Dynamics of Rotating machinery with Emphasis on Balancing P.

Muthu Technical Services- PSSR Bharat Heavy Electricals Limited

Dynamics of Rotating machinery with Case studies

Balancing fundamentals Critical Speeds and vibratory Modes- How to identify and understand its significance. Slow Roll and Bow shaft -Rotor dynamic perspective. Damping Bearings and support structures Foundations Case Studies

F=m*r*2

A disk with a mass M having an Unbalance weight m at a position r from its center. This unbalance causes an eccentric center of gravity e and results in a centrifugal force P when the disk is rotated at an angular speed

Centrifugal Force F=mr2 is angular velocity = 2n/60

P is in Newtons

The centrifugal force P changes its direction as the rotor rotates, which repeatedly acts on the bearing portion and so causes vibration of the whole machine.

Expression of unbalance Rotor Unbalance should not represented by Centrifugal force F since F changes as speed changes Unbalance U is represented by U=mr

m : mass of unbalance

r:

radius of unbalance

Dimension of unbalance gmm

Quality of Rotor Balance : ratio of unbalance U to rotor mass M

e=U/M=mr/M Here e is a vector having a dimension of length which is given as m where m is expressed in [g], r in [mm] and M in [kg] e is (eccentricity) of the center of gravity of the rotor.

Static unbalance

Single Plane balancing applied to thin disc shaped rotors

Dynamic Unbalance

Unbalances U1,U2 and U3 distributed on a rotor which is long in the axial direction can be substituted by two independent Unbalance vectors Ua and Ub on correction planes A and B respectively

Multi Plane balancing of flexible rotors

Balancing -First order mode is carried out on three correction planes Balancing -Second order mode is carried out on four correction planes Rotors become flexible when speed is increased The boundary speed which separates the rigid rotor and the flexible rotor is called the critical speed. The number of additional correction planes necessary for eliminating deformation of a rotor is the same as the order of the critical speed. Three correction planes eliminating rotor deformation up to first-order critical speed Four correction planes eliminating deformation up to second-order critical speed.

Accuracy of balancing

Balancing to the achievable limit is uneconomical

Specific unbalance (e [m]) expresses the unbalance state of a rotor independently of its mass and shape. Value of e is in inverse proportion to the maximum working revolution speed N [min-1] of the rotor, which means that eN is a constant value. (ISO) defines the product of specific unbalance and revolution speed as the balance quality. The balance quality has a dimension of [mm/s] because the dimensions of revolution speed and specific unbalance are [rad/s] and [mm] respectively. The grade of the balance quality is expressed by putting a letter G before a number which represents eN.

Procedure of determining allowable unbalance Rotor speed N , Position of rotor bearings Mass of the rotor m Position of correction planes

Set the grade of balance quality according to the type of the rotor. Find allowable residual specific unbalance eper from rotor speed Use equation or from diagram

Balance Quality = e*w

Calculate the allowable residual unbalance from the allowable residual specific unbalance and mass of the rotor: Allowable residual unbalance Uper = E
per*

M(gmm)

Allocate the allowable residual unbalance to unbalances on each actual correction plane.

G6.3 6.3

Machines for processing plants Turbine blades for main engines of merchant ships Drums for centrifugal separators Paper-making rolls and printing rolls Fans Completed gas turbine rotors for airplanes Flywheels Impellers of pumps Parts of machine tools and general machinery Medium- and large-sized armatures having no specific requirements for electric motors with axial center height of 80mm or more Small-sized armatures (mainly mass-production type) either for use being insensitive to vibration or for use with insulation against vibration Engine parts having specific requirements
Gas turbines, steam turbines and main engine turbines for merchant ships Rigid rotors for turbo generators Storage drums and disk turbo compressors for computers Main spindles for machine tools Medium- and large-sized armatures having specific requirements Small-sized armatures (excluding those defined in G6.3 and G1) Turbine-driven pumps,

