ABSTRACT
The present study focuses on elucidating the fundamental reasons underlying the emergence of vibrations in steam turbines. During operation, vibrations are observed not only in the components of the machinery that undergo cyclical motion but also in those components connected to the equipment. Therefore, vibration monitoring holds great importance in identifying malfunctions in the functional operations of turbomachinery, enabling timely detection, and prevention of potential accidents. Using the steam turbine unit as an example, it is noteworthy that the rotor primarily undergoes oscillatory motion, where it is essential to recognize that vibrations also manifest in bearings, housings, turbine foundations, pipe-lines, and surrounding components. The thorough examination of vibration should encompass not only turbine rotors but also the entire turbine assembly, including the generator and all associated equipment. It is essential to conduct a comprehensive evaluation of the overall system to ensure optimal functionality. Academic research papers typically do not often assess the specific number of working hours and conditions which are leading to rotor damage, also in that sense, not determining if damage is a result of wear and tear during prolonged undesired operation. Instead, the emphasis is commonly placed on analyzing elevated levels of vibrations and investigating the associated occurrence of cracks. This paper aims to provide a comprehensive summary of the main causes of vibrations through a unified perspective on the various conclusions available, regarding the diverse causes behind these common and complex vibration occurrences.
KEYWORDS
PAPER SUBMITTED: 2024-01-05
PAPER REVISED: 2024-02-09
PAPER ACCEPTED: 2024-02-12
PUBLISHED ONLINE: 2024-04-14
THERMAL SCIENCE YEAR
2024, VOLUME
28, ISSUE
Issue 6, PAGES [4451 - 4471]
- Mazur, Z., Hernandez-Rossette, A., Steam Turbine Rotor Discs Failure Evaluation and Repair Process Implementation, Engineering Failure Analysis, 56 (2015), Oct., pp. 545-554
- Ishida, Y., Cracked Rotors: Industrial Machine Case Histories and Non-Linear Effects Shown by Simple Jeffcott Rotor, Mechanical Systems and Signal Processing, 22 (2008), 4, pp. 805-817
- Matsushita, O., et al., Vibrations of Rotating Machinery, Basic Rotordynamics: Introduction Practical Vibration Analysis, Springer, Tokyo, Japan, 2019, Vol. 1, Chapter 5, pp. 105-152
- Kumar, P., Tiwari, R., Effects of Unbalance and AMB Misalignment in a Rigid Rotor with an Offset Disc Levitated by Active Magnetic Bearings: A Numerical Investigation, Proceedings, 12th International Conference on Vibrations in Rotating Machinery, London, UK, 2020, pp. 151-168
- Maurice, J., Adams, L., Rotating Machinery Vibration, 2nd ed., CRC Press, Taylor and Francis Group, Boca Raton, Fla., USA, 2010, Chapter 9, pp. 307-345
- Subbiah, R., Littleton, J. E., Rotor and Structural Dynamics of Turbomachinery, Springer, Cham, Switzerland, 2018, Chapter 5, pp. 147-195, Chapter 7, pp. 217-251
- Rieger, N., Rotordynamics 2 Problems in Turbomachinery, Springer-Verlag, New York, USA, 1988, Chapter 1, pp. 1-16, Chapter 11.2, pp. 423-452, Chapter 11.3 pp. 453-483
- Dohnal, F., et al., An Extended Field Balancing Procedure for Flexible Rotors Fully Levitated by Active Magnetic Bearings, Proceedings, 10th International Conference on Vibrations in Rotating Machinery, London, UK, 2012, pp. 335-345
