GE Oil & Gas

Turbine Supervisory Instrumentation

(TSI) Application Guide
Bently Nevada* Asset Condition Monitoring
Table of Contents
1 Purpose.........................................................................................................1
2 Scope.............................................................................................................2
3 References...................................................................................................2
4 System Design and Engineering................................................................2
5 Steam Power Plant Overview....................................................................2
6 Condition Monitoring and Protection Measurements.........................4
6.1 Radial Vibration...................................................................................................................5
6.2 Thrust/Axial Position........................................................................................................8
6.3 Keyphasor*.........................................................................................................................11
6.4 Eccentricity.........................................................................................................................13
6.5 Speed Measurements...................................................................................................13
6.6 Expansion............................................................................................................................16
6.7 Dual Case Expansion......................................................................................................20
6.8 Valve Position....................................................................................................................20
6.9 Temperature Monitoring..............................................................................................21
6.10 Monitoring - Other........................................................................................................22
6.11 Installation Best Practices....................................................................................... 24
6.12 Installation Guidelines and Pitfalls......................................................................25
7 Condition Monitoring/Machinery Management................................. 25

1 Purpose
To provide a single document which outlines the best practices in condition monitoring and protection for steam turbine generators with
respect to GE Bently Nevadas offering.

All drawings and diagrams contained herein were produced by GE and cannot be
reproduced or copied without GEs express consent.

application note

application note
2 Scope

5 Steam power plant overview

This document describes steam turbine generator best practices

including monitoring and diagnostics needs, and also provides
basic information such as steam power generation overview
and unplanned outage cost examples. This will help the reader
understand turbine supervisory instrumentation application and
monitoring best practices enableing users of this application guide
to gain a better understanding of proven monitoring and diagnostic
methodologies.

Steam power plants are very complex with a wide variety of

equipment. The overall goal of a steam power plant is to generate
steam and convert the high-pressure steam to electricity. The type
of plant creates variations in operation style and may add more
layers of complexity. Steam can be generated from a variety of
different sources, such as fossil fuels (coal, oil, natural gas), a nuclear
reaction, biomass products (sugar cane, wood chips, municipal
waste, methane gas, etc.), geothermal energy and concentrated
thermal solar energy to name a few.

3 References

Large steam plants are used for base load and the goal is to operate
them as steadily as possible with any fluctuations in operation
being due primarily to demand in electricity. In more recent years
there has been a growing business trend to cycle plants. The
decision to cycle a plant or use them as base load is primarily based
on the type and size of plant and business needs. For instance,
all nuclear power plants are base load due to the complexity of
generating steam from a nuclear reaction. Historically, coal-fired
plants were base load. However, with recent environmental concern
over coal burning and reduction in gas prices, many coal plants are
now being cycled in some parts of the world. Both simple cycle
and combined cycle plants are now being used for base load, load
following, and for peak demand .

API-670 Fifth Edition, November 2014;

EPRI Program on Technology Innovation: Integrated Generation
Technology Options 1022782 Technical Update, June 2011.

4 Transducer Installation Guide - System

design and engineering
Bently Nevada has more than 50 years of installation and
application experience. It is recommended for new applications or
upgrades that customers leverage this expertise. This will minimize
installation and application problems and provide the greatest
likelihood of successful system performance. Our involvement
would include:
System design and layout
Electrical system and interconnect designs
Electrical installation
Mechanical designs
Mechanical installation
Machine train diagrams

Lost revenue of an unplanned outage

An unplanned outage is extremely costly. Lets use some
hypothetical numbers and assume that the cost to generate a
Megawatt hour is $30 and the wholesale price is $60. The cost of
lost production is equal to (the time out-of-service x the power
output x (the wholesale price of the power the generation cost per
MWH)). If the unit generates 600 MW, and has to be removed from
service for 24 hours, the cost of lost production of an unplanned
outage would be 24 x 600 x $30 = $432,000.

Transducer check out

The above example only accounts for lost production, and does
not include any of the following, which also needs to be taken into
consideration:

Loop checks

Staff and public safety

Monitor configuration

Regulatory fines and fees and environmental impacts

IT system security design

Maintenance labor and materials

Software configuration

Product or production quality depending on available data

Software optimization

Cost of purchasing replacement power

Systems & Instrumentation (S&I) Reports

Power plant fuel contracts may oblige them to purchase fuel that
would have been used during the outage even if the fuel is not
used.

Transducer installation

Project documentation
Start-up assistance and diagnostics
System supporting services
Remote monitoring and diagnostics support

Total revenue loss of an unplanned outage for a medium to large

generating unit can be in the millions of dollars per day. Project
or opportunity specific ROI models can be built for Bently Nevada
customers by contacting your regional FAE, PG PLM or Global
Projects Manager for support.

application note
Machine overview
As illustrated in Figure 1, Turbine Supervisory Instrumentation
(TSI) is installed on large turbine generator sets (100 MW and
up) to monitor and protect the rotating machinery. The installed
machinery has characteristics driving the selection of proper
sensors and monitors.
Fluid Film Bearings The need for tight mechanical clearances
between casing and rotor coupled with fluid film hydrodynamic
bearings drives the need to measure the shaft vibration and
position relative to the casing. This leads to the selection of noncontacting proximity probes as a primary vibration monitoring and
protection sensor.
Counteracting and balancing the axial forces within the steam
turbine cases requires fluid film thrust bearings which also lend
themselves to the use of non-contacting proximity probes. Both
radial and thrust bearings also require monitoring of the bearing
temperature to avoid overloading and bearing damage. Both RTD
and TC measurement can be used to meet this need.
Differential Thermal Growth When the steam turbine is initially
brought up to operating conditions, a great deal of thermal growth
occurs in both the casing and the rotor(s). During this time, it is
imperative that design clearances between the rotor and casing are
maintained. The measurement of differential expansion between
the rotor and casing with a non-contacting proximity sensor is ideal
for this application.

Casing Vibration Thick walled, heavy casings are required to

contain the rotors and the high-pressure superheated steam
passing through the turbine. Significant levels of rotor vibration
usually does not pass through to these heavy casings, so casing
vibration is generally a poor indicator of rotor vibration and may not
be required in all instances. As a general rule, if the casing vibration
is less than 10% of the overall rotor vibration, casing vibration
sensors are not required.
Frequency of Vibration The relatively slow maximum speed
of the turbine generator set, 3000 RPM (50 Hz) or 3600 RPM (60
Hz), allows all significant vibration frequencies to be monitored
with shaft relative probes and possibly velocity transducers
for casing vibration. Because of the lack of high-frequency
vibration, accelerometers are generally not required for these TSI
applications.
Overspeed Finally, any condition that would cause the turbine
generator set to exceed approximately 112% of rated speed can
have dire consequences. As a minimum, shutdown and inspection
of the components may be required under this overspeed
condition, and higher levels of overspeed could result in failure
and destruction of one or more of the machine train components.
An overspeed detection system is a critical part of the overall
overspeed protection system that is provided to protect against
any failure that may result in excessive overspeed.

Casing Expansion The entire case of the turbine also must be

free to move under the forces of thermal expansion. This freedom
to grow is provided by fixing one end of the turbine casing and
allowing the other end to slide freely. To assure that the casing is
expanding uniformly without binding, sensors are placed at each
side of the free end of the turbine to monitor the growth. These
sensors are usually Linear Variable Differential Transformer (LVDT)
sensors.

application note
6 Condition Monitoring and Protection Measurements

Figure 1 - A typical transducer suite for a large Turbine Generator set connected to a 3500 series monitoring system. The monitoring
system in turn is connected to System 1 and a DCS system with Ethernet switches.

