LESSON

8
LECTURE
TURBINE SUPERVISORY
INSTRUMENTATION
SUB - OBJECTIVE
At the end of the lesson the Tranee !ll "e a"le to de#onstrate an $nderstand the
T$r"ne S$%er&sor' Instr$#entaton(
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,(3 TURBINE SUPERVISORY INSTRUMENTATION
Turbine supervisory instruments are used to monitory the operation of the turbine.
To use this instrumentation, it is necessary to understand what the instrument is
recording so that proper interpretation of the charts and graphs will result.
Regardless of the size of the turbine unit, the basic ideas underlying turbine
instrumentation are the same. or purposes of clarity, the e!amples discussed here
will be ta"en from smaller units #up to $% &' range(.
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The following systems are used for monitoring6
5. +ibration
7. .hell E!pansion
8. *ifferential E!pansion
9. .hell temperature
:. .hell 3ressures
$. +alve 3osition
;. Thrust 3osition
VIBRATION
)ll rotational e<uipment vibrates at some operating fre<uency or running fre<uency.
The causes of vibration are discussed below, along with information related to its
nature and detection.
MEC4ANICAL UNBALANCE
+ibration is the product of the a periodic driving stimulus and the response of the
associated rotors and structures to this stimulus. ) reduction in vibration can be
accomplished either by reducing the stimulus, or by reducing the response. 'hile
the response of various rotor types to such stimuli will vary considerably with
geometry, the relative variation 0 the response of structures is even more notable.
Unbalance, the most common vibration stimulus, may be reduced directly by
balancing. Rotors are unbalanced when they are forced to run about centers that
are not coincident with the center of the mass. ) hypothetical rotor, spinning freely
in space, will naturally rotate about its center of mass and will therefore run in a
perfectly balanced state. The machined =ournals will not necessarily run perfectly
true in this circumstance, but they are necessary to provide bearing surface for
weight support, and for accurate physical location of the rotor. Efforts must
therefore be made to bring the mass center as close as possible to the center of
these =ournal surfaces. This process, called balancing, is accomplished by adding
small weights to the rotor and changing the location of the center of mass to ma"e it
coincide with the rotational center.
Temporary unbalances are especially annoying because they produce vibrations
under certain conditions of temperature, speed, or load which can not be
permanently corrected by the addition of balance weights. These temporary
unbalances are usually due to temporary rotor bows which may be caused by
stationary pac"ing rubbing on the rotor, by non>uniform heat transfer into the rotor
periphery, uneven removal of the heat from windings, and so forth. 0t is important to
design turbine casings so that temperature distortion will not occur, and pac"ings
with sufficient clearance to minimize the rubbing interference which some times
causes very large unbalances to develop in a short period of time.
0t is e<ually important to provide even heat transfer surfaces between shrin" fits,
even ventilation of generator fields and to prevent other sources of uneven
temperature and conse<uential bowing. ,early all rotors change vibration
characteristics to a measurable degree over the operating load and temperature
ranges.
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&inute changes in balance due to e!pansion and contraction of the parts are
displayed with great amplification as running vibrations that are easily measured
with modern instruments. 0n general, changes in vibration amplitude over the
operating ranges should not be considered abnormal when these changes are less
than about :% percent of the low base or residual value of vibration.
RUBBIN5
There is seldom any value in attempting to balance a unit which is rubbing. There
have been many cases where a great deal of effort has been wasted in trying to
balance where this was the predominant difficulty. Rubbing by pac"ing or defectors
causes localized heating on the shaft surface. Circumferential temperature
gradients develop, because the rub is usually more severe on one side of the shaft
and the rotor gradually bows toward the hot spot.
Rubbing by spill strips on buc"et covers does not produce vibration symptoms,
although it can be very destructive.
MISALI5NMENT
1alancing is of little value in reducing vibration which is primarily caused by
misalignment. &isalignment should be suspected as a cause when there is
evidence of oil whipping, vibration instability, apparent change in the critical speed
range, unusual and e!ceptionally high critical speed vibration or where the critical
speed vibration occurs over a very wide range, say over :%% rpm.
&isalignment in itself, produces little vibration stimulus unless it is severe enough to
unload bearings to the point of oil whip. 'hen this is the case very large shaft
amplitudes will clearly identify the whip. &isalignment may significantly change the
vibrational response characteristics to the e!isting unbalance stimulus. 0n some
instances, for e!ample, the stationary vibration levels of the last turbine bearing
have been mar"edly improved by small alignment changes to the generator which
did not affect either the stimulus or the shaft vibration.
