TURBINE SUPERVISORY

INSTRUMENTATION (TSI)
 Why TSI ?

 Turbines needs very close monitoring and

supervising certain physical phenomena which
it undergoes during various stages of operation
like start-up, loading, load changes and
coasting down.

 The Turbo supervisory instrument system is an

aid which enables to interpret the information
for safe and proper operation of steam turbine.
TSI Arrangement
HP: High Pressure Cylinder
IP: Inter-space pressure Cylinder
LP: Low pressure Cylinder
E: Excitation Machine
KY: Key Phasor
SE: Speed
SP: Shaft Position
ECC: Eccentricity
DEHI: Differential Expansion HP&IP
DELP: Diff. Expansion LP
HEL: Heat Expansion – HP left
HER: Heat Expansion – HP Right
BV: Bearing Vibration
SV: Shaft Vibration
Total 8 Speed Sensors:
(1) SE-1 : To Measure Speed for TSI
(2) SE-2-4: To Measure Overspeed
(3) SE-5-7: To Measure speed for DEH
(4) SE-8: For Intellegent tachometer in turbine
 Eccentricity
 Absolute Expansion HP Cylinder – Left & Right
 Shaft Position
 Differential Expansion – HIP & LP
 Shaft Vibration (Bearing – 1 to 5, X & Y)
 Bearing Casing Vibration (Bearing - 1 to 5)
 Speed Measurement (Total 8 Nos.)
 Key Phase
Monitoring Parameter Description
Relative vibration (displacement) between
Shaft Vibration shaft and bearing at each bearing.
1 or 2 points par each bearing.
Absolute vibration (velocity or
Bearing Vibration acceleration) of bearing housing/casing.
1 or 2 points par each bearing.
To monitor clearance of thrust bearing.
Critical monitoring parameter during
Axial Position
operating machine, especially at start up
and shut down.
Shaft can be bent because of its own
weight and partial heating. It’s necessary
Eccentricity p-p to monitor bending of rotor as observing
shaft eccentricity during slow speed
turning at non-operating of turbine.
Monitoring Parameter Description
Differential Expansion between rotor and
casing because of different thermal
Differential Expansion
expansion of them during start up and
operating of turbine.
Thermal expansion of turbine case.
Case Expansion Contortion of case expansion is also
monitored.
Rotating Speed Rotating speed of turbine shaft (rotor).
Phase reference for vibration analysis.
Phase Marker Detection of one rotation for measuring
eccentricity p-p.
To observe opening position of main
steam inlet valve of steam turbine. This is
Valve Position
used for controlling rotating speed of
turbine.
 Eccentricity

It is measured as a deviation of the mass centre from

the geometrical centre of the bearing journal.

Every machine, when built is left with certain amount of

inherent eccentricity on account of the deficiency in
machining, sag due to its weight and the clearances at
the bearings.
 Eccentricity

 This is proportional to the maximum rotor deflection

occurring at the middle of shaft.
 The rotor deflection shifts the centre of gravity of the
rotor thus creating an unbalance in the rotating mass
which in turn generates excessive vibrations when the
machine is running at normal speeds.
 Thus eccentricity measurements provide information on
the onset of vibration even when the machine is at
barring gear speed or low speeds.
 Eccentricity

 A rotor which has been sitting idle during overhaul or

has been inadvertently stopped during coast-down for
an extended period will develop a bow or bend.
 This condition must be corrected by turning gear
operation and, possibly, with auxiliary heating prior to
high speed operation to prevent internal clearance
rubbing.
 Thus Eccentricity helps operator to make decision on
start-up of Turbine.
 Eccentricity measurement is important during Turbine
slow roll.
 After a turbine is brought to speed and under load
Eccentricity measurement is locked to zero.
 Eccentricity

Probe(s) are mounted outside the pressure case as far

from the bearing (Node Point) as practical as it is
impractical to mount Probe mid span on the rotor where
the eccentricity measurement would be the highest.

