LABORELEC

LABORELEC

Vibration analysis of turbo machines - CaseStudies

)
1th June 2012 - Linkebeek

~ABORELEC ©
 lABORElEC
Program (9u - 16u)

• Introduction

• Overview of the basic concepts of vibration theory

• Case studies:
-+ Rotor balancing
-+ Rotor-stator contact
-+ Blade loss
-+ Shaft eccentricity
-+ Structural resonance

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Part1:

Basic concepts of
vibration theory
 lABORElEC
Linear vibrations

1 1

"

Vibration analysis

5 LABCRELE~ ©

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Mechanical vibrations

• Sourcejorigin
Dynamic forces with a mechanical or non-
mechanicalorigin

• Followed path
How is the energy transferred?

.---------~-;
-
:1
MaXJmum recorded vlbratron

• Receiverjlocation of measurement
.- .
What vibration levels are acceptable?
What can one learn on early fault
detection?
Vibration trend before the incident

6
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"World most sim pie oscillator"

x
I. X < O .1. x >O .1

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-
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Vibration characteristics

x(t) = A cos (ot + <p)

- X: amplitude 10

- A: maxirnurn amplitude (11m,

mm/s, g, m/s2)
- T: period (s)
9: phase angle ( , rad)
- w = 2n:f: pulsation (rad/s)
- f = l/T: frequency (HZ,S-l)
- t: time (s) _10L----'----'--L----L----'- __ ~-'----'-____'

O 4 5 6 8 9 10

- à<f>: phase difference ( , rad) TIME

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Type of oscillations

Periodic Non periodic

Random Tra nsie nt/i m pact

9 L!\BORELES ©

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Amplitude?

i\\rerage<~ RlvIS < peak < peak-peak

Time

= T1 Jor IX(t)ldt
T Peak
Average Crest Factor: -M.·
R. S

[A2 2
R1vfS = ~2 Average (abs) = -A J[
Peak= A
Averaze•.... =O CF= f2
10
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Vector definition
y
Defined by:

- Direction
Sense
Magnitude
Initial point

Examples: force, velocity, weight, ...

Im porta nce of vector operations!

11 l.ABORELEC <0

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Mechanical parameters

Stiffness Damping Inertia

.. " "

--- •••• v --- .••• a

·~III:
~·.;ifl
.... 't
,"
f,
f
m
" 1
\

F=cxv F=m x a
 lABORElEC
Damping
101r---~--~--~----~--~--~
,
i
8'-

-10 ';-'
------.------;1';c-0 ------:'=-15----=2'0-- ---==-25----=30
0 0
TIME

<,
,
" ,
-15 " ,
,,

-25
° 10
'
5 25 3°
TIME

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T'

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, Displacement - velocity - acceleration

~ Velocttv [mm/s]
~ Acceleration [rn/s"] or [g] 19 = 9.81 m/s2

• The choice of the physical unit of measurement depends on the studied

phenomenon (e.g. measurement of the acceleration for shock phenomena)

• The unit of measurement can easily be derived from another quantity by

integration or differentiation (electronically or mathematically)

LABOPELr:C@
 lABORElEC
Displacement - velocity - acceleration

Relative Amplitude

100000 Acceleration
10000
1000
100
.....tQ

------------1-~~--------~
100
1000
10000
Displacement
100000
~--------------~------------~
0.1 1 10 100 1k 10 kHz
Frequency

15 LABORELEC ©
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Displacement - velocity - acceleration

• IIlustrates the position, velocity and

acceleration of a spring-mass system
for one full period of motion

• Kinetic and potential energy are

continuouslyexchanged

1~ -
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Fourier transformation
}5;-----.,------r---.--------.-----...,.----rl
. I
's·

• Split the original time signal into . e s-

different harmonic oscillations with

different amplitudes and periods

-:5'- .- .-_.-..-.-.- ..- .•.

--..--- - -- - ._--_.'-----" _ ..•.._._-_.~
-3 -a -1 o 1 ~

- There is often an clear relationship

between a certain vibration
phenomenon and the present
vibration frequency components

-a

Fourier decomposition of a square wave

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Fourier transformation: practical example

Amplitude

lmbalance

Bearill9 Defect

rsquencv

'P
.ic
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Resonance
• 3 different operating regimes 1M
depending on w:
-+ sub-critical regime
-+ critica I speed
-+ super-critical regime

«; ~ ~ (If damping is small)

-+ If kt andjor m] then wt
-+ If k~ and/or mt then w~
x
xco x>o

• Critica I damping factor ç ~ 2~:. m

LAi30"cLEC ©

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Examples of eigenfrequency excitation

• Tacomah Narrows (WA, 1940)

-+ 853m long, 12m wide

-+ Side wind of 70km/u gave excessive
torsional-flexural vibrations and led
to the total destruction of the
bridge

• Recently: Volgograd bridge (October

2009)

Examples of eigenfrequency excitation

20
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Eigenmode

= describes the axial distribution of

Cantilever beam
the amplitude and phase of a
vibration

,.. Higher resonance frequency

modes give more complex mode
shapes

,.. 1Jh;. continuous mass system:

-a

cantilever beam
I
-3"-:=' L ~~~~~o
_Statü;mode -lstmode -::mdmooe 3rdmode 4thmode

Figure: Eigenmodes for a continuous mass system

21 LABORE~EC Ç)

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Part2:

Vibration data
visua lization

'- ----- .~-~ ,_ . (;:'.= EC©

.-
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Visualisation of different measurements

c
sensor 7 '"E
e
eu -- - --
~
O

L-+- +__ -Í-~ Time

h,.-----~
~ _+. Time

1st Harmonic componenl 2nd Harmonic componenl Time signal Orbit Frequency spectrum

,
1 revolution
/I

B ; 30 urn pp
k
o
~~--

1 2
I I
3
I I
4

H2 polarplol Baragraph Average shaft position Linear time plol

.~
- ..
G-'cl:>a:l:>«>lc

A~

T"
.

23 ~ABORELEC ©

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Visualisation: Time signal
Time si nal

• Onlya small slice of time in vibration

history of the machine

• Shows the unprocessed data of a single

transducer

• Allows to detect the presence and

timing of short transient events

• "Vlrtual oscilloscope"

scaie (pk-pk): 120~m

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Visualisation: polar plot
PQI;jf

H1

• Direct representation of the filtered

(lX, 2X, 3X, ...) vibration vector
(amplitude & phase) of a single
transducer

• Mostly used to analyse data during

startup, shutdown and balancing
operations

• Straightforward identification of
resonances

cale (pk-pk): O = 120~m n

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Visualisation: Bode plot

• Contains the same information

as polar plots but in two
H1 .-
separate plots -eo

-, \~~~:::i0~,~:~;:.
.:~;;:~~;~_?':::>-:~.<:~
~ .
~or----~----<~::'-'="'~--~'~~
__ ~~'~~~~'
• Shows amplitude and phase of ~,~~ - ,~.'
a single transducer in function
of running speed
'~'. ".

• Presentation of data during

transient operation periods:
"00 200l

start-up and shutdown

L.Ó

...• UI.BORcLEC 5
 lABORElEC
Visualisation: linear time trend GL>F .s",ez

• Shows a measured para meter

versus time
3<00 ......,...,
::::9Q..,,':)110!S;:;~
.
"00

• Shows slowly changing

parameters ""
2000

• Same principie used for a Des 1200

system

• Data can be correlated by Sr-!(l) {o,3400]RPM ,)XlI Amptm-».KI(I) [O,12O)am5l

- MW [O.<K1.IOJ!lW.!'iI -p},·P.(I)[O.I20 •••••~:

plotting several variables on the o-- NVU' (-IO,200}W'V.u 3

same time scale

27 Li\BORELEC ©
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Visualisation: orbit

• The plot combines the input

signal of two shaft vibration
Vert 1(Channell) .

