Centrifugal Pump/ Steam Turbine/ VFD-Motor Torsional Analysis and Rotor

Modification

A series of centrifugal pumps were to be purchased and installed in a petrochemical

plant in Taiwan. Prior to purchase, the user contracted Msi staff to perform a complete
mechanical design evaluation, including rotor dynamic, torsional critical speed, and rotor
forced response analysis. In addition, the pressure-carrying capability of all casings at
full and part load was to be assessed. Some of the pumps were driven by motors
through variable frequency drives (VFDs, which have unique and strong torsional
excitation harmonics), and some of them were driven by steam turbines. Our analysis
showed that all aspects of the design were acceptable with sufficient factor of safety,
except for the second torsional natural frequency, which was excited by twice line
frequency of the motor (this is usually the strongest torsional excitation frequency in
electrical motors), and by the partial admission steam turbine’s second harmonic of
running speed, which could be easily excited by misalignment. A low-speed-shaft
coupling modification was determined through "what-if" analysis that allowed the second
torsional mode to be shifted up and out of the range of excitation by these harmonics,
without creating any new problems. The pumps were installed, and have operated for
several years without any mechanical difficulties.

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Identification and Solution of Pump/ Gearbox/Driveshaft/Turbine System Vibration

Problem

A major petrochemical company had a serious gear box failure problem in some service
water pumps, driven at variable speed by a steam turbine though a right angle 1:1 gear
box and hollow drive shafting. Many experts from the pump, turbine, and gear
manufacturers had attempted without success to understand and cure the problem over
a 3 year period. Replacement of the gear boxes with some built to more stringent
standards had no effect. External consultants, using test or analysis also had failed to
solve the problem. Analysis by Msi engineers of torsional and lateral rotor and structural
frequencies confirmed earlier
consultant findings that the design
should be sound in this regard.
Torsional modal testing, using testing
techniques that could be applied
while the pump/gear/turbine
operated, found that all rotor system
natural frequencies were close to
their predicted values, and with even more damping than predicted. However, impact
modal testing on the hollow drive shaft showed that it had a "bell-mode" at the gear
meshing frequency, where the hollow shaft ovalized with very little damping, causing the
shaft length to change through the "poisson effect". The driving force was shown by the
test to be the combined torsional and axial load from the bull/pinion gear meshing. The
drive shaft was filled with grease to damp out this unusual vibration. The gear box noise
immediate fell a factor of five, and all gear box problems ceased.

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 Hydro-cracking Pump Rotor Failures

Impact testing was used to determine the reasons for three failures of a hydrocarbon
cracking pump which was critical to a diesel fuel production process at a major California
refinery. Each failure closed down or severely curtailed fuel production at the refinery, at
an average cost of about $3/4
million per day. Vibration testing
was used to determine the shaft
critical speeds while the pump was
operating at various loads and with
various product densities and
viscosities. This allowed a rotor
dynamics analysis of the 11 stage
flexible shaft pump to be calibrated
by the test results, so that the
analysis could then be used to
accurately predict why certain
operations in the process might
have caused pump failure, and
whether proposed rotor changes would avoid future problems. The testing found the
critical speeds of the operating pump, and the combined testing and analysis showed
that the main reason for past failures was a poorly damped backward precessional
rotordynamic critical speed, which was
located at a lower speed than expected.
The critical speed would be excited
operationally during a rub of the balance
piston, which was possible when pumping
product with excessively low specific
gravity. The rotor design was changed to
make this mode more difficult to excite,
and the minimum permitted specific
gravity was increased to a safe level. The
pump, which had been failing roughly every three months, has now run for three years
without further difficulty.