Eccentricity Collar
 Eccentricity
Assuming uniform stiffness and weight, the rotor mid-
span eccentricity may be expressed as the ratio of the
transducer span from the bearing over the transducer
measured eccentricity to 1/2 the bearing span over the
mid span eccentricity or calculated using the following
formula,
(Tecc x ½Bspan)/Tspan = MSecc

Where Tecc = Transducer measured eccentricity

Bspan= Bearing Span

Tspan= Transducer span from bearing
MSecc= Mid span eccentricity
 Eccentricity

Monitor

Driver
Mounting bracket

sensor

Machine case

Shaft
 Rotor Position / Axial Shift

 The axial thrust is the result of the impact of the steam on

either sides of the blades in each stage.
 Though attempts had been made to balance and nullify
the thrust by reversing the direction of steam flow in H.P.
and I.P. cylinders and providing double flow L.P. cylinder,
there exists, however, a net thrust in the direction of
generator called working thrust.
 In order to take the thrust, thrust bearing is provided at
the front end of the H.P.cylinder where steam enters.
 The axial thrust, causes the thrust collar to move either
towards the working pads or towards the surge pads
depending on the direction of axial thrust.
 Rotor Position / Axial Shift
 The thrust bearing is the anchor point of the rotor in axial
direction.
 The axial thrust may increase on either directions on the
following conditions:
• More/less resistance developed in the steam flow path on account
of salt deposits/erosion, wearing off, etc.
• Thrust bearing failure.
• Oil flow failure/inadequate flow to thrust bearing.

 The measurement system indicates the position of the

thrust collar with respect to the working pads. The
indication determines the extent of wear of thrust pads. It
is imperative to continuously monitor the position of thrust
collar as axial shift beyond permissible limits could lead to
mechanical interference and severe rubbing.
 Rotor Position / Axial Shift
 The range of measurement is from (—1.5) to (1.5) mm of
axial shift. The ‘0’ reference position of the rotor is that
position when the collar touches the working pads.
 The positive axial shift as per convention is the
movement of the collar i.e. the rotor in the direction of
the generator and the negative axial shaft occurs when
the collar moves towards front pedestal direction.
 Usually the working value under normal condition will be
from 0 to -0.5 mm which is called Free Floating Zone
beyond which on either direction, the collar will start
rubbing the respective pads.
 Rotor Position / Axial Shift
Eddy current pick ups mounted facing the collar axially,
measure the gap and give the axial position of the rotor.
Oscillator-
Demodulator
Extension (Driver)
cable Thrust
Monitor

Rotor
Rotor Position / Axial Shift
 Differential Expansion
 Differential Expansion on a turbine is the relative
measurement of the rotor's axial thermal growth with
respect to the casing.
 Rotor Expansion on a turbine is the absolute
measurement of the rotor's axial thermal growth with
respect to the turbine's foundation.
 Due to the mass of casing, it will expand and contract
at a slower rate than the relatively thin (hollow) rotor.
 During turbine startup, extra care must be used to
ensure that the casing has been properly heated and
expanded sufficiently to prevent contact between the
rotor and the casing.
 Differential Expansion
 A standard convention is followed that if the shaft expands
more than the casing it is said to be a positive expansion.
 If the shaft contracts or casing expands more than the shaft
it is said to be negative expansion.
 A high positive expansion occurs:
• During start up conditions
• After extended period of no load/low load running
followed by sudden loading..
• When the exhaust temperature is too high
• Restraint of casing sliding/expansion
 A high negative expansion occurs:
• During cooling down/shut down
• After extended period of full load running followed by no
load/low load running
• When exhaust hood temperature is too low.
Differential Expansion
 Differential Expansion

Casing Expansion
HPT Expansion IPT Expansion LPT Expansion
 Differential Expansion
Sensor
A) Disc Type

Disc on shaft
Mounting Bracket
B) Ramp Type

Sensors
Ramp arrangement
Differential Expansion
 SHELL EXPANSION
 Shell Expansion – thermal growth of the ST casing as it
expands during start up and online operations

 The HP/IP ST shell is anchored or keyed to the foundation at

the Front Std & is free to expand axially on sliding shell arms
at the Front standard.