I'..

•
I
transducers at the same Left I.".- IRight
Horiz
(Chanoel 2)

measuring plane
f-
?Oj'"
Orbit

• Shows the whirling motion of 1

Presenlalion

the shaft relatively to the

average shaft position (De
content of the signal) • As seen from
Driver End

Vert

R
h

D
l/

•
Horiz
l
it"'

•• Shows the vibration amplitude Time Base

Pre senlation

in any direction
 LABORELEC
Visualisation: average shaft position
Zero Pos:Sensor 1••0 Sensor 2"0 Zero Pos:SenSOl" 3.0 Sensor 4z{)

• Shows the De content of the relative

shaft vibration probes relatively to the
installed clearances I + J I

", '
• Shows the dynamic shaft motion due
to the present oil film wedge OT.TII-O X:1.00

Zero Pos:Sensor
Y:O.50

5-<0 Senso- 6=0

T-corrc-n X:1.00 V:1.00

Zero Pos:Sensor 9 ••0 Sensor AzO

• Useful to detect misalignment andjor

coupling problems J I I I + I I I I

=.1
AlT Av-O X:LOO Y:1.00 Exc.b X:1.00 Y:1.00

29 LASOi-iELEC' @

LABORELEC

Part3:

Rotor balancing - Case

studies

\ ";,' ,'~,::C© -
~
 lABORElEC
Simplified rotor model
• Also known as Fõppl, De Laval or Jeffcott rotor

-+ M: mass of the disk

-+ n: rotation speed
-+ e: eccentricity
Z.Jr
-+ y: deflection of the shaft
-+ E: elasticity modulus (Young)
-+ I: bending moment of inertia
-+ f: length of the shaft y

0t> Flexible shaft

:"'l\jCRELEC (Ç

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Simpllfled rotor model

• If the mass .center of the disk M * rotation center o

-+ Centrifugal force:

F=M· n2 · (e+y)

-+ Counteracting force by the flexible shaft (Ks)

andjor by the bearing stiffness (Kb)
y

.-
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Vibration vector measurements

~- Accelerometer

Optical pickup

~- (optional)
_c
OQ)_
c:E
:B~ '\
<J> (reflective tape, tooth, ...)
-=
Q)
~-----+
DE

1 1 J 1 I. Optical pickup

o 360"

Accelerometer

V(f) =Vo cos(mr-ç6)

33 LABORE~EC ©

lABORElEC
Phase relation of a simplified rotor

Critical
Sub critical Super critical
y y y

""---'

0*<1 n' = 1 n* >1

(fi*' = fijwn)
 lABORElEC
Eigenmode of a simplified rotor

• E.g. Flexible rotor

lhe supported shaft has different

resonance frequencies that correspond
with a unique deflection shape
mEEfEEJ-
P1 P2 P3 P4

~r
= mode shape

In this case, these resonances are

ca lIed 'critical speeds'

35 -
lABORElEC
Eigenmodes of a shaft line

.,
,
, ,.:J

1 .• :
o

").:;.
 LABORELEC
Rotor balancing

A rotor is never geometrically perfect. The

unbalance may result from:

-+ Manufacturing process
-+ Machine tolerances
Material non-homogeneity
-+
-+ Machine erosion, thermal effects cp
I
q The inertia axis does not
correspond with the rotor spin axis

Xl

37 LABORELEC ©

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Relevant standards for rotor balancing

• Low speed balancing (IS01940) • High speed balancing (lS011342)

When?
For rigíd rotors (Vnom < 70% of Veriti)
When unbalance can be more or less
located on a flexible rotor
For flexible rotors with a modular
construction
When?
For flexible rotors (Vnom > 70% of Veritl)
Especially important when distributed
unbalance is present (e.g. new rotors,
important rework during overhaul, ...)

What?
Correction of residual unbalance and
unbalance moment in 2 (or more)
balancing planes
What?
Correct moda I unbalance at different
balancing planes
Evaluation at different critica I speeds and
at nominal speed in a high speed
balancing facility

ss :"/\BOREL te ©
 LABORELEC
Low speed balancing
10‫סס‬00
Balance Product Df lhe
Quality retaüonstap Reter lYI)es - General examptes
grade fA.. XQ mm/s

G<I'QO , 000 ~~!a::!~~~! lhe rigidlynlounted sbw mame diesel engincs with Ltne\'en

G'600 '600 Cr.uasl\8f1Jdrives. at rigkJIy rnount.ed IGrge two·cycte engioes

G630 .30 Crank:lhaft/dliveSc of rigídly mocntee Illrge Iour.cyele cnginez

Cr:Jntish3ftldrives ol elasliealy moUflled maMe diesel engll\~
G250 250
G'OO '00 CrankshalVCkfveS of Iasl diesel enofies with SÍX or more cylinders

Complete engirles. (g&oli~ or diesel) for C3111.

tNcks ond Ioeomoúves
G40 ,O Cnrwhooeb, wheel rims, ~ eets, dnvet.l thds
Cmnksh::lrJdrives of clas.."Ic.a1lynlOunted fast four-c.yde cOOineJ (gtlzolne Of dieseli

,.
with eíx or more cyUnders

mII~
CrankshllrJdrtves of engine5 of cers. trudts and IDcomotives

G,.

.S
1000
500 ~tlG'
mm
i".. "
9'0

G6.3 6.3 200

100

50

20

7.96 g.mmjkg
2

0.5

0.2

c.t

-
GO.4 0.-4 '~dbCS, anó ~orpt~çmder$ 30 50 100 zoa soe 1000 2000 SOOO1‫סס‬00 2‫סס‬00 5‫סס‬00 10‫סס‬00

Gyroscopes ~1->LXI.\lt'M SF-RVICE SPF.ED IN RPM

39 LABORELcC©

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Low speed balancing
 LABORELEC
High speed balancing

• The unbalance distribution is of greater

significance in a flexible rotor, since it
can emphasize the appearance of
certain modal deflection shapes

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High speed balancing
 lABORElEC
Case history 1: GT on-site balancing

'13 L.A,BOi=1E!...EC CD

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Case history 1: instrumentation

44
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Case history 1: vibration behaviour after overhaul

45 LABORELEC ©

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Case history 1: first balancing correction

L&O J

GT

f
Lager 1

Balancing plane:
• 24 bolts (= 15 o difference)
• 60g divided over bolt nr. 7 & 8

46 LAB0~?ELEC ©
 LABORELEC
...:s.'-"'ez.
Case history 1: influence coefficients G~F

• 2nd correction necessary: same mass + 45 rotated CCW

-~t--~-<
_.---- "T" ~- - •.. -c, .••.. ..-~. T ----- r

.,
\ \
'.
,
I
i / ".
\, \.
/;"
..-.- _1'_' ",
••.•
-. ,
I I
"
."

,I . . !\ {. ~I} f· r
..."--.
I, ,
\ i I, -. .' "
I '~

..-~'-" \.... 0_- •..•• ,-- ,/ i

\ /
"
\ .•.
I \. I ....
'. +1 .' .> \. ..--.-t - ..'
,/

•....••. , '."-'.-. _-ti -- _ .

-<, .~-.- J ~~~-_./ .. • <. ' •• _~----- - -_.-. -'" »> ,..'

