1031 1192105937 02 202109 FGH ST Mad11 Tanacs For Cep - PDF 50996599 v1

MAD11 Vibration
Improvement Summary
Gabor Tanacs
Siemens Energy Customer Conference / September 2021
Siemens Energy is a trademark licensed by Siemens AG. Confidential © Siemens Energy, 2021
Table of Contents
 System Overview
 Fleet Operating Experience
 Root Cause Analysis
 Improvement Development
 Summary
Page 2 FGH Conference Confidential © Siemens Energy, 2021. All rights reserved. September 2021
SST-5000 and MAD11 Overview
MKD12
MAD13 MKD11
MAD12
MAD11
Bearing Systems Overview
Example KN Bearing System
 Shared bearing systems behave

differently than the legacy, two bearing MAD11 MAD12 MAD13
systems
• Bearing loading on the KN system is
less evenly distributed
• Bearing elevation changes can result 0.15 1.0 0.65
in loading changes across the turbine Normalized Bearing Loading

train Example Legacy Bearing System
• Alignment changes can act to further
change bearing loading
#1 #2 #3 #4
• Proper alignment and assembly is
important
0.63 0.75 1.0 1.0
MAD11 has increased sensitivity to inputs across the rotor train

Reported Fleet Statistics
 65+ KN units in the Americas
 Approximately 36% of units have reported MAD11 vibration above alarm to Siemens Energy at some point
 12% of units have recently reported MAD11 vibration near alarm
 Fleet MAD11 vibration behavior has typically included combinations of the following characteristics:
Unit A Unit B Unit C Unit D Unit E Unit H Unit I
All other ST bearings X  X X X  X
Mostly 1x    X  X 
Minimal effect on seismic vibration   X    
Inconsistent amplitude       
Inconsistent phase angle   X   ? 
Correlates with axial position    X  X 
Relates to shaft centerline changes  X X X  X ?
Relates to bearing metal temperature changes    X  X ?
Reacts to load changes       
Reacts to CT blending       
Reacts to PAG operations  ? ? ? ? ? ?
Reacts to CT duct fire   ? ? ? ? ?
Reacts to ambient temperature changes  ? X X X  ?
Reacts to unit restarts    X   
Reports
Page 5
have indicatedFGH
different
Conference
combinations of vibration characteristics where elevated vibration has been
Confidential © Siemens Energy, 2021. All rights reserved.
reported
September 2021
Reported Fleet Statistics
 65+ KN units in the Americas

 12% of units have recently reported MAD11 vibration near alarm
Unit A Unit B Unit C Unit D Unit E Unit F Unit G Unit H Unit I
MAD11 bearing alignment  ?       
MAD11 axial key wear  ?       
MAD11 seat / saddle wear  ?       
MAD11 bearing wear  ?   X ? ?  
Elevated vibration can result in wear to mating components and an increase in maintenance events
Root Cause Analysis
 RCA performed with fault tree method

 Eliminated branches
• Rubs
• Self-excitation
• Distorted rotor shape
• External forces
• Data accuracy
 Most probable contributors Refuted
• Support system flexibility Partial Contributor

Most Probable Contributor
• Dynamic characteristics of rotor train
Root Cause Analysis concluded

Root Cause Analysis Statement
The most probable root cause for the elevated MAD11 vibration reported on some KN units is
a decrease in bearing / pedestal stiffness due to misalignment and/or motion of the bearing in
the pedestal
Root Cause Analysis concluded

MAD11 Bearing / Pedestal Findings
 Recent MAD11 bearings / pedestal interfaces exhibit wear beyond expected amount based on running time
• Keys found with increased clearance
• Significant fretting on active keys and bearing / pedestal surface
• Significant fretting on bearing seat and saddle
Axial Key Wear Saddle Wear Seat Wear
Potential measures developed

Potential Measures
1. Updated assembly procedure 1, 2 3
 Reduce potential for misalignment of bearing seat in the saddle
2. Installation of axial keys with an interference fit (standard or hardened)
 Reduce potential for axial movement of bearing and wear on keys &
pedestal surfaces
3. Doweling of the bearing saddle to the pedestal
 Reduce potential for relative motion between saddle and pedestal
4. Replacement of spherical bearing seat and saddle with cylindrical
seat & saddle 4 5, 6
 Improve ease of alignment between bearing and pedestal
 Reduce potential for bearing tilting / misalignment
5. Replacement of vertical keys with cup springs keys*
 Additional vertical loading to reduce potential for bearing misalignment / motion
6. Bearing straps*
 Additional vertical loading to reduce potential for bearing misalignment / motion
* Either measure 5 or 6
Page 10
Refer to Product Bulletin PB3-20-0332-ST-EN-01 in full for details & recommendations
FGH Conference Confidential © Siemens Energy, 2021. All rights reserved. September 2021
Improvement Development
 Install axial keys with an interference fit intended to:
• Reduce potential for axial movement of bearing
 Hardened axial keys intended to:
• Reduce potential for wear on keys and pedestal
Axial Keys
 Dowel bearing saddle to pedestal intended to:
• Reduce potential for relative motion between saddle and pedestal
• Reduce potential for misalignment / motion of the bearing in the pedestal during operation
Saddle Dowels
 Replacement of “saddle” with cylindrical design intended to:
• Reduce potential for misalignment between bearing and pedestal at assembly
• Reduce potential for misalignment / motion of the bearing in the pedestal during operation
Cylindrical Cylindrical
Bearing Saddle Bearing Seat
 Replacement of vertical keys with cup-spring keys
• Additional vertical loading intended to reduce potential for misalignment / motion of the bearing in the
pedestal during operation
• Adapted from global application on MAD13 single shaft units
Vertical Keys
Position 1:
1 Bottom Part
Position 2:
1 Upper Part
Position 3:
6 Cup Springs
Position 4:
2 Washers
Position 6:
2 M5 Cylinder Screws
Position 7:
2 Bushings
 Replacement of vertical keys with bearing straps
• Additional vertical loading intended to reduce potential for misalignment / motion of the bearing in the
pedestal during operation
• Adapted for legacy solutions
Bearing Strap
Measure Implementation Experience
 Measures implemented in addition to proper bearing clearance, shaft train alignment and balancing
 1X vibration amplitudes below ISO 20816-2 A/B levels
Unit A Unit H Unit I

Measure 1   
Measure 4  
Measure 5 
Measure 6  
Favorable experience when addressing underlying conditions along with implementation of measures
Thank you!
Siemens Energy Customer Conference / September 2021
Siemens Energy is a trademark licensed by Siemens AG. Confidential © Siemens Energy, 2021

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MAD11 Vibration

 Fleet Operating Experience

 Root Cause Analysis

 Shared bearing systems behave

in loading changes across the turbine Normalized Bearing Loading

0.63 0.75 1.0 1.0

MAD11 has increased sensitivity to inputs across the rotor train

 65+ KN units in the Americas

Unit A Unit B Unit C Unit D Unit E Unit F Unit G Unit H Unit I

MAD11 bearing alignment  ?       

MAD11 axial key wear  ?       

MAD11 seat / saddle wear  ?       

MAD11 bearing wear  ?   X ? ?  

 RCA performed with fault tree method

• Support system flexibility Partial Contributor

Root Cause Analysis concluded

Root Cause Analysis concluded

Axial Key Wear Saddle Wear Seat Wear

Potential measures developed

Unit A Unit H Unit I

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