System and method for detecting the occurrence, location and depth of cracks in turbine-generator rotors

• US 5,258,923 A
• Filed: 07/22/1987
• Issued: 11/02/1993
• Est. Priority Date: 07/22/1987
• Status: Expired due to Fees

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Bankert, Raymond J., Imam, Imdad, Azzaro, Steven H.
• Primary Examiner(s): Black, Thomas G.
• Assistant Examiner(s): Zanelli, Michael
• Application Number:
  US07/076,311
• Time in Patent Office: 2,295 Days
• Field of Search: 364/506-508, 364/550-552, 364/582, 364/574, 340/679, 340/680, 340/683, 73/570, 73/579, 73/593, 73/598, 73/600, 73/602, 73/658-660, 371/22.4, 371/25.1
• US Class Current: 702/36
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G01N 2291/2693 Rotor or turbine parts
• CPC Class Codes: G01N 29/12 by measuring frequency or resonance of acoustic waves measuring frequency or resonant frequency of mechanical vibrations or acoustic waves in general G01H1/06, G01H3/04, G01H13/00; acoustic resonators G10K11/04; vibration or shock testing of structures G01M7/00

Abstract

System and method for detecting the occurrence, location and depth of a crack in the rotor of a turbine-generator. The location and depth of a crack are determined by monitoring the fundamental and histogram harmonic components of vibrations at certain predetermined points along the length of the rotor. The histogram harmonic components are normalized relative to the fundamental component, and the normalized histogram harmonic components are monitored to determine the location of the crack. The unnormalized histogram harmonic components are analyzed to determine the depth of the crack. The occurrence of a crack is detected by monitoring the amplitude and phase of rotor vibrations during an accel or decel operation to detect harmonic resonances which are characteristic of a crack in the rotor. The amplitude and phase data is filtered to eliminate spurious data, and it is interpolated to provide baseline and current data at matching speed points.

Claims

1. A system for determining the location and depth of a transverse crack along the length of a turbine-generator rotor, comprising means for sensing mechanical vibrations of the rotor at a plurality of predetermined points along the length of the rotor while the turbine-generator is operating at running speed and providing electrical signals having a spectral content corresponding to the vibration of the rotor at each of the predetermined points, means for analyzing the spectral content of the electrical signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, means for normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, means for monitoring the normalized harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and means for analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components.

2. The system of claim 1 wherein the means for monitoring the normalized histogram harmonic signals includes a computer programmed to determine the location of a crack from the normalized second histogram harmonic signals at two points along the length of the rotor.

3. The system of claim 1 wherein the means for analyzing the unnormalized histogram harmonic components includes means for determining the depth of the crack according to the relationship:

space="preserve" listing-type="equation">(Y.sub.i).sub.n =(P.sub.i).sub.n e.sup.b.sbsp.1.sup.a-b.sbsp.2

where (Y_i)_n is the unnormalized n^th histogram harmonic component measured at point i, (P_i)_n is the unnormalized n^th histogram harmonic component of a vibration at point i produced by a crack of predetermined depth, e is the logarithmic exponential, b₁ and b₂ are constants which define the slope of a curve plotting the unnormalized histogram harmonic component as a function of crack depth, and a is the depth of the crack.

4. A method of determining the location and depth of a transverse crack along the length of a turbine-generator rotor, comprising the steps of sensing mechanical vibrations of the rotor at a plurality of predetermined points along the length of the rotor while the turbine-generator is operating at running speed and providing electrical signals having a spectral content corresponding to the vibration of the rotor at each of the predetermined points, analyzing the spectral content of the electrical signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components.

5. The method of claim 4 wherein a computer is programmed to determine the location of a crack from the normalized second histogram harmonic signals at two points along the length of the rotor.