.-. .. ,."
•••• , •••••
....
11I0 •• xor •.•. .,0.#.... •. loJ IV' •• ,~""'~____ •• tM'" •. Qc"' •••• I~""" T
••
~_ ••••. fl~~:t:\IB.l ·..,•• ~'C'Ioly·,~

4'1 LABORt:LEC ©

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Case history 1: influence 2nd balancing correction

-~'fOO"II/41Jl)'O:<.IIM' 'ffl "<>Jol;J.JUt~1L~''''f .•'""~.:tl ••)p.;tI1po

•••••~~:.:,Q.. ..•
~ -úq~~I{(P~ -~ •••.
'~:;:IW.
• :41 •••••••..;::t(. ~ -, I ,,;.i<\ •.••

~l\õI)REL ':C é)
 LABORELEC
Case history 2: field balancing of a LP rotor

• Steam turbine was tripped several times during start-up due to high vibrations
at 3000rpm

• Instrumentation overview:

r
B C 9 A 8 6 5 4 3 2

TOP

LO

~
I
~ ~
=
__ T
-}> o

49 LA80RCLEC <t;

LABORELEC
Case history 3: vibration behaviour LP rotor
Automatic shutdown due to high shaft vibrations
Linear

160

- ~•. scoc

~ 112- 24C!I

lSCO

0~~~ __ ~ __ ~ __ ~L- __ ~~ ~ -=~~

2&'(j6!2Cl00~:23:(I0 ~ rrlen 2Bl(lWD1(}()~·:2~:13

- Spué (1) rO,3400JR.?~1 2:9SS - Mol'l;tt.t..-Hl{~jla,!S(!]Mr!I ;2C,

- A11IplücG-!.jij (5:.(O,I601uln 112 -- Amplilo,;d.t-Hl (8'\ IC,}6C]1WI 12;
-A,~?1ih;t1·HIC6}IC,1E-Ohm 117

H1 H1 H1 Hl

Sea~ íJ)k-pk;: D. 15011"" SU~(pk-pl.:,:

se
tt· t7Cllm.

...-
 lABORElEC
Case history 3: vibration behaviour LP rotor

• Based on the vibration measurements it A 8 6 5

is clear that the 2nd bending mode is

excited nea r 3000 rpm

• A correction will thus be done near the

end planes and not in the middle of the
roto r

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...-

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Case history 3: estimation of the correction weight -s,-",ez G"DF

• G2.5 unbalance class:

(e -Q)-m
U =1000_~p_er _
per Q

= 1000- (2.5) - 62700kg

314.2rafs
= 498951 9 - mm
Radius af balancing plane = 953.3mm U 523
) per = 9
. ,~._'".

• Mass angle: see figure

.-
 lABORElEC
Case history 3: installation of the correction weight

53 LABORELEC ©

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Case history 3: vibration behaviour after balancing

Comparison

1,50
Acceleratíon Acceleratíou
170

1'0 160 ,
112 128

~ ~
~ •.. ~ 9ô

i
l![
I
~ f..;
••• ~
zz

o C
o 280 see 'SIlO o 2:BC 5f0 ",o 19€C 22.;0 2!:2C 22CC

-28,oe:7.J1~ O~':;:!i':l~ -:!8.~~.i-:·Ol:)04..2!ó:a!ó

-0" 11.~a':lZ~·;;:9.:.IO -O"-'''::l10n:Z9:011

Pclee
Hl Hl Hl Hl
A,.CC~ltbot'l .A.~atlon
ACctlH'al'Cl'I Atetlf-rabcn
'"

54
 lABORElEC

Part4:

Rotor-stator contact

lABORElEC
Rotor-stator interaction: introduction GL>F -S'-"CZ

• Turbo machinery have essential small internal radial c1earances for efficient
functioning (end seals, interstage seals, bearings, blade tips, ...)
• Vibration monitoring allows to detect if such a rotor-stator contact is possible
in case excessive rotor vibration appears
• Effects of rotor-stator contact:
Rotor Allowable
clearance
-+ Changes in system force balance
Rotor lateral
-+ Changes in dynamk stiffness vibratian
amplitude

-+ Changes in machine/rotor motion _____ Boundary of

stationary me
element
-+ Appearance of "parasitic" vibration
as a result Contact

Rotor centerline
displacement
 5

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Case history 3: installation of the correction weight

53 LABORELEC ~

LABORELEC
Case history 3: vibration behaviour after balancing

Acceleratíon Acceíerattou
I"r---,------,------,-----------_-_--~ 170r-----------...:..:.====---------~
1'0 160

112 128

,-,.

2BC 5S0 ~o 1120 1400 1S&: 19€C 22.;0 2!;:/O 2800

-28,oe':ro1!) O.«'~·O!. -:?8:0~0100o!.2!'.a!o

-041';;/0102:i<i9.00 -O,o!."1':OlD::?::9:00

Pcl ••
Hl H1 H1
.6.CCf:lerllticn .o.~atiDn Accdttaooft

54
 LABORELEC
Possible contact locations
Ccmbination
Ax,ial Radial or conical

• Radial direction - radial rub

• Axial direction - axial rub

-+ Thermal growth
-+ Constrained stator
-+ Compressor instabilities (surge, ...)
-+ Thrust bearing failure

• Combination of
both directions

57 LABORELEC G)

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Different categories of rotor-stator contact

58
 lABORElEC
Newkirk rub: stiffness modulated rub

• Rubbing occurs at the rotor "high spot" durihg synchronous operation

• Rub causes friction and related friction heat which leads to local thermal
expansion
• The local thermal expansion results in a rotor bowwhich dynamically behaves
as an additional unbalance
• Rub-generated heat can be dissipated by fluid flow (air, oil, ...)
• The time constant of this process depends on the friction surface (min ~
hours)

. L:Hotspot
--

Li\B0RELcC ©

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Newkirk rub: stiffness rnodulated rub

• Characterizing for single-point localized hard rub

• Rotor-stator contact force increases the more the rotor
displaces into the rub site
• Model for rubs against packings, oil deflectors,
interstage seals, end seals, ...

Below critical speed At critical speed Above critical speed

(<.O < merit) (m = ro cri!) (co > (Úeril)
60 :.L\SC·R::L>:::: © ~
 LABORELEC
Case history 1: single shaft design
• Step 1: Be surprised (30min - 1h)

<REl> J K REL
'0
ABS
,
I I
. i,,- - - - - - - - -
I f
!O/~ !:'H7 1144\ t .:-~a:; I
II ir n~1<IilI G1 111
.&ftGD
!'-"o\'!)!t-,
eR~
~WAP~)I
1illif.QJ1 BJtG SAG*'
!ll,,-"},~~~~!MJI~;L(;.
11.~~;';'1
""""
("lIm?f ."""
{lh.rf'D·l
~ti,!CI~1 ,'\"'8Dn!

<-''''-''- .~.
~~
.~.i(t.

( -. :~-

61 L,1l.BOFlELEC ©

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Case history 1
• Step 2: get vector measurements & call an expert - with a good memory
(30min)

-,
"'1;0

E2 lABORELEé ©
 lABORElEC
Case history 1
• Step 3: analyse the shaft deflection during the "rub" (lSmin)

»:
'-- - _/ )/
,,~----_. . .i->: ..--.•/

li llAILL Ji.f.lI.
SROI, BRG SRGa,
(IoIAOI11 (MAOI~, LC.
(IoIKO~OI

63

lABORElEC
Case history 1
• Step 4: analyse the shaft deflection at the run down and at slow speed (lSmin)

<REL J K

> 'G'

li li ll.&l!. 2fIi
...,
BR~~
!MAO)O)
BRGI<!
{MAD20}
BRO., BRO BRc.2
(MA0111 (MA0121 L.C.
B~tr2
L.O.C
B~J
(camp.)
8~"
(turb.)
(MKD20) (MK010) (MB012) (M801l)

.-
 lABORElEC
Case history 1
• Step 5: investigation, interrogation and think (lh)

Bushing

'
lt\'aPos"SenXll5o'.~Sa'I~50-e8

~
I I

W
<. "",)-
/ '

