Application Hydro Turbinesd fsdfsdfdssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssdf sdfds

7/29/2019 Application Hydro Turbinesd fsdfsdfdsssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssss…

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ProvibTech’s Application Note_ Power Generation

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23 / 33

Application_Hydro Turbine

Green power is playing an important role nowadays as its non‐pollution and long term power supply

from nature. Hydro power is one of the important part as the electric power is generated by the

water from the nature which is continuous and big quantity. ProvibTech is able to supply a vibration

protection and condition monitoring system for hydro turbines with different capacity.

Application Layout This layout has a clear but simple introduction about the main measurement points for Hydro

Turbine.




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PCM360 SYSTEM

AV

V

V

V

P

PowerSupply

PowerSupply

1 2 3 4 5 6 7 8

91

PT2060

101075 2030 40

K P

P

V

Partial Discharge

Monitoring System

Velocity Sensor.TM0793V

Accelerometer.TM0782A

RTD/TC Sensor(by other supplier)

Proximity probe.TM0180

“V” for shaft radial vibration

“P” for shaft axial position

“K ” for phase reference

Air Gap Sensor.(by othersupplier)

Partial Discharge Coupler.(byother supplier)

DAQ Card 6220

M o d b u s

R T U

Condition Monitoring System_Hydro Turbine

T r an s i ent / D yn ami c

Modbus RTU(static signal)




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ProvibTech Products

Transducers

TM0180 The TM0180 (8mm) is designed for long life cycles and are suitable for harsh environments.

ProvibTech realizes one of the most significant problems in proximity probe installations are ground

loops and loss of isolation due to

damaged cable jackets. ProvibTech’s

custom rugged cable jacket prevents

the probe cable from breaking and

tearing and is highly resistive to

corrosive environments.

The TM0180 probe and TM0181(extension cable) are equipped with a standard protective rubber

boot, which covers the connectors and prevents oil and dirt penetration.

The TM0180 series probes come in 0.5m and 1.0m cable lengths, as well as, special lengths of 5.0m

and 9.0m with an integrated probe and extension cable design.

The probe may be selected in English or metric units, as well as, reverse mounting options. Reverse

mount probes are used with TM0393X probe housings for hazardous areas.

With up to 2mm(80mil) linear range,TM0180 is generally applied for radial vibration , thrust position,

rotation speed ,eccentricity and phase reference. It is frequently used with ProvibTech’s extension

cable TM0181 and driver TM0182 and reverse probe housing TM0393X.

TM0110 The

11mm

probe

has

up

to

4mm

(160mil)

linear

range. The TM0110 probe is recommended when a

longer linear range is required. The TM0110 proximity probe system is designed to meet API 670

industrial standard.

TM0110 is generally applied for thrust position. It is frequently used with

ProvibTech’s extension cable TM0181 and driver TM0182.

TM0120 The

25mm

probe

has

up

to

12mm

(470mil)

linear

range.

The

probe

is




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4 / 34

designed for measuring differential expansion. The TM0120 integrates the probe, extension cable

and the driver into one unit. This integral proximity probe is designed for easy field installation.

The TM0120 probe comes in lengths of 1m, 5m and 9m standard cable (2 conductor shielded cable).

TM0793V/TM0782A TM0793V is with sensitivity 4.0mV/mm/sec (100mV/in/sec). TM0782A

is with sensitivity 100mV/g. TM0782A and TM0793V are piezoelectric

accelerometer/velocity transducer directly interfaces with

ProvibTech’s signal conditioners PT2060, DTMs, DM200 or TR1101.

TM0602 For steam turbine applications, the relative case expansion due to thermal effect should be

monitored. Case expansion is the thermal growth of the machine case as it expands during machine

start‐up and on‐line operations. The TM0602 is typically mounted on the foundation at the opposite

end from where the turbine casing is attached to the foundation. The case expansion transducer

system provides

information

on

the

growth

of

the

machine

case

relative

to

the

foundation.

LVDTs (linear variable differential transformers) are used to measure the case expansion. Three

different linear ranges are available: 25mm (1.0”),

50mm (2.0”) and 100mm (4.0”). The case

expansion transducer assembly consists of an LVDT

that is housed in a weatherproof protective

enclosure.

