STEAG O&M COMPANY LIMITED

2X520 HINDUJA NATIONAL POWER CORPORATION LTD.

VISAKHAPATNAM, A.P.

Standard Doc. No. :

SOMC/C&I/60A/19/xxx
Maintenance Title: Calibration of BFP Turbine
Procedure rotor expansion sensors

REV.NO. 00 VERSION NO. 00 DOC. NO : PAGE 1 OF 9

 STEAG O&M COMPANY LIMITED
2X520 HINDUJA NATIONAL POWER CORPORATION LTD.
VISAKHAPATNAM, A.P.

Revision

Revision Date Prepared By Checked By Approved By

No.
00 21/01/2015 Ashutosh Mayank M. Raghuram

REV.NO. 00 VERSION NO. 00 DOC. NO : PAGE 2 OF 9

 STEAG O&M COMPANY LIMITED
2X520 HINDUJA NATIONAL POWER CORPORATION LTD.
VISAKHAPATNAM, A.P.

Table of Contents

1. Purpose.................................................................................................................................. 4
2. Scope ..................................................................................................................................... 4
3. Reference Documents ......................................................................................................... 4
4. General Description ............................................................................................................. 4
5. Procedure .............................................................................................................................. 4
5.1) Pre-Checks before maintenance and calibration ............................................................ 4
5.2) Procedure for mounting of BFP turbine rotor expansion sensor:.................................. 4
5.3) Procedure for calibration BFP turbine rotor expansion sensor ..................................... 5
5.4) Procedure for Zero gap voltage setting (No calibration) ................................................ 6
5.5) Procedure for cable lay after GAP adjustment or Calibration ....................................... 6
6. Special Tools/Equipment .................................................................................................... 7
7. General Precautions ............................................................................................................ 7
8. Frequency.............................................................................................................................. 7
9. Responsibility ........................................................................................................................ 7
10. Record/Checklist .................................................................................................................. 7
11. Annexure-I ............................................................................................................................. 7

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 STEAG O&M COMPANY LIMITED
2X520 HINDUJA NATIONAL POWER CORPORATION LTD.
VISAKHAPATNAM, A.P.

1. Purpose

The purpose of this document is to make understand the standard calibration procedure of
the BFP turbine rotor expansion Sensors.

2. Scope

This document is applicable for Calibration of following in Turbine supervisory Instrument.

a) BFP turbine rotor expansion Sensors (SHINKAWA VL - 143P25A-9012)

There are a total Two No’s of expansion Sensors, one for each turbine.

3. Reference Documents

a) TSI STANDARD INST. DATA SHEET DRG FOR BFPDT 500 MW

b) TSI SCHEME HY-TC-MPA1013-0106-R00

4. General Description

For the measurement of the BFP turbine rotor expansion 1 no of Eddy Current Sensors is
provided at Turbine Exhaust side. Sensor is mounted on BFP side of the measuring collar
facing towards collar. The Measurement range of sensor is 10 mm. expansion of shaft
towards BFP side is taken as negative from rotor zero position while the measurement
towards BP side is taken as positive. The measurement of the sensor is taken through driver
unit to the monitoring channel of Vibration monitoring panel

5. Procedure

5.1) Pre-Checks before maintenance and calibration

Before starting the standard GAP adjustment confirm following:

a) The ZERO position of rotor for the turbine maintenance dept. .

b) Bearing cleared from the turbine maintenance dept. .

5.2) Procedure for mounting of BFP turbine rotor expansion sensor:

a) Mount the sensor in matching hole on bearing pedestal.

b) Tighten the lock washer
a) Tighten the Connect Extension Cable at Sensor and Junction Box end.

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 STEAG O&M COMPANY LIMITED
2X520 HINDUJA NATIONAL POWER CORPORATION LTD.
VISAKHAPATNAM, A.P.