6. A method of determining the location and depth of a transverse crack along the length of a turbine-generator rotor, comprising the steps of sensing mechanical vibrations of the rotor at a plurality of predetermined points along the length of the rotor while the turbine-generator is operating at running speed and providing electrical signals having a spectral content corresponding to the vibration of the rotor at each of the predetermined points, analyzing the spectral content of the electrical signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components according to the relationship:

space="preserve" listing-type="equation">(Y.sub.i).sub.n =(P.sub.i).sub.n e.sup.b.sbsp.1.sup.a-b.sbsp.2

where (Y_i)_n is the unnormalized n^th histogram harmonic component measured at point i, (P_i)_n is the unnormalized n^th histogram harmonic component of a vibration at point i produced by a crack of predetermined depth, e is the logarithmic exponential, b₁ and b₂ are constants which define the slope of a curve plotting the unnormalized histogram harmonic component as a function of crack depth, and a is the depth of the crack.

7. A system for determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising means for sensing vibrations at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, means for sampling the vibration signals prior to development of a crack to provide a background signal for each of the predetermined points, means for monitoring the vibration signals as the turbine-generator operates to provide a foreground signal for each of the predetermined points, means for subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, means for analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, means for normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, means for monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and means for analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components.

8. The system of claim 7 wherein the means for monitoring the normalized histogram harmonic signals includes a computer programmed to determine the location of a crack form the normalized second histogram harmonic signals at two points along the length of the rotor.

9. A system for determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising means for sensing vibration at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, means for sampling the vibration signals prior to development of a crack to provide a background signal for each of the predetermined points, means for monitoring the vibration signals as the turbine-generator operates to provide a foreground signal for each of the predetermined points, means for subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, means for analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, means for normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, means for monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and means for analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components according to the relationship:

space="preserve" listing-type="equation">(Y.sub.i).sub.n =(P.sub.i).sub.n e.sup.b.sbsp.1.sup.a-b.sbsp.2

where (Y_i)_n is the unnormalized n^th histogram harmonic component measured at point i, (P_i)_n is the unnormalized n^th histogram harmonic component of a vibration at point i produced by a crack of predetermined depth, e is the logarithmic exponential, b₁ and b₂ are constants which define the slope of a curve plotting the unnormalized histogram harmonic component as a function of crack depth, and a is the depth of the crack.

10. A method of determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising the steps of sensing vibration at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, sampling the vibration signals prior to development of a crack to provide a background signal for each of the predetermined points and for monitoring the vibration signals as the turbine-generator operates to provide a foreground signal for each of the predetermined points, subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components.

11. The method of claim 10 wherein a computer is programmed to determine the location of a crack from the normalized second histogram harmonic signals at two points along the length of the rotor.

12. A method of determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising means for sensing vibration at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, sampling the vibration signals prior to development of a crack to provide a background signal for each of the predetermined points and for monitoring the vibration signals as the turbine-generator operates to provide a foreground signal for each of the predetermined points, subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components according to the relationship:

space="preserve" listing-type="equation">(Y.sub.i).sub.n =(P.sub.i).sub.n e.sup.b.sbsp.1.sup.a-b.sbsp.2

where (Y_i)_n is the unnormalized n^th histogram harmonic component measured at point i, (P_i)_n is the unnormalized n^th histogram harmonic component of a vibration at point i produced by a crack of predetermined depth, e is the logarithmic exponential, b₁ and b₂ are constants which define the slope of a curve plotting the unnormalized histogram harmonic component as a function of crack depth, and a is the depth of the crack.

13. A system for determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising means for sensing vibration at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, means for taking a predetermined number of samples of the vibration signal at each of the predetermined points for a plurality of revolutions of the rotor prior to development of a crack, means for combining the samples to provide an enhanced background signal for each of the predetermined points, means for taking the same predetermined number of samples of the vibration signal at each of the predetermined points during normal operation of the turbine-generator, means for combining the samples taken during normal operation to provide an enhanced foreground signal for each of the predetermined points, means for subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, means for analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, means for normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, means for monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and means for analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram components.

