INSTALLATION OF BLADE VIBRATION MONITORING SYSTEM IN LP TURBINE OF UNIT-6, 500MW NTPC KSTPS KORBA

V.Veerapandi Sr.Manager/ Ser BHEL-PSWR Nagpur E-mail :vpandi@bhelpswr.co.in

Introduction
Continuous availability of steam turbine in a power plant directly related to its performance under all the operating conditions. In the recent past Low Pressure Turbine free standing stage blades failure experienced in many of large capacity steam turbines. Statistics shows that LP Turbine free standing blades are more susceptible to failure compared to those of HP & IP Turbine blades. The operational risks associated with high-cycle fatigue failures as well as other failure like stress corrosion cracking, blade root failure etc can be effectively monitored by the use of a non-contact Blade Vibration Monitoring System (BVMS) where the health of each blade can be assessed during actual running of a turbine. The BVMS was successfully implemented by BHEL corporate R&D with PSWR assistance at NTPC Korba Unit-6, 500MW LP Turbine during the capital overhaul in January 2011. This report embodies the testing methodology and details of various activities implementation at site.

Testing methodology
In a rotating system, the eddy current sensor is mounted directly above the tip of the blades with its surface normal to the direction passing through the rotating centre as shown in Figure.1 (a). The eddy current sensors generate analog pulses each time a blade passes in front of them. Through a suitable circuit, a positive or negative voltage peak corresponding to the arrival of a blade can be measured. All blade movements can be inferred by the measurements of their elapsed time. Comparing the arrival time and the amplitude of these voltage peaks as shown in Figure.1(b), the movement of blades can be derived. This kind of signal indicates the interval time between two blades and offers information on rotating speed, and on anomalous horizontal displacements including vibration signals. Figure.1 (c) illustrates different amplitudes of blades. This kind of signal can reflect the change of clearance between sensor coil and the tip of blade and can offer the information on the creep through long-term trend of turbine blade length, FOD (Foreign Object Damage) of the blade, and shifts in resonance blade looseness, initiation of crack etc.

Preamplifier

Amplitude Volts

Eddy current sensor Data System Acquire Blade Data Analyze Blade Vibration Monitor Time Figure.1 (b)

Amplitude Volts Rotor Figure.1 (c) Figure.1 (a)

Installation of BVMS components at site Eddy Current Sensor

Five (5) Nos eddy current sensors are mounted circumferentially in different angle on the LP Turbine diffuser top half (Turbine End) by drilling and welding of sensor holder. Figure.2 (a), 2(b),2(c) and 2(d) illustrates mounting of eddy current sensor in the LP turbine diffuser and blade tip postion.

Figure 2 (a) Sensor Holder

Figure 2 (b) Holder with sensor

Figure 2 (c) Sensor in LP Turbine diffuser

Figure 2 (d) Sensor & LP blade tip position

Eddy Current Preamplifier

The eddy current preamplifier was installed in LP Turbine outer casing front side wall. The sensor cables (Five nos) were routed from inner-outer and outer casing through air tight cable gland as shown in Figure.3 (a) & 3 (b) which implements pre-amplification for eddy current sensor. It can also act as a signal repeater for longer spans of cabling to the data console.

Figure 3 (a) Cable gland in LP outer casing

Figure 3 (b) Preamplifier

Data Acquisition Console & Acquire Blade Data

The data acquisition console installed at unit control room as shown in Figure 4 (a) takes the analog signals from the preamplifiers and turns them into timing data as shown in Figure.4(b), which can be interpreted into useful information.

Figure 4 (a) Data Acquisition Consol

Figure 4 (b) Multiple screen captures from Acquire Blade Data software.

Salient features of the system

Campbell diagrams are generated during every coast down and coast up of the unit, which will establish the integrity of all the last stage blades. Dynamic condition of all the last stage blades are continuously monitored and recorded to enable their health assessment and diagnosis of faults at incipient stages. BVMS can be used for increasing the plant availability and reduce unplanned shutdowns. Availability of BVMS will lead to the development of Prognostic Health Monitoring System of steam turbine.

Advantages of BVMS
Detection of crack prior to failure Minimizing downtimes of Machine Increasing life cycle Reducing liability risks.

Conclusion
BVMS system is in service at various capacity of Gas turbines & Wind turbines but it has not been installed in Steam Turbine anywhere in India. The BVMS was installed first time in India at NTPC KSTPS Korba Unit-6, 500MW LP Turbine. The system is working fine and continuous data acquire is in progress. There is also a provision for remote monitoring of the dynamic condition of the last stage blades through BHEL intranet.

References: 1. Presentation on Blade Vibration Monitoring System by Dr.A.D.Baone & Mrs.Mani Kumari ,BHEL corporate R&D. 2. 3. BVMS Application Notes, Hood Technology website:www.hoodtech.com Eddy current displacement sensor with LTCC technology by Yuqing Lai.