high performance turbomachinery
TRANSCRIPT
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Vorlesungen Mechatronik im Wintersemester
Vibrations in Nuclear Applications 2021
Annual Energiforsk Seminar (10.11.21)
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
Rainer NordmannTechnische Universität Darmstadt and Fraunhofer Institute LBF
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Introduction: High Performance Turbomachinery
Vibration Phenomena in High Performance Turbomachinery
Modelling of High Performance TurbomachineryModelling of the Laval ShaftModelling of High Performance Turbomachinery
Monitoring of High Performance TurbomachineryConventional MonitoringFuture Model Based Monitoring & Diagnosis
Vibration Control of High Performance TurbomachineryPassive Vibration ControlActive Vibration Control
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
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Introduction: High Performance TurbomachineryTurbogenerator: Steamturbine and Generator
Disciplines : Thermodynamics Mechanics Electrodynamics
StressesStrength of material
Lateral and TorsionalRotordynamics
Critical speedsUnbalance ResponseAir Gap Torques
Stability
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Introduction: High Performance TurbomachineryModel of a Steam Turbine Shaft Train
Power: 1000 MW Shaft Length: 55,8 m Shaft Weight: 426 toBearing Diameter: 600mm
Turbomachine with Turbine Shaft Train
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Introduction: High Performance Turbomachinery
Vibration Phenomena in High Performance Turbomachinery
Modelling of High Performance TurbomachineryModelling of the Laval ShaftModelling of High Performance Turbomachinery
Monitoring of High Performance TurbomachineryConventional MonitoringFuture Model Based Monitoring & Diagnosis
Vibration Control of High Performance TurbomachineryPassive Vibration ControlActive Vibration Control
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
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Vibration Phenomena in High Performance Turbomachinery -Static and Dynamic Forces
Rotor Weight
Unbalance ForcesSeal Forces
Oil Film Journal Bearing Bearing Forces
Machine Casing
Rotating Shaft with Blades
Seals and Balance Pistons
Process Forces
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• How is the influence of time dependent Forces and Moments on thedynamic behavior of a Machine?
• Which Motions of Vibration and which internal Stressesact on the rotating and on the non-rotating Machine Parts?
• Are Critical Conditions (Resonances, Instabilities) possible?
• Can Vibrations destroy Machine Parts?Rubbing, Blade Loss, Shaft Cracks, Bearing Failures, large Deformations,…
• Which Interactions have to be considered?Fluid Structure Interaction, Rotor Structure Interaction, Rotor Blade Interaction,
• Electromechanical Interaction
Vibration Phenomena in High Performance Turbomachinery Why do we need Rotordynamics?
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Vibration Phenomena in High PerformanceTurbomachineryLateral and Torsional Vibrations of Shaft Trains
Coupling of Lateral and Torsional Vibrations usually negligible
Lateral
Torsional
Machine with Rotating Shaft
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Vibration Phenomena in High PerformanceTurbomachineryLateral and Torsional Vibrations of Shaft Trains
Which Phenomena are of Practical Relevance?
Lateral Vibrations: Lateral Vibrations perpendicular to theShaft axis with Bending along the Shaft line. Physical Effects: Inertia (masses), Siffnessand Damping of System Components (Shaft, Bearings).
Dynamic Characteristics: Natural Frequencies, CriticalSpeeds, Natural Modes, Stability, Amplitudes and Phase angles of the Vibration Response due Excitations
Excitation: Mechanical and thermal Unbalances,Bow (Unbalance) due to Coupling Errors,Excitation due to Instabilities in Fluid Bearings and Seals
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Vibration Phenomena in High PerformanceTurbomachineryLateral and Torsional Vibrations of Shaft Trains
Which Phenomena are of Practical Relevance?
Torsional Vibrations: Torsional Vibrations around the Shaft axiswith torsional deformations along the Shaft line,Physical Effects: Moments of Inertia, Torsional Stiffnessand Damping of the System components
Dynamic Characteristics: Natural Frequencies, Natural Modes, Modal Damping, Amplitudes and Phaseangles of the Vibration Response due to Excitations.
Excitation: Air Gap Torques in Electrical Machines due to Electromagnetic Coupling. Higher Harmonics occur.