OIL 64IPPIN5
-il whipping is caused by an unstable oil stimulus in the bearing oil film that
develops as a comple! function of =ournal peripheral speed, oil viscosity, bearing
shape, radial bearing load, and =ournal attitude angle. &isalignment can contribute
to whipping by changing bearing loading.
Usually the oil whip will appear and disappear suddenly as operating conditions
change. The resulting amplitude of shaft vibration is usually very high, 5% 5: mils,
and most of the displacement will occur at near half running speed fre<uency. 0n
8$%% rpm units, whip has clearly been observed at fre<uencies varying from 59%% to
77%% cpm with different types of rotors.
-il whip instability develops when the pressure oil wedge develops a lifting force
greater than the weight of the =ournal, causing it to lift momentarily for relief.
Repeated periodically, this effect is self amplifying, especially in the presence of a
rotor resonance near half running speed fre<uency. The resonant fre<uency will
often determine the whip fre<uency in these cases.
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T4ERMAL INSTABILITY
There are a large number of causes of thermal instability. )mong them are heat
sensitivity of the shaft, water or oil in the shaft bore, uneven heat transfer between
rotor parts, loose wheels or pin bushings, other loose or poorly fitted parts, un>
symmetrical ventilation, and short>circuited turns in field coils. 0n general, it may be
said that thermal instability is characterized by mar"ed changes in vibration as
operating conditions vary. These vibrations will nearly always e!ist at running speed
fre<uency.
Change sin load, steam conditions, field temperature, or other variables may cause
a gradual change in overall vibration level. ) large variation in operating conditions,
one change at a time if possible, is useful in diagnosis of these phenomena.
CRITICAL SPEE/S
) ?critical speed@ of a rotor is the speed which corresponds to its natural fre<uency
of vibration or the speed at which it is resonant.
3ractically all large turbine>generator rotors run above the first critical speed, and
many run above the second critical ig. 2>;>7. &any times, of course, the rotors are
so well balanced the critical speed is not readily noticeable.
VIBRATION AS A )UNCTION O) /ISPLACEMENT VS( TIME
Turbine vibration is measured in displacement against time as shown in ig. 2>;>8.
'here displacement is the distance between fre<uency loops #distance against
time( fre<uency is the total time used to ma"e one complete vibration swing from
the high side to the low side of the time line.
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VIBRATION P4ASE AN5LE
The phase angle relationship is the unbalance point on the rotor in reference to
some spot on the rotor. 'e can put a magnetic plug or tee piece in the rotor and
use an electronic probe to pic" this reference point up. The impulse caused by the
plug passing under the probe can be aligned with the highest amplitude or
displacement of the vibration probe to give us a phase angle. This phase angle will
show the angle or distance in the time that the ?high spot@ and the plug location in
the rotor have in relation to one another. .ee fig. 2>;>9, which illustrates a phase
angle of 7$9A #8$%A > B$A(.
Loo"ing at the cross section of the rotor would provide the view shown in ig. 2>;>:.
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The phase angle of vibration meter is used to permit operators to easily monitor the
phase angle as well as the amplitude #size( of vibration. .uch information is
particularly useful for plotting trends in balance and for a more complete
understanding of vibration patterns. 0t also improves the accuracy and speed of any
balance ad=ustments that must be made.
The phase meter compare the phase of the vibration signals from various shaft
pic"ups with the angular position of a pulse from the phase reference generator.
The meter reads the specific angle between the ?positive direction crossing ? of the
pulse and the vibration signals. The phase reference generator is a small magnetic
pic"up usually mounted n the first or smallest coupling of the turbine generator unit.
This magnetic pic"up produces a pulse each time a pro=ecting bolt on the coupling
passes through the air gap. /igh spot readings on the rotor are thus referenced to
this bolt.
1oth the phase meter and a filter transformer switch unit are usually located
together Cig. 2>;>$(.
VIBRATION PIC;UPS
+ibration pic"ups are made in two types, the shaft riding pic"up and the pro!imity
#non>contact( probe. The shaft riding pic"up is shown in fig. 2>;>; as installed
through the bearing cap to the turbine shaft. The function of the vibration pic"ups is
to measure the magnitude of motion of the turbine shaft in a plane perpendicular to
its a!is.
+ibration is measured with a detector consisting of a wound coil, which is seismically
suspended by a spring in a permanent magnetic field , as shown in ig. 2>;>;.
