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12th IFToMM World Congress, Besanon (France), June 18-21, 2007 RD-818

Some results in steam whirl analysis


Nicol Bachschmid * Paolo Pennacchi Andrea Vania
Dept. of Mechanics Dept. of Mechanics Dept. of Mechanics
Politecnico di Milano Politecnico di Milano Politecnico di Milano
Milan, Italy Milan, Italy Milan, Italy

Abstract 1 Steam whirl instability occurrence and by the damping introduced by the oil film bearings, or by
modelling is described, and some weak point s in usual some additional external damping. When damping is
modelling and in standard stability criteria are discussed. The insufficient, instability can be overcome only by
motivation of the present study is a case history of a steam
modifying the seal geometry. Since the occurrence of this
turbine that experienced a heavy steam whirl instability though
the calculated stability margin in design conditions was
type of instability has limited the development of
sufficiently high. During the start up of a power plant the performances of turbo-machinery, many studies have been
425MW steam turbo generator showed an unstable vibrational devoted in the last 45 years, depending on the
behaviour as soon as maximum output power was approached. development needs of high performance turbo-machinery,
The combined effect of steam excitation in bladed rows, in the either to the analysis of steam whirl in steam turbines, or
steam glands and of low damping in some of the oil film to instabilities excited by air flow in the axial compressors
bearings was most likely the main cause of the observed of gas turbines, or to instabilities excited by the fluid in
malfunction. A model of the group has been set up, the steam labyrinth seals of high performance centrifugal gas
whirl exciting force coefficients and the oil film bearing
compressors as well as to instability excited by the liquid
coefficients have been applied and eigenfrequencies and
damping factors have been calculated. In order to check the
in the seals of high performance centrifugal pumps.
accuracy of this calculation also another method based on Despite the fact that there is a consolidated knowledge
energy balance has been used but very similar values have been about these problems at least in the scientific community,
obtained, confirming the accuracy of the standard stability there are still some weak points in modelling the steam
evaluation approach. The calculation showed that the machine whirl excitation, so that predictions of stability margins
should have been stable, with a sufficient margin of stability, in sometimes can fail.
design conditions. Therefore the steam whirl excitation models The motivation of the present study is exactly a case
have been analysed for identifying possible weak points which history of a steam turbine that experienced a heavy steam
could justify the discrepancies between experimental behaviour
whirl instability though the stability margin in design
and calculated results.
conditions, calculated by the turbine manufacturer
Keywords: Steam whirl, instability, steam glands, rotor according to a consolidated methodology, was sufficiently
dynamics high. A twin turbine operated in the same conditions had
no stability problems at all.
First the main results of the studies about instability
I. Introduction excited by fluid flow over seals or blade rows in turbo-
machinery are recalled. Then the recent steam whirl
Turbo-machinery like steam turbines and gas
instability event on the turbine is described, the
compressors may experience unstable vibrations due to
calculation results of standard modelling and stability
the interaction between the whirling shaft and the
margin evaluation are presented. Finally some possible
surrounding fluid forces in correspondence of seals where
weak points in standard modelling are identified, which
the clearance between rotating and stationary parts are
could justify the discrepancies between calculation results
small. These unstable vibrations arise in steam turbines
and experimental evidence.
most likely close to the maximum power condition, when
pressures and consequent flows are maximum. The
II. Steam whirl modelling
vibration amplitudes reach very quickly high unacceptable
values, the machines are shut down due to excessive Unstable behaviour occurring in HP steam turbines was
vibration levels and can then be operated only at reduced first analysed by Thomas [1] in Germany. He realized that
power levels. The unstable vibrations occur at the shaft the excitation was mainly due to the leakage steam flow
first bending natural frequency, and can be controlled only over blade rows. Krmer [2] used the model of Thomas
for the blade row steam leakage forces, which excite
forward whirl, and introduced the model of oil film
* E-mail: nicolo.bachschmid@polimi.it
E-mail: paolo.pennacchi@polimi.it
bearings showing the combined effect on stability. He
E-mail: andrea.vania@polimi.it defined a linearized cross coupling stiffness coefficient

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12th IFToMM World Congress, Besanon (France), June 18-21, 2007 RD-818

