I

EDDY CURRENT BASED TURBINE SPEED

MEASUREMENT

A Project Report
Submitted in Partial Fulfillment of the academic
Requirements for the award degree of

Bachelor of Technology
In
Electrical and Electronics Engineering
By

ABHISHEK KUMAR (06H51A0202)

PAWAN KUMAR REDDY (06H51A0223) G. RAJESHWAR REDDY (06H51A0230)

SRAVAN KUMAR REDDY (06H51A0252) M. J. SRIHARI (06H51A0253)

Under the esteemed guidance of

Mr. A. Muneiah
Asst. Professor, M. Tech (EPT)
(Internal Guide)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

CMR COLLEGE OF ENGINEERING AND TECHNOLOGY
(Affiliated to JNTU Hyderabad)
KANDLAKOYA, MEDCHAL ROAD, HYDERABAD - 501401.
2009-10
 II

CMR COLLEGE OF ENGINEERING & TECHNOLOGY

KANDLAKOYA, MEDCHAL ROAD, HYDERABAD - 501401

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

CERTIFICATE

This is to certify that the project entitled "EDDY CURRENT BASED TURBINE
SPEED MEASUREMENT" is a bonafide work done by

ABHISHEK KUMAR 06H51A0202

PAWAN KUMAR REDDY 06H51A0223
G. RAJESHWAR REDDY 06H51A0230
SRAVAN KUMAR REDDY 06H51A0252
M. J. SRIHARI 06H51A0253

in partial fulfillment of the academic requirements for the award of the degree of
Bachelor of Technology in Electrical & Electronics Engineering, submitted to the
Department of Electrical and Electronics Engineering, CMR College of Engineering &
Technology, Hyderabad during the period 2009-10.

Mr. A. Muneiah Mr. R. V. Reddy ( DGM)

Asst. Professor, M. Tech (EPT) ECIL (CAD-CC&I)
(Internal Guide) (External Guide)

Mr. G. Deva Das

(Head of the Department) External examiner
 III

Electronics Corporation of India Ltd

A Govt. of India Enterprise
(Dept. of Atomic Energy)
Control & Automation Division
Conventional Control & Instrumentation
Hyderabad- 500062, Phone: 27186784

CERTIFICATE

This is to certify that ABHISHEK KUMAR, PAWAN KUMAR REDDY, G.

RAJESHWAR REDDY, SRAVAN KUMAR REDDY & M. J. SRIHARI of CMR
COLLEGE OF ENGINEERING & TECHNOLOGY, Electrical & Electronics Engineering
branch, have successfully completed their project work on Eddy Current Based Turbine
Speed Measurement System, in Electronics Corporation of India Limited (ECIL).

I am impressed with their good performance, reflected in the quality of their work and
the systematic manner in which their group worked on the project assigned to them. I
appreciate their enthusiasm for learning, and extra initiative taken to complete the project
within the stipulated time.

Their attendance during the project work period has been very good. I wish their
bright future and good luck in all her future endeavors.

(R.V Reddy)
DGM, C.C&I, CAD
 IV

Acknowledgment

With great pleasure we want to take this opportunity to express our heartfelt gratitude
to all the people who helped in making this project work a grand success.

We are very much thankful to Mr. R.V. Reddy (DGM), ECIL (CAD- CC&I) for
giving us this opportunity to do this project. We express our deep sense of gratitude to him
for his constant guidance throughout our project work.

We are grateful to Mr. B. Babu Rao (Engineer-C), ECIL (CAD- CC&I) and Mr.
P. Sabari Vasa (Engineer-C), ECIL (CAD- CC&I) for their valuable suggestions and
guidance given by them during the execution of this project work.

We are grateful to Mr. A. Muneiah, our internal guide for his valuable suggestions
and guidance given by him during the execution of this project work

First of all we would like to thank Mr. G.Deva Das, Head of the Department of
Electrical & Electronics Engineering, for being moral support throughout the period of our
study in CMRCET.

We are highly indebted to Principal Prof. M. Ramalinga Reddy, for giving us the
permission to carry out this project.

We would like to thank the Teaching & Non- teaching staff of Department of
Electrical & Electronics Engineering for sharing their knowledge with us.

Last but not the least; we express our sincere thanks to Mr. Ch. Gopal Reddy,
Secretary, CMR group of institutions, for his continuous care towards our achievements.

