FFT Spectrum Analysis

What is FFT?

 Known as Fast Fourier Transformation.

 Developed by J.B. Fourier in 1874.
Time & Frequency
Representation of Time & Frequency
Why Spectrum Analysis?

CPM
 Pure sinus

t CPM

2 sine waves

t CPM
COMPLEX SYSTEM
FFT mathematically converts overall complex signal into individual
amplitudes at component frequencies
From time record to vibration spectrum

Time record

Sine waves
FFT = Fast Fourier Transfer

Vibration spectrum
amplitude - frequency scale
Characteristic machine part frequencies
 Different machinery problems cause vibration at different
frequencies.

 Overall vibration coming out from machine is combination

of many vibration signals form various machine parts and
it’s structure.

 FFT is a method of viewing the signal with respect to

frequency.
Importance of FFT
Importance of FFT
VIBRATION OF HYDRO
TURBINE – GENERATOR
UNITS
 VIBRATION OF HYDRO TURBINE- GENERATOR
UNITS
 VIBRATION : A VERY IMPORTANT PARAMETER OF MACHIN
 PERTURBATION FORCES THAT CAUSE VIBRATIONS IN A HYDRO
PLANT.
 CHECKING FOR VIBRATIONS:
1. Past and Present Vibration Data.
2. Selection of Vibration Instrument and Pickups.
3. Installation / Commissioning of Vibration Instrument.
4. Recording vibrations in mechanical run, with full excitation
and on loads.
5. Recording Frequency spectrum and phase angles
6. Check for blade pass frequency and vane pass frequency etc.
VIBRATION OF HYDRO TURBINE- GENERATOR
UNITS
 ANALYSING OF VIBRATION DATA.
 TRACING AND ELIMINATING VIBRATIONS.
 WHY PERIODIC VIBRATION ANALYSIS AND FREQUENT
BALANCING OF MACHINES ?
 CASE STUDY.
VIBRATION : A VERY IMPORTANT PARAMETER
OF MACHINE
 VIBRATION TO MACHINE AS HEARTBEAT TO HUMAN
BEING.
 VIBRATION – A PREDICTIVE MANTENANCE TOO
 VIBRATION – A CONDITION MONITORING
PARAMETER.
 HIGH VIBRATION CAN LEAD TO
1. COMPONENT FAILURE.
2. LONGER OUTAGE.
3. REDUCED PLF.
4. HIGH EXPENDITURE.
 VIBRATION ANALYSIS / BALANCING KEEPS MACHINE
HEALTHY AND OPERATOR HAPPY.
DISTURBANCE FORCES THAT CAUSE VIBRATIONS
IN A HYDRO
Steady PLANT regime :-
State Operating

1) Mechanical Disturbances Forces

(Related to Mechanical Fields)
2) Hydraulic Disturbances
Forces(Related to Turbine and Water
Flow Conditions)
3) Electrical Disturbances
Forces(Related to Electromagnetic
and Electrical Fields )
Mechanical Disturbance Forces
 Centrifugal force due to imbalance of the rotating
masses of the hydro unit.
 Looseness of bolted connections in the rotating parts
 Elastic forces of the shaft which appear when
centering is disturbed or when the shaft is distorted.
 Misalignment of shaft systems
 Poor bearing conditions
 Loose foundation bolts
 Poor structural rigidity
 Structural damage
 Frictional forces.
 Hydraulic Disturbance Forces
Periodic components of hydraulic moment appear due to the following
causes:
 Presence of a vortex plait in the spiral casing, wicket gates, runner and
draft tube.
 Obstruction in spiral casing
 Non-uniform velocity distribution in the various flow passages of the
turbinelike debris between the vane.
 Pressure fluctuations in the penstock of the hydro unit.
 Possible appearance of “flutter” – type vibrations in the blades of
adjustable-blade turbine runners.
 Incorrect vertical position of the runner with reference to the
distributor.
 Hydraulic imbalance of the runner.
 Cavitation regimes of operation of the turbine.
 Unfavorable operating conditions of guide bearings.
 Electrical Disturbance Forces
 Periodic components of the forces of interaction between the
generator stator and rotor(force of magnetic field).
 Forces due to non-uniform air gap between stator and rotor.
 Forces created by the short circuiting of the generator bus bars.
 Forces created by the partial or total short circuiting of the pole
winding of the generator rotor.
 Forces created by asymmetrical operating conditions of the
generator like out of roundness of rotor, eccentric or bowed rotor
etc.
 Forces created by asynchronous operation of the generator like
unbalanced phases.
 Shorted stator laminations
SELECTION OF VIBRATION INSTRUMENT AND
PICKUPS.
 VIBRATION INSTRUMENTS GENERALLY IN USE:
1) CONVENTIONAL TYPE – IRD 308.
2) SINGLE CHANNEL ANALYSER – VIBROPORT.
3) FFT ANALYSER – IRD 885 / VIBROPORT 41.
4) DUAL / MULTI-CHANNEL – DATAMANAGER 2000 /
ADRE.