Kxy (force in x direction due to shaft displacement in y different types of labyrinth seals is based on the
direction) proportional to the equivalent tangential driving previously described research results. Seals and bearings,
force acting on the stage divided by the length l of the represented respectively by these excitation constants
blade: (also called cross coupling stiffness) and by the stiffness
and damping coefficients of the oil film bearings,
N
K xy = k (1) constitute the connections between stationary casing and
Dm l the rotating shaft, where they can cause unstable whirling
motion, or stable behaviour.
where N is the power of the stage, Dm the mean diameter Finally Hauck [7] and [8] resumes main excitations
of the blade row, the rotating speed, and k a parameter related to unequal circumferential pressure distribution in
which has to be calculated modelling the leakage flow the seals of a deflected shaft, and to entry swirl. He
over the blades (which depends obviously on the presents accurate pressure and velocity measurements in
clearance). Reliable values of k are not given, but can be the cavities between seal strips showing the presence of
calculated with thermodynamic models of flow through different flows: one mainly peripheral and another mainly
seals. axial. He shows also results of typical shrouded turbine
Values of k can be derived from diagrams in Thomas et stages with labyrinth seals.
al. [3]. These first experimental results, obtained with an Childs [9] describes exhaustingly all results obtained
offset rotating shaft, and not with a whirling shaft, showed and models used in liquid and gas annular seals and
that the forces are not linear with the shaft displacement, turbines and pump impellers. Recently also CFD codes
and are much higher for shrouded blades than for single are available for analysing the behaviour of seals: test
standing blades, revealing the influence of the results are compared to calculated results obtained with
circumferential flow, which is also sometimes called the two different CFD codes in Schettel and Nordmann [10],
gas bearing effect. This effect, which is present and well giving insight in capabilities of CFD codes to represent
known in all hydraulic machinery, is obviously the only experimental results.
one present in the labyrinth seals where no blades are
present (such as the balancing drum in HP steam III. Steam whirl case history
turbines); it is mainly due to the rotation of the shaft and
could be easily separated from leakage over blades effect The machine-train of a 425 MW power unit was
which is apparently independent from rotation. composed of a single-flow high pressure turbine (HP), a
Pollman et al. [4] presented an overview of different single-flow intermediate pressure turbine (IP), a double-
excitation mechanisms, and compared calculated and flow low pressure turbine (LP) and a generator. The shafts
measured excitation factors for 3 different types: single of the machine-train were directly coupled each other by
50% reaction stage, three-stage 50% reaction and impulse means of rigid couplings. The operating speed of this
stage. The agreement is not very good, measured values reheat unit of reaction design was 3000 rpm. The steam
are much higher than calculated values for the impulse admission to the HP section was full arc. The shaft-train
stage, which is attributed to the gas bearing effect, are was mounted on six main oil-film journal bearings having
generally lower for the single 50% reaction stage and can nearly the same geometrical properties. They were two-
be higher or lower for the three-stage model, depending lobe journal bearings which showed two large pockets
on pressure levels. Applications to real turbo-groups are located at the horizontal partition of the bearing casing.
also shown, and prediction of stable or unstable behaviour The pre-load of the lower lobe was 0.3. Figure 1 shows
is claimed to be possible at design stage. the layout of the machine-train and the bearing numbers.
Benckert and Wachter [5] report accurate measurements Each support was equipped with a pair of XY proximity
made in different labyrinth seal geometries and attributes probes and one vertical seismic transducer.
the exciting lateral forces to swirl entry flow (for short
seals) and to circumferential flow and related drag of Exciter
rotating shaft (for long seals). These effects are shown HP IP LP Generator
separately. Linear behaviour is observed up to
eccentricities of 40-60% of clearance, which is partially in #1 #2 #3 #4 #5 #6
contrast with the findings of Thomas et al. [3]. Results are
applied successfully to steam turbines and compressors.
Figure 1: Machine-train layout and bearing numbers.
Calculations of stability margins in the design stage of
steam turbines have been introduced in the design The HP turbine was mounted on two journal bearings
computer codes of steam turbine manufacturers [6]: these whose lower lobe showed an angular width of only
are based on the evaluation of the real part of the 60 degrees. The experimental vibrations measured during
eigenfrequencies of the rotor system. For this calculation a run down transient at bearing #1 (Figure 2) showed that
the evaluation of the excitation constant for each reaction the first critical speed of the HP turbine was split into two
blade row (with corrections for shrouded rows) and for the values: 1850 rpm and 1970 rpm.

