the flow differential. E. A variety of logical relay output configurations

Acoustic flow monitoring systems are mounted at the penstock, and F. Flexibility in configuration of bandpass frequency ranges and
are usually installed by the manufacturer. Third party systems with the number of the bandpass ranges available for each dynamic
compatible signal outputs can be integrated into 3500 and System 1, signal.
or flow values can be imported from the control system as a process G. Number and type of alarms that can be configured for each
variable. Although flow may be used in the protection scheme, it is measurement.
not recommended for shutdown within Bently Nevada systems.
H. Configuration possibility / flexibility for the ALARM TIME DELAY
I. Number and type of measurements derived from the dynamic
content of the transducer signal (filtered values, phase angles,
calculated vectors, etc.)

32
 application note
J. TRIP-MULTIPLY functionality [10] (TRIP-MULTIPLY dynamically
set, and TRIP MULTIPLY resolution)
K. Number and types of protocols that can be used for digital
interfacing with various DCS suppliers and other systems.
L. Possibility of remote access to the CM&PS.
M. Number of transducers that can be connected to each rack in
the system
N. Number of racks that can work together for one HTG as a
compatible system
O. Ease of interfacing with a Diagnostic System
P. Multimode functionality, as described below
A CMS with a well-developed feature set will allow better alarm
management [11] and avoid overloading operators with alarms.

10.12.4 CMS Hardware: multimode

functionality
As it is described in [13], the Bently Nevada 3500/46 Hydro Monitor
incorporates a unique “Multimode” feature. This allows the end
user to establish up to eight distinct machine modes, each with its
own unique set of alarm parameters, including Alert and Danger
thresholds. Figure 29: Front view of 3500/46 monitor (left) and partial
It also allows a control system to automatically tell the monitor view of its I/O module, showing the three inputs for selection
which mode exists at any particular time so the correct alarm of operating mode (in red rectangle).
settings will be used automatically. The selection of various Seemingly obscure environmental variables may not be recognized
operation modes is executed by three contacts located in the Input/ as important factors impacting generator rotor dynamics. For
Output (I/O) module of the monitor (labeled IN-1, IN-2, and IN-3 in) example, a run-of-river hydro power plant with vertical Kaplan
(Figure 29). turbines observed that the vibration level depended on direction
The monitor can be used for HTG machines having vibration of the wind! For some wind directions (coming from one side of
characteristics that are strongly correlated to the process and/ the river or the other), the difference in head from one end of the
or the environmental variables. It can be programed specifically dam to the other was more than 1.6 ft. (0.5 m). This change in head
to accommodate the most important variables that accompany was enough to introduce significant errors in the average head
operation in situations such as: various load ranges, generation measurement – with impact on rotor vibration. Once the plant
versus pumping mode (for pumped-storage units), synchronous staff recognized this effect, individual head measurement systems
condenser mode, and so on. were implemented for each unit. With the more accurate head
measurements available, it became possible to increase
the sensitivity of the Alert threshold. With this accomplished, an
accurate correlation curve was created comparing Rotor Vibration
(Symptom) with Head (Environmental Variable) – like the Rotor
Vibration vs. Load correlation curve that was created at the plant in
the earlier example.

33
application note
11 LOWER LEVEL OF CMS: types of alarms can start the special data collection used for alarm
conditions. The type of collected data is presented in Figure 30:
S/W build systems
This paragraph, addresses stage 3 of the structure presented in
Figure 1.

11.1 Components of a diagnostic system

The main components of a diagnostic system are:
• diagnostic system server,
• diagnostic system software,
• communication processor,
• diagnostic system network.
Note: the network structure is also a critical element in a successful
diagnostic system. Figure 30: Details of data collection during alarm conditions
It is strongly suggested
• to use a separate network “diagnostic network” for
communication between communication processors, and the 11.4 Type of analysis
diagnostic server, The diagnostic system should provide the following data formats:
• to have the diagnostic server connected additionally to i. WAVEFORMS (time base presentation)
the Ethernet; this connection allows remote access to the
ii. ORBITS (x verses y presentation)
diagnostic server, and its database.
i. Direct ORBITS
Note: Only a limited number of machines and communication
processors can be connected to the system server. ii. Filtered ORBITS: 1X, 2X, NX,
iii.
Compensated ORBITS

