DIAGNOSTYKA’30 45

BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

ABSOLUTE AND RELATIVE VIBRATION INCONSISTENCIES IN DYNAMIC

ANALYSIS OF HIGH POWER TURBOGENERATOR ROTATING SYSTEM
Vytautas BARZDAITIS*, Remigijus JONUŠAS*,
Rimantas DIDŽIOKAS**, Vytautas BARZDAITIS V***.

*Kaunas University of Technology. Faculty of Mechanical Engineering Mickeviþiaus St. 37,

LT-44244, Kaunas, Lithuania
**Klaipeda University Faculty of Marine Engineering Bijunu St. 17, Klaipeda, Lithuania
***Vytautas Magnus University Computer Science Department Vileikos St. 8, Kaunas, Lithuania
E-mail:[email protected]

Summary
The paper presents the research results of machine condition monitoring and fault diagnostics
of the High Power Steam Turbines and Electric Generator rotating system. The inconsistencies of
journal bearings absolute vibration parameters of the rotating system and journal bearings shafts
relative vibration parameters have been shown. In the low frequency range the shafts relative vi-
bration displacements are decisive informative in defects diagnostics. The journal bearings sup-
ports absolute vibration velocities of low frequencies are being strongly damped by massive bear-
ings supports, etc. Journal bearings absolute vibration parameters supply the information errone-
ously attributed to the rotor. High frequency absolute vibration acceleration, however, make it
possible to provide monitoring of coupling.

Keywords: steam turbine, electric generator, journal bearings, absolute and relative vibration

1. INTRODUCTION a rugged construction and the endurance against

aggressive media, this type of proximity probes is
More than 25 turbo generators whose power successfully used in turbo machines – Steam tur-
exceeds 20 MW are operating in Lithuanian Ther- bines Generator sets.
mal Power Stations. Most of these machines opera-
tion period is more than 20-40 years as through the The monitoring results (Smax , Sp , S0-p , ǻr ,
world. But perspective requirements to those ma- etc.) are given in steady state and transient data
chines are to operate not only safely under long – formats and adapted for the analysis with diagnostic
period mode but to provide higher efficiency. Only software DDS 2000 [1-3]. The diagrams of the
after modernization used in automatic control and maximum values of shaft displacement from time
mechatronic systems this task will be achieved. In integrated mean position of the 1st and 2nd bearings
this presentation the modernization of 60 MW shafts Smax1, Smax2 under the varying loads are
power turbogenerator have been studied. Permanent shown in Fig. 2.1a and Fig. 2.2a. According the
monitoring system provides vibration, temperature, recommendations of ISO 7919-2:2001 standard the
geometric parameters and process variable infor- steam turbine HPR technical condition is not ac-
mation.. The experimental research has been pro- ceptable for continuous long term operation - the Sp-
vided to evaluate technical condition of the tur- p exceeds permissible safe operation values – zone
bogenerator as a whole machine, journal bearings boundaries C/D is Sp-p=260 ȝm.
and tooth wheeled coupling. The inconsistencies
between absolute and relative vibration parameters
are examined in this study.

2. 60 MW POWER TURBOGENERATOR

The rotor of a turbogenerator unit with some

data formats of on line monitoring system is shown
in Fig.1.
Measuring system with eddy current transducers
(proximity probes) serve the measurement of me-
chanical quantities: peak-to-peak values of shafts
vibration displacements Sp-p and radial clearances
Dr between the shafts and the bearings. Due to the
contact less measuring principle, small dimensions,
46 DIAGNOSTYKA’30
BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

Fig.1 The schematic plot of 60 MW turbogenerator with monitoring system results

Fig. 2.1a HPR 1st bearing maximum value of shaft displacement Smax1 plot at varying load:
365 µm/41 MW, 299 µm/49 MW, 270 µm/55 MW and 325 µm/43.5 MW