Turbine Supervisory Instrumentation (TSI) is capable of providing

machine monitoring, protection, machine diagnostics and
instrument diagnostics. These capabilities are briefly defined as:
Monitoring TSI monitoring provides continuous on-line
measurement of critical parameters which provides an indication
of the condition or health of the operating machinery. The state of
the machine train is available to operators and alarms can be set to
bring the operator's attention to conditions that may compromise
the operation of the machine train. The critical nature and large
capital investment involved in these machine trains justifies the
cost of purchase and installation of continuous monitoring systems.
If a machine train is only monitored, operator intervention is
required to shut down the machine if monitoring levels indicate an
operating condition requiring a shutdown.
Protection operators are nearly always present during the
operation of these TSI machine trains, but TSI end users may
choose to protect the machine using automatic shutdown of
the equipment when critical levels are exceeded. This provides
protection when an operators intervention may not occur
quickly enough to prevent damage. The decision to tie the TSI
system output into the machine control/shutdown system

without operator intervention is dependent upon the operating

methodology of the end user.
Diagnostics operating data should be trended and archived so
that when a monitoring/protection system indicates an alarm, the
end-user can determine the proper corrective action. With this
data, diagnosis methods may be applied well before conditions
become severe enough to require a shutdown, thus allowing
continued operation until planned corrective action can be taken.
When an unexpected shutdown occurs, whether automatic or
operator initiated, diagnostic data is very critical in determining
root cause and corrective action. Clear quantitative data on
machine conditions just prior to and throughout the shutdown
can assist machinery experts and operators in determining the
cause of the shutdown and facilitate a restart of the machine.
Collection of operational data is performed through interfacing
the monitoring/protection system with proper software and
computer systems such as the GE Bently System 1*. Sometimes it
is helpful to temporarily install equipment, both transducers and
separate data collections instruments such as GE Bently ADRE*
408 system, to facilitate a complete machinery diagnostics study.
This is frequently done on the initial commissioning of a new TSI
installation.

application note
Instrument Diagnostics:
Every TSI instrumentation package has extensive self-testing that
is performed continuously. A self-test failure will be displayed to
the end user in several ways such as the green OK LED light going
off, the instrument rack OK relay (normally energized) changing
state, (in the operator display, if supplied) and in the monitor events
list. It is extremely important that end users are aware of and take
advantage of these self-test indicators so that instrumentation
problems can be addressed before there is a false or missed alarm
event.

Shaft Absolute Vibration vibration of the shaft motion

referenced to free space. It is measured using a vector summation
of shaft relative motion and bearing seismic motion with both
transducers mounted at the same location (proximity and
integrated Velocity signals).

Vibration transducer mounting considerations:

The first consideration should be the measurement of the

shaft motion (dynamic and position) relative to the bearing or
bearing constraint.

The second consideration should be the measurement of the

bearing or bearing constraint absolute motion.

Radial vibration measurement types

The third consideration should be based upon the

measurements of shaft absolute. When shaft absolute is to be
monitored, it is essential that the relative and seismic sensors
are mounted properly to sum to the absolute signal (see Figure
2).

Three distinct types of vibration measurements can be made on

Steam Turbine Generators (STGs):

The fourth consideration should be based upon transducer

accessibility and ease of maintenance.

Based upon the four best practice considerations above, our

best practice is XY proximity probes mounted relative to and
near the bearing, with XY seismic transducers mounted to the
bearing support structure with redundant or spare transducers
applied where ease of maintenance is an issue.

Below is an overview of the measurements that are typical in

Turbine Supervisory Instrumentation (TSI).

6.1 Radial Vibration

Shaft Relative Vibration Vibration measured with respect to a

chosen reference. Proximity probes measure shaft dynamic motion
and position relative to the probe mounting, usually the bearing or
bearing retainer.
Absolute (Seismic) Vibration Vibration of an object as
measured relative to an inertial (fixed) reference frame.
Accelerometers and velocity transducers measure absolute
vibration typically of machine housings or structures; thus they are
referred to as seismic transducers or inertial transducers.

If the machine bearing structure is sufficiently stiff and cost

is a consideration, it may be acceptable to use XY proximity
probes only as long as they are mounted to the bearing or
bearing retainer. As a rule, monitoring of casing vibration is
recommended if the casing vibration is 10% or more of the
overall machine vibration.

Figure 2 - Recommended Shaft Relative and Absolute Seismic Transducer installation design (the two transducers can be
summed for shaft absolute)

application note

Figure 3: Recommended Shaft Relative Vibration Probe Installation Design

In the 1950s and 60s, many Turbine-Generator (TG) sets were

equipped with shaft riders to measure shaft absolute vibration.
The shaft rider was an assembly consisting of a moving coil Velocity
Transducer mounted on top of a mechanical assembly which
contacted the shaft surface but was decoupled from the bearing
housing by a lubricated sliding bearing. When in perfect condition,
the shaft rider transducer follows the shaft dynamic motion within
a narrow frequency band from about 500 cpm up to approximately
7200 cpm or 2X shaft rotative speed. This is a measure of shaft
absolute vibration, thus some end-users may request to shutdown
on shaft absolute vibration. Bently Nevada does not consider this
a best practice (see further discussion below.) The potential for
deterioration of the rider contacting tip and friction to develop
in the sliding bearing was considerable, resulting in inaccurate
measurements due to intermittent contact between the probe
and the bearing. With the availability of non-contacting proximity
probes which also provide shaft radial position measurements
(impossible with a shaft rider), the shaft rider was rendered
obsolete about 30 years ago.
When a customer does replace their shaft rider system, some will
try to use the location where the shaft rider was mounted, using an
externally mounted Dual Probe Housing assembly.

It is important to note that with this type of probe or dual

probe installation, all shaft relative radial position and relative
shaft vibration is measured with the outer bearing housing as
the reference point. This installation practice conveniently
reduced installation complications and cost; however significant
measurement inaccuracies can arise as a result of this type of
installation for the following reasons:

The bearing cover has no bearing retention function and is

structurally weak. When mounted there, seismic vibration
measured by the Velomitor element of the dual probe
may be dominated by vibration of the cover and give a
poor measurement of the bearing vibration. Structural
resonance of the cover can lead to grossly inaccurate
measurements of both shaft relative and shaft absolute
vibration, with varying impact depending on machine
speed and operational mode.

When the bearing cover on many STGs is only weakly

referenced to the bearing, measurements of shaft radial
position can be very inaccurate. The bearing cover may
expand differentially or distort; since the reference point
for the measurement of shaft radial motion is the mounting
point of the dual probe on the cover, the position of the
shaft relative to the bearing surface will be inaccurate.

application note
If the bearing cover does not move relative to the bearing surface,
the position measurement equates to the shaft minus the bearing
movement.
When installing a dual probe using an existing shaft rider
tube/sleeve with its flange on the outer bearing cover, there is
typically a substantial radial distance from the flange to the shaft
surfacein some cases as much as 15-inches (38 centimeters).
A correspondingly long tube or sleeve is required for mounting
the proximity probe component of the dual probe. Transverse
mechanical resonance of the tube can occur and be excited
by machine vibration. This can lead to inaccurate vibration
measurements and the potential for fatigue failure of the probe
sleeve. Whenever a probe sleeve is longer than 15-inches, a
support should be provided at or near the probe tip. This is to avoid
excitation of a mechanical resonance in the probe sleeve that could
cause structural fatigue and potentially inaccurate measurements.
All external mountings of radial vibration probes for steam turbine
generators should be reviewed for proper application prior the
decision to use an external mounting. GE Bently Nevada Field
Application Engineers (FAE) can perform or assist in this review. If
required the FAEs can engage appropriate service departments,
trained in design and installation such as the Minden Application
Engineering group, the GE Power Generation Product Line Manager
or Power Generation Global Project Manager as required.

6.1.1 Shaft Relative Proximity Probes

in an X-Y configuration installation
considerations
Two orthogonally mounted shaft relative proximity probes must
be installed at each bearing, preferably mounted directly to the
bearing. If the probes cannot be mounted directly to the bearing,
the bearing constraint may be used, but only if it is the primary

bearing retaining device. Secondary covers which are not the

bearing constraint do not provide adequate support for shaft
relative vibration or radial position measurements. Figure 3 above
illustrates an example of a typical installation.

6.1.2 Bearing Absolute Vibration (Seismic)

Transducers in an X-Y Configuration
Two orthogonally mounted bearing absolute vibration transducers
(Velomitor*) are recommended at each bearing location, using a
mounting position as close as practical to the mounting position of
the shaft relative proximity probes. If the signals will be summed
for a shaft absolute measurement, both the proximity transducers
and the seismic transducers need to be mounted on the same
structure. Care must be exercised to ensure that the mounting
position provides a meaningful indication of the bearing relative and
bearing absolute vibration behavior.
Note: A Bently Nevada Velomitor is an accelerometer-based device
with internal electronics that integrate the signal; the output of the
device is in velocity units.
Note: Accelerometers are not suitable for bearing absolute
vibration, because it would require double integration of the signal
at the monitor, which greatly increases susceptibility to noise.
Note: Moving coil velocity transducers are not suitable for bearing
absolute vibration. Moving coil transducers have suspension springs
which have a finite service life; failure of the suspension springs
may occur after a relatively short period of service. The presence of
high-vibration in a plane perpendicular to the transducer's direction
of measurement (cross axis vibration) significantly reduces the
service life of the transducer and can cause signal spiking.
Figure 2, illustrates an example of a typical installation.