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Boiler Feed Pump Diagnosis Allowing Parts Order

Redesign of the internals of a main boiler feed pump pair at a Southeastern power plant
was able to be performed "sight unseen", based on results of modal test "sounding" to
determine the stiffness, mass, and damping of all internal components prior to pump
disassembly. From this information, it was able to be determined which bearing and seal
components required repair due to excessive clearances. This made it possible for
redesigned and repaired components to be available at the next plant outage, to
minimize the time to repair the pump.
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Nuclear Power Plant Boiler Feed Pump

A newly constructed European nuclear power plant had all of its main feed pumps
exhibiting vibration on the bearing housings in excess of the vibration specifications, by
up to a factor of three, depending upon operating load. Nearly all of the vibration was at
vane passing frequency. It was believed by the plant and the OEM that a shaft critical
speed was at fault, possibly aided by excess vane/ volute "B-gap" hydraulic forces which
could only be reduced by giving up about half a point of efficiency, worth about 1 million
dollars per year in increased operational costs and lost peak production opportunity.
Testing showed that the rotor natural frequencies were nearly critically damped, at all
operating conditions, and were not
the problem. B-gap forces were able
to be "backed out" of the vibration
signal once the rotor’s transfer
function was determined by impact
modal testing, and were found to be
in an acceptable [Link] of
rotor critical speed or excess
hydraulic load, testing proved that a
complicated bearing housing
resonance was the culprit. The
mode shape movement involved
combined horizontal bending and
twisting of the housing through the
180 degree "drip pocket" that
connected it to the casing. Its
frequency shifted down during
operation because of mass-loading
of the housing by the shaft assembly when operation caused the bearing film to become
stiff, which is why the OEM had not discovered the problem by stationary impact testing.
A bolt-on "bridge" was designed to span
the top of the drip pocket, such that the
torsional part of the motion was
discouraged, shifting the natural
frequency out of the range of the vane
pass frequency. Peak vibration dropped to
within specification, and this problem was
removed as an obstacle to the plant
commissioning, which was only several
weeks away. A delay in plant
commissioning would have cost about 1/2 million dollars per day.

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Use of Experimental Modal Analysis (EMA) to Support Pump Retrofits

Msi principals were contracted through a major OEM to perform their unique
 experimental modal analysis on three 30 year old, reliable, packed-stuffing box,
multistage barrel pumps in critical refinery process (Benzene) service. Upgrades from
the packed-stuffing box to mechanical seals were required due to new OSHA
requirements for pumpage containing benzene. The user and OEM had previous bad
revamp experience when up-front modeling was not performed. TAP was performed on
TM

the operating pumps to determine existing rotor and structural critical speeds and
damping coefficients. This information was used by the OEM to accurately calibrate their
"as built" finite element analysis (FEA), which were then extrapolated to calibrate the
"revamped" models. The resultant upgraded pumps have performed very successfully
and additional knowledge was gained to improve typical assumptions made when
performing FEA. The methodical approach described has helped users meet new federal
regulation ("Process Safety Management - OSHA 29-1910-116") requirements when
performing turbomachinery upgrades.

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All Content Copyright © 1996-2004, Mechanical Solutions Inc.

Reciprocating Pump/Torsional Analysis #1

MSI engineers were contracted by a major domestic pump manufacturer to determine the torsiona
frequencies of a machinery train consisting of a five plunger reciprocating pump, a gear set inclu
intermediate shaft, and a VFD (Variable Frequency Drive)/motor driver. The natural frequencie
calculated and compared to likely excitation frequencies. A complete forced response analysis
performed, with modal damping and excitation force strengths based upon theoretically maximum
worst case torque spectra from shop and field testing of similar machines. To accomplish this anal
3D finite element model was constructed which explicitly modeled both the reciprocating and rotat
including all connecting rods, crossheads, and [Link] torsional critical speed analysis sho
some intersections of excitation frequencies and natural frequencies caused several resonances t
the operating range. However, the worst-case forced response analysis proved that the maximum
stress which would occur at these resonances was acceptable relative to shaft fatigue criteria, wit
factor of safety. Using the information from these analyses, the manufacturer was able to proceed c
with parts ordering and fabrication of the pump/gear/motor assembly , with the design unmod
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Reciprocating Pump/Torsional Analysis #2

MSI engineers performed torsional analysis of a reciprocating pump/ gear/ motor system being des
large overseas petroleum drilling venture. Analysis of the initially designed system indicated that th
possibility of resonant torsional vibration, driven by 50 Hz line frequency. The customer request
additional analysis be performed to investigate how coupling options could be modified to provide
factor of safety relative to the occurrence of torsional resonance. It was discovered that, by switc
pump coupling to a double engagement gear coupling from a flexible spring element coupling, the
problem was fixed, but a new resonance problem was created at twice line frequency. By lengthe
coupling hubs on each side to the maximum available length, a factor of safety of over 15 perce
obtained relative to the closest torsional resonance, consistent with good engineering practice
manufacturer of the system included the recommended design change. The pump was placed in s
is functioning with no vibration or reliability problems.

