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TAC121-E001E
Notes
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differ in certain respects from the actual product.
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may not be distributed or reproduced in whole or in part without permission.
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this document.
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questions or comments or find mistakes, please notify us.
TAC121-E001E
Table of Contents
1. Analyzing and Diagnosing Turbine Vibration .................................................. 1
1.1 Overview............................................................................................... 1
1.2 Unbalance-induced Vibration ............................................................... 1
1.3 Oil Whip ................................................................................................7
1.4 Rub .......................................................................................................8
2. About the Remote Turbine Vibration Diagnostics Service ............................ 12
2.1 Overview .............................................................................................12
2.2 Details about the Remote Support ......................................................12
2.3 System Configuration ..........................................................................14
2.4 Number of Input Points for Monitoring ................................................15
2.5 Intervals of Collecting and Analyzing Data ..........................................15
2.6 Method of Detecting Abnormalities..................................................... 16
2.7 System Operation ...............................................................................19
TAC121-E001E
1.1
Overview
The vibration of a turbine occurs because of many reasons. To analyze the vibration phenomenon,
Mitsubishi Heavy Industries provides an assured technology that is developed based on the years
of experiences in designing, manufacturing, and installing steam turbines for power plants.
The vibration of a turbine differs greatly due to the status of the turbine. Therefore, by measuring
and analyzing the vibration, you can determine whether the turbine is running normally.
Mitsubishi Remote Turbine Vibration Diagnostics Service collects vibration data, analyzes
frequencies and phases, and compares the vibration of the target turbine in the normal and
abnormal states. Mitsubishi Remote Turbine Vibration Diagnostics Service analyzes and
diagnoses the vibration of the target turbine based on the highly accurate, useful data that is
collected.
The following subsections describe some main causes of vibration.
1.2
Unbalance-induced Vibration
The most typical vibration of a rotating machine is caused by unbalance of the machine. More
than 90% of vibration problems is due to unbalance. Therefore, in analyzing and diagnosing
vibration, the basic method of determining the cause of vibration is checking the unbalance of the
target machine since unbalance can be caused by many reasons. To determine the cause of selfexcited vibration or other abnormal vibration, we usually check the difference from the
unbalance-induced vibration such as the nature of vibration, chronological changes, and
components of frequencies.
The cases and features of unbalance-induced vibration, which is the base for analyzing and
diagnosing all types of vibration, are described below.
(1)
1.1 Overview
1
TAC121-E001E
Vibration value
Vibration
Vibrationvalue
value
Vibration value
Vibration value
Rotation count
Vibration value
Vibration value
Time
Frequency
Figure 1-1 Normal Unbalance-induced Vibration
TAC121-E001E
Figure 1.2 shows a Bode diagram of normal unbalance-induced vibration and Figure 1.3 shows a
Nyquist plot of normal unbalance-induced vibration.
File name
Time (hour)
TAC121-E001E
I: Initial
P: Previous
C: Current
I: Initial
P: Previous
C: Current
I: Initial
P: Previous
C: Current
I: Initial
P: Previous
C: Current
Figure 1.4
I: Initial
P: Previous
C: Current
TAC121-E001E
Vibration value
Vibration value
Vibration value
Vibration value
Rotation count
Time
Vibration value
Vibration value
(2)
Frequency
Figure 1-4 Unbalance-induced Vibration That Changes Over Time
TAC121-E001E
(3)
The vibration at the critical speeds becomes greater compared to the initial status. However,
the change of vibration is not proportional to the elapsed time.
The vibration value suddenly changes in the course of time. However, the value may return to
the previous value in rare cases.
Vibration value
Vibration value
Rotation count
Vibration value
Vibration value
Time
Vibration value
Vibration value
Frequency
Figure 1-5 Unbalanced-induced Vibration That Suddenly Changes
TAC121-E001E
1.3
Oil Whip
Oil whip occurs in rare occasions if an error occurs in a turbine shaft for a generator. Oil whip is
mainly caused by the cross term (Kxy - Kyx) of spring moduli. A spring modulus is one of the oil
film characteristics of a hydrodynamic bearing. The features of oil whip are as follows.
