Case Study 14

Case Study, 38th Turbomachinery Symposium
Title:
Torsional Lateral Coupled Vibration of Centrifugal Compressor System at
Interharmonic Frequencies Related to Control Loop Frequencies in Voltage Source
PWM Inverter
Abstract:
Centrifugal compressor train in a refinery experienced high vibration problem due to
torsional resonance. Sidebands in the VFD output current based on VFD control loop
frequencies were identified as the root cause. In this VFD, stator current was used for
torque and speed control, hence control loop frequencies had a potential to generate
such sidebands. Frequencies of this type of sidebands widely vary with the rotation
speed (proportional to harmonics of the fundamental frequency), hence it is difficult to
avoid resonance at the train torsional natural frequency. In addition, even if a
compressor system is proven to have sufficient safety margin against high cycle fatigue
failure due to the torque pulsation by this mechanism, such minute torque pulsation may
have a potential to excite high lateral vibration at speed adjusting gear. If unpredicted or
overlooked during design stage, such high vibration may disturb plant operation. This
case study therefore proposes guidelines to predict such vibration levels by a simplified
torsional-lateral coupled vibration analysis.
Authors:
Akira Adachi, Toyo Engineering Corporation
Kenji Tanaka, Hitachi Plant Technologies, Ltd.
Naohiko Takahashi, Hitachi Plant Technologies, Ltd.
Yasuo Fukushima, Hitachi Plant Technologies, Ltd.
Torsional-Lateral Coupled Vibration of

Centrifugal Compressor System at
Interharmonic Frequencies Related to Control
Loop Frequencies in Voltage Source Inverter
Kenji Tanaka
Akira Adachi
Naohiko Takahashi
Yasuo Fukushima
14-17 September 2009, 38th Turbomachinery Symposium
Hitachi Plant Technologies, Ltd.

Toyo Engineering Corporation
Introduction
Train Data
VFD Induction Motor + Gear + Centrifugal Compressor
HS
4-Pole
LS
Coupling
Coupling
1200kW
Centrifugal
Induction
Compressor
Motor
VFD
10001500rpm
High vibration was

sometimes observed at
gear LS shaft
Speed
Increaser
Gear
858812882rpm
Figure 1. Compressor Train

1
Onset of Problem
Lateral Vibration on Low Speed Gear Shaft
Vibration Amplitude
(mp-p)
fn1=16Hz
2N
1N
3N
4N
5N
1145
Speed
(rpm)
1100
20m
1040
0Hz
50Hz
Frequency [Hz]
Figure 2. Cascade Plot of

LS Gear Shaft Vibration
100Hz
50m (p-p) Vibration

Detected on LS Gear Shaft
around 1040-1140rpm
(17.3-19.0rps), 570kW
Dominant Frequency
Component: ca. 16Hz
Close to Calculated 1st
Torsional Natural Freq. fn1
15.71Hz
No Significant Vibration on
Compressor Shaft or
Motor Shaft
2
Onset of Problem
Lateral Vibration on High Speed Gear (Pinion) Shaft
Vibration Amplitude
(mp-p)
fn1=16Hz
1145
Speed
(rpm)
1100
20m
Max. 10m (p-p) Vibration

with 16Hz Detected on HS
Gear Shaft
Lower Vibration on HS
Gear Shaft
1040
0Hz
50Hz
Frequency [Hz]
Figure 3. Cascade Plot of

HS Gear Shaft Vibration
100Hz
Stiffer Pinion Bearings

Than Bull Gear Bearings at
Part-Load Due to Uploading
Bull Gear and Downloading
Pinion
Concern: What is the Excitation Source? Pinion Lighter Than Bull

Gear
Torsional Natural Frequencies

Analysis for Torsional Natural Frequencies (FEM)
Motor
5000
3000
2000
Max. operating speed (LS shaft): 1500rpm
Min. operating speed (LS shaft): 1000rpm
4000
Torsional natural frequency [cpm]
Gear
Compressor
2 x rotor speed
1 x rotor speed
Second natural frequency: 2752cpm (45.87Hz)
First Natural Frequency: 15.71Hz (943cpm)
Second Natural Frequency: 45.87 Hz (2752cpm)
First natural frequency: 942.6cpm (15.71Hz)

