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48 Case History
48 Case History
Case History:
Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference
Peek ’n Peak Resort , Clymer, NY
April 30th, 2015
My Background…
� Stan Bognatz
� 30+ years Rotating Machinery & Reliability field experience
� Prior to founding M&B in 2005, managed & staffed GE / Bently Nevada’s Machinery Diagnostic
Services (MDS) field-engineering team for nearly 20 years
� Specialize in critical machinery analysis (gas/steam/hydro-turbines; high-speed drives, etc.);
balancing of turbo-machinery; modal/ODS analysis; optical / laser / 3D alignment; predictive
maintenance; oil analysis; customer training
� Authored technical papers on diagnostics, modal analysis, balancing, optical alignment, systems
integration & oil analysis
� B.S. degree, Mechanical Engineering, Penn State University
� Masters Degree in Business Administration, Wilkes University
� Registered Professional Engineer (in PA)
� Certified Level III Vibration Analyst via the Vibration Institute
� Certified Maintenance & Reliability Professional (CMRP) via the Society for Maintenance &
Reliability Professionals (SMRP)
© M&B Engineered Solutions, Inc. Case History: Field Balancing of a Bowed Steam Turbine Rotor 2
www.mbesi.com April 30th, 2015
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 1
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
Our Company
© M&B Engineered Solutions, Inc. Case History: Field Balancing of a Bowed Steam Turbine Rotor 3
www.mbesi.com April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Field Balancing of a Bowed Steam Turbine Rotor 4
www.mbesi.com April 30th, 2015
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 2
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Field Balancing of a Bowed Steam Turbine Rotor 5
www.mbesi.com April 30th, 2015
Machinery Layout
� 3 Bearings for the HP-IP & LP turbines
� Note Bearing #2 is “shared”, which creates interesting dynamics when balancing on the HP-IP
or LP rotors
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 6
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 3
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
HP IP
B1 B2
N1 N2 N3
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 7
www.mbesi.com Rev. 4/29/15
� Bode plots below show the low vibration at Bearing #1 & #2 during shut-down:
Brg. 1X Brg. 2X
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 8
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 4
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
� At this point the site recognized that the rotor may have incurred a bow earlier in the
day, so the unit was shut-down and put on turning gear for the night.
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 9
www.mbesi.com Rev. 4/29/15
Brg. 1X
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 10
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 5
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
Brg. 1X FS: 11.5 mils p-p Brg. 2X FS: 10.0 mils p-p
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 11
www.mbesi.com Rev. 4/29/15
'n
ot
ot
R
375 375
640 640
200 200
1,250 1,250
270° 90° 270° 90°
1,520 1,520
3,580 3,580
1,830 1,830
3,120 3,120
Correction Correction
180° 180°
Weight Weight
Inboard Inboard
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 12
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 6
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 13
www.mbesi.com Rev. 4/29/15
Brg. 1X – Start-up
Brg. 1X – Shut-down
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 14
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 7
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
Brg. 2X – Start-up
Brg. 2X – Shut-down
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 15
www.mbesi.com Rev. 4/29/15
Brg. 3X – Start-up
Brg. 3X – Shut-down
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 16
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 8
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
Brg. 1X – Start-up
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 17
www.mbesi.com Rev. 4/29/15
Moving along….
� 12/8/14:
� We were eventually contacted by the site to discuss situation
� Vibration data from the various runs was gathered & reviewed
� 12/13/14:
� Shell removal was completed
� Some rubbing damage was found on the blade shrouds and inter-stage diaphragms near rotor-
center, and at/near the N2 glands (labyrinth seals)
� Dial indicator run-out readings showed a significant rotor bow across the rotor
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 18
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 9
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 19
www.mbesi.com Rev. 4/29/15
HP Diaphragm Rubs
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 20
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 10
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 21
www.mbesi.com Rev. 4/29/15
� 12/17/14:
� Site decides to reassemble the unit & run at 1000 rpm to attempt to alleviate the rotor bow
� Last-ditch attempt, low probability given the number of runs already performed
� Sometimes, as a consultant, resistance is futile…
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 22
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 11
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 23
www.mbesi.com Rev. 4/29/15
� So, if we are going to balance the rotor, we need a weight amount & angular location
� Vibration-based CF calculations will often provide a more accurate weight amount
� However, for a bowed rotor, the TIR data will provide the best phase angle value
� The balance weight would be installed opposite the TIR ‘high spot’
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 24
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 12
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 25
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 26
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 13
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 27
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 28
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 14
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 29
www.mbesi.com Rev. 4/29/15
Results
� 1/6/15: Unit startup was successful !
� Start-up: 6 mils through the 1st critical; acceptable starting point
� On-line: Vibration started 6 mils at 3600 rpm / full-speed/no-load (marginal)
� Unit was kept on-line to warm-up & thermally stabilize the turbine casing & piping
� Vibration began trending down quickly, stabilizing at 4 mils at 75% load
� Unit kept on-line for 1 week, no significant 1X vector amplitude or phase angle changes
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 30
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 15
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 31
www.mbesi.com Rev. 4/29/15
Conclusion
� Primary risk at this time – We continue to monitor the HP-IP turbine 1X vectors for any
changes in amplitude or phase that might indicate the bow was changing.
� Some lessons learned by the client:
� Operators need to understand the dynamics of rotor rub behavior in terms of what is happening
with the overall vibration, and how they manage the situation to avoid damage
� Monitoring & understanding how eccentricity & slow-roll readings provide primary rotor bow
indications, and that run-out small changes can produce high 1X vibration during start-up
� When a rub does occur, understand that vibration can change rapidly, and that without
automatic high-vibration trips that operators may not be able to respond quickly enough to avoid
machine damage
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 32
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 16
Machinery Diagnostics Case History: Field Balancing of a Bowed Steam Turbine Rotor
Vibration Institute Regional Training Conference - Clymer, NY - April 30th, 2015
Thank you !!
Any questions?
© M&B Engineered Solutions, Inc. Case History: Balancing A Bowed Steam Turbine Rotor 33
www.mbesi.com Rev. 4/29/15
© M&B Engineered Solutions, Inc. Contact: Stan Bognatz, P.E. Rev. 4/29/15
75 Laurel Street, Carbondale, PA 18407 Ph (570) 282-4947
www.mbesi.com pg. 17