 TYPES OF VIBRATION PICKUPS.

1) NON CONTACT PICKUPS.
2) VELOCITY PICKUPS.
3) ACCELERATION PICKUPS.
RECORDING VIBRATIONS IN MECHANICAL RUN, WITH FULL
EXCITATION AND ON LOADS
 ANALYSIS OF VIBRATION DATA

Hydro Unit
Vibration

Resonance Frequency of
Steady State Disturbance forces and Transient
Operation natural vibrations of Operation
components
 Analysis under Steady State

Centrifugal Friction Forces

Mechanical Elastic Internal Friction Dry Friction
Force Friction Due to
Disturbance Forces Forces Forces
due to Forces interference of
Forces of Shaft of Metal of Bearing
Unbalance mass Rotating parts

Steady Height at which

Variable Cavitation
Hydraulic Non-Uniform Flutter of runners of Rotor Hydraulic
State Disturbance Velocity
Vortex
Runner Radial /Axial Lift
Component of
Imbalance Phenomenon
Oil Film
Moment in In Bearings
Formation Forces In Turbine
of Runner
Operatio Forces Distribution Blades turbines are Pelton Wheels
located
n
Electrical Forces due to Forces under Forces Appearing Short Circuit
Magnetic
Disturbance Unequal Asymmetrical during Of
Forces
Forces Air Gaps Conditions Short Circuits Rotor Winding
 Analysis under Resonance Frequency

Resonance Frequency of
Disturbance Forces and Natural
Vibrations of components

Shaft Turbine Hydro Unit Pen-stock

Spider Runner Generator
Extension Cover Shaft Pipe

KAPLAN Bending Vibration

FRANCIS Rocking Vibration

Torsional
PELTON
Vibration
 Analysis under Transient Operation

Transient Operation

Mechanical Disturbance Forces Hydraulic Disturbance Forces Electrical Disturbance Forces

Starting of Turbine Starting of Unit Short Asynchronous

Synchronization
Circuiting Operation

Stopping of Turbine Load Shedding

Manual

Uploading Loading
Automatic
Continuous Change of
Loading
Load
Self
Transient to Synchronization
Acceleration
Synchronous
Compensator regime

