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A Review of Morton Effect: From Theory to Industrial Practice

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DOI: 10.1080/10402004.2017.1333663

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A Review of Morton Effect: From Theory to


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Lili Gu

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Tribology Transactions, 61:2, 381-391, DOI: 10.1080/10402004.2017.1333663

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TRIBOLOGY TRANSACTIONS
2018, VOL. 61, NO. 2, 381–391
https://doi.org/10.1080/10402004.2017.1333663

A Review of Morton Effect: From Theory to Industrial Practice


Lili Gu
Department of Mechanical Engineering, Texas A&M University, College Station, TX, USA

ABSTRACT ARTICLE HISTORY


The Morton effect (ME) is known to cause spiral vibrations of rotors supported by fluid lubricant bearings Received 5 July 2016
when there is significant differential heating at rotor journals. The root cause of ME is accumulative Accepted 17 May 2017
asymmetric heating brought on by the viscous shearing effect of the bearing lubricant, mainly during KEYWORDS
synchronous vibrations. The thermal nature of the cause together with the symptoms of spiral vibrations Morton effect; thermal
make ME a thermal-induced instability. This article provides an in-depth review of the ME. It starts with a instability; thermal bow;
general introduction and assessment of the significance of ME, noting its widespread nature. Subsequently, spiral vibrations; synchronous
key findings are introduced about general ME mechanisms, including the important relationship between vibration
journal orbits and the hot spot. The circumstances and typical symptoms of ME-induced instability are
summarized and followed by a discussion of the critical issues to be tackled in both the theoretical analysis
and the experimental techniques regarding ME phenomenon. Lastly, this article includes a discussion about
the inconsistencies found in the literature regarding topics such as the excitation models for the thermal bow.

Introduction In the late 1990s, Faulkner, et al. (4) and Berot and Dourlens (5)
observed local differential heating effect on the journals orbiting
The Morton effect (ME) is a phenomenon of synchronous ther-
within fluid lubricant bearings in overhung compressors. Despite
mal instability (STI). It is most often reported in turbomachinery
the widespread nature of ME, there remains a present lack of
applications. This effect has been a latent threat to rotor stability
research about ME. This paucity might possibly mislead the
since fluid bearing–supported rotating machinery was first put in
trouble-shooting of ME-related vibrations (Berot and Dourlens
use. However, it did not come to the spotlight of turbomachinery
(5)). As an inherent nature of synchronous orbits, the differential
applications until the end of the last century, which was described
heating makes ME a ubiquitous phenomenon, as concluded by
as “a late 20th century entertainment” by Childs (p 12) (1).
Childs (1): “They keep happening …”; “Morton Effect instabil-
Unbalance had been believed to be the most likely cause of
ities were like a widely-spread but undiagnosed disease” (p 13).
synchronous vibrations. As a matter of fact, synchronous vibra-
This undiagnosed “disease” makes ME a latent threat to the
tions are always present, although the unbalance is negligible in
applications of turbomachinery due to the widespread use of
a well-balanced rotor. Synchronous orbits are prone to induce
fluid bearings/seals where viscous fluid is trapped in a small
a local differential heating effect due to the relative movement
clearance. Thus, the American Petroleum Institute added the
between the journal surface and the viscous fluid trapped in a
concern regarding rotor thermal instability, the Morton effect,
small clearance, such as in fluid bearings and seals. Figure 1a
into the rotordynamics tutorial in API 684 2015, according to
illustrates the evolution process of this differential heating.
the related citation in Panara, et al. (6).
Under circumstances of synchronous forward whirl, the outer-
Some case studies and predictive approaches have manifested
most point across the journal, also called “high spot,” is always
since the initial experimental findings reported by Morton (3).
subjected to the highest viscous shearing effect due to the thin-
A state-of-the-art review was conducted by De Jongh (2) in 2008
nest film corresponding to this point (De Jongh (2)). As a
and focused on experiment/test findings and pragmatic solutions.
result, this high spot experiences the greatest localized heating.
However, there remains a pressing need for an up-to-date com-
The point opposite to the high spot is subjected to the smallest
prehensive review due to the growing interest in ME-induced
viscous shearing and, therefore, the lowest heating effect. How-
synchronous instability (Bradley (7); Murphy and Lorenz (8);
ever, due to the heat convection of the oil film, a phase lag
Suh and Palazzolo (9)) in turbomachinery applications.
occurs between the hottest spot and the high spot, as illustrated
in Fig. 1b. Under certain circumstances, the differential heating
leads to increased thermal bending, which aggravates the syn-
History: Major findings
chronous vibration to an unacceptable level.
In 1975, Morton (3) first reported such heating effects that The earliest observations of ME reported by Morton (3) in 1975
induced abnormal vibrations of several large power generators. were associated with oil-lubricated shaft seals. Morton found

CONTACT Lili Gu liligu@mail.com


Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/utrb.
Review led by Samuel Howard.
© 2018 Society of Tribologists and Lubrication Engineers
382 L. GU

Nomenclature rj D Journal radius


rT D Thermal bow
Cb D Bearing damping matrix
DT D Temperature difference between the hot spot
D D Bearing inner radius
and the cold spot
e0 D Static journal eccentricity
VD Journal volume
eT D Eccentric distance vector corresponding to the
vT D Thermal bending vector
equivalent mass unbalance
x–y–o D Inertial coordinate system with origin o coincid-
F D External force vector applied to the rotor system
ing with the bearing center
GR D Gyroscopic matrix
xT , x D Thermal deflection vector and shaft displace-
ha;C D Film thickness at the cold spot for orbit a
ment vector in Eq. [3]
ha;H D Film thickness at the hot spot for orbit a
aD Thermal expansion coefficient
hb;C D Film thickness at the cold spot for orbit b
bD Phase difference between the high spot and the
hb;H , D Film thickness at the hot spot for orbit b
hot spot
Ij D Area moment of inertia
’T D Thermal bow angle
Kb D Bearing stiffness matrix
VD Rotating speed
KR D Rotor stiffness resisting rotor deformation
L D Bearing length
Subscripts
MR D Rotor mass matrix
Q D Viscous shearing heat a D Journal orbit with radius ra
r ¡ z ¡ ’ D Cylindrical coordinates for Eq. [3] b D Journal orbit with radius rb
ra ; rb D Sizes for orbits a and b, respectively C D Cold spot
H D Hot spot