Figure 4: Example of mode identification probes on spool pieces

application note
6.1.3 Mode Identification Probes
Mode shape identification probes can be useful to view the true
mode shapes of the coupled turbine rotors and generator rotors.
The span between two machine cases can be very long and mode
identification probes can help identify issues such as misalignment,
shaft mode shapes and balance issues. Mode shape identification
probes are a set of XY proximity transducers, mounted between
bearings on the coupling side, that observe a jack shaft or spool
piece near the coupling. These mode shape probes are optional,
but can prove to be useful for machine diagnostics. If the end
user desires, these can be connected to a 3500/40 or 3500/42 for
enhanced diagnostics.

6.1.4 Radial Vibration Monitors

The 3500/42M Proximity/Seismic monitor is the recommended
monitor for this application. Configuration of 3500/42 monitors
should take advantage of the many variables that can be configured
in this monitor. The 3500/42 incorporates alert and danger time
delays to avoid nuisance alarms. Time delay settings for radial
vibration measurements should not exceed three seconds for
alert and one second for danger on TG sets. Actual time delays for
alert and danger need to be determined by the machinery OEM or
customer.

Shaft Relative
For shaft relative measurements, alert and danger should be
configured for the following parameters: overall direct values
and probe gap voltage alarms. Alerts should be configured for 1X
amplitude and phase, 2X amplitude and phase, not 1X, and Smax
dependent on geographical region.
Smax is defined in ISO 7919-1 as the maximum peak to peak shaft
vibration. For a circular orbit, Smax and the X or Y vibration are
identical. For an orbit where vibration is purely in a line oriented
at 45 degrees relative to the X and Y probe mounting axes, direct
vibration (measured by the probes) will understate the true
vibration amplitude by 30%. This error is not generally a significant
issue for machinery monitoring, and it is generally ignored. Some
geographical regions may require Smax to eliminate this concern.

Bearing Absolute
For bearing absolute measurements, alert and danger should be
configured for the following parameters: overall direct values.
Alerts should be configured for 1X amplitude and phase and 2X
amplitude and phase.

Shaft Absolute
Shaft absolute is a vector summation of shaft relative and
bearing absolute amplitude and phase to provide a shaft absolute
measurement equal to that provided by the obsolete shaft rider
sensor. Alarming can be provided on shaft absolute, but shutdown
using shaft absolute is not recommended because of the risk for
false shutdown due to errors in the summation process. It may
be appropriate to alarm and shutdown on the absolute bearing
vibration if the stiffness of the bearing allows significant absolute
bearing motion. End users may also require shutdown on shaft

absolute to allow correlation of machine data previously gathered

using shaft riders. However, the end user needs to be aware that
there is an increased risk for false alarms and shutdowns when
shaft absolute is the shutdown parameter. Shaft relative should
always be the first line of defence on these large turbomachines.
If shaft absolute vibration is to be monitored, the vibration signals
from the X-Y shaft relative probes and the X-Y bearing absolute
transducers should be connected to monitor channel pairs in a
single monitor module.
Caution: When a bearing absolute vibration signal is integrated
from velocity to displacement, high-pass filtering of the signal is
required. The high-pass filter must have a corner frequency setting
not lower than 10 Hz (600 cpm) in frequency. In many cases a
setting of 15 Hz may be applicable. Filtering is applied to eliminate
low-frequency noise from the velocity signal to obtain an accurate
and stable integrated displacement signal. When the machine
operating speed is in the region of the high-pass corner frequency,
significant errors in amplitude and phase of shaft absolute vibration
signal may occur. These errors will be especially apparent during
start-up or shut-down when the shaft rotative speed (1X or
synchronous frequency) passes through the corner frequency of the
high-pass filter. Non-synchronous vibration (nX frequency) will be
affected according to the actual vibration frequency relationship to
the filter corner frequency.

6.2 Thrust / Axial Position

6.2.1 Thrust Position
Thrust position is the measured axial position of a machine rotor
relative to the thrust bearing. The thrust bearing is the point of
axial constraint of the rotor within the machine casing. Ideally, the
thrust bearing must be fixed in the machine case, if it is not, then an
additional application measurement called rotor position (defined
below) must be made.
Under normal operation the rotor can shift axially within the
clearance limits of the thrust bearing. This movement is known
as axial float or end float. The range of float (the float zone) is
mechanically set and is a direct function of the size and design
of the machine. The float zone is determined by measuring the
tightest clearance between the stationary and rotating elements
of the machine being monitored and then adjusting the position
of the thrust bearing (shimming) to some percentage of that
clearance as defined by the OEM or customer, and then locking
the bearing into position. The shimmed float must be less than the
tightest clearance between the rotating and stationary elements
with thermal factors taken into consideration. The thrust bearing
takes the axial load being applied to the turbine and under normal
operation prevents stationary and rotating element axial rubs.
A thrust bearing failure can quickly lead to a catastrophic
machine failure. Because of the potential for rapid thrust bearing
failure, thrust monitors are nearly always enabled for machinery
shutdown. The dual voting thrust monitor, 2 out of 2 voting (2oo2),
was developed by Bently Nevada in the early 1970s to increase
the reliability of this shutdown measurement. Two proximity

application note
transducers must be installed in an axial plane at each thrust
bearing in order to detect thrust bearing degradation and/or failure.
Thrust monitors set up in a dual voting configuration, 2 out of 2
(2oo2), has a proven reliability in machinery protection. The dual
voting 2oo2 is a best practice as recommended in API 670. An OEM
or end user may specifically request a triple modular redundant
(TMR) configuration, 2 out of 3 voting (2oo3), to conform with local
operating practices or to achieve a required SIL level. When OEMs
or end users require triple modular redundancy (2oo3 voting), a
separate monitor is required for each transducer and a TMR Relay
card is required.
If TMR or 2oo3 thrust voting is requested, GE Bently Nevada FAEs
are available to provide assistance.

of-specification probe response and inaccurate readings. This

becomes even more important with larger transducer sizes (25mm,
50 mm), where side view constraints can severely limit use with
small thrust collars. Contact your FAE for advice.
The linear range of the transducer used must be suitable for
expected rotor axial position changes relative to the thrust bearing
under both normal and abnormal thrust bearing loading and wear.
A common mistake on steam turbine generators is to make the
monitored thrust position too small and built around the axial
float. The system should be designed to look at the total range
of potential rotor axial position change in reference to the thrust
bearing INCLUDING designed or worst case thrust bearing wear.
When designing for this application it is mandatory to understand
the tightest axial clearance of rotating to stationary components,
typically in the HP turbine. The thrust bearing is designed to take
the turbine load and to restrain the rotor so that this clearance is
never exceeded. In the event of thrust bearing wear it is ideal to
be able to monitor that wear and manage a safe shutdown of the
machine before an axial rub occurs.

Figure 5

Thrust position has to be measured by two or more proximity

probes, which observe the thrust collar or other integral, axial
shaft surface relative to the thrust bearing or non-moving integral
support. The preferred mounting arrangement for the thrust
position transducers is directly attached to or through the thrust
bearing, however in many cases the machine design does not
permit this. Thrust position transducer installations may also be
engineered to observe the end of the shaft (within 300mm or 12
inches from the thrust bearing), or another integral collar on the
shaft (within 300 mm or 12 inches from the thrust bearing) but only
if the thrust bearing is an integral component within the machine
casing (it does not move). The 12 inches is recommended in API 670
based on the following:

Example calculation: 12 inches (300 mm) of 4140 steel with a

temperature change of 100F (38C) will grow 0.008 inches (0.2
mm). Therefore, the measurement will show 8 mils. of apparent
thrust motion that is due only to thermal growth. This must
be considered when establishing thrust Alert and Danger
setpoints.

If the location of the thrust position transducers requires observing

a shrunk-on or bolt-on collar, only one of the two or three voting
transducers should observe that collar. The other transducers
should observe an integral part of the shaft. Otherwise, if the
collar were to come loose, the shaft could move and provide a false
indication of axial position change. Specialty transducer designs
such as Button probes and Right Angle probes may be employed
when the geometry of the machine prohibits the use of standard
transducers. For most applications, custom transducer mounting
brackets will be required to adapt the transducers to the proper
mounting location and observed surface. Shown in Figure 6 below.