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Rotor-Fluid Rotor-BladeInteraction: Oil Film Bearings, Seals Interactions
Rotor-Structure Interaction: Elektromechanical Casing, Foundation Interaction: Generator,Grid
Shaft Line
Vibration Phenomena in High PerformanceTurbomachineryDifferent Interactions have an Influence on Rotordynamics
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Modelling, Monitoring and Vibration Control
Monitoring of High Performance
Turbomachinery
Modelling of High Performance
Turbomachinery
Passive and Active Vibration Control of High Performance
Turbomachinery
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Introduction: High Performance Turbomachinery
Vibration Phenomena in High Performance Turbomachinery
Modelling of High Performance TurbomachineryModelling of the Laval ShaftModelling of High Performance Turbomachinery
Monitoring of High Performance TurbomachineryConventional MonitoringFuture Model Based Monitoring & Diagnosis
Vibration Control of High Performance TurbomachineryPassive Vibration ControlActive Vibration Control
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
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Modelling of the Laval Shaft - Jeffcott Rotor
Laval - Laufrad
Gustav de Laval (1845 – 1913)Swedish Engineer,Theory by Föppl 1895
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Mass m
Stiffness c
Lager starr
Ω
x
y
Modelling of the Laval ShaftEquations of Motion for Lateral Vibrations
Mass m
Stiffness c
Inertia Damping Stiffness Unbalance
m e Ω2
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Modelling of the Laval ShaftForced Unbalance Vibrations
Increase damping d
Amplitude of unbalance vibrationx
4
3
2
1
ex /ˆ
Ω=ωΩ
Self-centering
Lager starr
Ω
x
y
Shaft vibrations with circular orbit,
( ) ( )222
2ˆΩ+Ω−
Ω=
dmcm
ex
xr ˆ=Resonance
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Mass m
Stiffness c
Lager starr
Ω
x
y
Modelling of the Laval ShaftNatural Frequency of Laval-Shaft (Lateral)
Natural Frequency: Laval Shaft
mc /=ω
Excitation with Frequency
Resonance Case
ωMass m
Stiffness c
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Modelling of the Laval ShaftInfluence of the Fluid Film Bearings
Flexible shaftwith bending stiffness k
Rigid diskwith mass m
masseccentricity
Fluid film bearingsSo-number Stiffness CoefficientsDamping Coefficients
Ω
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Modelling of the Laval ShaftFluid Film Bearings (Linear Theory)
Dynamic forces Z1, Z2:
2221212221212
2121112121111
qdqdqkqkZqdqdqkqkZ
+++=
+++=
kik: stiffness coefficients dik: damping coefficients
MZ0
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Modelling of the Laval ShaftInfluence of Oil Film Bearings in comparison to Rigid Bearings
Influence of Oil film bearings:
Stiffness, Damping, AnisotropyDanger of self-excitation
Shaft vibration with elliptical orbits
Ω
x
ye
r
4
3
2
1
er /ˆ
Ω1ω 2ω
Rigid bearings
Ω limit
With oil film bearings
Unstable natural vibrations
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Modelling of the Laval ShaftStiffness and Damping Coefficients
The stiffness and damping coefficients can be determined by numerical calculations (Reynolds-equations, CFD) or by Experiments. For a bearing with a special geometry the coefficients depend on the Sommerfeld number or on the static displacement.
Fluid film bearings have usually anisotropic behavior :
k11 ≠ k22 and d11 ≠ d22
The coupling coefficients differ from each other
k12 ≠ k21 and d12 ≠ d21
A measure for instability sensitivity is the difference: (k12 – k21).Damping Coefficients d11 and d22 are good for stability. Coefficients can be found in tables or diagrams.
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Modelling of the Laval Shaft Test Rig with AMB‘s to measure Rotordynamic Coefficients
Journal Bearing Test Rig
Force Measurement
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Introduction: High Performance Turbomachinery
Vibration Phenomena in High Performance Turbomachinery
Modelling of High Performance TurbomachineryModelling of the Laval ShaftModelling of High Performance Turbomachinery
Monitoring of High Performance TurbomachineryConventional MonitoringFuture Model Based Monitoring & Diagnosis
Vibration Control of High Performance TurbomachineryPassive Vibration ControlActive Vibration Control
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
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Rotor-Fluid Rotor-BladeInteraction: Oil Film Bearings, Seals Interactions
Rotor-Structure Interaction: Elektromechanical Casing, Foundation Interaction: Generator,Grid
Shaft Line
Modelling of High Performance TurbomachineryDifferent Interactions on Rotordynamics
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The Equations of Motion for Lateral Vibrations of the Turbogenerator contain the stiffness and damping information of the shaft train, the bearings and the supports
Modelling of High Performance TurbomachineryLateral Vibrations of Shaft Train
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Modelling of High Performance Turbomachinery Oil Film Bearing Types, used in Turbine Trains
HP IP LP1 LP2 LP3 GEN EXC
Cylindrical Bearings Elliptical bearings (Lemon Bore)3-Wedge BearingsPocket Bearings with one or two Oil InletsTilting Pad Bearings
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Modelling of High Performance TurbomachineryRotor Structure Interaction – Foundation
Typical for Foundations:− many modes in speed range
− Significant coupling effectsbetween the Bearingshorizontal and vertical
Foundation couples with the shaft train
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Modelling of High Performance TurbomachineryRotor – Structure Interaction - Foundation
Procedure− Estimation of mode shapes and natural
frequencies of the foundation without the rotor (FRF for bearing locations)
Input for Rotordynamics:
Components of the mode shapes at the bearing locations.
