Stabilizing a 46 MW Multistage Utility Steam Turbine Using Integral Squeeze Film Bearing Support Dampers

2015 ◽  
Vol 137 (5) ◽  
Author(s):  
Bugra Ertas ◽  
Vaclav Cerny ◽  
Jongsoo Kim ◽  
Vaclav Polreich
Keyword(s):  
Steam Turbine ◽  
Critical Speed ◽  
Stability Margin ◽  
Experimental Tests ◽  
Turbine Rotor ◽  
Squeeze Film ◽  
Full Load ◽  
Vibration Data ◽  
Full Speed ◽  
Full Load Operation

A 46 MW 5500 rpm multistage single casing utility steam turbine experienced strong subsynchronous rotordynamic vibration of the first rotor mode; preventing full load operation of the unit. The root cause of the vibration stemmed from steam whirl forces generated at secondary sealing locations in combination with a flexible rotor-bearing system. Several attempts were made to eliminate the subsynchronous vibration by modifying bearing geometry and clearances, which came short of enabling full load operation. The following paper presents experimental tests and analytical results focused on stabilizing a 46 MW 6230 kg utility steam turbine experiencing subsynchronous rotordynamic instability. The paper advances an integral squeeze film damper (ISFD) solution, which was implemented to resolve the subsynchronous vibration and allow full load and full speed operation of the machine. The present work addresses the bearing-damper analysis, rotordynamic analysis, and experimental validation through waterfall plots, and synchronous vibration data of the steam turbine rotor. Analytical and experimental results show that using ISFD improved the stability margin by a factor of 12 eliminating the subsynchronous instability and significantly reducing critical speed amplification factors. Additionally, by using ISFD the analysis showed significant reduction in interstage clearance closures during critical speed transitions in comparison to the hard mounted tilting pad bearing configuration.

Stabilizing a 46 MW Multi-Stage Utility Steam Turbine Using Integral Squeeze Film Bearing Support Dampers

2014 ◽  
Author(s):  
Bugra Ertas ◽  
Vaclav Cerny ◽  
Jongsoo Kim ◽  
Vaclav Polreich
Keyword(s):  
Steam Turbine ◽  
Critical Speed ◽  
Stability Margin ◽  
Experimental Tests ◽  
Turbine Rotor ◽  
Squeeze Film ◽  
Full Load ◽  
Vibration Data ◽  
Multi Stage ◽  
Full Load Operation

A 46 MW 5,500 rpm multistage single casing utility steam turbine experienced strong subsynchronous rotordynamic vibration of the first rotor mode; preventing full load operation of the unit. The root cause of the vibration stemmed from steam whirl forces generated at secondary sealing locations in combination with flexible rotor-bearing system. Several attempts were made to eliminate the subsynchronous vibration by modifying bearing geometry and clearances, which came short of enabling full load operation. The following paper presents experimental tests and analytical results focused on stabilizing a 46 MW 6,230kg utility steam turbine experiencing subsynchronous rotordynamic instability. The paper advances an integral squeeze film damper (ISFD) solution, which was implemented to resolve the subsynchronous vibration and allow full load and full speed operation of the machine. The present work addresses the bearing-damper analysis, rotordynamic analysis, and experimental validation through waterfall plots, and synchronous vibration data of the steam turbine rotor. Analytical and experimental results show that using ISFD improved the stability margin by a factor of 12 eliminating the subsynchronous instability and significantly reducing critical speed amplification factors. Additionally, by using ISFD the analysis showed significant reduction in interstage clearance closures during critical speed transitions in comparison to the hard mounted tilting pad bearing configuration.

Suppression of Subsynchronous Vibrations in a 11 MW Steam Turbine Using Integral Squeeze Film Damper Technology at the Exhaust Side Bearing

2016 ◽  
Author(s):  
Riccardo Ferraro ◽  
Michael Catanzaro ◽  
Jongsoo Kim ◽  
Michela Massini ◽  
Davide Betti ◽  
...  
Keyword(s):  
Steam Turbine ◽  
Labyrinth Seal ◽  
Squeeze Film ◽  
Stable Operation ◽  
Steam Turbines ◽  
Squeeze Film Damper ◽  
Full Load ◽  
Steam Admission ◽  
Before And After ◽  
Full Speed

The presence of high subsynchronous vibrations and other rotordynamic instabilities in steam turbines can prevent operation at full speed and/or full load. The destabilizing forces generating subsynchronous vibrations can be derived from bearings, seals, impellers or other aerodynamic sources. The present paper describes the case of an 11 MW steam turbine, driving a syngas centrifugal compressor train, affected by subsynchronous vibrations at full load. After the occurrence of anomalous vibrations at high load and a machine trip due to the high vibrations, the analysis of data collected at the site confirmed instability of the first lateral mode. Further calculations identified that the labyrinth seal at the balance drum was the main source of destabilizing effects, due to the high pre-swirl and the relatively tight seal clearance. The particular layout of the turbine, a passing-through machine with a combined journal/double thrust bearing on the steam admission side, together with the need for a fast and reliable corrective action limited the possible solutions. Based on the analyses performed, adjusting the clearance and preload of the journal bearings could not have ensured stable operation at each operating condition. The use of swirl brakes to reduce the steam pre-swirl at the recovery seal entrance would have required a lengthy overhaul of the unit and significant labor to access and modify the parts. The final choice was a drop-in replacement of only the rear bearing (on the steam exhaust side) with a bearing featuring integral squeeze film damper (ISFD) technology. In addition to being a time efficient solution, the ISFD technology ensured an effective tuning of stiffness and damping, as proven by the field results. The analyses carried out to understand the source of the subsynchronous vibrations and to identify possible corrective actions, as well as the comparison of rotordynamic data before and after the application of the bearing with ISFD technology, are discussed.

Experimental Evaluation of Multiplane-Multispeed Rotor Balancing Through Multiple Critical Speeds

1976 ◽  
Vol 98 (3) ◽  
pp. 988-998 ◽  
Author(s):  
J. M. Tessarzik ◽  
R. H. Badgley ◽  
D. P. Fleming
Keyword(s):  
Experimental Tests ◽  
Influence Coefficient ◽  
Critical Speeds ◽  
Vibration Data ◽  
Vibration Sensors ◽  
Flexible Rotors ◽  
Speed Range ◽  
Full Speed ◽  
Influence Coefficient Method ◽  
Rotor Balancing

Experimental tests have been conducted to further demonstrate the ability of the Influence Coefficient Method to achieve precise balance of flexible rotors of virtually any design for operation through virtually any speed range. Four distinct practical aspects of flexible-rotor balancing were investigated in the present work: (1) Balancing for operation through multiple bending critical speeds; (2) balancing of rotors mounted in both rigid and flexible bearing supports, the latter having significantly different stiffnesses in the horizontal and vertical directions so as to cause severe ellipticity in the vibration orbits; (3) balancing of rotors with various amounts of measured vibration response information (e.g., numbers of vibration data sets, and numbers and types of vibration sensors), and with different number of correction planes; (4) balancing of rotors with different (though arbitrary) initial unbalance configurations. Tests were made on a laboratory quality machine having a 122-cm (48-in.) long rotor weighing 50 kg (110 lb) and covering a speed range up to 18,000 rpm. The balancing method was found in every instance to be effective, practical, and economical, permitting safe rotor operation over the full speed range covering four rotor bending critical speeds.

Stability Characteristics of Steam Turbine Rotor Seal System With Analytical Floating Ring Seal Force Model

2013 ◽  
Author(s):  
Guang-hui Zhang ◽  
Gui-long Wang ◽  
Zhan-sheng Liu ◽  
Rui-xian Ma
Keyword(s):  
Dynamic Response ◽  
Steam Turbine ◽  
Critical Speed ◽  
Turbine Rotor ◽  
Rotor System ◽  
Force Model ◽  
Oil Film ◽  
Steam Turbine Rotor ◽  
Ring Seal ◽  
The Stability

The analytical oil film force model for floating ring seal is established including the effect of axial pressure gradient. The analytical model is based on the oil lubricated Reynolds equation and the short bearing assumption, where the fluid Lomakin effect is considered. The pressure distribution of the floating ring and static characteristics is studied by numerical simulation. The three dimensional flow model is established and solved by the CFD method. By employing the finite element method, the dynamic model of the floating ring seal-steam turbine rotor system is established. The critical speed, mode shape and dynamic response of the steam turbine rotor with different bearing support stiffness are obtained. The effect of the floating ring oil film force on the critical speed and instability speed with different bearing support stiffness is studied. The effects of floating ring parameters (groove geometrical dimensions) on dynamic response are studied, and the stability of floating ring seal-rotor system with variation of the factor is analyzed. The floating ring seal can play the role of increasing the supporting effect, which will increase the critical speed of the rotor system. The floating ring seal can cause the sub synchronous vibration and the groove can significantly increase the stability of system.

Aeromechanical Characterization of a Last Stage Steam Blade at Low Load Operation: Part 1 — Experimental Measurements and Data Processing

2020 ◽  
Author(s):  
A. Bessone ◽  
R. Guida ◽  
M. Marrè Brunenghi ◽  
S. Patrone ◽  
L. Carassale ◽  
...  
Keyword(s):  
Steam Turbine ◽  
Stability Margin ◽  
Turbine Rotor ◽  
Test Facility ◽  
Part Load ◽  
Turbine Rotor Blade ◽  
Partial Load ◽  
Elastic Instabilities ◽  
Last Stage