ABHISHEK KUMAR
PAWAN KUMAR REDDY
G. RAJESHWAR REDDY
SRAVAN KUMAR REDDY
M. J. SRIHARI
 V

ABSTRACT

The measurement of speed (RPM) of the rotor has long been a standard
procedure. Most major machine trains have a need for continuous indication of the RPM of
the machine, with the advent of reliable digital circuitry; digital speed measurement has
become more popular for speed indication.

The eddy current probe system is a field proven method for reliably
detecting various machine displacement parameters such as speed, axial position and
expansion etc. In the earlier years the probe design was based on reluctance, which was not
that much as accurate as compared to the eddy current based speed systems. Besides being
more accurate and easier to read, the digital speed system lends itself very well in providing
the over speed protection. The digital indication of RPM measurement eliminates many of
the earlier problems associated with the RPM measurement. Accurate and easily readable
indication of RPM is provided at control room for operators to observe. Many users also
prefer a remote digital indication at the machine train for use during start up procedure.
 VI

LIST OF TABLES

S.NO TABLE.NO: DESCRIPTION PAGE NO:

1 9.1 Practical Results 77

 VII

LIST OF FIGURES

S.NO FIG.NO: DESCRIPTION PAGE NO:

1. 1.1 Block Diagram of Eddy Current Probe System 02

2. 1.2 Setup of the Eddy Current Probe System 03
3. 1.3 The Probe 04
4. 1.4 Magnetic Field in the target material 04
5. 2.1 The Eddy Current Probe 08
6. 2.2 Speed Transducer 10
7. 2.3 Arrangement of Probe 11
8. 2.4 Block Diagram of Signal Converter 14
9. 3.1 Block Diagram of Speed Monitor Card 20
10. 3.2 Internal Circuit of Speed Monitor Card 22
11. 4.1 Block Diagram of Quad Limit Monitor 31
12. 4.2 Internal Circuit of Quad Limit Monitor (QLM) 35
13. 5.1 Seven Segment LED Display 48
14. 5.2 Block Diagram of Speed Indicator 49
15. 5.3 Internal Circuit of Speed Indicator 50
16. 6.1 Block Diagram of Local Speed Indicator 54
17. 6.2 Internal Circuit of Local Speed Indicator 55
18. 7.1 Block Diagram of ARM 59
19. 8.1 Electromagnetic Relay 64
20. 8.2 Contact Positions of Relay 65
21. 8.3 Circuit symbols of relays 67
22. 8.4 Ice-Cube Packaging 67
 VIII

INTRODUCTION TO ECIL

ECIL (Electronic Corporation Of India Limited) a company fully owned by

the Government of India was incorporated in April, 1967 with the objective of carrying
out all areas of business related to Electronic Industry the objectives of the company
are to promote and develop indigenous technology and to blend indigenous foreign
technology wherever necessary.

The company has about 8000 ECIL area of operations includes automation
instruments and systems, computers and systems, Defenses products, Electronic voting
machines, automatic ticket issuing machine, color and black and white television
receivers, Antenna systems & Electronic communication equipments. It caters to the
special equipments of Nuclear and Thermal power projects, Cement, Steel, Oil and
other industries like Railways, Defenses communications, Radio & T.V broad casting,
Police and Paramilitary organization, Civil aviation, Research and teaching institutions
in addition to general consumers.

ECIL activities are organized into five business groups Viz.

1. Control & Automation systems

2. Information Technology and Telecommunications
3. Strategic Electronics and Communication Systems
4. SCADA & Instruments
5. Components & Special products.

Lays constant emphasis on R&D, which is essential part of any valuable

Electronics industry where the rate of obsolescence is extremely rapid. At ECIL
rigorous quality and reliability in its products are ensured by well equipped
environmental and calibration test center which continuously monitors the quality of
the products through independent evaluation quality is built into ECIL products
through a system of checks and control at stages of production cycle. The move
towards ISO9002 Certification is an example of testimony of ECIL efforts in this
direction.
 IX

ECIL has a network of four Zonal offices and branch offices throughout the
country, which looks after its sales & service function. The Zonal offices are located at
Delhi, Mumbai, Kolkata and Chennai. ECIL has specialties to tailor its products to
meet the special needs of overseas consumers. ECIL’s products have already found
acceptance in Bangladesh, UAE, Russia and African countries.