(1)
The vibration count is the same as that of the critical speed of the rotor.
(2)
Oil whip occurs when the rotation count becomes twice or greater than that of the first
critical speed of the rotor.
Critical
speed
Rotation
count
component
Critical
speed
Oil whirl
Oil whip
Rotation
count
component
Self-excite
d vibration
component
(3)
(4)
Once vibration occurs, it does not decrease even if the rotation count increases.
(5)
The direction of shaft center orbit is the same as that of shaft rotation.
TAC121-E001E
Amplitude (PmP-P)
Frequency (Hz)
Frequency (Hz)
Amplitude (PmP-P)
Frequency (Hz)
Frequency (Hz)
Amplitude (PmP-P)
Frequency (Hz)
Frequency (Hz)
1.4
Rub
In a steam turbine generator, if the gland seal or the bearing oil thrower comes in contact with the
rotor, vibration of the rotating component occurs. This type of vibration changes over time in a
peculiar way. Figure 1.7 shows the mechanism of this phenomenon. Note that when the rotating
part and the stationary part contact, the generated heat bends the shaft and unbalance-induced
vibration occurs.
Since the direction of the heat-induced bending caused by the contact (that is, direction of
unbalance) and the vibration vector caused by this bending have a phase difference, the direction
of contact always changes and the vibration vector changes as well.
1.4 Rub
8
TAC121-E001E
Point of contact
Direction of rotation
New vibration
vector
Original
vibration vector
Figure 1.8 shows the typical patterns of vibration vector changes. Each pattern has the following
features:
(1)
Spiral pattern
The vibration vector continuously increases up to a certain size and draws a spiral.
(2)
(3)
(1) Spiral
(2)
Stationary rotation
(3)
Constant change
Figure 1-8 Vibration Spectra of Rub-induced Vibration When the Turbine Rotation
Speed Increases
Figure 1.9 shows a case of rub-induced vibration in a steam turbine generator. In this case, the
turbine successfully restarted a continuous operation at rated 3600 rpm after an inspection. About
ten minutes later, the vibration amplitude increased rapidly and the rotation failed. As shown in
Figure 1.7, the phase of the vibration vector changes in a wide range of amplitude (greater than
180 degrees) in the polar diagram, which is a typical behavior of rub-induced vibration.
1.4 Rub
9
TAC121-E001E
In addition to the vibration abnormalities described so far, Mitsubishi Remote Turbine Vibration
Diagnostics Service can diagnose the following abnormalities. The items that can be diagnosed
differ depending on which bearing a vibration pickup is installed on. Table 1.1 lists the
abnormalities that can be diagnosed.
1.4 Rub
10
TAC121-E001E
Table 1-1
No.
Cause of Vibration
1
2
3
4
5
6
7
8
9
Initial unbalance
Permanent bending of the rotor or missing parts of the rotor
Temporary bending of the rotor
Seal contact
Misalignment
Eccentricity of the shaft and bearings
Damage to bearings
Vibration added by a bearing or a support such as oil whirl
Horizontal and vertical anisotropic stiffness of bearing oil film
characteristics
Insufficient adhesion of setting shims
Insufficient tightening of the bearing housing
Critical speed of the rotor and bearings
Basic structural vibration
Transmission of vibration
Low-frequency resonance
Harmonic resonance
Dry frictional vibration
Critical speed
High-frequency vibration
Oil whip
Oil whirl
10
11
12
13
14
15
16
17
18
19
20
21
One
Vibration
Pickup
per
Bearing
Y
Y
Y
Y
Y
P
P
P
N
Two
Vibration
Pickups
per
Bearing
Y
Y
Y
Y
Y
Y
Y
Y
Y
N
N
Y
P
P
Y
Y
N
Y
Y
Y
Y
P
P
Y
Y
Y
Y
Y
P
Y
Y
Y
Y
1.4 Rub
11
TAC121-E001E
About
the
Remote
Diagnostics Service
2.1
Overview
Turbine
Vibration
This service helps to assure the reliability of the operation and maintenance of the steam turbine
that we delivered to you. We hope that this service helps you to increase your trust in our product
and allows you to run the power plant more successfully.
