ProvibTechsApplicationNote_PowerGeneration

Application_Hydro Turbine
Greenpowerisplayinganimportantrolenowadaysasitsnonpollutionandlongtermpowersupply fromnature.Hydropowerisoneoftheimportantpartastheelectricpowerisgeneratedbythe waterfromthenaturewhichiscontinuousandbigquantity.ProvibTechisabletosupplyavibration protectionandconditionmonitoringsystemforhydroturbineswithdifferentcapacity.

ApplicationLayout
ThislayouthasaclearbutsimpleintroductionaboutthemainmeasurementpointsforHydro Turbine.

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 ProvibTechsApplicationNote_PowerGeneration Condition Monitoring System_Hydro Turbine

Velocity Sensor.TM0793V

Accelerometer.TM0782A

RTD/TC Sensor(by other supplier)

DAQ Card 6220

Transient/Dynamic

PCM360 SYSTEM
Proximity probe.TM0180 V for shaft radial vibration P for shaft axial position K for phase reference Air Gap Sensor.(by other supplier) Partial Discharge Coupler.(by other supplier)

Modbus RTU(static signal)

Modbus RTU

91

Power Supply

Partial Discharge Monitoring System

Power Supply
30 1 75 2 10 3 10 4 20 5 40 6 7 8

PT2060

P A

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P P

 ProvibTechsApplicationNote_PowerGeneration

ProvibTech Products
Transducers
TM0180
TheTM0180(8mm)isdesignedforlonglifecyclesandaresuitableforharshenvironments. ProvibTechrealizesoneofthemostsignificantproblemsinproximityprobeinstallationsareground loopsandlossofisolationdueto damagedcablejackets.ProvibTechs customruggedcablejacketprevents theprobecablefrombreakingand tearingandishighlyresistiveto corrosiveenvironments. TheTM0180probeandTM0181(extensioncable)areequippedwithastandardprotectiverubber boot,whichcoverstheconnectorsandpreventsoilanddirtpenetration. TheTM0180seriesprobescomein0.5mand1.0mcablelengths,aswellas,speciallengthsof5.0m and9.0mwithanintegratedprobeandextensioncabledesign. TheprobemaybeselectedinEnglishormetricunits,aswellas,reversemountingoptions.Reverse mountprobesareusedwithTM0393Xprobehousingsforhazardousareas. Withupto2mm(80mil)linearrange,TM0180isgenerallyappliedforradialvibration,thrustposition, rotationspeed,eccentricityandphasereference.ItisfrequentlyusedwithProvibTechsextension cableTM0181anddriverTM0182andreverseprobehousingTM0393X.

TM0110
The11mmprobehasupto4mm(160mil)linear range.TheTM0110probeisrecommendedwhena longerlinearrangeisrequired.TheTM0110proximityprobesystemisdesignedtomeetAPI670 industrialstandard. TM0110isgenerallyappliedforthrustposition.Itisfrequentlyusedwith ProvibTechsextensioncableTM0181anddriverTM0182.

TM0120
The25mmprobehasupto12mm(470mil)linearrange.Theprobeis
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 ProvibTechsApplicationNote_PowerGeneration designedformeasuringdifferentialexpansion.TheTM0120integratestheprobe,extensioncable andthedriverintooneunit.Thisintegralproximityprobeisdesignedforeasyfieldinstallation. TheTM0120probecomesinlengthsof1m,5mand9mstandardcable(2conductorshieldedcable).

TM0793V/TM0782A
TM0793Viswithsensitivity4.0mV/mm/sec(100mV/in/sec).TM0782A iswithsensitivity100mV/g.TM0782AandTM0793Varepiezoelectric accelerometer/velocitytransducerdirectlyinterfaceswith ProvibTechssignalconditionersPT2060,DTMs,DM200orTR1101.

TM0602
Forsteamturbineapplications,therelativecaseexpansionduetothermaleffectshouldbe monitored.Caseexpansionisthethermalgrowthofthemachinecaseasitexpandsduringmachine startupandonlineoperations.TheTM0602istypicallymountedonthefoundationattheopposite endfromwheretheturbinecasingisattachedtothefoundation.Thecaseexpansiontransducer systemprovidesinformationonthegrowthofthemachinecaserelativetothefoundation. LVDTs(linearvariabledifferentialtransformers)areusedtomeasurethecaseexpansion.Three differentlinearrangesareavailable:25mm(1.0), 50mm(2.0)and100mm(4.0).Thecase expansiontransducerassemblyconsistsofanLVDT thatishousedinaweatherproofprotective enclosure.