Today ECIL is well known in India for pioneering the electronics and
computer revolution and has always been the leader in these fields by bringing out a
number of 'firsts', especially in the area of national infrastructure building. Over the
years the company has blossomed into a multi-product and multi-disciplinary
organization providing key technology inputs, system integration and system solutions
in the areas of Information Technology, Strategic Electronics, Communications,
Control and Automation, Instrumentation and Components.

Over the years, ECIL has set up extensive infrastructure for design,
development, manufacturing and quality assurance which includes, computer aided
design and manufacturing, computer networks for material management and MIS,
antenna spinning facility, antenna test range, quality control and calibration
laboratories and all that is required to enable the company to perform.
 X

CONTENTS

CERTIFICATE ii

ACKNOWLEDGEMENTS iv

ABSTRACT v

LIST OF TABLES
vi
LIST OF FIGURES
vii

INTRODUCTION TO ECIL
viii

CHAPTER 1 - INTRODUCTION
1.1 PROBLEM ANALYSIS……………………………………………………….
01
1.1.1 TACHOMETER
………………………………………………………………………. 01
1.1.2 RELUCTANCE METHOD …….
01
1.1.3 LASER LIGHT METHOD ………………
01
1.1.4 WIRED CONTACT METHOD
………………………………………………………………………. 02
1.2 OVERVIEW OF THE EDDY CURRENT PROBE SYSTEM ……………..
02
1.3 WORKING OPERATION………………………
03
1.4 INTRODUCTION TO TURBINE GOVERNANCE…………………………….
05
1.5 BASIC SYSTEM ……………………. .
05
1.6 DETECTORS…………………..
06
1.7 SIGNAL PROCESSING MODULES………………
06
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1.7.1 SPEED MEASUREMENT MODULE…………….

06
1.7.2 ABSOLUTE SHAFT VIBRATION MEASUREMENT………………
06
1.8 GENERAL DESCRIPTION……………………….
07

CHAPTER 2 - SPEED TRANSDUCER

2.1 INTRODUCTION-SPEED TRANSDUCER………..
08
2.1.1 CONSTRUCTION………………..
09
2.1.2 OPERATION…………………….
09
2.1.3 PRINCIPLE OF OPERATION OF EDDY CURRENT
PROBE/DETECTOR……. 11
2.2 SIGNAL CONVERTER…………
12
2.2.1 HIGH FREQUENCY OSCILLATOR………………
12
2.2.2 RECTIFIERS & FILTERS…………
12
2.2.3 AMPLIFIERS…………….
12
2.2.4 OPEN COLLECTOR OUTPUT…….
13
2.2.5 FUNCTIONAL DESCRIPTION……..
13
2.2.6 INSTALLATION…………..
13
2.2.7 CONDUCTING AND ROUTING OF CABLES………
14
2.2.8 CONDUCTING FOR NON-CONTACT PICK-UPS…….
15
2.3 SPECIFICATIONS…………….
15

CHAPTER 3 – SPEED MONITOR CARD

3.1 INTRODUCTION TO SPEED MONITOR………………….
17
3.2 COMPONENTS…………………………………….
17
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3.3 SCHEMATIC DESCIPTION……………………….

18
3.4 TERMINAL FUNCTION INDEX…………………
21
3.5 FUNCTIONAL DESCRIPTION…………
23
3.5.1 VOLTAGE REFERENCES…………
23
3.5.2 TRANSDUCER POWER SUPPLY…………….
23
3.5.3 CIRCUIT FAULT………..
24
3.5.4 TEST SIGNAL………………
24
3.5.5 DISPLAY…………………….
24
3.6 NEED FOR SPEED MONITORING…………
25
3.7 SPECIFICATIONS………………….
25
3.7.1 INPUT……………….
25
3.7.2 OUTPUT……………….
25
3.7.3 DIGITAL OUTPUTS………………..
25
3.7.4 TRANSDUCER OK………….
26
3.7.5 TEST SIGNAL……………..
26
3.7.6 ENVIRONMENTAL CONDITIONS……………….
26