~...-'IL------+V) I
D.8m

flón..•.
dxui'JYijJííj

I
I
00
t t
400' SOO
t ~. j
____ .J. _
~ ~NERATCR[ 1\

-e -t,
.
,
-, ----.-.---.------------1-+ , I

65 LABORELEC ©
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lABORElEC
Case history 1: conclusion

• Detecting a rub in 5 steps:

-+ Be aware of the possibilities of rub on new units or after an overhaul
~ Problem was analyzed in less tan 2 hours with our LVMS system
-+ Get the manufacturer to clearly documentall clearances and have this
data available on site

• Step 6: convince the OEM to solve the problem

Lt,BJFE~:::C ©
 LABORELEC
Newkirk rub: inertia modulated rub
• The non-rotating contact rub surface is comprised by masses
that are soft-spring loaded against the shaft
(e.g. exciter brushes)
• A normal dynamic contact force proportional to the radial.
acceleration,180 out of phase with the shaft vibration

Below critica I speed At critical speed Above critica I speed

(00 < oocrit) (Cú = ro critl (to > Cúcril )

57 LABORELEC (0

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Case history 1: spiral vibrations
Single Shaft Power Train
Gl GEN EXC 555 HP

DoJ1flDn -'=-.-~.~. _.~_._=.-~.-='-'=-'-='-:::;:'-~'-'-~A\t:=dÃ-.- ._--

~~-=B=e=ar~in=g~N=o~.==#2====#=3~=====-~=====#4==~#=5==#6====~#~7
~#8
I Bearing # 5 II Bearing # 6 I

f/
~~-.,~
~.
~
~Mi·:l..~;: .-:
..!,~..- ~',
'O::.1~::.t:-n
~'~~.:..L,"
.~ $ • "T __ -~~t '2":l"~rr"'::' ':~.
.• ~~~-- :.:..~ -I

.(':~I: Li.
..- - ~
I Bearing # 3 I

l p5ú?fl.E~ ©
 LABORELEC
Case history 1: vibration signature

e • Linear trend plot of the lX vibration amplitudes during normal operation near
bearing 5, 6 and 7

linear Polar
120 - ------ _, .•17JÜ1/201110:53.14._ 3400 Hl
;17101f2!l11 09:21:32 3360

100
2800

2240

1120

1 hour 5 IIOu! ~

- Speed (1) {O,3400]RPM 2999 30Ct-j - Arnplitude-Hl (7) [O,120]~ 76 75 - Amplitude-Hl (A) [O.120)~1513
- Amplitude-HI (5) [1),120]..,. 21 21 - Amplitude-HI (8) [1),120]..,. 61 60 - MW [1).500]MW O O
- Amplitude-HI (6) (O,120Jj.lltl1616 - Amplitude-H1 (9) ro.120]1Jl1\19 -16 - SpeedÔl) [O,3400JRPM 2999 :3001 Scale (pk-pk~ D = 8Ü1Jm •••

69 LAElORELEC ©

LABORELEC
Case history 1: vibration signature

• linear trend plot of the lX vibration amplitudes during normal operation near
bearing 5, 6 and 7
Lnoar P",r
120 Hl

100

ao
~
;;;:
7i 60

I
~ 40

20

0~20~~~8n~Ol-0-09-:1S-:33+---------~--~----~----~----~--~---+-----20-~-8m--'0-22-:~~:32
I hour3! ".e .
- $peoe,d (1) lO.3400JRPM 2998 3(lO1.l - Amplitude-H I (7) {O,120}.u:n 333"2 - Amplitude-HI (A) [O,120]11lt\ 65 fi:?-
-Am.plitude_HI (5) [O,I20)prn27 2B - Amplitude-H I (8) [O,l20j.un 1011 -- MW[O,500]MW 421 4:::3
r__ A_"'.;..Pli",,-_=-H.:.::I (::!.6)!.':![O,:.::120;!""'=37.;;)7 ..::.A:::;rnp~li_:::::-H:c;1(:::!9)~[O'-!;,120::,-,jan~11:.:.5.:.:li.::..3-,-_...:-:......:S:!::p.:::..d:::.(2)~[O:::::,34::::00:::JRP::::M::..:"::::il9:::.9 ':.:.~J'::.:._O --I scee (pk-pk): o =-1~ ama

70 U\BOnEl.E:': ©
 LABORELEC
Case hlstorv 1: vibration signature of a ST

Hl 30 ~23AJ2~0S:4951 : O:?.';:JL::r'$ XI.~;

2.
i

o '
23.0212008 04:43:58 23ro2l2OO8 08: 59: 54
51J't11"11r~

- Amplitudt-HI (4) l.O.30lun13!~ - Am:plitude-Hl (7) [o,.30han 16 I~ - Amp~Rl (A) [O,30}.m :?5.?S
11õ=====..------------I1 - AmpliNdo-Hl(5) LU,30lun 16" - AITIJ'lifude..Hl(3)[o.30lJml8S
cee (pIc-pk): O· 3O!-m - Amplitude-HI (6) [D,.30p 6 6 Amp~-HI m [O,30p 25_~

71

LABORELEC
Case history 1: general findings

• Spiral vibrations are always observed near the same bearings (near the
excitation brushes)

• Although the shaft lines are identical, different periods of the cyclic
phenomenon are measured on each unit

• Also the attained vibration amplitudes vary in-between the different units and
depending on the actual operational condition (base load +-+ part load)

• Spiral vibrations have not exclusively been detected on single shaft units, it was
also measured on conventional stearn turbine shaft lines

72
 lABORElEC
Case history 1: generator testing

um p-p
16:15 -17:11:
RIJn ar rated speed of 3600 rpm without brushes

/ 113.
',<oS 200,]
~ Stable vibration amplitude.
17: 12: Brushes installed
~ Spiral vibration started (red line)
18:05: Brushes removed
~ Spiral vibration stopped (green line)

18:05
\ -,
. ,
-..- .•.••••..•..
f __
17:12

.....x.
-t- __ \•..•.
/

/~-

Horizontal slip ring mede (D=15.4%;3310 rpm) Vertical slip ring mode (D=2.5%;4940 rpm)

73 LABORELEC ©

lABORElEC
Case history 1: rotordynamic calculations

Natural Frequency Calculation

Simulation of reduced Stiffness

+
-
F.~

..".
• .,.: ••••• ,

of the Support Condition

at Bearing No: 5

Hypothetical
Assumption:
Bearing No. 5
removed

111))

ero

,;
1--If--l---+---+--'-1--+-+--+--+1
.
1".GIl IE· li IE'H l'UJml'il u eamt [!OOOI DilUI cc-
+
lQ

Vanatjon of retenve Suppot Sdtfness et 8earing No. S ( in peecent % I

7<,
 LABORELEC
Case history 1: what if stiffness is further reduced?

Automatic shutdown due to high vibrations

~'- Polao

2'0 3400 Hl
:lOAJ1f.2Ô111536Sr

216i------_ ••••••••
_
---~_,.------~---~-.-,I""-fi 3120

180

0~~=m~11~11:1~~01~--~--~~--~--~~~--+-~~~m-_11~la~~:$
t5rrW'l.lr,~
- Spud (1) {O.3400]RPM 3006 300a - Amplitude·HI (D) {O,240)am 15715":1 - Amplitude·HI (1) {O,240)nn as 35
- A",pli~HI (B) [O,240w,m 28 43 - Amplitud.t.HI (E) [O,240p..1S1 21(: - MW [O,400JMW 204 212
- Amp~Hl (C) [D,240llmt32 58 - Amplitude-HI (H) {o,2-40)an 57 57

75 LABORELEC ©

LABORELEC
Case history 1: conclusions & recommendations

• Using off-set tiltingpad supports at bearings no. 5 & 6 instead of symmetric

tilting pad bearings - increase stiffness and increase the separation margin of
the slip ring eigenmodes with respect to the operating frequency
• Update of the assembly instruction of the tilting pad bearings 5 & 6 -
improved clearance measurement of the bearing ring
• Changed shaft alignment at bearing 5 - O.1-0.15mm positive vertical
coaxiality instead of complete coaxiality in order to preload bearing 5 during
clutched conditions

• Even with ali new specifications within tolerance, spiral vibrations still occur!!