11.2 Types of data acquisition iii. SHAPE & POSITIONS

i. Shaft Center Line (SCL)
System licenses permit various data acquisition configurations.
ii. Generator components: AIR GAP
These are:
iv. HALF SPECTRUM ANALYSIS
• data acquisition during steady state conditions
v. FULL SPECTRUM ANALYSIS
–
STOP condition,
i. SPECTRUM vs. ROTATING SPEED – (CASCADE PLOTS)
– full speed – no power,
ii. SPECTRUM vs. TIME – (WATERFALL PLOTS)
– full speed – operation w/ nominal conditions;
vi. BODE PLOTS 1X, 2X, NX
• data acquisition during transient conditions
vii. POLAR PLOTS 1X, 2X, NX
–
START-UP
viii. CORRELATION PLOTS X-Y and MULTI-TRENDS
–
OVERSPEEDING
ix. Special analysis HYDRO e.g. Air Gap
–
SHUT-DOWN.
The PD data are presented in a separate software package,
For transient data acquisition to be applicable, the unit speed
according to hardware capabilities provided by PD-system vendor.
transients must occur slowly, i.e. only a small change in operating
Transient analysis can be useful for HTGs that operate close to or
speed can occur during one revolution of the shaft. In other words.
above the first rotor resonance.
the speed during one revolution can be considered quasi static.
Since some HTG can cover zero to full speed range in just few
revolutions traditional transient plots are not applicable for them.
11.5 AIR GAP analysis
The slow speed machines use multi-pole generators, and therefore
11.3 Data acquisition in Alarm Conditions the generators have a large diameter that could reach over twelve
meters. This large-scale construction is subject to mechanical and
Some systems initiate additional data acquisition upon the
thermal malfunctions. Therefore, a measurement of the AIR GAP
detection of an alarm condition. There are two types of alarms
becomes very significant for machine condition monitoring.
generated in the CMS. These are H/W alarms and S/W ones. Both

34
 application note
The figure below illustrates some basic stator-rotor system
problems:
11.6 Multi State Analysis in CMS
In condition monitoring and protection systems, it is often
possible to establish two separate alarm levels for each measured
parameter. In Bently Nevada systems, for example, the lower
severity alarm is called the “Alert,” while the higher severity alarm is
called the “Danger” alarm. Crossing these alarm thresholds provides
information about a minor deviation of the measurement from
normal conditions (Alert), and a more serious deviation (Danger).
The Danger alarm usually indicates that a significant change in
physical condition of the monitored asset has occurred. When
the monitoring system is configured to interact with a protection
system, the Danger setpoint is normally selected to actuate
protective trip logic, which shuts down the protected machine
without human intervention. Of course, such a protective trip
impacts the production process, but this outcome is preferable to
allowing the machine to be damaged by continued operation.
With diagnostic systems that do not provide automatic protective
functions, it is often possible to use more than two thresholds
for each measurement. Consequently, the diagnostic system can
distinguish between more subtle changes in physical condition
of the monitored assets. In this article, we will describe typical
measurements (and symptoms) that are used specifically for
evaluation of physical condition of hydro turbine-generator
machines. However, the approach presented here can be used for
any other assets covered by a diagnostic system as well.

11.6.1 Operating Conditions

Figure 31: Rotor-stator system problems
Ideally, observed symptoms should only depend on actual condition
The magnetic attraction between rotor and stator is a very strong of the monitored asset, and unambiguously describe failure modes.
force. When rotor and stator are round and concentric, this force However, in the real world, production assets can operate in various
is evenly distributed. Any asymmetry can cause performance challenging environments with different operating conditions.
problems (overheating, rubs, vibration, etc.). Observed symptoms can be significantly affected by these factors,
The air gap is not significant in proportion to the generator rather than indicating the true physical condition. Many observed
diameter, so it is quite possible to exceed the gap and create a symptoms are functions of not only the physical condition of the
rotor to stator rub. This malfunction can result from the following asset, but also of the following variable factors:
conditions: • Process Variables
1. A protruding or loose pole extending into the air gap. Therefore, • Environmental Variables
over time, this particular pole may eventually come into
contact with the stator.
2. The eccentricity of a rotor may gradually increase with time, 11.6.2 Logic Rules
and may reach a point where it exceeds the available air gap. When empirical relationships describing the expected vibration
This problem can be due to imbalance or thermal expansion of for various process/environmental variable ranges have been
the stator. developed, it is easy to convert them into a set of logic rules for
3. Rotor radial expansions: two (2) components of rotor radial use in System 1 Decision Support tools as described later (see
expansions are speed and heat. additionally, some examples in [14]). These logic rules are created in
Rule Desk tools, or installed as pre-configured RulePaks™ [15] that
During normal operation, the generator parts are subject to will detect when abnormal conditions (anomalies) are identified
uneven thermal expansion, potentially resulting in a rub. Uneven such as:
thermal expansion may also be caused by an electrical hot spot
on the rotor. For example, breakdown in the insulation on the • for machine bearings,
windings can cause local heating. • for transducers or measurements,
• for states such as the example in [14]