Monitors

PT2060/10/20/31/35/40/43/53/91/96/98/90/99




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PT2060/10

Proximity Module (4 channels)

z Radial vibration

z Axial/ Thrust position

z Eccentricity

z Differential expansion

z Low-frequency vibration

z Speed output

z Zero speed and speed

z Reverse rotational protection output

PT2060/20

Seismic Module (4 channels)

z Acceleration, Velocity and Displacement

z Low Frequency acceleration, Velocity or Displacement

z Case Expansion

z Case expansion output—paired

z Case expansion output—single

PT2060/31

Temperature Module(8 channels )

z RTD, TC

PT2060/35

Process Input Module

z 16 channels per module

PT2060/40

Relay Module(16 channels)

z Relay output (SPDT)




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PT2060/43 Redundant Relay Module(8 channels)

z Relay output(DPDT)

PT2060/53

Over Speed Module(1 or 3 channels)

z Over-speed protection

z The following function only for channel 3 and channel 4.

z Radial vibration: monitoring shaft vibration, single or dual XY

z Axial/ Thrust position: monitoring shaft thrust position, with 5mm,

8mm, and 11 mm proximity probes

z Eccentricity

z Differential expansion

z Low-frequency vibration

z Speed output

z zero speed

z Reverse rotational protection output

PT2060/91

System Interface Module

z Connect to a configuration station

z Communicate to PT2060 system racks

z Communicate to other control systems (PLC/DCS or Historian)

z Provides two phase references channels

z Provide storage of system and alarm events

PT2060/98

Display Module

z ID each channel, and arrange the routing

z Setup data collection strategy

z Display machine photo and real-time data and status on top of the

photo

z Real-time bar graph/ status list/ alarm status of each channel

z Alarm events

z Trend plot on each channel

z Touch-panel for easy operation

z Network to control systems (PLC/DCS or Historian) via Modbus




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PT2060/90

Power Supply Module

z Redundant Power supply

PT2060/99

Standard 19” or 12” rack

DTM10/DTM20/ DTM96

DTM10‐301 Proximity Distributed Transmitter Monitor.

With internal driver, for Radial Vibration


With internal driver, for Axial Position


With internal driver, for Rotation Speed /Phase Reference


With external driver, for Radial Vibration


With external driver, for Axial Position




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With external driver, for Rotation Speed /Phase Reference

DTM20‐101 Seismic Vibration Distributed Transmitter Monitor.

Run with current mode accelerometer with 100mV/g, velocity sensor with

4mV/mm/s or seismic velocity sensor

DTM96 Communication module. Optical isolated, RS485, RS422, RS232

PCM360 Online Condition Monitoring System

Introduction of PCM360 ProvibTech’s PCM360 is a machine

condition management system that collects,

stores, analyzes and is capable of

transmitting machine status monitoring

information over local or wide area network.

The PCM360 provides static, dynamic and

transient data collection and analysis; such

as graphical indication of vibration level,

trend, waveform, spectrum, bode plots,

cascade plots and much more.

All ProvibTech’s monitors and transmitters

can quickly and easily be integrated to upload machine status and its dynamic data to the PCM360.

The PCM360 obtains both critical machinery running status and balance of plant running status.

Additionally, the PCM360 collects process data as 4‐20mA input or digital monitor input via Modbus,

etc. The PCM360 provides an integrated system solution for asset management resulting in a total

solution for machine maintenance and protection.

Leading Features of PCM360 z Integrates plant condition monitoring and process data into one database

z User friendly interface for instant data analysis with minimal training required of field staff

z Maximum flexibility and expandability of the software system with object oriented modular

design

z Transient , dynamic and process data collection

z Built on Microsoft® SQL Server database to assure better data management and reliable

networking




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z Client/ Server architecture enables user to access data anywhere on intranet/ internet

z Readily integrates with third party vibration monitors and process monitors with minimum

hardware requirements

z Multiple digital I/O Protocols, such as Modbus RTU/ TCP

z Multiple hardware output modules ready for further data transfer and annunciation in relays

and current transmission

z 24 hour notification through on site alarms, operator interface and even SMS messaging on

GPRS mobile

z Remote notification with SMS messages to any cellular phone with machine running status

z Advanced post‐processing of transient data minimizes data loss, maximizing analysis capability

PCM360 Data Flow Introduction In addition to running well with transmitters/monitors of ProvibTech itself, with great integrate

ability and versatile interface, PCM360 is also able to interface with diverse transmitters /monitors

/sensors or Modbus TCP Server or OPC server from third party which takes great convenience for

retrofit projects and makes the plant management more efficient and effectively without spending

much money.

Apart from these, PCM360 also can play a role as Modbus TCP Server or OPC Server which makes

interfacing with third party condition monitoring system available.

In conclusion, PCM360 is very flexible and functional. With its reliability, it not only can acquire the

data from

third

party

but

also

share

its

data

with

third

party.