G2.5 2.5

Mechanisms resulting in Syncronous 1X vibration other than unbalance Excessive Bearing Clearance Bent Shaft Misalignment or other Preload Electrical Influence Compliant Support or Foundation Soft Foot

CROSS SECTIONAL ARRANGEMENT SEIMENS TURBINE

VIBRATION MEASURING TRANSDUCERS

SHAFT VIBRATION - PROXIMITY PROBE BEARING VIBRATION -VELOCITY PICK UP , ACCELEROMETER
PHASE -OPTICAL PROBE , EDDY CURRENT PROBE

RECOMMENDED LOCATIONS OF VIBRATION MEASUREMENTS FOR PEDESTAL BEARINGS (AS PER ISO)

RECOMMENDED LOCATIONS OF VIBRATION MEASUREMENTS FOR HOUSING TYPE BEARINGS (AS PER ISO)

Measuring Amplifier Proximity Pick-up

45O

45O

SHAFT

RECOMMENDED LOCATIONS OF SHAFT VIBRATION MEASUREMENTS AS PER ISO

PROXIMITY PROBE & ACCELEROMETER

Natural Frequency The frequency of free vibration of a system. The frequency at which an undamped system with a single degree of freedom will oscillate upon momentary displacement from its rest position. Resonance Resonance is the condition which occurs when such forcing frequencies do in fact coincide with one or more natural frequencies. These may be a natural frequencies of the rotor, but often can be a natural frequency of the support frame, foundation . Forcing frequencies include those from sources such as unbalance, misalignment, looseness, bearing defects, gear defects, belt wear, etc.

Critical speed Critical speeds are a special case of resonance in which the vibrating forces are caused by the rotation of the rotor

Kayamkulam CCPP I ,115 MW

Generator Front Vertical Coast up , Before Balancing
360 300 240 180 120 60 0 0 90 80 70 60 50 40 30 20 10 0 0 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300 RPM 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300

Kayamkulam CCPP I , 115 MW Generator Rear Vertical Coast up , Before Balancing

360 300 240 180 120 60 0 0 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300

80 70 60 50 40 30 20 10 0 0 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300 RPM

ROTOR AND BALANCE FORCE DETAILS GENERATOR ROTOR WEIGHT : 37000 KG GENERATOR ROTOR STATIC WEIGHT PER BEARING : 18500 KG BALANCING RADIUS FAN PLANE : 310 MM RETAINING RING PLANE : 460 MM DISTANCE BETWEEN RETAINING RING PLANE : 4850 MM DISTANCE BETWEEN FAN PLANE : 5740 MM APPROXIMATE WEIGHT OF TRIAL WEIGHT : 93 GRAM CENTRIFUGAL FORCE FOR 93 GRAMS AT BALANCE RADIUS AT 3000 RPM , FORCE UNITS : 430 KG RETAINING RING PLANE

Kayamkulam CCPP I , 115 MW Generator Rear Vertical Coast up

with 5x93 grams Couple correction weights
360 300 240 180 120 60 0 0 80 70 60 50 40 30 20 10 0 0 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300 RPM 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300

GENERATOR FAN BLADES-BALANCING PLANE

Dynamics of Rotating machinery

Critical Speeds are dependent upon:

Rotor Flexibility - Mass and Stiffness ( D-dia of rotor, L- Bearing Span) Support Stiffness which also includes the foundation stiffness. The damping from the bearings dictates the amplification factor

To Summarize on critical speeds

It is always due to synchronous excitation. Critical speeds in horizontal and vertical direction called as horizontal and vertical Modes depend on stiffness in those directions. Horizontal mode is predominantly effects the vibration in horizontal direction and so in case of vertical mode. Can be measured by seismic in that direction only. Since we also measure shaft vibrations at 45 deg so it is measuring both.

Let us understand the vibratory modes.

The modes below the first flexural critical speed are called as rigid modes. Rigid modes are bouncing or translatory have same phase on both bearings while in conical modes the phase is 180 deg. In bending modes also the phase relationship in first and second modes is similar. We need to study the phase angle vis a vis the design critical speed in overhung modes.

