APPLICATIONS

APPLICATION
Considerations for

EDDY-CURRENT
Proximity Probes
he plants rotating machinery engineer
breathed a sigh of relief. After nearly half
a decade of having his requests turned
down, he had finally gotten capital
budget approval to retrofit an aging
compressor with proximity probes. He understood
the value of the data they could provide, as many
of the newer machines in the plant were fitted with
probes and he used the information regularly to plan
maintenance and diagnose mechanical problems.
However, unlike the machines in newer sections
of the plant that had been supplied from the OEM
with probes already installed, the machine he
was now retrofitting dated back to the 1960s
and did not have provisions for probes. As a result,
bearing housings would have to be drilled and
tapped, shaft surfaces would have to be checked

for suitability, mounting brackets would have to be

designed, and a host of other details would have to
be properly engineered for the application at-hand.
Unfortunately, the rotating machinery engineer
assumed that his biggest hurdle was to obtain
budget approval; the myriad of application details
were ignored simply because he didnt know what
he didnt know. When the items finally arrived and
were installed, it was discovered during system
check-out and commissioning that the transducers
were calibrated to the wrong target material,
that the probe holes were drilled and tapped
incorrectly introducing crosstalk and counterbore
interference and that the cable lengths were
mismatched. While it eventually got sorted out, the
project took three times as long as it should have
and cost nearly twice as much to complete.

Nathan Littrell Senior Systems Engineer GE Energy [Link]@[Link]

Andrew Bell Lead Engineer Bently Nevada Asset Condition Monitoring GE Energy [Link]@[Link]
4 4 O R B I T Vol.29 No.1 2009

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Want to avoid a similar scenario in your plant? You can,

1. Target material

but only when you have a firm grasp of the fundamen-

2. Target geometry

tals of eddy-current proximity probes and application

3. System length

considerations that can spell the difference between

4. Mounting considerations (e.g., counterbore,

failure and success when instrumenting a machine. This

article is designed to help you do just that.

bracket resonances, installation convenience)

5. Environment (e.g., temperature, chemicals,
radiation)

Principle of Operation
An eddy-current probe works by passing an alternating
current through a coil of wire and measuring the coils
impedance. This impedance changes when the probe is
brought near an electrically conductive material and the
impedance change is proportional to the physical gap
between the coil and the conductive target. The sensing
electronics in turn convert this impedance change to a
voltage, providing an electrical output directly
proportional to physical gap.

6. Frequency response
7. Linear range
8. Signal-to-noise ratio (e.g., device resolution,
electrical runout)
9. Field wiring

1. Target Material

The impedance change of the probe is dependent

on the electrical properties of the target material. All

probe systems state the material to which they are

calibrated (typically AISI 4140 steel). Although some

While the operating principles are simple enough, that

products claim to be insensitive to target material, these

is where the simplicity ends. A probe must be rugged,

should be approached cautiously as there are usually

accurate, linear, repeatable, interchangeable, and

performance compromises involved. The point here is

impervious to its environment. Building such a probe

that you must know the target material and verify that

is daunting. Building millions of such probes is even

the probe system is calibrated appropriately, or at least

more daunting. Advanced, proprietary manufacturing

that the performance deviation is known and that the

processes involving precision winding and sealing

transducer system can be compensated to account for

techniques have been perfected over more than 50

this deviation. Generally, the factory should be consulted

years to allow mass production of eddy-current probes

to quantify this performance deviation and to offer

that possess all the necessary attributes demanded by

advice on whether the deviation would be excessive

both industrial and laboratory applications.

for the intended application. When the deviation is

Likewise, applying eddy-current transducers requires

careful attention to detail. Only by understanding the

unacceptably large, transducer systems calibrated

to the specific target material can be supplied.

factors that affect the probes performance and

applying the probe accordingly can one be assured
that the installation will perform as specified. This
article discusses each of the following nine basic
factors that the installer must consider:

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2. Target Geometry
Typically, the eddy-current system is designed to
operate with a flat target. Rotating shafts of sufficient
diameter introduce no significant error, but there can
be problems if the shaft is too small. The effect of an
undersized shaft is that the sensor scale factor will be
reduced; consequently, vibration levels will be under

Probes used for differential expansion measurements

frequently observe collars or ramped features on

the shaft. The size and shape of the collars must be
adequate or the probe will not function properly (Figure
1). The probe may have scale factor problems and can
also pick up radial vibration of the shaft if the probe is
too close. The probes used in these applications are

reported. The minimum shaft size or target diameter for

typically larger (11, 25, and 50 mm tip diameters). The

flat targets should be stated on the product data sheet.

data sheet and manuals for these products contain

Look for it and take note.

the details for correct application.