35
application note
11.6.3 State-Based Analysis
Bently Nevada System 1 software offers a unique System Extender
application called State-Based Analysis, which is dedicated to
the monitoring of assets with more than one mode of operation.
This application allows you to define any requested number of
dimensions of the analysis, and for each dimension, establish a
designated number of ranges.
For example, let’s define a 3-Dimensional (3D) state case for a HTG
described by the following parameters (Figure 32):
• Generator load (3 ranges, shown with red shading),
• Head (2 ranges, shown with blue shading), and
• Temperature (3 ranges shown with green shading).
Figure 33: An example of State Histogram build by State
Based Analysis Tool

11.6.4 Conclusions for the Multistate

Analysis
The hardware and software tools accommodate a more precise
condition monitoring and protection operation, and a more
accurate diagnostics capability than lesser systems could handle.
System 1 software uses MultiMode states from the hardware (such
as defined in the 3500/46M monitor) or as defined by maintenance
specialists in the software. Different alarm setpoints can be used
– not only for direct vibration, but also for other measurements
and analysis (for instance, specific alarms for amplitude vs. phase
“acceptance regions” that can vary with changes of selected
process variables).
At the expert level of diagnostic software (as it is described below),
specific rules can also be created to reduce the “noise” in symptoms
that can be caused by the influences of process and environmental
Figure 32: An example of 3D space used for state based
variables – thus facilitating more accurate detection and diagnosis
analysis with three input parameters.
of actual changes in asset condition. The custom rules dedicated
Now, when the “symptom” data (such as vibration) is collected for each state result in a more efficient predictive maintenance
in the System 1 database, it can be correlated to these three approach. Even in an organization that hasn’t advanced beyond
parameters, by indexing it to the 18 different subspaces that we a traditional Preventive Maintenance (PM) program, System 1
have defined. The State-Based Analysis system extender has no software can provide more accurate diagnostic information,
limitations on either the number of dimensions that can be used to allowing users to detect (and act earlier on) anomalies recognized
define states or on the number of sub-ranges that can be defined using state-based analysis techniques.
for each dimension.
The State Based Analysis tool allows building of State Histograms
which can be observed and reported whenever State Indicators 12 UPPER LEVEL OF CMS:
have been configured. Figure 33 presents as an example such
histogram build for 4 states.
S/W build systems The Industrial Internet
This paragraph, addresses stage 4 of the structure presented in
Figure 1.

12.1 Variety of analysis system solutions

Three stages of development of On-Line analysis systems can be
recognized:
• black-box2 systems – these include the instruments that were
widely used in the 1990s. These systems were applicable for
overall monitoring of a wide class of rotating machinery.

36
 application note
They had some configurable parameters; however, these did To address each asset’s unique and personal behavior, anomaly
not typically include rotor system orientation and they did detection systems create a baseline of the asset’s normal operating
not consider the specific malfunctions that are common for a profile using the asset’s own historical data.
machine. Although these systems used specific data generated Thus, for the use of an anomaly detection system, it is imperative
from advanced dynamic (waveform) signal post-processing, to have access to historical data, usually achieved through the
only very generic malfunctions could be recognized; installation and use of a data historian type of server. The same
• anomaly detection systems – these systems can accommodate historian server would also be used for the online monitoring of
diagnosis of various types of abnormalities. First generation the equipment. At periodic time moments, the anomaly detection
systems were implemented in nuclear power plants in system collects values of all the equipment parameters and these
early 1990s and are used for these applications to this day. are compared against the normal baseline behavior. When there is
Nowadays, nuclear plants use more advanced nondeterministic a significant deviation from the normal behavior the system flags it
algorithms of anomaly detection. These systems explore as an anomaly.
the correlation between variables without needing to define One of the main benefits of anomaly detection systems is the user
complicated equations. Consequently, they can be used for can define the criteria that trigger an anomaly. Additionally, they can
anomaly detection of many asset types (e.g. turbines, pumps, be normalized against the equipment operating conditions. These
transformers, metrological instruments, etc.). These systems characteristics, combined with the learning of the normal baseline
have been successfully and broadly implemented within various behavior, permit anomaly detection systems to generate very early
other branches of power generation including HPP; warning of abnormal equipment behavior, in the order of weeks or
• user programmable expert systems3 – these systems months before traditional monitoring systems, would alert. This
originated at beginning of this century. These systems are early warning is key to converting reactive, preventive, or predictive
designed to accommodate specific types of machinery (e.g. maintenance into proactive activities that significantly benefit plant
a vertical hydro-turbine-generator). They have a rich set of operations and maintenance efficiency.
rules that can identify a complete set of malfunctions based As discussed earlier, anomaly detection systems learn the behavior
on deterministic algorithms. More advanced systems of this of a piece of equipment exclusively from its “personal” historical
type provide specialized tools that allows the creation of data in its unique operating context. These systems are data-
new deterministic rules by system users (e.g. a maintenance driven and do not require specific knowledge of the engineering/1st
specialist, an employee of OEM, an employee of a diagnostic principles of the equipment. This “agnostic” approach facilitates the
service, and so on). application of such systems to many diverse systems, equipment
APM systems have evolved dramatically during the past decade, or environment. In addition, and thanks to their relatively simple
due in large part to the advances in technology that enable interface, users can become very quickly acquainted with such
solutions to meet the increasing needs of power plant operation systems without having to become experts in one more system.
and maintenance personnel. Such anomaly detection systems are widely used today to drive
In the next sections, we will describe examples of two currently a proactive maintenance strategy in multiple industries, most
used analysis system solutions that have demonstrated their commonly in power generation, O&G, aviation and mining. In the
usefulness for maintenance as well as for operational staff. next section we will describe in more detail an application of such a
system in a large HPP facility.