Rocking mode

Conical mode
First bending mode

Second bending mode

Overhungcantilever bending mode

A typical shaft bow Bodes Plot of a 120 MW generator.

Turbo machinery damping

Viscous damping Proportional to velocity

Bearings and Oil seals of large rotating machinery damping provided by lubricating oil

Rotor system process fluids

Pumps significant
Gas turbines, Centrifugal compressors insignificant

Turbo machinery damping

Coulomb damping Sliding friction rub Coulomb friction force is constant , depends on

1. Nature of sliding surfaces and

2. Perpendicular pressure between surfaces

Turbo machinery damping

Structural damping Internal friction in material due to vibratory stress and strain Proportional to maximum stress and therefore deflections Independent of frequency vibratory stress Rotating machinery small compared to viscous damping

Hydrodynamic bearings
One of the basic purposes of a bearing is to provide a frictionless environment to support and guide a rotating shaft. Industrial machinery with high horsepower and high loads, such as steam turbines, centrifugal compressors, pumps and motors, utilize journal bearings as rotor supports.

TO Develop Hydro Dynamic Pressures the following three parameters are required : 1) Load, 2) Speed and 3) Oil Wedge

Hydrodynamic principles, which are active as the shaft rotates, create an oil wedge that supports the shaft and relocates it within the bearing clearances. Hydrodynamic bearings have relatively a low frictional resistance to turning but more importantly provide viscous damping to reduce lateral vibrations.

All heavy industrial turbo-machines use fluid film journal bearings of some type :
To support the shaft weight To control the motions caused by I) unbalanced forces

II) aerodynamic forces

III) external excitations from seals and couplings.

 The damping is very important in many types of rotating machines where the fluid film bearings are often the primary source of the energy absorption needed to control vibrations. Fluid film journal bearings also play a major role in determining rotor dynamic stability, making their careful selection and application a crucial step in the development of superior rotor-bearings systems.

Journal bearings have many differing designs to compensate for differing load requirements, machine speeds, cost, or dynamic properties.
Cylindrical Journal Bearings with & without oil rings . Multi lobe Journal Bearings:

2 Lobe , 2 Lobe with loading arc, 2 Lobe Offset

& 4 Lobe type

Tilting Pad Journal Bearings

4 Pad and 5 Pad type

CAPACITY OF HYDRODYNAMIC BEARINGS

Under operation, the capacity of hydrodynamic bearings is restricted by: Minimum oil film thickness & Babbitt temperature. The critical limit for low-speed operation is minimum oil film thickness. In high-speed operation, babbitt temperature is usually the limiting criteria.

FLUID FILM JOURNAL BEARINGS

HIGH SPEED

SLOW SPEED RING LUBRICATED BEARINGS

PRESSURE FED BEARINGS

RADIAL LOADS

RADIAL AND THRUST LOADS

MULTI LOBE BEAINGS

TILTING PAD BEARINGS

CYLINDRICAL

2- LOBE

3- LOBE

4- LOBE

VERTICAL ELLIPTICITY

HORIZONTAL ELLIPTICITY

SYMMETRICAL 4- LOBE 4- PAD

TILTED 4- LOBE

5-PAD

DESIGN LIMITS FOR SAFE OPERATION OF HYDRODYNAMIC BEARINGS:

g.1. Limits for Satisfactory Bearing Operation under Hydrodynamic Condition.

Fig.1. Limit for Satisfactory Bearing Operation under Hydrodynamic

Condition.