'hen vibration causes the core and permanent magnet assembly to vibrate, the
suspended coil will not follow the vibration motion since it will stay motionless in
spaceD thus an alternating current is generated and fed bac" to the recorder.
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The pro!imitor>type probe does not come in contact with the shaft. 0n this system a
coil is e!cited near the shaft where the vibrations are to be measured. This probe
uses eddy currents to measure the distance from the coil on the probe tip to the
shaft surface. The coil in the probe has radio fre<uency generated in it. This radio
fre<uency surrounds the end of the probe li"e a transmitting unit from a radio
station, ig. 2>;>2. The distance between the probe and the shaft surface is directly
proportional. The closer the shaft comes to the probe, the greater will be the loss of
the radio fre<uency field. )s the shaft moves away from the probe, the greater the
field becomes.
This field strength is brought out and measured on a meter. The displacement of
the field strength meter is calibrated in thousandths of an inch for vibration
amplitude or displacement.
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This type of an arrangement can also be used to chec" a shaftEs eccentricity, thrust
position, shaft position, rotor e!pansion, differential e!pansion and shell e!pansion
all without physical contact between the reference parts. This e<uipment can also
be aligned with a "eyway or other shaft mar"ing to give a phase angle. The probe
use in this manner may be called a ?"ey>phaser@ and tie to the vibration amplitude
recorded as the phase angle. 1entley ,eveda corporation manufactures Company.
ig.2>;>2 shows the system parameters associated with this e<uipment.
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VIBRATION LIMITS
)s a general rule, balancing should be considered at the first opportunity if the
vibration of a turbine generator e!ceeds the following limits, when it is operating
under load and steady state conditions6
0n most cases, the balance can be considered satisfactory if the vibration is within
the following limits6
) unit have vibration amplitudes e<ual or better than those listed in the following
tables can be considered very good and attempts at refinement would generally not
be =ustified.
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S4ELL - AN/ /I))ERENTIAL E?PANSION RECOR/IN5 E@UIPMENT
This type of e<uipment, ig. 2>;>B, is used to provide a periodic indication and
recording of the e!pansion of the turbine shell, and a practically continuous
indication and recording of the difference in e!pansion between the turbine shell
and its shaft. The measurement of differential e!pansion not only provides an
indication of the operating clearances between the rotating and stationary elements
of the turbine, but also provides e!tremely valuable in formation for setting up
proper starting and operating procedures. The shell>and differential e!pansion
recording e<uipment typically is designed to operate within the specified accuracy
over an ambient temperature range of from F9% to F57% . the temperature eof
the differential e!pansion detector coil may, however, increase to 5;: without any
additional change in accuracy.
The recording instrument is basically a recording *C milliammeter which gives a
record on a chart four inches wide. ) scale is provide above the chart to give a
point indication of the value being recorded. 1oth the chart and the scale are
calibrated in mils #thousandths of an inch(.
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The scale has one gree inde! and two red bands. The green inde! is placed on the
scale at a point denoting the cold gap setting between the coil at the turbine end
and special ring. The red bands are set at the points beyond which any further
movement will result in a rubbing between the stationary and moving members of
the turbine.
The differential e!pansion detector consists of two pairs of stationary coils on
laminated cores mounted on the turbine shell in such a position that the special ring
moves between the coils. The difference in a!ial motion between the turbine shaft
#on which special ring is mounted% and the turbine shell changes the air gap, thus
varying the impedance of the coils.
E?PANSION /ETECTOR A CASE TO )OUN/ATION
rom ig. 2>;>B, we can see that the turbine is anchored at the centerline of the
condenser flow. The turbine is free to move longitudinal on the steel fle! legs in
this case. 0n other e!pansions systems the front standard which carries the high
pressure bearing may move on gibbed ways or sliding feet so that the e!pansion of
the case in reference to the turbine base or foundation can be measured. -ne way
of doing this involves a scale mounted in the foundation at the front standard and a
pointer attached to the turbine case. The movement of the case due to e!pansion
can then be measured, in inches.
0n another method, a Linear +ariable *ifferential Transformer #L+*T( is mounted on
the foundation and the L+*T rod attached to the turbine case. The resulting output
of the L+*T would then be transferred to a meter calibrated in inches. #.ee ig. 2>
;>5%(. .ome units have used straight mounted differential electrical coils with an
armature mounted between them. The eddy currents are then read by meter similar
to the action noted on the L+*T units.