Figure 6: Thrust Position & Keyphasor Installation

The figure above depicts a thrust position installation on a steam

turbine generator with 3300 Series 8mm proximity probes. The
custom-made bracket allows the probes to be mounted on the
thrust bearing so that they observe an adjacent collar. In this
particular example, the mounting brackets also serve as a mounting
bracket for the Keyphasor* probes, which is fairly common. This
particular installation clearly illustrates the use of safety wire to
secure all nuts and bolts. The extension cables would have been
secured to the machine case and sealed where they exit the
machine with a Bently Nevada 43501 cable seal.

Thrust collars must be large enough to ensure adequate side

view clearance and provide the minimum required observed
target size for installed probes. Either situation can result in out-

application note
6.2.2 Rotor Position Measurement
Some large steam turbines have thrust bearings that have axial
clearances relative to the machine casing. For these machines, the
measurement of the rotor position relative to the thrust bearing
may not provide adequate warning of insufficient axial clearance
between the rotating and stationary elements of the machine.
In these cases a second measurement, rotor position, is used to
measure the axial position of the machine rotor relative to the
casing. For machine designs where the thrust bearing is designed
such that it can move within its point of constraint (casing), an
additional set of transducers needs to be installed to measure rotor
position relative to the machine. In this case both thrust position
and rotor position are required measurements for proper machine
protection and diagnostics (See Figure 7).
In Figure 7, the left drawing illustrates a machine where the thrust
bearing supports are integral with, or are rigidly connected to,

the machine casing. For such a machine, the thrust position

measurement will be adequate for monitoring the axial position of
the rotor within the casing, as well as the axial position of the thrust
collar within the thrust bearing itself.
The right drawing in Figure 7 shows a larger machine (such as a mid
or large power generation steam turbine) where the thrust bearing
is supported independently of, and is able to move separately
from, the machine casing. For such a machine, the thrust position
measurement alone may not be adequate for indicating the
axial position of the rotor within the casing. In this situation, it is
appropriate to install a separate probe (or set of probes) to directly
measure the axial position of the rotor relative to a fixed point on
the machine casing.
For these machine designs, both Thrust Position and Rotor Position
are required from proper machinery protection.

Figure 7

The actual installation will require the creation of two custom-made

brackets to mount the probes on the machine case, adjacent to
the thrust bearing, allowing the probes to observe a hub on the
coupling within 12" (305mm) of the thrust bearing. Probes and
brackets should be installed using safety wire to secure the nuts
and bolts. The extension cables will also be secured to the machine
case and sealed where they exit the machine through a Bently
Nevada 43501 cable seal. It is recommended that two separate
brackets are used, affixed to the machine case."

6.2.3 General considerations for proper

Thrust Position and Rotor Position
measurements
If the installation requires observing a shrunk-on or bolt-on collar,
only one of the dual voting probes should observe that collar. The

10

second probe should observe an integral part of the shaft. If both

probes are viewing the collar and the collar becomes loose, the
shaft could move without any indication on the monitor, resulting in
a missed trip, or collar motion could cause a false trip. If one of the
probes is observing the shaft and one the collar, the monitor will
show a discrepancy between the two probe readings visible on the
monitor alerting the operator.
As noted above the Thrust Bearing is the point of constraint of the
rotor within the casing. When designing for this application it is
always good to understand the tightest axial clearance of rotating
to stationary components, typically in the HP Turbine. The Thrust
Bearing is designed to take the turbine load and to restrain the
rotor so that this clearance is never exceeded. In the event of Thrust
Bearing wear it is ideal to be able to monitor that wear and manage
a safe shutdown of the machine before an axial rub occurs.

application note
6.2.4 Thrust/Axial Position Monitors
For thrust position, a 3500/40M, 3500/42M or 3500/45 monitor
can be used. Thrust position measurements are made using as a
minimum, 2 out of 2 voting with both channels wired to the same
monitor.
The transducers can be wired to the same monitor or for additional
redundancy, separate monitors can be used. If transducers are
wired to different monitors, failure of one module does not impact
the operation of the protection system.

6.3 Keyphasor
The Keyphasor signal is a once-per-turn voltage pulse provided
by a transducer, normally a proximity probe that is used for the
measurement of machine rotative speed and the phase lag angle of
the vibration. The Keyphasor signal is essential in the generation

Keyphasor information can help the operator or machinery

specialist identify developing machine problems or distinguish
serious problems from less serious ones.
A Keyphasor transducer must observe the shaft of the driver. In
machine trains with shafts turning at different speeds, a Keyphasor
must observe each shaft speed. The target notch or protrusion shall
be designed to generate the correct signal at all machine states
and care must be taken to place the Keyphasor transducer in the
correct location.
A Keyphasor transducer should be located as close to the thrust
bearing area as possible to minimize thermal growth effects which
could move the reference marker out of view of the transducer.
The notch or projection must be integral to the driver rotor, not
the coupling or coupled component. When reference markers
are located on non-integral rotor components such as couplings,
stub shafts, jack shafts and shrunk on collars, historical phase
information may be jeopardized due to rearrangement of the rotor
components during reassembly after an outage.
Because notches are stress concentrators, they should not be
located in high torque areas, such as at coupling hubs or flanges.
Notches or projections should be designed into the machine. The
design should include proper internal radiuses, with the width,
depth or height and length based on transducer type, rotative
speed and rotor size. They should be lined up with the #1 balance
hole, 0 on the balance ring, or some other obvious feature of the
shaft.

Figure 8

of much of the information regarding the condition of the machine,

including shaft rotative speed. Because loss of Keyphasor
information severely impacts machine monitoring and diagnostics,
installation of redundant Keyphasor probes is a recommended
best practice. This is especially critical for machines with internally
mounted transducers. A spare transducer should be installed, with
the extension cable routed to the transducer interface housing,
external to the machine.
The Keyphasor signal is used for monitoring, diagnostic, and
management systems to generate filtered vibration amplitude,
phase lag angle, speed, and a variety of other information, including
vector information for balancing the rotor. It is also an essential
element in measuring rotor slow roll bow or runout information.

Figure 9: Motor Thermal Growth Effects

11

application note

Figure 10: Example of Keyphasor notch and projection

An axial Keyphasor transducer is not normally recommended

and should never interfere with or double as a thrust position
transducer.
Keyphasor transducer locations, angular mounting orientations,
and notch locations should be properly documented. Accurate
documentation is critical to the proper use and configuration of
diagnostic instruments and software.

12

Of the two methods for obtaining a Keyphasor pulse, a notch is

more desirable than a projection because a notch is easier to set up
and is less likely to damage the probe. When the marker is a notch,
the probe gap is set while observing the smooth shaft surface, not
the notch. When the marker is a projection, the probe gap is set
while observing the top of the projection.

application note

Figure 11

6.3.1 Keyphasor Module

For Keyphasor Signals, a 3500/25 module is used. These modules
are the height of a standard monitor and has two Keyphasor
signal connections. Two Keyphasor modules can be installed in a
rack position for a total of 4 Keyphasor signals per rack.

The eccentricity transducer provides two measurements, direct

Eccentricity, which is the instantaneous eccentricity value, and
peak-to-peak eccentricity, which is the difference between the
positive and the negative extremes of the rotor bow. Peak to
peak eccentricity requires the use of a Keyphasor transducer to
determine one full revolution of the machine shaft.

If a tachometer (3500/50) card is used in the rack and the

tachometer is driven by the Keyphasor probe, the tachometer can
double as the Keyphasor module, in which case no Keyphasor card
is needed.

6.4 Eccentricity
In large steam turbines, it is desirable to provide an indication of
eccentricity at slow-roll, also called peak-to-peak eccentricity.
Eccentricity is the amount of bow in the rotor measured at slow roll
speeds, typically below 600 RPM. Eccentricity is best measured
by the peak-to-peak amplitude as the rotor turns on turning gear.
Before a machine can be brought up to speed, the peak-to-peak
amplitude has to be at an acceptable level, to prevent damage to
seals caused by rotor rubs. Eccentricity is measured by a Proximity
Probe, typically mounted at the high pressure steam turbine.
Eccentricity: A single shaft relative non-contact proximity
transducer installed on the HP turbine (normally NDE) to observe
potential rotor bow conditions.
The eccentricity measurement is made with a proximity probe
mounted away from the bearing so that maximum bow deflections
can be measured. Most machines that require this measurement
already have an eccentricity collar designed on the rotor
specifically for making this measurement. Since there is a mass
suspended between two bearings, common causes of bow in the
rotor are gravity and temperature changes. By slow rolling the
machine, the bow will work itself out over time.