Sensor 1004-527L-012
Driver VW-143PL-3
Extension Cable VK-143-P1
Monitor VM – 5D / 11012

5.3) Procedure for calibration BFP turbine rotor expansion sensor

a) Place the calibration kit VZ-30A-3 near the driver unit of HP rotor expansion sensor.
b) Mount the sensor in front of target plate.
c) Adjust the Sensors for Set gap of 3 mm for the zero position by adjusting the
micrometer.
d) Ensure the drivers are connected and communicating to application software.
e) Ensure - 24V DC supply healthiness at Driver Unit.
f) Ensure Sensor is placed at zero position (8 mm from the collar/target plate).
g) Ensure the upper and lower range is set in application software as per annexure –I
for BFP turbine including the safety gap of 3mm.
h) Check for Zero reading in Monitor/DCS and record the voltage reading.
i) if monitor is showing ZERO fix the position and if current reading after adjusting gap
is not ZERO use Zero Shift parameter to Set current position of ‘Rotor Zero’
j) Slide the sensor away from the target plate up to the gap of maximum range in
positive side and check the reading in DCS and the application software in measured
column. If the reading in measured in application software and DCS not matching
adjust the gain and keep the reading to maximum range.
k) Again move the sensor to zero position using the micrometer and matching the
recorded gap voltage for zero position.
l) Slide the sensor away from the target plate at the gap of 1 mm up to +5 mm and
record the reading of gap voltage at driver, DCS reading, and Vibration monitor
system PC reading.
m) Again move the sensor to zero position.
n) Slide the sensor towards the target plate at the gap of 1 mm up to -5 mm and record
the reading of gap voltage at driver, DCS reading, and Vibration monitor system PC
reading..
o) Compare the DCS and field reading.
p) Ensure the gap voltage from deviation from initial calibration report (Annexure-I) is
not very high.
q) Bring the sensors to Zero position
r) Remove the sensor from calibration kit and place safely.
s) Remove the calibration kit from the site.

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 STEAG O&M COMPANY LIMITED
2X520 HINDUJA NATIONAL POWER CORPORATION LTD.
VISAKHAPATNAM, A.P.

5.4) Procedure for Zero gap voltage setting (No calibration)

a) Adjust the Sensors to set gap voltage as mentioned for zero position as per latest
calibration record.
b) Ensure the driver is connected to the sensor and
c) check for Zero reading in Monitor/DCS
d) if monitor is showing ZERO fix the position
e) Lock the sensor position by locking the sliding plate with screw nuts.
f) Tighten the sensor screw with the mounting bracket.
g) Give clearance to mechanical maintenance dept. for placing the bearing pedestal
covers.

5.5) Procedure for cable lay after GAP adjustment or Calibration

a) Detach the Sensor cable from Extension Cable.

b) Guide the Sensor Cable through Bearing pedestal Junction Box.
c) Route cable in pedestal Junction Box through Cable Seal (fixed inside Junction Box)
and tighten it sufficiently. Cable Seals are used to prevent oil leakage from pedestal.
d) Insert the Insulation Sleeve supplied with sensor, over the Extension Cable
Connector.
e) Connect the Extension Cable & Sensor Cable connectors inside the Junction Box.
f) Cover gold plated Connector joint with Teflon Tape & finally slip the Insulation Sleeve
to entirely cover it.
g) Check Gap Voltage at the Driver. Make sure reading is same as noted above.
h) Check & tie properly, loose cable loops of sensor & extension cables, which are
open & close to rotating parts.
i) This ensures protection against damage to sensor + extension cables due to
touching rotor parts.

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 STEAG O&M COMPANY LIMITED
2X520 HINDUJA NATIONAL POWER CORPORATION LTD.
VISAKHAPATNAM, A.P.

6. Special Tools/Equipment
6.1. Digital Multi meter with range microvolt measurement range
6.2. Calibration kit no. VZ-30A
6.3. 3 no of walkie-talkie

7. General Precautions

Ensure healthiness & safety of the entire activities with respect to electrical and
Mechanical system.
Ensure the safety gap of minimum 3mm sensor while rotor is at zero position.

8. Frequency

Calibration to be done yearly once at the time of turbine overhauling or after replacement
of bearing Parts

9. Responsibility

C&I Engineers are responsible for monitoring and reviewing the effectiveness of the system.
The Authorized persons shall ensure that all instruments and instrumentation are regularly
checked and maintained in serviceable condition.