- Choi, Y.-S., Experimental Investigation of Partial Rotor-Rub Against a Non-Rotating Part, Proceedings, 7th International Conference on Vibrations in Rotating Machinery, London, UK, 2000, pp. 281-290
- Muszynska, A. A., Rotordynamics, Taylor and Francis Group, Boca Raton, Fla., USA, 2005, Chapter 3, pp. 79-207,Chapter 6, pp. 711-937, Chapter 5, pp. 555-709
- Vance, J., et al., Machinery Vibration and Rotordynamics, Hoboken, John Wiley and Sons, New York, USA, 2010, Chapter 1, pp. 1-34
- Patel, T. H., Darpe, A. K., Application of Full Spectrum Analysis for Rotor Fault Diagnosis, Proceedings, IUTAM Symposium on Emerging Trends in Rotor Dynamics, New Delhi, India, 2009, pp. 535-545
- Wowk, V., Machine Vibration: Alignment, McGraw-Hill, New York, USA, 2000, Chapter 1, pp. 1-13, Chapter 2, pp. 14-24
- Gibbons, C., Coupling Misalignment Forces, Proceedings, 5th Turbo Machinery, Symposium Gas Turbine Laboratory, Texas A & M University, College Station Tex., USA, pp. 111-11306
- Pennacchi, P., Vania, A., Diagnostics of a Crack in a Load Coupling of a Gas Turbine Using the Machine Model and the Analysis of the Shaft Vibrations, Mechanical Systems and Signal Processing, 22 (2008), 5, pp. 1157-1178
- Mobley, R. K., Maintenance Fundamentals, 2nd ed., Elsevier Butterworth-Heinemann, Burlington, Canada, 2004, Chapter 7, pp. 71-111
- Rao, S. S., Mechanical Vibration, 6th ed., Pearson, London, UK, 2018, Chapter 10, pp. 924-992
- Girdhar, P., Practical Machinery Vibration Analysis and Predictive Maintenance, IDC Technologies, Elsevier, Oxford, UK, 2004, Chapter 6, pp. 134-167, Chapter 2, pp. 11-28, and Chapter 5, pp. 89-133
- Ehrich, F. F., Handbook of Rotordynamics, Krieger Publishing Company, Malabar, Fla., USA,1999, Chapter 1, pp. 1-156
- Piotrowski, J., Shaft Alignment Handbook, 3rd ed., CRC Press, Taylor and Francis Group, New York, USA, 2007, Chapter 1, pp. 1-33
- Frosini, L., Pennacchi, P., Detection and Modelling of Rotor Eccentricity in Electrical Machines - An Overview, Proceedings, 8th International Conference on Vibrations in Rotating Machinery, Wales, UK, 2004, pp. 111-122
- Pennacchi, P., Frosini, L., Dynamical Behaviour of a Three-Phase Generator Due to Unbalanced Magnetic pull, IEE Proceedings - Electric Power Applications, 155 (2005), 6, pp. 1389-1400
- Smalley, A. J., et al., Managing Fatigue Failure Probability Caused by Misalignment and Vibration in Large Turbine Generators, Proceedings, 7th International Conference on Vibrations in Rotating Machinery, London, UK, 2000, pp. 619-632
- Tanuma, T., Advances in Steam Turbines for Modern Power Plants, 2nd ed., Cambridge: Woodhead Publishing is an Imprint of Elsevier, Amsterdam, The Netherlands, 2022, Chapter 8, pp. 163-194, Chapter 16, pp. 383-448
- Strzelecki, S., Effect of the Misalignment of Journal and Sleeve Axis on the Operation of Turbo Unit Journal Bearings, Tribologia, 293 (2020), 5, pp. 73-84
- Bachschmid, N., et al., Steam-Whirl Analysis in a High Pressure Cylinder of a Turbo Generator, Mechanical Systems and Signal Processing, 22 (2008), 3, pp. 121-132
- Guo, H., et al., Experimental and Numerical Study on Mixed Lubrication Performance of Journal Bearing Considering Misalignment and Thermal Effect, Lubricants, 10 (2020), 10, 262
- Si, H., et al., Steam Flow Excited Vibration and Dynamic Characteristics of Seal in Different Rotor Whirling Motion, Tribology International, 160 (2021), 107029
- Fang, J., Atassi, H. M., Compressible Flows with Vortical Disturbances Around a Cascade of Loaded Airfoils, Proceedings, 6th International Symposium; Unsteady Aerodynamics, Aeroacollstics, and Aeroelasticity of Turbomachines and Propellers, South Bend, Ind., USA, 1991, pp. 148-176