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Plots Supported By Different Measurement Points Measurement Point

Device

Type

Channel

Type

Data Type

Single

Channel

Dual

Channel

Plots and Lists

9

bar graph, waveform, spectrum,

bode, polar, cascade,

(dynamic, transient) waterfall,

(dynamic, transient, historical) trend,

status list,

alarm

list,

transient

list

Acceleratio

n, Velocity

Dynamic

data,

Transient

data

9


full spectrum, shaft XY vibration,

bode, polar, cascade, full cascade,



status list,

alarm

list,

transient

list

9


bode, polar, cascade,

waveform with DC coupling,



status list,

alarm

list,

transient

list

DAQ

Card:

6013,

6220,6

250

Vibration[f rom Prox]

Dynamic

data,

Transient

data

9 bar graph, waveform, spectrum,


shaft centerline,

waveform with DC coupling,

shaft XY vibration with DC coupling,




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bode, polar, cascade, full cascade,



status list, alarm list, transient list

9 Position[fr

om Prox],

Process

Static data

9

bar graph, static trend,

status list, alarm list

9

Modbu

s DAQ

for

Proces

s

Acceleratio

n, Velocity,

Vibration[f rom Prox],

Position[fr

om Prox],

Process

Static data

9



9


dynamic waterfall, alarm list,

(static,

dynamic)

trend,

status

list

Modbu

s DAQ

for DW

—

Dynamic

data, Static

data

9



dynamic waterfall, alarm list,

(static, dynamic) trend, status list

9

OPC

Client

Acceleratio

n, Velocity,

Vibration[f

rom Prox],

Position[fr

om Prox],

Process

Static data

9






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Plots

Waveform

plot

(real time and historical)

Waveform

plot with DC coupling


Spectrum

plot (real time and historical)

Full

spectrum plot (real time and historical)




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Shaft XY

vibration


Shaft XY

vibration with DC coupling


Trend plot

(static, dynamic, transient, historical, and real time, gap)

Waterfall

plot

(dynamic and transient)




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Bar Graphshaft

centerline plot (real time and historical)

Bode plotCascade

plot

Full

cascade plot Polar plot




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Shaft centerline

mode

shape

Shaft

XY

vibration

mode

shape

Lists

Transient list

Alarm list

Status list




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Measurement Illustration

Shaft X, Y Vibration (Radial Vibration) Shaft X, Y Vibration is for shaft dynamic motion

which is generally measured in a direction

perpendicular to the shaft axis, it is also called

radial vibration or lateral vibration. It is indicated

by PK‐PK with unitμm or Mil. 5mm or 8mm

proximity probes are often used to observe Shaft X,

Y Vibration. ProvibTech’s proximity probe

TM0105(5mm) and TM0180(8mm) will supply

complete solution.

Please refer to the Figure 1.1 and Figure 1.2 .They are showing the typical way for probe installation

for Radial Vibration.

Apart from the installation way of Figure 1.1 and

Figure 1.2, there’s another installation way, please

refer to Figure 1.3. Probe X is horizontally installed

and Probe Y is vertically installed.

Sometimes, proximity probes will be mounted

inside the machine by probe clamp, and sometimes probes will be mounted with help of probe

holder. ProvibTech’s TM0393X supply a very cost

effective solution for mounting the proximity probes

for these machines whatever for normal pressure or

high pressure purpose. Customer can replace the

probe without

opening

the

machine

case

which

takes

great convenience and save lots of time and

maintenance cost. Adjustable penetration depth

+/‐13mm(0.512”) makes the installation very flexible.

Please refer to Figure 1.4 and Figure 1.5 for

installation reference.




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Thrust Position (Axial Position) Thrust Position is to measure the movement of shaft in

the axial direction with respect to some fixed reference.

Typically, the reference is the thrust bearing support

structure or other casing member to which the

displacement probe is mounted. The probe is generally

to observe the thrust collar directly or axial shaft surface.

Thrust Position is also called Axial Position, and it is

indicated by average with unitμm or Mil. 5mm or 8mm

proximity probes

are often used to

observe Thrust

Position.

ProvibTech’s

proximity

probe

TM0110(11mm) and TM0180(8mm) will supply complete

solution.

Due Thrust Position is very important for some essential

machines, it is strongly recommended to use dual proximity

probes to monitor Thrust Position as the redundancy will

increase the reliability of the monitoring.

Please refer

to

Figure

2.1

and

Figure

2.2.