Figure 12

6.4.1 Eccentricity Monitor

For eccentricity, a 3500/40M or /42M monitor is used. The
eccentricity monitor can be programmed to display both
instantaneous eccentricity and peak-to-peak eccentricity. For
peak to peak eccentricity, the eccentricity channel needs to be
associated with the Keyphasor sensor.

6.5 Speed Measurements

In a typical TSI installation, several types of speed related
measurements are made. These are rotor speed, zero speed and
rotor acceleration. The same transducers can be used for all three
measurements. For zero speed, two transducers are required to
minimize the generation of a false zero speed indication due to a
transducer failure.

13

application note
6.5.1 Rotor Speed (Tachometer)
Machine speed measurements are typically made by a
Proximity Probe observing a keyway or multi-event wheel
or gear. A multi-event wheel provides faster updates of
speed changes and increased resolution of the speed
measurement at slow speeds. The 3500/50 tachometer
also allows up to four Danger/Alarm 2 setpoints (two over
and two under setpoints).
If observing a turning gear, it is recommended to use an
11 mm reverse mount probe installed in a 21000/31000
assembly. If using a multi-toothed wheel, the transducer
can also be used for zero speed and rotor acceleration
measurements, but two transducers should be installed
to make these measurements.

6.5.2 Zero Speed

Zero speed is a speed measurement that indicates the
machine is nearing or has reached zero RPM (thus the
term zero speed). The zero speed set point can range
between 0 and 300 RPM. When the zero speed set point
has been reached a relay can be activated. Zero speed is
measured by two proximity probes observing a multievent wheel.

Figure 13

Zero speed monitoring is frequently used as part of a

permissive for the engagement of the turning gear
For turbines that require zero speed indication, two
probes must be utilized in lieu of a single Keyphasor
transducer.
Most often, zero speed measurements are used on steam
turbine generators to indicate that the shaft has reached
a pre-selected speed
Magnetic pickups are not recommended for zero speed
because the signal pulses become too small to be useful
at low speeds.

6.5.3 Rotor Acceleration

Rotor acceleration is the rate of acceleration of a rotor
(rpm/minute) as its speed increases from zero rpm
to running speed. The machine operator needs this
information to prevent operational errors and to help
get the machine up to speed without damage. This
measurement is most often used on large turbine
generators that require a slow rate of acceleration while
machine components expand as they reach operating
temperatures. Rotor acceleration is measured by a
proximity probe observing a multi-toothed wheel. Rotor
acceleration is sometimes used in smaller machines
instead of a differential expansion measurement.
Following the OEMs rotor acceleration guidelines is
essential to assure that the casing and rotor thermal
growth rates stay within the OEMs limits during machine
startup.

14

Figure 14

application note
6.5.4 Overspeed
Overspeed of machines can cause catastrophic damage to the
machinery and plant. An overspeed detection system detects
when a turbine exceeds its rated operating speed. An overspeed
condition can be caused by a number of conditions ranging
from a coupling failure, a control valve malfunction, a turbine
overspeed test, a control system failure etc. Bently Nevada
provides the 3500/53 Overspeed Detection System (OSD) or the
3701/55 Emergency Shutdown Device (ESD) as a speed detection
component of an overall Overspeed Emergency Shutdown system.

Three (3) non-contact proximity transducers (ODS speed

transducers) should be installed on the driver and mounted in the
same radial plane. No secondary shafts or gears are allowed and
sensors cannot be on the driven side of any coupling.
Other control system sensors, such as governor speed are to be
independent of the ODS speed transducers.

Figure 15

Figure 16

Typical Overspeed System

1. Interposing Relays

6. Trip valve

2. Control oil supply

7. Power supplies

3. Solenoid

8. 3500 Overspeed Detection System

4. Drain

9. Operator

5. Fuel

15

application note
For detailed information about an ODS, please refer to the
best practice ODS document and application note. Due to the
complexity and criticality of the design of an Overspeed Emergency
Shutdown system, Bently Nevada recommends that any request for
a complete Overspeed Emergency Shutdown be quoted separately
from the TSI system. The GE M&C Controls group can handle these
quotations.

6.5.5 Speed Monitors

For speed measurements, a 3500/50 tachometer is used. The
tachometer can be programmed to display speed, zero speed
and rotor acceleration. Each of these measurements can be
programed to provide alarms. The tachometer can accept signals
from a transducer observing a multi-toothed wheel or a Keyphasor
transducer. Using a multi-toothed wheel results in a faster
tachometer update time when monitoring a lower speed machine
or a machine on turning gear.
A tachometer module may be used in lieu of the Keyphasor module
when a Keyphasor transducer is used for speed indication.
The 3500/50M tachometer modules are two-channel modules
that accept a pulse input from either a proximity transducer or a
magnetic pickup when used with multiple events.
Caution: The Bently Nevada 3500/50M tachometers are not
designed for use independently as, or components of, a speed
control or overspeed protection system. The monitors do not
provide the protective redundancy and the response time needed
for reliable operation as a speed control or overspeed protection
system.

6.5.5.1 Zero Speed

The 3500/50 tachometer is designed to indicate zero speed but
should not be used to automatically engage the turning gear
or automatically activate some other process. The zero speed
input can be a Keyphasor signal or multi-event signal from a
proximity probe. The Zero Speed function requires inputs from two
transducers. Voting logic between two transducers minimizes false
zero speed indication in the event of a failed transducer.

6.5.5.2 Rotor Acceleration

Although this monitor has alarms for positive or high acceleration
rates, it is typically used for indication only.

6.5.5.3 Overspeed
An Overspeed Detection System (ODS) can be part of a TSI system,
however a stand-alone ODS or ETS Module is the recommended
Best Practice (i.e. separate rack, power supplies etc.). When the
ODS is placed in a rack with other monitors, there is a possibility
a failure of one of the other monitors causing the OSD to trip the
machine. Please reference the Overspeed Detection best practice
document.

16

6.6 Expansion
6.6.1 Differential Expansion
Differential expansion is the relative thermal growth between
rotating and stationary parts, and it is a vital parameter in the
operation and management of large steam driven turbines. It is a
critical factor in avoiding internal rubs during the start-up of the
turbine since the non-rotating parts and the rotating parts have
significantly different thermal mass and will grow at different
rates. Wherever practical, end users should install a redundant
Differential Expansion probe and route the lead to an external
junction box. This allows the end user to switch to the backup
sensor should the internal probe fail. The harsh environment
within the casing and potential for the probe to be exposed to
high-temperature steam, increase the possibility of Differential
Expansion probe failures.
Under similar conditions of cooling or heating, casing and rotor
contraction and expansion characteristics can be different.
Expansion differences are always present in machinery that is
heated or cooled as a result of operation or process performance.
Thermal contractions and expansions of machine trains are
proportional to the size of the machinery involved. The machine
case consists of the non-rotating elements (case, nozzle blocks,
guide vanes, etc.) and houses the rotating elements (rotor, shaft
with assembled wheels, vanes, etc.) necessary to accomplish the
intended work.
Proper location and position of the differential expansion
transducer is as important as the range capability of the transducer.
The expected growth differential should be based on the tightest
allowable casing to rotor clearance which may be obtained from
the original equipment manufacturer and/or customer. With the
acceptable growth differential known, the proper transducer can be
selected and installation methods determined to assure clearances
are maintained during the start-up.
Depending on the size of the turbine there may be more than one
differential expansion measurement location.

application note
6.6.2 Single Differential Expansion

6.6.3 Complementary Input Differential

Expansion

Figure 17

The drawing above illustrates a method of measuring differential

expansion using a single transducer. The transducer is referenced
(attached) to the case and measures the rotor thermal contraction
and expansion relative to the case.
Note: knowledge of expansion toward the probe (top) or away
from the probe (bottom) needs to be known to properly set up the
DE monitor.

Figure 18

The drawing above illustrates a complementary input application.

Probes may be as shown in the diagrams above. The range of one
probe is complemented by the range of the second probe. This
installation allows the measurement of twice the range of a single
probe.

17

application note
6.6.4 Ramp Differential Expansion

Figure 19

The drawing above illustrates a probe installation on a shaft with

dual ramps. Two probes (A and B) are necessary to determine the
shaft radial position shifts unrelated to differential expansion.
Ramp differential expansion can be measured on ramps of 5 to
45. Measurable range depends upon the angle of orientation and
the linear range of the transducer used.

