Sie sind auf Seite 1von 14
cl Diagn sti ok iE wea . e” 9 ulakoT se hone © oa whut does BE Tel re ee ler bee poest Additronsk ON + te Prove Z Get Data @ usa rents: Proly ss 2 BS. How Os hk opertisy modes 2 L Olfervh web IR & Dineet 2. Shaft Crack Detection Page 11 VI. vu. Conclusions A. Remember the first and second rules: 1. If ashaft is cracked it is almost certainly bowed!! 2. A rotor system with an asymmetric shaft and a radial sideload force, rotating at a speed near half of any resonant frequency may experience high 2X vibration amplitude and 2X phase shift. B. In roughly 75% of the cases, the 2X component does not occur at operating speed. New Shaft Crack Detection Developments Torsional vibration measurements show promise of providing confirmation of crack propagation. Torsional vibrations may be insensitive to the long distances sometimes seen between the actual crack location and the available transducer locations. Torsional vibration measurement, along with lateral vibration measurement, may create a new tool in machine diagnostics, especially useful in early shaft crack detection. wars Page 10 Machinery Diagnosties creates a major shaft stress concentration and asymmetry. E. Keep accurate records (in computer files if possible) V. Shaft Crack Detection Thresholds A. At operating speed ba sae g BNC Dual Vector Monitor: a a clear warning as early as a 25% transverse crack B. During startup/shutdown BNC ADRE and other BNC diagnostic tools: indications as early as a 20% transverse crack ~/ IE raring (SQ) BRK tppesrel) Any claims of early detection of shaft cracks that are based on a particular rotor (then generalized for all rotors) should be treated with caution. Crack symptoms vary widely both with the longitudinal location and type of crack as well as with the rotor dynamics of that machine. REVE 127386 Shaft Crack Detection Page 9 B. The torsional spiral crack occurs less S i frequently than the transverse crack, and is identified using the same techniques. C. Longitudinal cracks must be larger than a transverse crack to show the same S @ level of symptoms. Fortunately, this type crack rarely occurs. It is believed that the application of the same diagnostics and machine protection techniques will yield data on these cracks before catastrophic failures occur. D. Transverse symmetric cracks are rare, S but since symmetry is maintained, there D possibly could be no cracked shaft symptoms atall except for the decrease in stiffness. IV. Recommendations 1g REED 25 eee ee 4 APEKAS Cy OC A. Avoid operating machine in a speed region of half of any lateral or torsional resonance B. Avoid heavy shaft misalignment C. Avoid a discontinuity or asymmetry under a shrink fit, especially near the end of the fit D. Avoid using a torch in localized areas to straighten a shaft. It REVE i773. Pages Machinery Diagnosties There is an increased chance of fatigue cracking today because: 1, machines are running longer due to life extension programs, and 2, more machines are used in cyclic (peaking) service. se Vem A. The transverse crack is the most frequent type of shaft crack. A subset of transverse shaft cracks that happens ae frequently is a cup shaped crack under a shrink ee fit. Often called a “Ratcheting” crack, it looks just like a tension fracture of ductile material: 1. The shaft lengthens under tension due to bending. 2. The shrink fit prevents the shaft from returning to_ its original position. 3. A tension crack occurs where only a shear crack should occur due to the ratcheting action and compression of the shrink fit Avoid any type of aye ee eee discontinuity under the RETAINING. shrink fit, especially SS > near the end. It acts as a stress concentrator and crack initiator. REVE, Lai3Ks Shaft Crack Detection Page 7 E. Acceptance Regions Note: This plot shows four The Acceptance Region trend format is a polar plot produced by sampling goe vibration vector components as a function of time. The term Acceptance Region describes the region formed around vector movement considered 1X or 2X Amplitude sant Piaes Vectors 780" acceptable. Such trends should be maintained for 1X, 2X, and slow roll vectors. Any movement of these trend vectors outside of these boundaries should be viewed with suspicion. Correlation of the 1X, 2X and slow roll vector with load, field current, steam conditions, or other parameters is used to determine whether vector shifts were caused by a shaft crack or other