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The history

From
Sub-critical to super critical
Turbo Supervision
GEN.

The
LP
turbine

IP

HP
• Safety
• Cost of spares
THE • Cost of repair
• Procurement
NEED difficulties
• The criticality
FOR • The process
• The thermal effects
• The speed
TURBINE
HYDRO THERMAL
SLOW SPEED HIGH SPEED

MODERATE TEMPERATURE COMBINATION OF HIGH AND


MODERATE TEMP. AND PRES.

QUICK TO START / STOP LONG START UP TIME

MOSTLY SELF LUBRICATION FORCED LUBRICATION

SUITABLE FOR SOFT ROTORS ( soft & rigid )


GENERATOR/SYCHRONOUS
CONDENSER OPERATIONS REQUIRES LOT OF CARE EVEN
DURING SHUT DOWN
ONCE ERRECTED REQUIRES
LITTLE MAINTENANCE PERFORMANCE DEPENDS ON
PURITY OF STEAM AND COOLANT,
NO THERMAL ENCOUNTERS AND ALSO OF THE LUB

LOT OF MAINTENANCE WORRIES


EVEN AFTER ERRECTION
$ SLOW SPEED

$ MODERATE TEMPERATURE

$ QUICK TO START / STOP

$ MOSTLY SELF LUBRICATED

$ SUITABLE FOR GENERATOR /


SYCHRONOUS CONDENSER
OPERATIONS

$ ONCE ERRECTED REQUIRES


LITTLE MAINTENANCE
DYNAMIC
BALANCING
OF
TURBO MACHINES

HRD -TTI -TNEB


HIGH SPEED

COMBINATION OF HIGH AND MODERATE TEMP. / PRES.

LONG START UP TIME :: FORCED LUBRICATION

SOFT ROTORS ( soft & rigid )

REQUIRES LOT OF CARE EVEN DURING SHUT DOWN

PERFORMANCE DEPENDS ON PURITY OF STEAM AND


COOLANT, AND LUB

LOT OF MAINTENANCE WORRIES EVEN AFTER ERRECTION


TURBINE - GENERATOR
TURBINE
T – G BLOCK DIAGRAM
Vacuum, 1000C

5400 C, 135
ATA
5400C, 40 ATA
Hollow shaft,
moving blades / impellers,
quick expansion,
affected by flow and
HP-MP-LP temperature

EXPANSION ?
Rotor
Heavy shell,
Fixed
stator
impellers/blad
es,
TURBINE
Bearings out-of-operational area

hpf hpr lpr


JB
LP
HP IP

JB JB

Mpr || lpf

JB AND AXIAL THRUST


300 bar /
600°C for the HP turbine
The LP turbine consists of a
double flow with a horizontal split
casing.
The typical steam conditions are up
to 7 bar and 350°C.
The steam will expand to the
condenser at condenser pressures in
the
range of 30 - 100 mbar. Because of
the high volumetric flow rates special
care has to be attributed to the
appropriate choice of LP turbine
exhaust area and design.
The development of optimal last
stage blade families and long last
stage blades is the key for reasonable
exhaust areas, i.e. reduced exhaust
Generator
Bearing in operational area
• Moderate temp. and just hydrogen
pressure, added with electromagnetic and
bearing - shaft interaction forces

gnde
gde generator
Assembly of turbine rotors
• No !
• They are not done as below, because….

HP IP LP gEN

~
Assembly of turbine rotors
• Catenary : a bow : bearing level , slope
HP IP LP G

||

Datum
Assembly of turbine rotors
Assembly of turbine rotors
Assembly of turbine rotors
• THEY ACHIEVE LEVEL PLAYING WHEN
ON NORMAL RUN AS THE THERMAL
GROWTH ARE ACCOMPLISHED
HP IP LP
g

• When the machine achieves its normal


speed and parameters
Turbo supervision
HP – to measure
• Thermal growth of
• stator ( casing or shell ) - overall
• rotor ( shaft ) - differntial
• Oscillation of rotor in the bearing w.r.t
housing ( relative motion of the shaft in
relation to the stator )
• Overall vibration of bearing measured
on the housing
IP- to measure
• Thermal growth of
• stator
• rotor
• Oscillation of rotor in the bearing w.r.t
housing ( relative motion of the shaft in
relation to the stator )
• Overall vibration of bearing measured on
the housing
LP- to measure
• Thermal growth of Rotor
• Oscillations of the rotor w.r.t stator
• Vibration of the bearing