 If the ability of the shell to expand becomes impaired,

internal clearances could become compromised resulting in
damage to the unit.

 Shell expansion Detector – Provides a measurement of shell

expansion & can also be used to create a record of
expansion & enable the operator to determine whether
expected temperature growth differentials are being
exceeded on the ST.
 SHELL EXPANSION

 A linear variable differential transformer (LVDT), which is

mounted at the front standard. As the shell expands &
contracts, the rod of the LVDT moves inside the device.

 This movement causes a change in the LVDT signal which is

conditioned electrically and output as a DC voltage to the
turbine controller.

 Shell expansion is used for indication only & has no alarm or

trip function.

 This parameter is monitored primarily during startup to

ensure that the steam turbine casing & rotor grow thermally
at nearly the same rate.
 SHELL EXPANSION

Case
Dual case
exp. Monitor
Sensor

LVDT

Drive Unit
 Shaft Vibration

Vibration is the back and forth motion of the machine or

machine parts under the influences of oscillatory forces
caused by dynamically unbalanced masses in the rotating
system.

 Vibrations originate from the rotating mass centre and are

transmitted radially and axially to the supports. i.e. bearing
pedestals called radial and axial vibration.
Initial level of vibrations depend upon the net unbalance
left in the machine during the manufacturing and erection
stages
This initial vibration level increases in due course of
operation of the machine on account of:
 Fast out of balance changes like fracture etc.
 Slow out of balance changes like corrosion, erosion,
deposits bends, etc.
 Self excited rotor vibrations like steam pulsation etc.
 Mechanical looseness in pedestal faults in coupling,
bearing etc.
 Shaft Vibration

 Excessive vibrations may lead to mechanical failure of the

turbine components and calls for extremely reliable monitoring
system.
 Bearing pedestals are the points where normally the vibration
measurements are made.
 Vibrations are usually measured as the amplitude of the
maximum exercise of the vibrating point in microns. It is either
given as the single amplitude (peak) or double amplitude (peak
to peak).
 The other way of measuring vibrations is by measuring the
velocity of the motion of the vibrating point. This measurement
is being considered very useful. It is measured in mm/sec
(R.M.S).
 Sometimes a third mode i.e. the acceleration of the motion of
the point adopted. The acceleration measures the amount of
vibrating “Force”.
 Shaft Vibration

Eddy Current Probe

bearing

bearing housing

Oil Wedge (load

Soft Metal zone)
(Babbit)
 Shaft Vibration
Radial Shaft Vibration in X&Y direction

45 Deg

Mounting arrangement

Sensors

Shaft
 Shaft Vibration

Oscillator-
Vibration
Demodulator
Extension Monitor
(Driver)
Vertical cable
center

45° 45° Sensor

Sensor
Rotor
 Casing Vibration

Velocity sensor/
accelerometer Monitor

Mounting pad

Junction box
Bearing housing

shaft
Shaft Vibration
 Speed Measurement

 This is the speed at which the Turbine is rotating and it is

indicated in revolutions per minute.

 Turbine speed is measured by observing a multi-toothed

gear wheel located inside the front pedestal.
Speed Measurement

Oscillator-
Extension Demodulator Speed Monitor
cable (Driver) (Tachometer)

Sensor

Rotor
 Phase Marker

 Phase or phase angle, is a measure of the relationship of

how one vibration signal relates to another vibration
signal and is commonly used to calculate the placement
of a balance weight.


 This parameter is not usually displayed continuously but

is monitored periodically.

 Installation involves locating or installing a once-per-turn

event such as a key or notch that the Eddy Probe will
view.
 Phase Marker

It’s a reference pulse used for analysis & Diagnosis purpose

sensor

Notch for reference or

Key way
Key Phasor
 Bearing Temperature

 Bearing temperature is a measure of the how hot a

bearing is operating. It may be due to overloading,
misalignment, improper lubricant pressure and/or
flow.

