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Steam Turbine-Generator Torsional Response


due to Interaction with the Electrical Grid
Hans D. Giesecke, MPR Associates, Inc.

Abstract--The rotating part of a large steam turbine-


generator is typically composed of individual turbine rotors I. INTRODUCTION
that support the turbine blades or a generator rotor that
holds the generator windings. These individual parts are
usually attached together by bolted couplings. Although
T URBINE-generators that provide power to the electrical
grid can be sensitive to the various torques that the grid
can impose on them during normal operation. For example,
this combined rotating part of the turbine-generator can be the turbine-generator must be capable of operating with
excited in torsion by oscillating torques applied to its
specific steady-state oscillating torques such as those
various components, most of the torques that can damage
generated by its interaction with the natural frequencies of
the large steam turbine-driven machines that provide power
some electrical grids (for example, sub-synchronous
to the grid is due to interaction with the electrical grid.
resonance), or due to negative sequence current torques that
Due to the increasing size of these turbine-generators,
are generated at twice the grid frequency as a result of
they can have between 20 to 30 torsional modes of
vibration with frequencies in the range where they can be unbalanced load on the generator terminals. In addition,
excited by the grid during normal operation. Since sudden transient torques often imposed on turbine-generators
damping for torsional modes can be very low (in the order from upsets or transients such as synchronization, line
of 0.1 per cent of critical damping or less), vibratory switching, turbine or generator trips, and electrical grid faults
response at resonance can exceed 500 times the response can result in impulse loads that excite all the torsional modes.
that would occur from an equivalent static load of the same These sudden impulse loads that occur from rapidly applied
magnitude. As a result, turbine-generators can be quite torques must also be sustainable by the design.
sensitive to torsional vibration stimulus from the electrical The torsional response of a turbine-generator can be
grid and they should not be allowed to be operated at near- significant if operating near resonance because torsional
resonance conditions. In addition the steam turbine- modes generally have very low damping. In some cases, the
generator must be capable of sustaining suddenly applied damping may even decrease more due to aero-elastic
impulse torques that can be generated by electrical grid amplification of some torsional modes when there is sufficient
faults, mal-synchronization, turbine or generator trips, and amplitude of vibration to generate the required feedback. As a
switching of transmission lines. result, it is critical that turbine-generators be designed to avoid
One way that torsional resonance can occur is if the resonance by ensuring they don’t have any excitable torsional
turbine generator is allowed to operate with unbalanced modes with natural frequencies that are close to the frequency
load on the generator terminals while it has a torsional of the significant exciting torques.
mode with a frequency close to twice the grid frequency. This paper discusses the torsional characteristics of a
The unbalanced load can result in a steady oscillating
typical turbine generator, the mechanisms that can excite the
negative sequence current torque at twice the grid
torsional response of the turbine generator, and how the
frequency that can cause significant damage to the turbine-
turbine design can avoid large torsional responses that can
generator if it has an excitable torsional mode with a
frequency too close to that of the exciting torque. It is result in fatigue damage to the blades and the shaft and
important to design the turbine generator to provide ultimate failure of the machine.
sufficient torsional frequency margin with respect to such
steady oscillating torques at twice the grid frequency while II. TORSIONAL CHARACTERISTICS
also providing a sufficiently rugged design that can Turbine generators will respond to torsional stimuli by
withstand the suddenly applied torques that occur due to vibrating in a combination of their torsional modes of
transients, upsets, and faults that occur from time-to-time vibration. Therefore, it is important to understand what
during operation. torsional modes a turbine generator has and how they can be
influenced by the grid. A typical steam turbine generator is
Index Terms— Finite element methods, Generators,
comprised of a high pressure turbine (HP), one or more
Harmonic analysis, Power grids, Power system transients,
Surges, Torsion, Turbines, Vibrations.
intermediate pressure (IP) or low pressure (LP) turbines, a
generator, and possibly a rotating exciter or a collector.

