Beruflich Dokumente
Kultur Dokumente
2012/9/25
Introduction and basic concepts
Vibration theory
Rigid rotor balance
Flexible rotor balance
Reasons and features of rotor vibration
Fault diagnosis
Case study
Test//
B A
1 2 3 4 5 6 7 8
3300 9200
No 1 BRG
No 2 BRG
No 3 BRG
No 4BRG
X No 5 BRG
No 6 BRG
No 7 BRG
No 8 BRG
Alarm
No 1 BRG
No 2 BRG
No 3 BRG
No 4BRG
No 5 BRG
No 6 BRG
unbalance misalignment Oil whip
No 7 BRG
Orbit No 8 BRG
speed
Speed(n/10rpm) Y Time (s) Y
No 1 BRG
No 2 BRG
No 3 BRG
No 4BRG
X No 5 BRG
No 6 BRG
No 7 BRG
No 8 BRG
No 1 BRG
No 2 BRG
No 3 BRG
No 4BRG
X No 5 BRG
No 6 BRG
No 7 BRG
No 8 BRG
RBPF = RB * Fshaft
3) Rotor misalignment
1x 2x 3x 4x
Waterfall plot
Orbit Plot
2012/9/25
Rotor vibration and its balance - Dr. Danmei Xie 40
Hogging is a fast process
It may take only several minutes to bow the shaft enough to
close some radial clearances in the machine
An attempt to turn the rotor in this condition could damage the
machines internals (e.g., turbine blades) and brgs through
rubbing
Incidentally, hogging also affects the machines casing
its bowing introduces a mass unbalance, which does not affect
the casing
rotor hogging is faster and larger than casing hogging
The reason for this is that the rotor changes its temperature
faster than the casing, which is heavier and therefore needs
more heat transfer to change its temperature//
E
cce
ntric
ity S
haft
B
ea
rin
g B
ea
rin
g
11
15 15
12
21
11 12 12 1 1
10 19 10 2 14
13 20
16 17
10
8 1 2 4 13 8 8
7 9 18 9
4
2 4
6 4 3 4
4 4
14
9 5 3 3
9
Parallel
Coupling Angular
Bearing Elevation
Angular
Coupling faults
1x 2x
4x
Radial
f
1
1xf 2
2xf 3
3x f 4
4xf
Amplitude
2XFL
1X
2X
Frequency 12kcpm
1/3 FL sidebands
Amplitude
around 2X FL
1X
Frequency
(b) power supply phase problems (loose connector)
Rotor vibration and its balance - Dr. Danmei Xie
2012/9/25
rotor
SYNCHRONOUS MOTOR
(Loose Stator Coils)
stator
Features of Electrical Problems (1)
I. Loose stator coils in synchronous motors generate
high amplitude at coil pass frequency
II. The coil pass frequency will be surrounded by 1X
RPM sidebands//
Rotor vibration and its balance - Dr. Danmei Xie
2012/9/25
Features of Electrical Problems (2)
ROTOR PROBLEMS
horizontal
axial
bearing bush
bearing pedestal
Rotor vibration and its balance - Dr. Danmei Xie
2012/9/25
tilting pad
1
Rotor vibration and its balance - Dr. Danmei Xie
76
Rotor vibration and its balance - Dr. Danmei Xie
77
Rotor vibration and its balance - Dr. Danmei Xie
78
Rotor vibration and its balance - Dr. Danmei Xie
79
Stg 10T
St10TS
G-X 12CrMoNiWVNbN 10 11
X 10CrMoWVNbN 10 11
St 461 TS
20 Cr Mo Ni V 47
St 461 TS
20 Cr Mo Ni V 47
Self-excitation vibration
Oil film whirl/whip of bearings
Caused by
Working fluid (rotor clearance)
200
150 f dmax
f dmin 100
50
10 20 30 40 50 60 70
0
n(r/s)
k=3
f dmax
C
A
k=2
f dmin
B
n2 =49 n1 =50.5
Rotor vibration and its balance - Dr. Danmei Xie
2012/9/25 10Dr.
Multi-phase marks
2 phase marks
2012/9/25
Rotor vibration and its balance - Dr. Danmei Xie 123
Mutiple phase marks
3
1
0.7mm
Transverse
Longitudinal
Symmetric
Torsional
Tensile
PhaseChange
2X
D. Sub- resonance
F. Grid disturb //
This one was actually used to drive a positive displacement oil pump.
Lubricant/bearing conditions.
Noise/Sound levels.
Blade failures:
Foreign object damage
Can cause damage to leading edge, trailing edge,
shroud, etc.
Can damage the stationary and/or rotating blades.
Erosion
Can be caused by moisture in the steam or solid
particulates in the steam.