When quoting differential expansion, as with any proximity

system, target size and side view needs to be a consideration.
Transducers that are used in differential expansion measurements
are our 50 mm, 25 mm, 16 mm or 11 mm transducers. Below is a
chart showing the minimum target size required for each of the
transducers
Probe Size

Minimum Target

System Linear Range

50 mm

102 mm (4.0 in) or larger

27.9 mm (1100 mils)

25 mm

61 mm (2.4 in) or larger

12.7 mm (500 mils)

16 mm

31 mm (1.2 in) or larger

4.0 mm (160 mils)

14 mm

31 mm (1.2 in) or larger

4.0 mm (160 mils)

11 mm

31 mm (1.2 in) or larger

4.0 mm (160 mils)

35mm transducers are no longer available for new sales.

Figure 20

The drawing above illustrates an application on a shaft with a single

ramp. Two probes (A and B) are necessary to determine the shaft
radial position shifts and differential expansion. The A or A1 probe
is used to determine shifts in radial position, while the B probe
determines differential expansion. Shifts in radial position seen by
the A or A1 probe are used to modify the B probe reading to provide
an accurate differential expansion measurement.

18

If insufficient target area is available for a system that can cover

the range requirements, two smaller probes observing a collar in
a complementary fashion can be used (Figure 18) or two probes
observing ramps on the shaft (Figure 19).

application note
When using probes observing a ramp, consult the chart below for transducer selection. Allowed ramp angles in degrees for various ramp
transducers and full-scale ranges.
Composite Full-scale
Range

3300XL 11mm,
3300 16mm HTPS,
7200 11 & 14mm

3300XL 25mm,
25mm and 35mm
Extended Range

50mm DE and
50mm Extended Range

3300XL
50mm

5-0-5mm
2-0-8mm
0 - 10mm
Custom

4 to 18

4 to 45

11 to 45

11 to 45

0.25-0-0.25inch
0.15-0-0.35inch
0 - 0.5inch
Custom

4 to 15

4 to 45

11 to 45

11 to 45

10-0-10mm
5-0-15mm
0 - 20mm
Custom

4 to 9

4 to 33

11 to 45

11 to 45

0.5-0-0.5inch
0.25-0-0.75inch
0 - 1.0inch
Custom

4 to 7

4 to 25

11 to 45

11 to 45

25-0-25mm
10-0-40mm
0 - 50mm
Custom

Not allowed

4 to 12

11 to 28

11 to 28

1.0-0-1.0inch
0.5-0-1.5inch
0 - 2.0inch
Custom

Not allowed

4 to 12

11 to 28

11 to 28

1.10-0-1.10inch
0 - 2.20inch
28-0-28mm
0-56mm

Not allowed

Not allowed

Not allowed

11 to 28

6.6.5 Rotor Expansion

6.6.6 Special Applications

Rotor Expansion is the measurement of the rotor thermal

expansion measured from a non-rotating fixed point, such as the
machine foundation. The difference between differential expansion
and rotor expansion is that in differential expansion, both the nonrotating and the rotating elements expand (or contract) and in rotor
expansion, the non-rotating element is fixed, while the rotating
element expands.

In addition to the above common differential measurements there

are additional types of differential expansion measurements, such
as a collar that is too small for proximity probes. On some machines,
a magnetic pendulum is used which employs magnets to follow a
short collar. The movement of the top of the pendulum is measured
with proximity probes to derive the differential expansion of the
rotor.

19

application note
6.7 Dual Case Expansion
Case expansion is a measurement of the machine casing growth
relative to its foundation. During startup of a steam turbine,
thermal growth of the casing is expected. Casing expansion can be
measured at multiple points along the machine train and is used to
confirm proper case thermal growth.
Often, casing growth is accommodated by sliding guides on either
side of the case that are designed to slide as the case grows. Nonuniform case expansion can occur when one side of the casing
guide sticks or the casing does not expand uniformly. This condition
can cause misalignment of rotor to casing components potentially
leading to a rub, excessive vibration, or thrust bearing failure. Dual
case expansion measurements are used to detect non-uniform
casing growth and to annunciate this condition, but are generally
not used as an input for automatic turbine shutdown. Best
practice is to measure both sides of the case using Linear Variable
Differential Transformers (LVDTs).
Figure 21 shows the application of 2 LVDTs to measure Case
Expansion

6.8.1 Linear Variable Differential

Transformer (LVDT) Application
If the predominant motion for making the valve position
measurement is linear (not a cam or rotating motion), use an LVDT.
Due to high temperatures at the valve location, AC type LVDTs are
always used.
It is best practice to install the LVDTs with weatherproof housings.
Several types of valve position measurements can be made
requiring anywhere from one to eight LVDTs. The application and
quantity are based upon the design of the machine.
The biggest concern when installing LVDTs for valve position
measurement is high temperature, which can cause thermal
expansion between various parts of the valve assembly. When
installing LVDTs make sure the installation design will not damage
the LVDT or valve assembly as thermal expansion between the
valve assembly and the mounting brackets occurs.
Figure 22 is an example of a typical valve position LVDT installation.

Note: If one sliding foot binds, it will show up as uneven growth.

It is best practice to install the LVDTs where the core is physical
attached to the case rather than use a spring return core. Over
time, the spring can wear out and dirt build-up can prevent the core
from moving. Physically attaching the core connecting rod to the
transducer target bracket eliminates this problem.

Figure 21

6.8 Valve Position

Valve position is the measured position of a valve stem or
cam in relation to valve opening or crack and full valve stroke.
These measurements are most often made with Linear Variable
Differential Transformers (LVDTs), or with Bently Nevadas
specially designed linear rotary position transducers (LRPTs). This
measurement is used to validate steam flow and is measured as a
percent of full or 100% open. Valve position can be measured on
various valve installations such as throttle valves, stop valves and
control valves. In our application, these transducers are not used
for machine control and must be completely independent of valve
position sensors used for the control of the turbine. Any valve
position sensor used in the control loop of the turbine must never
be paralleled into the Bently Nevada TSI system.

20

Figure 22

The LVDT mounts to a stationary assembly with a bracket and

the LVDT connector rod (plunger) attaches to the moving valve
linkage with a connector rod bracket. Connecting the core to the
bracket with a ball joint rod end works well, because it allows easy
adjustment and locking of the core to set up the zero point and it
rotates in all planes to accommodate thermal expansion.

application note
6.8.2 Valve Position - Linear Rotary
Position Transducer
A linear rotary position transducer is used to measure valve
position on rotating cam applications. The Transducer is mounted
to the end of the valve cam assembly by attaching the transducer
housing to the Valve block (stationary) and connecting the
Transducer shaft to the rotating cam with a coupling. The centerline
of the input shaft must coincide with the centerline of the rotating
part. If the shaft and rotating part are off center, stress could
damage the transducer and cause erroneous measurements.

Best practice for temperature sensor installations is described in

API 670.
For radial bearings, API 670 uses the definition of short and long
bearings as shown in the picture below. API 670 defines long
bearings as having a length/diameter (L/D) ratio greater than
0.5. Short bearings have an L/D < 0.5. For long bearings, API
recommends temperature sensor placement at 25% of the length
from each end. For short bearings, mount the sensors in the middle.
In the case of big turbine-generator bearings there is nothing wrong
if the distance between the measurement points is > 50%.
Note: The sensors are mounted in the minimum film thickness
location of the bearing for normal loading in a well-aligned
horizontal machine.
2-axial plane temperature measurements are useful when a
misalignment between the bearing and the shaft occurs. Figure 24
presents a situation where having only one transducer in the mid
part of the bearing could possibly miss the misalignment of the
bearing rotor system.

Figure 23

6.8.3 Expansion / Valve Position Monitors

For Differential Expansion, Case Expansion and Valve Position a
3500/45 monitor is used.
Differential expansion, DC LVDTs (case expansion) and linear rotary
position transducers use the same IO module, while AC LVDTs,
often used for valve position uses a different IO module.

6.9 Temperature Monitoring

Temperature transducers for condition monitoring systems
are an important source of data for condition monitoring and
machine protection. Temperature changes can be an indication
of change of mechanical condition of a machine component,
and can be correlated with vibration changes. Temperature
can also be correlated to changes in the process. Typical TSI
temperature measurements include radial and thrust bearing metal
temperatures and bearing lube oil temperatures.