that even a relatively small disk orbit can yield a significant dia- however, there was a phenomenon known as the Newkirk effect
metrical temperature difference in a shaft due to an asymmetri- (NE), which is similar to the Morton effect but induced by a
cal viscous fluid shearing effect. In the following year, Keogh different source of differential heating. The heating source of
and Morton (10) spotted a similar temperature difference the Newkirk effect originates from rotor–stator rubbing (De
across a journal and later identified it as the source of the spiral Jongh (2)) and was firstly observed by Newkirk (11) in 1926.
vibrations for an overhung rotor. This phenomenon has been found in various types of rotors
The phenomenon, now known as the Morton effect, was associated with rubbing heating effects (Eckert, et al. (12)).
named after P. G. Morton in honor of his pioneering work on A sound theoretical analysis regarding the Newkirk effect can
this phenomenon. Before Morton’s groundbreaking work, be found in Dimarogonas (13). Bachschmid, et al. (14) con-
ducted a detailed case study in a real rotor covering the NE.
The differential heating evolutions of ME and NE are simi-
lar, despite their different sources of differential heating. There-
fore, knowledge accumulated from the study of the NE helps
one better understand ME. In 1926, Newkirk (11) first used the
term “hot spot,” pertaining to the NE. In 1939, Kroon and Wil-
liams offered a closer look at the NE via a qualitative analysis
(Bradley (7); Keogh and Morton (8)). Their test results revealed
a phase change over a wide range of time durations. The
recorded time for phase change varied from minutes to hours
due to the combined effect of the thermal bow and mechanical
imbalance (Bradley (7)). Kroon and Williams aspired to build
an analytical model of this particular vibration. However, they
assumed the rotor to be a thin walled cylinder of infinite length.
This assumption limited its applications to practical problems
in turbomachinery. It was not until the early 1970s that this
problem was addressed again by Dimarogonas (13), (15), (16).
His study covered analytical models of thermal bow, resulting
from a packing rub (Dimarogonas (15)); for example, rubbing
against seals. In addition, Dimarogonas (13), (16) computed
the numerical dynamic responses due to an arbitrary heat
input, albeit with the assumption of infinite rotor lengths. Via
numerical calculations, he was able to find three vibration
modes induced by asymmetrical heating: spiraling, oscillating,
Figure 1. Mechanism of differential heating of a journal orbiting in fluid film. and constant. The role of phase angle was highlighted as the
Reprinted from De Jongh (2) by permission of the Turbomachinery Symposium,
Turbomachinery Laboratory, Texas A&M University). (a) The formation of differen- critical factor to determine the type of vibration mode that
tial heating and (b) phase lag between hot and high spots. would manifest during vibrations (Dimarogonas (13)). The
TRIBOLOGY TRANSACTIONS 383

spiral pattern indicating the onset of NE proved undesirable. performed satisfactory. Based on this case study, Faulkner,
Because both NE and ME are induced by asymmetrical heating, et al. (4) inferred that ME was not recognized earlier because of
it is reasonable to presume the importance of the role that its complex nature rather than its rarity.
phase angle plays in the evolution of ME. In addition to the In 1998, De Jongh and van der Hoeven (22) reported
phase angle variations, the heat input and dissipation in another case on ME, specifically about a compressor failing to
the shaft proved a major factor for determining the stability of pass a running test after being installed onsite by the manufac-
the spiral vibrations (Kellenberger (17)). turer. The vibration at the impeller-end bearing side exhibited
In 1987, Schmied (18) refined Kellenberger’s (17) by a pseudo hysteresis during the coast down (De Jongh and van
extending the sources of differential heating to broader sit- de Hoeven (22)), as shown in Fig. 2a. De Jongh and Morton
uations. This enabled the switching of heating sources (20) observed a similar hysteresis behavior, shown in Fig. 2b, in
between fluid viscous shearing and rotor–stator rubbing. an overhung compressor. Believing that the hysteresis-like
Schmied’s study prompted the awareness of differential vibration was induced by the onset of thermal bending, De
heating in fluid bearings among researchers, although many Jongh and van der Hoeven (22) located the source of the differ-
years had passed since the earliest evidence was docu- ential heating to the journal. As a result of a trade-off between
mented in 1975 (Berot and Dourlens (5)). The first compre- compressor performance and synchronous stability, a heat bar-
hensive theoretical model on ME was not developed until rier sleeve was installed between the journal and fluid film. To
1993 by Keogh and Morton (10), (19), which took into prevent any additional change in the bearing condition, the
account the thermohydrodynamics (THD) of fluid film journal diameter was reduced to make the sleeved journal
bearings. Upon analysis of the gain of thermal bow, diameter the same as that before the heat barrier was intro-
researchers found that the rotor speed influenced stability duced. Both theoretical calculations and experimental tests
due to its direct impact on the net heating input (Keogh demonstrated elimination of STI upon introduction of heat
and Morton (10), (19)). This new THD model allowed for a barriers.
more detailed analysis of differential heating across journals Under specific circumstances, ME-induced STI can occur in
and improvement in the accuracy of the phase lag between a series of machines. In 1999, Berot and Dourlens (5) reported
the hot spots and high spots. An interesting finding of on a series of larger compressors troubled by cyclic vibrations
Keogh and Morton (19) is the process direction of thermal induced by differential heating in tilting pad bearings. It is diffi-
bow changes over the critical speed, from forward preces- cult to find universal technical solutions to efficiently stabilize
sion to backward precession. This change might be such a group of rotors. First, an empirical approach to adjust
accounted for by the jump of the phase between the the overhung mass suggested by De Jongh and Morton (20)
dynamic response and the vector of mechanical imbalance. was excluded because each compressor within the group was
Keogh and Morton’s (10), (19) work offered theoretical per- equipped with a different impeller. Nonetheless, the masses of
spectives about rotor vibrations when THD is involved. overhung impellers were adjusted either separately or com-
However, their work neglected to consider cavitation within bined with other changes; for example, bearing oil film temper-
the fluid film and assumed an isoviscous lubricant to sim- ature, bearing preload, and clearance. None of the adjustments
plify the theoretical model. Such simplifications could suppressed the instabilities. Inspired by the fact that a more
induce temperature gradients in the fluid film that deviate circular orbit yielded a greater temperature difference across
considerably from the practical case.
In 1994, De Jongh and Morton (20) detailed the operating
conditions prone to induce ME. Moreover, a test rig was
designed to reproduce ME instabilities. They reported that the
experimental results agreed with those obtained from the origi-
nal compressor. In 1997, Faulkner, et al. (21) dealt with abnor-
mal vibrations of a large turbocharger with overhung wheels.
The rotordynamics analysis revealed excessive vibrations after
the radial inflow turbine wheel was upgraded while the com-
pressor remained unchanged. The cause was initially traced to
a loose connection of the turbine wheel to the shaft that
induced a significant thermal expansion (Faulkner, et al. (21)).
After modifications of the attachment to the upgraded turbine
wheel, tests indicated satisfactory vibrations at speeds within
the operating speed range (Faulkner, et al. (4)). However, the
problem arose again while operating at a steady speed close to
the operating range’s upper limit. After several tests, the cause
of the abnormal vibrations was traced to thermal bow, which
resulted from a journal hot spot. Thermal bow was more likely
to occur with low eccentricity of the journal. Recognition of the
onset of ME led to changes in the turbine end bearing to Figure 2. Hysteresis behavior of synchronous (1 £) component at impeller-end
bearing. (a) Reprinted from De Jongh and van de Hoeven (22) by permission of
increase its operating eccentricity. By applying a central under- the Turbomachinery Symposium, Turbomachinery Laboratory, Texas A&M Univer-
cut in the loaded bearing, the turbocharger eventually sity). (b) Reprinted from De Jongh and Morton (20) by permission of ASME.
384 L. GU

the journal/shaft, Berot, et al. (5) reduced the L/D ratio proposed theoretical model, Panara, et al. (6) conducted experi-
(length-to-diameter ratio) of the bearing. This was an attempt ments in a full-scale dummy rotor supported by two tilting pad
to decrease the isotropies of the bearing dynamic properties bearings. Their study revealed that an overhung mass increase
and hence for the journal to produce an elliptical orbit. Both does not necessarily result in the deterioration of synchronous
simulation results and experimental validations confirmed that thermal stability (Panara, et al. (6)). This point differs from the
the L/D ratio played an important role in the elimination of conclusion made by previous studies (Morton (3); Berot and
rotor STI. Dourlens (5)), which recommended that a reduction of over-
The findings by Berot and Dourlens (5) imply that an ME hung mass helped to decrease the STI for overhung rotors.
has a high tendency to occur in rotor systems supported by Even with the conflicting view about the impact of overhung
fluid film bearings. Nevertheless, the differential heating can mass, both points are reasonable due to the finding from Cor-
originate from a journal/shaft orbiting within any small- coran, et al. (29), which suggests that either significantly
clearance viscous fluid. Recall that the first documented ME increasing or decreasing the overhung mass helped to bring
phenomenon was induced by the oil-lubricated seals applied in down the “unacceptable vibration levels” (pp 75–77) for an
large power generators (Morton (3)). In 1998, a high-pressure overhung compressor. Although not recognized as a case of
steam turbine rotor encountered a synchronous vibration insta- ME, the vibration symptoms and the theoretical confirmations
bility and exhibited intermittent vibrations with large time by Corcoran, et al. (29) indicate an onset of ME. Kocur and De
intervals (Haq, et al. (23)). The cause was traced to the sealing Jongh (30) concurred. Another interesting point by Panara,
steam system, though the problem was not solved by the time et al. (6) is that the predictions of rotor thermal gradient phase
the paper was published. The symptoms described in the paper remain a problem in simplified linear models due to its com-
consisted of the typical features of ME; for example, a phase plex nature lying within THD.
change as large as three cycles and the vibration amplitude
increasing gradually to the tripping vibration level. It is very General mechanism of ME
likely that ME was taking place and that the differential heating Although it remains unclear so far as to how the phase lag of the
was generated in the seals (Berot and Dourlens (5)). hot spot evolves with rotor orbiting in the fluid film, the root
To better understand the complex nature of ME, researchers cause of ME is believed to be differential heating, as has been
have conducted various theoretical analyses. After the initial recognized and confirmed in the literature. The role of differen-
theoretical work by Keogh and Morton (10), (19), Gomiciaga tial heating in the rotor vibrations may be clearly illustrated with
and Keogh (24) employed computational fluid dynamics the help of the control loop in Fig. 3, where O1 denotes the out-
(CFD) techniques to tackle the THD analysis involved in the put of rotor vibrations and O2 denotes the differential tempera-
process of the thermal bow. The CFD confirmed that the differ- ture. The idea of a control loop has been previously utilized by
ential temperature across the journal increased with rotational Gomiciaga and Keogh (24) in the study of orbit-induced journal
speed. Furthermore, Gomiciaga and Keogh (24) conducted a temperature variation in fluid-film bearings. A simplified version
case study of the journal orbiting within a circular two-inlet was adopted by Keogh and Morton (19) and Morton (31) to reveal
bearing. The numerical results revealed a temperature differ- the influence of thermal bending moment on rotor vibrations. The
ence increase of over 1 C for orbit size at 10% of the radial differential heating generated via viscous shearing of the fluid
clearance. The rate of increase in the differential temperature results in thermal bow of the journal, which eventually acts as a
relative to the orbit size proved significant because the tempera- source of excitation to the rotor–bearing system. The plus–minus
ture difference across the journal was less than 10 C in most sign of I2 determines whether the thermal bow results in a positive
situations. In the early 2000s, Balbahadur and Kirk (25) devel- or negative feedback to the system.
oped a simplified theoretical model for overhung rotor struc- Distribution of the film thickness has been long understood
tures, with the temperature field calculated by the energy to play an important role in differential heating as illustrated in
transport equation alone. Although the STI speeds obtained Fig. 1a. The thinner the film, the greater the heat input due to
with their theoretical model reflected a relatively large discrep- viscous fluid shearing, for the same surface speed of the journal
ancy when compared to those found in the literature (Balbaha- (or of the shaft portion where the fluid sealing system is
dur and Kirk (26)), their work reflected an urgent need for an applied). Because the film thickness is a function of shaft orbits,
efficient and reliable analysis tool, a tool able to analyze and the following explores how the orbit influences the differential
solve ME without being limited to overhung rotors. Toward heating. There are three major elements to define an orbit; that
this end, relatively new theoretical models can be developed is, its size, direction and its shape.
and can be categorized into two types: a simplified theoretical
model combined with numerical iterations of journal orbit
with existing “in-house” code (Panara, et al. (6); Lorenz and
Murphy (27)) and computationally demanding numerical
models that deliver more accurate results (Su and Palazzolo (9);
Childs and Saha (28)). Further discussion of the models, as well
as comparisons between them, occur later.
As Childs and Saha (28) posited, no sufficient validations of
these models can be made due to a lack of in-rotor temperature
measurements. Nevertheless, the data provided by Panara, et al.
(6) in 2015 have proven an exception. To validate their newly Figure 3. Feedback loop of rotor–bearing system subject to ME.
TRIBOLOGY TRANSACTIONS 385

orbit. On the contrary, the hot and cold spots for the backward
orbit migrate in a backward direction as shown in Fig. 5b. The
migration behavior alternates the two key points during the
backward whirling, which theoretically weakens the overall dif-
ferential heating. Moreover, the convection by the lubricant
could introduce a phase difference between the hot spot and
the thinnest film (De Jongh (2); Bradley (7)). Numerical investi-
gations by Gomiciaga and Keogh (24) and Childs and Saha (28)
revealed that the phase lag generated by the forward orbit is dif-
ferent from that generated by the backward whirl. Therefore,
Figure 4. Hot and cold spots induced by forward circular orbits with radii.
the final differential heating is a combined consequence of the
cumulative heating effect and the heat dissipations by
The orbit size influences how film thickness varies circum-
convections.
ferentially. Take the circular orbit, for example, as illustrated in
Orbit shape also matters. Most of the time, a rotor–bearing
Fig. 4, where the phase lag between the hot spot and the high
system exhibits an elliptic orbit that can be decomposed into
spot is neglected. Figures 4a and 4b show hot spots and cold
forward and backward orbits (De Jongh and Morton (20);
spots induced by circular orbits of radius ra and radius rb ,
Gomiciaga and Keogh (24)). Therefore, the viscous shearing
respectively, where ra is smaller than rb . The following relation-
heating effect induced by the elliptic orbit can be divided in the
ships hold:
same fashion, as illustrated by Fig. 5. As a result of the opposite
migrating direction of the differential heating in backward cir-
rj C e0 C ra C ha;H D rj ¡ e0 ¡ ra C ha;C cular orbits, the resulting differential heating generated by the
[1]
rj C e0 C rb C hb;H D rj ¡ e0 ¡ rb C hb;C ; synchronous elliptical orbit is smaller than a forward one.
The foregoing discussions utilized simplified orbits for a bet-
where ha;H and ha;C represent the film thickness at the hot spot ter illustration of the mechanism. However, the orbits produced
and cold spot, respectively; e0 is the static eccentricity; and rj is by real rotors vary with specific duty cycles and running condi-
the journal radius. From Eq. [1], the differential temperature tions. Moreover, in reality, the hot and cold spots shift from the
amplitudes induced by the two orbits hold the following rela- idealized positions because of cavitation, differential heating,
tionship (see Appendix for derivation). and convection of the fluid film. Therefore, a detailed descrip-
tion would require a comprehensive analysis to reflect specific
DTa D Ta;H ¡ Ta;C < Tb;H ¡ Tb;C D DTb : [2] rotor conditions.

Therefore, the larger the orbit size, the higher the differential The circumstances of ME-induced instability
temperature between the two points, as concluded in Bradley Aware of the general mechanism of ME-induced instability, it is
(7), Murphy and Lorenz (8), and Gomiciaga and Keogh (24). possible to understand the frequently reported occurrences of
Gomiciaga and Keogh (24) found a similar trend via a CFD ME. Categorizing the occurrences may help the industry to
study, in which a general elliptic orbit was decomposed into a diagnose ME in the first place. According to the literature, ME
forward circular orbit and a backward circular orbit. Their phenomena usually take place when certain changes were made
results, well noted in the literature, revealed a nonlinear rela- to the rotor system and more likely occur in some specific types
tionship, with a decreasing slope along the curve of DT versus of machine sets.
orbit sizes (Gomiciaga and Keogh (24)).
An orbit direction can be either forward or backward,
System changes
depending on system dynamic behaviors. Under the assump-
tion of no phase lag, the hot spot due to the forward synchro- Recall that ME is an inherent feature of a rotor with a fluid
nous orbiting remains at the same location, as shown in Fig. 5a. bearing/seal system. In most cases, the rotors are well balanced
Therefore, the differential heating is enhanced by the forward and thus exhibit satisfactory vibration levels. The satisfactory

Figure 5. Illustrations of hot and cold spots with various orbits.


386 L. GU

level can be maintained as long as the factors that influence the bearings (De Jongh and Morton (20)). ME-induced instabil-
differential heating remain the same. However, the incubation ity can also be initiated during variations of bearing clear-
time of ME will come to an end under certain circumstances; ance (De Jongh and Morton (20)) or quick changes in
for example, relocations (De Jongh and van de Hoeven (22)) or bearing oil temperature (Berot and Dourlens (5)). In addi-
upgrades of rotor systems (Faulkner, et al. (4)). tion, bearing load, L/D ratio (Berot and Dourlens (5)), and
oil inlet temperature (Marscher and Illis (38)) are critical
factors determining bearing conditions and therefore can
Machine types
either aggravate or eliminate ME-induced instability.
Most often, overhung rotors have a high tendency to exhibit
STI. As illustrated in Fig. 6, the thermal bend of the journal Other factors
induces the impeller center to shift significantly from the bear-
ing centerline. The shaft length L has a magnifying effect on In addition to those factors mentioned above, other factors
the impeller thermal bow rT because of the relation rT D L’T . have been reported to influence ME; for example, the length
Therefore, the machine types that have been reported to and mass of overhung impellers (Berot and Dourlens (5)) and
encounter ME usually have overhung structures; for example, the rotor system start-up speed rate (De Jongh and Morton
turbochargers (Faulkner, et al. (4), (21)), single-stage compres- (20)). However, no quantitative results have been presented
sors (De Jongh and van de Hoeven (22); Morton (31)), and corresponding to these two factors.
double-overhung compressors (Marscher and McGinley (32)).
Nonetheless, Larsson (33), (34) used a mid-span rotor sup- Typical symptoms of ME
ported by tilting pad bearings as an example to illustrate asym-
metric heating effect on journal thermal bow and its influence Slow process
on rotor vibrations. His theoretical results suggested that a few An interesting description was made by Berot and Dourlens
degrees of temperature difference along the journal surface can (5): “The fact that it did not appear immediately and did not
alter rotor vibrations significantly. Inspired by this, Guo and disappear once initiated. …” (p 3).
Kirk (35), (36) explored ME-induced instability conditions for The mysterious cause of the phenomenon described by
a mid-span rotor supported by two identical hydrodynamic Berot and Dourlens (5) is due to the relatively large thermal
bearings that are assumed to have linear and isotropic dynamic inertia. As a result, ME usually maintains a high level of vibra-
characteristics. Their findings revealed that mid-span rotor sys- tions for a relatively long time without causing a catastrophic
tems, although less sensitive than overhung rotors to ME, may disaster. The long manifestation time may vary from around
also experience instability under certain circumstances such as 10 min to quite a few hours (Bradley (7)) due to large thermal
changing bearing length. inertia.

Fluid–bearing conditions Spiral vibrations and phase lags


It is difficult to provide specific fluid–bearing conditions On a polar plot, ME-induced vibrations exhibit in a spiral
that can trigger ME induced instability. In general, any manner, although not in a perfect spiral shape most of the
bearing conditions that tend to produce significant differen- time. The outward spiral curve implies an increasing ampli-
tial heating are prone to aggravate ME. Such bearing condi- tude that originates from a cumulative differential heating
tions can occur in plain sleeve bearings (Murphy and and the consequential thermal bow. The phase varies with
Lorenz (8); De Jongh and Morton (20)), axial groove bear- time, as revealed by the spiral curve. The phase change can
ings (Faulkner, et al. (4), (21)), tilting pad bearings (Berot reach many times 360 if no upper vibration limit is given
and Dourlens (5); Schmied (18); De Jongh and Morton (Berot and Dourlens (5)). The root cause of the phase
(20); Schmied, et al. (37)), bearings with a tapered dam or change is due to a lubricant convection effect, which indu-
offset half fixed geometry (Bradley (7)), and partial arc ces the phase difference between the shaft response and the
ME-induced thermal bow (in other words, between the high
and hot spots). This phase difference has not only been
observed experimentally (De Jongh and Morton (20); Phut-
tipongsit (39)) but has also been validated theoretically
(Panara, et al. (6); Keogh and Morton (19); Gomiciaga and
Keogh (24)).

Pseudohysteresis
The slow process of thermal evolution results in a hysteresis
behavior of thermal bow. The thermal bow continues impact-
ing the rotor vibrations even during coast down (De Jongh and
Morton (20); De Jongh and van de Hoeven (22)). The hysteresis
behavior influences both the vibration amplitude and the corre-
Figure 6. Thermal bow in overhung structures. sponding phase angle (Bradley (7)).
TRIBOLOGY TRANSACTIONS 387

