October 2004

Steam Turbine Vibration

Characteristics
Mike McGuire
 Works Assembly of 1130 MW
HP Turbine

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 LP Rotor

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 Introduction

z Avoidance of damaging vibration essential for long

term plant reliability
z Comprehensive dynamic analysis tools used at
design stage to assess:
– Shaft vibration
– Blading Integrity
z Assessment tools utilise modern analytical techniques
which have been validated by well established
feedback from service experience and test rigs
z Ensure that new designs are developed with
confidence and without risk

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 z Shaft Vibration

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 Shaft Vibration

z Comprehensive shaft line analysis performed

– rotor (inertia & stiffness)
– bearing oil films (stiffness & damping)
– pedestal/foundation (mass, stiffness & damping)
– blading & seals (steam excitation & damping)
– excitation (unbalance, concentricity errors, rotor
asymmetry)
z Steady state response (synchronous) - unbalance
z Stability assessment (sub-synchronous) - oil/steam whirl
z Acceptance criteria based on detailed R&D programmes
and well established practical experience
z Results in low levels of vibration which are continuously
monitored

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 Dynamic Modelling of Rotor Line

ROTORS
BEARINGS
PEDESTALS

FOUNDATION

z Rotor and oil films most important elements

z Design guidelines ensure that same rotor line
operates successfully on different foundations

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 Bearing Oil Films
8 dynamic coefficients:

⎛ Fx ⎞ W ⎛ a xx a xy ⎞ ⎛ x ⎞ W ⎛ b xx b xy ⎞ ⎛ x& ⎞
⎜⎜ ⎟⎟ = ⎜ ⎟ ⎜⎜ ⎟⎟ + ⎜ ⎟ ⎜⎜ ⎟⎟
⎜a a yy ⎟⎠ ⎝ y ⎠ Ω Cr ⎜b b yy ⎟⎠ ⎝ y& ⎠
⎝ Fy ⎠ C r ⎝ yx ⎝ yx

– anisotropic
– coupling between horizontal and vertical vibration
– provide stiffness and substantial damping
– coefficients influenced by bearing type (fixed arc, tilting
pad), geometry (length, diameter, clearance), steady
load, speed, lubricant properties (viscosity)
– derived from thermo-hydrodynamic analysis for both
ALSTOM and third party bearings
– can induce self excited vibration (oil whirl)

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 Steady State Response

z Vibration response to unbalance

z Non dimensional response calculated for
different modal unbalance cases, e.g.
– Centre span excitation for first mode
– Couple excitation for second mode
z Assessment made at ‘critical speeds’ and normal
operating speed using established guidelines
z Each rotor high speed balanced in factory to long
established criteria (ref: ISO 11342)
z In service vibration meets international standards
(ref: ISO 7919-2 & ISO 10816-2)

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 Shaft Line Stability

z Sub synchronous bearing instability

phenomenon well known for many
years (oil whirl/whip)
z Steam whirl phenomenon emerged from 1960’s onwards as unit
outputs and steam conditions increased
z Significant experimental and theoretical work carried out for
steam turbines in UK, USA and Europe during 1970’s (Benckert,
Slocombe/C.E.G.B.)
z Analysis methods initially developed based on previously
established theory for compressors (e.g. Wyssmann)
z Increasing use of modern aerodynamic analysis methods for
assessment of steam excitation forces

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 Factors Influencing Stability

z Rotor mass and stiffness - ‘critical speed’

z Oil film characteristics - bearing type

z Bearing support stiffness

z Steam Excitation - ‘steam whirl’

– Steam density - HP/Supercritical most susceptible
– Tip seals and shaft glands
> Thomas effect (Tip seals only)
> Influence of inlet swirl (Tip seals & shaft glands)

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 Steam Excitation: Thomas Effect
Variations in blade force

Tip leakage

Blading force

Net destabilising
force….

... system rotates

causing Whirl

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 z Steam Excitation: Influence of Swirl

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 Steam Excitation: Influence of Swirl
B
P(A) > P(B) Inlet Point P(B)
P out

B
Steam Swirl

A Destabilising B
Outlet Point Force… Outlet Point

... rotor moves

to close clearance…
A

P(A)
P in
A ... system rotates
Inlet Point causing Whirl
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 z Swirl Breaks

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 Swirl Breaks
High exit steam swirl (circumferential velocity)
from fixed blades

Swirl Breaks reduce circumferential

velocity thus reduce the destabilising
force

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 Tip Seal with Swirl Breaks

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 Diaphragm Gland Segment
Inlet Swirl Breaks

zUsed successfully
on a UK 500MW
turbine (1980’s)
Tested efficiency :
75%
(removes 75% of
inlet swirl)

33% of tip seal effectiveness

10% of power loss

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 Stability Analysis Process

z Full shaft line stability analysis carried out to establish datum

case in absence of steam excitation
– shaft line stable to maximum overspeed (i.e. no oil whirl)
z Complete audit of steam excitation forces carried out
– shaft/diaphragm glands & blade tip seals
z Influence of steam excitation on rotor stability assessed
z If lower limit stability criterion not satisfied at full load rotor
geometry and/or bearing oil films improved.
z If necessary steam excitation forces reduced by use of swirl
breaks
– shaft/diaphragm glands and/or tip seals
z Full shaft line stability analysis repeated
z Conservative approach applied for third party retrofits

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 Shaft Vibration - Summary

z Comprehensive rotordynamics analysis assesses both steady

state response and stability
z Acceptance criteria based on detailed R&D programmes and
long established practical experience
z Complete audit of steam forces carried out
z If necessary, steam excitation forces reduced by use of swirl
breaks
z Swirl break behaviour validated by comprehensive test
programme
z Proven operational experience with standard sealing
arrangements
z Low levels of vibration in service

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 z Torsional Vibration

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 Torsional Vibration

z Low Damping ( Damping Factor D ≈ 0.001) with high resonance

amplification factors ( >100 ) - no influence from bearings or supports
z During normal resonance free operation very small vibration amplitudes
(< 0.1 °)
z Torsional excitation due to the electrical system
z Short term transient disturbances (e.g. mal-synchronisation, line to line
fault) can induce transient torques ~6-8 times normal full load torque
z Long term disturbances of electrical system frequency - negative
sequence current - due to unbalanced phases or interactions with long
transmission lines.
z Frequencies tuned to avoid first two harmonics of electrical system
frequency (e.g. 50/60 & 100/120 Hz)
z Potential excitation of coupled blade/rotor modes
z Excitation magnitude dependent on generator mode shape

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 Torsional Vibration

2 x Grid Frequency
at Generator Rotor
Exciter

Transformer

Required Conditions for Failure

z Excitation from the electrical Grid High-
Voltage Bus
due to non-symmetrical electrical loading
e.g. Steel Industry, Aluminium Production, ...
z Torsional natural Frequency close to 100/120 Hz R S T -
Lines
z Coupled Mode Shape Shaft / Blade
to the Consumer

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 Torsional Vibration Summary

z Conservative design criteria adopted to avoid resonance at

1x & 2x electrical system frequency
z Coupled blade/rotor modes fully assessed
z Low interaction between blades and welded drum type LP
rotors
z Accuracy of analysis confirmed by experimental validation
z Routine in situ validation unnecessary - if confirmation is
required this can be achieved with confidence in factory
spin pit
z Good Experience with new machines and LP-Retrofits
(Zion 1 & 2, Indian Point 3, Maanshan 1 & 2, Kori 1-4, San
Onofre . . . . . .) - no adverse experience

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