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12th IFToMM World Congress, Besanon (France), June 18-21, 2007 RD-818

Figure 3 shows the frequency spectrum of the shaft


vibrations measured at bearing #1 few seconds before the
occurrence of a machine trip caused by the sharp growth
of the amplitude of the sub-harmonic vibrations of the HP
turbine. Figure 4 shows a waterfall diagram of the shaft
vibrations measured at bearing #1 in occasion of one of
the instability events. It is possible to note that the sub-
harmonic vibrations immediately disappeared after the
machine trip. The sudden and sharp increase of amplitude
at constant speed when maximum power is approached,
and still more the sudden and sharp disappearance of the
subharmonic component when the power is removed are
clear symptoms of steam whirl: other causes of instability
(such as oil whirl) could be discarded. It was decided to
Figure 2: Synchronous transient vibrations (1X) measured at bearing #1
check the stability margin calculation in design
of the HP turbine: passing through the first critical speed. conditions.
Few months after the first rollout of the power unit the
HP turbine showed multiple events of high vibration
levels that occurred in operating condition and caused
several machine trips. These high vibrations always
occurred when the electrical load exceeded the 80% of the
nominal rating, that is when the opening degree of the
main control valves of the HP section reached its upper
range.
The vibrations measured at bearings from #3 to #6 were
nearly unaffected by the abnormal vibrations that occurred
at the bearings #1 and #2 of the HP turbine. The analysis
of the harmonic content of the vibration signals showed
that, in general, in occasion of each machine trip the
amplitude of the synchronous component (1X) measured Figure 4: Waterfall plot of the shaft vibrations measured at bearing #1 in
at 3000 rpm was not excessively high. On the contrary, occasion of a steam-whirl instability onset and during the subsequent
few minutes before each machine trip a sub-harmonic coast-down caused by the machine trip.
component at 32 Hz suddenly appeared in the vibration
signals. This value was rather close to the first flexural IV. Model of the machine and of the instability
critical speed of the HP turbine. The amplitude of this excitation
component grew very quickly reaching considerable Figure 5 shows the finite element model of the machine
levels in less than 10 seconds. used for simulating its dynamic behaviour: unbalance
response and eigenfrequency calculation, taking account
of the steam whirl excitation constants. In order to check
the accuracy of the model the unbalance response in
bearing 1 of the machine has been calculated without
considering the effect of the seals, simulating the start up
of the machine without load. Equation (2) is the standard
frequency response matrix equation:
[M ] x + ([ R ] + G ( ) ) x + [K ] x = F ( t ) (2)
where M is the mass matrix, R the damping matrix due to
the bearings, G the gyroscopic matrix, K the stiffness
matrix. The last can be considered as the superposition of
the stiffness matrices of the shaft train, journal bearing
coefficients, seals and supporting structure.
Figure 3: Spectrum of the shaft vibrations measured at bearing #1 in [K ] = [K ]shaft train + [K ]bearings + [K ]seals + [K ] foundation (3)
operating condition few seconds before the onset of the instability.

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12th IFToMM World Congress, Besanon (France), June 18-21, 2007 RD-818

Figure 5 Finite element model of the turbogroup.


Unbalance of 1 kgm has been applied in the middle of 6
the HP shaft, in order to excite its first critical speed. 2.5 x 10 Seal stiffness coefficients
Figure 6 shows the results: the agreement with [N/m]
experimental results of Figure 2 in critical speed value,
and in the associated damping proves that the model is
satisfactory. 0
180
Phase [degrees]

90

0
#1
Operating speed
-90 #2
Frequency response in node 3 (Bode plot) seal
-180
RAFT 3.0 HP Turbine
-4
x 10
8

6
Figure 7 Nominal absolute values of the seal stiffness coefficients
Module [m]

provided by the machine manufacturer.


4

The k-th eigenvalue of the model can be written as:


Operating speed

0
0
RAFT 3.0

500 1000 1500 2000 2500 3000


k = k + i 2 f dk (5)
Rotating speed [rpm]
where fdk is the k-th damped natural frequency of the
Figure 6 Unbalance response in bearing 1 of HP steam turbine. system while k is the respective modal damping factor. In
The dynamic effects caused by the seal stiffness in order to have energy dissipation the factor k must be
steam turbines can be modelled by means of a pair of negative. The respective undamped natural frequency is
cross-coupled coefficients, having the same magnitude given by:
1
and opposite sign, that are assembled in the off-diagonal ( 2 f dk ) + k2
2
f nk = (6)
locations of the stiffness matrix associated with the j-th 2
seal. In a fixed frame coordinate system xy this matrix can The k-th dimensionless damping factor, hk, can be
be written as: expressed in the following form:
0 k hk = k ( 2 f nk ) (7)
[K s ] j = k 0xy k yx = k xy (4)
In order to have oscillating motions the dimensionless
yx j
damping factor must be positive and lower than the unity.
These stiffness coefficients, which are assembled in Under the assumption that the rotor system vibrates in the
suitable locations of the global stiffness matrix K, depend free motion with an harmonic law having a frequency
on various factors: over the blade rows expression (1) has equal to the k-th damped natural frequency fdk, the time
been used, with corrective factors for the short labyrinth history of the displacements evaluated at the j-th degree of
seal over the shrouded blade row and for the long freedom xj can be written as:
labyrinth seal in the balancing drum the seal stiffness
depend on axial and circumferential steam flow velocities, x j (t ) = X j e hk 2 f nk t cos(2 f dk t + j ) (8)
on seal geometry, the steam pressure. The distribution of Let us denote Tk the time period associated with the
the seal cross coupled stiffness along the shaft is shown in frequency fdk. The instability factor Vk can be expressed by
Figure 7. the ratio between the vibration amplitudes evaluated at the
As shown in expression (1) the stiffness over the blade two instants t1 and t2 which satisfy the following
rows is proportional to the power, giving rise to the relationship: t2 = t1 + Tk .
highest excitation in maximum power conditions. x (t2 )
Therefore, at high power levels the cross-coupled stiffness Vk = (9)
x (t1 )
terms of the matrices defined by Eq.(2) can be responsible
for self-excited rotor instability phenomena characterized Then, the logarithm of the instability factor is given by:
by a subsynchronous shaft whirl that is associated with the ln(Vk ) = 2 hk 1 hk2 , Vk < 1 (10)
first flexural normal mode of the rotor. The analysis of the
When the instability factor Vk exceeds the unity, the
eigenvalues of the rotating machine model can be used to
rotating machine can be affected by instability
point out the conditions that must be satisfied for the
phenomena.
occurrence of unstable vibrations.

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12th IFToMM World Congress, Besanon (France), June 18-21, 2007 RD-818

The sensitivity of the machine-train to the values of the seals which contribute more to the onset of instability, or
seal stiffness coefficients regarding the occurrence of the bearings which contribute more to stability. This
steam-whirl instability phenomena caused by the seal calculation showed exactly the same results: a good
excitation constant has been investigated. This study has stability margin in design conditions. Therefore the loss of
been carried out by multiplying all the nominal values of accuracy was attributed to errors in bearing and seal
the seal stiffness coefficients of the model by a scaling coefficients evaluation, and an analysis was made for
factor, cs. Different analyses have been performed by trying to detect where modelling errors have occurred.
varying this scaling factor from 0 to 3. The null value of cs
can be associated with the off-load condition while the
unity value of cs corresponds to the full-load operating
condition. For each value assigned to the constant cs the
eigenvalues of the machine model have been evaluated.
The real part of each eigenvalue has been used to calculate
the instability factor V associated with each flexural
critical speed of the shaft-train. Instability factors that
exceed the unity indicate the presence of conditions that
can cause the occurrence of steam-whirl instability
phenomena. Table 1 shows the flexural critical speeds in
which the HP steam turbine is involved and the respective
instability factors of the machine-train evaluated at the
operating speed without considering the stiffness of the
seals. The damping of the oil film bearings lowers the
instability factor of mode 6 of the complete group (which
is also the first mode of the HP steam turbine rotor) to Figure 8: Instability factor versus exciting constant scaling factor
0.79, which is sufficiently below the unity threshold.
V. Accuracy of actual stability calculations of steam
Flexural Instability Flexural Instability turbines
Critical Factor Critical Factor
Speed Speed The results of this calculation shows that accurate
Mode [rpm] (V) Mode [rpm] (V) calculations made using well assessed procedures for
n. n. standard design machines are insufficient to avoid steam
whirl conditions: this could be attributed to some
5 1781 0.8862 6 1853 0.7964
modelling inaccuracies which have not been recognized.
TABLE 1: Flexural critical speeds and instability factors evaluated with Analysing the standard approach for calculating stability
the model n.1, at 3000 rpm, without considering the stiffness of the seals margins of steam turbines one could find following
(off-load operating conditions: cs = 0).
aspects which are neglected, or taken into account by
If the effect of the seals is considered, in design more or less rough approximations or interpolations.
conditions (cs=1.0) the instability factor is still 0.81, as Oil film bearings: the damping coefficients of oil film
shown in Figure 8. Instability should not occur. Only bearings can be affected significantly by bearing
when the scaling factor reaches 2.15 the damping factor misalignment, by higher oil film temperature with respect
approaches unity, and the rotor becomes unstable. This to design, and by deviations from design geometry.
indicates a good stability margin. The only mode which Labyrinth seals: the excitation coefficient for blade row
becomes unstable is the 6th mode of the group, which is is calculated assuming standard fluid dynamic behaviour.
also the first mode of the HP turbine shaft. This means that:
The results provided by this case study, using the a. possible swirl components in circumferential direction
machine nominal model, do not explain the reason for the are neglected and the circumferential fluid velocity
occurrence of steam-whirl instability phenomena. distribution across the clearance is considered linear;
In order to check the accuracy of the eigenvalue b. flow contraction and carry over flow are also
calculation, also another approach has been used, based on neglected;
energy balance. A whirling motion at critical speed is c. differences due to the dynamic behaviour of the fluid
imposed by a rotating force; the energies introduced by around a whirling shaft instead of eccentric rotating
seals and dissipated by damping in bearings can be shaft are neglected, because the experiments have
evaluated considering the different elliptical orbits in the mainly be made with eccentric rotating shafts rather
different locations. If the net energy is positive the system then with whirling shafts;
is unstable, if negative stable. d. the gas bearing effect due to shrouds on the blade
This method could be more robust with respect to row is represented by a corrective factor which is
eigenvalue calculation. It would also allow to localize the interpolated between some few experimental results;