There are other symptoms of the ME occurrence induced by lubricant. To attain an efficient CFD calculation, Gomiciaga
thermal properties. Notably, there is usually more than one and Keogh (24) applied a quasi-steady method to solve the
speed range of instability (Berot and Dourlens (5)). In addition, thermo-fluid transiently. The heat fluxes from the lubricant
ME-induced instability can occur not only at transient speeds into structures were averaged over one orbit period. Gomiciaga
but also at steady speeds (Berot and Dourlens (5)). and Keogh (24) showed an efficient model that tackled THD
problems with perturbations from the journal orbit. However,
the study had a major limitation related to presetting the orbit
Critical issues in ME study
during calculations.
Theoretical analysis To overcome this deficiency of prescribed orbit, Childs and
Saha (28) developed an algorithm to generate converged orbits
As depicted in Fig. 3, the prediction of ME involves rotordy-
for a journal in plain journal bearings, during which the THD
namics, heat transfer, and THD related to the bearing perfor-
and rotordynamics were analyzed numerically. However, the
mance. In short, the predictions of ME require a
accuracy of their algorithm remains debatable considering that
comprehensive understanding of broad topics related to turbo-
the author assumed constant viscosity and neglected cavitation
machinery performance. The early theoretical work focused
effect. Later, Lee and Palazzolo (41) developed finite element
more on the aspect of rotordynamics, with many simplifica-
numerical models that integrated temperature-dependent vis-
tions on the thermal aspects. The work carried out by Schmied
cosity and corrected the dissipation terms at cavitation regions.
(18) and Schmied et al. (37) assumed a linear model: the chang-
The employment of a 2D model for tilting pad bearings and
ing rate of thermal deflection is a linear function of the net heat
insulated boundary conditions at the bearing side of the film
input, which resembles the following form:
reduced the computational complexity. However, it induces
deviation of the simulation results from the literature results.
x_ T D pVx ¡ qxT ; [3] A subsequent study by Suh and Palazzolo (9), (42) improved
the finite element model by utilizing a 3D bearing model and
where p and q are constants determined by the rotor systems. by applying a heat flux boundary at the interface between the
The model neglected heat transfer and the THD behavior. In bearing pads and fluid film. Inspired by the work in Gomiciaga
addition, Eq. [3] did not account for the phase lag between xT and Keogh (24), Suh and Palazzolo’s work (9), (42) employed
and x. time-averaged heat flux to reduce the calculation of the temper-
A fully qualitative analysis made by Keogh and Morton (10), ature field in the both fluid film and spinning shaft. Their work
(19) was based on THD. Using the short bearing assumption, further revealed that the 2D energy equation is insufficient for
they calculated the velocity and pressure fields about the fluid predicting ME due to its inaccurate calculation of the hot spot
lubricant. The temperature field was calculated with energy phase. Following that, Tong and Palazzolo (43) extended the
equations and heat transfer models. Applying the bend angle study from a single overhung structure to a double overhung
solution derived by Dimoragonas (15), the bend angle for the structure using a nonlinear transient method.
asymmetric field was then given as follows (Keogh and Morton A typical feature of numerical simulations is that the
(19); Childs and Saha (28)): dynamic models are built per a specific case, which might
induce oblivion of important mechanisms of ME exhibited in
Z Z Z
a general cases. Moreover, the concern regarding efficiency in
bT D ¡ j DT ðr; z; ’Þrj2 ej’ dV; [4] industry sheds light on the justification for development of less
Ij
V computationally demanding methods for ME analysis. Lorenz
and Murphy (27) and Panara, et al. (6) utilized a linear model
where j is the imaginary unit; a, Ij denote the thermal expan- for both shearing viscous heating and thermal bow. However,
sion coefficient and the area moment of inertia of the journal; D the pursuit of simplicity is at the cost of accuracy, especially
T represents the temperature difference between the hot spot that of the thermal model. The comparisons between the mea-
and the cold spot; r ¡ z ¡ ’ denotes the cylinder coordinates; surement and the theoretical models (Panara, et al. (6))
and rj , V correspond to the journal radius and the journal vol- revealed that their linearized model was not accurate enough to
ume, respectively. In Eq. [4], the temperature field was solved predict the differential temperature within the range of operat-
considering cavitation effects using short bearing theory. The ing speed.
fractional film width was utilized to scale the temperature gra- As a matter of fact, the best accuracy and efficiency trade-
dient, which improved the temperature accuracy. To capture offs remain unclear. Good accuracy requires more precise
more details about the fluid film with cavitations, in 1996, modeling that results in an increase in time-consuming compu-
Tucker and Keogh (40) included the time-dependent property tations. Conversely, efficiency limits accuracy. Therefore, it is
of fractional film and then used the theory of mass conservation imperative to find a better blending of accuracy and efficiency
to average the fluid properties. However, this work only studied via a combination of theoretical analyses and experiment vali-
the temperature field produced by a forward circular orbit. In dations. A possible solution could be a combination of simpli-
1999, Gomiciaga and Keogh (24) extended the study to a more fied analytical models and CFD analysis. For instance, CFD
general journal orbit that was decomposed into forward and techniques could be used instead of analytical formulae to cal-
backward circular orbits. It has been well recognized that simu- culate the two thermal factors, heating and dissipation, before
lation of thermal development is very time consuming due to integration into a simplified rotordynamics model to assess
the large time-constant difference between the rotor and the ME-induced stability (44). The combination of CFD analysis is
388 L. GU

capable of considering bearing geometries, journal transient corrected by referring to the data obtained at non-drive end
motion, temperature distribution, and other important factors (NDE) bearings. For this purpose, De Jongh and Morton (20)
that determine the accuracy of the ME prediction. distributed three noncontacting eddy-current displacement
probes at the NDE bearing (three clearances between pads) in
addition to applying 2 £ 6 others along the test rotor.
Experimental techniques
To replicate ME proves difficult because the system might
The temperature measurement for a high-speed journal not be able to maintain a sustainable differential temperature
remains a major experimental concern. The selections and dis- across the journal (Bradley (7)). The management of speed and
tributions of temperature probes should be capable of capturing other conditions may be crucial to successfully replicate ME-
the temperature difference circumferentially. In this regard, induced instability.
thermocouples and resistant thermal detectors (RTDs) are
widely used. Due to its advantage of accuracy and repeatability,
Extended discussions
RTDs are gradually replacing thermocouples in many indus-
trial applications. The mounting of temperature probes proves Excitation mechanism—equivalent imbalance versus rotor
another key concern in temperature measurement. Most ME bow/bending
phenomena occur in rotor systems at high operating speed.
As discussed earlier, though differential heating is the root
Hence, it is a crucial task to transmit temperature data to acqui-
cause of the ME, ME-induced instability is a direct consequence
sition systems with an acceptable precision. During the mount-
of rotor thermal bending because it alters the orbit size by
ing process, special attention should center on good thermal
changing the resultant vibration vector. Therefore, it is impera-
contact between the probes and the journal (De Jongh and
tive to properly incorporate the effect of thermal bending into
Morton (20)). Moreover, the disturbance to rotordynamics
the equation of motion (De Jongh (2); Koegh and Morton (10);
caused by the mounting of probes should be minimal. Usually,
Larsson (34)). To date there are two approaches to model the
temperature probes are installed at the journal close to over-
influence of thermal bow in the governing equation. The first
hung impellers/disks (Bradley (7); De Jongh and Morton (20)).
approach is to use the shaft bow theory to incorporate the ther-
Moreover, it is important to retain the original heat conduction
mal bending effect, as presented in Keogh and Morton (10),
path in the journal as much as possible. More information
(19), Larsson (34), Eckert, et al. (12), and Schmied, et al. (37).
regarding temperature measurement can be found in Bradley
Larsson (33), (34) used the term “geometrical unbalance” to dif-
(7) and Panara, et al. (6).
ferentiate the thermal bending from mass unbalance. The sec-
In 1996, De Jongh and Morton (20) published the first open
ond method is to treat the thermal bending as an addition to
experimental data on ME. To replicate the phenomenon of STI
the existing mass imbalance (Murphy and Lorenz (8); Balbaha-
occurring in a compressor, they designed a scaled-down test
dur and Kirk (25); Lee and Palazzolo (41)); that is, modeling
rotor based on an existing R&D test compressor. The process
the geometrical unbalance as an equivalent mass unbalance.
necessitated many adjustments during the design phase to cre-
The simplified equation of motion corresponding to the first
ate dynamic characteristics identical to those of the original
approach—that is, the shaft bow theory—is given by Keogh
machine. Four PT-100 RTDs were uniformly placed peripher-
and Morton (10), (19), Schmied, et al. (37), and Grigor’ev, et al.
ally and embedded in holes 1.3 mm below the journal surface.
(45) as
Oil supply and drain temperatures were measured with ther-
mocouples. Measurement data revealed that the test rig was
MR €v C ðCb C GR Þv_ C ðKR C Kb Þv D F C KR v T .t/; [5]
completely stable at a differential temperature of 3 C. However,
this value increased significantly upon acceleration toward the
upper limit of the operating speed range. Therefore, eventually, where the term KR v T .t/ represents the excitation due to a bow
instability occurred. The test rig was successful because the var- vector, which is consistent with bow theory (Chen (46); Childs
iations in differential temperature coincided with the occur- (47)). The matrix KR represents the rotor stiffness resisting
rence of vibration instability. rotor deformation, and MR and GR denote the rotor mass and
In 2015, Panara, et al. (6) conducted another experiment gyroscopic matrices, respectively. The bearing damping and
worthy of mention. The experimental setup was equipped with stiffness matrices are represented by Cb and Kb . The vector F
eight thermocouples at the journal close to the non-drive end. models external forces exerted on the rotor system. The ther-
It proved able to detect high orders of circumferential tempera- mal bending vector v T .t/ is expressed as
ture variations. The temperature data were transmitted electri-
cally via wires connected to a ring placed at the rotor end. In v T .t/ D ½vT;1 .t/ vT;2 .t/ . . . vT;n .t/T ; [6]
addition, two bearing pads were selected and PT-100 RTDs
were installed. Moreover, the overhung load was adjustable and with the subscript T referring to the thermal effect and n denot-
was varied via various idling adaptors hydraulically mounted ing the vector dimension. It is worth noting that v T .t/ varies
on the shaft. This device enabled the influence of the overhung with time during the development of ME, which implies that
weight to be investigated. the thermal bow excitation KR v T .t/ has a time-varying ampli-
As to the acquisition of the ME vibration signal, ordinary tude and phase. The thermal bending arising from ME is natu-
sensors for general rotor vibrations can be applied. However, if rally a function of the factors that can cause ME-induced
vibrations are obtained at rotor locations other than bearings instability (discussed in The Circumstances of ME-Induced
where the significant differential heating occurs, they should be Instability section). Those factors include the rotational speed,
TRIBOLOGY TRANSACTIONS 389