1000
0
0
1000
2000
3000
4000
5000
Rotor speed [rpm]
Figure 4. Campbell Diagram

for Torsional Vibration
Third Natural Frequency: 422.1Hz (25324cpm)
Figure 5. Torsional Vibration

Mode Shapes
4
Critical Speeds Predicted by Rotor Analyses

Lateral & Torsional Vibration Calculation
Critical Speeds [rpm]
Lateral
First
Second
Operating
Speed
Compressor
5220
17700
8588-12882
Pinion
(HS Shaft)
21200-25600
Dependent on
Load
8588-12882
Bull Gear
(LS Shaft)
3380-9450
Dependent on
Load
1000-1500
Motor
2078
1000-1500
943
2752
Torsional
Shaft Synchronous Resonance is

Excluded. Only Possibility = VFD?
Estimation of Shaft Torque and Motor Torque

Estimation of Shaft Torque Causing 50m Shaft Vibration
Shaft Torque Deduced by One-Way Lateral-Torsional Analysis
Force Applied on Teeth Causing 50m (p-p) Shaft Vibration
(1/2)Ft
Ft
Fn
Fr
HS Gear
(1/2)Fa
cancelled
(1/2)Fn
(1/2)Ft
(1/2)Fr
(1/2)Fn
(1/2)Fa
cancelled
Excitation
LS Gear
Figure 6. Force Applied

on Gear Teeth
(Double Helical)
(1/2)Fr
Transverse Pressure Angle

= tan-1tan/cos
= Normal Pressure Angle
= Helix Angle
Tt = (PCD/2) Ft
= (PCD/2) Fn cos

Lateral Vibration Analysis of LS Gear Shaft
X-Probe Angle=15 degree right of vertical
Y-Probe Angle=15 degree above horizontal
Amplitude [mp-p]
1.20E-1
X
Y
0.101m
1.00E-1
Unit Excitation on Tooth Surface

Fn_p.u.=9.8sin(2fn1t) [N]
8.00E-2
6.00E-2
4.00E-2
16Hz
2.00E-2
0.00E+0
0
10
15
20
Excitation Frequency [Hz]
25
Figure 7. Frequency
Response to Unit Excitation
Force of Gear Shaft
(Bearing Stiffness and Damping
Calculated @ 1140rpm, 570kW)
LS Gear Shaft Vibration

Amplitude at Probe @ 16Hz
=0.101m (p-p) (Calculated)
Fn=9.8(50/0.101)=4851 [N]
Tt = (PCD/2) Fncos
= (0.806/2) 4851 cos 21.9
= 1815 [Nm]
0.213 Times Rated Torque
7

Estimation of Excitation Torque at Motor Air Gap
Amplification Factor for Torsional System
Torque at bul gear shaft /
air gap torque at motor shaft [p.u.]
20
TAG1815 / 16.9
107 [Nm]
16.9 p.u.
15
10
fn1=15.7 Hz
1.3Rated Torque at
Motor Air Gap Suspected.
0
0
10
20
30
40
Excitation frequency [Hz]
50
60
Close to Maximum
Measured Data among
Figure 8. Frequency
Interharmonic Frequencies
Response at LS Gear Shaft
during Factory Test
Assuming 0.02
(1.5Rated Torque)
Merely 1.3% of air gap torque fluctuation
canSeptember
cause
m p-p lateral
8
14-17
2009,50
38th Turbomachinery
Symposium vibration!
fn1
Cause and Effect

Actual Cause and Effect
Sequence of Lateral-Torsional Analysis
Cause
Effect
LS Gear
Shaft
Vibration
50m
16Hz
AF
0.101/9.8
Lateral
Frequency
Response
Effective
Force on
Bull Gear
Teeth
4854N
16Hz
Bearing
Stiffness,
Damping
Torque at
Bull Gear
Teeth
1815Nm
16Hz
Geometry
(, PCD)
Air Gap
Torque on
Motor
Shaft
107Nm
(1.3%)
AF
16Hz
16.9
(=0.02,
Geometry)
Torsional
Frequency
Response
Strength Evaluation
High Cycle Fatigue Evaluation
1200
Alternating stress a [N/mm 2 ]
Mechanical Strength
Verified
Fatigue Factor of
Safety 1.25 for
107 Cycle Life
1000
800
107 Cycle Life
600
400
No Modification
Made on Machinery
or VFD
Stress at the
Condition
200
0
0
200
400
600
800
1000
1200
1400
Mean stress m [N/mm2 ]
Figure 9. Modified Goodman Diagram

