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SteamTurbineRotorVibrationFailures:CausesandSolutions

SteamTurbineRotorVibrationFailures:CausesandSolutions
04/01/2013|FarshadShamoradi,NaserMohammadi,andMahdiHeidariKahkesh,AhwazPowerGenerationManagementCo.
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Steam turbine rotors bend during operation, but the bearing and supports are designed to keep the static and dynamic forces under control. However,
bending can cause impact between stationary and rotating partsoften cascading impacts. An operator of many utility-scale steam turbines shares its
extensive field experience identifying the root cause of failures as well as successful solutions.
Rotorbendingthatresultsinprematurefailureofsteamturbinebladesandotherinternalcomponentsisoneofthemostseriousproblems
experiencedinpowerplantoperations.Theproblemsoftenreduceplantavailabilitybylimitinggenerationandincreaseplantoperationand
maintenancecost.Extremerotorbendingproblemsofteninvolveinteractionbetweentheturbinesrotorandstationaryparts.Rotorbendingmaybe
causedbyavarietyofstaticanddynamicfactors,manyofwhichwillbeexploredinthisarticle.
Webeginwithmechanicalfactorsrelatedtotherotor,thelargestrotatingassemblyintheturbine.Workingfromtheinsideout,wenextlookatrotor
balanceissues,followedbyrotorandcasingmisalignmentproblems,andproblemscausedbythecasing.Thediscussionisbasedontheauthors
experiencesatthesix-unit,1,890-MWRaminPowerPlant,locatedinAhwaz,Iran.Theunitswerecommissionedfrom1980through1985.

AvoidRotorRubs
Italmostgoeswithoutsayingthatrubbinginthelabyrinthsordiaphragms,causedbyinsufficientclearances,disruptstheendsealingoftherotor.
Thissituationcommonlyoccurswhenthehigh-massrotoratoperatingspeedcomesincontactwithastationarysurface,typicallycausedbyatoosmallclearancebetweenthelabyrinthordiaphragmglandsealsandtherotor.Secondarily,theremaybealocalizedtemperatureincreaseatthe
pointofcontact,causingincreasedmetaltemperaturesatthepointofcontactduetofriction.
Theforcesproducedbytheimpactofthelargerotatingrotormasswiththepoorlyfunctioningstationarysealsoftenimpressalayerofmetalonthe
surfaceoftherotor.Therubcancauseelasticdeformationoftherotoratthepointofimpactandtemporaryrotorshaftbending.Theshaftbending
willusuallycauseincreasedvibrationlevels(Figure1).

1.Bladerubscausebending.Rubbinginthesealingofahigh-pressurerotorofa300-MWunitcausedbendingofthisrotorandbladetiprubs.Courtesy: Ahwaz Power


Generation Management Co.

Unevencoolingoftherotor,particularlyaftershutdown,alsocausestherotortocontactstationaryparts.Afteraunitshutsdown,therelativelyhightemperaturerotormaybendsolelyduetothemassoftherotorandthedistancebetweenbearingsupports,ifleftinastationarypositiontocool.
Thissituationcancausepermanentshaftbending.
Theeffectofapermanentshaftbendcausedbyunevencoolingwillimmediatelyappearashighrotorvibrationatthenextstartup.Thevibrationis
causedbyinsufficientclearancebetweenstationaryandrotatingparts,aswellasashaftlocatedoff-centerinitsbearing.Eveniftheclearance
changeissmall,theremaybesignificantrubbingalongtherotortocausedamage.Again,therubbingcausesfrictionbetweenstationaryand
rotatingparts,localizedheatingoftherotormetalatthecontactpoint,andshaftbending.
Furthermore,unevenshaftwarmingcausedbyrubbingbetweenrotatingandstationarypartscancausefurtherbendingoftheshaftinthesame
directionoftheexistingbowandcauseadditionalcontactwithstationaryparts,increasingtemperaturesandthereforecausingmorebending.The
effectcascadesifallowedtocontinue.Ifthebendingisallowedtocontinue,itispossiblethattheyieldstrengthofthemetalcouldbeexceeded,
causingapermanentdeformationoftheshaft.Theallowedbendingin3,000-rpmturbinesisupto0.020.03mmineachsection.Whenonturning
gearing,thelimitis0.05mm.

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Jointhediscussion
LIJUPHILIP 2yearsago

Cantherebevibrationsinasteamturbineduetoitsglandsteamsystem.wehadproblemswithbearingvibrationofintermediatepressure
turbine..periodicallythevibrationusedtogettoitspeakin2to3daysandwheneverthevibrationshootedupweusedtodeceasetheboiler
loadfirstthenbypassthesteamfromipturbinetocondensorandstartthestandbyblowerofglandsteamsystem.
thevibrationusedtogetasurgebyusingthesemethodsbutwouldperiodicallyriseagain
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EduardoAndrzejewski 3yearsago

Thankyoufortheyourinterestigreport.Duringsomecommissioningworks,wehaveevidencedanothersourceofvibrationontheSteam
Turbine.ItwasrelatedtospiralvibrationscausedbytheGeneratorscarbonshaftgrounding
brushes.AtechnicalletterfromSTvendor,informsthatthevibrationsignaturewasaresultofrubs
fromthecarbonshaftgrounding
brushes.Periodiccleaningorreplacementofthecarbonbrushassemblybycopperbraidassemblyeliminateorreducethespiralvibration
issues.
1

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VikashPratyaksh 6monthsago

WhatCouldbethereasonofLPTurbineBearingHousingVibration??WehavecheckedallbearingclearancesandInterferances.Alignment
alsofoundgood.wehavecheckedforallbearingsofHP,IP,LPandGenerator.CouplingalsoalignedbutstillLPBearinghousingvibrations
increases.itsalwayshighfromthetimeofstartupupbutgoestoomuchbetween2500RPMto3000RPMandTurbineTrips.Any
Suggestions??

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kapilRakhani 8monthsago

Inourcase,turbinebladegotdamagedandnowweareplanningtooperatetheturbineafterremovingthethirdstagebladescompletelyfrom
twopassLPturbine.itsa220MWrating?whatisthelossweshouldexpectandwhataretheprecautionstobetakencare

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