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ROTOR=CASE /I))ERENTIAL E?PANSION
'ith 0nstrumentation of the type shown in igure 2>;>55, two electrical coils are
used. The movement detection device is secured to the turbine shell and the gap
between a collar on the turbine shaft is measured electrically. This will show if we
have a ?rotor long@ or ?rotor short@. These two terms are used to describe the
difference between the rotor and the case. 'hen first started up, the rotor will ?see@
the steam first and e!pand <uic"ly. The case, being a large mass, will ta"e time to
soa" up the heat and reach the relationship the case and rotor had at even
temperatures.
Thus, when the heat of the steam contacts the rotor, it will grow and the case will be
somewhat less in temperature. This will cause the rotor to go long in reference to
the case. .o we have a long rotor at startup. 0f the differentials of this e!pansion
are not "ept within certain limits, the rotor can rub the turbine case. The reverse is
true if the rotor receives less heat, as during load changes.
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The smaller area of the rotor is heated as before, and becomes shorter. The case
with its mass will lose its heat more slowly. .o we have the differential of these two
heated elements to consider on startup and load change and shutdown. The
operator should not where this difference is on his recorder. The recorder scale is
mar"ed to indicate a safe operating range ig. 2>;>55.
ECCENTRICITY
The purpose of the eccentricity meter is to indicate the straightness of the shaft.
This is measured by means of an air gap, usually located in the front of the turbine,
ig. 2>;>57. )ny change in this air gap causes a change in the impedance in the
pic"up coils. This is recorded on a meter that shows shaft deflection in thousandths
of an inch. ) rotor with a .%%$ bow can cause centrifugal unbalance forces of over
five or more tons depending on the mass and length of the rotor. .haft deflection,
or eccentricity, should be less than one thousandth of an inch. #.%%5( before rolling
off turning gear. ig. 2>;>58 depicts the eccentricity detector mounted over the
shaft.
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T4ERMOCOUPLES
TURBINE METAL TEMPERATURE
T4ERMOCUPLES
To assist the operator in controlling shell metal and steam chest temperatures
during starting and when applying or reducing load, thermocouples #TCEs( are
provided. The number and descriptive location of the thermocouples are noted on
the turbine wiring diagram for the unit.
) multi>point printing type strip chart recorder for these thermocouples should be
located so that it can be referred to during starting and loading of the turbine. The
printing type recorder has the distinct advantage over a temperature indicator in that
it shows both the difference in temperature across walls, and the change sin
temperature which are producing the differentials.
The information provided by the recorder is e!cellent for monitoring the boiler and
turbine operation to ensure that temperature limitations set forth in the starting and
loading instructions are strictly observed. 2>;>59.
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BEARIN5 METAL T4ERMOCOUPLES
0t has become increasingly evident that bearing metal thermocouples provide a
valuable diagnostic tool in evaluating thrust bearing and =ournal performance.
Thermocouples are typically provided in the following locations6
5. Thrust 1earings
5. 3ivoting show type G two TCEs per end.
7. Tapered land type G Two TCEs per plate
7. &ain Hournal 1earings
5. Tilting pad type G -ne TC furnished per bearing.
7. Elliptical bearings G -ne TC furnished per bearing.
8. -il *rains
5. -ne TC per main bearing drain.
7. -ne TC per thrust bearing drain.
8. -ne TC per )lterre! bearing drain.
9. -ne TC per 13 bearing drain.
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or all locations #especially for thrust bearings( it is recommended that the bearing
metal temperatures be continually monitored on a recorder in order to detect
significant temperature changes or trends that may develop.
The thermocouples in the thrust bearings are more sensitive to thrust load than is
the bearing discharge oil, and they are useful in indicating any changes in thrust.
The average of continuous periodic readings should be fairly constant at full load. )
gradual increase in temperature at the same load, over a period of time, may mean
that the steam path has become dirty or damaged, or that the bearing has worn.
,-TE6 *uring initial operation of a new unit, a record should be made of the thrust
metal temperature while there is a high load on the machine #preferably a full load(.
These readings will serve as a reference point for comparison with future bearing
temperatures. )ny subse<uent readings which show a significant metal
temperature increase #5%A or greater( are a clear indication that thrust conditions
within the turbine have changed. 0t is important that such temperature comparisons
be made at the same value of load.
&etal temperatures on a loaded thrust plate may normally b 59%A G 5;:A, and
57:A G 5:%A on an unloaded plate. The high temperature alarm on the
thermocouple recorder should be set for 52:A. )ny sudden increase in metal
temperature #5%A or greater( above the initial reference point or any readings over
52:A should be reported to the 4eneral Electric -ffice.