Figure 1. Differential expansion probes observing a ramp (left) or collar (right) must be selected and installed
carefully to ensure that the probes observe only the intended portion of the shaft. If a radial vibration probe is
installed near a collar, it must be located adequately distant from the collar to ensure it observes only the shaft
not the collar.

Crosstalk is another issue associated with the target

The symptom is that a beat frequency will be evident

geometry. For machines using probes in an XY configu-

on the sensor output. This beat frequency is dependent

ration, the two probes can interfere with each other if

on probe gap and will exhibit frequencies in the range of

they are too close. The mechanism that causes this is

several hundred Hz to a few kHz.

when the magnetic fields emanating from the probes

are at approximately the same frequency (Figure 2).

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3. System Length
The probe, Proximitor* sensor, and extension cable are
expressly designed to work in specific combinations.
The probe and extension cable have a very tightly
controlled impedance characteristic and the Proximitor
sensor will only work for that specific probe/cable combination within a particular probe product family (e.g.
3300XL 11 mm). Mixing either the lengths incorrectly or
parts from different product families (such as a 3300XL
8 mm probe connected to a 3300XL 11 mm extension
cable) will result in problems. For this reason, the probes,
Proximitor sensors, and extension cables within a
particular product family are usually color coded [1].
The system length of a probe refers to the combined
Figure 2. These two probes are located too close
together, allowing the fields from each to interfere with one another. This results in so-called
crosstalk.

length of the probe and extension cable. This length

must match the system length of the Proximitor sensor
and is typically 5 or 9 meters. For example, a 1-meter
probe must be matched with a 4 meter cable to create
a 5-meter system; likewise, a half-meter probe must be

One solution to this problem on machines with small

matched with a 4.5-meter extension cable, and so on.

shafts is to displace one probe axially from the other.

The situation for 9-meter systems is analogous.

This separation will remove the crosstalk while still

Connecting probes and cables of the wrong lengths can

providing a useful X-Y probe pair (Figure 3).

cause performance problems ranging from inaccuracy

to a complete failure. These problems are significant
and, unfortunately, common. For example, a half-meter
probe connected to a 4 meter extension cable is only 4.5

meters. When connected to a 5-meter Proximitor sensor,

the output will be at least 20% higher than expected.
Similarly, a 5.5-meter system would have an output
lower than nominal.

Also note that the lengths are considered as electrical

lengths. The probe and extension cables are physically
trimmed to meet an electrical performance characteristic. This means that the actual physical lengths can be
different than the electrical length. As such, a 4.5-meter
extension cable may not be exactly 4.5 meters as meaFigure 3. The probes of Figure 2 have now been
offset from one another axially, preventing their
fields from interfering with one another, allowing
X-Y radial vibration measurements without the
problem of crosstalk.

sured by a ruler and it is necessary to allow for nominal

physical length variation when planning your systems
cable runs. The length tolerance is always stated on the
product data sheet. When planning the installation, be
sure that the minimum physical length of the probe and
cable will be sufficient to reach the Proximitor sensor.

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4. Mounting Considerations

pipe experiencing vibration. To avoid probe resonance,

A number of physical constraints can affect the quality

mounting features should include a support secondary

of the output from a proximity transducer system:

to the main fitment whenever possible for installations

that have more than a few inches of probe extending

Counterbore

beyond the bracket (see Figure 5).

Since the probe is sensitive to conductive material, any

conductive machine components (other than the shaft)

that are too close to the probe can affect the signal. It is
common for probes to protrude directly through metal
to view the target shaft. In this case, a counterbore
should be employed to avoid metal too close to the
probe tip (Figure 4). Any metallic machine components
that protrude into the region defined by recommended
counterbore spacing requirements should be removed if
possible. Recommendations vary by transducer model.
This issue is similar to that discussed earlier for probes
observing collar or ramps in expansion measurement
applications (refer to Figure 1).

Figure 4. Cutaway rendering showing a probe

with proper counterbore. This ensures that the
probes field will see only the rotating shaft,
not the sides or back of the hole.

