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Abstract
The paper discusses a classic resonance problem of a vibration probe mounting installed on a hydro
turbine during retrofit project commissioning. Fluctuating vibration was detected within the online machine
condition monitoring system. Experimental Modal Analysis (EMA) was performed to confirm the presence of
a resonance issue at each probe bracket mounting at the Turbine Guide Bearing (TGB). Actual natural
frequency was identified with associated mode shape and damping. Finite Element Analysis (FEA) was then
used to perform modal/frequency analysis of the probe bracket with calibrating to match the actual modal
impact test result. Consequently, the model was used for structure modification and redesign of a new
probe bracket with higher natural frequency to prevent natural frequency excitation. Multiple disciplines
and tools are required to analyze and solve this problem.
Introduction
Modal analysis has been used in many industries and applications to find natural frequencies along with
associated mode shapes within relevant frequency ranges in both engineering design and field
troubleshooting work [1, 2]. The main objective is to avoid excessive vibration amplitude due to resonance
excitation which can shorten the operating life of the test object or machine part due to fatigue, or even
prevent the machine from operating reliably in some cases. Experimental Modal Analysis (EMA) results are
also used for correlation with Analytical Modal Analysis (AMA) models which are constructed using Finite
Element Analysis (FEA) based on precise dimensions, geometry, material properties, and boundary
condition (e.g. restrains/constrains, pre-stretch, etc.). Once the FEA model is calibrated to match actual
modal test data from EMA with acceptable tolerance, the model can be used to find the optimum design
for future fabricating or manufacturing without a trial and error approach (saving cost and time). The
machine and associated parts are free from natural frequency excitation throughout operating speed
range. Consequently, vibration amplitude is acceptable for long-term continuous operation.
Application Information
This project was performed to provide an online machine condition monitoring and diagnostics system for
a hydro power generation plant covering four Francis hydro turbine-generator sets (4 x 250 MW) and two
Pelton hydro turbine-generator sets (2 x 37.5 MW). Examples of hydro turbine types installed in this plant
are shown in Figure 1 below. All units have casing vibration transducers installed at all bearings, and a
Keyphasor transducer on each rotor. Vibration signals are then connected to the existing vibration
monitor rack, serving as a simple machinery protection system. However, the existing machinery protection
system is not sufficient for machinery diagnostics and long-term machine condition monitoring. Hence, the
new project work scope includes designing and installing a shaft vibration transducer at all bearings;
proper monitors; software for an online Condition Monitoring System (CMS); and system integration
between the machine control and online machine condition monitoring system. Selected process variables
are integrated into the CMS via OPC (OLE for Process Control) protocol. The Francis hydro turbine-generator
set has three radial journal bearings installed: Generator upper and lower guide bearings and a turbine
guide bearing. The Pelton hydro turbine-generator set has two bearings: Generator upper and lower guide
bearings. The Francis turbine discussed in this paper incorporates a 15 blade runner, 26 wicket gates, and
stay vanes. The tilting pad thrust bearing has six pads.
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
Project delivery depended on machine overhaul schedule so it was started with unit #3. The first set of
vibration probe brackets was designed based on engineering judgment and experience from past projects
without calculations. As commonly known, a shaft vibration probe measures relative vibration between the
rotor and the bearing housing where the probe is mounted. The probe bracket and its mounting must be
rigid with natural frequencies well above machine operating speed and possible exciting frequency range
depending on machine configuration and operation such as blade passing frequency, fluid induced
vibration, etc.
A machine train diagram after all transducers were installed is shown in Figure 2 below. There are two
casing vibration transducers installed and two X-Y shaft vibration probes installed at each bearing. A
Keyphasor transducer is also installed to observe a notch on the shaft surface so as to provide the
vibration phase angle and supplementary machine speed. The online machine condition monitoring and
diagnostic software platform retrieves all vibration data from the vibration monitor rack and processes the
variables data from the machine control system. The data is processed, stored in a database, and
presented as various kinds of plots Such as trend, time base, orbit, spectrum, bode, polar, average shaft
centerline plots, and others. Plant personnel and machinery specialists can then utilize those plots to view
vibration data in correlation with applicable process or environmental variables to monitor and diagnose
machine problems.