12.2 Anomaly detection systems

Anomaly detection systems are based on the general acceptance 12.3 An example of anomaly detection
that equipment demonstrates a normal operational behavior which in HPP
is consistent throughout their healthy operation. A significant
Proficy SmartSignal* is the most globally wide-spread early
deviation from this behavior signals an anomaly, indicating that
warning anomaly detection system. With more than 40 proprietary
a potentially significant equipment or operational problem is
algorithms built around its similarity-based modelling methodology
developing. In a sense, the Monitoring and Protection systems
[6], the Proficy SmartSignal solution detects equipment anomaly
described in section 1, are a type of anomaly detection highlighted
problems earlier and more accurately than any other solution.
by a value change beyond some fixed thresholds. In these cases,
the thresholds are globally predefined, typically by the OEM or
upon asset commissioning. They do not consider the behavior
of the equipment or normalize against operational and ambient
conditions.
On the contrary, modern advanced anomaly detection systems are
based on a personalized approach for each asset. They consider 2
A “Black-box system” means a solution with internal functionality not clearly
that no two pieces of equipment are identical, even equipment of understood but providing some diagnostic outputs.
the same OEM type and model; they are operated differently, they 3
These systems, allow creation of new expert rules using measured values as well as
are exposed to different ambient conditions, they are maintained complex functions, (e.g. waveforms) to provide recommended actions.
separately, they might even be manufactured at different sites.

37
application note
Within the Proficy SmartSignal technology, related parameters of significantly from the estimate, several rules are evaluated, such as
the asset in surveillance are modelled together. The models read in the persistence of the deviation in time, the extent of the deviation,
an actual value for each parameter every 10 minutes and generate the instruments deviating, the concurrent changes in ambient and
an estimate for each of them. The estimates are based on the operating conditions, etc. These strict rules minimize spurious
equipment’s historical behavior, its current operating mode, and the alerts, and reassure that system advisories are generated and sent
process and ambient conditions. When the actual value deviates to the end user only for real anomaly situations (Figure 34).

Figure 34: Proficy SmartSignal Early Warning Detection [7]

For typical medium to large size HPP, the equipment of a generating

unit is split into four main models:
1. The HTG model, which detects turbine performance issues, as
well as gate, valve and seal failures.
2. The Generator/Exciter model, which identifies electrical or
thermal/cooling issues.
3. The Mechanical model, which detects abnormal mechanical
behavior, relevant to the bearing and shaft.
4. The Transformer model, which is in place to identify abnormal
conditions such as overheating, or gas composition deviations
in the transformer.
This model set covers all major components of an HPP unit, and .
they are proven to provide early detection of a wide range of
problems in terms of nature and importance, such as cavitation,
wicket gate failure, runner failure, overcooling, and others [7]. Figure 35: Proficy SmartSignal screenshot, clearly depicting
the actual (blue) and estimated (green) values for the Phase A
For example, the Proficy SmartSignal solution detected an winding temperature (middle chart)
overheating issue at a 230MW Francis type unit. The Phase A
generator winding temperature was found to be recording between The condition was deteriorating over time, and a long holiday
45 and 50 degrees Celsius, while SmartSignal was estimating it to weekend was coming up, so an electrician was dispatched to the
be running between 38 and 43 degrees Celsius (see Figure 35). In site. During a short outage, the electrician inspected the flow switch
parallel, an adjacent Phase B winding temperature was operating at the generator, and could adjust the cooling water flow to Phase A
about 3 degrees higher than expected. Apart from the rest of the of the generator. Shortly after the adjustment was made, the Phase
generator winding temperatures, other significant parameters that A winding temperatures returned to normal cooler values.
were contributing to the generation of the SmartSignal estimates The client stated that without this timely intervention, a hot spot
were the load, speed, reactive power, generator current and voltage, would develop on the generator. If this would be left unchecked
exciter current and voltage, as well as the cooling water flow and during the upcoming vacation period, the temperature rise could
inlet/outlet temperatures, the radiator air inlet/outlet temperatures, eventually reach an alarm limit, trigger a turbine trip and cause loss
and rotor winding temperature.