Monitors
PT2060/10/20/31/35/40/43/53/91/96/98/90/99

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 ProvibTechsApplicationNote_PowerGeneration

Proximity Module (4 channels) z z z Radial vibration Axial/ Thrust position Eccentricity Differential expansion Low-frequency vibration Speed output Zero speed and speed Reverse rotational protection output

PT2060/10

z z z z z

Seismic Module (4 channels) z z Acceleration, Velocity and Displacement Low Frequency acceleration, Velocity or Displacement Case Expansion Case expansion outputpaired Case expansion outputsingle

PT2060/20

z z z

Temperature Module(8 channels )

PT2060/31

RTD, TC

Process Input Module

PT2060/35

16 channels per module

Relay Module(16 channels)

PT2060/40

Relay output (SPDT)

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 ProvibTechsApplicationNote_PowerGeneration
Redundant Relay Module(8 channels)

PT2060/43

Relay output(DPDT)

Over Speed Module(1 or 3 channels) z z z z Over-speed protection The following function only for channel 3 and channel 4. Radial vibration: monitoring shaft vibration, single or dual XY Axial/ Thrust position: monitoring shaft thrust position, with 5mm, 8mm, and 11 mm proximity probes Eccentricity Differential expansion Low-frequency vibration Speed output zero speed Reverse rotational protection output

PT2060/53

z z z z z z

System Interface Module z z Connect to a configuration station Communicate to PT2060 system racks Communicate to other control systems (PLC/DCS or Historian) Provides two phase references channels Provide storage of system and alarm events

PT2060/91

z z z

Display Module z z z ID each channel, and arrange the routing Setup data collection strategy Display machine photo and real-time data and status on top of the photo Real-time bar graph/ status list/ alarm status of each channel Alarm events Trend plot on each channel Touch-panel for easy operation Network to control systems (PLC/DCS or Historian) via Modbus

PT2060/98

z z z z z

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 ProvibTechsApplicationNote_PowerGeneration
Power Supply Module

PT2060/90

Redundant Power supply

PT2060/99

Standard 19 or 12 rack

DTM10/DTM20/DTM96

DTM10301 ProximityDistributedTransmitterMonitor. Withinternaldriver,forRadialVibration DTM10302 ProximityDistributedTransmitterMonitor. Withinternaldriver,forAxialPosition DTM10502 ProximityDistributedTransmitterMonitor. Withinternaldriver,forRotationSpeed/PhaseReference DTM10201 ProximityDistributedTransmitterMonitor. Withexternaldriver,forRadialVibration DTM10202 ProximityDistributedTransmitterMonitor. Withexternaldriver,forAxialPosition

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 ProvibTechsApplicationNote_PowerGeneration DTM10501 ProximityDistributedTransmitterMonitor. Withexternaldriver,forRotationSpeed/PhaseReference DTM20101 SeismicVibrationDistributedTransmitterMonitor. Runwithcurrentmodeaccelerometerwith100mV/g,velocitysensorwith 4mV/mm/sorseismicvelocitysensor DTM96 Communicationmodule.Opticalisolated,RS485,RS422,RS232

PCM360 Online Condition Monitoring System

IntroductionofPCM360
ProvibTechsPCM360isamachine conditionmanagementsystemthatcollects, stores,analyzesandiscapableof transmittingmachinestatusmonitoring informationoverlocalorwideareanetwork. ThePCM360providesstatic,dynamicand transientdatacollectionandanalysis;such asgraphicalindicationofvibrationlevel, trend,waveform,spectrum,bodeplots, cascadeplotsandmuchmore. AllProvibTechsmonitorsandtransmitters canquicklyandeasilybeintegratedtouploadmachinestatusanditsdynamicdatatothePCM360. ThePCM360obtainsbothcriticalmachineryrunningstatusandbalanceofplantrunningstatus. Additionally,thePCM360collectsprocessdataas420mAinputordigitalmonitorinputviaModbus, etc.ThePCM360providesanintegratedsystemsolutionforassetmanagementresultinginatotal solutionformachinemaintenance and protection.