 Nearly all turbine generator bearings are installed

with bearing temperature sensors. These sensors
may be Thermocouples or RTDs.
 Details of Sensors

 Velocity Probe

 Accelerometer

 Proximity Probe

 LVDT
Velocity Probe

 Velocity Transducers basically

comprise of a Seismic mass
which as a result of the
vibration, allows a magnet to
move relative to a coil in which
is generated an e.m.f. Either
the magnet or the coil may be
fixed to the vibrating body.
 A typical detector consists of
permanent magnet rigidly fixed
to the casing with coils
arranged as seismic mass.
Piezoelectric Acceleration Transducer

Mass Weight

Electrode

Piezoelectric e
Device
Electrode
Casing
Stud Bolt

Vibrating Object Vibration

Output Voltage Force Acceleration Vibration

Accelerometer
 Proximity Probe

 One very common type of proximity probe is known

commercially as a "Proximeter", which is a trademark of
the Bentley Nevada Company.

 The Proximity Probe, also called an "Eddy Current Probe"

or "Displacement Transducer", is a permanently mounted
unit, and requires a signal-conditioning amplifier to
generate an output voltage proportional to the distance
between the transducer end and the shaft.

 It operates on a magnetic principle, and is thus sensitive to

magnetic anomalies in the shaft. Care should be taken that
the shaft is not magnetized to assure the output signal is
not contaminated.
 Proximity Probe

A Eddy Probe system consists of a matched component system: a

pickup, an extension cable, and a signal sensor.
The signal sensor generates a high frequency oscillating RF signal
that is sent through the extension cable to the pickup tip.
The pickup tip, having a wound coil of fine wire, radiates a
electromagnetic field.
As the radiated field is bisected by the rotor surface, eddy currents
are created on the rotor surface.
As the rotor surface moves closer to the pickup tip, a greater
amount of eddy currents are created inversely proportional to the
gap between the surface and the pickup tip.
The signal sensor contains a demodulator which measures the
increase in eddy currents, and generates an equivalent DC voltage
proportional to the gap.
 Proximity Probe

Gap
When installed, Eddy Current Probes must be gapped properly.
Gap should be set for -12.0 VDC, this corresponds to an
approximate mechanical gap of 0.060" or 60 mils.

• The voltage method of gapping the Probe is recommended

over mechanical gapping.
 Proximity Probe

Principle of Eddy Current Sensors

Demodulat
or
Driver

Sensor
Coil
Condition
Bridge
`
Circuit
er .
Amplifier
.

Oscillator
. Linerizer
.
Magnetic
Flux
Eddy
Current
Target(Metal) Voltage ∝
Displacement
 Proximity Probe

Field Installation

Driver

Sensor
Extension cable
Driver

Junction box
 Proximity Probe

 Whenever the expected range exceeds a single transducer

range a complimentary system is required. A complimentary
system utilizes two (2) Eddy Probe transducers viewing the
opposing faces of the collar or ramp. The complimentary
system extends the operating full range of the system. This
system operates such that as the collar or ramp moves out
of the operating range of one transducer it moves into the
operating range of the second transducer.
 As Eddy Probe systems operate on the proximity theory of
operation, they are not effected by oil or other non-
conductive material that may come between the target area
and the transducer.
 Proximity Probe

Calibration
All Eddy Probe systems (Probe, Cable and Oscillator
Demodulator) should be calibrated prior to being
installed. This can be done by using a Static Calibrator,
24 VDC Power Supply and a Digital Volt Meter.
 The Eddy Probe is installed in the tester with the target
set against the Eddy Probe tip. Target attached is then
moved away from the Eddy Probe in 0.005" or 5 mil
increments. The voltage reading is recorded and
graphed at each increment. Eddy probe will produce a
voltage change of 1.0 VDC ±0.05 VDC for each 5 mils
of gap change while the target is within the linear
range.
 LVDT
Theory of Operation