Can affect the stationary and rotating blades.
Fatigue
Will more typically affect the rotating components and
typically be a catastrophic event if the condition is not
identified during an inspection.
Rotor vibration and its balance - Dr. Danmei Xie
Part I Condition Monitoring for Steam Turbines
Machine Condition Discussion:
Called in to evaluate condition of machine.
Site management knew that routine maintenance had
been deferred for a significant amount of time.
Could they defer further or were there indications of
developing problems?
What were the results of the condition assessment?
Vibration levels were good (below 0.7 mils) using proximity
probes.
Power output was down.
Steam discharge conditions were at saturated steam
conditions.
Steam leakage at shaft seals was excessive, causing constant
moisture contamination in the lube oil system.
My recommendation was and
Rotor vibration notitstobalance
defer- Dr.
theDanmei
overhaul.
Xie
Part I Condition Monitoring for Steam Turbines
Blade failure/damage:
Mechanical
Engineering
Reference
Manual
Michael R.
Lindeburg Rotor vibration and its balance - Dr. Danmei Xie
Part I Condition Monitoring for Steam Turbines
Oil Condition
Viscosity
Additive packages
Oil Contamination
Moisture
Particulates
Equipment Condition
Wear particles
Material or source
Ferrography
Load
Speed
These items become even more critical for a variable load process!
Condenser conditions
Vacuum pressure changes
Condensate temperature changes
Air in-leakage changes
Noise/Sound levels.
Summary
Basically, the more we know about the machine, the better we can
diagnose a changing condition.
Fault
Recovery
Processing
0.01
0.40 0.51 35 Odd High Grid
No Sorts of fault 0.5f1 1f1 2f1
0.49f1 0.99f1 f1 Fre f1 Fre f1 Fre f1
0.39f1
1 Unbalance 90 5 5
2 Parts ripped off 90 5 5
3 Thermal bend 90 5 5
Gland impact and
4 10 10 10 20 10 20 10 10
rubbing
Rubbing of axis
5 10 10 10 20 10 20 10 10
direction
Bearing
6 40 50 10
misalignment
Eccentricity between
7 bearing & steam 80 20
turbine
8 Axis crack 40 20 20 20
Insufficient of shrunk
9 40 40 10 10
fit
Loose of
10 40 40 10 10
bearing .block
Rotor vibration and its balance - Dr. Danmei Xie
2012/9/25
0.01
0.40 0.51 35 Odd High Grid
No Sorts of fault 0.5f1 1f1 2f1
0.49f1 0.99f1 f1 Fre f1 Fre f1 Fre f1
0.39f1
11 Loose of b. pedestals 30 20 50
12 Inaccurate coupling 10 20 10 20 20 10 10 10
13 Self-excited of rotor
20 20 20 40
clearance
14 Sub- resonance 10 10 80
17 Steam turbulence 50 50
18 Electromagnetic
50 50
excitation
19 Valve vibration 100
20
Grid disturb 100
1 Unbalance 50 50
2 Parts ripped off 100
3 Thermal bend 60 40
Gland impact and
4 100
rubbing
Rubbing of axis
5 100
direction
Bearing
6 60 40
misalignment
Eccentricity
7 between bearing 100
& steam turbine
8 Axis crack 100
Insufficient of
9 100
shrunk fit
Loose of Rotor vibration and its balance - Dr. Danmei Xie
10 100
bearing .block
2012/9/25
Amp Vib**. Amp. Amp. Vib.
Amp*. * Shaft Amp not Shaft
N vary In axis Saltati Amp incr. Saltati Vary
o
Sorts of fault Saltation
with directi
track
on at
vary with
with speed on in
swing
with.
in oper. change load incr.
load on ncr run-up Fem **
Loose of b.
11 100
pedestals
Inaccurate
12 100
coupling
Self-excited of
13 100
rotor clearance
14 Sub- resonance 100
15 Oil film whirl 100
16 Oil film oscillation 50 50
17 Steam turbulence 50 50
Electromagnetic
18 50 50
excitation
19 Valve vibration 100
20 Grid disturb 100
f1 ncr 2f1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3
4
5
7
8
9
10
11
12
13 Rotor vibrationand its balance - Dr.
Danmei Xie
2012/9/25
14
6.3 Trends
New methods of vibration analysis (wavelet, gray theory)
New methods of faults diagnosis
Condition monitoring and predictive maintenance
Coupled vibration between lateral and torsional vibration
of the rotor
Coupled vibration between long moving blade and the
rotor
Modeling of the mechanical system has been recognized as
very important in the prediction and analysis of vibration
Stability of rotor-dynamic system
Sensitivity analysis of rotor rigidity and damping etc.