7ê
 LABORELEC
Newkirk rub: SUMMARV

• In both models, the thermal distortion attempts to make the hot spot become
the high spot - continuous attempt to reach an equilibrium
• Importance of the margin between the operating speed and the critical speed,
the thermal bow will be more arnplified if running speed is eloser to the critical
speed with high modal participation at the rub site
• Both co-rotational and counter-rotational vector changes are possible
• The appearance of this phenomenon is often related to modifications of
operation parameters:
~ Condensor vacuum for a LP turbine
~ Load changes or steam temperature variations for MP or HP turbines
• Heat removal capacity near the hot spot plays an important role to reach a
lirnit cyele

77 LABG;:';E:"'E~ ©

LABORELEC
Partial rub

• Also know as Mathieu rubi intermittent rub

• Continuous or dynamically intermittent contact between rotating and

stationary machine components

• Cause of vibration: coincidence of the rotating speed with a multiple of a shaft

critica I speed facilitates shaft vibrations when a contact occurs

• Result: appearance of important subharmonic shaft vibrations at Y2 I Y3I %""

times the rotating speed
 lABORElEC
Case history 1: introduction

• Shaft line suffered severe trauma from a compressor crash

• Only GT part was checked during overhaul
• IP bearing was O.2mm raise during re-alignment

m
M

c~

Retative shaft vibration probes

Absolute bearing casing vibration probes

Phase reference

79 U\80k~LEC ©

lABORElEC
Case history 1: findings

Linear

250 • .26'1)71200818:33:13. _ 400

r,----
:261071200818:07"02 o~u

350
224 -- - - --- -- - - - -- - -- ---- - - -- - ~- - - - ~ - - - - -- - -- r tl~ - - -- -
0'0-0-0-0'0-0-.'0-0-0-0'0-0-0-0-
0
'.'0'0-0-0_0-0-0-0,0-o-1~ : :-·-~I ~I', tI 310

;1~'"
: ~ ::~. - r·-h -"~ - --
' 11 fl~- I';"
192 --- - -
it .
1
270

j -; { l - - r·-~-o-o'o-o-.-
r
160 230
t .• I .•..•..•.....•.
-•.•.~.'
"ti:I.-
" ~ *" I..

~:;;r 128 -
! fi -
I \[II!
V ,
190 ~
6
~ 150 ~
~ I
96 -----f - ,I
110

~ ,L:
64 \, - 'I --;"--lf-v-- --_~___;_-- _ -- 70

~_,:t:.11-"'"~ "'--~-~ 30

-10

0~~-+~~ __ ~~~~~~~-+~ __ ~~~~-+ __ ~ __ +-~~~ ~~~~~~~-50

261071200813:17:09 15min I h'.. 261071200823:32:14

0_ - - MW [-50,400JMW 320 20"1 - Pk-Pk (7) [O,250J"", 43 43

- Pk-Pk (5) lD,2501"", 7667 - Amplitude-Hl (7) [O,200J"", 30 20
- Amplitude-Hl (5) lD,200J"", 51 39

bO LABORf~EC e
 lABORElEC
Case history 1: influence on H1 vibrations

H1 H1 H1 H1

'scere (pI<.pk~ D '" 45iJm •• 3 11 Sce'e (pk-Pk): D = '201Jf1'1 11.

81 LA80RELEC ©

lABORElEC
Case hlstory 1: time signallP bearing

Raw Raw
M·r-~.~:--:~~~~----:--:--~:
~----:~~:---,

o\7:\.i!\,l\!:\7:\j\l:,}~,+.+'\+j6!i\A\.!,\j
.60' : :::::::

82 LABmlELEC ©
 LABORELEC
Case history 1: resulting FFT spectra

FFT FFT
SC&le(pkpk):O.~ 3BOT-l1 Se'" ~), o • 1201>n • HO l2

1 1
..tê •
o I
o 1
I
2 3
I
40
I I
1 2 3 4

FFT m
ScaJe (pkpk): o • 12D\Jm lI]j MD-L 1 seee (pkpk): V : 1 OnYn/s IIGr-L 1-AbsHuis

. 1
3 4
'"rJIlIi
o I
o
I
1

U\SO 't::LEC ©

LABORELEC
Case history 1: orbit plots

o••

Before:

, , ,C1, \ i
, , I
, \ +
\,j '

After:

Ol-Ll S&=Jíe:12ó1Jí1í MOOLl Scií!e:l2õíJfTí

84
Fi5u SCefe: 124iií J LO-lJ S&IIe: l20íiií

LABCf.. EL::T Q:.)

.-
 lABORElEC
Case history 1: what happens?

• A partial rub contact, impacting contact

• Coincidence of the rotating speed with a multiple of the shaft critica I speed
• Gives rise to subharmonic vibrations at exactly Yí Y3, X, ... of the rotational
I

speed
• High shaft vibrations are maintained with low input energy
• No hot spot creation!

-125'"--- -'------'-_--'---- ----'

Scale (pk-pk): 250l-lm

85 L.A.80FlELEC ©

lABORElEC
Case history 1: intermittent contact

• Whatto do?
-+ Find the rub contact
-+ Try toavoid contact
- Change the oil film condition (use of lifting oil pumps)
- Balancing?

• Where does it hurt?

-+ Analysis of the vertical shaft lift and experience on similar machines led
to a fast rub location (interstage seal)
-+ IP/HP casing was removed and ali clearances were installed as needed

86
 LABORELEC
Case history 1: intermittent contact location

~nRiVfE D2. Vfl.PE:lIA \;'Ip #o9!At'o.II!.e OEVAF'EUR HP

fP STEAIIf ~õJf'/JSSKJN 1"11> ST&./,f A.uWSSlOlV
ECHAPfElI('hlT MI' VERS cYlNORf IV
rP SlEANEXH.4'.ISTTOLPCYl.f.lDSi
__ ~ _... \I,1,f'Et.rnO'I:IJW,';ti"IU
, .~ - CUIOOSI'lJAl

ECHAI'PCMCtiJ VoI.!>(:\.>RIH' vens 1li:r.;Il;l,ll,,-r, v"fl

''PS'tt:.AME,l~r()lifffFÁl

87 LABORELEC ©

LABORELEC
Case history 1: conclusions

• Phenomenon can occur when a critical speed is dose to Yz X, ]4,... of the I

rotating speed
• Causes a very rapid increase of subharmonic vibrations
• A small change in shaft position is sufficient to trigger the phenomenon
• WiII normally not cause an important damage to the machine (depending on
the damping characterlstics, ...)