 LVDTs are electromagnetic devices that

have three coils of wire wound on a hollow
tube and a metal rod moving inside the
hollow tube.
 The center coil of wire is excited by a
supply voltage which induces a voltage in
the other coils as the rod or plunger travels
throughout its range.
 When the plunger is centered in its range
the induced voltage of the two secondary
coils is equal in magnitude, but opposite
polarity.
 As the plunger moves to either side of the
center position the voltage of one of the
secondary coils increases while the other
secondary coil experiences a decreased
voltage.
 Features of TSI System:

a) Dual channels and built-in processor for each module；

b) Interface with host computer and system；
c) Communication at two modes via standard RS485 interface；
d) Prevent dangerous operating condition；
e) Extend the service life of system；
f) Minimize spare part consumption；
g) Improve maintenance plan；
h) Modular concept provides most compact system configuration
One 19” rack accommodating 14 cards/28 channels；
e) Data read and configuration via RS232 serial port；
f) Communication via RS485 interface
Features of TSI System
 Features of TSI System :

Speed Monitor And Overspeed Control Module

• Three monitors to perform speed measurement and over speed
control.

Differential Expansion and Shaft Displacement Monitor

Module MMS6210
• Two modules used for shaft displacement and differential
expansion measurement
 Features of MMS6000:

Shaft Vibration Monitor Module

• The two channels of each module respectively monitor the
vibration values in X-direction and Y-direction for each point.

Eccentricity Monitor Module

• The eccentricity monitor module uses eddy current sensor.
 Features of MMS6000:

Communication Unit
Communication unit modules continuously access monitoring
system modules connected with RS485 bus to perform real time
data acquisition and convert characteristic value, alarm and module
status data into standard MODBUS and TCP/IP protocol， and it can
be exported through the TCP/IP interface. The data can be accessed
and displayed by DCS and DEH system.
 Features of MMS6000:

Bearing Vibration Monitor Module

• The vibrations at eight points are monitored for entire turbine
generating unit. Each module monitors two points

Absolutely Expansion Monitor

• Two monitors are used as thermal expansion measurement in the
device (left and right HP).
 Features of MMS6000:

Intelligent Transient Speedometer

The speedometer with special sensor is used to measure rotating
machine speed. Its speed measurement range of 0 to 5000r/min can
meet the requirements of speed measurement for turbine operating
normally. The maximum dynamic speed of turbine may be locked
and stored to obtain accurate runaway value. When conducting over
speed test, you can select rapid display function to capture turbine
speed more frequently.
Speed monitoring :

There are 8 speed sensors(5 Epro sensors), 5 of them are used to TSI, 3of
them used for DEH.
• Speed and key phasor have a speed sensor individually, corresponding to
0~5000 r/min speed measuring range, the monitor instrument have 4~20mA
signal output to user.
• When speed down to 2r/min, Signal send from zero speed relay as turning
gear start command.
• There are one measure module used for phase monitoring and Speed
monitoring. there is one signal outputs from the monitoring module.
• “2 out of 3” electric over-speed protection: Electric over-speed protection
use 3 sensors. When the unit speed n≥3300r/min and through the “2 out of 3”
logic, over-speed protection relay send signal, via ETS to trip the turbine.
Displacement monitoring:

Differential expansion of HP/IP:

• Differential expansion of HP/IP use a sensor, and the monitor have 4~20mA
DC to output. When HP differential expansion ≥+4.2mm or ≤-1.5mm, alarm
relay act to output alarm signal; when HP differential expansion ≥+5.0mm or
≤-2.5mm, trip relay act to output tripping signal.