The outline of the support is as follows. At your power plant, Mitsubishi Remote Turbine
Vibration Diagnostics Service collects, modifies and analyzes the shaft vibration data and process
signals of your steam turbine, and sends the results to Nagasaki Shipyard via a telephone line or
the Internet. Then we diagnose the data in our design, manufacturing, and installation
departments.
2.2
Monthly report
We send the results of diagnostics once every month. Table 2.1 lists the criteria of diagnostics in
the monthly report.
2.1 Overview
12
TAC121-E001E
Table 2-1
No.
1
5
6
7
8
9
10
11
12
13
Item
Criteria
Rotation
count
vibration
(selected
channel)
Rotation
count
vibration, phase (per
channel)
Time - rotation count,
amplitude, phase (per
channel)
Time - load, vibration
(per channel)
Is there a large vibration that exceeds the permitted value or the threshold
in the speed-up condition?
Time - temperature,
pressure
Nyquist
plot
(all
channels)
Nyquist plot, rotation
count - amplitude
Nyquist plot, time load, amplitude
Overall
vibration
levels
Generated waveform
FFT data
Cascade
diagram
(based on the rotation
count)
Water fall diagram
(based on time)
14
15
Data list
Orbit plot*
16
Shaft centerline*
17
Absolute vibration**
Does the vibration change over time or when the load changes?
Can the vibration change be reproduced?
Does the data match the existing data?
Is there any sudden change of the vibration value that may be abnormal?
Does the list of measurement data have an error?
Determine the direction of shaft center orbit (forward whirl: normal
unbalance-induced response vibration, backward whirl: high possibility of
contact-induced vibration).
Do the shaft center eccentricity float characteristics change in the speedup condition?Do the shaft center eccentricity float characteristics change
over time or when the load changes?
Is there a large difference between the shaft vibration (normally the
relative vibration of the bearing pedestal and the shaft) and the absolute
vibration?Does the absolute vibration value change over time or when the
load changes?
TAC121-E001E
2.3
System Configuration
Figure 2.1 shows the system configuration for enabling the remote support of a steam turbine.
Customer power plant and vibration diagnostics device (additionally installed)
Customer power plant and vibration diagnostics device (additionally installed)
DCS
TSI
Operation
data input
Vibration
data input
Vibration
diagnostics device
Communication line or
Data
Internet
Vibration
analysis system
Firewall
FireWall
Evaluation and
reports by
turbine
experts
Printer
Figure 2-1 Configuration of the Remote Support System for a Steam Turbine
TAC121-E001E
2.4
2.5
of
Number of Points
1
6 (up to 12)
TSI
TSI
Source of Signal
Up to 20
DCS
Type of
Data to be
Analyzed
Vibration
data
Operation Mode
Outline of Analysis
FFT data
Plant data
TAC121-E001E
2.6
TAC121-E001E
Enter data
OA value
1N component
Alarm
See
SeeFigure
Figure2-3.
2.4(b)
NO
OA value
< alarm value
Abnormality
YES
diagnosis
NO
YES
-25% or greater
Rate of change
+25% or greater
1N Phase
YES
YES
NO
NO
Prealarm
Prealarm
TAC121-E001E
1N component data
Amplitude
Phase
Alarm
1N phase
NO
1N value <
alarm value
YES
YES
NO
Abnormality
Abnormality
diagnosis
diagnosis
NO
Prealarm
YES
-25% or greater
Rate of change
+25% or greater
1N phase
YES
YES
NO
NO
Prealarm
Prealarm
TAC121-E001E
2.7
System Operation
Before you use this system, please note the following: