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    0 - Diagnosing Rubs PDF

    Hochgeladen von

    Hossein

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    © All Rights Reserved
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    von 9
    DIAGNOSING RUBS IN TURBOMACHINERY Steven M. Schultheis, PE. Equistar Chemicals LP ‘2502 Sheldon Road Channelview, Texas 77530 ‘Steven Schultheis(@Equistarchem.com ‘Abstract: In the current environment of high speed and high efficiency turbomachinery, one ofthe most common malfunctions that can occur i contact between rotating and stationary elements in a machine. In other words, rubs. A good bit of mythology has developed around symptoms and signal characteristics of rubs in turbo machinery that has led many analysts astray. This paper will examine several case histories of known rubs, and examine the vibration signal characteristics that lead tothe conclusion that a rub is present ‘The paper aiso will discuss the most common rub locations and what actions to take when rubs occur in compressors, steam turbines, and gas turbines. Examples ofthe damage associated with rub events will also be presented. Key Words: Compressors; diagnostics; rubs; turbines; turbomachinery Introduction: Rubs are generally defined as contact between rotating and stationary components of a machine. This can result ina wide range of damage severity from minor cosmetic damage to full destruction of the equipment. Rubs, however, are a symptom of some other problem, not the root cause of a machine failure, Rubs may 'be caused by an unbalanced rotor, clearances that are too tight, differential thermal growth of various ‘components, mis-alignment, instability, or other malfunctions. Often rubs are a result of several ‘malfunctions occurring at the same time. The most common occurrence of rubs in turbomachinery is during startup after an overhaul, since that is when things are most likely to go wrong, Where do rubs oceur?: Rubs can occur due to contact in either he axial or radial direction, Axial rubs are usually due ether to differential axial thermal growth between the rotor andthe ese or high amplitude axial dynamic motion a8 ina comprescor surge, Ox ange steam turbines it acral tht ie machine be ware up propery to ‘void a oor to case differential expansion conditions tat causes an axial ab; Radal beta be Cue 6 +high radial vibration, shaft centerline position changes that cause contact, case distortion, or insufficient clearance. In the continued effort toimprove machine effiency, a rub due to insufficient clearance fas become te rst common type In turbines, this kind of rub iis most often due to contact with ineratage packing seals and in centrifugal compressors itis due C) to ontet with tering, impeller eye, oF balance piston | seal, Given te highspeed and ite very tp clearances in mt modern turbomachinery, itis IMPACT FRICTION Surprising tat rbs don’t happen Figure 1: The two types of rub. 1] more often than they do. Vibration signal characteristics: There are two primary types of rub as shown in figure 1. The first isan impact rebound type of rub. In this case an impact occurs, and then the rotor bounces back, and the process is repeated. The second isa friction rub that causes a fairly constant contact between a rotating and a stationary part. ‘The main effect of this type of rub is heat buildup due to the friction. The main myths regarding rubs are that a rub will always cause integer fraction sub harmonies of running speed 1/2X, 3X, VAX, or that rubs will always cause integer harmonies of running speed, 1X, 2X, 3X, 4X, or odd integer harmonies of running speed, 1X, 3X, Figure 2: Amplitude and phase over time. (1] 3X. ‘The truth is that these are all signal characteristic of rubs, but each is @ special case, and they DO NOT apply to every rub. These signal characteristics are associated with the impact type of rub, but the most ‘common rub signal characteristic in turbomachinery is a high IX vibration, with no harmonics, and no sub ‘harmonics due to the friction type rub. This vibration response is due either to localized heating of the rotor as friction contact occurs that causes the rotor to bow, oF to stiffening of the rotor system that changes the rotor resonance characteristics. As mentioned before, in turbines, this kind of rub is most often due to ‘contact with interstage packing seals, and in centrifugal compressors itis due to contact with interstage, impeller eye, or balance piston seals. This type of rub has become very common in compressors as they have been retrofitted to abraidable seal materials The fiction type ofrub often {ZMEbimaton. Lermin xcour sRAENLA sain looks like unbalance, and as a Fre ?swovz002 s6:32:20.9% result ofthe rotor bow the " ‘machine is indeed unbalanced; however, the cause isthe rub induced bow rather than the 3 tore normal sources of a unbalance. Itis possible to sort this out from a balance issue by looking tthe IX amplitude and phase over time. Ifa shaft is unbalanced, the 1X phase angle should not change over time ata constant speed. However, ifthe rotor is bowed due oa rub, the amplitude and phase angle may shift with : fime as shown in figure 2. Figure 3: Rub effect on transient 1X data “Another good way to identity this kind of rub is to slow the machine down. In this case the amplitude and phase line during the roll down will not tack the amplitude and phase on the startup, as shown in figure 3. This isazain due tothe rotor bow. By slowing down, it is often possible to clear the rub, resulting in @ very quick reduction in vibration amplitude as the bow clears, PMT: Sampt8ven ten rKUNcoMP In figure 3 this occurs at fmm 2uavzee 1s3uteTezunyz01 198897 SUR about 2700 rpm. In this case the machine was run up, rubbed and slowed down several times to clear the rub prior to successful startup. Inet eds not been bowed, but has Cee Saugus tes timeiecwmigea (poser that is higher, and in some cnet sie Gore Tor Pewee eran cre pe balance piston seal rub or Pare che pm tt of ih ov ie ii of Sresavoyt msde baie lehrces set ba tease into the rotor to cause a bow. Rubs often can be identified by their effect on the startup/shutdown transient a Expected Crit ‘At 4000-4208 rps SPEED pm ‘A good way to detect an impact type of rub is to view the shaft orbit. The orbit will often be distorted and cA eascentaeens int Rub Malti Point Rub rebound effect associated with WV VY ‘the rub as shown in figure 5. is AX Highly preloaded orbits due to Orbit Shaft internal or external mis- oS alignment may be a precursor toarub, Observing changes in ° the orbit shape either with changing speed or with changing load can help identify a rub as it is occurring. Atthe same time, observing shaft centerline position changes with speed or load can also help pinpoint where arub Figure 5: Distorted orbits due to impact rebound type of rub. [1] is occurring. Shaft centerline position measurement generally indicates position relative to the bearing, however, and may not indicate shaft position relative to seals or other contact points Single ‘The most common machinery myth is that ifa rub is occurring there must be sub-synchronous frequencies at integer fractions of running speed like 1/2, /3, 1/4. In certain impact conditions a rub will generate these sub frequencies, but the conditions have to be just right for it to happen. According to Bently Nevada [1] the general rule is, for a 1/2X vibration to occur due to @ rub, the rotor speed must be twice the first critical speed or more. For a 1/3X to occur, the rotor speed must be at leat three times the first critical speed. So this type of rub characteristic occurs most often in very high speed equipment. In addition for sub- synchronous vibration to occur, the rub must be an impactebound type of rub (figure 5). Even in high speed equipment that meets the Bently criteria, a friction type rub will simply bow the rotor causing only a 1X response. ‘Another common misconception is that if a rub is occurring there will be many multiples of running speed. ‘These multiples are due in part to the squared off shape of the time waveform when an impact type rub occurs. The FFT process translates a square wave as multiple harmonics of the fundamental frequency. If the time waveform is not significantly clipped to the point that it is approaching the shape of a square wave, ‘then the presence of many harmonics in the spectrum will not occur. Looking for harmonics in the spectrum as a means of identifying a rub will work sometimes, but not always. ‘What action can be taken when a rub is suspected?: ‘The number one action that can be taken is to slow down. This works well on turbines where speed is easily controlled. It is not so easy to do on other equipment. On a turbine, slowing down has the effect of changing the shaft eccentricity, as well as the differential heating of the rotor versus the case. Figure 3 clearly shows the effect of slowing down in order to clear the rub. Speed up. Ifa rub is occurring asthe rotor is passing through a resonance (critical speed) then accelerating the rotor through that speed quickly can have the effect of reducing the severity of the rub. The rotor does not have a chance o respond tothe resonant condition, and the vibration level is often lower if it passes through the resonance range quickly. In addition, ifthe rotor does not have a chance to heat up and bow, then the high imbalance vibration due tothe bow does not occur. Ths is the main reason most turbine stat _up procedures require a high rotor acceleration rate through the critical speeds. ‘Reduce the load. Some times a rub may occur due to loading a machine too fast, by reducing the load and then reloading the machine at a slower pace the rub can be avoided. [Increase the load. Rubs may occur when the machine is unloaded and not in a stable operating regime. This often happens when starting a process unt, asthe operator leaves a machine ina bad spot while

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