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Reciprocating Pump Valve Failure Analysis

An offshore rig septuplex pump was experiencing chronic suction and discharge valve failures. A m
valve design implemented by the manufacturer did not solve the problem. Msi engineers performed
and on-rig pulsation and vibration testing. Structural and acoustic natural frequencies were determ
test, as well as the harmonic content of the pressure waves in the cylinders and manifolds. Tribolo
metallurgical tests were also performed on the valves, guides, and seats. It was determined that a f
film which was forming on the valve guides was hanging-up the valves, causing them to close l
slamming shut. Finite element analysis proved that the impact stress waves were strong enough t
fatigue of the valve plates. The valve guide clearances and seat angle were changed slightly to di
hang-up and high closure rate, solving the problem.

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 Aeroderivative Gas Turbine Analysis and Test

The staff of Mechanical Solutions, Inc. has background and experience in the analysis and tes
aeroderivative gas turbines, such as the popular FT-4, LM2500, and LM6000 PC units. One of
principals was one of the design analysis team-members for the original ground-based and marin
conversions of the FT-4. Generally, problems with these units are installation or system related. M
to separate and evaluate rotordynamic, casing, and support structure effects allows such problems
any warranty issues to be quickly identified, such that responsibilities can be determined, and app
fixes can be developed and implemented.
In a new power plant overseas, two newly installed aeroderivative gas turbine/ generator sets
experiencing sudden and dramatic increases in vibration level over certain operating torque range
was at first fixed on the engine rotordynamics. MSI performed impulse excitation of the operating
casing and rotor, using its time-averaged pulse (TAP ) technique. Forward and backward critical s
TM

the rotor were determined, along with rotor modal damping. It was clearly shown that rotordynamic
the issue. Very detailed experimental modal analysis (EMA) was then performed on the engine cas
supports, I-beam support structure, and turbine bay foundation. Complex mode shapes were const
animated, and modal damping was determined, for all natural frequencies in the running speed r
addition, operating deflection shapes (ODS) of vibration amplitude and phase were produced ba
measurements at many casing and support locations.

This was repeated for various torque conditions, including both problem and non-problem conditio
and ODS animations were compared, allowing the identification of excitation force locations and
nonlinearities. Situations were identified in which the support structure was behaving much more fle
it was designed to. Strain gages on support struts were used to verify these conclusions. A fix was
by MSI to fundamentally and completely cure the problem, on a permanent basis at all operating c
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Centrifugal Pump/ Steam Turbine/ VFD-Motor Torsional Analysis and Rotor Modificat

A series of centrifugal pumps were to be purchased and installed in a petrochemical plant in Taiwa
purchase, the user contracted Msi staff to perform a complete mechanical design evaluation, inclu
dynamic, torsional critical speed, and rotor forced response analysis. In addition, the pressure-c
capability of all casings at full and part load was to be assessed. Some of the pumps were driven b
through variable frequency drives (VFDs, which have unique and strong torsional excitation harmo
some of them were driven by steam turbines. Our analysis showed that all aspects of the desig
acceptable with sufficient factor of safety, except for the second torsional natural frequency, whi
excited by twice line frequency of the motor (this is usually the strongest torsional excitation frequ
electrical motors), and by the partial admission steam turbine’s second harmonic of running spee
could be easily excited by misalignment. A low-speed-shaft coupling modification was determined
"what-if" analysis that allowed the second torsional mode to be shifted up and out of the range of ex
these harmonics, without creating any new problems. The pumps were installed, and have oper
several years without any mechanical difficulties.