LeadingFeaturesofPCM360
z z z z z Integratesplantconditionmonitoringandprocessdataintoonedatabase Userfriendlyinterfaceforinstantdataanalysiswithminimaltrainingrequiredoffieldstaff Maximumflexibilityandexpandabilityofthesoftwaresystemwithobjectorientedmodular design Transient,dynamicandprocessdatacollection BuiltonMicrosoftSQLServerdatabasetoassurebetterdatamanagementandreliable networking
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 ProvibTechsApplicationNote_PowerGeneration z z z z z z z Client/Serverarchitectureenablesusertoaccessdataanywhereonintranet/internet Readilyintegrateswiththirdpartyvibrationmonitorsandprocessmonitorswithminimum hardwarerequirements MultipledigitalI/OProtocols,suchasModbusRTU/TCP Multiplehardwareoutputmodulesreadyforfurtherdatatransferandannunciationinrelays andcurrenttransmission 24hournotificationthroughonsitealarms,operatorinterfaceandevenSMSmessagingon GPRSmobile RemotenotificationwithSMSmessagestoanycellularphonewithmachinerunningstatus Advancedpostprocessingoftransientdataminimizesdataloss,maximizinganalysiscapability

PCM360DataFlowIntroduction
Inadditiontorunningwellwithtransmitters/monitorsofProvibTechitself,withgreatintegrate abilityandversatileinterface,PCM360isalsoabletointerfacewithdiversetransmitters/monitors /sensorsor ModbusTCPServerorOPCserverfromthirdpartywhichtakesgreatconveniencefor retrofitprojectsandmakestheplantmanagementmoreefficientandeffectivelywithoutspending muchmoney. Apartfromthese,PCM360alsocanplayaroleasModbusTCPServerorOPCServerwhichmakes interfacingwiththirdpartyconditionmonitoringsystemavailable. Inconclusion,PCM360isveryflexibleandfunctional.Withitsreliability,itnotonlycanacquirethe datafromthirdpartybutalsoshareitsdatawiththirdparty.

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 ProvibTechsApplicationNote_PowerGeneration

PlotsSupportedByDifferentMeasurementPoints
MeasurementPoint Device Type Channel Type DataType Single Channel Dual Channel bargraph,waveform,spectrum, DAQ Card: 6013, 6220,6 250 Dynamic Acceleratio n,Velocity data, Transient data bargraph,waveform,spectrum, fullspectrum,shaftXYvibration, bode,polar,cascade,fullcascade, 9 (dynamic,transient)waterfall, (dynamic,transient,historical)trend, statuslist,alarmlist,transientlist bargraph,waveform,spectrum, bode,polar,cascade, waveformwithDCcoupling, 9 (dynamic,transient)waterfall, Dynamic Vibration[f romProx] data, Transient data (dynamic,transient,historical)trend, statuslist,alarmlist,transientlist statuslist,alarmlist,transientlist 9 bode,polar,cascade, (dynamic,transient)waterfall, (dynamic,transient,historical)trend, PlotsandLists

bargraph,waveform,spectrum, fullspectrum,shaftXYvibration, shaftcenterline,

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waveformwithDCcoupling, shaftXYvibrationwithDCcoupling,

 ProvibTechsApplicationNote_PowerGeneration bode,polar,cascade,fullcascade, (dynamic,transient)waterfall, (dynamic,transient,historical)trend, statuslist,alarmlist,transientlist Position[fr omProx], Process Acceleratio Modbu sDAQ for Proces s n,Velocity, Vibration[f romProx], Position[fr omProx], Process bargraph,waveform,spectrum, 9 Modbu sDAQ forDW Dynamic data,Static data fullspectrum,shaftXYvibration, 9 dynamicwaterfall,alarmlist, (static,dynamic)trend,statuslist Acceleratio n,Velocity, Vibration[f OPC Client romProx], Position[fr omProx], Process Staticdata 9 statuslist,alarmlist bargraph,statictrend, 9 bargraph,waveform,spectrum, dynamicwaterfall,alarmlist, (static,dynamic)trend,statuslist Staticdata 9 statuslist,alarmlist bargraph,statictrend, Staticdata 9 9 statuslist,alarmlist 9

bargraph,statictrend,

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 ProvibTechsApplicationNote_PowerGeneration

Plots

Waveform plot (realtimeandhistorical) plotwithDCcoupling (realtimeandhistorical)

Waveform

Spectrum plot(realtimeandhistorical) spectrumplot(realtimeandhistorical)

Full

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 ProvibTechsApplicationNote_PowerGeneration

ShaftXY vibration (realtimeandhistorical) vibrationwithDCcoupling (realtimeandhistorical)

