PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085

565 402)
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1
COMMON SENSE VIBRATION ANALYSIS
Turbine Generator Set
Sumatra, Indonesia
Matthew Fallow
Asset Reliability Services Pty Limited
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
www.asset.au.com
2
Background
This Generator Set has had various vibration studies carried out
during 1988 (commissioning),1996 (o/h) and 2003 (o/h) to
investigate high Axial vibration at the Generator NDE bearing
location. We reviewed these reports to assist us in our analysis.
Some $1 Million USD has been spent on the generator and turbine
in an attempt to resolve this issue.
Our data collection was carried out using relative bearing casing
measurements only.
Horizontal
Axial
Vertical
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Observations:
Data below is typical of the Generator NDE bearing axial casing
vibration at 21MW load, in fact vibration amplitude varied little
between observed 13 to 21MW load changes during our testing.
This can be seen below where the highest vibration amplitudes
recorded where at 2 times generator shaft speed.
tb - Turbine post bracing
291T 04 -G2A Generator NDE Outboard Axial
Route Spectrum
23-Jun-04 16:54:54
OVERALL= 3.83 V-DG
PK = 3.80
LOAD = 70.0
RPM = 3021.
RPS = 50.35
0 10000 20000 30000 40000
0
3
6
9
12
15
Frequency in CPM
PK Velocity in mm/Sec
3020.7
6041.9
6608.3
7168.7
12083.0
Freq:
Ordr:
Spec:
7031.3
2.327
.07070
Vibration after bracing - Resonance partly 'de tuned'
2x vibration now typ. 1.1 to 2.5mm/s
The revelation!!
Amplitudes are extremely high for this machine type,
vibration is highly directional – Suspect Resonance
tb - Turbine resonance
291T 004 -G2A Generator NDE Outboard Axial
Route Spectrum
23-Jun-04 12:36:22
OVERALL= 15.14 V-DG
PK = 15.12
LOAD = 70.0
RPM = 3019.
RPS = 50.32
0 10000 20000 30000 40000 50000
0
3
6
9
12
15
18
Frequency in CPM
PK Velocity in mm/Sec
392.46
3018.9
6038.7
9059.0
12076.6
Freq:
Ordr:
Spec:
12844.
4.254
.00331
2x shaft speed. Typ. between 14 to 17mm/s rms
Suspected Resonance prior to bracing
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Our work-scope – approach taken
1. Data: Take basic machine FFT Vibration data to view high
vibration, review past reports. Use hands on practical
approach.
2. Data: Establish highest point of suspected
vibration/resonance on Generator NDE
3. Test Theory: Add temporary stiffness (to change pedestal
natural frequency to prove resonance theory
4. Confirmation: Using a phase trigger, construct a “bubble”
diagram of machine relative phase and vibration amplitude
modes (relative motion). This was to determine relative
vibration mode of the Generator and Turbine, and bearing
casings relative to one another.
5. Confirmation: Carry out an on-line “Bump Test” to identify
Generator NDE bearing pedestal Natural Frequencies under
these conditions. Use a “Negative Averaging” technique to
resolve bump test data from the machine operating vibration.
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Identify Resonance anti-node:
Using a simple live FFT plot with 2x shaft speed identified, we took
‘clock face’ readings around the Generator NDE bearing pedestal
and housing to identify the suspected resonance anti-node from
the simple standing wave of vibration observed.
To prove the resonance theory a simple timber brace was added
at the anti-node (the most effective point to change natural
frequency and add stiffness).
Only a light load was applied (approx 1kg) in the direction of
suspected resonance (axial) initially using a hardwood brace(s),
vibration reduced from 17mm/s rms to as low as 1.6mm/s rms.
This would indicate that a resonant condition does exist when
generator is on load. Eventually after some testing, a simple M20
stud and nuts were used on one side of pedestal only, to good
effect. This and the orientation can be seen below.