critical speeds, rotor/bearing geometry, oil properties, etc. (De leaves an open conclusion regarding the differences between
Jongh (2); Faulkner, et al. (4); Bradley (7)). Gu and Chu (48) temperature fields generated by synchronous forward and
established analytical models to define the thermal bow excita- backward whirl. The fact that the differential heating is weaker
tion for a generalized thermal field that is applicable to both in the backward orbit than in the forward orbit can be misused
ME and NE problems. sometimes. De Jongh and Morton (20) concluded that the heat
The second method—that is, the theory of equivalent mass input to the journal was always smaller by the backward orbit.
unbalance—adopts an equivalent mass unbalance to account However, Gomiciaga and Keogh (24) showed that the tempera-
for the thermal bending effect. The equation of motion employ- ture difference induced by backward whirl was larger than that
ing the equivalent mass unbalance theory has the following induced by forward whirl based on CFD calculations. The
general form (Guo and Kirk (36); Lee and Palazzolo (41); Tong inconsistency between the two works regarding this aspect
and Palazzolo (43)): implies that the forward orbit does not necessarily lead to a
larger DT than the backward orbit in the presence of heat con-
vection. The ultimate results depend on specific situations such
MR €v C ðCb C GR Þv_ C ðKR C Kb Þv D F C MR eT V2 eiVt C b ; [7]
as orbit shapes, running speeds, and lubricant properties.

where eT;i D 1;2;...;n corresponds to the magnitude of time-depen-


dent variable vT;i D 1;2;...;n .t/ at time t and, therefore, eT denotes Pressing need for theoretical guidance
the eccentric distance vector for the equivalent mass unbalance.
Almost all of the case studies (or troubleshooting) reviewed
The term V is the rotational speed, and b denotes the phase dif-
previously attempted to solve ME-induced problems by reduc-
ference between the high spot and the hot spot. This method
ing the differential heating of journals. The sole exception is the
requires an iterative computation between the vibration vector
work by De Jongh and van der Hoeven (22). They utilized a
and the thermal field, because eT is the number taken from a
heat barrier to isolate the journal from the differential heating
time instant t or an average value over a short period (Murphy
generated in the fluid (De Jongh and van de Hoeven (22)). Little
and Lorenz (8); Tong and Palazzolo (43)). The equivalent mass
evidence of theoretical guidance could be traced during those
imbalance approach provides a simple method to model ME
case studies. This lack of theoretical guidance might sometimes
instability—for example, setting a threshold of mass imbalance
have resulted in failure to eliminate ME-induced instability
as proposed by Balbahadur and Kirk (25) and Kirk, et al. (49)—
(Berot and Dourlens (5)). The theory-guided solutions greatly
but the results may differ from those obtained using the geo-
rely on the development of a more complete theory that can
metrical unbalance method. From a physics standpoint, the
reflect the relationship between rotordynamics and the thermal
excitation mechanism of the equivalent mass unbalance is dif-
field. Pragmatic guidance for field operators can be to provide a
ferent from that of a shaft thermal bow (or “geometrical unbal-
series of maps, tables, or plots that indicate the range of differ-
ance”). Larsson (34) provided an easily understood example to
ential temperature for the most common rotor systems.
state the difference between the two mechanisms, which is
Toward this end, various rotor systems—for example, with sin-
quoted here as “… as can easily be understood if one thinks of
gle or double overhung masses—of single or multiple stages,
a rotor at low speed. The mass unbalances will produce only
supported by plain journal bearings or tilting pad bearings,
small vibrations as the unbalance forces are small. However,
require intensive quantitative studies.
geometric unbalances can give large vibrations even at low
speed” (p 164). The comparison given by Larsson (34) is made
at low speed.
Conclusions
Recently, Tong, et al. (50) compared the equivalent mass
imbalance method with the thermal bow theory for an over- This article provides a detailed review of the ME rotor instabil-
hung rotor supported by tilting pad bearings. Their study ity phenomenon. Earlier studies have revealed many important
showed that the two methods led to significantly different features of ME, such as spiral vibration curves, the slow insta-
vibrations at the rotor overhung end and shaft temperature at bility evolution process, phase lags between the hot and high
the running speed of 8,500 rpm, about 500 rpm higher than the spots, and the pseudohysteresis behavior of the vibration. These
second critical speed. In particular, the equivalent mass unbal- features help not only to detect the onset of ME, but also to
ance method predicted a synchronous instability, whereas the improve understanding of its underlying mechanisms.
thermal bow method showed no occurrence of rubbing (i.e., The involvement of the bearing THD would result in a high
stable operation). From these comparisons against experimen- level of complexity of the theoretical models developed in the
tal data from De Jongh and van der Hoeven (22), Tong, et al. literature. Therefore, it is relatively challenging to achieve high
(50) concluded that the thermal bow model might be more accuracy for the prediction of phase lag between the hot and
accurate than the equivalent mass unbalance model. high spots. Moreover, the difficulty in maintaining the differen-
tial heating in a certain way may induces failure to replicate
ME experimentally. The aforementioned two problems indicate
Temperature differences by orbiting: Forward versus
that to fully understand ME necessitates further study.
backward
Some important findings obtained from computationally
It was discussed in the General Mechanism section that the dif- demanding analysis and time-consuming experimental investi-
ferential heating is a combined consequence of the accumula- gation can be explained in simplified theoretical analytical
tive heating effect and heat convections. In this respect, it models in a fundamental fashion. A good example is the
390 L. GU