38
 application note
of power production. In addition, the client acknowledged that such xix. Increased Amplitude due to thrust bearing wear/
higher temperature could accelerate aging of the insulation, causing damage or unexpected frequencies
a short in the long run. Finally, after the intervention was completed, • Generator rotor and stator mechanical malfunctions –
the solution validated that everything returned to normal, as the based exclusively on air gap measurements:
temperature actual values returned to expected levels.
xx. Core or rotor rim distortion
xxi. Rotor or stator eccentricity
12.4 Deterministic expert system for HPP xxii. Rotor misalignment
In the case of an anomaly detection system, input data is provided
xxiii. Rotor rim mechanical distortion
from a historian type computer. This data is usually made up of
numbers that represent the values of monitored parameters. The xxiv. Core frame assembly stunted growth
digital interface capabilities of such systems assure high flexibility • Generator stator insulation malfunctions – based
for incorporating new measurements when needed. exclusively on Partial Discharges (=PD) measurements:
The deterministic type expert system usually needs to have a xxv. Field Winding turn shorts
very specific organization of the database (for data acquisition).
The expert rules can use data from the database as well as from a xxvi. Thermal Deterioration
process control system. The data from the process system can be xxvii. Load Cycling
(a) process variables (e.g. type of generator operation, active
xxviii. Loose Coil /bars
power, percentage of wicket gate opening), (b) environmental
variables (e.g. head, water temperature), and (c) in some cases xxix. Electrical slot discharge
additional physical measurements that are not already connected xxx. Improper impregnation
to the main part of a CMS (e.g. temperatures of windings, bearing
metal, cooling fluids). xxxi. Contamination at connections

An example of an expert system using deterministic rules is xxxii. Stress interface

HydroX* developed and implemented for the first time by New York • Other unit malfunctions – based mostly on static
Power Authority (NYPA) [8], [9]. The current version of this system (it means non-waveform) measurements (including
provides expert support for the following malfunction categories: temperatures):
• Mechanical malfunctions – based mostly on mechanical xxxiii. Stator and/or rotor winding overheating due to unit
vibration and position measurements: overload, cooling system problem, air gap distortion,
i. Shaft Centerline Out of Position due to Magnetic or ventilation system problems
Hydraulic Pull or Bearing Misalignment xxxiv. Bearing overheating problem
ii. Unit Unbalance due to Unknown Reasons xxxv. Bearing cooling water supply problem
iii. Possible Loose Shaft Coupling xxxvi. Bearing clogged strainer
iv. Rub xxxvii. Oil Leakage
v. Vortex Whirl (Rough Load Zone Operation named xxxviii. Bearing cooler fouling problem
alternatively as Rheingans Influence)
xxxix. Oil Debris Problem
vi. Bearing Wear or Loose Bearing
xl. Bearing overheating problem due to unknown reason
vii. Increased Amplitude at non-fault specific frequencies
xli. Water leakage into the oil
viii. Thrust Bearing Position Problem due to thrust bearing
xlii. Low oil pressure
wear/damage or misaligned/loose thrust collar
xliii. Shortened coast-down time.
ix. Unit Unbalance due to magnetic or hydraulic unbalance
The malfunctions listed above are grouped in four sets that are
x. Mechanical Unbalance
associated with specific condition measurements. Each set
xi. High Overall vibration of malfunctions are named for the associated RulePak (pre-
xii. Misalignment and possible misalignment engineered set of rules) and all of them together are named the
HydroX RulePak. The purpose of this RulePak is to package the
xiii. Head Cover Vibration Problems knowledge of experts providing automatic anomaly diagnosis
xiv. Wicket gate shear pin failure recommendations and event detection relating to medium- to
xv. Wicket gate problem
4
The HydroX RulePak is one of the most comprehensive solutions available for
xvi. Runner Damage monitoring and diagnosing hydro turbine generator faults, merging the expertise of
NYPA, IRIS Power and GE Energy.
xvii. Stator Core instability
5
HydroX uses data collected in a System 1 database and online imported data from a
xviii. Bearing radial preload control system.