Natural FrequenciesModal Damping
FE - MethodModal Analysisfor the Foundation
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Modelling of High Performance TurbomachineryRotor – Structure Interaction - Foundation
FRFs from
- 3D FEM Calculations (Natural frequencies, Mode shapes)
- or Modal Analysis- Measurements
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Modelling of High Performance TurbomachineryCoupling of FRF‘s from Foundation with Rotor Train
TFU =frequency response function (FR
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( λ2 M + λ(D(Ω) + G(Ω)) + K(Ω))∙ x = 0
Eigenvalue Problem for Turbogenerator
Complex Eigenvalues : λ = α + j ω
Information for damping (stability) and natural frequencies
Modelling of High Performance TurbomachinerySome Eigenvalues of a large Turbogenerator
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Modelling of High Performance TurbomachinerySelected Eigenvalues and Mode Shapes
1. LP1 mode at 10.7 HzModal Damping 1,1 %
1. Generator mode at 11.0 HzModal Damping 0,9 %
2. LP1 mode at 27.6 HzModal Damping 9 %
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Complex System Response contains Amplitude and Phase
Complex Equations for Unbalance Response
Modelling of High Performance TurbomachineryUnbalance Response of a large Turbogenerator
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Modelling of High Performance TurbomachineryUnbalance Vibration Response of Shaft Train
HP LP1 LP2 LP3 GEN
25 Hz
100 µm
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Modelling, Monitoring and Vibration Control
Monitoring of High Performance
Turbomachinery
Modelling of High Performance
Turbomachinery
Passive and Active Vibration Control of High Performance
Turbomachinery
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Introduction: High Performance Turbomachinery
Vibration Phenomena in High Performance Turbomachinery
Modelling of High Performance TurbomachineryModelling of the Laval ShaftModelling of Large High Performance Turbomachinery
Monitoring of High Performance TurbomachineryConventional MonitoringFuture Model Based Monitoring & Diagnosis
Vibration Control of High Performance TurbomachineryPassive Vibration ControlActive Vibration Control
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
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CT Rotordynamics - 1104121 - P 37
Conventional Monitoring: High Performance Turbomachinery
For Monitoring of High Performance Turomachinery absolute vibrationvelocities in mm/sec and/or relative shaft vibrations in µm at definedlocations (Bearings) are usually measured. Evaluation by ISO Standards
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Conventional Monitoring: Relative Vibrations of the Shaft
Example: Relative Vibrations of the Shaftin horizontal and vertical direction. By Superposition of the two signals Orbits can be determined. These are the shaft motions in the measurement plane.
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Lecture: Interactions in Turbomachinery Rotordynamics - 11/11/2021 - P 39
Conventional Monitoring : Amplitudes and Phase versus speed (Run up and down)
Phase
Bearing 5 Amplitude
Bearing 6Amplitude
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Conventional Monitoring: Frequency Analysis of forward and backward frequencies.
Frequency Spectra with Forward- and Backward frequencies. Both are very helpful to analyze Vibrations and to diagnose Failures.
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Introduction: High Performance Turbomachinery
Vibration Phenomena in High Performance Turbomachinery
Modelling of High Performance TurbomachineryModelling of the Laval ShaftModelling of Large High Performance Turbomachinery
Monitoring of High Performance TurbomachineryConventional MonitoringFuture Model Based Monitoring & Diagnosis
Vibration Control of High Performance TurbomachineryPassive Vibration ControlActive Vibration Control
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
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xF
Failure diagnosis
Future Model Based Monitoring & Diagnosis Failure Diagnosis by means of FRF H( jω )
Question:
How strong is the influence of failures on the FRF H(jω)?
Additional Information
Future Model Based Monitor.