ShaftXY

Trendplot plot (static,dynamic,transient,historical,andrealtime,gap) (dynamicandtransient)

Waterfall

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 ProvibTechsApplicationNote_PowerGeneration

BarGraph centerlineplot(realtimeandhistorical)

shaft

Bodeplot plot

Cascade

Full cascadeplot

Polarplot

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 ProvibTechsApplicationNote_PowerGeneration

Shaftcenterlinemodeshape ShaftXYvibrationmodeshape

Lists

Transientlist Alarmlist

Statuslist

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 ProvibTechsApplicationNote_PowerGeneration

Measurement Illustration
ShaftX,YVibration(RadialVibration)
ShaftX,YVibrationisforshaftdynamicmotion whichisgenerallymeasuredinadirection perpendiculartotheshaftaxis,itisalsocalled radialvibrationorlateralvibration.Itisindicated byPKPKwithunitmorMil.5mmor8mm proximityprobesareoftenusedtoobserveShaftX, YVibration.ProvibTechsproximityprobe TM0105(5mm)andTM0180(8mm)willsupply completesolution. PleaserefertotheFigure1.1andFigure1.2.Theyareshowingthetypicalwayforprobeinstallation forRadialVibration. ApartfromtheinstallationwayofFigure1.1and Figure1.2,theresanotherinstallationway,please refertoFigure1.3.ProbeXishorizontallyinstalled andProbeYisverticallyinstalled. Sometimes,proximityprobeswillbemounted insidethemachinebyprobeclamp,andsometimesprobeswillbemountedwithhelpofprobe holder.ProvibTechsTM0393Xsupplyaverycost effectivesolutionformountingtheproximityprobes forthesemachineswhateverfornormalpressureor highpressurepurpose.Customercanreplacethe probewithoutopeningthemachinecasewhichtakes greatconvenienceandsavelotsoftimeand maintenancecost.Adjustablepenetrationdepth +/13mm(0.512)makestheinstallationveryflexible. PleaserefertoFigure1.4andFigure1.5for installationreference.
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 ProvibTechsApplicationNote_PowerGeneration

ThrustPosition(AxialPosition)
ThrustPositionistomeasurethemovementofshaftin theaxialdirectionwithrespecttosomefixedreference. Typically,thereferenceisthethrustbearingsupport structureorothercasingmembertowhichthe displacementprobeismounted.Theprobeisgenerally toobservethethrustcollardirectlyoraxialshaftsurface. ThrustPositionisalsocalledAxialPosition,anditis indicatedbyaveragewithunitmorMil.5mmor8mm proximityprobes areoftenusedto observeThrustPosition.ProvibTechsproximityprobe TM0110(11mm)andTM0180(8mm)willsupplycomplete solution. DueThrustPositionisveryimportantforsomeessential machines,itisstronglyrecommendedtousedualproximity probestomonitorThrustPositionastheredundancywill increasethereliabilityofthemonitoring. PleaserefertoFigure2.1andFigure2.2.

SeismicVibration(CasingVibration)
SeismicVibrationmeasurestheabsolutevibrationofmachinecaseorstructure.Thismeasurement doesntrequireotherobjectspositionormovementasareference.Accelerometersandvelocity sensorsareoftenusedforSeimicVibration.ItisalsocalledCasingVibration.Itwillbeindicatedby PKorPKPKorRMS. Theinstallationdirectioncouldbehorizontalorvertical.PleaserefertoFigure3.1.
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 ProvibTechsApplicationNote_PowerGeneration

RotationSpeed
Rotorspeedisimportantmeasurementsduringnormalmachineoperatingconditionsaswellas duringstartupandcoastdown.Suddenunexpectedchangesinrotorspeedmaybeanindicationof machineryorprocessmalfunction.

OverSpeed
OverSpeedprotectionsystemismandatoryforcriticalmachinesespeciallylikesteamturbines.Due therotationspeedforthesteamturbineisthemostimportantfactor,sogenerallyweusetwo proximityprobesorthreeproximityprobestocomposeasystem.Itcouldbe2outof 2or2outof 3.

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 ProvibTechsApplicationNote_PowerGeneration

ReverseRotation
Forboilerfeedpumporsomemachines,ReverseRotationmonitoringisnecessaryasthereverse flowwillcausethetotalmachineshutdownfinallystopwatersupplying.TypicallyReverseRotation requirestwoproximityprobestomountonthegearorshaftwithanotch.Pleaserefertobelow Figure6.1fordetails.