• The LP cylinder sits literally on the


spring foot condenser. Hence it will be
forced to float. The casing bolts are not
set to full tight
Generator – to measure
• Only vibration of the bearings
• The heavies part of the T-G , which is
solidly placed on the basic structure.
• Hardly subjected to any thermal growth of
its own
• In many cases bearings are located on its
shell or body
Common data
• The axial shift – the axial movement of
the shaft due to forces of electrical,
mechanical, hydraulic and structural
interaction when the machine attains full
dynamic status and also in-service
• ( salt formation in HP area is diagnosed by
slightly higher curtis pressure than normal,
and increase in axial shift )
• Rotational speed ( RPM )
The salient parameters
• Overall expansion ( casing )
• Differential expansion ( rotor )
• Axial shift ( rotor movement on the axis of the entire
machine )
• Eccentricity ( oscillation of the rotor with respect to
stationary body, ie., shaft axis with respect to
machine or neutral axis )
• Speed ( especially to cross over critical speeds of
the Gen., LP, IP, AND HP VERY CAUTIOUSLY – the
cross over should be gradual and quick , as stalling
at or near about critical will create resonance forcing
the operator to stop and restart the machine )
TURBO - GEN
• STARTUP : process, expansion,
eccentricity, axial shift,
vibration ( at critical N )

• OPERATION : process, vibration


( monitoring : continuous
and periodical )

VIBRATION ANALYSIS :
on alarm and on demand
Stator Expansion
Stator Expansion
In Turbine Supervisory
Instrumentation (TSI), case
expansion is an important
measurement.

Case expansion (or shell


expansion) is the growth of the
machine shell with increase of
temperature during machine
startup and on-line operations.
Stator Expansion
The LVDT is mounted to the
foundation at the opposite
end from where the turbine
casing is attached.

The LVDT provides


information on the change of
position of the point
measured relative to the
foundation.
Stator Expansion
• This is primarily a startup parameter allowing
the machine casing and rotor growth to
increase at a proportional rate. Thermal
growth

• As different growth rates can cause internal


rubbing between rotating and stationary parts
of the machine.
Stator Expansion
• Case expansion should be measured by a pair of
LVDT as this provides information on the position of
both of the sliding feet on the machine case.

• This allows for a comparison of readings preventing


damage should one foot become obstructed or
jammed.

• Case expansion measurements also allow


determination of whether expected thermal growth
differentials are being exceeded on the machine.
Stator Expansion
(overall expansion)
• Normally referred to as overall expansion

lvdt

HP
STATOR
Linear Variable Differential Transformer
LVDT
Features:
• 2" Range
• Stainless Steel Housing
• NEMA 4X
• 1-6 VDC Output
• 2.5 mV/mil
LVDT
The growth watch
• The turbine will be rolled initially to 500
RPM to warm the cylinders when starting
from cold condition
• Then the speed is maintained at about
1000 RPM so that more steam can enter
the shell allow it to develop thermal
expansion. At the same time rotor also
achieves some growth
Moving on
• Until the turbine stator attains the required
growth the speed will not be increased
further
• This type baking the machine in steam is
referred to as SOAKING
Rotor Differential
• Using LVDT
lvdt

Bearing
housing

Shaft disc
Eddy probe
• Proximity or Non-contact pickup
Eddy Probe
Eddy Probe Mounting
to
measure rotor differential
Eddy probe

Air gap
Eddy Probe to measure
Eccentricity
• To measure rotor oscillations or vibrations
of the shaft with respect to bearing
housing ie., w.r.t stationary part

• Referred generally as ECCENTRICITY


Eddy Probe mounting
to measure eccentricity

Bearing housing
Probe

Machine axis

Shaft center line


Eddy Probe for Speed

Tacho gen
Shaft end

probe

Teeth pulses
Teeth wheel
Typical probe in service
Dual probe setup
for orbit analysis to examine alignment
Typical probe set up
recommended by western
manufcturers
Bearing Overall Vibration
Velocity Pickup
Mounting of Vibration pickups
• On all turbine bearings as per
recommendations
v

