October 2004

Steam Turbine Vibration

Characteristics
Mike McGuire

Works Assembly of 1130 MW

HP Turbine

PMM - ROVSING 2004

LP Rotor

PMM - ROVSING 2004

Introduction
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Avoidance of damaging vibration essential for long

term plant reliability
Comprehensive dynamic analysis tools used at
design stage to assess:
Shaft vibration
Blading Integrity
Assessment tools utilise modern analytical techniques
which have been validated by well established
feedback from service experience and test rigs
Ensure that new designs are developed with
confidence and without risk

PMM - ROVSING 2004

PMM - ROVSING 2004

Shaft Vibration

Shaft Vibration
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PMM - ROVSING 2004

Comprehensive shaft line analysis performed

rotor (inertia & stiffness)
bearing oil films (stiffness & damping)
pedestal/foundation (mass, stiffness & damping)
blading & seals (steam excitation & damping)
excitation (unbalance, concentricity errors, rotor
asymmetry)
Steady state response (synchronous) - unbalance
Stability assessment (sub-synchronous) - oil/steam whirl
Acceptance criteria based on detailed R&D programmes
and well established practical experience
Results in low levels of vibration which are continuously
monitored

Dynamic Modelling of Rotor Line

ROTORS
BEARINGS
PEDESTALS
FOUNDATION

Rotor and oil films most important elements

Design guidelines ensure that same rotor line

operates successfully on different foundations

PMM - ROVSING 2004

Bearing Oil Films

8 dynamic coefficients:
Fx W
=
Fy C r

a xx

a
yx

a xy x
W
+
a yy y Cr

b xx

b
yx

b xy x&

b yy y&

anisotropic
coupling between horizontal and vertical vibration
provide stiffness and substantial damping
coefficients influenced by bearing type (fixed arc, tilting
pad), geometry (length, diameter, clearance), steady
load, speed, lubricant properties (viscosity)
derived from thermo-hydrodynamic analysis for both
ALSTOM and third party bearings
can induce self excited vibration (oil whirl)

PMM - ROVSING 2004

Steady State Response

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PMM - ROVSING 2004

Vibration response to unbalance

Non dimensional response calculated for
different modal unbalance cases, e.g.
Centre span excitation for first mode
Couple excitation for second mode
Assessment made at critical speeds and normal
operating speed using established guidelines
Each rotor high speed balanced in factory to long
established criteria (ref: ISO 11342)
In service vibration meets international standards
(ref: ISO 7919-2 & ISO 10816-2)

Shaft Line Stability

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Sub synchronous bearing instability

phenomenon well known for many
years (oil whirl/whip)

Steam whirl phenomenon emerged from 1960s onwards as unit

outputs and steam conditions increased
Significant experimental and theoretical work carried out for
steam turbines in UK, USA and Europe during 1970s (Benckert,
Slocombe/C.E.G.B.)
Analysis methods initially developed based on previously
established theory for compressors (e.g. Wyssmann)
Increasing use of modern aerodynamic analysis methods for
assessment of steam excitation forces

PMM - ROVSING 2004

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Factors Influencing Stability

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Rotor mass and stiffness - critical speed

Oil film characteristics - bearing type

Bearing support stiffness

Steam Excitation - steam whirl

Steam density - HP/Supercritical most susceptible
Tip seals and shaft glands
> Thomas effect (Tip seals only)
> Influence of inlet swirl (Tip seals & shaft glands)

PMM - ROVSING 2004

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Steam Excitation: Thomas Effect

Variations in blade force

Tip leakage
Blading force
Net destabilising
force.

... system rotates

causing Whirl

PMM - ROVSING 2004

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PMM - ROVSING 2004

Steam Excitation: Influence of Swirl

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Steam Excitation: Influence of Swirl

P(A) > P(B)

P(B)

Inlet Point

P out

B
Steam Swirl

A
Outlet Point

Destabilising
Force

Outlet Point

... rotor moves

to close clearance

P(A)
P in

A
Inlet Point

PMM - ROVSING 2004

... system rotates

causing Whirl
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PMM - ROVSING 2004

Swirl Breaks

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Swirl Breaks
High exit steam swirl (circumferential velocity)
from fixed blades

Swirl Breaks reduce circumferential

velocity thus reduce the destabilising
force

PMM - ROVSING 2004

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Tip Seal with Swirl Breaks

PMM - ROVSING 2004

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Diaphragm Gland Segment

Inlet Swirl Breaks
zUsed

successfully
on a UK 500MW
turbine (1980s)
Tested efficiency :
75%
(removes 75% of
inlet swirl)

33% of tip seal effectiveness

10% of power loss

PMM - ROVSING 2004

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Stability Analysis Process

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PMM - ROVSING 2004

Full shaft line stability analysis carried out to establish datum

case in absence of steam excitation
shaft line stable to maximum overspeed (i.e. no oil whirl)
Complete audit of steam excitation forces carried out
shaft/diaphragm glands & blade tip seals
Influence of steam excitation on rotor stability assessed
If lower limit stability criterion not satisfied at full load rotor
geometry and/or bearing oil films improved.
If necessary steam excitation forces reduced by use of swirl
breaks
shaft/diaphragm glands and/or tip seals
Full shaft line stability analysis repeated
Conservative approach applied for third party retrofits

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Shaft Vibration - Summary

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PMM - ROVSING 2004

Comprehensive rotordynamics analysis assesses both steady

state response and stability
Acceptance criteria based on detailed R&D programmes and
long established practical experience
Complete audit of steam forces carried out
If necessary, steam excitation forces reduced by use of swirl
breaks
Swirl break behaviour validated by comprehensive test
programme
Proven operational experience with standard sealing
arrangements
Low levels of vibration in service

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PMM - ROVSING 2004

Torsional Vibration

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Torsional Vibration
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PMM - ROVSING 2004

Low Damping ( Damping Factor D 0.001) with high resonance

amplification factors ( >100 ) - no influence from bearings or supports
During normal resonance free operation very small vibration amplitudes
(< 0.1 )
Torsional excitation due to the electrical system
Short term transient disturbances (e.g. mal-synchronisation, line to line
fault) can induce transient torques ~6-8 times normal full load torque
Long term disturbances of electrical system frequency - negative
sequence current - due to unbalanced phases or interactions with long
transmission lines.
Frequencies tuned to avoid first two harmonics of electrical system
frequency (e.g. 50/60 & 100/120 Hz)
Potential excitation of coupled blade/rotor modes
Excitation magnitude dependent on generator mode shape

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Torsional Vibration
2 x Grid Frequency
at Generator Rotor
Exciter

Transformer

Required Conditions for Failure

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Excitation from the electrical Grid

due to non-symmetrical electrical loading
e.g. Steel Industry, Aluminium Production, ...

Torsional natural Frequency close to 100/120 Hz R S T -

HighVoltage Bus

Lines

PMM - ROVSING 2004

Coupled Mode Shape Shaft / Blade

to the Consumer

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Torsional Vibration Summary

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PMM - ROVSING 2004

Conservative design criteria adopted to avoid resonance at

1x & 2x electrical system frequency
Coupled blade/rotor modes fully assessed

Low interaction between blades and welded drum type LP

rotors

Accuracy of analysis confirmed by experimental validation

Routine in situ validation unnecessary - if confirmation is

required this can be achieved with confidence in factory
spin pit

Good Experience with new machines and LP-Retrofits

(Zion 1 & 2, Indian Point 3, Maanshan 1 & 2, Kori 1-4, San
Onofre . . . . . .) - no adverse experience

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