ZeroSpeed
Whenthesteamturbineormachineisunderturningstate,therotationspeedshouldnotbevery slow.Ifitrotatesslowerthanitshouldbe,thenitwilltrip.ZeroSpeedissimilarlikespeed monitoring,butSpeedmonitoringistotripwhenitrotatetoofastthanitshouldbe,andZeroSpeed monitoringistotripwhenitrotatetooslowthanitshouldbe.

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 ProvibTechsApplicationNote_PowerGeneration

PhaseReference
PhaseReferenceisatransducerthatproducesavoltagepulseforeachturnoftheshaft.Thissignal isusedprimarilytomeasureshaftrotativespeedandservesasareferenceformeasuringvibration phaselagangle.Typicallyproximityprobe,magneticpickup,opticalpickupareusedformeasuring PhaseReference. PleaserefertobelowFigure7.1fordetails.

DifferentialExpansion
DifferentialExpansionistomeasuretheaxialpositionoftherotorwithrespecttothemachine casingatsomedistancefromthethrustbearing.DifferentialExpansionisusuallymeasuredwhen machinestartupandshutdownasthemachinehasabigthermalexpansionduringthatperiod. Themeasurementistypicallymadewithaproximityprobetransducermountedtothemachine casingandobservinganaxialoftherotor. Theproximityprobecouldbemountedbytwoways.Oneisbynormalshaftdirection,pleaserefer tobelowFigure9.1.

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 ProvibTechsApplicationNote_PowerGeneration

Anotherwayismountedbyrampshaftdirection.PleaserefertobelowFigure9.2.

CaseExpansion
CaseExpansionistomeasureaxialpositionofthemachinecaserelativetoafixedreference,usually thefoundation.Changesincasingaxialpositionaretheresultofthermalexpansionandcontraction ofthecasingduringstartupandshutdown.ItisgenerallymeasuredbyLVDT(LinearVariable DifferentialTransformer). PleaserefertobelowFigure10.1forCaseExpansion.

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 ProvibTechsApplicationNote_PowerGeneration

Eccentricity
Eccentricityisveryimportantformonitoringturbinerotorbow.PT2060/10PROXproximitymodule canprovidesophisticatedonlineeccentricitymonitoring.Themonitorissuitableforvirtuallyall typesofrotatingmachineryintermsofeccentricity.ThePT2060/10PROXproximitymodulewillbe continuouslymeasureandmonitoringinuptotwochannelspermodule.

Eccentricitymeasurementsindicatethedeviationoftherotorphysicalcenterandthetheoretical center.Thedifferencehastobesmallenoughtoallowmachinestartupwithoutcausingdamage. ThePT2060/10PROXproximitymoduleprovidespeaktopeakeccentricitymeasurement,which measurethedifferencebetweenthepositiveandthenegativeextremesoftherotorbow.Italsohas onemorechannelthatoutputthepositionoftherotor.

Operatorsuseeccentricitymeasurementstodeterminewhenacombinationofslowrollandheating havereducedtherotoreccentricitytothepoint wheretheturbinecansafelybebroughtupto speedwithoutdamagefromexcessivevibrationor rotortostatorcontact. EccentricityisthemeasurementofRotorBowat rotorslowrollwhichmaybecausedbyanyora combinationof z z z Fixedmechanicalbow Temporarythermalbow Gravitybow

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 ProvibTechsApplicationNote_PowerGeneration

ValvePosition
ValvePositionistomeasurethepositionoftheprocessinlet valvesonamachine,usuallyexpressedasapercentageof thevalveopening;zeropercentisfullyclosed,100percentis fullyopen. PleaseseebelowFigure12.1forValvePosition.

Temperature
Temperaturemonitoringisalsoanimportantparameterto monitorthemachinehealthstatus.Whensomethingwrong insidethemachine,itwillcausemorefrictionwhichwillcausetemperaturegettinghigher.Typically welluseRTD/TCsensortoacquiretheprocesssignalandtransfertotransmitters/monitors,finally transfertoconditionmonitoringsystem.

FlowRate,Pressureandotherprocessvariables
Alltheseparametersareliketemperatureastheyareprocessvariables,andthesearetocontrol somethingorfeedbackthehealthstatusofthemachine.Typicallywellusedifferentkindsof sensorstogettheprocesssignalsandfinallytransfertoconditionmonitoringsystem.

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