H
Recommended by TNEB
• Pickup locations : _|_ , and || to axis

V
A Bearing

SHAFT BEARING
HOUSE
The circuit block
Continuous monitoring
DCS ON DATA MODE
DCS on TIME MODE
TREND CHART
Hourly, Weekly, Monthly
Variation of one parameter w.r.t another
RESONANCE
NATURAL FREQUENCY

CRITICAL SPEED

RESONANCE
RESONANCE
While designing the machine every care
is taken to keep the natural frequency
of the rotating (dynamic) and stationary
(static) parts including that of civil
structures very well above or well
below the operating speed
RESONANCE
Critical speed any rotating part of T – G
will be crossed on its way from zero to
rated RPM
While crossing critical speed of any part
of the machine that particular
component will experience high
vibration
RESONANCE
It is a must that the critical speed should

be crossed smoothly and quickly

• If resonance sets in due to any reason, then


the only recourse is to trip the machine and
restart it
• If the machine continuous to stay at critical
speed for long, the rotor will be subjected to
severe fatigue due to abnormally high
continuously raising vibration, which may
result in damage to the rotors and its
component parts
RESONANCE
• The natural frequency of bearing housing and
structures are not identified openly as is done for
critical speed
• If due to any external excitation like grid
disturbance or sudden abnormality in the process,
the area whose natural frequency coinciding with
the excitation frequency will start resonating
RESONANCE
• Then the only way out is to reduce
or increase load to change stress
• When that fails the one and only
option available is to stop the
machine and restart it from rest
• If the high vibration vanishes on
restarting the cause is resonance
RESONANCE
• Analysis will reveal only 1XRPM component
which may be due to unbalance or eccentric
alignment of rotor
• Only the gradual increase of the vibration to
abnormal levels in spite of our effort is the
clear indication of the presence of resonance
Identifying critical speeds
• From the front pedestal legends :
Typical ::
Gen 1200 rpm
LP – IP 1700 – 1900 rpm
HP 2350 rpm
Identifying Critical speed
by the rise in vibration at specific speed
Critical speeds
when more than one occurs
Identifying critical speed
by rise in vibration of individual rotors

Gen. LP IP
HP
AMPLITUDE

SPEE
1 2 3 D
( x 1000 rpm )
What happens when the machine
crosses over critical ?
• The SHAFT under goes some bending movements

• This is christened as MODE SHAPES

• At each critical the SHAFT AXIS or MACHINE AXIS


undergoes several modes

• Care is taken at the time of design to accommodate


this modes by adopting necessary bearing
clearances, and spacing between the stator – rotor,
not forgetting alignment
Mode Shapes
Instruments to monitor vibration
Portable
vibration
monitor

A
Analyser
Periodic Monitoring /
Alarm investigation
• Machine : UNIT IV T-G Load : 214 MW

• d/v H V A

• Beag. 5 ( LPR) 25/4 18/3 59/10


Continuous monitoring Y Y N

No alarm from DCS - yet scheduled vibration


measurement revealed high Axial vibration
indicating development of a fault requiring
detailed investigation and diagnosis
Alarm from DCS
• On instrumentation front :
• Verification of the data by portable meter
• Checking the cable, connections, and
pickup fastening

• On condition monitoring side :


• If confirmed that high vibration is
present do investigate to diagnose
the fault/defect
Investigation
• Signature analysis
• Phase analysis
• Coast / run-down time signature (to study
critical speed behavior, compatibility to the last
recorded plot )
• Stethescoping ( scanning the vibration on
the bearing house and supports inclusive
of the civil structure )
Vibration signatures
Frequency vs amplitude
In service Time wave
Bode / coast down plot
Some clues
Phase ?
- the direction of forces of individual parts
• Talks about bearing – journal
misalignment, and coupling misalignment
between any two consecutive stages
OIL WHIRL
-- due to insufficient bearing clearance
1 / 2 X RPM

bearing

1XRPM 2XRPM

Oil clearance

shaft
MISALIGNMENT – PHASE MEASUREMENT
• HIGH AXIAL VIBRATION
• UNEVEN PHASE DIFFERENCE BETWEEN TWO BEARINGS ACROSS ANY
COUPLING
• 360 /12 = 30 8X30 = 240 2X30 = 60
• 240 – 60 = 180 OFF-SET MISALIGNMENT
• ie., the centre lines of A and B are not in line