10. Record/Checklist

Calibration Checklist shall be prepared as per Doc. No. SOMC/C&I/60A/06/XXX

11. Annexure-I
Reference Calibration Sheet for TDBFP-1A turbine Rotor expansion

DT Rotor Expansion (Range - 5 to 5 mm)

KKS No: XAD11CY011 Date: 09.12.14
Probe Model No: 1004-52YL-012 Sr.No: MACS0015
Driver Model No: VK143P1 Sr.No: N2410019
Extension Cable Model No: VW143PL-3 Sr.No: N27C0012
Direct Position
S.No (mm) Actual Gap Voltage Kit Reading (mm) Card display DCS display
Reading (VDC) (mm) (mm)
1 -5 -12.98 22.6 -5.1 -5.07
2 -4 -12.19 21.6 -4.1 -4.09
3 -3 -11.38 20.6 -3.1 -3.05
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 STEAG O&M COMPANY LIMITED
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VISAKHAPATNAM, A.P.

4 -2 -10.55 19.6 -2 -2.04

5 -1 -9.72 18.6 -1 -0.99
6 0 -8.91 17.6 0 0.015
7 1 -8.1 16.6 1 1.01
8 2 -7.31 15.6 2 2.01
9 3 -6.52 14.6 3 3
10 4 -5.7 13.6 4 4.02
11 5 -4.89 12.6 5.1 5.05

Reference Calibration Sheet for TDBFP-1B turbine Rotor expansion

DT Rotor Expansion (Range - 5 to 5 mm)

KKS No: XAD21CY011 Date: 28.03.15
Probe Model No: ID04-527L-012 Sr.No: MACS0014
Driver Model No: VK143P1 Sr.No: N2410017
Extension Cable Model No: VW143PL-3 Sr.No: N27C0013
Direct Position Card
S.No (mm) Actual Gap Voltage Kit Reading (mm) display
Reading (VDC) (mm) DCS display (mm)
1 -5 -10.32 19 -5.3 -5
2 -4 -9.37 18 -4.1 -4.14
3 -3 -8.47 17 -3 -3.21
4 -2 -7.59 16 -2.1 -2.14
5 -1 -6.73 15 -1 -1.05
6 0 -5.87 14 0 -0.06
7 1 -5.02 13 1 -0.97
8 2 -4.17 12 2.1 2.02
9 3 -3.34 11 3.1 3.03
10 4 -2.53 10 4 4.01
11 5 -1.78 9 5 4.92

Reference Calibration Sheet for TDBFP-2A turbine Rotor expansion

Name Model No. Location Sr No Range

Sensor 1D04-527L-012 MACS0016
Ex. Cable VW-143PL-3 N27C0010
Driver VK 143 N27C0010 -5 TO 5 mm
Monitor VM5D R2/S7/CH-1 N2670006
CAL. KIT VZ – 30A MA840007
Sr. No Input Card Display DCS Gap vtg.
(mm) (mm) Vdc
1 5 4.8 4.77 -5.04
2 4 3.8 3.77 -5.82
3 3 2.9 2.83 -6.60
4 2 1.9 1.85 -7.36
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 STEAG O&M COMPANY LIMITED
2X520 HINDUJA NATIONAL POWER CORPORATION LTD.
VISAKHAPATNAM, A.P.

5 -1 0.9 0.9 -8.13

6 0 0.0 -0.06 -8.90
7 -1 -1.0 -1.02 -9.67
8 -2 -2.0 -2.01 -10.46
9 -3 -3.0 -2.99 -11.24
10 -4 -3.9 -3.94 -12.00
11 -5 -4.8 -4.85 -12.73

Reference Calibration Sheet for TDBFP-2B turbine Rotor expansion

Name Model No. Location Sr No Range

Sensor 1D04-527L-012 MACS0018
Ex. Cable VW-143PL-3 N27C0011
Driver VK 143 N27C0018 -5 TO 5 mm
Monitor VM5D R2/S7/CH-1 N2670005
CAL. KIT VZ – 30A MA830008
Sr. No Input Card Display (mm) DCS Gap vtg.
(mm) Vdc
1 5 4.9 4.95 -4.92
2 4 3.9 3.94 -5.73
3 3 2.9 2.95 -6.52
4 2 2.0 1.96 -7.31
5 -1 1.0 0.98 -8.09
6 0 0.0 0.00 -8.89
7 -1 -1.0 -1.00 -9.70
8 -2 -2.0 -2.04 -10.53
9 -3 -3.1 -3.09 -11.36
10 -4 -4.1 -4.09 -12.17
11 -5 -5.0 -5.00 -12.94

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