Fig. 2.1b HPR 1st bearing shaft relative vibration displacements spectra in horizontal direction at 41 MW
load, Smax1=365 µm
 DIAGNOSTYKA’30 47
BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

2nd bearing shaft with two

proximity probes

Fig. 2.2a HPR 2nd bearing maximum displacement Smax2 plot at varying load:196 µm/41MW,
207 µm/49MW, 211 µm/55MW and 192 µm/43.5 MW

The shafts relative vibration displacements bearings are dominant in horizontal (and vertical)
spectra shows that 1X frequency vibration dis- plane as shown in Fig. 2.1b and Fig. 2.2b but in
placements amplitudes are prevailing in 1st, 2nd , 3rd horizontal plane vibration severity is higher than in
and 4th bearings. The maximum vibration displace- vertical. The 2nd bearing shaft is less sensitive to
ment amplitudes of 1X frequency of 1st and 2nd load changes in comparison with 1st bearing shaft.

Horizontal Vertical

Fig. 2.2b HPR 2nd bearing shaft relative vibration displacements spectra in horizontal and vertical
directions at 41 MW load, Smax2=196 µm

1st 2st

Fig. 2.2c HPR 1st and 2nd bearings shafts relative displacement orbits at 41 MW load

The orbits shapes of 1st and 2nd bearings are orbits of the 1st and 3rd bearings shafts have the
very different in values, but both are close to ellip- same shape but differ more from the ellipse shape
tical orbit shape as orbits of 3rd,4th bearings shafts because these two bearings are radial-axial type.
(not shown) and 6th bearing [1]. The maximum val- The orbits of 2nd, 4th and 6th bearings shafts are
ues of shaft displacements Smax plots and orbits in- close to elliptical shape because these bearings are
dicate that the most vibroactive are the 1st and 2nd radial and provide the similar dynamic motion.
bearings shafts and that vibration severity is inde-
pendent of the load level of turbogenerator. The
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BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

5th 6th

Fig. 2.3a GR 5th and 6th bearings maximum values of shafts displacements Smax5 ,Smax6 plots at varying load:
43 µm/41MW, 42 µm/49MW, 38 µm/55MW and Smax6 : 33 µm/41MW, 34 µm/49MW, 37 µm/55MW

The generators rotor maximum values of shafts values the kinetic orbit of 5th bearing shaft is very
displacements of the 5th bearing Smax5 and of 6th differs from the ellipse shape despite the radial, not
bearing Smax6 under varying load are shown in Fig. radial-axial design of this bearing as shown in Fig.
2.3a. Evaluating vibration severity according ISO 2.3b. The vibration displacement spectra of 5th
7919-2 recommendations the technical condition of bearing is shown in Fig.2.3c and indicates that 1X
generators bearings is acceptable for long-term ope- and 2X frequency vibration displacement ampli-
rations – peak-to-peak values of shaft displace- tudes have the same values in horizontal direction,
ments 60 ȝm. Despite low vibration displacement but 2X is dominant in the vertical direction.

5th 6th

Fig. 2.3b GR 5th and 6th bearings shafts relative vibration displacements kinetic orbits at 41 MW
loading

Horizontal Vertical

Fig. 2.3c GR 5th bearing shaft relative vibra-tion displacements spectra in horizontal and vertical
directions at 41 MW load, Smax5=43 µm
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BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

Horizontal Vertical

Fig. 2.3d GR 6th bearing shaft relative vibration displacements spectra in horizontal and vertical di-
rections at 41 MW loading, Smax6=33 µm