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
Figure 2: Machine train and transducer layout of unit #1 to #4 of Francis hydro turbine-generator set
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
X Probe
Y Probe
Figure 3: Shaft vibration measurement at turbine guide bearing with original probe bracket design
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
Recognized best practices suggest normally having seismic transducers installed adjacent to rotor
vibration proximity transducers. However, this could not be done in this case due to limitations of probe
mounting and fixture The reason being that the seismic transducers were installed by the Original
Equipment Manufacturer (OEM). When XY measurements were added during the provided retrofit, the
existing bracket accommodation did not provide adequate angular shift between the X-probe and the
visible seismic transducer. The situation was the same between the Y-probe and the next visible seismic
transducer.
Y Probe
X Probe
Figure 4: Trend plot of overall shaft vibration amplitudes (X and Y probes) measured at turbine guide bearing after commissioning
Y Probe
X Probe
Figure 5: Orbit plot of shaft vibration measured at turbine guide bearing after commissioning
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
Vibration frequency at the guide bearing measurement point was reviewed and found predominantly at 95
Hz at the Y probe (Figure 6). There was some low amplitude vibration presented at 120 Hz at the X probe
(Figure 7). There was no high frequency vibration excited at the generator upper and lower bearings (Figure
8).
The waterfall plots show clear evidence of excitation at the turbine guide bearing, only with higher
amplitude at the Y probe. Nevertheless, those high vibration frequency components are not coincident with
any vibration frequency generated from the machine and associated components. Consequently, it was
suspected to be caused by a resonance problem, which natural frequency of the probe bracket and
mounting that could be excited, resulting in fluctuating vibration amplitude predominantly at the Y probe.
The difference of vibration amplitude and frequency between the X and Y probes could be due to varying
stiffness of the probe mounting, as the physical installation of these two probes is different. We are most
likely seeing guide bearing angular stiffness anisotropy (at the bearing shown in Figure 3). For example, the
X probe mounting may be influenced by the adjacent oil cooler structure, which can increase stiffness.
Somehow, higher frequency excitation in this case has lower energy as lower excited vibration amplitude.
The source of excitation was unknown at this stage. A modal impact test was required to identify the
natural frequency of the fixtures mechanical structure and associated mode shapes.
Vibration component at 95 Hz
Figure 6: Waterfall plots of spectra versus time of the Y probe measured at the turbine guide bearing after commissioning
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
Figure 7: Waterfall plots of spectra versus time of X probe measured at turbine guide bearing after commissioning
1X vibration
Figure 8: Waterfall plots of spectra versus time of X probe measured at generator lower guide bearing after commissioning
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
Heavy accelerometer
with magnetic base
Seismic vibration
transducer
Figure 9: Photo of modal impact test performed at site with heavy accelerometer
NT2_Francis_U3 - 2 - +Y - Modal Accelerance 1000 Hz - Coherence
Cursor A:
100
91.25 Hz
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183.9 ?
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Figure 10: Modal impact test result of Y probe with original fixing
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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116.3 Hz
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Cursor A:
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Figure 11: Modal impact test result of X probe with original fixing
Mode#3
Mode#1
Mode#2
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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After natural frequency was obtained as a preliminary check, it was confirmed to be a resonance problem
of the vibration probe installation. The test was continued to identify mode shape at each particular
frequency. An impact force hammer was used as a roving point and the accelerometer was fixed where it
was expected to sense high vibration amplitude near the end of the bracket. A grid of the measurement
points was drawn on the bracket, so that data collection could be carried out accordingly. Frequency
Response Function (FRF) was then calculated for each point as a ratio of acceleration/force. Curve fitting
might be implemented to find the damping value at each mode [4] and select the number of interest
modes E.g. the first three modes are identified in Figure 12. The first mode shape is shown in Figure 13
with maximum deflection at the bracket end where the vibration probe is installed. This can partially
explain how a resonance problem influenced the excessive vibration amplitude observed at the Y probe.
Similarly, the second mode shape is identified in Figure 14 with only minimal deflection. Therefore, we did
not consider it at later stages of analysis. The first mode is the main contributor to the observed problem.