Acceleration
 TRACING AND ELIMINATING VIBRATIONS
Operating Nature of Possible Cause of Methods of eliminating Cause
Condition of Vibrations Vibrations of Vibrations
Unit
No load Vibration increase Generator rotor or Unit must be dynamically balanced.
operations with increasing speed turbine runner is not During subsequent maintenance
without excitation of rotor, directly balanced. Exciter rotor turbine runner must be balanced
proportional to which is directly on special balancing rigs. Exciter
square of speed. mounted on generator rotor should be properly balanced.
shaft may not be
properly centered.
No load operation Increase in vibration Short circuit of coil of Site of short circuit must be
with excitation with increasing rotor winding. ascertained by an oscillograph
current. which records current in conductor
while traversing each pole. Damage
Significant increase in must be repaired.
Continuous decrease Air – Gap between Air –Gap between stator and rotor
in vibration with stator & rotor. should be checked with unit
decrease in voltage at stationary and displacement of
stator terminal. rotor should be ascertained after
putting unit into operation. Air-gap
should be adjusted to obtain
Rotor mounted Continued
uniform value all over periphery.
Vibration cease eccentrically on shaft. Allowable variation in Air – Gap
 TRACING AND ELIMINATING VIBRATIONS
Operating Nature of Possible Cause of Methods of eliminating Cause
Condition of Vibrations Vibrations of Vibrations
Unit
Operation with Oscillations of Shaft Interference Labyrinth seal clearance must
and without at some particular between stationary be increased so that
load on unit (for opening of wicket and rotating parts, interference between
High-Head radial gates irrespective for instance between stationary and rotating parts is
– axial turbines ) of speed or load on runners, rotating ring eliminated. Normally gap in
unit. etc., and housing labyrinth seal should be 0.001D
due to small where, D is Diameter at seal
labyrinth clearance. gap. If interference is from
other causes they must be
traced and eliminated(for
instance, by re-centering etc.).
Operation with Run out of shaft Improve alignment Unit should be centered.
or without load and vibration of of generator and Height of key should be
on unit. unit irrespective of turbine shafts. checked with dial gauge by
turning speed. It is Wrong height placing it on surface plate and
sometimes found adjustment of it should be finished to desired
Continued
that shaft run-out circular key at size.
 TRACING AND ELIMINATING VIBRATIONS
Operating Nature of Possible Cause of Methods of eliminating Cause
Condition of Vibrations Vibrations of Vibrations
Unit
Operation with Amplitude of Asymmetrical Salient parts which are placed
or without load vibration increases positioning of salient asymmetrically should be
on unit. in direct proportion parts at rim of either removed or covered with
to turning speed runner (ribs, sheet to provide streamlined
and load. balancing masses surface.
etc.). Runner and Wicket gates
should be cleaned and debris
Clogging of flow cleared.
passages of runner
or wicket gates (with
clay, debris, stones Eccentricity of seal ring should
etc.). be ascertained, if needed ring
Eccentric mounting should be changed or
of labyrinth seal ring. machined to eliminate
eccentricity .
Continued
Bolted joints should be checked
Looseness of bolted for joints.
 TRACING AND ELIMINATING VIBRATIONS
Operating Nature of Possible Cause of Methods of eliminating Cause
Condition of Vibrations Vibrations of Vibrations
Unit
Unit on no-load Vibrations become Turning speed is During Start-up and stopping of
severe at some some multiple of unit this speed must be passed
particular speed. critical speed. through quickly.
Natural frequency of structure
should be altered.
Unit operation Vibrations increase Magnetic
on load with increase in Asymmetry. a) Center properly.
load. a) Incorrect
centering of thrust b) Eliminate misalignment of
or journal bearing. flange coupling by
b) Misalignment of introducing insert or by
shaft at flange machining faces of coupling.
coupling. c) Ensure proper mounting of
footsteps at shaft.
c) Footstep loosely d) Provide for external flow
mounted on shaft. areas at exit sections in
d) Outlet sections of runner. Continued
runner flow
passages have e) Either increase length of hub
 TRACING AND ELIMINATING VIBRATIONS
Operating Nature of Possible Cause of Methods of eliminating Cause
Condition of Vibrations Vibrations of Vibrations
Unit
Unit operating Vibrations suddenly Cavitation occur due Avoid loading unit at levels at
on load increase over to change in draft which excessive vibration
narrow range of height, poor profiles occurs.
load and are of runner blades or Provide arrangements for
accompanied by vortex filament shed injection of air below runner.
severe water by runner blades. Modify shapes of trailing edges
hammer in draft of runner blades.
tube.
Unit operating Vibrations increase Generator Check Governor characteristics
on load at certain loads(for characteristics not and suitably modify to obtain
adjustable blades properly matched to smooth operation of unit and
turbines). available head. maximum efficiency.
Operation with Increasing shaft Excessive clearance Adjust clearance between shaft
or without load run-out at all between shaft and and liner in accordance with
on unit. operating bearing liner. guidelines provided by
conditions manufacturer.
SHAFT VIBRATION LIMITS
VIBRATION VELOCITY CHART
Significance of zones is as under;
Zone A represents new machines that can be
operated without restriction.
Zone B is acceptable for long term operation.
Zone C represents machines that may be
operated for a limited period until a
suitable opportunity arises for remedial
action to be taken.
Zone D is identified as a trip level as these
values are considered to be sufficient to
cause damage.
Cause Characteristic Remarks
Unbalance 1 X (once per revolution) Changes in balance will give changes in the 1X
vector. Vibration will be highest when running
speed coincides with a rotor system critical speed.
Significant vibration phase change will occur when
passing through critical speeds. At a fixed speed
vibration level are constant.

Misalignment 1X , 2X , 3X Various types and causes for misalignment are:

angular, parallel, foundation movement. The axial
vibration component may be as significant as the
radial component, particularly for geared system.
Bearing wear 40-50% of operating speed Excessive clearance due to wear, damage or
or at first rot0r critical improper assembly can cause bearing oil film
speed destabilizing forces to act on the rotor.
Oil film bearings Vibration level will be unsteady and can
quickly reach high magnitudes.
Rolling element bearings Various frequencies, Vibration tends to be localized to the region
particularly high orders of of the defective bearing.
running speed and ball
pass frequencies Vibration readings are usually unsteady and
increase with time
Stiffness dis-symmetry 2X Vibration peaks when 2X stimulus is
(e.g., axial winding slots coincident with a rotor critical speed. At a
in generator/ motor fixed speed vibration levels are constant.
rotors)
Bent rotor 1X , 2X , or higher If the rotor is bent near the coupling, a high
harmonics 2X axial vibration is frequently observed. At
a fixed speed, the rotor vibration levels are
constant.
Cracked rotor 1X , 2X , or higher A growth in the 2X vector is an indication
harmonics that the growth of a transverse crack is
getting critical. Changes in the 1X or higher
harmonic vector can also occur.

Componrnt looseness in 1X harmonics of running Vibration level may be erratic and

rotor speed frequency inconsistent between successive start-stop
cycles. Sometimes sub-harmonic frequencies
are also observed.
Eccentric or noncircular 1X and for noncircular Vibration levels can be abnormal or
baring journals journal at harmonics of excessive at low rotor speeds as well as at
running speed frequency rotor critical speeds. At a fixed rotor speed,
the vibration levels are constant.
UNIT # 4 AT URI POWER STATION