14. The system of claim 13 wherein the means for monitoring the normalized histogram harmonic signals includes a computer programmed to determine the location of a crack from the normalized second histogram harmonic signals at two points along the length of the rotor.

15. A system for determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising means for sensing vibration at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, means for taking a predetermined number of samples of the vibration signal at each of the predetermined points for a plurality of revolutions of the rotor prior to development of a crack, means for combining the samples to provide an enhanced background signal for each of the predetermined points, means for taking the same predetermined number of samples of the vibration signal at each of the predetermined points during normal operation of the turbine-generator, means for combining the samples taken during normal operation to provide an enhanced foreground signal for each of the predetermined points, means for subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, means for analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, means for normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, means for monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and means for analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram components.

16. A system for determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising means for sensing vibration at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, means for taking a predetermined number of samples of the vibration signal at each of the predetermined points for a plurality of revolutions of the rotor prior to development of a crack, means for combining the samples to provide an enhanced background signal for each of the predetermined points, means for taking the same predetermined number of samples of the vibration signal at each of the predetermined points during normal operation of the turbine-generator, means for combining the samples taken during normal operation to provide an enhanced foreground signal for each of the predetermined points, means for subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, means for analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, means for normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, means for monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and means for analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components according to the relationship:

space="preserve" listing-type="equation">(Y.sub.i).sub.n =(P.sub.i).sub.n e.sup.b.sbsp.1.sup.a-b.sbsp.2

where (Y_i)_n is the unnormalized n^th histogram harmonic component measured at point i, (P_i)_n is the unnormalized n^th histogram harmonic component of a vibration at point i produced by a crack of predetermined depth, e is the logarithmic exponential, b₁ and b₂ are constants which define the slope of a curve plotting the unnormalized histogram harmonic component as a function of crack depth, and a is the depth of the crack.

17. A method of determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising means for sensing vibration at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, taking a predetermined number of samples of the vibration signal at each of the predetermined points for a plurality of revolutions of the rotor prior to development of a crack, combining the samples to provide an enhanced background signal for each of the predetermined points, taking the same predetermined number of samples of the vibration signal at each of the predetermined points during normal operation of the turbine-generator, combining the samples taken during normal operation to provide an enhanced foreground signal for each of the predetermined points, subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram components.

18. The method of claim 17 wherein a computer is programmed to determine the location of a crack from the normalized second histogram harmonic signals at two points along the length of the rotor.

19. A method of determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising the steps of sensing vibrations at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, taking a predetermined number of samples of the vibration signal at each of the predetermined points for a plurality of revolutions of the rotor prior to development of a crack, combining the samples to provide an enhanced background signal for each of the predetermined points, taking the same predetermined number of samples of the vibration signal at each of the predetermined points during normal operation of the turbine-generator, combining the samples taken during normal operation to provide an enhanced foreground signal for each of the predetermined points, subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram components.

20. A method of determining the location and depth of a transverse crack along the length of a turbine-generator rotor while the turbine-generator is operating at running speed, comprising the steps of sensing vibrations at a plurality of predetermined points along the length of the rotor to provide vibration signals having a spectral content corresponding to the vibrations at respective ones of the predetermined points, taking a predetermined number of samples of the vibration signal at each of the predetermined points for a plurality of revolutions of the rotor prior to development of a crack, combining the samples to provide an enhanced background signal for each of the predetermined points, taking the same predetermined number of samples of the vibration signal at each of the predetermined points during normal operation of the turbine-generator, combining the samples taken during normal operation to provide an enhanced foreground signal for each of the predetermined points, subtracting the background signals from the foreground signals to provide a difference signal for each of the predetermined points, analyzing the spectral content of the difference signals to provide fundamental and unnormalized histogram harmonic components for each of the predetermined points, normalizing the histogram harmonic components relative to the fundamental components to provide normalized histogram harmonic signals in addition to the unnormalized histogram harmonic components for the respective points, monitoring the normalized histogram harmonic signals to determine the location of a crack along the length of the rotor relative to the predetermined points, and analyzing the unnormalized histogram harmonic components to determine the depth of the crack as a function of the logarithm of the unnormalized histogram harmonic components according to the relationship:

space="preserve" listing-type="equation">(Y.sub.i).sub.n =(P.sub.i).sub.n e.sup.b.sbsp.1.sup.a-b.sbsp.2

where (Y_i)_n is the unnormalized n^th histogram harmonic component measured at point i, (P_i)_n is the unnormalized n^th histogram harmonic component of a vibration at point i produced by a crack of predetermined depth, e is the logarithmic exponential, b₁ and b₂ are constants which define the slope of a curve plotting the unnormalized histogram harmonic component as a function of crack depth, and a is the depth of the crack.

21. A system for detecting an occurrence of a transverse crack in a rotor of a turbine-generator, comprising means for sensing the amplitude and phase of vibrations in the rotor at different speeds during a change in the speed of the rotor prior to development of a crack to provide baseline amplitude and phase data, means for monitoring the amplitude and phase of the vibrations at different speeds during a subsequent change in the rotor speed to provide current amplitude and phase data, means for taking a vector difference between the current data and the baseline data, and means for monitoring the vector difference to detect the occurrence of a crack.

22. The system of claim 21 wherein the means for sensing the amplitude and phase of vibrations to provide baseline data and the means for monitoring the amplitude and phase of the vibrations to provide current data each include means for providing fundamental and harmonic components, the vector differences of the harmonic components being monitored to detect the occurrence of a crack.

23. The system of claim 21 including means for filtering the baseline data and the current data by discarding data which differs from preceding data by more than a predetermined amount.

24. The system of claim 23 wherein the means for filtering the baseline data and the current data includes means for discarding both the amplitude data and the phase data for a data point if the phase data changes by more than a predetermined amount between successive data points or if the amplitude data changes by more than a predetermined amount relative to the speed data between successive data points.

25. The system of claim 23 wherein the means for filtering the baseline data and the current data further includes means for discarding data if the rotor speed changes by more than a predetermined amount between successive data points.

26. The system of claim 21 including means for interpolating the current data to provide current data and baseline data at matching rotor speeds.

27. The system of claim 26 wherein the means for interpolating the data includes means for determining a quadratic least squares fit between successive data points of the current data.

28. A method of detecting an occurrence of a transverse crack in a rotor of a turbine-generator, comprising the steps of:

sensing the amplitude and phase of vibrations in the rotor at different speeds during a change in the speed of the rotor prior to development of a crack to provide baseline amplitude and phase data, monitoring the amplitude and phase of the vibrations at different speeds during a subsequent change in the rotor speed to provide current amplitude and phase data, taking a vector difference between the current data and the baseline data, and monitoring the vector difference to detect the occurrence of a crack.

29. The method of claim 28 wherein harmonic components of the baseline data and the current data are monitored to detect the occurrence of the crack.

30. The method of claim 28 including the steps of filtering the baseline data and the current data by discarding data which differs from preceding data by more than a predetermined amount.

31. The method of claim 30 including the steps of monitoring changes in the amplitude data and the phase data between successive data points of the baseline data and the current data, and discarding the data for a data point if the phase data changes by more than a predetermined amount or if the amplitude data changes by more than a predetermined amount relative to a change in the rotor speed between successive data points.

32. The method of claim 30 including the steps of monitoring changes in the rotor speed between successive data points of the baseline data and the current data, and discarding the data for a data point if the rotor speed changes by more than a predetermined amount between successive data points.

33. The method of claim 28 including the step of interpolating the current data to provide current data and baseline data at matching rotor speeds.

34. The method of claim 28 wherein the data is interpolated by determining a quadratic least squares fit between successive data points of the current data.