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
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Bubble Diagrams: Relative Motion.
After interpreting the relative motion plots for 1x and 2x shaft speed, it is
apparent that the Turbine to Generator and each machines own bearing
relative shaking modes are not consistent with any unbalnce or misalignment
condition (phase anomlaies from resonance can mask misalignment etc).
‘End to end’ and ‘horizontal to verticle’ shaking modes are not consistent with
expected phase relationships for ‘normal’ machine behaviour, amplitude ratios
in the same planes are also erroneous. Likely sources of this relative motion
are usually ‘mechanical looseness’ or ‘resonance’, both of which can cause
phase anomalies. Given this, and that vibration is highly directional, we
suspected resonance.
Note that after a resonant condition root cause has been recitified, then a new
bubble diagram to identify machine relative motion should be carried out to
ensure a second mechanical problem is not present.
Relative Motion Data: from casing
Generator Turbine
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Bump Test:
A bump test was carried out (whilst machine was operating) to
identify Generator NDE bearing pedestal Natural Frequency under
loaded operating conditions. We used a FFT Spectrum Analyser
and a “Negative Averaging” technique to resolve bump test data
from machine operating vibration data. We also carried out the
same test with no ‘bump’ as a ‘control’ to ensure we had valid data
and the technique was successful.
The data below indicates a natural frequency response (the
quality/amplitude of which is not known due to test type) at approx
6150cpm/102.5hz when machine is loaded at 20MW.
tb - Turbine spare
spare -G2A Generator NDE Outboard Axial
ANALYZE SPECTRU
23-Jun-04 12:46:39
PK = 2.17
LOAD = 70.0
RPM = 3000.
RPS = 50.00
0 3000 6000 9000 12000
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Frequency in CPM
PK Velocity in mm/Sec
Natural Frequency at approx 6150cpm
Generator NDE. Energised at 21Mw
Natural Frequency at approx 6150cpm
ANALYZE WAVEFOR
23-Jun-04 12:46:39
RMS = 1.16
PK(+) = 3.17
PK(-) = 3.02
CRESTF= 2.92
2800 2900 3000 3100 3200 3300 3400 3500
-3
-2
-1
0
1
2
3
Time in mSecs
Acceleration in G-s
ALERT
ALERT
FAULT
FAULT
Time:
Ampl:
Dtim:
Freq:
2875.0
1.447
228.52
4.376
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Next, a second bump test was carried out under load (14MW) with
brace/bolt fitted, this can be seen in the plot below. As can be seen
below the natural frequencies now present are quite different. The
natural frequency at 6150cpm is no longer present (and has
increased to approx 7029cpm) and would indicate that the
stiffening of the pedestal has moved the structure out of resonance
to a stable vibration level of 1.625mm/s at a load of 14 to 21MW.
It was noted that if we applied too much force (although a very low
force was only ever used) when adding stiffness, the vibration
went up by approximately 4mm/s rms, this is likely to be the result
of the 5713cpm frequency seen in the bump test increasing in
frequency as more stiffness was added, therefore putting the
machine into another resonance mode.
tb - Turbine spare
spare -G2A Generator NDE Outboard Axial
Analyze Spectrum
24-Jun-04 16:54:02
PK = 1.58
LOAD = 58.0
RPM = 3000.
RPS = 50.00
0 3000 6000 9000 12000
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Frequency in CPM
PK Velocity in mm/Sec
5713.1
7029.7
6000.0
Freq:
Ordr:
Spec:
4815.0
1.605
.00000
Bump test with brace fitted 17MW
previous nat freq @ 6150 now 7029, this why vibration is low
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Vibration After Stiffening Pedestal:
Turbine was run at typical operating parameters, initially at 13MW
and finally at 20MW, the results are plotted below.