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12th IFToMM World Congress, Besanon (France), June 18-21, 2007 RD-818

e. non linearity are not taken into account, therefore: [8] Hauck, L., Vergleich gebraeuchlicher Tubinenstufen hinsichtlich
des Auftretens spaltstroemungsbedingter Kraefte (Comparison of
e.1. the effect of misalignment of shaft with respect usual turbine stages as regards clearance flow induced forces),
to casing, as well as the resulting unequal Konstruktion 33, n.2, 59-64 (1981).
pressure and velocity distributions in the seal is [9] Childs, D., Turbomachinery Rotordynamics: phenomena, modeling
not considered; and analysis, John Wiley & Sons, (1993).
[10] Schettel, J., Nordmann, R., Rotordynamics of turbine labyrinth
e.2. the effect of actual orbit size and shape in seals - a comparison of CFD models to experiments, IMechE paper
correspondence of each seal is also completely C623/018, 13-22 (2004).
neglected;
f. effect of different operating conditions with respect to
design cannot be considered.
It seems reasonable to decouple the onset of instability
from steady state vibrational behaviour, but considering
the non-linearity in seals and bearings it could also result
that a strong 1X component in bearings and seals, due to
unbalance and bow, would be able to overcome the onset
of instability.

V. Conclusions
In the same plant, another machine of the same design
did not show any instability. Therefore the onset of the
instability must depend on the effect on the exciting
coefficients of some parameters which are not completely
controlled during the installation of the machine. This
could be mainly the alignment of the bearings, which
define also the position of the shaft with respect to the
stator. Loads on the bearings may change with the
alignment and therefore also the damping coefficients of
the oil film, as well as the velocity and the pressure
distributions in the seal due to the eccentricity of the rotor.
The velocity and pressure distribution may influence
significantly an important parameter affecting the exciting
coefficients, which is the pre-swirl velocity.
Only CFD calculations and accurate measurements of
actual values of the geometrical parameters, such as
clearances and alignment conditions, could improve the
accuracy of steam whirl stability calculations.

References
[1] Thomas, H.J., Instabile Eigenschwingungen von Turbinenlaeufern,
angefacht durch die Spaltstroemungen in Stopfbuchsen und
Beschaufelungen (Unstable vibrations of turbine rotors excited by
clearance flows in sealings and bladings), Bull. De lAIM, 71,
n.11/12, 1039-1064 (1958).
[2] Krmer, E., Selbsterregte Schwingungen von Wellen infolge
Querkraefte (Self-excited vibrations of shafts due to transverse
forces), Brennst.-Waerme-Kraft, 20, n.7 (1968).
[3] Thomas, H.J., Urlichs, K., Wohlrab, R., Laeuferinstabilitaet bei
thermischen Turbomaschinen infolge Spalterregung (Rotor
instability in thermal turbomachinery due to clearance excitation),
VGB Kraftwerkstechnik, 56, n.6 June 1976, 377-383 (1976).
[4] Pollman, E., Schwerdtfeger, H., Termuehlen, H., Flow excited
vibrations in high pressure turbines (Steam whirl), ASME J. of
Eng. for Power, 100, 219-228 (1978).
[5] Benckert, H., Wachter, J., Flow induced spring constants of
labyrinth seals, IMechE paper C258/80, 53-63 (1980).
[6] Stability calculation overview, ABB (1994).
[7] Hauck, L., Measurement and evaluation of swirl-type flow in
labyrinth seals of conventional turbine stages NASA Conference
Publication, 242-259 (1982).

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