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Identification and Solution of Pump/ Gearbox/Driveshaft/Turbine System Vibration Prob

A major petrochemical company had a serious gear box failure problem in some service water pum
at variable speed by a steam turbine though a right angle 1:1 gear box and hollow drive shafting
experts from the pump, turbine, and gear manufacturers had attempted without success to unders
cure the problem over a 3 year period. Replacement of the gear boxes with some built to more s
standards had no effect. External consultants, using test or analysis also had failed to solve the p
Analysis by Msi engineers of torsional and lateral rotor and structural frequencies confirmed earlier
findings that the design should be sound in this regard. Torsional modal testing, using testing techn
could be applied while the pump/gear/turbine operated,
found that all rotor system natural frequencies were close
to their predicted values, and with even more damping
than [Link], impact modal testing on the
hollow drive shaft showed that it had a "bell-mode" at the
gear meshing frequency, where the hollow shaft ovalized
with very little damping, causing the shaft length to
change through the "poisson effect". The driving force was
shown by the test to be the combined torsional and axial
load from the bull/pinion gear meshing. The drive shaft was filled with grease to damp out this u
vibration. The gear box noise immediate fell a factor of five, and all gear box problems ceas

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Power Steam Turbine Evaluation

 Vibration testing was performed on an African power plant steam turbine/ generator set to determ
reasons for excessive vibration. Based on the test results and evaluation, the plant decided to c
operation, successfully, in spite of the excessive vibration readings obtained using standard signatu
The alternative was a premature turbine overhaul, with associated but unbudgeted downtime costs
$1.5M/ day.

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Steam Turbine Driver Blade Erosion

Following a lengthy period of service, the LP stages of a nuclear plant boiler feed pump turbine wer
have suffered erosion damage. A mechanical redesign of those stages was undertaken by Msi en
Analytical modal analysis found the first several natural frequencies for each stator blade. A possib
problem in one redesigned turbine blade was discovered, and was avoided by shortening the blad
The casing stresses were also investigated, and the alteration in stress field was determined d
modification of the inner casing. Both the casing and stator blade stress analyses were performed
case pressure and transient thermal loading. The stator blade vibration and stress analyses and ca
analysis predicted that all aspects of the redesigned LP turbine components should perform satisf
terms of structural and reliability characteristics.

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Aeroderivative Gas Turbine and Gearbox / Genset

MSI was called on behalf of a customer who had seen a large increase in the vibration levels of a
LM500 Gas Turbine Generator Set being used to supply power to a large pharmaceutical facilit
increase in vibration levels was serious enough to warrant [Link] power
facility was used to meet much of the electrical power needs of the entire
complex and any loss of generating capacity translated straight into increased
electrical operating costs because of the need to buy power from the grid at a
time of the year where such purchases were particularly expensive. The plant
wished to continue operation another 3 months, until there was a planned
shutdown.

The OEM had not been able to find the reason for the difficulty. Therefore MSI was called in to help
and fix the excessive vibration. The customer had noticed that the large increase in the overall vibr
particularly troublesome in between the gas turbine and the generator. They suspected that the pro
a torsional natural frequency of the gearbox. MSI performed testing using generator shaft strain ga
sophisticated radio telemetry. Because of MSI's experience conducting such tests, the generator
down for only an hour in order to install the telemetry system.

The testing was to focus on torsional oscillation, but showed that the torsion did not cause the high
vibration. MSI continued testing and was able to quantify the vibration levels with increasing load.
the shape of the vibration spectrum, the strength of the vibration appeared to be associated with
frequency resonance. However, impulse testing on exposed components detected no strong n
frequencies near 1X or 2x gear mesh. It was also noted that the vibration increase was sensitive to
In light of this, the sudden increase in vibration suggested a possible shaft or casing crack that o
under increasing load. This crack could open up further as the load transmitted through the gear
increased. Stationary "bump" tests did not indicate this crack but vibration measurements at many l
various loads made it apparent.

In order to be completely certain that this was the most likely cause, MSI also tested the electrical g
confirm that the problem was not generator or electrically based. This testing revealed nothing unu
phase to phase characteristics of the system and left a crack as the most likely cause of the pro
On the recommendation of MSI, die penetrant testing of the gear box was conducted. The die pe
testing revealed that a crack had formed on the foot of the gear box casing. The crack was welded
subsequently the vibration of the gearbox was reduced to earlier acceptable levels. This work allow
user to continue power generation during a critical portion of production.