Abstract This paper is the first of a two-part publication that aims to experimentally evaluate, simulate and compare the aerodynamic and mechanical damping for a last stage steam turbine rotor blade at part load operation. Resulting strong off-design partial load regimes expose the last stage moving blade (LSMB) to the possible onset of aero-elastic instabilities, such as stalled and un-stalled flutter. This interaction can lead to asynchronous blade vibrations and then the risk of blade failures for high cycle fatigue. In this framework, it is necessary to develop and validate new tools for extending operating ranges, controlling non-synchronous phenomenon and supporting the design of new flutter resistant LSMB. To this end, a 3-stage downscaled steam turbine with a snubbered LSMB was designed by Ansaldo Energia and tested in the T10MW test facility of Doosan Skoda Power R&D Department within the FlexTurbine European project. The turbine was operated in a wet steam environment at very low volume flow conditions simulating different part load regimes. The steady flow field throughout the LSMB was characterized and the occurrence of flutter was investigated by inducing the blade resonance through an AC magnet excitation and measuring the overall damping. The results presented in this paper indicate that the blade always operates over the flutter stability margin validating this new blade design. In the second part of this work, the mechanical and aerodynamic contribution to the damping will be separated in order to validate the aerodynamic damping prediction of an upgraded CFD tool, already adopted in the design phase of the blade at design point.

scholarly journals A linear cascade tunnel for flow investigations of steam turbine rotor tip blades in subsonic nucleating flows

2021 ◽  
Vol 3 (2) ◽  
Author(s):  
Vital Kumar Yadav Pillala ◽  
B. V. S. S. S. Prasad ◽  
N. Sitaram ◽  
M. Mahendran ◽  
Debasish Biswas ◽  
...  
Keyword(s):  
Steam Turbine ◽  
Turbine Rotor ◽  
Turbine Cascade ◽  
Flow Measurements ◽  
Linear Cascade ◽  
Dry Air ◽  
Steam Turbine Rotor ◽  
Pressure Distributions ◽  
Working Medium ◽  
Exit Mach Number

AbstractThe paper presents details of a unique experimental facility along with necessary accessories and instrumentation for testing steam turbine cascade blades in wet and nucleating steam. A steam turbine rotor tip cascade is chosen for flow investigations. Cascade inlet flow measurements show uniform conditions with dry air and steam and dry air mixture of different ratios. Exit flow surveys indicate that excellent flow periodicity is obtained. Blade surface static pressure and exit total pressure distributions are also presented with dry air and with steam and dry air mixture of different ratios as the working medium at an exit Mach number of 0.52.

scholarly journals On the creep fatigue and creep rupture behaviours of 9–12% Cr steam turbine rotor

2019 ◽  
Vol 76 ◽  
pp. 263-278 ◽  
Author(s):  
Xuanchen Zhu ◽  
Haofeng Chen ◽  
Fuzhen Xuan ◽  
Xiaohui Chen
Keyword(s):  
Steam Turbine ◽  
Turbine Rotor ◽  
Creep Rupture ◽  
Steam Turbine Rotor ◽  
Creep Fatigue

On real-time creep damage prediction for steam turbine

2022 ◽  
pp. 014233122110689
Author(s):  
Yongjian Sun ◽  
Bo Xu
Keyword(s):  
Finite Element ◽  
Steam Turbine ◽  
Real Time ◽  
Creep Damage ◽  
Element Model ◽  
Turbine Rotor ◽  
Theoretical Research ◽  
Element Analysis ◽  
Damage Prediction ◽  
Time Calculation

In this paper, in order to solve the calculation problem of creep damage of steam turbine rotor, a real-time calculation method based on finite element model is proposed. The temperature field and stress field of the turbine rotor are calculated using finite element analysis software. The temperature data and stress data of the crucial positions are extracted. The data of temperature, pressure, rotational speed, and stress relating to creep damage calculation are normalized. A real-time creep stress calculation model is established by multiple regression method. After that, the relation between stress and damage function is analyzed and fitted, and creep damage is calculated in real-time. A creep damage real-time calculation system is constructed for practical turbine engineering. Finally, a numerical simulation experiment is designed and carried out to verify the effectiveness of this novel approach. Contributions of present work are that a practical solution for real-time creep damage prediction of steam turbine is supplied. It relates the real-time creep damage prediction to process parameters of steam turbine, and it bridges the gap between the theoretical research works and practical engineering.

Metallographic and Materials Evaluation of a Cracked Radial Steam Turbine Rotor

2018 ◽  
Author(s):  
Vamadevan Gowreesan ◽  
Wayne Greaves
Keyword(s):  
Steam Turbine ◽  
Manganese Sulfide ◽  
Turbine Rotor ◽  
Impact Testing ◽  
Composition Analysis ◽  
Tempered Martensite ◽  
Material Defects ◽  
Fracture Appearance Transition Temperature ◽  
Fracture Appearance ◽  
High Level

A radial steam turbine developed cracks after 220,000 hours of service. The rotor had an integral disc with eight rows of blades, and a short stub. Nine inlets on the disc channeled steam from one side to the other, and then radially outward. Analysis of the fracture surface revealed cracks originating in some of the inlet holes, and propagating by fatigue. No material defects were found at the crack initiation sites. Hardness and microstructure (optical) across the disc were uniform, but chemical composition analysis of the alloy revealed high level of phosphorus and sulfur. In addition, the microstructure consisted of uniformly tempered martensite with manganese sulfide stringers. Although tensile properties were normal, impact testing indicated embrittlement by a shift in Fracture Appearance Transition Temperature (FATT). Metallurgical evidence of embrittlement was also found. It was concluded that service induced cyclic loading in combination with reduced crack resistance caused by embrittlement lead to cracking.

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