factors. IL. Types of Shaft Cracks Over the last 10 years there have been over 30 large turbo-generator shaft crack incidents, and some have been catastrophic. There have also been numerous reactor coolant pump shaft crack problems, none of which has caused documentable reactor damage. REVE ad Page 6 Machinery Diagnostics D. 2X Orbits Associated with APHT Plot The top orbits show the q Fe vo initial 2X reverse High x iN \\ x precession caused by the on ev "=v | high sideload. The lower Fore war orbits show the sideloading effect being ey Ne High XX SS dominated by the normal dieadarite 7 | forward action of the and wo Resonance resonance excitation. ROT Xt V (COW) ROX To ¥ (COW) st0cT NOV REVE, 17386 Shaft Crack Detection Page5 Note: Phase Changing in Leading Direction 0? 270° ru scale Amp.=40 mis pp Rurp 270° Date: 19 June" Date: 28 June a AS Ads uth Avedion Yawdanen Nw i piean Cscue in stfhess) C, 2X Amplitude Phase Time-(APHT) Plot Sernnee ae RCP-1A _APUMP TREND {2wk SPEED: 1187 pin BEGIN: 9SEP_ 9:95 END: | 21NOV 9:35 POINT: APUMP 1AX TYPE: 2X PHASE LAG 0. ELEC RE ECE a en 90. EEE EEE eee eta tee 180! PEE EEE Eee eee eee Net eee 270) | ' Veet | 1 : | ope ae ets ceees ese ES eS ee 1SEP25SEP_ 190CT —‘t2NOV—_aDEC’“"f 10.0 P ONT, APMP (AX TYPE: BK AMPLITUDE Sree reece ree eeceee 6.0 | i IEEE EE i eee Ee ea ee Ce 7 aop ff tb MINE t eutscate ”” Rotation aol —j pt ee | somite Xto¥ (ecw) gp ees eee eee eee 1SEP 25SEP_ 190CT 12NOV—«GDEC This 2X APHT plot (the motor-pump ran at a constant speed) shows the effect of the resonance frequency decreasing through twice running speed on November 12. The resonance frequency decreased due to a crack-induced reduction of shaft stiffhess. REVE 127386 Page 4 I. REVE, es S ue oe SN ae” Machinery Diagnostics Shaft Crack Diagnostics A. Cascade Plots with Associated Orbits Vertical relationships reflect an asymmetry which may be crack induced. Horizontal relationships result from nonlinear mechanisms. Additional information from plots such as orbits and 1X/2X polar plots are always required to confirm cascade plot relationships Inconclusive Is an Indicator (Not Enough Data) of a Crack Vertical Relationshi Typical Orbits z 4.0 = E 3 ae) 3 3.0 3 . 5. 3 2 & Horizontal Relationship: a 25) £_ Is Not an Indicator of a 2 2.0) 1 Ctack. This is due to = Nonlinear Stiffness go T5 2” etal = : 3 0.507 4 ® 56 @m Frequency (kcpm) B. Polar Plots Abnormal direction of phase change in a polar plot (leading vs lagging) and a large increase in 2X vibration amplitude are significant indicators of crack activity, 127386 Shaft Crack Detection Page3 A Strong 2X motion may occur when the Phase Lag 3 rpm is at or near 1/2_ ssonance of any resonance 180) <— % Any R Vibration Amplitude Unfiltered Orbits s* ee Internal Orbit Loops (x and 2x components)" C)) ieee aa) anes precession of the 2X component when a resonance occurs. Shaft asymmetric stiffness and a radial sideload cause 2X vibrations. Sideload forces or radial preloads can come from gravity, misalignment, process or pumping forces. REVE L286 Page 2 Machinery Diagnostics A rotor system with an asymmetric shaft and a radial sideload force, rotating at a speed near half of any resonant frequency may experience high 2X vibration amplitude and 2X phase shift. Other 2X vibration effects on a cracked shaft will result in a more rapid growth of the crack. Included are the following: a. increased reversal stresses b. low or high cycle fatigue c. “snapping” action due to a sideload force acting on an asymmetric stiffness Effective Damping Gradual decrease in effective damping (quadrature stiffness) is also an effect of shatt cracking. This subject is covered in more detail in the BNC Advanced Machinery Diagnostics and Dynamics Course. REVE ames. Shaft Crack Detection Page 1 L The Rules of Shaft Cracks A. The Ist Rule of Shaft Cracks: If the Shaft Is Cracked ItIs Almost Certainly BOWED! 4X Shaft Orbit Saree Caused by ——> Transverse Crack This bowing of the cracked shaft causes: 1. changing 1X (synchronous) vibration behavior at speed and load 2. erratic response to attempted balancing erralie response to attempted balane 3. changes in the slow roll vector prc snaeuahapetindadeomrabonene Approximately 75% of the time, only 1X behavior is exhibited at operating speed. B. The 2nd Rule of Shaft Cracks: Crack \ 2X Vibration Radial Load Radial Load (e.g. Gravity) REVE ras How to Detect and Identify Shaft Cracks

Das könnte Ihnen auch gefallen