-+ Benefits of the vibration monitoring system

- The problem was recognized immediately and the fault was located
correctly
- Repair action was reduced to an absolute minimum

8il
 LABORELEC
Case history 2: introduction

~ • Gas and generator coupled through a gearbox

• Shaft line had a major overhaul and re-alignment

4 5

N2= 3000 rpm

ALT

Nl = 5410 rpm

1
8 lP.80RELEC ©
.-
LABORELEC
Case history 2: vibration signature
srco

5520

i' 3680··

Í 276(1

0'~'M~=OO~~:~~;'9~~~L2~~~~~~==~~~~==~~~~~~~~~,,=.~==,,~.~m
lSIf.n 1 ~_ ~

- Sptoed(l) (O,6100)RPIoI 1531f..:i

-- SpMd. (2} [O.6100JRPY es ~

H1 H1 H1
~ ~ ~

seere (P+:-pk): §A = 10mmfs lIrB

90
 LABORELEC
Case history 2: vibration signature

---..
zo
"" "'"
'860

Just before run-down 504'

-t coo
'"
asse ~

:;o.'
" ..
-.
-
:~,-~~-~~~~~'~,,-~:~:-~~~~~~~~~~~~~~~~::~=====:======
Sõ'ftd(2) [D,6000JRPN .!C<n -Pk.Pt(A)('O,200)imà'
-p".Pl:(B)[D.200P~
-P):·Pk(DJ[D,200p..
-Pk·Pk(t)[D.200lI' .ec
••
••~

-Pk-P1:(C) .~

m
se •••. [pI.,pi.)O·fQp

I / Sudden appe rance of

sub harmoni vibrations

m
Scoie(J:l:poID·~_ASlOfN

]
91 lABORELEC ©

LABORELEC
Case history 2: vibration signature
350

280 Sudden increase

after reaching
2<0 42'"
nominãl speed
----~ 3363 ~
(';
,,-

120
2520 J
80 "'"
.0
+~ ~~~~~~~~-~.':, /-- ----.~
~"'"
,9f12f2OOB11:53:10
1m."'''''
- SPHd (2) [O,6000JRPM ,2962 l4{J; Pk-Pk(5)[O.350~4349 -Pk-Pk(A) [o,JSO},aajl 44 - Pie-Pio: (O) lO,350)1m!lJ 10'::
- Pk-Plc (1) {O,350}.!m 22 29 - Pk-PIr.(1)[O,350).Lm511Q.1 - PIr.-Pl (li) [O,3SOl!un n cI -- PIt·Pk (E) [0,350)= 8'; ,J4
Pk-PIc(3) (O,3SO}.m!3: :::1 PIe·Pk(9) [O,3S0jun (5 4. - PIe-PI!( [0,350 65 M

/ ±16Hz

, ~
--~~':.=:' ~~~
-=-

.... -==---------=---
m
~i_JD.':n. • ...s:lCbl
 LABORELEC
Case history 2: vibration signature

400 .. - -- _ .. 6000
l~ln2r..{JOI31e:O:'~4
5760

360

5120
Phenomenon
320 Sudden increase
disappears when a

--
after reaching 4400
2BO certain minimum
nominal speed
load is reached
2'"
3200
200

2560
160

1920
120

_ 1200

- SpHd (2) lO.6000]RPN ':'9S3 Pk.Plr: (5) ltl.400j,am 55 - Pk·Plr: (Aj lO.4(0)mt 20 - Pk·Pk (O) (O.400)Im 1:0
- Pk·Plr: (I) [O,4(0)&m 20 - Pl:.Pk (7) lO,400j,un W - Pk·Pk (B) [O,4(0)lm 85 - Plr:·Pk (E) lO,400)un 119
- Pl:·Pl: (9) ,400)lm ~i - Pk·Pk (O lD,4(0)lm 91 -l'llW MWH

92 L BO>iELEC ©

LABORELEC
Case history 2: vibration signature before incident

•..•..•
leroPo$~~Of9~_180Sen~~218 Zto"o~~Ofa-_62SensorC",,'64
Average shaft
position during
vibration
phenomenon

AS2fW(GEN )1-0.66 y,o.oo

~.)
(;...
.-
AS2T1/\4<GEN seeÍle 12t\i'í
 lABORElEC
Case history 2: vibration signature after incident
c

BU$t-.rog
ZerllPo:sêSeMor9,..160~n$(lI'A •• 218

Change in average
shaft position
- when minimum
load is reached

b
AS2fWKOr.4p )(;0 66 y:OM AS2f1í\M'EN )(:Õ.6& Y·O.ro AS2GãJ )(0.60 y:o 26

I 'l.a
, (..jA
,F
t+ I,
,
u t ./

95 LJ-\,BO-.ELEC ©

lABORElEC
Case history 2: vibration signature

H1
"" <::-~0-..
. .....•.
~~ ~
_---.._-.~ •.......:::::::::::::: ..
.•..•.....•.
. .
~o _
------ --"'-'.__.-»~"""
" .
:<::::;,;;~~
... li

...............................................
, .".ror,. ~ ' •.••. _. _..
.•........

.:~======~========~======================~============~~ Critical speed of the

:.' '. / generator at ± 1000rpm
'. (16Hz)
.....•.
.:,:":<::: ...
-------- .------._ - . ..
J......
':.';. .... .

-----~~~< •••••• "...

. .' .;:~~~~: ••••••••••••• " ••••••••••••••••••••••••••••••••••••

-"'" ',
• •• r ••••••••••

:
'••••• '. '•••• ,.::;: ;;::::::;;::;;: ::-:;; : ••• :. e

1000 2000

;Speed: 3100 scee (pk-pk): O •• 200!,m ~1inI

96
 lABORElEC
Case history 2: vibration signature

2QQ •••• ! '-.!: !••. ! ! !.' !•• ! '.•••••

~;?:'t\~i,-'f\L~ED±/~~F·~8[f~
11 scee (pk-pk): 400um

97 LflBORELEC ©

lABORElEC
, Case history 2: conclusion

• Inspection of the bearing seals of the two generator bearings is recommended

(rub marks were found at the front bearing seals)

• Vibration monitoring only based on the absolute bearing vibrations is not

enough

• Make sure vou do not filter relevant vibration data away « 50Hz)

• Do not rely completely on the OEM for the evaluation of the shaft line after an
overhaul, consider ali signals (absolute bearing vibration measurements alone
are not sufficient)

98 lli.BORELEC ©
 LABORELEC
Dry rub
z,

• Cause: excitation of resonance frequencies due to contact between roto r and

stator

• Tangential force due to rotation and friction • possibility to excite backward

whirling eigenmodes

• A serious malfunction in which the rotor maintains contact with the stationary
part (almost) continuously (e.g. transient operation without oil flow to the
bearings)

• Result: shaft whirl movement in opposite direction of the rotating direction

93 U\60RELECG

LABORELEC

Part5:

Shaft eccentricity

.:» -;':;"ê{:-C (Í~

..-
l:
 LABORELEC
Introduction

• The shaft bow will be directed upward,

vertically for a warm machine

• Stabilization of the shaft eccentricities is

necessary before every start-up

• Residual bow willlead to additional

unbalance during start-up of the unit

• Turning gear operation is necessary both

before start-upand after shutdown

101
-.,
LA80RELEC <0

LABORElEC
Turning gear principie '

Melall metal - ccnl act , sh.aft ai slandslill Groundm9 b.Lu~

II Knu

Beatin
7~
l
-~'KH'-~"
L-:f v-:J C;r--çl1lC;
K ~~I
L---CJ \
::5:1 0"
e a 1 nng
~g7S:l~
f xci] alion

t t t t tt tt t
Oamag! ",heo shafl-turning wilhout me asur e s t aken

Shaft rol aling wilh lhermal s aq

Shatl rolaling lIilhoul Ihermal sag

-\--~
<>
-\
Detlee! lon curve Adual rotating curve
r.ddition •• doU«'íon by
IImmill str illilícilion)

J02
 LABORELEC
Case history 1

• Industrial heavy duty gas turbine

• Start-up with very high relative shaft vibration amplitudes (540 11mpk-pk)
• The vibration behaviour at nominal speed seemed normal
• What happened and is action needed?