- Berry, J. E., ANALYSIS I - How to Implement an Effective Condition Monitoring Program Using Vibration Analysis, Technical Associates of Charlotte, Charlotte, N.C., USA, 2002
- Matsushita, O., et al., Vibrations of Rotating Machinery Volume 2, Advanced Rotordynamics: Applications of Analysis, Troubleshooting and Diagnosis, Springer, Tokyo, Japan, 2019, Chapter 7, pp. 167-216, Chapter 4, pp. 59-86
- Leung, P. S., et al., A Theoretical Study into the Effects of Damped Flexible Foundations on the Dynamic Behaviour of a 660 MW LP Steam Turbine, Proceedings, oNATO Advanced Study Institute on Vibration and Wear Damage in High Speed Rotating Machinery, Troia, Sebutal, Portugal, 1989, pp. 253-261
- Gasch, R., et al., Rotordynamik, Springer, Berlin, Germany, 2006, Chapter 12, pp. 217-250
- Taylor, J. I., The Vibration Analysis Handbook, Vibration Consultants, Tampa, Fla., USA, 1994, Chapter 1, pp. 1-34
- Ahmed, H., Nandi, A. K., Condition Monitoring with Vibration Signals, Chichester: John Wiley and Sons Ltd., New York, USA, 2020, Chapter 2, pp. 17-30
- Subbiah, R., Littleton, J. E., Rotor and Structural Dynamics of Turbomachinery, Springer, Cham, Switzerland, 2018, Chapter 2, pp. 24-72
- Mazur, Z., et al., Steam Turbine Blade Failure Analysis, Engineering Failure Analysis, 15 (2008), 7, pp. 129-141
- Walker, D. N., Torsional Vibration of Turbomachinery, McGraw-Hill Companies, New York, USA, 2004, Chapter 3, pp. 11-22
- Perera, U., et al., Sub Synchronous Oscillations under High Penetration of Renewables - A Review of Existing Monitoring and Damping Methods, Challenges, and Research Prospects, Energies, 15 (2022), 22, 8477
- Giesecke, H. D., Steam Turbine-Generator Torsional Response due to Interaction with the Electrical Grid, Proceedings, IEEE Power and Energy Society General Meeting, San Diego, Cal., USA, 2012, pp. 1-6
- Tsai, G.-C., Rotating Vibration Behavior of the Turbine Blades with Different Groups of Blades, Journal of Sound and Vibration, 271 (2004), 3-5, pp. 547-575
- Li, P., et al., Investigation on the Unsteady Pressure Fluctuation Characteristic in the Blade Tip Seal of Steam Turbine Based on Spectrum, Thermal Science, 24 (2020), 6A, pp. 3823-3834
- Xie, L., et al., Analysis on the Causes of Cracking at the Last Stage Blade of the Low-Pressure Rotor in Thermal Power Plant, Proceedings, E3S Web of Conferences 165, Changchun, China, 2020, 06010
- Rzadkowski, R., Stator-Rotor Aeroelastic Interaction for the Turbine Last Stage in 3-D Transonic Flow, Proceedings, 10th International Symposium on Unsteady Aerodynamics, Aeroacoustics, and Aeroelasticity of Turbomachines September, Durham, N. C., USA, 2006, pp. 569-580
- Morita, R., et al., Flow Induced Vibration of a Steam Control Valve in Middle-Opening Condition, Proceedings, ASME Pressure Vessels and Piping Division Conference, Denver, Tex., USA, 2005 pp. 485-490
- Niuia, Q., et al., Diagnosis Method of Turbine Blade Loosening, Proceedings, 7th International Conference on Mechanical Engineering, Materials and Automation Technology, Dali, India, 2021, 012075
- Niu, Q., et al., Diagnosis Method of Turbine Blade Loosening, Journal of Physics, 1986 (2021), 1, 2021, 012075
- Sanders, W. P., Turbine Steam Path - Maintenance and Repair, PennWell, Tulsa, OK, USA, 2002, Chapter 10, pp. 388-651
- Bachschmid, N., et al., Cracked Rotating Shafts: Typical Behaviors, Modelling and Diagnosis, Proceedings, IUTAM Symposium on Emerging Trends in Rotor Dynamics, New Delhi, India, 2009, pp. 441-454