Seismic Vibration (Casing Vibration) Seismic Vibration measures the absolute vibration of machine case or structure. This measurement

doesn’t require other object’s position or movement as a reference. Accelerometers and velocity

sensors are often used for Seimic Vibration. It is also called Casing Vibration. It will be indicated by

PK or PK‐PK or RMS.

The installation

direction

could

be

horizontal

or

vertical.

Please

refer

to

Figure

3.1.




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Rotation Speed Rotor speed is important measurements during normal machine operating conditions as well as

during startup and coast down. Sudden unexpected changes in rotor speed may be an indication of

machinery or process malfunction.

Over Speed Over Speed protection system is mandatory for critical machines especially like steam turbines. Due

the rotation speed for the steam turbine is the most important factor , so generally we use two

proximity probes or three proximity probes to compose a system. It could be 2 out of 2 or 2 out of

3.




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Reverse Rotation For boiler feed pump or some machines, Reverse Rotation monitoring is necessary as the reverse

flow will cause the total machine shutdown finally stop water supplying. Typically Reverse Rotation

requires two proximity probes to mount on the gear or shaft with a notch. Please refer to below

Figure 6.1 for details.

Zero Speed When the steam turbine or machine is under turning state, the rotation speed should not be very

slow. If it rotates slower than it should be, then it will trip. Zero Speed is similar like speed

monitoring, but Speed monitoring is to trip when it rotate too fast than it should be, and Zero Speed

monitoring is to trip when it rotate too slow than it should be.




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Phase Reference Phase Reference is a transducer that produces a voltage pulse for each turn of the shaft. This signal

is used primarily to measure shaft rotative speed and serves as a reference for measuring vibration

phase lag

angle.

Typically

proximity

probe,

magnetic

pickup,

optical

pickup

are

used

for

measuring

Phase Reference.

Please refer to below Figure 7.1 for details.

Differential Expansion Differential Expansion is to measure the axial position of the rotor with respect to the machine

casing at some distance from the thrust bearing. Differential Expansion is usually measured when

machine startup and shutdown as the machine has a big thermal expansion during that period.

The measurement is typically made with a proximity probe transducer mounted to the machine

casing and observing an axial of the rotor.

The proximity probe could be mounted by two ways. One is by normal shaft direction, please refer

to below Figure 9.1.




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Another way is mounted by ramp shaft direction. Please refer to below Figure 9.2.

Case Expansion Case Expansion is to measure axial position of the machine case relative to a fixed reference , usually

the foundation. Changes in casing axial position are the result of thermal expansion and contraction

of the casing during startup and shutdown. It is generally measured by LVDT(Linear Variable

Differential Transformer).

Please refer to below Figure 10.1 for Case Expansion.




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Eccentricity Eccentricity is very important for monitoring turbine rotor bow. PT2060/10 PROX proximity module

can provide sophisticated on‐line eccentricity monitoring. The monitor is suitable for virtually all

types of

rotating

machinery

in

terms

of

eccentricity.

The

PT2060/10

PROX

proximity

module

will

be

continuously measure and monitoring in up to two channels per module.

Eccentricity measurements indicate the deviation of the rotor physical center and the theoretical

center. The difference has to be small enough to allow machine startup without causing damage.

The PT2060/10 PROX proximity module provides peak‐to‐peak eccentricity measurement, which

measure the difference between the positive and the negative extremes of the rotor bow. It also has

one more channel that output the position of the rotor.

Operators use eccentricity measurements to determine when a combination of slow roll and heating

have reduced

the

rotor

eccentricity

to

the

point

where the turbine can safely be brought up to

speed without damage from excessive vibration or

rotor to stator contact.

Eccentricity is the measurement of Rotor Bow at

rotor slow roll which may be caused by any or a

combination of

z Fixed mechanical bow

z Temporary thermal

bow

z Gravity bow




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Valve Position Valve Position is to measure the position of the process inlet

valves on a machine, usually expressed as a percentage of

the valve

opening;

zero

percent

is

fully

closed,

100

percent

is

fully open.

Please see below Figure 12.1 for Valve Position.

Temperature Temperature monitoring is also an important parameter to

monitor the machine health status. When something wrong

inside the machine, it will cause more friction which will cause temperature getting higher. Typically

we’ll use RTD/TC sensor to acquire the process signal and transfer to transmitters/monitors, finally

transfer to condition monitoring system.

Flow Rate, Pressure and other process variables All these parameters are like temperature as they are process variables, and these are to control

something or feedback the health status of the machine. Typically we’ll use different kinds of

sensors to

get

the

process

signals

and

finally

transfer

to

condition

monitoring

system.

Documents

Application Hydro Turbinesd fsdfsdfdssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssdf sdfds