3 C 4
7 8
/
5
/
6
~/
1-6. B 2

rotation

GEHERATOR TURBINEJ
-A
9

lCl3 yBORELEC <0

LABORELEC
Case history 1: vibration signature

Pols
H1 H1

• ••• •

Scale (pk-pk) D = 540~m 11!13 o cale (pk-pk): D = 230~m "li

'04 -
 LABORELEC
Case history 1: vibration signature

Normal eccentricity values Eccentricityvaluesjust before start-up

x
x

105 LABORELEC ©

LABORELEC
Case history 1: vibration signature

120
: 17;;1J200214:42:51

roo

80

60
•
40

20

Ot.17~N-1~-OO2-13-.~-.~-------------------U~~~~~~-~~~~~~~~~--~::=====1;7N=W;00:21=70~954
5 min.1 hU'.!1

- Amplitode_Hl (1)[0,1201
••• 1 68 - Amplitude-Hl (4) [0,1201
um o2 - pm o 4
Amplitude-Hl (7) [0,1201
- Amplitode_Hl (2)[O,120Jluno 42 -- Amplitude-Hl (5) [O,120]jUtl o 8 - ••• o 2
Amplitude-Hl (8) [0,1201
o 27
Amplitode_Hl (3) [O,120)jun - Ampli",",-HI (6) [O,120)jun o 14 - Speed (1) [O,3400}RPM 035

106 LI'r30FEd:C ©
 lABORElEC

Part6:

Blade 1055

.-
-
lABORElEC
Introduction

• Sudden change of the unbalance

distribution of the rotor
• The effect will be determined by the
modal deformation at the shaft at
the actual speed
• Most damage is caused by first
blade, cumulative effect
• linearization principie for oil film
stiffness is not longer useable due to
high shaft vibrations in comparison
with the bearing c1earance

lQ8
.-
 LABORELEC
Case history 1: introduction GL>F -s"-"ez.

• Normal start-up of gas turbine

• Unit is automatically stopped due to high vibrations
• Is it allowed to restart the unit?

E o C B
7 8 5 6 3 4 2

A
Axial
measurement

109 ~ABORELEC ©
.-
LABORELEC
Case history 1: vibration signature

Zero pos.sensor 1~13 Sensor 2~92 lero sos.senso- 3,,·50 senscr 4-50 zero Pcs.Seoso- 5=-13 Sensor 6=19 ero soe-senso- 7"·65 seneor 8"'-142

I I I I I

TurtJne x:oM Y:O.Sõ Cõft'íP x:0.60 Y;o:50 AI voar X:1.00 Y:O.60 ectee- '1.

3400

32(1() increase in ~ LVMS

vibrations no speed information
2560

sso
~ 1920 speed
i 1280
run up 320

1~~~~~~~~~~~~~~;;~~~'!1======~=======t=
640 • 160

.l!! -1'

005,(1312008(6:26:16 15sE<t 1 r. ~ 05J0312OO806:3-4:49

- SpNd(l) [O,3400}RPM 29813 •..... Amplitude.HI (5) [0,80011= 43

- MW (·lO,lOO)MW O
- Amplitudt-Hl (1) [O,SOO)1Ul\ 73
 lABORElEC
Case history 1: vibration signature
j-

Polar
H1 H1 H1 H1
Acceleralion Acceleralion Acceleralion

Scale (pk-pk): D = 120~m n Scale (pk-pk): D = 12~m li Scale (pk-pk): D = 120~m 3 Scale (pk-pk): D = 120~m 11

Pol~r
H1 H1
Acceleralion

-281021200806:34:21 -28/U2l2oo806:34:21 -281021200806:34:21

~510312008 06 :26:42 -0510312008 06:26:42 -051031200806:26:42

Scale (pk-pk): D = 120~m Scale (pk-pk); D = 120~ 11 Scale (pk-pk): D = 120~m • Scale (pk-pk); D = 120~m

11 LABORELf:.C ©

lABORElEC
Case history 1: vibration signature details
Stepwise
-: evolution
/ Evolution
PoIa< Bushing
H1 Zero Pos:SensOf 1.-13 Sensor 2~ ZetOsce.se-eo- 3--50 Sensa' 4-50 zero Pos:Sensa 50<-13 Sensor 6_19 Zero PO!::Sensor 7-·65 Sensor 8=.142

Scele (pk-pk): D· 8IX\Jm 11 •• v •• 8Omm!s 11I

3400 800

3200

2560

",,, ~
E

320
~
l!.
~
160

- Speed(l) lO,3400JRPM 29S9

- MW [-lO,200]MW _1
- AmpliNcM-HI 7 SOO)lm 411
 lABORElEC
Case history 1: vibration signature detalls

~--- -_.
Polar
H1 H1

.~ = 182 5J-ltrlP = 270"

<,..!l,
I
= 23 OJ-ltrlF' = 88"
';-~=-==--:~==~~;;;;;::~i:::::::=~==--
__ I A = 3S.2J-lmP = 212" A = 21ll-lm P = 122"
Seale (pk-pk): Seale (pk-pk): D = 120J-lmDI!I3 D9

113 U\BCRELEC ©

lABORElEC
Case history 1: vibration signature detalls

Before
incident

Bushing

Zero Pos.Sensor 1=13 Sensor 2=92 Zero Pos:Sensor 7••-65 Sensor 8"'-142

f + I r I I

;
Turblne X:O.80 Y:O.50

After incident

114 u\BORELEC; ©
 lABORElEC
Case history 1: vibration signature summary

• Incident occurs +/- 20 sec after the unit reached nominal speed

• Excitation was on +/- 10 sec before jump in vibrations

• Jump in vibration was highest at the generator excite r side

• At the same moment, change of the shaft position at generator bearing

• Evolution in shaft position in generator and GT turbine bearings

• Different shaft position before and after incident

115 U\BORELEC © -
lABORElEC
Case history 1: possible malfunctions

• Lubrification problems within the generator bearings

• Unbalance (Ioss of mass)

• Electrical problem

• Bearing degradation in the generator

.-
 lABORElEC
Case history 1: findings

117 LABORELEC ©

lABORElEC
Case history 1: conclusions

• Normal situation
-+ Generator trips on shaft vibrations (200 um pk-pk)
-+ GT trips on bearing vibrations
• Problem
-+ 4 sensors of the generator were simultaneously out of range (200 ~mpk-pk)
due to the first blade loss
- Sensor fault - Trip blocked
• Solution
-+ At short term:
- Increase measurement range of shaft vibrations
- Issue a trip when measurements are unavailable
• At longer term:
- Review alarm logic more thoroughly

118
 LABORELEC

Part7:

Structural resonance

1_ ;(.r-r:_:C©
.-
l:

LABORELEC
Structural resonance: introduction

MUOFdiscr!'(e
parameu~'rmede!

• Real structures: Multiple degrees of freedom

- multiple eigenfrequencies or resonance
frequencies

• From the design phase one mostly tries to

avoid these dynamic ranges during operation Alf)OF fn·qut.'J1cl
rl"Spoust'

J~O
 lABORElEC
Case history 1: introduction GL>F
-- .5,-"ez

J • Newly built pawer plant

• Since cammissianing ail seals near the generatar bearings brake and caused oil
leaks 1~~OOEA!!-szoa9'49:::J
-=:-t-- -------+: --+----+-----t~=~~~--:
r5iil

. :: ~- - 1- i
!
'00- - ,--I----t--!----+---1---f----+---- -- ..
--.---
....
--...
90·,-- _._~.__ _ ._.__ __._

",cc_,- __ .- _ I'

e 70' !
g 60 i
--t-- ---~-------------- ---------
50

: ----t-
- --.---m:

-1-- --- -----~==--=-.:...~

f--i-----t----- ------j
r--------
20 - - , -

'o - -, - ,-- I
o-ó 100 -. 2:00 300 .dxJ
.•
500 100 BOO 900 1,000

I_TY_P.",.;"E
__ --JIL-!R_.
A_IN_-.J~'_OA_T_E_T_I!V1_E I'_p"'_OI_N_TIMEASUREipARAM~DlRECTI

ISPECT!\A Gi',21 o 18 Sep 08 9:4q :03 DE: fi 5._697 mõn/s o 1000 Horizont
G'l',21 o 18 Se!1-0a 9,49:12 DE A 132.199 m..,,/s o 1000 lU<ial

,o oa
GT421 19 S@p 9:50:50 DE v 14.735 liUl\/S o 1000 Vertical

121 LABORELEC ©

lABORElEC
Case history 1: first advice

GT 21 Motor Vibration measurements.

