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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
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
JB JB
Mpr || lpf
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
VIBRATION ANALYSIS :
on alarm and on demand
Stator Expansion
Stator Expansion
In Turbine Supervisory
Instrumentation (TSI), case
expansion is an important
measurement.
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
Bearing housing
Probe
Machine axis
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
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
A
Analyser
Periodic Monitoring /
Alarm investigation
• Machine : UNIT IV T-G Load : 214 MW
• d/v H V A
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
Dual
input
FFT
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
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