978-1-4673-2729-9/12/$31.00 ©2012 IEEE


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Typical rotors for each of these components contain a fairly of the flexible shafts that connect them together. These sub-
stiff body of larger diameter that supports the turbine blades or synchronous modes can interact with any sub-synchronous
current windings and smaller diameter shafts that are natural frequencies of the grid on transmission lines with
supported by the bearings and connect them to other series capacitance installed on them. Mode 2 in Fig. 2 is the
components. The connecting shafts are usually more flexible fundamental torsional mode of the turbine generator where the
than the major components and the shafts ends are bolted to whole turbine-generator rotor twists from end to end. Since
other components by bolted couplings. Fig. 1 provides an most of the major stiffer regions are represented by horizontal
example of a typical large nuclear turbine-generator that will lines, these parts of the rotor are merely rolling as rigid bodies
be used here to study typical torsional characteristics of a while shafts that connect them are being twisted from end-to-
large steam turbine-generator. Understanding the modes and end. Mode 6 has only the exciter rolling back and forth with
frequencies of the turbine-generator will help in understanding the shaft to the generator taking all the strain.
how to avoid torsional problems.

Fig. 1. Example of a large nuclear turbine-generator rotating section with a


high pressure turbine rotor, 3 low pressure turbine rotors, a 4-pole generator
rotor, and a rotating exciter.

The susceptibility of the turbine-generator to torsional


vibration depends on its torsional frequencies and mode
shapes. As the size of turbine-generators increases, the
natural frequencies will decrease so there will be more
torsional modes with frequencies low enough to be a potential
problem for torsional vibration. The large, nuclear turbine–
generator depicted in Fig. 1 will be used as an example to help
demonstrate the things that may make the turbine-generator
susceptible to torsional vibration problems.
Each turbine-generator that is comprised of separate
components has a series of torsional modes where the major
components rotate as relatively rigid bodies while the
distortion is primarily in the more flexible shafts that connect
them together. There will be one such mode for each major
component that makes up the turbine-generator. Since the Fig. 2. Example of sub-synchronous modes for the turbine-generator shown
in Figure 1. There are 6 modes for the 6 separate components but the first
whole turbine generator rotor is not restrained against rotation,
mode is not shown.
the lowest frequency torsional mode will be the free body
rotation of the complete turbine-generator rotor and the The next set of torsional modes are those for which the
associated torsional mode will have a constant amplitude over major components themselves twist in their first twisting
its complete length and a frequency of Zero Hz. This modes with the ends rotating in opposite directions. Usually,
torsional mode is usually not included in the torsional modes the first twisting modes of the low pressure turbines are the
that are listed and the first mode considered is often labeled as ones with the lowest frequencies, particularly when the
the second torsional mode as a result. This is the convention turbines are designed with impulse blading that require lower
that is used here. diameter seals for the stationary blade rows. The first LP
Examples of the other low frequency modes for the twisting modes typically interact with the umbrella modes of
example turbine-generator shown in Fig. 1 are shown in Fig. the largest blades in the lowest pressure blade rows since the
2. The mode figures show the modes overlaid over a picture blades have natural frequencies that are often close to the
of the turbine-generator such that each mode shows the frequency of the underlying torsional modes of the LP rotors.
torsional displacement along the complete turbine-generator The combination of the LP rotor twisting mode with the
rotor that is displayed at the top. The sub-synchronous modes umbrella modes of the blade row will result in two additional
shown in Fig. 2 are the modes where the major components torsional modes for each LP rotor, 6 additional modes when
act as rigid cylinders rotating relative to each other by twisting all three LP rotors are included. These are in addition to the 3
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LP twisting modes which results in 9 modes overall for the


three LP rotors. The interaction of the umbrella modes with
the LP twisting modes results in one mode for each LP rotor
where the blades vibrate with the rotor, one where they vibrate
in the standard umbrella mode with little rotor participation,
and one where the blades vibrate opposite to the rotor. Fig. 3
shows the three torsional modes where the blades vibrate with
the rotor (since there are 3 LP rotors), Fig. 4 shows the blade
umbrella modes that interact primarily with the second LP
torsional modes, and Fig. 5 shows the 3 modes where the
blades vibrate opposite to the rotor. In these figures, the
magnitude of the blade response is depicted by the length of
the lines emanating from the rotor at the position of the blade
row.

Fig. 5. Example of the first LP twisting modes of the turbine generator


coupled with the L-0 umbrella modes where the blades vibrate in the opposite
direction to the rotor..

For this turbine-generator the umbrella modes for the first


L-0 blade frequency do not interact significantly with the
second LP torsional mode because the frequencies of the two
modes are well separated so the frequency of the umbrella
modes remain very close to the natural frequencies of the
blade modes as they would appear on a Campbell diagram.

Fig. 6 is a plot that shows the measured torsional frequency


response from the turbine-generator that was shown in Fig. 1.
This plot was generated from measurements obtained by on-
line monitoring [1] of the turbine rotor at full power operating
Fig. 3. Example of the first LP twisting modes of the turbine generator conditions. The modes that have been discussed and shown in
coupled with the L-0 umbrella modes where the blades vibrate in the same
direction as the rotor. Both L-0 and L-1 blade rows participate.
Fig. 2, 3, 4, and 5 are easily identified although the response
of the umbrella mode frequencies from Fig. 4 is small and
requires a more detailed analysis to obtain than that shown in
Fig. 6.
The sub-synchronous modes are labeled as Rigid Body
Modes on Fig. 6 and include all 5 of the sub-synchronous
modes. Mode 6, which is primarily the exciter rotating on the
end of the generator, appears just below the first harmonic of
the running speed. The apparent mode at about 1 Hz is not a
torsional mode but is the frequency response of the complete
rotor relative to the restoring force of the air gap torque. The
sharp peaks that are labeled at 1/Rev, 2/Rev, etc. are the
response of the rotor to the forced vibration at the harmonics
of the running speed where the dominant forces exist for all
rotating equipment.
The three modes that were shown in Fig. 3 are labeled as
1st LP Twisting L-0 In Phase on Fig. 6. The small bump at
about 73 Hz is due to the first L-0 umbrella modes that are
shown in Fig. 4. As discussed previously, they do not respond
well on the shaft because the second LP modes are at much
higher frequency and don’t interact well with the blades at this
Fig. 4. Example of the first L-0 umbrella modes of the turbine generator. frequency. The peak at about 80 Hz is actually three peaks
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when resolved in more detail and represents the 3 modes on The generator modes are important because they are the
Fig. 5. They are labeled as 1st LP Twisting L-0 Out of Phase mechanism by which transient air gap torques can excite the
on Figure 6. turbine-generator. If the generator participates in a mode
whose frequency is close to twice the grid frequency, negative
sequence current torques will excite it. If the mode also has
the participation some of the turbine blades, the possibility of
a loss of blades from fatigue due to torsional vibration may be
high. Fatigue of turbine blades due to torsional vibration has
resulted in loss of turbine blades, significant unbalance
conditions on the turbine generator, and catastrophic failures
due to the resulting high lateral vibration. Since torsional
vibration can occur without any knowledge by the operators,
such failures often occur suddenly without warning after the
turbine generator has operated successfully for an extended
time period.
As can be seen in Fig. 6, this particular turbine-generator
has many torsional modes with frequencies close to twice the
grid frequency and may be susceptible to torsional vibration
from negative sequence current torques. In fact, a turbine-
generator similar to this one suffered a torsional failure due to
Fig. 6. Measured Torsional Frequency Response of turbine-generator in Fig.1
loss of L-1 blades and had to be modified to shift the 2nd
as obtained by On-Line Monitoring. generator mode away from 120 Hz.

There are 6 additional modes associated with the 1st L-1


umbrella modes and 6 more for the 2nd umbrella modes of the III. APPLIED TORQUES FROM THE GRID
L-0 blade; however, the interaction of these modes with each The grid can generate both steady-state and transient
other and with the generator makes them more difficult to oscillating torques on the generator. Steady oscillating
identify as individual modes in the response. Most of these torques are generally due to two causes:
modes can be identified in the cluster of modes near the 4/Rev
harmonic response. Of particular importance are the two • Sub-synchronous resonance (SSR) that can result when a
generator modes which are labeled as 1st Generator and 2nd turbine-generator is connected to a transmission line that
generator on Fig. 6. The mode shapes for these two modes, has series capacitor compensation or is connected to a
along with the mode shape for the 1st HP mode, are shown on direct current grid.
Fig. 7. • Negative sequence current (NSC) torques that are caused
by unbalanced load on the generator phases and have a
frequency at twice the grid frequency.

SSR is primarily a problem that is mitigated by changes to


grid parameters and not by the design of the turbine. Since
this discussion is primarily about the turbine-generator, it will
concentrate on the effect of negative sequence current.
Negative sequence current torque is caused by operation
with unbalanced load on the terminals of the generator which
results in an oscillating torque at twice the grid frequency.
Some amount of unbalance is always present during normal
operation and a torque with a magnitude of about one to two
per cent of the full power-torque is typical. Steady negative
sequence current torques can also occur due to a sustained
fault if the circuit breaker that isolates the fault malfunctions
or if the fault occurs inside the circuit breaker protection zone.
Transient torques occur when there is a sudden change
in operation. They can occur as a result of the following:

• Synchronization has to balance the torque from the steam


Fig. 7. Example of the first and second generator modes (Modes 21 and 26).
Also shown is the first HP twisting mode (Mode 22). flow that is applied to the blades against the reacting air
gap torque. When the turbine-generator is synchronized
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to the grid, there will always be some mismatch and the vibration conditions. A frequency difference of as little
changes that occur to cause the torques to equalize will as a few tenths of a hertz is often sufficient to reduce the
generate a transient condition. response to acceptable levels.
• Line switching is similar to synchronization except it can • Although the torsional frequencies are very stable during
occur with the plant at power. operation, they will change by up to one Hz due to
• Faults on the grid can cause a significant transient torque temperature changes associated with changes in operating
to be applied to the generator. Torques at the grid conditions. Typically, for a large nuclear turbine
frequency and at twice the grid frequency can occur. The generator with reheat, the frequency of the LP torsional
torque at the grid frequency will decay rapidly but the one modes that reside around twice the grid frequency will
at twice the grid frequency can be sustained as long as the decrease by 0.3 to 0.5 Hz as the plant moves from
fault persists. Often, after a fault is cleared, the breaker synchronization to full power.
will attempt to re-close which can result in another
transient. The best way to ensure that a steam turbine generator will
not be damaged by torsional vibration is to provide sufficient
frequency margin with respect to steady-state oscillating
IV. TURBINE-GENERATOR TORSIONAL RESPONSE torques that can originate from the grid. This requires that the
CHARACTERISTICS AND MITIGATION grid be designed to confirm that SSR will not occur for sub-
The torsional response of the turbine generator depends on synchronous modes and that sufficient frequency margin
the frequency of the torsional modes and the mode shapes. exists for any torsional mode near twice the grid frequency to
Specifically, operating the turbine-generator with an excitable ensure that grid disturbances and grid frequency variations
torsional mode that has a frequency that is too close to twice will not result in excessive torsional response. The standard
the grid frequency where it can be excited by a sustained recommended frequency margin around twice the grid
negative sequence torque is not acceptable for the following frequency is two Hz on either side of the double-grid
reasons: frequency. In the U.S. this would require that no torsional
mode that can be excited through the generator should have a
• Torsional damping is generally very low, in the order of frequency that is between 118 Hz and 122 Hz.
0.1 per cent of critical damping or less. Aero-elastic Fig. 8 (from Reference [2]) shows the calculated peak
amplification of torsional modes that include blade torsional response to a specific grid fault for an excitable
vibration can occur and it can effectively lead to negative torsional mode with a frequency near twice the grid
damping and instability of the torsional vibration. Large frequency.
steam turbine-generators have long, twisted, low-pressure
blades with natural frequencies that are tuned to avoid
harmonics of the running speed. These blades typically Peak Stress in Transient Response During Fault
have natural frequencies at running speed that are near the L-0 Blade on Generator End of LP-B

grid frequency and twice the grid frequency when


Peak Transient Stress (KSI)

