Chapter 12

TURBINE SUPERVISORY INSTRUMENTATION

12.1 Vibration, Expansion & Axial Shift Measurement
12.1.1 Significance of Monitoring System
In operation of large steam turbines certain vital parameters are required to be continuously
supervised and monitored in order to provide information related to the operational conditions of the
turbine during various stages of operation like start-up, loading, load changes and coasting down.

The aim of the monitoring of these parameters is early detection of malfunction due to wear,
thermal stresses and the effect of external forces so as to save the possible damage. The operation of
the highly stressed machine, i.e. turboset, operating at high temperatures and pressures is affected by
expansion and vibrations encountered.

This special measurement system includes all necessary sensors mounted on the turbine with
flexible leads for connection to junction boxes, circuits for processing the sensors signal along with power
supply monitoring, signal level monitors, test circuits etc., in a cabinet to generate information about the
following parameters.

a) Absolute bearing vibrations

b) Absolute shaft vibrations
c) Axial shaft position of the rotor
d) Differential expansion
e) Absolute expansion
f) Valve position

Other important parameter like speed is measured electrically by Hall Probe & signals are
provided to Electro-hydraulic governor & for display in unit control room after conditioning.

12.1.2 Absolute Bearing Vibration

Turbine rotors are manufactured and balanced with high degree of precision. Some residual
unbalance is unavoidable. It results during operation in vibrations, which transmitted through the bearing
on to the casing. Hence bearings should provide proper damping of vibrations.

For measurement of absolute shaft vibrations, the seismic mass type pick-ups are mounted on
the pedestal cover. The bearing vibrations are transmitted directly to the seismic device.

The device operates on the plunger coil principle. The mechanical vibrations are converted to an
electrical signal, which is proportional to velocity of vibration. In seismic device (Fig. 12.1), a coil is
suspended in an air gap in a resilient way by a spring. The magnetic flux in an air gap is constant. The
permanent magnet is firmly connected to the housing and to the magnetic return path. Above the natural
frequency, the plunger coil is steady in space due to its mass inertia. Thus a fixed point in space is
created and vibrations can be referred to this point. The relative motion between the coil and magnet
generates a voltage, which is proportional to the rate of vibration.

The measurement system is designed to operate satisfactorily over a frequency range of 16 Hz to

200 Hz and measures the amplitude of the vibrational displacement. The output voltage of the sensor is
amplified in a differential amplifier, which suppresses any interference voltages picked up by the cable.
Then the signal is integrated in an active integrator to form signal proportional to the vibrational
displacement. It is then rectified and displayed.

236 Steam Turbines for Power Generation

 The functioning of the amplifier can be checked with the help of a standard oscillator built in the
system. Failure of sensor and field cable will be annunciated. Similarly, supply voltage is also monitored.
The range of measurement is 0- 160 microns peak-to-peak.

Fig.12.1 Seismic Type Vibration Pick-up

12.1.3 Absolute Shaft Vibrations

Measurement of absolute shaft vibrations is done by measuring the relative shaft vibration with
respect to the bearing pedestal and adding the absolute bearing vibration to it.

The measurement of relative shaft vibration is carried out by a contactless pick-up according to
the eddy current method. An oscillating circuit consisting of the disc-shaped coil of the sensor and the
cable capacitance of the feed line receives a high frequency alternating current from the adaptor mounted
on the bearing cover, corresponding to the resonant frequency of this oscillating circuit. The
electromagnetic alternating field generated in the process includes eddy currents on the shaft opposite to
the coil. The smaller the distance between coil and the shaft larger is the current. The eddy current feed
back to the coil is felt as an increasing effective load, so that the a.c. voltage at the coil is proportional to
the distance between the sensor and the shaft.

This signal is filtered in a band-pass filter, then rectified and smoothened. A linerisation circuit
corrects the output of the sensor, which is a measure of relative shaft vibrations.

The vibration signals from the absolute bearing vibration measuring unit and relative shaft
vibration measuring unit are added in a computing unit for obtaining the absolute shaft vibration. The
measuring range is 0 – 400 microns peak-to-peak.

12.1.4 Axial Shaft Position of the Rotor

This measurement yields information on the position of the shaft in the thrust bearing and on wear
of the bearing pads. It is imperative to continuously monitor the position of the shaft, as axial shift beyond
permissible limit would lead to mechanical interference and surface rubbing.

The measuring principle is based on the fact that the impedance of a coil with iron core depends
upon the size of the gaps in the magnetic circuit as shown in Fig. 12.2. There are two such coils
(Fig.12.3) mounted on either side of the measuring disc and connected to form a measuring bridge. A
high frequency voltage is fed to the bridge, the output of which changes proportionally to the change in air
gap (Fig.12.4). The bridge output voltage is rectified by phase selection and amplified. On load test
facility of the measuring attachment is provided. The range of measurement is –0.5 to +0.5 mm.

Chapter-12: Turbine Supervisory Instrumentation 237

 Fig.12.2 Impedance Characteristic of Inductive Coil with Air Gap

Fig.12.3 Inductive Type Axial Shaft Position & Differential Expansion Pick-up

Fig.12.4 Bridge Circuit

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12.1.5 Differential Expansion
When steam turbine is running relative displacement occurs between rotors of the turbine and their
casings due to their different thermal inertia. This is the case particularly during start-up and in case of
major load changes. These expansions are monitored continuously by contactless measurements.

Differential expansions of HP, IP and LP turbines are monitored in the same way as described
earlier for axial shaft position measurement by inductive type of sensors.

Fig. 12.5(b) elaborates the location of sensors for the measurement of differential expansion of
HP, IP and LP turbine, which are fitted in front pedestal, pedestal No.3 and pedestal No.4 respectively.
The difference lies in the size of the measuring discs and the sensors arrangements. For the large range
of relative expansion in LP turbine, the measuring disc is in the form of a double cone to produce less
change in expansion.

As the bridge output for a larger air gap changes non-linearly a linearising network is employed.
The ranges of measurement are –

For HP turbine - 5 to + 16 mm
For IP turbine - 5 to + 16 mm
For LP turbine - 10 to + 32 mm

Fig.12.5 (a) Casing & Rotor Expansions

Fig.12.5 (b) Location of Differential Expansion Sensors for HP, IP & LP Turbines

Chapter-12: Turbine Supervisory Instrumentation 239

 (b) Measurement of Shaft Position in Thrust Bearing

(a) Mechanical Shaft Displacement Indicator

(c) Pick-up for Absolute Expansion Measurement

(d) Measurement of LPT Differential Expansion

Fig.12.6 Expansion & Shaft Position Pick-ups

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12.1.6 Absolute Expansion
Measurement of absolute expansion is carried out both at the front pedestal as well as at the
middle-bearing pedestal (Fig. 12.5(a)). The displacement sensor is mounted on the foundation and
connected to the casing via a rope (Fig.12.6(c)). The other end of the rope is connected to a rotatable
measuring device, which forms the magnetic return path for the two sensor coils. The rotating measuring
device rotates eccentric to the two sensor coils, which creates different air gaps and thereby different
inductances. Thus the air gaps between the measuring device and the coils depend on the angle of
rotation. The principle of measurement is same as in the case of axial shaft position measurement
described earlier.

12.1.7 Valve Position

The measurement is carried out for both the HP & IP control valves with the help of displacement
sensors. The principle of measurement is the same as has been described for absolute expansion
measurement.

12.2 Turbine Stress Evaluator

12.2.1 Function
The turbine is equipped with Turbine Stress Evaluator to assist in attaining optimized start-up,
operation and shutdown without impairing the expected operating life. As such during start-up and
loading operations of steam turbine, time is of prime importance as also reaching full load keeping the
stresses of the turbine components within permissible limits. Turbine wall stress evaluator is specifically
designed for achieving the above objectives. During changes in operation of the turbine, the internals of
turbine are subjected to temperature fluctuations resulting in thermal stresses. The maximum thermal
stress is proportional to the difference in temperature at the surface on the steam side and the mid wall
temperature. This difference is compared with the permissible temperature difference, which is
determined on the basis of -

- Estimated load cycle on turbine

- Thermal fatigue strength of material
- The geometry of the components.

The difference between permissible temperature difference and the actual difference between
surface & middle wall temperatures is known as available temperature margin. The margins are
evaluated in an analogue computing circuit and displayed in the instruments as upper and lower
temperature margins upto the stage of synchronization and as load margins during subsequent loading.
The display also indicates the component, which is critical at any given time.

12.2.2 Arrangement
The scheme of TSE consists of following five computing channels as shown in Fig. 12.7 :

1. Emergency Stop Valve

2. IP turbine shaft
3. HP turbine casing
4. HP turbine shaft
5. HP Control Valve

Channels 1 & 5 (ESV & HPCV) form the steam admission area and channels 2, 3 & 4 form the
turbine area. The indicator (TSE Display) is shown in Fig. 12.8.

The input to turbine stress evaluator is supplied by thermo-couples mounted on stop valve, high
pressure turbine and intermediate pressure turbine. Ni Cr-Ni thermocouples (WT Sensors), as shown in

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 Fig.12.7 Turbine Stress Evaluator Scheme

Fig.12.8 Turbine Stress Evaluator Display

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Fig.12.9, are used for measuring the surface temperature near steam (i) and mean temperature (midwall
temperature) (m) for the above five channels mentioned. But for channels 2 & 4 (HP & IP shaft), the
mean shaft temperature m is derived by computation from i. The output of thermocouple is fed to
analog signal conditioning cabinet CJJ05 where it is converted into 4 – 20 mA signal and fed to TSE
cabinet CJJ01.

The actual load of the turbine generator set Pact is measured separately and a current signal of
4-20 mA is available for load indication and computation of load margins. The speed is also measured
separately and 4 – 20 mA signal is available for display in TSE indicator.

Fig.12.9 Wall Temperature (WT) Sensor

12.2.3 Computation
The permissible temperature margins are converted into permissible load margins with the help of
mechanical stress calculations for on load operation of the TG set. The available temperature margins are
converted into corresponding load margins by TSE circuitry with the help of mathematical algorithms.
These load margins are the guiding factors to further load or unload the TG set on both manual and
automatic mode.

12.2.4 Principle of Operation

In each computing channel, the difference between m and i is calculated as  and this is
compared with the permissible upper and lower temperature difference u per. and L per. which are
dependent on the midwall temperature and are derived from function generators. The difference between
u per. and  gives the upper temperature margin whereas difference between L per and  gives
the lower temperature margin. These margins are called available temperature margins and are

Chapter-12: Turbine Supervisory Instrumentation 243

represented by u and L. the lower temperature margins of admission area and turbine area are
selected for display and for further processing.

During no load and start-up and shutdown operations the temperature margins are indicated for
admission (or for the turbine area whichever is lower or as selected), together with the instantaneous
speed. During on load operation the upper and lower load margins Pu and PL are computed from
available minimum temperature margins and are displayed together with instantaneous load value.

12.2.5 TSE Display

The TSE indicator (Fig.12.8) has two separate sections one for starting upto synchronization sage
and the other for on load conditions. The sections are illuminated according to the operating mode. The
sector shaped aperture formed by two semicircular discs display margins. The top rectangles get
illuminated & indicate the component, which is the cause for imposing the minimum margin. The upper
boundary of the transparent sector indicates the upper margin for start-up/increasing load and the lower
boundary indicates lower margin for decreasing load/lowering of speed.

During speeding up and upto synchronization, the markings on the white scale indicate the actual
speed of the set. The operature formed by the red discs indicates the safe temperature margin (in degree
Kelvin) in which components remain stressed within the permissible level only.

These indicated margins along with the actual metal temperature help to assess the matching
steam temperature requirement prior to rolling. Correcting action has to be taken when the margin
narrows down or become zero.

During the loading operation the display indicates the load range in which the output can be
altered without any restriction on rate offload load change. The margin is a step change in load permitted
on the turbine at that moment. The actual load is indicated in the white scale. It is possible to switch back
to the variable speed range in order to check the instantaneous temperature margins at admission area or
turbine area.

Two 12-point recorders of Kompensograph model are provided for recording of absolute
temperature, temperature margins actual speed, actual load and load margins.

For checking the proper functioning of the computing circuit from the input section upto display, a
known input can be applied to get a predetermined reading in the indicator for each channel. It is
advisable to test the circuits periodically. If there are deviations the TSE should not be used till the fault is
cleared.

12.2.6 Significance of TSE Margins

The difference between permissible temperature difference and actual difference in temperature
is known as temperature margin. Fig. 12.10 gives the maximum permissible temperature difference
allowed Vs m (midwall temperature). These curves depend upon the thickness of the material at the
point where the margins are calculated, and as well as on material composition. Hence all the five
channels of TSE (as described earlier) have different curves.

The basic philosophy for computing the margin remains the same. For example, as shown in Fig.
12.10, the margins with respect to m of 250oC are computed as follows :

Steam Temperature i = 280oC

Midwall temperature m = 250oC
 act = (i - m)
= (280 – 250) = 30oC

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 Fig.12.10 Computation of TSE Temperature Margins

Fig.12.11 Effect of TSE Influence on Speeding Rate Fig.12.12 Effect of TSE Influence on Loading Rate

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 From Upper Curve, Fig.12.10, when m is 250oC;
Maximum upper permissible difference = 60oK
Maximum lower permissible difference = 30oK
The maximum upper margin =  permissible - act
= 60 – 30 = 30oK
Similarly from Lower curve,Fig.12.10 :
The maximum lower margin = - 80 – 30 = - 110oK
Hence i maximum = 280 + 30 = 310oC
i minimum = 280 – 110 = 170oC

The inference of the above computation of upper and lower temperature margins is that the steam
temperature i can be increased by 30 oC (to the level of 310 oC) safely. This is known as upper margin.
Similarly i can be decreased by 110oC safely and this is known as lower margins.

The temperature margins for all the five channels are calculated in the similar way and the
minimum upper margin and minimum lower margin among them is selected separately for display
purpose as well as fed to Electro-hydraulic controller for controlling the rate of rise of speed and rate of
rise/fall of load. However, the rate of fall of speed can not be controlled as it will come down on its own
after trip out or closing of valves.

The influence of margin during rolling is such that the rate of rise of speed is directly proportional
to TSE margins between 0 – 30oK as shown in Fig. 12.11.

If margin is more than 30oK, then the speed increases at a constant maximum rate of 600
rpm/min.

During loaded condition, the rate of rise of load depends upon upper margin and rate of decrease
of load depends upon lower margin as follows:

TSE Margin 0 – 30oK = 0 – 25 MW/min. If the margin is more than 30 oK load will
increase/decrease at a constant maximum rate of 25 MW/min. As shown in Fig.12.12, between 0 – 30oK
of margin, the rate of rise of load is directly proportional to margin

Hence operator should maintain TSE margins well above 30 oK while rolling & loading the set by
proper control of MS & HRH steam temperatures.

-o0o-

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Chapter-12: Turbine Supervisory Instrumentation 247