35. A system for detecting an occurrence of a transverse crack in a rotor of a turbine-generator, comprising means for sensing the amplitude and phase of vibrations in the rotor at different speeds during a change in the speed of the rotor prior to development of a crack to provide baseline amplitude and phase data having fundamental and harmonic components, means for monitoring the amplitude and phase of the vibrations at different speeds during a subsequent change in the rotor speed to provide current amplitude and phase data having fundamental and harmonic components, means for taking a vector difference between harmonic components of the current data and the baseline data at matching rotor speeds, and means for monitoring the vector difference of the harmonic components to determine the occurrence of a crack.

36. The system of claim 35 wherein the means for providing the baseline data and the means for providing the current data each include means for discarding the data if the rotor speed changes by more than a predetermined amount between successive data points.

37. The system of claim 35 wherein the means for providing the baseline data and the means for providing the current data each include means for discarding the data if the fundamental component or a harmonic component of the phase data changes by more than a predetermined amount between successive data points.

38. The system of claim 35 wherein the baseline data and the current data include amplitude and phase data for 1Rev, 2/Rev and 3/Rev harmonics, and the means for providing the baseline data and the means for providing the current data each include means for discarding the data for a data point if the 1/Rev, 2/Rev and 3/Rev phase data changes by more than a predetermined amount between successive data points.

39. The system of claim 35 wherein the means for taking the vector difference at matching rotor speeds includes means for interpolating the current data to provide current data and baseline data at matching rotor speeds.

40. The system of claim 39 wherein the means for interpolating the data includes means for determining a quadratic least squares fit between successive data points of the current data.

41. The system of claim 35 wherein the baseline data and the current data include amplitude and phase data for 1Rev, 2/Rev and 3/Rev harmonics, and the means for providing the baseline data and the means for providing the current data each include means for discarding the data for a data point if the 1/Rev, 2/Rev and 3/Rev amplitude data changes by more than a predetermined amount relative to a change in rotor speed between successive data points.

42. A method of detecting an occurrence of a transverse crack in a rotor of a turbine-generator, comprising the steps of:

sensing the amplitude and phase of vibrations in the rotor at different speeds during a change in the speed of the rotor prior to development of a crack to provide baseline amplitude and phase data having fundamental and harmonic components, monitoring the amplitude and phase of the vibrations at different speeds during a subsequent change in the rotor speed to provide current amplitude and phase data having fundamental and harmonic components, taking a vector difference between harmonic components of the current data and the baseline data at matching rotor speeds, and monitoring the vector difference of the harmonic components to determine the occurrence of a crack.

43. The method of claim 42 including the steps of monitoring the rotor speed between successive data points of the base line data and the current data and discarding the data for a data point if the rotor speed changes by more than a predetermined amount between that data point and the preceding data point.

44. The method of claim 42 including the steps of monitoring changes in the fundamental and harmonic components of the phase data between successive data points of the baseline data and the current data, and discarding the data for a data point if the fundamental component or a harmonic component of the phase data changes by more than a predetermined amount between successive data points.

45. The method of claim 42 wherein the baseline data and the current data include amplitude and phase data for 1Rev, 2/Rev and 3/Rev harmonics, and the method includes the steps of monitoring changes in the amplitude data and the phase data between successive data points of the baseline data and the current data, and discarding the data for a data point if the 1/Rev, 2/Rev and 3/Rev phase data changes by more than a predetermined amount between successive data points.

46. The method of claim 42 including the step of interpolating the current data to provide current data and baseline data at matching rotor speeds.

47. The method of claim 46 wherein the data is interpolated by determining a quadratic least squares fit between the data from successive data points of the current data.

48. The method of claim 42 wherein the baseline data and the current data include amplitude and phase data for 1Rev, 2/Rev and 3/Rev harmonics, and the method includes the steps of monitoring changes in the amplitude data and the phase data between successive data points of the baseline data and the current data, and discarding the data for a data point if the 1/Rev, 2/Rev and 3/Rev amplitude data changes by more than a predetermined amount relative to a change in rotor speed between successive data points.