10
Investigation of Source of Excitation Torque

Detailed Measurement (LS Gear Shaft Vibration)
fn1=16Hz
fc=1024Hz, n=25, slope: -24
1300
(N/60)
Rotor Speed (LS Shaft) [rpm]
(2N/60)
1250
fc=1024Hz, n=29, slope: +30

Rotor Speed [rpm]
fc=1024Hz, n=23, slope: +24
1045
1035
1025
1005
10
Amplitude
(50mp-p/div)
1015
1200
15
Frequency [Hz]
fc=1024Hz, n=31, slope: -30
1150
1100
(3N/60)
20
50m
1050
50m
1000
0
10
fc=256Hz, n=7, slope: -6

fc=1024Hz, n=31, slope: -30
20
30
Frequency [Hz]
40
50
60
fc=1024Hz, n=29, slope: +30
Figure 10. Cascade Plot of LS Gear Shaft Vibration

11
Investigation of Source of Excitation Torque

Detailed Measurement (VFD Output Current)
fc=1024Hz, n=25,
slope: +25
fc=1024Hz, n=23, slope: -23
f - fn1
Fundamental Frequency
f
fn1=16Hz
fn1=16Hz
f + fn1
VFD Output Current

(50dB/div, min.0.1% Rated Curent)
Rotor Speed (LS Shaft) [rpm]
1300
1250
1200
1150
1100
1050
1000
0
10
20
fc=1024Hz,
n=29, slope: -29 fc=256Hz, n=7, slope: +7
50dB
=32%
30
40
Frequency [Hz]
50
60
fc=1024Hz, n=31, slope: +31
Figure 11. Cascade Plot of VFD Output Current

12
Pattern of Interharmonic Frequency Component

Inclined Streaks of Interharmonic Frequencies in Shaft
Vibration Frequencies and VFD Output Frequencies
z LS Shaft Vibration Frequency Content
Difference of Harmonics of Multiples of 6 and
Sampling Frequencies of VFD (1024Hz, 256Hz)
z VFD Output Current Frequency Content
Difference of Harmonics of Odd Numbers Other Than
Multiples of 3 and Sampling Frequencies of VFD
Inclination Opposite to That of Shaft Vibration
Firm Correlation Between Shaft Vibration and
VFD Output Current Suspected
13
Pattern of Interharmonic Frequency Component

Relation of Between Shaft Vibration Frequencies
and VFD Output Frequencies
VFD Output Freq. [Hz]:
fVFD Fundamental Freq. [Hz]
fbi = |fc-nf| Sideband
fcArbitrarily Existing
Frequencies
Constant Freq. [Hz]
Shaft Vibration Freq. [Hz]:
nPositive Odd Integer
fbt =|fc-(n1)f|
Other Than 3
Frequencies of Fluctuating Torque Generated by 3-Phase IM
faArbitrarily Existing
Te = pMIs_aIr(9/4)sin(2(fa-f)t+)
Current Freq. [Hz]
If fa = fbi = |fc-nf|
TepMIs_aIr(9/4)sin(2(|fc-(n1)f|)t +)
Shaft Vibration Caused

by Excitation of Motor
Torque
14
Sampling in VFD
VFD Control Loop
Speed
Ref.
re*
Automatic
Torque
Boost
Flux
Ref.
1
+ +
+
+
V/f
Pattern
+
-
Voltage
2-phase /
3-phase
Transform
ation
PWM
Control
Inverter
Cell
Starting
Torque
Boost
1dt
Voltage
Compens
ation
Frequency
Compensat
ion
Several Sampling Frequencies

Used in VFD Control Loop
Current
3-phase /
2-phase
Transfor
mation
CT
IM
Compressor
System
Figure 12. Block Diagram of VFD Control System