6ATER /ETECTION T4ERMOCOUPLES
E!perience has demonstrated that serious damage can occur in high temperature
sections of turbines as a result of water entering one or more of the various opening
sin the shells while the turbine is hot and running or hot and shut down on turning
gear. .uch operation can result in cover stressed and humped castings, badly
rubbed internal parts, and even permanently bowed rotors. -ccurrences of this
type can also lead to ma=or disassembly and repair.
3ossible sources of water are the main steam and hot reheat lines, cold reheat lines
#due to reheat attemporation valves which fail to close properly(, flooded heaters
combined with non>return valves which fail to close or are warped, bac"ed>up water
in drains due to plugging or a flooded drain manifold, un>drained pipes, etc. 0t can
be seen from this that various comple! station piping systems are involved in the
problem, ma"ing identification of the source a difficult tas".
0n order to aid in the detection and correction of the cause of this "ind of mishap,
units have been provided with thermocouples intended to aid in the identification of
the presence and possibly the source of the water. These inner surface metal
thermocouples are arranged in pairs, top and bottom, and located in the various
chambers of the outer shell. Under normal conditions, the top and bottom
thermocouples will read appro!imately the same.
/owever, if water enters, the lower half thermocouple will show a sudden trend
downward, thereby creating a temperature differential between top and bottom.
These thermocouple signals are recorded on multi>point strip recorders of the type
described.
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E?4AUST 4OO/ OVER4EATIN5 PROTECTION
*uring starting and low load operation, when the turbine stages remove only little
energy from the steam, the e!haust steam is usually at a temperature that is too
high for the last stages and the e!haust hood.
0n order to reduce this temperature, water sprays are installed =ust downstream of
the last stage wheels. The supply of water to the spray nozzles is ta"en from the
condensate from the discharge of the condensate pump at ;: psig minimum at
turbine no load.
The flow rate of water to the sprays is controlled by a pneumatic control valve that
receives its demand signal from one or more pneumatic temperature transmitters
located in the e!haust hood or hoods. This temperature control system will start
opening the control valve at 57%A and have it fully open at 52%A.
) bypass valve is also provided in case the automatic valve fails to function properly.
) compound pressure gage is used to monitor the water ahead of the spray
nozzles.
0t is recommended that the control drawing be chec"ed for the proper rate for the
unit of interest.
E?4AUST 4OO/ T4ERMOSTATES
0n case the water spray is not capable of holding the e!haust temperature below
5;:A, e!haust thermostats #one in each e!haust hood( will typically close a contact
and sound an alarm.
) second set of contacts #set to close at 77:A( should also be present to activate
the emergency trip system by energizing the master trip relay.
E!act readings in each case should be ta"en from the control drawing for the
turbine being chec"ed.
)IRST-STA5E PRESSURE
Each turbine is supplied with a first>stage pressure curve. irst>stage pressure of a
turbine is ta"en after the steam passes through the nozzle and the first stage wheel.
#The area around the first>stage wheel is called first>stage pressure.( 0n most cases
a turbine casing drain is supplied at this point also.
The first stage pressure #.3( can be used in operation in many ways. 0t is first an
indication of the pressure load on the thrust bearing. 0t can also be used to control
the steam producing unit, as the first>stage pressure is proportional to steam flow in
pounds per hour versus the power or "ilowatts generated. irst stage pressure and
steam flow are plotted in ig. 2>;>5:, which shows that load is directly proportional
to steam inlet flow.
The first stage pressure and flow charts are considered to be essential tools of the
turbine operator.
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VALVE POSITION IN/ICATORS
1y means of an L+*T #linear variable differential transformer( attached to the
operating rods of the control valves and stop valve, a signal is returned to the
E./.C. control board to indicate the position of the valves.
,ormal operation will soon indicate the proper setting of these valves for each
normal load carried. 3ower for the feedbac" from the L+*T is supplied by 8>IC
oscillators.
CONCLUSION
,ormal operating records can be used by the operator to chec" normal operation
and to note or compare any unusual conditions on the machine.
.imply recording the readout of the turbine and generator is not ma"ing an analysis
of operationD only through an understanding of the tools of turbine supervisory
instrumentation can operation be properly monitored.
) typical assortment of supervisory instruments deployed throughout a large unit is
shown in ig. 2>;>5$.
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