In addition to knowledge of the LM500, the staff of Mechanical Solutions, Inc. has background and
in the analysis and testing of aeroderivative gas turbines, such as the popular FT-4, FT-8, LM2500
PC, and Frame 7FA units. One of MSI's principals was one of the design analysis team-member
original ground-based and marine-based conversions of the FT-4. Generally, problems with these
installation or system related. MSI's ability to separate and evaluate rotordynamic, casing, and s
structure effects allows such problems as well as any warranty issues to be quickly identified, su
responsibilities can be determined, and appropriate fixes can be developed and implemente

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Multi-rotor Gas Turbine Rotordynamic Analysis Incorporating Casing Supports

An area of concern for gas turbine OEM's and end users is the
effect of casing and structural supports on the rotordynamic
response of multi-rotor systems. MSI has conducted sophisticated
analysis of such problems utilizing the latest technology available
in Finite Element Analysis (FEA) and rotordynamics. Figure 1
shows an aircraft gas turbine FEA model developed utilizing
ANSYS. By conducting a forced response analysis of a proposed
weight reduction of the casing, the frequency dependent response
of the structural forces and vibrations at the bearing support
locations was determined.

Figure 2 shows the

transfer function
representation of this frequency dependent respon
transfer function was then incorporated into a mu
rotordynamics model for analysis.

Figure 3 shows the rotor model created utilizing the

of Virginia ROMAC suite of rotordynamics codes. T
incorporated the structural supports as determin
ANSYS with the full multi-rotor system. The resulting
model was able to analyze the engine for forced response, lateral stability and both damped and u
mode shapes.
Based on this more complete model, issues associated with structural supports and their affect o
rotordynamics can be properly assessed.
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425 MW Steam Turbine Commissioning

MSI was called on behalf of an engineering construction firm building a new power plant in the S
Hemisphere. The plant was only weeks away from the commissioning deadline, after which hund
thousands of US$ per day liquidated damages would be due. The plant consisted of two 425 MW
turbine/ generator sets, the first of which had been commissioned without a hitch. The sister unit,
which was nominally identical in all design details
including the piping and foundation, tripped out at the first
critical speed every time the OEM tried to bring it up to
operating speed.

The vibration was almost entirely at 1x running speed., and the OEM had assumed that the issue w
one of appropriate balancing. However, the addition of balance weights, based on information at lo
and at a speed just below where the unit tripped on start-up, was not making any progress, even
trials. The OEM concluded that the problem was not balancing after all, but rather some machinin
other internal anomaly which could only be determined by full disassembly of the unit in the fiel
subsequent repair at the OEM shop. Unfortunately, this path would lead to many weeks, and perha
of schedule slippage, at enormous contract cost.

MSI used its 14 channel B&K Pulse Spectrum Analyzer/ Digital Recorder to monitor proximity prob
housing, and casing accelerometer signals simultaneously. It was determined that no internal rub w
place, although a mild rub on the HP outboard bearing was indicated. In addition, the shaft orbits s
that both of the HP bearings were misaligned, such that the shaft was constrained from developing
circular orbit, but was forced instead into a highly elongated orbit. Furthermore, an inconsistent an
20% shift in the HP first critical speed was observed as the shaft approached the trip point, such
phase angle of the vibration response (as related back to the keyphasor) would vary considerably a
speed in the trip zone.

MSI concluded that the bearing misalignment situation was leading to significantly different bearing
than the turbine was designed for. However, the transient thermal growth of the rotor and casing m
bearing "pinch", and therefore the critical speed shift, different from one run-up to the next. This m
basing the balance correction weight angular positions on the phase information from one run, g
would not hold true for what was required for proper balance in a succeeding run. Therefore, althou
with the OEM balance team MSI was able to get through the first critical speed in only two trials u
influence coefficient approach, MSI also advised that balancing efforts could not come close to spe
bearing problem was fixed.

Based on these findings, MSI firmly recommended a week long shut-down for inspection and repai
bearing installation. The OEM felt that this was a waste of effort. However, it was discovered tha
outboard bearing had been installed horizontally cocked, forcing the shaft out of the intended ope
position on the bearing fixed central pad, and into the center of the anti-whirl pocket, greatly shif
bearing k. In addition, the HP inboard bearing pedestal was found to be cocking during the start-u
growth, because of accidental mis-placement of one of the thick shims between the casing and th
pedestal. Fixing of these bearing issues eliminated the critical speed shifting near the original probl
and allowed balancing to quickly progress. The disassembly of the turbine was avoided, and the
coupled machinery train was brought fully within the ISO-7919 vibration specification, one week p
initiation of contract liquidated damages.
 Recent other steam turbine projects that MSI has performed include design audits of re-rates, bl
bladed disk natural frequency resonance identification and fix, an impulse stage shroud failure fix,
identification of rotor critical speeds without unit shut-down.