15
Assumed Cause of Sideband

Assumed Cause of Sideband in VFD Output Current
Coarse Pulse of Fundamental Frequency Remained in
Current (e.g. Improper Dead Time Compensation)
Harmonics of Odd Numbers Produced by Pulse
(Rectangular Wave) of Fundamental Frequency
Harmonics of Multiple of 3 Eliminated in Balanced
Three-Wire System
Sideband Frequencies Raised by Modulation between
Harmonic Frequencies and Sampling Frequencies
Harmonics enhance
Occurred in VFD Control Loop
sidebands.
16
Other Possible Cause of Sideband

Sideband Frequencies Due to PWM
Sum and Difference of Frequencies
of Harmonics of Triangular Carrier
Wave (4.8kHz) and Harmonics of
Signal Wave (Fundamental
Frequency)
Sideband Frequencies Due
to PWM Not Observed in
This VFD Output Current
ET
Triangular Carrier Wave fc_PWM

Fundamental Wave f
0
- ET
Ed/2
0
- Ed/2
Inverter Output
Figure 13. Mechanism

of PWM
17
Concluding Remarks
z
Measurement of torque & current in factory test is important

in case VFD characteristics are unknown.
Strength evaluation by lateral-torsional analysis is essential to
determine mechanical soundness.
Information of any possible frequencies used in VFD control
and the resulting amplitude of torque pulsation should be
disclosed in advance by VFD vendor.
Reduction of amplitude of fundamental frequency harmonics
would decrease amplitude of sideband frequencies.
18

Case Study 14

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Case Study, 38th Turbomachinery Symposium

Torsional-Lateral Coupled Vibration of

14-17 September 2009, 38th Turbomachinery Symposium

Hitachi Plant Technologies, Ltd.

High vibration was

Figure 1. Compressor Train

Figure 2. Cascade Plot of

14-17 September 2009, 38th Turbomachinery Symposium

50m (p-p) Vibration

Max. 10m (p-p) Vibration

Figure 3. Cascade Plot of

Stiffer Pinion Bearings

Concern: What is the Excitation Source? Pinion Lighter Than Bull

14-17 September 2009, 38th Turbomachinery Symposium

Torsional Natural Frequencies

Max. operating speed (LS shaft): 1500rpm

Min. operating speed (LS shaft): 1000rpm

Second natural frequency: 2752cpm (45.87Hz)

First Natural Frequency: 15.71Hz (943cpm)

Second Natural Frequency: 45.87 Hz (2752cpm)

First natural frequency: 942.6cpm (15.71Hz)

Rotor speed [rpm]

Figure 4. Campbell Diagram

Third Natural Frequency: 422.1Hz (25324cpm)

Figure 5. Torsional Vibration

Critical Speeds Predicted by Rotor Analyses

Shaft Synchronous Resonance is

Estimation of Shaft Torque and Motor Torque

Figure 6. Force Applied

Transverse Pressure Angle

Estimation of Shaft Torque and Motor Torque

Unit Excitation on Tooth Surface

LS Gear Shaft Vibration

Estimation of Shaft Torque and Motor Torque

Cause and Effect

14-17 September 2009, 38th Turbomachinery Symposium

Alternating stress a [N/mm 2 ]

107 Cycle Life

Mean stress m [N/mm2 ]

Figure 9. Modified Goodman Diagram

Investigation of Source of Excitation Torque

fc=1024Hz, n=25, slope: -24

Rotor Speed (LS Shaft) [rpm]

fc=1024Hz, n=29, slope: +30

fc=1024Hz, n=23, slope: +24

fc=1024Hz, n=31, slope: -30

fc=256Hz, n=7, slope: -6

fc=1024Hz, n=29, slope: +30

Figure 10. Cascade Plot of LS Gear Shaft Vibration

Investigation of Source of Excitation Torque

fc=1024Hz, n=23, slope: -23

VFD Output Current

Rotor Speed (LS Shaft) [rpm]

Figure 11. Cascade Plot of VFD Output Current

Pattern of Interharmonic Frequency Component

Pattern of Interharmonic Frequency Component

14-17 September 2009, 38th Turbomachinery Symposium

Shaft Vibration Caused

Several Sampling Frequencies

Figure 12. Block Diagram of VFD Control System

Assumed Cause of Sideband

Other Possible Cause of Sideband

14-17 September 2009, 38th Turbomachinery Symposium