influence of orbit size on the temperature difference at the jour- Behaviour,” Proceedings: Mathematical and Physical Sciences, 441
nal, as covered in the General Mechanism section. (1913), pp 527–548.
Finally, the article discusses two inconsistencies found in the (11) Newkirk, B. L. (1926), “Shaft Rubbing,” Mechanical Engineering, 48,
pp 830–832.
literature. The first is found between the two methods that are (12) Eckert, L., Schmied, J., and Ziegler, A. (2006), “Case History and
used to incorporate the thermal bow into the governing equa- Analysis of the Spiral Vibration of a Large Turbogenerator Using
tions. A comparison study suggests that the shaft thermal bow Three Different Heat Input Models,” ALSTOM & DELTA JS AG, 7th
theory might be more accurate than the equivalent mass unbal- IFToMM Conference on Rotordynamics, Vienna, Austria, September
ance approach. The second inconsistency is related to the com- 25–28.
(13) Dimarogonas, A. D. (1973), “Newkirk Effect: Thermally Induced
parisons of journal differential temperatures between the Dynamic Instability of High-Speed Rotors,” ASME Gas Turbine Con-
forward orbit and the backward orbit. The combination of vis- ference and Products Show, Washington, DC, April 8–12.
cous shear heating and heat convection made the differential (14) Bachschmid, N., Pennacchi, P., and Vania, A. (2007), “Thermally
temperature generated by the forward orbit unnecessarily larger Induced Vibrations Due to Rub in Real Rotors,” Journal of Sound
than that generated by the backward orbit. Eventually, it is and Vibration, 299(4–5), pp 683–719.
(15) Dimarogonas, A. D. (1970), An Analytical Study into the Packing Rub
implied that there is a need to carry out intensive quantitative Effect in Rotating Machinery, Ph.D. Dissertation, Rensselaer Poly-
studies to provide practical guidance for turbomachinery technic Institute, Troy, NY.
applications. (16) Dimarogonas, A. D. (1972), “Heat Distribution and Flash Tempera-
tures in Radial Seals,” Wear, 23(1), pp 113–119.
(17) Kellenberger, W. (1980), “Spiral Vibrations Due to the Seal Rings in
Turbogenerators Thermally Induced Interaction between Rotor and
Acknowledgment Stator,” Journal of Mechanical Design, 102(1), pp 177–184.
(18) Schmied, J. (1987), “Spiral Vibrations of Rotors, Rotating Machinery
The author owes many thanks to Dr. Dara Childs and Dr. Luis San Andres
Dynamics,” ASME Design Technology Conference, Boston, Septem-
for many fruitful discussions and sharing of their perspectives on the Mor-
ber 27–30.
ton effect. Finally, a special thanks is extended to Dr. Adolfo Delgado for
(19) Keogh, P. and Morton, P. (1994), “Dynamic Nature of Rotor Ther-
his insightful discussion on the comparisons of the excitation models
mal Bending Due to Unsteady Lubricant Shearing within a Bearing,”
between the thermal bow and the equivalent mass unbalance.
Proceedings of the Royal Society of London, Series A: Mathematical
and Physical Sciences, 445(1924), pp 273–290.
(20) De Jongh, F. M. and Morton, P. G. (1996), “The Synchronous Insta-
Funding bility of a Compressor Rotor Due to Bearing Journal Differential
Heating,” Journal of Engineering for Gas Turbines and Power, 118,
The author acknowledges the Texas A&M University Turbomachinery pp 816–823.
Research Consortium for financial support. (21) Faulkner, H. B., Strong, W. F., and Kirk, R. G. (1997), “Thermally
Induced Synchronous Instability of a Radial Inflow Overhung Tur-
bine, Part I,” ASME Proceedings of Design Engineering Technical Con-
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ogy, 139(1), pp 011705.1–011705.11. For the same rotor with the same heat conduction proper-
(44) DELTA JS. MADYN 2000. “Hot Spot Stability Analysis Available in ties, the temperature differences between the hot spot and the
MADYN 2000 Version 4.2.” Available at: http://www.delta-js.ch/file/ cold spot hold the following relationship for the two orbits:
344/MADYN_2000_Release_42.pdf (accessed April 5, 2016).
(45) Grigor’ev, B. S., Fedorov, A. E., and Schmied, J. (2016), “New Mathe-
matical Model for the Morton Effect Based on the THD Analysis,” DTa D Ta;H ¡ Ta;C < Tb;H ¡ Tb;C D DTb : [A2]

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