39
application note
large-sized vertical hydro turbine generators (operating with speed
up to 600RPM, and having power over 20MW). When a malfunction
12.5 Variety of analysis system solutions
condition is diagnosed, the operator or plant maintenance
personnel can be notified regarding the following topics:
A. What is wrong,
B. What needs to be done,
C. How long before an action must be taken, and
D. What will happen if no corrective action is taken.
Informative notification messages are available to the user via a
special Actionable Information Tool. However, clearly every unit is
unique, and depending upon the unit’s design specifications, the
notifications must be customized for each specific application.
The HydroX RulePak utilizes a unique process to assign a confidence
weighting to all processed data. The resulting confidence levels
are combined with each fault’s knowledge algorithm to generate
a fault “belief” representing the certainty that a fault is occurring.
GE’s new focus is upon “the convergence of the global industrial
This hierarchical design allows the HydroX RulePak to realize
system with the power of advanced computing, analytics, low-
a high degree of diagnostic interaction between multiple data
cost sensing and new levels of connectivity permitted by the
acquisition systems, to corroborate fault diagnoses and provide a
Internet.” It’s about how “the deeper meshing of the digital world
comprehensive approach to condition-based monitoring.
with the world of machines holds the potential to bring about
profound transformation to global industry, and in turn to many
aspects of daily life, including the way many of us do our jobs.” It’s
fundamentally about data — Big Data — and how it transforms and
even revitalizes the work of manufacturing, transportation, and
energy production.
The Big-Data-Approach accesses both condition and process
related plant data to present quick and accurate anomaly detection.
This is made possible through the application of expert rules based
on HPP Specialist’s knowledge together with historical data from
operation of the HPP and other critical and essential plant assets.

12.6 Final Remarks Regarding the

Intelligent Diagnostic
The anomaly detection systems and expert systems described in
this paper provide a powerful combination of foresight and insight
Figure 36: A screen from process in-progress of new expert for changes in asset mechanical and electrical integrity.
rule generation
The anomaly detection systems provide early warning of developing
Some organizations will provide services for to design HPP RulePaks equipment issues. They leverage the existing historical data of
dedicated to specific types of hydro generators or installations an asset, which they use to “understand” its normal operating
equipped with special sets of condition measurements - e.g. envelope and to create “personalized” models, which are exclusive
additional XY rotor measurements installed between guide bearings to the specific asset. They can provide weeks or months of early
(Reference 10), air gap magnetic flux, etc. For these situations, a warning, increasing lead time before failures, and allowing the
special tool called “RuleDesk” allows new rules to be designed or asset owners to take proactive measures to prevent or mitigate the
existing rules to be modified. Figure 36 presents a screen of new developing problem. They are typically easy to use, scalable systems
rule in the process of being generated. that do not require deep expertise or equipment knowledge to
manage and understand. As such they fit very well with a variety of
monitoring approaches and proactive maintenance strategies.

6
RulePak software is a system extender to System 1 software. A RulePak is a pre-
configured set of rules designed specifically to perform real-time data validation,
real-time calculations and analysis, and real-time detection of specific events and
malfunctions.

40
 application note
These anomaly detection systems are already being used as part
of smart CMSs that generate not just one but a set of informative
References
measurements for each signal from connected transducers. [1] R. Nowicki, Y. Pappas, INTELLIGENT MAINTENANCE SUPPORT
of HYDRO STATION ASSET MANAGEMENT, Proceedings of
Additional benefit can be provided by using waveforms and more
International Conf. OCT 29-31, 2012, Bilbao, Spain
advanced data available from signal post processing, and
[2] Nowicki R., Monitoring Bearing Vibration with Seismic
additionally, when incorporating process dedicated measurements
Transducers, ORBIT, Vol. 31, No. 2, 2011, p. 78 - 91
into the anomaly detection process. Finally, instrument condition
can be continuously evaluated as well as the condition of the [3] Nowicki R., Thrust Bearing Position Monitoring, ORBIT, Vol. 31,
production assets. No. 1, 2011, p. 52. - 59
The expert systems provide valuable insight through anomaly [4] Nowicki R., Macvaugh R., XY-Measurements for Radial Position
diagnosis for production assets. Available tools allow and Dynamic Motion in Hydro Turbine Generators, ORBIT, Vol.
modernization, optimization and refinement of existing solutions. 30, No. 1, 2010, p. 32
Using such intelligent maintenance support, it is possible to [5] Wiley Ch., March P., Using Proximity Probes to Monitor Seal
accomplish the following goals: Rings, Hydro Review / APRIL 1998, p. 72 -73
• Extend asset life (e.g. runners, generators, transformers), [6] Wegerich S., “Condition Based Monitoring using Nonparametric
• Reduce the probability of catastrophic failures and forced Similarity Based Modeling”, Proceedings, Japanese
outages, Maintenance Society Meeting 2006
• Optimize plant maintainability and, consequently, reduce the [7] Doan D., “SmartSignal* is Now Part of GE – What Does It Mean
cost of operations by optimizing the ratio of unnecessary- to- for You?”, Orbit, Vol. 31, No2, 2011
necessary maintenance expenditures, [8] Kakkar V., Krikorian M. K., Lloyd B., Rasmussen J. R.,
• Mitigate operational risks, and therefore Westmacott A., Whitcomb B.: “The HydroX System”, Orbit,
2004 Q2
– maximize plant availability and
[9] Levis P., Grant J., Evans J.: “Experience with Hydro Generator
– improve plant profitability
Expert Systems, Iris Rotating Machinery Conference”,
• Rapid application of expertise from outside your business Proceedings, JUN 2008, Long Beach, CA, GER-4488
Implementation of such intelligent maintenance support is [10] Nowicki R., Creating smarter condition management system
essential for transition from time-based maintenance to condition- with Trip Multiply functionality, HRW Hydro Review Worldwide,
based maintenance. Nov- Dec 2015, p. 16,18,36
11] Nowicki R., Snyder M., Alarm Management for Hydropower
Plants, Power Engineering, Nov 2015, p. 124…131
[12] Nowicki R., Derani A., ASSET CONDITION MANAGEMENT in a
PUMP STORAGE - HYDRO POWER PLANT, National Meeting,
NOV 2014, BRAZIL onf. presentation: http://www.eletronorte.
gov.br/ opencms/opencms/seminarioTecnico/programacao.
HTM .
[13] Snyder M., 3500/46M Hydro Monitor – Smart Monitoring for the
Intelligent Machine Age, Orbit V34 N1
[14] Nowicki R., MULTI STATE ANALYSIS in CONDITION
MANAGEMENT, ORBIT, Vol. 34, No. 2, 2014, p. 25
[15] HydroX RulePak - Diagnostic Monitoring for Hydro Turbine
Generators, GEA-15031C (10/08)
[16] Snyder M. (6 Oct. 2016). The Lowdown on Vibration
Measurements for Non-Rotating Components of Hydro Turbine
Generators, Orbit Magazine (online).
[17] Applications note “GLITCH” Definition, Sources and Methods of
Correcting.