6.9.1 Radial Bearing temperature

Babbitt bearings are susceptible to excessive temperature and
many of the failure modes in turbine-generator sets will cause an
abnormal temperature in one or more bearings.
The location of the sensors and the choice of RTD vs. thermocouples
is based on OEM recommendations and/or end user preferences.

Figure 24

The rules of temperature transducer location for multi-pad bearing

are clearly described in API 670.

6.9.2 Thrust / Axial Temperature

Measurements
Thrust bearing metal temperature is measured on both the
active and inactive thrust bearing segments. The location of the
sensors and the choice of RTD vs. thermocouples is based on OEM
recommendations and/or end user preferences. Best practice for
temperature sensor installations is described in API 670.
Note: The thrust bearing position measurement should never be
voted with thrust bearing temperature for the danger alarm. This
voting was promoted by some end users in the past based upon
the premise that excessive thrust motion also generated elevated
bearing temperature. There are two reasons not to do this. First,
temperature measurements can have a long lag time because of
the time it takes for surface heat to heat the bearing babbitt and
reach the sensor. This can produce a significant time lag that will
delay protection alarming. Secondly, an internal rub frequently
occurs at the limit of the thrust motion which will unload the
bearing and cause the temperature to fall below the alarm level and
prevent a danger alarm resulting in damage that could have been
prevented by tripping on thrust position.

21

application note
6.9.3 Bearing lube oil temperatures
Bearing lube oil temperature measurements are used to detect
changes in inlet and outlet temperatures across the bearing.
It provides an indication that oil temperatures remain in an
acceptable range. This measurement can help provide an indication
of problems with bearing loading or the lubrication system.
It is best practice to make two bearing lube measurements for each
bearing. They are:

Input oil temperature

Output oil temperature

For normal operation at steady state load, the difference between

these temperatures should not change significantly. Changes in
either direction can indicate a problem.

accept isolated tip thermocouples, 3-wire RTD, 4-wire RTD, or a

combination of TC and RTD inputs. The 3500/65 does not provide
recorder outputs. When using thermocouples, the length of the
field cable run needs to be considered.
If temperature transmitters are used (typically providing a 4-20
mA proportional signal) and the customer wants to incorporate
these temperature measurements into their TSI system, a 3500/62
monitor can be used. The 3500/62 process variable monitor is a
6-channel monitor for processing machine critical parameters
(pressures, flows, temperatures, levels, etc.) that merit continuous
monitoring. The monitor accepts +4 to +20 mA current inputs or
any proportional voltage inputs between -10 Vdc and +10 Vdc. It
conditions these signals and compares the conditioned signals to
user-programmable alarm setpoints.
If needed, temperature monitors can be configured to make
differential temperature measurements.

6.9.4 Additional optional temperature

measurements

6.10 Monitoring Other

For steam turbine generators additional temperature

measurements can be incorporated in a TSI system. These
measurements can include:

6.10.1 TSI Monitors General

Seal temperatures

Generator Temperature Monitoring

Note: Most generators have temperature sensors designed in the

windings.

The recommended platform for turbine supervisory

instrumentation is the 3500 system. The 3500 system provides
continuous, online monitoring suitable for machinery protection
applications, and is designed to fully meet the requirements of the
American Petroleum Institutes API 670 standard for such systems.
The systems components consist of:

6.9.5 3500 Temperature Monitors

For condition monitoring purposes it is best to have the
temperature measurements discussed above connected to
the 3500 rack dedicated to the steam turbine/generator. This
configuration is shown by the 3500/65 monitors in the example TSI
system in Figure 1. The reason for this is that all measurements
for the machine are made at the same moment when connected
to System 1 software. Time stamping provided by various DCS
systems can be very different, and therefore data will be hard to
correlate.
For temperature measurements, a 3500/60, 3500/61 or 3500/65
monitor is used.
The 3500/60 & 61 modules provide six channels of temperature
monitoring and accept both resistance temperature detector (RTD)
and thermocouple (TC) temperature inputs. The modules condition
these inputs and compare them against user-programmable alarm
setpoints. The 3500/60 and 3500/61 provide identical functionality
except that the 3500/61 provides recorder outputs for each of its six
channels while the 3500/60 does not.
The 3500/65 monitor provides 16 channels of temperature
monitoring and accepts both resistance temperature detector (RTD)
and isolated tip TC temperature inputs. The monitor conditions
these inputs and compares them against user-programmable
alarm setpoints. The 16-channel monitor can be configured to

22

3500/05 instrument rack(s)

Two 3500/15 power supplies per rack

3500/22M transient data interface module per rack

3500/32 6 channel or /33 16 channel relay card

3500/25 Keyphasor Module(s)

3500/92 or /91 Communications Gateway for connection to a

DCS, historian or any other device accepting MODBUS inputs
(Optional)

3500/94 display (optional)

Various TSI monitors as discussed under the individual

transducer sections

The 3500 Series monitoring system has alarm set points, which
automatically raise an alarm when the predetermined alarm level
is reached. The 3500 monitoring system has alarm relays for alert
and danger conditions, which can be used as an indication to an
operator or as a permissive to a shutdown system.
The radial vibration and axial position modules can be certified to
SIL 1 if required by the end user.

6.10.2 Rack Chassis

The 3500/05 Instrument Rack can be 19" EIA rack mount, panel
mount, or bulkhead mount if access from the back of the rack is
limited. If needed, panel mount racks can be mounted in a 3500/06

application note
weatherproof housing. Multiple racks can be mounted in custom
enclosures offered by Bently Nevada. Refer to the Enclosures
section for more detail.

6.10.3 Power Supplies

The 3500/15 power supplies can be configured with low and high
AC or DC voltage options. True redundant power supply modules
reside in the TSI rack(s) and operate in auto-changeover mode.
Failure of one power supply module does not affect or interrupt
the protection and monitoring functions of any module in the rack.
Power regulation is done at the monitor level (not at power supply)
so that in the event of a regulator failure, only a single monitor will
be affected. The following input voltage options are available.

Supported protocols include:

Modicon Modbus protocol (via serial communications)

Modbus/TCP protocol (a variant of serial Modbus used for TCP/

IP Ethernet communications)

The following measurements should be trended if appropriate for

the measurement type:

Overall channel level

Channel OK status

Channel alert and danger

Probe gap

Direct vibration amplitude

85 to 125 Vac

1X amplitude and phase

175 to 250 Vac

2X amplitude and phase

20 to 30 Vdc

Not 1X

88 to 144 Vdc

Smax (depending on region)

It is recommended that each power supply in the rack is powered

from a different source for increased reliability. AC and DC power
supplies can reside in the same rack. It is highly recommended
that at least one of the power supplies is connected to an
uninterruptable power supply (UPS).

6.10.4 Transient Data Interface (TDI)

Module
The 3500/22M TDI is the interface between the 3500 monitoring
system and System 1 software. The TDI provides an interface for
rack configuration using 3500/01 configuration software loaded on
a portable computer. For enhanced security, the TDI incorporates
key-lock access in conjunction with software passwords for rack
configuration. It is recommended that the key is removed from the
rack, kept in a secure place and only made available to authorized
personnel to prevent unauthorized configuration changes.
Every 3500 rack requires one TDI, which always occupies Slot 1
(next to the power supplies).
Many end users have cyber security requirements built into their
networkable equipment. Bently Nevada has numerous hardware,
such as TDI_Secure, and service solutions available to cost
effectively mitigate cyber security risks. Bently Nevada Services
can work with users to identify the most cost effective solution for
their needs.

6.10.5 Communication Gateway Module

The 3500/92 communication gateway module provides
communication capabilities of all rack monitored values and
statuses for integration with process control and other automation
systems using both Ethernet TCP/IP and serial (RS232/RS422/
RS485) communications capabilities. Every 3500 rack should
incorporate at least one communications gateway for connection to
a historian or DCS.

If an interface to a GE system that requires ethernet global data

(EGD) is required, the 3500/91 EGD communication gateway module
is used. EGD is a GE-proprietary protocol used in a wide variety
of GE control and automation products such as programmable
controllers, turbine control systems, plant data historians and
human machine interfaces (HMI). Support of the EGD protocol
provides customers with easier and less costly integration options
when a 3500 system must share data with other GE control and
automation products. The EGD protocol used in 3500 has been
specifically tested to work with the GE SPEEDTRONIC* Mark* VIe
turbine control platform, allowing the machinery protection system
to integrate tightly with the turbine control system.
Multiple Gateways of both types can reside in the same 3500 rack.