Bracket Resonances
Brackets or probe mounting hardware should always
be chosen to provide mounting and support that is
as rigid as possible. In some instances, probes with a
long metal casing (for example, a probe with five or
more inches of thread) can be prone to resonance at
transient or steady state operating speeds. This is due
primarily to the physical behavior exhibited by a tube or
4 8 O R B I T Vol.29 No.1 2009

Figure 5. The probe on the top has a long unsupported length, resulting in mechanical resonance
and erroneous readings as the probe is no longer
stationary with respect to the shaft it observes.
The probe on the bottom is identical, but has
a mounting bracket to support and stiffen the
probe stinger. This ensures that the machines
vibration will not excite the probe mountings
resonance.

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Installation Convenience
For applications requiring long probes or installation
in tight spaces, a smooth body probe should be considered. As the name implies, smooth body probes have
no threads and this eliminates the need to laboriously
thread the probe into a bracket. The probe may be
slid into place and secured in position using a special
clamping-type bracket. For threaded installations,

Ether Ether Ketone (PEEK) tips and are widely compatible

with steam and petroleum products. If the environment
contains anhydrous ammonia (NH3) or other reactive
substances, probes manufactured with a ceramic tip
can be used to resist corrosion or degradation. The
ceramic tip probes are also excellent for highly pressurized applications where the probe is required to seal
differential pressure.

brackets should be designed to match the thread

For nuclear power plant or research applications involv-

tolerance of the probe in order to avoid binding. It is also

ing exposure to radiation, specially designed probes are

good design practice to ensure that there is sufficient

available which can withstand Gamma radiation.

threaded material for a solid joint. A good rule of thumb

is five full threads of engagement.

6. Frequency Response

Typical machinery vibration monitoring applications

5. Environmental Considerations

require the probe to provide vibration data at one or

A key consideration when selecting probes is the

two times the running speed of the machine. This is

temperature for each location on the machine that will

normally well within the ability of the probe to respond.

be occupied by the sensors. The temperature ratings of

Occasionally there are machines that run very fast

the probe tip, cable, and Proximitor sensor are all differ-

or have a need to monitor at a higher multiple of the

ent and should be considered separately. The machine

running speed (e.g., blade pass frequencies for pumps

temperatures must be within the rated temperature

or turbines). The response of the proximity probe will be

limits of the probe, extension cable, and Proximitor sen-

attenuated at higher frequencies. Check the data sheet

sor during idle, startup, shutdown, and (especially) base

of the probe to find the maximum frequency response.

running conditions.

This can be particularly important for speed sensing

The system must also be undamaged by any of the

process gases or liquids present. Standard probes
commonly feature PolyPhenylene Sulfide (PPS) or Poly

applications when a sharp trigger is required and

multiple harmonics of running speed are required
to give a crisp square wave output [2].

THERE ARE MANY CONSIDERATIONS WHEN SELECTING

EDDY-CURRENT PROXIMITY PROBES AND DESIGNING THE
INSTALLATION. AT FIRST GLANCE, IT MAY SEEM THAT MUCH
OF THE INFORMATION INCLUDED IN THE DATASHEET IS
EXTRANEOUS, BUTAS DISCUSSED IN THIS ARTICLETHIS
INFORMATION IS PRESENTED FOR GOOD REASON.
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7. Linear Range

For a thrust or differential expansion measurement,

For a vibration measurement, it is critical that the probe

has enough range to measure the motion of the shaft.
To pick the correct probe, estimate the maximum peakto-peak vibration level that is expected and choose a
probe that has at least that much linear range. When
installing the probe it is important to gap the probe in
the middle of the linear range in order that the vibration
will fit into the probes linear range. It is good practice
to select a probe that has more linear range than is
strictly required by the application to allow for some
flexibility when gapping the probe. Figure 6 shows the

it is even more critical that the probe has the ability to

measure the entire motion of the shaft. The selection
process is similar in that the probe is chosen based on
the expected shaft movement. The difference with a
thrust application is that the gapping of the probe needs
to be considered relative to the often asymmetrical
motion of the shaft. A complete discussion of gapping
for thrust is beyond the scope of this article, but suffice
to say that careful attention must be paid to ensure
that the probe will remain in the linear range during all
operating conditions [3,4,5].

typical voltage response versus gap for a probe system.

The consequence of an error in application of probes for

The probe must stay in the linear range at all times in

thrust or expansion measurements is severe as it will

order to provide a valid measurement.

typically mean that the machine can fail in a manner

The consequence of choosing a probe with insufficient

linear range or gapping the probe incorrectly is that the

that allows rotating and non-rotating parts to contact,

such as blades and casings.

monitor system will enter a NOT OK condition or there

will be data errors instead of protecting the machine.