Drive Errd Side

Vertical = 14.7 rnm/s

Horizontal 56 mm/s
E! = 132Ji~

The vibration measurements shows unacceptable vibration level 00 the drive end side of
the motor. We would Iike to let you know the position measuring points and it's area of
concentration. Vertical measurement concentrares mainly 011 the strength of the
foundation and the bearing housing condition, Horizontal vibration concentrares on lhe
unbalance ofthe rotating parts sueh as rotors, fans and blowers. The Axial vibration
concentrates on the integrity ofyour rotor and shaft if'bended and if there is a great
misalignment ofthe motor. We highly recommend for you to undertake a re-alignment
procedure on your motor as what lhe vibration suggest We do believed that as 800n as
lhe we reduce the Axial vibration, vihrations on the Horizontal and Vertical positions will
be reduced dramatically as well. Hard copies of the frequency analysis will be delivered
to you on Sunday. Tbank you and regards,

122 i..L\SCJRELEC ©
 lABORElEC
Case history 1: instrumentation overview

F o A 9

LABORELEC ::J)
.-
lABORElEC
Case history 1: vibration signature
1.2.3.10,13.16.1.8.19

4,7,8.1.1 .. 12.14,15,17
Arialmtuur"mE'!nI1

Vertical me asureme nts

//
/.

»:
5,6.9 Horitonl,J! m(',nor"01~J'lt~ 1

Bearing TE 8earing EE
Overall (RMS) H1 [mm/sRMJ H2 [mm!SRMJ Overall (RMS) H1 (mm/SRMJ H2 [mm/sRM,)
" --1
#
-------- -------- -------- 1----------
#
-1 --------- --------- --------
D I 2
3
57.99
90.11
29.64
57.96
89.62
29.38
2.98
9.81
3.85
axial
axial
axial
8.79
2
3
14.67
4.06
8.75 .
14.54
4.04
0.67
1.94
0.40
4 3.86 3.76 0.63 vertical 4 1.96 1.84 0.56
5 3.00 2.87 0.82 horizontal 5 0.85 0.70 0.45
6 1.04 0.99 0.21 horizontal 6 0.77 0.67 0.34
7 2.60 2.53 0.51 vertical 7 1.48 1.46 0.17
8 9.00 8.92 1.09 vertical 8 2.33 2.32 0.09
9 0.59 0.11 0.54 horizontal 9 0.88 0.77 0.38
10 21.56 20.93 5.17 axial 10 2.93 2.88 0.46
11 4.05 3.85 1.23 vertical 11 1.68 1.67 0.17
12 3.61 3.57 0.43 vertical 12 1.71 1.70 0.11
13 17.92 17.02 5.62 axial 13 2.35 2.28 0.49
14 2.99 2.90 0.70 vertical 14 1.74 1.73 0.12
15 9.58 9.55 0.64 vertical 15 2.43 2.41 0.19
16 57.75 57.74 1.98 axial 16 9.51 9.49 0.84
17 7.60 7.35 1.91 vertical 17 2.18 2.11 0.47
18 14.60 13.70 4.94 axial (concrete) 18 2.06 1.96 0.50
19 8.80 8.19 3.19 axia I (co ncrete) 19 1.32 1.11 0.37

L~B;)~.r-:LEC ©
 LABORELEC
Case history 1: vibration signature

Hl Hl Hl Hl

Sc81e (pk-pk): o '" 6O~ 3 D

Hl Hl Hl Hl

Scelle (P'C-pk): Y '" 2Oml'Tl/s IIJ seee (pk-plc): v '" 1 Omm/s • scee (pk-pk): V .• 22Omrn1s lIIiI

125 L.A.80RELEC ©

LABORELEC
Case history 1: vibration signature

Hl Hl Hl Hl

cale (pk:-pk): V = 1cmnts sceie (pk-pt::): V = 20mmls [I scee (pi(-pk): V = 10mmfs

Hl Hl

m
scee (pIc-pk): V" 21Ommls 11I Scele (pk-pk): Y = 20mmfs li Scale (pk-pk): V'" 60mmls fB
 lABORElEC
Case history 1: impact testing

• Hammer Excitation

127 -
lABORElEC
Case history 1: impact testing

• Axial impact and axial measurement

Cross Ph.ase

IS0.0000 ]'OS ID, .AL EZ

\
--
I OS,OLI7
16-ok.t.-OS

Degrees
\
~
-v'v ,/ <-, I ,..r-

,~
.r:
.---/' Degr: -98.1003

-IS0.0000 I
11"- Hert: 59.0000

~-
Hertz I 100.0000

Transfer Fu.n.ction S/A

0.035 o I
-- ]'OS ID, .AL EZ

;---._---- -- 1 59Hz
---- 1---------
OS,OLI7
16-okt-08

11\ --
c--
52Hz
I \
IA-J \
/'" \.
-- 49,5Hz
~ ~ ~
O.
o ..•.•..
0.0
-
~ ~ -------- I ---r----.... -
n"'l.rnIg: 0.0300
Hert' 59.0000

Hertz
I 100.0000

1?c.c
._~
iABORcLE: ©
.-,
 LABORELEC
Case history 1: impact testing

J • vertical impact and axial measurement

erass Chan..n.el Cohere:n.ce

1.0000
~
fY1
I~ ~
,i
vl ~r vv
~
!'I'V'
''''1 .r "V'

I
JOB
08:06:37
1D:

16-okt.-08
Jl..L EZ 11vD

-
~ V
1--- J! .L.
I

! I
t1___
~. ; 0.2039
~ Hert: 50.0000
0.0 ~ I
0.0 420.0000
Hertz

Tra:n.sfer Functi.o:n. H/A

0.00500
~,---'I--=-
! --+-----+-----+-----+---
JOB
08:06:37
ID:

16-okt-08
.Jl.J.- EZ!1-..1]

I
----l-----!---
I
rnrn/::!: 0.00309
Hert: 50.0000

Hertz

LABORELEC ©

LABORELEC
..s.'-"'ez
Case history 1: conclusions G L:>F

• High axial vibrations that are not advisable for long term operation

• Most probably due to axial resonance of the bearing structure excited byan
acceptable (or normal) unbalance state ofthe rotor. However, no re-alignment "
is necessary.

• A more extensive balance operation decreased the axial vibration levels which
proved the radial-axíal relation

• A final solution imposeda further stiffening of the bearing structure

130 Lfl,BORELEC ©
 LABORELEC
Case history 1: conclusions
I
,.l..
• This theory was more detailed studied by the OEM and the findings were
published in 2010 a technical paper. ..

Bearing _

Vertical Axial
Vibration ;-

, .+
•+
.
V~ib~l'3.::.t!.:.io~n~

h-=-.",,',:......-
-~- . ..
...•.••••••
......
~- ..•..
._
~~-------- ~
...••••
f _,
--- ----;---_.

/
/1
.'

I.nnnrilil
~
• :..AB2>;:ELES ©

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processes and energy use, with almost fifty years of experience.
We are part of the Research and Innovation Division of the GDF
SUEZ Group, a world leader in the energy sector.

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