6.10.6 Relay Modules

Two types of relay modules are available for the 3500 system, the
4-channel 3500/32 and 16-channel 3500/33 modules.
The 3500/32 4-channel relay module and 3500/33 16-channel
module are full-height modules that provide 4 or 16 relay outputs.
Any number of 4 and or 16 channel relay modules can be placed
in any of the rack slots to the right of the Transient Data Interface
Module. Each output of the 4 or 16 channel relay module can be
independently programmed to perform AND and OR voting logic.
For machinery protection, at least one relay card shall be installed
in each TSI rack. It is not recommended to use a Modbus link or
4-20 mA recorder outputs as an input to an auxiliary system for
machinery protection. The TSI system considers the critical path
to be from measured parameter sensor to the closure of the relay
contacts. Modbus links and 4-20 mA recorder outputs are not
considered part of the critical path for protection and thus may
not provide the same level of reliability for machine protection as
the relay contact closure. End users need to be aware of these
potential limitations when these links are interfaced to their digital
control systems.

23

application note
The use of danger bypass is not recommended for turbinegenerators. In situations where machines temporarily exceed
danger levels during a start up or shut down resonance, it is
recommended that trip multiply is used. Extreme caution should
be used applying trip multiply. It only should be used if the machine
design dictates a trip multiply to pass the machine through a
resonant frequency. Trip multiply maintains a level of protection
against catastrophic failures during transient resonances. Levels of
trip multiply should be determined by the customer or machinery
OEM. Alert and danger levels should be based on machine
configuration and design.
Timed OK channel defeat (TOCD) is a feature that prevents the
channel measured value from participating in alarm voting when
the transducer is in a Not OK state. This feature is designed to
prevent false alarms when noise in the transducer signal causes
the signal level to repeatedly go beyond OK limits. For most radial
vibration applications, 30 seconds after the transducer returns
to an OK state, the channel measurement will be allowed to
participate in alarm voting. This option is available only if the OK
mode is set to Non-latching. The option to use TOCD is a customer
preference. The customer end user should be informed of the risks
and benefits of this feature. TOCD involves a trade-off between
initiating a false alarm verses failing to initiate a valid alarm. The
customers operating requirements should dictate the proper
decision on use of this feature.

6.10.7 System Display

The 3500/94 color VGA touch screen display is recommended for
TSI applications if a local display is required.

6.10.8 Monitoring System Segregation

Best practices for maintainability and availability dictate that
each Turbine/Generator train should have a dedicated machinery
protection rack (or racks). Combining multiple machine trains in
one rack may hinder unit maintenance when one unit is down while
the other is operating. Additionally, a failure occurring in a shared
rack could potentially affect the monitoring and/or protection for
multiple units. In summary:

Turbine generating units should not share common racks (for

example Unit 1 and 2 do not reside in the same rack.

Individual monitor modules may not be shared across machine

trains.

24

Each machine is provided with its own relay module (where

shutdown is required).

6.10.9 Monitoring Rack Expansion

Capacity
It is recommended that future system expansion is reviewed closely
with the customer and that rack expansion slot capacity is defined.
Whenever possible, there should be spare slots available for
additional monitoring rather than filling every rack position.

6.10.10 System Enclosures (Packaged

Systems)
If free standing system enclosures (cabinets) are required it is
recommended that Bently Nevada supply these enclosures.
Full system configuration and factory acceptance testing (FAT)
is available to assure full system functionality prior to system
installation.
Packaged systems provide a fully engineered, pre-mounted,
pre-wired, site-ready, and factory-tested industrial enclosure
solution for machinery protection and condition monitoring
instrumentation. A packaged system is designed to simplify
site installation, provide suitable protection for the installed
instrumentation from the surrounding environment, and facilitate
ongoing ease of use and maintenance. Packaged systems are
supplied with all the needed enclosure and electrical drawings.

6.11 Installation Best Practices

It is recommended that additional field wiring be pulled from the
machine train to the instrument rack for future expansion and an
additional 10% spares in the event of a cable failure and to facilitate
adding monitoring capability in the future.
Connector protectors should always be used, both internal and
external to the machine.
Often, the generator bearing pedestals are isolated. If this is the
case, transducers should be isolated from the bearing. Phenolic
isolation blocks are available as standard parts.

application note
Additional Drawings and Photos

Figure 25
Absolute Vibration with Redundant Relative and Seismic Transducers.

Temperature:
From a practical viewpoint, it is advised to use a similar approach
to installing temperature sensors as is used to install Proximity
Probes. This means that the temperature sensors have an integral
cable with a connector that will work well in an oil environment.
The cable length should match that of the proximity system,
in most cases, 9 meters. Typically, silicon or Teflon cables are
used for temperature transducers. Often, the connection of the
temperature sensor cable to the extension cable is made under
the bearing cover. Therefore, the same feed through that is used
for XY transducer cables can be used for the temperature cables.
A mechanical protection of the transducer cables between the
feed through and terminal housing can be provided using flexible
conduits.

7 Condition Monitoring / Machinery

Management
Many additional tools are available to monitor the condition of
the machine. It is a best practice to use condition monitoring
and management software tools. A vital element in performing
machine management and diagnostics a reliable Keyphasor signal.
As indicated in the Keyphasor discussion above, best practice is to
install a redundant Keyphasor to assure that this signal is available
for the machinery specialist and the diagnostic tools. It is also
a recommended practice to input the Keyphaser signal into one
channel of a 3500/42 monitor to allow capture of the Keyphasor
signal.
The System 1 software platform enables operators, equipment
engineers, process engineers, instrument technicians, and other
plant personnel to quickly identify, evaluate, and respond to
important events. This increases equipment availability and
reliability, and reduces maintenance costs.

25

application note
Best practice for System 1 software used on a TG set includes the
following System 1 modules / capabilities:

Depending on customer needs/requirements, additional tools and

services are available.

User notification

These tools / services include:

Anomaly detection

Decision Support:

Integration with DCS and plant historians

Thermal performance

Current values

Bargraph

Decision support is a system extender to System 1 software using

pre-configured sets of rules designed specifically to perform
real-time data validation, real-time calculations and analysis, and
real-time detection of specific events and malfunctions. System 1
has steam turbine generator specific decision support tools which
use the data to look for patterns that would indicate one or more
known failure modes. Below is a list of the malfunctions that can be
detected with these tools:

Machine train diagram

Shaft bow

Alarm/System event list

High synchronous vibration

Trend / multivariable trend/vector trend (amplitude/phase/time

(APHT))

Fluid induced instability (Whirl and Whip)

Radial pre-load forces (Including Misalignment)

Tabular list

Acceptance region violation

Timebase (with option for superposition of baseline data)

Rotor rubs

Orbit / timebase (with option for superposition of baseline

data)

Loose rotating parts

Orbit (with option for superposition of baseline data)

High runout

Shaft average centerline

Spectrum / full spectrum (with option for superposition of

baseline data)

Campbell diagram

X vs. Y

Waterfall / full waterfall

Polar/acceptance region

Bode

Cascade / full cascade

Specific plot types are available in System 1 Display for Power

Generation. For steam turbine generators the following plots
should be configured as a best practice.

26

Customer Training:
Training on the use, maintenance and management of the systems
should be included with every proposal.

Supporting Services:
If an end user is not investing in in-house capabilities to support
their condition monitoring equipment, a Bently Nevada Supporting
Service Agreements (SSA) should be considered. . These
agreements are tailored to the end users needs and a customized
asset care service program can help to maximize the value of
their investment in asset condition monitoring technology. These
services can be performed on-site and are enhanced by remote
connectivity. For additional help, contact your SSA regional lead.

application note

27

 2015 General Electric Company. All rights reserved. Information provided is subject to change
without notice. Best practices and recommendations herein are applicable to most aeroderivative
gas turbines contingent on OEM design and adherence to OEM guidelines.

GE Oil & Gas

1631 Bently Parkway South
Minden, NV 89423

*Denotes a trademark of Bently Nevada, Inc., a wholly owned subsidiary of General Electric
Company. The GE brand, GE logo, Bently Nevada, System 1, Keyphasor, Proximitor, Velomitor,
RulePaks, Bently PERFORMANCE SE, ADRE, SPEEDTRONIC, Mark, and SmartSignal are trademarks
of General Electric Company.

24/7 customer support: +1 281 449 2000

geoilandgas.com/

Modbus, Modicon, and Teflon are trademarks of their respective owners.

GEA31795 (05/2015)