Table 1 Bearings shafts relative vibration displacements parameters: S0-px, S0-py , Smax and
harmonics Sp1x, Sp2x in X and Sp1y, Sp2y in Y directions (1X=50 Hz frequency) 41 MW load
Rotors HPR MLPR GR
Bearings shafts 1 2 3 4 5 6
Maxima displacement of total vibration, Smax, ȝm
Smax 365 196 123 100 43 33
Peak values of vibration displacements S0-px in X and and S0-py in Y directions, ȝm
S0-px 324 161 84 70 42 17
S0-py 173 129 110 89 22 32
1X and 2X frequency amplitudes Sp1x, Sp2x in X and Sp1y, Sp2Y in Y directions, ȝm
Sp1x 291 152 68 65 22 11
Sp1y 152 124 103 81 6 26
Sp2x 23 15 3 1 19 3
Sp2y 31 11 1 6 18 6

The vibration displacement spectra of 6th bear- 3. HPR AND MLPR BEARINGS ABSOLUTE
ing shown in Fig.2.3d indicates that 1X frequency VIBRATION
vibration displacement amplitudes are prevailing in
comparison with 2X vibration amplitudes in both Turbo generator’s bearings absolute vibration
horizontal and vertical directions. velocities and accelerations were measured with
The summary of relative vibration displace- two different kinds of seismic transducers. The vi-
ments parameters is shown in Table 1. Despite the bration velocity measuring transducer that operates
fact that GR vibration severity is low, it is impor- on the inertial mass-moving case principle and pro-
tant to establish main sources of these vibrations vide measurements directly in velocity units and the
that caused kinetic orbit shape changes from ellipse vibration acceleration measuring transducer that
shape. operates on piezoelectric crystal physics and pro-
vide measurements directly in acceleration units
and after integration – in velocity units. These
measurements signals have been analyzed with
Vibration Signal Analyzers for diagnostics pur-
poses [1-3]. The absolute vibration velocities pa-
rameters are shown in Fig. 3.1, Fig.3.2 and Table 2.

Horizontal, Vrms=2.0 mm/s Vertical, Vrms=1.6 mm/s

Fig.3.1 HPR 1st bearing absolute vibration velocity spectra in horizontal and vertical at 44 MW load
50 DIAGNOSTYKA’30
BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

According absolute vibration velocities root 1st bearing shaft Smax1=365 µm and for 2nd bearing
mean square values Vrms and ISO 10816-2 shaft Smax2=196 µm, and Sp-p>400 ȝm has been
recommendations the techical condition of HPR reached not acceptable evaluation zone D.
both bearings are good, because vibration velocity Only 1X=50 Hz frequency vibration velocities
Vrms value is in A vibration evaluation zone. amplitudes dominant in HPR 2nd and 1st horizontal
According ISO 10816-2 A/B vibration severity vibration spectra and in MLPR 3rd and 4th bearings
evaluation zone boundary is Vrms=3.8 mm/s (page 6, vibration spectra. In vertical direction vibration
Annex A). This result is to the contrary with HPR velocities amplitudes of 2X frequency is slightly
bearings shafts relative vibration displacements greater than 1X component.
peak-to-peak values. Vibration severity values for

Horizontal, Vrms=1.6 mm/s Vertical , Vrms=1.3 mm/s

Fig. 3.2 HPR 2nd bearing absolute vibration velocity spectra in horizontal and vertical directions at
44 MW load

The higher Vrms value of MLPR 3rd and 4th bearings shafts relative vibration displacements
bearings as shown in Table 2 reached values for 3rd bearing shaft Smax3=123 µm and for 4th
Vrms=3.7 mm/s when measured in vertical direction bearing shaft Smax4=100 µm that Sp-p .260 ȝm
on 4th bearing support. The 1X frequency harmonic reaches not acceptable evaluation zone D. This
vertical velocity amplitude reached Vp=3.6 mm/s. result is in contrary with MLPR bearings shafts
The technical condition of HPR and MLPR bea- relative vibration displacements values as with HPR
rings is acceptable according ISO 10816-2 recom- too.
mendations. This result is in contrary with MLPR