LP differential expansion:
• LP differential expansion use a sensor, and the monitor have 4~20mA DC to
output. When LP differential expansion ≥+8.0mm, alarm relay act to output
alarm signal; when LP differential expansion ≥+8.5mm, alarm relay act to
output tripping signal.
Displacement monitoring:

Shaft position:
• There are two sensors used for shaft position monitoring. Corresponding to
the shaft position measuring range of -2mm～+2mm , the 4～20mA DC
signals are output from monitor. When shaft position ≥+0.8mm or ≤-0.8mm,
alarm relay act to output alarm signal; when a shaft position ≥+1mm or ≤-
1mm, danger relay acts, and output a contact signal to ETS, trip turbine.

Eccentricity:
• The eccentricity use a sensor, which correspond to 0～100μm measuring
range, monitor have the 4～20mA DC signals to output. When eccentricity is
greater than 30μm of installation value, alarm relay act to output alarm
signal.
Displacement monitoring:

Thermal expansion:
• There are two monitoring channels for thermal expansion located at both
sides of the front bearing box respectively to monitor the casing expansion
related to the foundation of unit. Two 50mm absolute expansion sensors and
two absolute expansion monitors are used for Thermal expansion.
Corresponding to the measuring range of 0~50mm, the respective channel of
monitor outputs the 4～20mA DC signal； Two alarm relays of each monitor
are actuated to send out the corresponding alarm signal while the expansion
exceeds the setting value I and II respectively
Vibration:

Shaft vibration:
• In order to monitor the radial vibration of rotor related to the bearings, the 1#
～5# journal bearings of unit are provided with two monitoring channels for
shaft vibration respectively, one of which is in horizontal (X) direction and
the other in vertical (Y) direction, totally 10 monitoring channels. 10 eddy
current sensor are used for them, corresponding to the shaft vibration
measuring range of 0～400μm, each channel of monitor will output the
respective 4～20mA DC signal. When a channel’s shaft vibration ≥ 0.125mm,
corresponding alarm relay in monitor’s channel act to output alarm signal;
when a channel’s shaft vibration ≥ 0.2mm, corresponding danger relay in
monitor’s channel act to output danger signal.
Vibration:

Vibration at cover of bearing pedestal:

• In order to monitor the absolute vibration of bearing pad related to the free
space, the 1#～5# journal bearings of unit are provided with a monitoring
channels vertical vibration at cover of bearing pedestal respectively，totally
5 monitoring channels. Using 5 eddy current sensor Corresponding to the
bearing pad vibration measuring range of 0～100μm, each channel of the
monitor will output the respective 4～20mA DC signal; When a channel’s
bearing pad vibration ≥50μm, corresponding alarm relay in monitor’s channel
act to output alarm signal; when a channel’s bearing pad vibration ≥80μm,
corresponding danger relay in monitor’s channel act to output danger signal.
Vibration:

The tachometer on head of turbine:

• Speed monitor on head of turbine use DF6101 type magnetism- resistance
speed sensor and DF9011 type intelligent transient digital-display tachometer
and sensor, the tachometer have two stage over speed alarm, zero speed
alarm, rapid speed display, the highest speed store and re-appearance, self-
diagnosis and debugging function. Two stage over speed and zero speed
alarm have relay contact to output individually.
 5. Alarm & Trip settings

No Name Normal value Alarm value Shutdown value Remarks

Rotor is positioned based

+0.6 -1.05 +1.2 -1.65 on working pad; rotor
1 Series bearing mm
mm mm facing generator is positive
and vice versa

Differential expansion of HP
2 +6mm -3mm +6.2mm -3.2mm
and LP mm
3 LP differential expansion mm +8mm +8.2mm
0.127
4 Bearing vibration mm ≤0.076mm 0.25mm
mm

≤0.03
5 Bearing cover vibration mm 0.05 0.08 Manual shutdown
mm
6 Lubricating oil temperature 40~45°C
Bearing returning oil
7 <65°C 65°C 75°C
temperature °C
Babbitt metal temperature of
8 105°C 115°C Manually shutdown
supporting bearing °C
Babbitt metal temperature of
9 100°C 110°C Manually shutdown
thrust bearing °C
 Thank
You

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