- Miller, K. J., Metal Fatigue - Past, Current and Future - Part C: Journal of Mechanical Engineering Science, 205 (1991), 5, pp. 291-304
- Bovsunovsky, A., Estimation of Efficiency of Vibration Damage Detection in Stepped Shaft of Steam Turbine, Electric Power Systems Research, 154 (2018), Jan., pp. 381-390
- Sabnavis, G., et al., Cracked Shaft Detection and Diagnostics: A Literature Review, The Shock and Vibration Digest, 36 (2004), 4, pp. 287-296
- Bachschmid, N., et al., A Survey on Static and Dynamic Behaviour Incl ing Modelling and Diagnosis, Springer-Verlag, Berlin, Germany, 2010, Chapter 2, pp. 16-35
- Banaszkiewicz, M., Rehmus-Forc, A., Stress corrosion cracking of a 60 MW Steam Turbine Rotor, Stress Corrosion Cracking of a 60 MW Steam Turbine Rotor, 51 (2015), May, pp. 55-68, 2015
- Wang, W., et al., Influence of High-Temperature Dwell Time on Creep-Fatigue Behavior in a 1000 MW Steam Turbine Rotor, Engineering Fracture Mechanics, 166 (2016), Oct., pp. 1-22
- Eldridge, T. M., et al., Morton-Newkirk Effect in Overhung Rotor Supported in Rolling Element Bearings, Proceedings, ASME Turbo Expo 2009: Power for Land, Sea and Air, Orlando, Fla., USA, 2009
- Rajora, R., Dixit, H. K., Effect of Lube Oil Temperature on Turbine Shaft Vibration, International Journal of Mechanical Engineering and Robotics Research (IJMERR), 2 (2013), 2, pp. 324-334
- Keogh, P. S., Morton, P. G., The Dynamic Nature of Rotor Thermal Bending Due to Unsteady Lubricant Shearing within a Bearing, Journal The Royal Society, 445 (1994), May, pp. 273-290
- S. Li, S., Qu, T., Causes and Troubleshooting of High Bearing Bush Temperature of a Nuclear Power Steam Turbine, Proceedings, 6th International Conference on Fluid Mechanics and Industrial Applications (FMIA 2022), Taiyuan, China, 2022, Vol. 2280, 012035
- Febriansyah, D., et al., Influence of Thermal Expansion on Steam Turbine Shaft Alignment, Majalah Ilmiah Pengkajian Industri, 14 (2020), 1, pp. 71-76
- Plantegenet, T., et al., Experimental Analysis of the Thermal Unbalance Effect of a Flexible Rotor Supported by a Flexure Pivot Tilting Pad Bearing, Mechanical Systems and Signal Processing, 145 (2022), 106953
- Giesecke, H. D., Steam Turbine-Generator Torsional Response due to Interaction with the Electrical Grid, Proceedings, IEEE Power and Energy Society General Meeting, San Diego, Cal., USA, 2012, pp. 1-6
- Liu, P., et al., Development of Instantaneous Transient Torque Protection Against Torque Amplification for Turbine Generators In A Series-Compensated Power System, International Journal of Electrical Power and Energy Systems, 134 (2022), 107444
- Petit, F., et al., Investigating Grid-Induced Turbo-Generator Vibrations: A Multidisciplinary Challenge, Proceedings, 9th IFToMM International Conference on Rotor Dynamics, Milan, Italy, 2015, pp. 625-636
- Pennacchi, P., Frosini, L., Dynamical Behaviour of a Three Phase Generator Due to Unbalanced Magnetic pull, IEE Proceedings - Electric Power Applications, 152 (2005), 6, pp. 1389-1400
- Bovsunovskii, A. P., Assessment of Fatigue Damage in Steam Turbine Shafting Due to Torsional Vibrations, Strength of Materials, 43 (2011), Nov., pp. 487-497
- Bovsunovsky, A., Effect of Abnormal Operation of Turbine Generator on the Resource of Steam Turbine Shafting, Proceedings, International Conference on Design, Simulation, Manufacturing: The Innovation Exchange, Sumy, Ukraine, 2018, pp. 247-254