Table 2 Turbogenerator’s bearings absolute vibration velocities

root mean square values Vrms (mm/s) at 44 MW load

Rotors HPR MLPR GR ER

Bearings 1 2 3 4 5 6 7 8
Direction
V,vertical 1.6 1.3 1.5 3.7 3.0 1.8 2.6 1.7
1X
0.79 1.0 1.3 3.6 2.3 1.6 2.4 1.6
2X
3X 0.96 0.68 0.35 0.61 1.7 0.21 0.98 0.46
0.18 0.13
H 2.0 1.6 1.3 2.4 3.3 0.97 0.54 1.4
horizontal
1X 1.4 1.2 0.87 2.3 2.2 0.52 0.49 0.56
2X 0.35 0.49 0.17 0.22 2.4 0.73 1.2
3X 0.40 0.25 0.13
A, axial 0.91 1.2 - 1.6 3.2d 1.8 - 2.2
1X 0.35 0.77 - 1.4 3.1 1.3 - 1.7
2X 0.37 0.78 - 0.51 1.1 1.1 - 1.3
4X - 0.18 -
and vertical directions and results are shown in Fig.
4. GR BEARINGS ABSOLUTE VIBRATION 4.1 and 4.2.
VELOCITIES AND STATOR VIBRATION The 1X and 2X vibration velocity amplitudes
are prevailing in both bearings vibration velocities
The generator’s bearings absolute vibration spectra. The absolute vibration velocity of 1X fre-
velocity spectra have been measured in horizontal quency in vertical direction is greater than 2X
frequency of 5th bearing.
 DIAGNOSTYKA’30 51
BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

Horizontal, Vrms=3.3 mm/s Vertical, Vrms=3.0 mm/s

Fig 4.1 GR 5th bearing absolute vibration velocity spectra in horizontal and vertical directions at
44 MW load

Horizontal, Vrms=1.76 mm/s Vertical, Vrms=0.97 mm/s

Fig 4.2 GR 6th bearing absolute vibration velocity spectra in horizontal and vertical directions at
44 MW load

The vibration velocity amplitudes in horizontal approximately equal. But difference between vibra-
direction of 1X and 2X frequencies are tion parameters spectra is accented as shown in Fig.
approximately equal as shown in Fig.4.1. The main 4.2 and Fig. 2.3 d. Only 1X frequency vibration
difference between relative and absolute vibration displacement amplitude is in horizontal direction
spectra are shown in Fig. 4.1 and Fig. 2.3c in (Fig.2.3d.) in comparison with horizontal vibration
vertical direction. The vibration severity is higher velocity spectrum in Fig. 4.2. The 6th bearing sup-
according to the absolute vibration parameters in port has large mass in comparison with 5th bearing
comparison with relative vibration parameters. The support mass and this phenomenon provides inten-
1X and 2X frequency bearing absolute vibration sive damping of absolute vibrations.
data is in contrary with 5th bearing shaft relative The differencies in absolute and relative vibra-
vibration displacement data as shown in Fig. 2.3c. tion spectra of 5th and 6th bearings have been
The vibration severity of 6th bearing is lower explained after generator‘s stator vibration monito-
than of the 5th according to the absolute vibration ring that shown in Fig 4.3.
velocity Vrms values. The 5th and 6th bearings shafts .
relative vibration displacements values are

1
1

5 6
A B C

2
2

Point B vibration Measurement points A, B, C

Fig 4.3 Generator’s Stator vibration velocity spectrum measured at the middle point B in
horizontal direction at 44 MW load
52 DIAGNOSTYKA’30
BARZDAITIS…, Absolute and relative vibration inconsistencies in dynamic analysis…

In Table 3 the Stator’s points A, B and C electromagnetic energy transformation mechanism

absolute vibration velocities measured in horizontal in the electric generator –unbalance magnetic and
direction are shown. The midle point B provides the centrifugal forces magnify the initial eccentricity,
highest vibration severity. The 2X frequency vibra- both static and dynamic
tion velocity amplitude 9.30 mm/s is excited by