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Failed Compressor Impeller

Msi was contracted by a customer to investigate a failed compressor impeller. An FEA

model of the impeller was created to perform a natural frequency modal analysis. The
model closely correlated with experimental modal analysis test results.

The model calculated the first 200 natural frequencies of the impeller. Most of these
occured in groups distinguished by the "lobes" in their mode shape, known as the
number of "nodal diameters."
The analysis confirmed that the failure was vibration-induced fatigue caused by the
synchronization between vane/blade "sum and difference" pressure-pulsation at blade-
pass frequency and the natural frequency of the disc three nodal diameter mode shown
in the lower right mode shape picture. Based on the worst case loading situation
occurring in service, the design was marginal, and the factor-of-safety was very close to
1.0. Several possible modifications were tried using the FEA model, and a final
recommendation which was suggested by MSI was able to increase the factor- of-safety
by a minimum of 50%, as shown in the Goodman Diagram.

The whole project was compressed into a very small time window due to a pressing
overhaul schedule requirement. MSI was able to meet the requirement by constructing
and running the complicated model very quickly and recommending a fix that minimized
component changes.

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Shop Compressor Shaft and Casing Fatigue Study and Modification

A new design of motor-driven shop compressor in France was needed to run reliably
and quietly. Staff of Msi analyzed the casing and shaft/rotor assembly (both laterally and
torsionally) for fatigue under expected worst-case variable loading. A fatigue problem in
the casing discharge end corner fillet was identified under circumstances of rapid load
cycling. The manufacturer at first did not agree that the analysis was realistic, but
agreed to perform a shop test under cyclic conditions which were worst-case, but
possible in many services. After accelerated cycling that represented several months of
operation, a fatigue crack occurred, and a through-crack punctured the compressor
casing, causing an explosion hazard. The design was revised per the original
recommendations, and performed without structural hazards.

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Screw Compressor Noise and Vibration Elimination

A Midwest coal-fired power plant was experiencing high vibration and noise in an
extensive screw compressor/ piping system required for pollution control. A piping
acoustic resonance was anticipated by the plant. Time averaged modal testing was
used to acoustically test the piping, as well as the blower frames and rotors. It was
discovered that an axial resonance was occurring in the blower driver shaft, which in
turn caused occasional rotor rubs, and was driving the noise in the piping. The modal
testing proved that no piping resonance of any significance was occurring, and
expensive unwarranted piping modifications were avoided.

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Process Compressor Re-design

FEA stress and vibration analysis was performed for three process compressor
impellers installed in highly erosive service. The objective of the analysis was to design
a rerated impeller that would result in accurately predicted peak stresses that were at
least a factor of safety of 2.0 below both the tensile yield strength and the conservatively
estimated fatigue endurance limit for the selected impeller material. In addition, optimal
shaft attachment pressfits and bolt-down torques were determined. Finally, all natural
frequencies that were close to potentially strong excitation frequencies were
investigated. This investigation included evaluation of the shape of the excitation force
distribution in space, such as would be created for example by the presence of diffuser
vanes. This shape was compared to the number of nodal diameters associated with a
potentially resonant natural frequency. Only if shapes as well as frequencies matched
on the basis of direct or sum-and-difference excitations was a natural frequency
considered potentially resonant. If it was considered potentially resonant, then the
structural performance was further evaluated, and would be judged acceptable only if
either the natural frequency in question was lightly excited compared to the available
damping, or if it possessed a margin of at least 10 percent relative to the excitation
[Link] acceptable configuration to avoid structural fatigue was determined for
each impeller, as well as appropriate shaft attachment fits and torques to resist
loosening by running torque and combined thermal and centrifugal deflections. Stresses
were well within acceptable limits. The highest stresses were in the impeller backface
and bore, which is typical, and were substantially below the material yield and fatigue
strengths everywhere, so that cracking was determined to be unlikely, even in the case
of the severe erosion damage which was expected in this service. On the vibration
Campbell Diagram (which plots natural frequencies and excitation frequencies versus
speed), all anticipated excitation force frequencies were shown to miss significantly
excitable natural frequencies by more than the 10 percent margin.