Model of Rotating System Parameter-Estimation
Rotating SystemH(jω)
H(jω) F (jω) = x (jω)
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Future Model Based Monitoring & Diagnosis Centrifugal Pump with Active Magnetic Bearings AMB‘s
Centrifugal Pump
Active BearingAMB
Saugleitung
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Sensor CharacteristicDisplacement x: Eddy Current Sensor
F ~ B2Force F: Hall ProbeHall Probe
Measuring of the system behaviour ispossible during regular operation (rotation)Frequency response functions H(jω)
Actuator Characteristic
Excitation up to 1 kHz
Eddy Current Sensor
Magnetic BearingController
Amplifier
Hall Probes
Future Model Based Monitoring & Diagnosis Rotating Pump Shaft with Active Magnetic Bearings
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Normal Operation
Centrifugal Pump with Failure: Dry Run
Alarm
Future Model Based Monitoring & Diagnosis.Centrifugal Pump Shaft with Active Magnetic Bearings
Failure Diagnosis in a Centrifugal Pump with FRF H(jω)
FRF H( jω )
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Modelling, Monitoring and Vibration Control
Monitoring of High Performance
Turbomachinery
Modelling of High Performance
Turbomachinery
Passive and Active Vibration Control of High Performance
Turbomachinery
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Introduction: High Performance Turbomachinery
Vibration Phenomena in High Performance Turbomachinery
Modelling of High Performance TurbomachineryModelling of the Laval ShaftModelling of Large High Performance Turbomachinery
Monitoring of High Performance TurbomachineryConventional MonitoringFuture Model Based Monitoring
Vibration Control of High Performance TurbomachineryPassive Vibration ControlActive Vibration Control
Modelling, Monitoring and Vibration Control ofHigh Performance Turbomachinery
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Increase of:Effectiveness, Complexity, more Solution Variants
Vibration Control of High Performance Turbomachinery Passive and Active Vibration Control
Vibration Control Measures
Without Energy
ConversionWith Energy Conversion
Passive semi-Active Active
Reduction of Excitation
System Tuning
Damping
Vibration Absorber
Isolation of disturbance
Isolation to protect the receiver
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Vibration Control of High Performance Turbomachinery Passive Vibration Control: Reduction of Excitation
Balancing weights
Balancing of LPT - Rotor
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Vibration Control of High Performance MachineryActive Vibration Control: Reduction of Excitation
Active Balancing Device
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Vibration Control of High Performance MachineryPassive Vibration Control: Tuning and Damping
IncreaseStiffness or reduce mass!
Increase Damping
Amplitude
4
3
2
1
ex /ˆ
Ω=ωΩ
Lager starr
Ω
x
y
Shaft Vibrations
( ) ( )222
2ˆΩ+Ω−
Ω=
dmcm
ex
xr ˆ=
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Rotor test rig for the LP shaft of an Aero Engine
Foundation
Motor
B. 7 B. 8
LP-Shaft
Rotor test rig for the LP shaft of an Aero Engine
Vibration Control of High Performance MachineryPassive Vibration Control: Squeeze Film Damping (SFD)
BearingsTurbineDisk
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Sensitivity runs with unit unbalance at different shaft locations measured in the middle of the LP-shaft
Dis
plac
emen
ts P
tP /
mm
2
1.5
1
0.5
speed / rpm1000 2000 3000 4000 5000 6000 7000 80000 confirmation run
Sensitivity Run up curves of LP Turbine due to Unbalance
Rotor test rig for the LP shaft of an Aero Engine
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Vibration Control of High Performance MachineryPassive Vibration Control: Squeeze Film Damping (SFD)
Passive Damping SFD
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Lecture: Interactions in Turbomachinery Rotordynamics - 11/11/2021 - P 55
Vibration Control of High Performance MachineryPassive Vibration Control: Squeeze Film Damping (SFD)
Rotor test rig for the LP shaft of an Aero Engine: Bearings with SFD
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Vibration Control of High Performance MachineryActive Vibration Control: Damping with Piezo-Actuator
Active Dampingwith Piezo Actuator
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Vibration Control of High Performance TurbomachineryActive Vibration Control: Damping with Piezo Actuator
Active damping optimzation of the entire
operation range diagnosis / failure
identification no oil supply 1. step to More Electric
Engine (MEE)
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Vibration Control of High Performance TurbomachineryActive Vibration Control: Damping with Piezo Actuator
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Vibration Control of High Performance TurbomachineryActive Vibration Control: Damping with Piezo Actuator
FUnbalance
qSensor
Legend: F= Force, q= Displacement Controller Amplifier
Pros: vibration damping in whole speed range fault detection
Cons: temperature-sensitive expenditure
FPiezo
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Result:
Reduction 60 %
Sensors: Eddy current Sensors, RotormitteController: PD – Controller
Vibration Control of High Performance TurbomachineryActive Vibration Control: Damping with Piezo Actuator
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Vorlesungen Mechatronik im Wintersemester
Vibrations in Nuclear Applications 2021
Annual Energiforsk Seminar (10.11.21)
Modelling, Monitoring and Vibration Control forHigh Performance Turbomachinery
Rainer NordmannTechnische Universität Darmstadt and Fraunhofer Institute LBF