Table 3 Absolute vibration velocities 1X and 2X frequency amplitudes

Measurement points on Stator’s case
Harmonics A B C
Turbine side Exciter side
1X=50 Hz 1.7 mm/s 0.66 mm/s 1.3 mm/s
2X=100 Hz 0.52 mm/s 9.30 mm/s 0.63 mm/s

The Stator vibration 2X frequency excites 5th [4] Barzdaitis V. ýinikas G. Monitoring and diag-
bearing support 2X frequency vibration. This 5th nostics of Rotor Machines (in Lithuanian). -
bearing’s support vibration is accting on proximity Kaunas: Technologija, 1998.-364p.
probe’s attached point. The proximity probes [5] Barzdaitis V., Barzdaitis V.V., Didžiokas R.,
SV5xy and SV6xy mounting locations are in the Pocius Z. Inconsistence of Absolute and Rela-
bearing support. This absolute vibration displa- tive Vibration in Rotors Diagnostics. Mecha-
cements acted on the Dual Radial Vibration nika. ISSN 1392-1207.-Kaunas: Technologija,
proximity probes and 2X frequency displacements 2003, Nr.3 (41), p.48-54.
are changing 5th bearing orbit as shown in Fig.
2.3b.
Professor Habil. Dr. Vytau-tas
5. CONCLUSIONS BARZDAITIS, b. 1946,
1. The HPR bearings shafts provide the highest, not Lithuania. Head of Mecha-
acceptable relative displacements peak-to-peak tronics laboratory. Scientific
values Sp-p and maximum value of shaft displace- interests: Modelling and Si-
ment Smax that caused by the unbalance of the mulation of Mechatronics
rotor. systems using Bond Graph
2. The 1X=50 Hz frequency shafts relative vibra- Approach.
tion displacements amplitudes predominate in
vibration displacement spectra of all bearings Professor Habil. Dr. Remi-gijus
shafts except 5th bearing shaft. JONUŠAS, b. 1940, Lithuania.
3. The HPR and MLPR bearings absolute vibration Head of the De-partment of
velocities values Vrms are low. The absolute vi- Manufacturing Systems.
bration values of HPR bearings supports are very Scientific interests: Inve-
low and are direct opposite in comparison with stigation and mo-deling of
high relative vibration displacement values. precise Rotor Sys-tems, Study
4. The vibration severity of GR bearings is high of technological equipment dy-
according to the absolute vibration velocities and namics and vibrodiagnostiocs.
this issue is in contrary with maximum values of
shaft relative displacements Smax5 and Smax6. Associate professor Dr. Ri-
5. High power turbogenerator stationary machine mantas Didžiokas ZEMAI-TIS,
condition monitoring system at first must pro- b. 1953 in Lithuania. Head of
vide shafts relative vibration measurements and Mechanical Engineering Depa-
after that - bearings absolute vibration measure- rtment Faculty of Marine
ments. Engineering at KU. Trends of
scientific activity: Modeling and
REFERENCE Simulation of Rotors Dyna-
[1] Bently Donald E. Fundamentals of Rotating mics.
Machinery Diagnostics. Library of Congress
Control Number 2002094136, ISBN 0- Master of Science Vytautas
9714081-0-6. Bently Pressurized Bearing Com- BARZDAITIS, b. 1972
pany, printed in Canada, 2002. – 726p. Lithuania. Graduated from
[2] Childs, D. Turbomachinery Rotordynamics. Kaunas University of Tech-
Phenomena, Modeling & Analysis. –New York: nology Faculty of Infor-matics.
John Wiley & Sons, Inc., printed in USA, Studied in Oulu university,
1993.-476 p. Finland at 1996 - 1997 and
[3] Goldin A. S. Vibracija Rotornich Mashin (in Darmstadt Technical University
Russian). – Moskva, Mashinostroenije, 1999. - in 1999, 2000.
344 p.