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Rotor Instability Problems in an Integrally Geared Compressor

MSI was called in by an end-user to help troubleshoot a newly commissioned critical

compressor train experiencing unexplained vibration trips. These sudden vibration trips
threatened to jeopardize delivery of product and thereby result in a substantial loss of
revenue. The combined
service six-stage (three plus
three) integrally geared
compressor was installed in
an industrial gas facility
supplying a major
petrochemical plant. The
compressor was electric
motor driven with three
stages for high-pressure
nitrogen compression and
three stages for high-
pressure dry air
compression. The
compressor was
commissioned with bearing
pad temperatures that were
operating continuously over
200 F. Subsequent bearing inspections showed excessive oil coking and wear. The
OEM attempted to modify the bearings to reduce the pad temperatures but this was
unsuccessful due to unacceptably high vibration amplitudes. Following the vibration
trips MSI traveled to the facility on very short notice and began testing. The data
collection involved a series of process and bearing oil tests to recreate the trip
phenomena. MSI
was able to
conclusively identify
the
problem as a
rotordynamic
instability caused by
a strong
subsynchronous
excitation of a
cantilevered rotor
natural frequency
located at 47
percent of running
speed (refer to
figure).
Rotordynamic analysis suggested that the subsynchronous excitation was due to
labyrinth seal cross coupling effects. Based on the recommendation of MSI, the
manufacturer installed swirl breaks to decrease the subsynchronous vibration excitation.
This eliminated the rotordynamic instability and allowed the bearings to be modified in
order to reduce bearing pad temperatures. Following the installation of swirl breaks the
machine has not experienced a vibration related trip. Because of the successful field
testing and redesign work, the end customer has used MSI for subsequent upfront
design audit work on other integrally geared compressor trains. MSI utilizes its state-of-
the-art rotordynamic and FEA codes along with years of design audit experience to help
identify possible problems. This experience base includes the use of empirical stability
criteria such as the Fulton/Sood
Stability Map. Use of this
screening criteria would have
identified the instability seen in
this particular compressor (refer
to figure). MSI's audit and field
testing expertise has made it a
leader in successful
commissioning of critical
compressor trains. The results of
this successful testing were
summarized as a lecture at the
30th Turbomachinery
Symposium of Texas A&M
(2001).

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Strain Measurement of a Centrifugal Compressor Impeller via FM Telemetry

MSI worked closely with a major compressor OEM to specify, install and conduct strain
gage testing of a centrifugal compressor impeller on the OEM test stand. MSI utilized its
state-of-the-art FM telemetry system to transmit 5 simultaneous channels of data with
each channel at either 5 or 10 kHz. Data transmission included dynamic strain
measurements and dynamic pressure measurements from key locations on the rotating
impeller. MSI also installed stationary pressure probes in the suction and discharge as
well as accelerometers and
acoustic quality
microphones. Figure 1
shows the natural frequency
response of the impeller
the rotating impeller during testing. The natural frequency modes near 3 kHz are clearly
evident since they were excited by the flow turbulence in the vicinity of the blades.
However, much
higher strain levels
are seen at lower
frequencies. Based
on the testing
program, MSI was
able to determine
that the high strain
levels at the low
frequencies were
forced vibration
caused by rotating
stall. This stall
phenomenon was
occurring at non-
audible levels and was significant enough to cause high cycle fatigue failure. This
conclusion would never have been reached if the advanced testing program put
together by MSI had not been conducted. The natural frequencies observed during
testing correlated well both with stationary impact test results and predictions by MSI
using 3-D finite element analysis (FEA). The analysis was then used to investigate
"what-if" scenarios, to determine how strong the stall needed to be to cause fatigue and
to investigate design modifications to reduce peak stresses and cracking potential.
Overall, the efforts of MSI in conjunction with the OEM contributed to a successful
redesign effort.

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