41
application note
APPENDIX TABLES APPENDIX 2: Technology Discussion
The CM&PS should be implemented into the HPP infrastructure. The
most important are connections with:
Appendix 1: Industry Related Standards i. A Digital Control System (DCS) that is used by operators is
and Guidelines referred to in this document as “DCS.” The DCS can be a Unit
1. API Standard 670 Fifth Edition Nov 2014 Control System or a Station Control System and should have
built-in interfacing providing a 2-way flow of data between the
2. ISO 7919-5:2005 - Mechanical vibration -- Evaluation of machine DCS and CM&PS. Best practices would provide redundancy for
vibration by measurements on rotating shafts -- Part 5: Machine this interface.
sets in hydraulic power generating and pumping plants
ii. If the CM&PS is used for protection of the unit (for example: rotor
3. ISO 10816-5:2000 - Mechanical vibration -- Evaluation of machine vibrations and AIR GAP), then it is strongly suggested to use
vibration by measurements on non-rotating parts -- Part 5: relay outputs, and to organize the wired connection directly from
Machine sets in hydraulic power generating and pumping plants CM&PS to the Emergency Shutdown Device. This is another part
4. CEATI - Hydroelectric Turbine-Generator Units Guide for Erection of DCS and is referred to as the “ESD” in this document.
Tolerances and Shaft System Alignment The ESD can apply different logic (the most frequently applied
a. Part I: Definitions to an HPP is DUPLEX ESD, which can be configured as “1oo2” or
“2oo2” voting logic. Occasionally a SIMPLEX ESD will be applied,
b. Part II: Vertical Shaft Units with Francis Turbines or Reversible
and for large HPPs a TRIPLEX ESD may be applied allowing “2oo3”
Pump-Turbines
protection logic to be applied.
c. Part III: Vertical Shaft Units with Propeller or Kaplan Turbines
To simplify interfacing of a CM&PS with an ESD, the same number
d. Part IV: Vertical Shaft Units with Impulse Turbines of RELAY MODULES should be used in each system - (for example:
e. Part V: Maintenance of Vertical Shaft Units (All types of use 2 relay cards in the CM&PS to interfacing with a DUPLEX ESD,
turbines or pump-turbines) Limit for key parameters each having the same configuration).

5. IEEE 492-1999 - IEEE Guide for Operation and Maintenance of iii. A modern CM&PS can be equipped with dual power supplies.
Hydro-Generators When a CM&PS is used exclusively for condition monitoring, not
protection, then a single power supply is acceptable. However,
6. IEC 60994:1991 - Guide for field measurement of vibrations and when the CM&PS is used for protection of the unit it is strongly
pulsations in hydraulic machines (turbines, storage pumps and advised to use a CM&PS with dual power supplies and to feed the
pump-turbines) power supplies from two independent power sources.
7. IEC 60193 Ed. 2.0 - Hydraulic turbines, storage pumps and pump- A CM&PS used for monitoring and protection with the required
turbines ⎯ Model acceptance tests interfaces is presented in the Figure 37 below:

Figure 37: Typical CM&P Interfacing

42
 application note
The figure above shows all the dedicated measurements for not be enough, therefore, similar measurements may be grouped
preventative condition monitoring and protection connected to together in racks providing an advantage in correlation of the
one rack. It is possible to use several racks dedicated to various measured variables; i.e. a rack may be dedicated to temperature
measurements: for example [i] temperature monitoring, [ii] Air measurements.
Gap monitoring, [iii] vibration monitoring, and so on). However, On the other hand, several smaller HTGs that need a lesser number
if the objective is to implement predictive maintenance, now of transducers for their CM&P system, can be aggregated one rack
or in the future, it is advantageous to have all the necessary of a CM&PS, see example below:
measurements connected to one multichannel rack if possible. A
high density modern CM&PS will allow forty or more transducers An example of such aggregated solution is presented in Figure 38:
to be connected to one rack. For some HTGs forty transducers may

Figure 38: Typical interface of a CM&PS for several smaller HTG’s

43
application note
A CM&PS shown in Figure 38 can accommodate up to four HTGs. a two-way interface providing diagnostic system data and/or
recommendations to operators, instrumentation staff, managers
To implement a HTG predictive maintenance strategy, the CM&PSs
and diagnosticians concerning the operating conditions of the
must be capable of being interfaced with a diagnostic system. Most
HTG and associated monitored assets. The diagnostic system also
diagnostic systems allow several machines to be connected to one
receives process and environmental data from the DCS that is used
diagnostic server.
to perform correlation analysis such as Multistate Analysis.
Figure 39 shows an enhancement of the systems in the previous
Consequently, the diagnostic system can provide a superior level
figures by implemention of a diagnostic system. The diagnostic
and quality of information on the operating condition of the assets.
system is normally interfaced to multiple racks containing
CM&PS and is also interfaced to the DCS. The DCS interface is

Figure 39: An Example of interfaces for a Diagnostic System

44
 application note
APPENDIX 3: CEATI Tolerances for Air Gap Monitoring

Min. Air Gap Minimum Air

Stator Stator Rotor Rotor
Intervention Gap Critical
Circularity Concentricity Circularity Concentricity
Value Value
Erection Tolerances (Based 8% of Nominal 5% of Nominal
on all readings calculated design air design air 8% of Nominal
separately)1 gap (1.5 mm gap (1.0 mm design air gap
maximum) maximum)
Erection Tolerances (Based
1.2% of
on average of top and 6% of Nominal
Nominal design
bottom readings at each design air gap
air gap
location)1
Operating Tolerances (Top 5% of Average
20% of Average 15% of Average 12% of Average 5% of Average 50% of Average
& Bottom Separately)2 air gap 70% of
air gap air gap air gap air gap air gap
Average air gap
Operating Tolerances 10% of Average 2.5% of Average
(Average of Top & Bottom)2 air gap air gap
Notes:
1) CEA Technologies Inc. (CEATI), (May 1989), part II - Vertical Shaft Units with Francis Turbines or Reversible Pump-Turbines, Hydroelectric Turbine-
Generator Units Guide for Erection Tolerances and Shaft System Alignment, Tables 7A and 8A.
2) CEA Technologies Inc. (CEATI), (May 1998), part V - Maintenance of Vertical Shaft Units (All types of turbines or pump-turbines), Limit for key parameters,
Hydroelectric Turbine-Generator Units Guide for Erection Tolerances and Shaft System Alignment, pp. 54, 59-61.

45
application note

46
application note

47
Baker Hughes, a GE company
1631 Bently Parkway South
Minden, NV 89423
24/7 customer support: +1 281 449 2000

bhge.com

*Trademark of Baker Hughes, a GE company.

© 2017 Baker Hughes, a GE company, LLC – All rights reserved.

Baker Hughes, a GE company, LLC and it affiliates (“BHGE”) provides this information on an “as is” basis for general information purposes and believes it to be accurate as of the date of publication.
BHGE does not make any representation as to the accuracy or completeness of the information and makes no warranties of any kind, specific, implied or oral, to the fullest extent permissible by law,
including those of merchantability and fitness for a particular purpose or use. BHGE hereby disclaims any and all liability for any direct, indirect, consequential or special damages, claims for lost profits,
or third party claims arising from the use of the information, whether a claim is asserted in contract, tort, or otherwise. The Baker Hughes, a GE company, the GE monogram, Bently Nevada, System 1,
Keyphasor, Proximitor, Velomitor, RulePaks, HydroX, Bently PERFORMANCE SE, ADRE, SPEEDTRONIC, and SmartSignal are trademarks of the General Electric Company.”. MAXIMO*, ORACLE*, and SAP*
are trademarks of their respective owners.

GEA33306 (11/2017)