Introduction to Rotor Dynamics Analysis as API

Standard related to Centrifugal Machines -Part IV-

Overview of API RP684 - Torsional Analysis
 Published on November 21, 2019

Mahendra Prabhu SUBRAMANI.,CEng (U.K) MIMechE

Rotating Equipment Engineer at Saipem SA, France through Titan Engineering

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In the rotating machine trains driver and driven are connected by multiple elements like coupling and gears. The
torsional analysis of the complete train is important to ensure the reliable operation of the machine train. Like
the lateral analysis the torsional analysis and behavior of the machine depends on the two parameters mainly
force and stiffness but here it is called torque and torsional stiffness. The small various in the torque and
stiffness can excite the rotor and cause torsional vibration. The objective of the torsional analysis is to find out
the torsional natural frequency and find out the ways to damp the system.

The torsional analysis is very critical for the large rotating machines which has gearbox of very high rating ,
driven by large induction , Synchronous motor and Synchronous generators. These are very sensitive to the line
frequency ranges , synchronization to the electrical grid in the case of generators. The small variation in the
torque due usually in the order of 0.5% to 1% of the rated torque can create significant torsional excitation. The
torque variation may be due to any some reasons like the variation in line frequency, slip in the synchronous
motors, improper synchronization with the grid in the case of synchronous generators and short circuit in the
induction , synchronous motor winds , surge flow rate in case of centrifugal compressor, stall conditions.

The different short circuit cases which cause the transient vibration are Three phase short circuit, Two phase
Short Circuit, Single phase, Three phase to ground and Two phase to ground. Among the above the Three phase
short circuit can be identified if the torsional frequency is one or times the line frequency. And it produces the
maximum electro magnetic torque. All other short circuit cases occur in one time the line frequency.

Unlike lateral analysis the torsional analysis is simple but has its own challenges. Because the stiffness of the
support system like bearing and foundation does not influence the torsional frequency. Hence the stiffness
calculations are very simple. But challenge here is calculating the effective combined stiffness of the system.
The basis for torsional analysis and calculation of torque variation and deflection is the torsion equation (Please
refer below). The torsional analysis shall be performed from 0 to 125% of the rotor speed of two times the
electrical line frequency which ever is higher.
The calculation of the torque variation with two for two mass system is given below.
The torsional stiffness properties various with temperature. Experience from the researchers and suppliers
indicates that material properties at the temperature difference and influence of the same on the torsional
stiffness values can create significant differences in the calculated undamped torsional natural frequencies. Care
should be taken care about this point during the analysis.

The care should be taken care in modelling the rotor system to perform torsional analysis such as Speed
referencing inertia (Ip) and Stiffness (Kt) , Step shafting, shrink fits , integral disks or hubs , Couplings. The
important points to be taken care about all the above points and in its significance on the outcome of analysis
are described in detail in the respective sections of API RP 684 in Chapter 4 and associated reference
publications.

The first output from the torsional analysis is the undamped torsional natural frequencies of the system. The two
outputs are campbell diagram and train torsional mode shape. The campbell diagram is the lot between the
Torsional Natural Frequency Vs Operating speed. The constant frequency excitation is presented as horizontal
line , variable frequency excitation as sloped line in campbell diagram. The typical diagram is shown below.
If the margin between the torsional natural frequency and operating speed is more than 10% the further analysis
is not required. If not the damped natural frequency analysis and High cycle fatigue analysis are required to
compare the induced stress is with in the allowable limits of the good man diagram.

The train mode shapes are plot between the relative angular deflection versus the axial distance along the
coupled rotor. This plot gives the idea of where the additional inertia or flexibility can be added to modify the
torsional natural frequency of the system. Also it gives an idea that system is sensitive to Inertia or sensitive to
flexibility. The sample mode shape plot from API RP 684 is shown below.
There are two approaches defined in the Standard to modify the torsional natural frequency of the system. One
is strain energy principle and the other one is kinetic energy principle. The formula's for calculating the strain
energy and kinetic energy , changes in natural frequency with respect to strain, kinetic energy are given below.
The transient torsional study is important in case of machine driven by the large induction and synchronous
motors, generators. Because it is required to define the fatigue life and load cyclic limitation which is the basis
for defining the no.of. starts. As per API 541 standard the no.of . started required is 5000 times in the span of 20
years of life time. It is not possible / required in all cases. Putting this requirement on some cases may require a
significant redesign of rotor and consequently complete machine. The main outputs of the transient analysis are
a) The maximum vibratory torque response and b) Maximum alternating shear stress in shaft. This is used to
define the no.of .starts during the life time of the machine.

The torque limiting devices ,couplings shall be used to avoid torque transmission due to transient conditions.
And circuit breakers in switch board shall be designed to disconnect the machine to prevent the torque
transmission due to electrical faults, premature closure in case of faults.