Figure 13: Experimental modal analysis result of first mode shape with original bracket design
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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Figure 14: Experimental modal analysis result of second mode shape with original bracket design
The example in Figure 15 shows proper instrument setup to avoid a mass loading problem which can
affect the accuracy of the test result. It also presents an alternative transducer attachment for a more
complete modal test The transducer axis has the same orientation as the axis of the non-contacting
probe. However, we are still not able to improve our test due to change of modal characteristics (modal
mass and stiffness) for running versus not running unit conditions of the TGB shell that supports the
bracket, creating the mechanical system that resonates.
A two channel portable data collector with a modal test feature (such as SCOUT140-Ex or vb8) is required. A
miniature accelerometer is used together with a small magnetic base or wax for mounting to suit the
frequency range of interest. An appropriate impact force hammer should be used with consideration of tip
material and size to ensure sufficient frequency response range as well as enough force to strike the test
object in order to get a good response. The harder the tip is, the higher the frequency response range will
be. The product datasheet should be referred to for more detail and precise data.
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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Miniature accelerometer
Figure 15: Example of typical setup for modal impact test with SCOUT140-Ex and miniature accelerometer
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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A new bracket was redesigned by changing the dimensions and geometry to increase thickness, add more
ribs, and then re-run modal analysis. Such bracket construction will result (through the bracket fixing) in
increasing of TGB shell stiffness in the horizontal direction as well. First mode of the new bracket was
increased to 179 Hz (Figure 17) which is about 32 times the machine running speed at 333.33 RPM (5.56 Hz).
This is considered safe from excitation. The new bracket was then fabricated and installed in the field.
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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X Probe
Y Probe
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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Figure 19: Orbit shape of vibration data measured at turbine guide bearing with new probe bracket design
Figure 20: Vibration spectrum of Y probe installed at turbine guide bearing with new bracket design when the unit was operated at
235 MW with 75% IGV opened
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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Figure 21: Waterfall plot of vibration spectra versus time measured by Y probe at turbine guide bearing with new bracket design
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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Gen Load, MW
IGV Position, %
Casing vibration, YV
Casing vibration, XV
Turbine speed
Figure 22: Trend plots of seismic vibrations measured at TGB (top) correlating with process variables (bottom)
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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Conclusions
Modal analysis is an effective tool for solving vibration problems as it can be used in the field for
troubleshooting, design phase, simulation study, as well as structure modification and improvement. This
paper discussed the approach of applying modal analysis to successfully solve vibration problems
observed from an online machine condition monitoring system installed on a hydro turbine-generator set
during project commissioning. EMA was used to identify a resonance problem of vibration probe mounting
at TGB, allowing the natural frequency and associated mode shape to be identified. FEA was then used to
model probe bracket structure based on precise dimensions and material properties before
modal/frequency analysis was carried out to find the calculated natural frequency and associated mode
shape. The result was then calibrated with EMA by adjusting the boundary condition before the structure
modification was studied and simulated for probe mounting improvement to increase the natural
frequency. FEA can save manufacturing costs and time without doing trial and error for new product
design. The new bracket design resulted in stiffness increase of the probe mounting, which was acceptable
and resulted in improving the noise-to-signal ratio.
References
[1] Avitabile, P., 2001, "Experimental Modal Analysis: A Simple Non-Mathematical Presentation," Sound and
Vibration.
[2] Vzquez, J. A., Cloud, C. H., and Eizember, R. J., 2012, "Simplified Modal Analysis for the Plant Machinery
Engineer," 41st Turbomachinery Symposium, Texas A&M University, Houston, Texas.
[3] International Standard Organization, 2005, "ISO 7919-5 Mechanical Vibration - Evaluation of Machine
Vibration by Measurements on Roating Shafts - Part 5 Machine Sets in Hydraulic Power Genrating and
Pumping Plants," Internation Standard Organization.
[4] Lee, M., and Richardson, M., 1992, "Determining the Accuracy of Modal Parameter Estimation Methods,"
IMAC X.
[5] Richardson, M. H., 1978, "Measurement and Analysis of the Dynamics of Mechanical Structures,"
Hewlett-Packard Conference for Automotive and Related Industries, Hewlett-Packard, Detroit.
Modal Analysis with SCOUT/vb8 Vibration Probe Mounting used for Condition Monitoring of a Hydro Turbine
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