Figure 6. Actual probe voltage versus gap response (red) overlaid on expected output (blue) showing that the
probe response is highly linear.

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8. Signal-to-Noise Ratio

9. Field Wiring

Eddy-current proximity probes are amazingly accurate

Proximity sensors are low-voltage devicesthe output

devices, but they do not have infinite resolution. There

of a typical sensor is usually only a few volts. As such,

is always a noise floor for any electrical device below

it is important to maintain a clean signal path to the

which any measurement is not reliable. Typically this

monitoring system. Magnetic fields from power cabling

value is several tens of millivolts for a proximity probe

and transformers can cause a significant voltage to be

system. Check the data sheet of the product and

induced in the sensor system, introducing noise that

consider the resolution required of the system.

can cause erroneous readings. Cabling for sensors

Electrical Runout is another problem that may be

encountered in an installation. This phenomenon is
caused by variation in the material properties of the
shaft appearing as a spurious vibration signal. The

should always be routed away from power cables. If the

instrumentation field wiring must cross power cables it
should cross perpendicular to the power cables in order
to avoid coupling the electromagnetic field.

magnitude of electrical runout can be quite high

The frequency response of the sensor is also strongly

depending on the quality of the shaft material. The

affected by the amount of capacitance in the wiring

causes and cures of electrical runout have been

between the sensors and the monitor [8]. Extra

discussed in previous ORBIT articles [6,7].

capacitance on the output of the sensor acts as a filter

and reduces the magnitude of the high frequency
components of the signal. DC and low frequency
components are not affected. Reference Figure 7 to see
a graph showing the effects of added capacitance.

Figure 7. Added capacitance of long field wiring lengths will affect the frequency response of the probe system,
behaving essentially as a low-pass filter. This effect must be carefully considered, particularly when the probe
system will be required to detect very high frequencies, such as observing a toothed wheel or detecting vibration harmonics on a high-speed machine such as a turbo-expander.

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In summary, long wire runs can cause attenuation of

high frequency signals in addition to increased risk of
noise. Long runs of instrumentation cabling should be
avoided whenever possible by locating the monitor near
the machine. Digital communication from the monitor

References
1. Transducer Color Codes Help Eliminate Installation
Errors, ORBIT magazine, Vol. 26, No. 1, 2006, pg. 20
2. Nurcombe, B., Considerations When Retrofitting

to the control room via IP-based ethernet or other

Overspeed Dection Systems, ORBIT magazine, Vol.

protocols is not as susceptible to noise issues.

25, No. 1, 2005, pp. 16-28

Conclusion
Eddy-current proximity probes offer excellent sensitivity
and robust performance when installed correctly.
However, there are many considerations when selecting
probes and designing the installation. At first glance, it
may seem that much of the information included in the
datasheet is extraneous, butas discussed in this article
this information is presented for good reason.

3. Sabin. S, Voting Thrust Measurments with Other

Parameters, ORBIT magazine, Vol. 22, No. 1, 2001,
pp. 51-54
4. Axial Thrust Position Monitoring Part 1, ORBIT
magazine, Vol. 8, No. 2, 1987, pp. 21-22
5. Axial Thrust Position Monitoring Part 2, ORBIT
magazine, Vol. 10, No. 1, 1989, pp. 27-29
6. Littrell, N., Understanding and Mitigating Shaft

An abundance of resources exist in addition to the

Runout, ORBIT magazine, Vol. 25, No. 3, 2005, pp.

product datasheet and this article, as noted in the

4-17

references at right, and the reader is strongly encouraged to make use of these items. In addition, your local
GE Energy sales professional specializing in the Bently
Nevada* product line has deep knowledge of application considerations and pitfalls, and can be a valuable
asset when planning your installation.
* denotes a trademark of Bently Nevada, LLC, a wholly owned
subsidiary of General Electric Company.

7. DeBlock, M., McDonnell, J.W., Wood, B., Predicting

Proximity Probe Track Runout on API Motors and
Generators, ORBIT magazine, Vol. 27, No. 2, 2007, pp.
36-49
8. Angel, J., Considerations When Using Extended Field
Wiring Lengths With Bently Nevada Transducers,
ORBIT magazine, Vol. 27, No. 1, 2007, pp. 52-59
9. Machinerys Handbook 28th Edition, Oberg, Jones,
Ryffel, McCauley, Heald and Hussain. Published:
February, 2008. ISBN (978-0-8311-)2800-5

5 2 O R B I T Vol.29 No.1 2009