8
2
8 2 2 8
2
a b
8

• 900 for angular and in-between for other positions


Misalignment - orbit

Dual
input
FFT

Dual trace oscilloscope


rubbing
Casing Distortion
• When casing was prevented from free
expansion
• Uneven heating in casing
• Rotor – stator clearances are uneven
• Unit III at ETPS : DUE TO TIGHTENING OF
CASING BOLT IN EXCESS –
• The HP rotor got bent near curtis – confirmed
by shaft run out test at works
Casing Distortion
• Confirmed by the vibration data obtained
on casing of HP on all corners and sides
• Overall expansion could not detect it
• Added evidence that the speed could not
be taken beyond 2790 RPM
• Observation of the casing noise pattern
Loose Discs on rotor
• Vibration changing abnormally even
when machine is operating on constant
load
• Abnormal noise occasionally
• No change in phase – no misalignment
detected

in a day
Loose discs on rotor
• During overhaul the LP rotor root gap
between discs were found to be “ nil ”
for one and in “ excess ” for other

• Rotor was taken to works and checked


and found the run out with discs and
without discs were found to be much
beyond permitted levels
Loose discs on rotor
• Analysis confirmation of rotor trueness
difficiency and moving of discs while in
service were based on the large
variation of vibration levels over a day (
trend ) and the noise pattern indicating
the changes in blade excitation due to
shifting of discs
Interference in Bearing
Unit I at ETPS
• Machine could not be run up to rated speed
of 3000 RPM on commissioning just after
overhaul
• The critical speed of generator was down to
about 950 RPM instead of the design speed
of 1200 RPM
• Shows mass or stress changed the machine
generator rotor resonance
• Since mass could not be changed drastically
to create such a situation only stress need to
be suspected
Interference in Bearing
Unit I at ETPS
• Discussion with the maintenance revealed
the presence of interference in GDE bearing
due to catenary restrictions
• Suggested the reduction interference to zero
or better bringing some clearance in the
bearing setup
• Interference reduced to possible extent and
machine was on bars
• The critical speed was found to be as per
design after bearing correction
Journal – Bearing misalignment
Unit II at ETPS
• Uneven bearing clearance
• Poor journal – bearing blue matching
( the contact area should be upwards of
90 % )
• Machine was stopped and checked
24 / 4 ( 17 / 3
) 67 / 7 . 5 ( 19 / 4. .
3)

generator

gnde
Rotor thermal instability
Unit V at TTPS
• The machine vibration in turbine were
normal, but the generator vibration varied
with time just after synchroning from mere 12
/ 3 to 77 / 12 ( as observed during one of
the several trials at GNDE in H )
• m/s BHEL suggested balancing and after
umpteen attempts started blaming the
machine structure
• TNEB did its own study and concluded that
the rotor is thermally unstable and is beyond
any possible repair based on previous
experience on rotors
Rotor thermal instability
Unit V at TTPS
• No structural abnormality could be detected
after conducting extensive study of the
pillars, bearing pedestal fastening and other
possible areas including causes for
suspected resonance
• The rotor was replaced thereafter and
unfortunately that was placed in UNIT II at
NCTPS and experience was the same as
encountered at TTPS.
Machine could not be loaded
beyond certain level

• Unit III at ETPS could not be loaded


beyond 65 MW after R & M

• Detailed vibration analysis, especially


the phase analysis revealed that the
catenary was deficient
Machine could not be loaded
beyond certain level
• The IP rotor bearing was below its correct level,
causing severe LP – IP coupling misalignment
causing excessive loading of IP bearing revealed
by high vibration in IP

• Due to this the machine could not be loaded


beyond certain level, in this case it is 65 MW

• It was encountered every time the machine was


subjected to load beyond 65 MW
Machine could not be loaded
beyond certain level
• The same could occur if the journal
bearing alignment and clearances are
not adequate

• The effort of M/S BHEL to correct this


by balancing was in vain, only resulted
in further straining and causing
damage to the machine
No overhaul, please
Vote for condition based maintenance

• Never attempt to repair a running


machine if it is performing absolutely
• When attempted, please note down the
existing alignment and clearance values
at the time of opening the machine
• If no change in components and
modifications are in schedule, set
the old levels before closing
Please care for them, as
they are like children
Thank you,
Wishing you all the
very best

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