180
coupled with torsionally flexible LP rotors. The second 160
140
mode mode-shape of the blades often includes some 120
0.1 Second
0.5 Second
twisting around the radial axis of the blade that can affect 100 1 Second

the critical flow area between the blades. When operating 80 2 Seconds
3 Seconds
60
with supersonic relative outlet velocities, the pressure 40
ratio across a stage where these blades all move in phase, 20
0
as is required by torsional vibration where the base of the 118 119 120 121 122
blades must move together as the shaft vibrates in torsion, Frequency of Torsional Mode (Hz)
can be significantly affected by the vibration. If an
increasing mode vibration amplitude results in an Fig. 8. Peak Response as a Function of Frequency for a Mode
with a Frequency near 120 Hz and for various Fault Clearing
increasing pressure ratio across the stage, aero-elastic Times (From Reference [2])
amplification of the torsional vibration is possible.
• Due to the low damping involved, it requires about 300 to The response is given as a function of the torsional mode
400 vibration cycles to attain the full vibratory response frequency as well as the time that the torque is sustained. The
of a torsional mode when operating at resonance. results show that for faults cleared in the typical clearing time
However, if the mode frequency and the driving for a fault which is less than one-tenth of a second, the peak
frequency do not coincide, the vibratory response will magnitude of the response is not significantly affected by the
result in “beating” at a beat frequency that is equal to the mode frequency. Thus, for such faults the impulse load, for
difference in the two frequencies. As the forcing function which the response is relatively independent of mode
alternates between driving the response and suppressing frequency, dominates. When the negative sequence torque is
the response, it becomes difficult to reach resonance
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sustained for a longer period of time, the frequency of the


mode has a large impact, but if the standard frequency margin
is maintained, the response is again limited to that caused by
the impulse load. Therefore providing sufficient frequency
margin around twice the grid frequency will be sufficient to
eliminate torsional concern.

V. REFERENCES

Papers from Conference Proceedings (Published):


[1] Giesecke, H. D. "Measuring Torsional Vibration Frequencies by
On=Line Monitoring”, Proceedings of IJPGC03 Atlanta, Georgia USA,
2003

Technical Reports:
[2] “Steam Turbine-Generator Torsional Vibration Interaction with the
Electrical Network”, EPRI Tutorial 1011679, Final Report, Nov. 2005.

VI. BIOGRAPHIES

Hans D. Giesecke was born in Berlin, Germany in


1942. He immigrated to the United States with his
family in 1949 and graduated from Rutgers
University with a degree in Physics in 1964. While
doing graduate studies at the University of
Maryland in Physics and Nuclear Engineering, he
began working at MPR Associates Inc. and is still
working there in partial retirement..
Giesecke’s work at MPR has involved
numerous disciplines including turbine flow field
analysis for transonic blade rows as part of efforts to improve low pressure
blade designs. He has been involved in many facets of turbine design and
analysis since the early 1970s and his work included the development of
software tools for fluid dynamics, structural analysis, stress analysis, thermal
analysis and thermo-hydraulic analysis. Among other things, these tools have
been used to analyze turbines from the fluid flow in the blade path to start-up
transients and vibration problems. Also included were nuclear power plant
safety analysis, power plant transients, the effects of water hammer in piping
systems including two-phase flow and the entrainment of gases, and various
unique problems that he worked on at MPR.
On numerous occasions Giesecke participated with the investigation of
several major turbine failures including several that were catastrophic. In
conjunction with others at MPR and with instrumentation developed by GE-
LES, Giesecke was at the forefront of developing the techniques and
understanding currently used for on-line monitoring of turbine generators to
determine their torsional modes and frequencies. These techniques are now
being used by most OEMs to measure the torsional frequencies of turbine
generators.

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