CHAPTER 4 – QUAD LIMIT MONITOR

4.1 INTRODUCTION……............
27
4.2 COMPONENTS……………..
28
4.2.1 LIMIT SWITCHES…………
29
4.2.2 COMPARATOR……
29
4.2.3 DELAY CIRCUIT………….
29
4.2.4 LATCH………………….
29
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4.2.5 OPTOCOUPLER……………….
29
4.2.6 BUFFERS…………….
30
4.2.7 FLASHER OSCILLATOR…………
30
4.2.8 LEDS……………
30
4.3 SCHEMATIC DESCRIPTION…………..
30
4.4 TERMINAL FUNCTION INDEX…………
34
4.5 FUNCTIONAL DESCRIPTION…………….
36
4.5.1 CASE-I……………………
36
4.5.2 CASE-II…………..
39
4.5.3 CASE-III………….
42
4.5.4 CASE-IV………………………
42
4.6 SPECIFICATIONS……….
44
4.6.1 INPUT…………….
44
4.6.2 SET POINTS………..
44
4.6.3 OUTPUT……..
44
4.6.4 LIMIT DETECTION……….
44
4.6.5 ENVIRONMENTAL CONDITIONS………..
45
4.6.6 MECHANICAL DATA………
45
4.6.7 REAR TERMINAL OUTPUTS………
45

CHAPTER 5 – SPEED INDICATOR

5.1 INTRODUCTION…………
46
5.2 GENERAL DESCRIPTION……………..
46
5.3 FUNCTIONAL DESCRIPTION………………
46
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5.3.1 REGULATED DC SUPPLY FOR THE CMOS IC’S………….

47
5.3.2 1MHZ CLOCK SIGNAL GENERATOR…………….
47
5.3.3 DIVIDER CHAIN……………
47
5.3.4 LATCH AND CLEAR PULSE GENERATOR…………….
47
5.3.5 PULSE COUNTER………………….
47
5.3.6 LED DISPLAY……………
48
5.4 SPECIFICATIONS………………
51

CHAPTER 6 – LOCAL SPEED INDICATOR

6.1 GENERAL DESCRIPTION………….
52
6.2 FUNCTIONAL DESCRIPTION…………….
52
6.2.1 POWER SUPPLY REGULATION:……………….
52
6.2.2 LOCAL GENERATION OF TIME BASE AND TEST
SIGNALS…………. 52
6.2.3 TURBINE SPEED INDICATOR AND SHAFT ROTATION
DISPLAY……….. 53
6.3 SPECIFICATIONS……………..
56
6.4 FRONT PANELS, CONTROLS AND INDICATIONS……………
57
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CHAPTER 7 – ALARM RELAY MODULE

7.1 INTRODUCTION……………..
58
7.2 CIRCUIT DESCRIPTION…………
60
7.3 FUNCTIONAL DESCRIPTION………….
61
7.3.1 CASE-I: ENERGIZING MODE…………….
61
7.3.2 CASE-II: DE-ENERGIZING MODE…………………..
62
7.4 SPECIFICATIONS……………………
63
7.4.1 CONTROL INPUT:…………….
63
7.4.2 SUPPLY INPUT:………………..
63
7.4.3 RELAY DATA…………….
63
7.4.4 ENVIRONMENTAL DATA………………….
63

CHAPTER 8 – RELAY
8.1 INTRODUCTION……………
64
8.2 WORKING OPERATION………………….
64
8.3 RELAY DATA…………………..
69

CHAPTER 9 – CALIBRATION & TURBINE SPEED

MEASUREMENT
9.1 INTRODUCTION………………………………………………….
70
9.2 CALIBRATION PROCEDURE OF TURBINE SPEED…………….
70
9.3 DETAILS OF ICS USED IN SPEED MEASUREMENT………………..
72
9.4 LOWER POWER DUAL OP AMP………………
74
9.5 FREQUENCY OF THE LC TANK CIRCUIT…………..
74
9.6 MERITS OF CIRCUITRY OVER OTHER METHODS…………
75
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9.7 CAPACITOR BY PASSES LEAD INDUCATANCE OF SUPPLY

LINE…… 76
9.7.1 MERITS………
76

RESULT ……………………………………………………….
……………………………………. 77

CONCLUSION ……………………………………………………….
………………………….. 78

BIBLIOGRAPHY………………………………………………….
………………………..…………… 80