As we can see above, vibration is now at approximately
1.625mm/s. This is significantly lower than the up to 24mm/s rms
experienced and better than the 1988 start-up vibration of
approximately 4.5mm/s rms.
tb - Turbine post bracing
291T 04 -G2A Generator NDE Outboard Axial
Route Spectrum
24-Jun-04 18:21:03
OVERALL= 2.42 V-D
RMS = 2.41
LOAD = 70.0
RPM = 3026.
RPS = 50.43
0 5000 10000 15000 20000
0
0.4
0.8
1.2
1.6
2.0
2.4
Frequency in CPM
RMS Velocity in mm/Sec
Freq:
Ordr:
Spec:
18188.
6.010
.01269
2x shaft speed @ 1.625mm/s
1x
Generator NDE Axial Casing Vibration @ 13MW
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Conclusions:
It appears that the bearing pedestal has had some resonant issues
since commissioning in 1988 (based on relatively high directional
vibration levels from O.E.M report). There was a step change in
vibration as reported by engineering staff post 1996 O/H. It is
therefore important that some basic tests be carried out to further
establish machine behavior and determine if the bearing pedestal
(natural frequency) or the Generator (100hz forcing frequency) is
the root cause. I.e. overhaul induced a 100hz vibration.
Actions recommended:
1. Bump test Generator pedestal bearing with and without fields
excited. This will help determine the conditions under which
the resonance (natural frequency) is present and assist in
the root cause identification. Will also assist in determining
the electrical effect on pedestal natural frequency. Stiffener
removed.
2. Bump test Generator pedestal bearing with machine shut
down and oil on. Stiffener removed.
3. Fit any bracing required to replace the ‘bolt’ now in place.
4. Take live phase data whilst fitting the brace with machine
fields excited under load. Look for phase shift to further
prove resonance and any solution (bracing) fitted.
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Report from site visit during May 2005 Shutdown
Background
Since the last site visit this Generator has run successfully at up to 24MW with
vibration being recorded by site Condition Monitoring staff as satisfactory
whilst the damping bolt is fitted.
During this site visit the scope of work was to carry out further tests to
prove the resonance theory and fit a permanent solution to the damping
bolt whilst maintaining access to bearing pedestal.
Observations:
Generator 17MW Load: NO damping bolt fitted
High vibration in axial plane up to 17mm/s at 6000cpm. Data June 2004
tb - Turbine resonance
291T 004 -G2A Generator NDE Outboard Axial
Route Spectrum
23-Jun-04 12:36:22
OVERALL= 15.14 V-DG
PK = 15.12
LOAD = 70.0
RPM = 3019.
RPS = 50.32
0 10000 20000 30000 40000 50000
0
3
6
9
12
15
18
Frequency in CPM
PK Velocity in mm/Sec
392.46
3018.9
6038.7
9059.0
12076.6
Freq:
Ordr:
Spec:
12844.
4.254
.00331
2x shaft speed. Typ. between 14 to 17mm/s rms
Suspected Resonance prior to bracing
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Generator 20MW Load: M20 damping bolt fitted
High vibration in axial plane reduced to 1.6mm/s at 6000cpm. Data
June 2004
tb - Turbine post bracing
291T 04 -G2A Generator NDE Outboard Axial
Route Spectrum
24-Jun-04 18:21:03
OVERALL= 2.42 V-DG
RMS = 2.41
LOAD = 70.0
RPM = 3026.
RPS = 50.43
0 5000 10000 15000 20000
0
0.4
0.8
1.2
1.6
2.0
2.4
Frequency in CPM
RMS Velocity in mm/Sec
Freq:
Ordr:
Spec:
18188.
6.010
.01269
2x shaft speed @ 1.625mm/s
1x
Generator NDE Axial Casing Vibration @ 13MW
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Generator No Load, No field excitation: NO damping bolt fitted
Vibration data was taken on generator NDE bearing casing in the
axial plane, satisfactory data was recorded. In fact with the
damping bolt removed from the NDE bearing, vibration data
changed little in amplitude indicating that the bearing is not in a
resonant mode when there is no field excitation and or a forcing
frequency is absent.
6000cpm data now at 0.78 mm/s
tb - Turbine resonance new
291T new -G2A Generator NDE Outboard Axial
Route Spectrum
09-May-05 12:51:46
OVERALL= 1.48 V-DG
RMS = 1.47
LOAD = .0
RPM = 3000.
RPS = 50.00
0 3000 6000 9000 12000 15000
0
0.3
0.6
0.9
1.2
1.5
Frequency in CPM
RMS Velocity in mm/Sec
3020.2
6040.3
9060.5
12080.6
Freq:
Ordr:
Spec:
6000.0
2.000
.781
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565 402)
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Natural frequency ‘Bump’ test On-line: 3000rpm: No field
excitation, no load, no damping bolt
We then carried out an on-line bump test to determine if the
resonance issue is present at no load. The bearing natural
frequency (6150cpm) and resonance observed when machine is
under load was not present in the bump test with no field
excitation.
Phase Shift:
To gather further data to ensure the bracket is a more permanent
solution and resonance a major contributing force to the vibration
at 6000cpm we carried out a simple phase test on the NDE
Generator bearing in the axial plane.
Whilst the Generator was running at 7MW and temporary damping
bolt was fitted we measured the phase angle of the 6000cpm
vibration, we then removed the bolt and observed a change of
some 90 degrees in the phase angle with a corresponding
increase in vibration. We also measured the phase angle of the
6000cpm component with no temporary bolt and the generator
fields ‘excited’ and ‘non excited’ and also observed a phase shift of
approximately 90 degrees (136deg to 41deg)
The above observations would indicate that when the generator is
on-load and fields excited this effects the damping of the NDE
bearing changing it’s natural frequency and inducing a resonant
condition as observed in the vibration data..
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Generator 7.1MW Load: New Bracket fitted
At 7.1MW the 6000cpm component in the axial plane reduced considerably to less t
han
0.1mm/s. Previously this had been up to 14mm/s at this load and some 17mm/s at h
igher
loads.
PO BOX 3090, DURAL NSW 2158 PHONE: 612-9651-6444 FAX: 612-9651-6411 (ABN: 17 085
565 402)
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Generator 17MW Load: New Bracket fitted
At 17MW the 6000cpm component in the axial plane was recorded at 0.76mm/s. Down
from
17mm/s.
tb - OFF ROUTE MACHINE
OFF ROUTE -ORP OFF ROUTE MEASUREMENT POINT DATA
Label: SGPLOAD1 -14 /
Route Spectrum
22-May-05 11:51:04
OVERALL= 1.31 V-AN
RMS = 1.23
LOAD = 100.0
RPM = 3000.
RPS = 50.00
0 3000 6000 9000 12000
0
0.3
0.6
0.9
1.2
Frequency in CPM
RMS Velocity in mm/Sec
3008.2
6016.4
9024.6 Freq:
Ordr:
Spec:
6015.0
2.005
.750
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Bracket fitting Procedure:
The new bracket was fitted by first applying a light force with the
bolt at the “10 o’clock” position whilst monitoring vibration for the
lowest level @ 6000cpm, therefore looking for a reduction in
resonant vibration. Then the bolt at the “12 o’clock” position was
tightened until a further reduction in vibration was achieved
10 o’clock
12 o’clock
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565 402)
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Conclusion:
Given that we were able to prove a resonant condition exists when
the fields are excited the permanent brace was fitted and tuned
with good results, similar to those achieved with the temporary
solution.
The remaining vibration in the Generator at 6000cpm, is likely to
be sourced from an electrical issue induced at the last major
overhaul, this is not an uncommon occurrence. Whilst the
Generators are robust machines and often run in this manner, it
would be good maintenance practice to eliminate this issue
(6000cpm forcing frequency) as unwanted forces are placed on
insulating systems.