Pressure Distribution in a Journal Bearing

Oil Ring Bearing

Different Oil Ring Designs

RING LUBRICATED BEARINGS

Cross Sectional View of Ring Lubricated Journal Bearing

Pressure Fed Bearings

Cylindrical and Multi-Lobe Journal Bearings

Fluid film Thrust bearings

1. Supports Axial Forces Constant thrust loads Differential pressure across wheels (Turbines and Compressors) Gears Axial force components Dynamic axial loads Bent rotors , Misaligned shafts

2. Maintains rotor in fixed axial position with respect to Casing

Axial clearances between Blade rows determine Turbine efficiency Wheels and diaphragms in Compressors

Dynamics of Rotating machinery

Fluid film Thrust bearings Thrust bearing assembly should fulfill requirement for
Axial position Axial float
Axial location axial position shims behind active thrust shoes Axial float Total thrust float shims behind inactive thrust shoes

Motors and Generators no thrust bearing Magnetic forces across air gap center the rotor within the stator

Thrust Float
Stationary Casing

Journal bearing

shaft Thrust probe

Normal Thrust

Shims for axial position

Shims for thrust float

Active pads

Inactive pads

Thrust bearing ---Centrifugal compressors, BFP,small turbines

Thrust cum Journal bearing

Thrust Float

Active thrust collar Normal Thrust

Inactive thrust collar shaft

Thrust probe

Shims for axial position Active pads

Shims for thrust float Inactive pads

Thrust bearing ---Large Steam and Gas turbines

Steam Turbine Design Philosophy

KWU Design Russian Design

Run-out Diagram , Rotation angle of Shaft alignment and Bearing Height Correction (Before Initial Correction for BKTPP unit 2 ) = Rotation angle of Shaft Alignment 0.205 D740 V 0.158 D760

HP

V 0.085 D870

h1

IP h2 hH1

h5 h3 hG Gen 405 3495 485 5825 475 1100

3350 HP = IP 0.085/870 h2= hH1 + 405 * HP h1= h2+3350* HP

3900 IP = 0.205 / 740 h3 = 485* IP hH1=(485+3495)*IP

6310 = h3/6310

1575

7810

Gen = 0.158 / 760 h5=1100*Gen h6=(1100+7810)*Gen

Alignment correction of case 1

h1

h2

h5

h6

h1=h1-(6310+3900+3350)* h2=h2-(6310+3900)*

h3=h3-6310* = 0 h4=0

h5=h5-1575* h6=h6-(1575+7810)*

Run-out Diagram , Rotation angle of Shaft alignment and Bearing Height Correction (Before Secondary Correction for BKTPP unit 2 ) = Rotation angle of Shaft Alignment 0.04 D740 V 0.158 D760

HP

0.03 D870 IP

h1

h2

hH1 h5 h3 hG Gen 405 3495 485 5825 475 1100

3350 HP = IP + 0.03 / 870 h2= hH1 + 405 * HP h1= h2+3350* HP

3900 IP = 0.04 / 740 h3 = 485* IP hH1=(485+3495)*IP

6310 = h3/6310

1575

7810

Gen = 0.158 / 760 h5=1100*Gen h6=(1100+7810)*Gen

Alignment correction

h1

h2

h5

h6

h1=h1-(6310+3900+3350)* h2=h2-(6310+3900)*

h3=h3-6310* = 0 h4=0

h5=h5-1575* h6=h6-(1575+7810)*

SCHEMATIC FOR GERB SPRING

TG DECK

SHIM TIE ROD

TG COLUMN

NOTE: 1. THESE READINGS ARE IN ADDITION TO READING TAKEN BY GERB ON THE PROTOCOL DOCUMENT. 2 TURBINE ENGINEER ALONG WITH CIVIL ENGINEER TO ASSOCIATE.

A.

B. C

STICK MICRO METER READING AT FOUR LOCATIONS BETWEEN DECK AND COLUMN. MARK THE LOCATION OF READING (USE METAL MARKER). STICK MICROMETER READING AT FOUR LOCATION OF EACH SPRING ASSEMBLY. RECORD TOTAL THICKNESS OF SHIM HEIGHT AND NUMBER OF SHIMS.

SCHEMATIC FOR M/S GERBS CONDENSER SPRING ASSEMBLY

CONDENSER BOTTOM PLATE

TIE ROD JACK BOLTS SHIM

CONDENSER FOUNDATION

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