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Steam Turbine Intermittant Rub Vibration

The steam turbine driving a hydrogen compressor experienced intermittent high vibration spikes. Vibration analysis determined the cause was intermittent rubbing of the rotor. After a trip, inspection found carbonized oil in the bearing housing from lack of sealing air. The oil baffles were cleaned and sealing air recommissioned. No significant vibration spikes occurred after restart, showing the mitigations were effective.

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MANOJ KUMAR
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168 views14 pages

Steam Turbine Intermittant Rub Vibration

The steam turbine driving a hydrogen compressor experienced intermittent high vibration spikes. Vibration analysis determined the cause was intermittent rubbing of the rotor. After a trip, inspection found carbonized oil in the bearing housing from lack of sealing air. The oil baffles were cleaned and sealing air recommissioned. No significant vibration spikes occurred after restart, showing the mitigations were effective.

Uploaded by

MANOJ KUMAR
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Vibration Diagnostic of

Steam Turbine
Intermittent Rubbing

KER PIN JUN – EXXONMOBIL


NG WEI SING - EXXONMOBIL

S Y M P O S I A : 2 4 – 2 6 M AY 2 0 2 2
SHORT C O U R S E S : 2 3 M AY 2 0 2 2
Author
Ker Pin Jun Ker Pin Jun is a Machinery Engineer in ExxonMobil Singapore. He has
Machinery Engineer 14 years of rotating equipment experience in refining and
petrochemical industry. Ker Pin Jun holds a Bachelor’s degree in
Mechanical Engineering from University of Melbourne.

Ng Wei Sing Ng Wei Sing is a Lead Machinery Engineer in ExxonMobil Singapore


Lead Machinery and has 9 years of rotating equipment experience in refining and
petrochemical industry. Ng Wei Sing has a Postgraduate Doctoral
Engineer degree in Mechanical Engineering from University of Leeds.
Abstract
A special purpose steam turbine has started to experience intermittent radial vibration spikes. The turbine is used to drive a
Hydrogen Recycle Gas Compressor in Aromatics unit. No abnormality observed on the compressor end. ADRE 408 external
data acquisition and diagnostic system was used to collect vibration data during steady state operation. Detailed vibration
diagnosis was performed to evaluate overall rotor dynamic behavior of the machine train, assess vibration levels against the
OEM set-points and ISO 7919-3 standards, troubleshoot potential mechanical malfunctions that leads to intermittent
vibration spike and provide recommendations for safe operation of the unit. From the analysis, the cause of high vibration was
determined to be intermittent light rubbing of the steam turbine rotor with the bearing housing oil baffle (seal).

Temporary mitigation actions were implemented: (i) increase vibration alarm limit from 30um to 42um and; (ii) commission
sealing air to both DE and NDE bearing housing oil baffle, which was later on found to be clogged with oil carbonization. The
intent of the mitigation actions is to reduce the probability of tripping the machine. However, it was not adequate and
deemed to be too late to prevent the force outage.

After the trip, both DE and NDE bearing housing were opened for inspection. Severe oil carbonization was observed on the
NDE bearing housing oil baffle which has close clearance and the sealing air port was plugged. The oil carbonization was
cleaned without removing the steam turbine rotor (extensive work) in order to minimize the turbine downtime. Top halve oil
baffle was completely cleaned while bottom halve oil baffle was cleaned to the best effort due to access constraint. The
turbine was restarted successfully. No significant vibration spikes observed after 2 months of running. Proper visual cue
(signage) was implemented to ensure sealing air supply valve is opened at all time when turbine is in operation.
Agenda
1 Case Study Background

2 Problem Description

3 Analysis

4 Findings, Mitigation & Results

5 Key Learning
Equipment General Info
Steam Turbine Details
Type: Back pressure turbine
Rating: 1.2MW (3 stages)
Inlet: 4,000kpag; 400degC
Exhaust: 1,200kpag; 215degC
Flow: 18,000 kg/hr

Rated Speed: 9,500 RPM


Max. Speed: 11,550 RPM
Min. Gov.: 6,050 RPM
1st Critical: 5,000 RPM
Trip Speed: 12,705 RPM
Equipment General Info
Steam Turbine Probe Orientation

1Y 1X 2Y 2X 3Y 3X 4Y 4X

KPH 1

Alarm set point: 30 µm


Trip set point: 48 µm
Problem Description
• The steam turbine was last overhauled in April 2019. The turbine typical overhaul interval is between 12 – 15 years. Rotor, bearings, casing and
inter-stage seals were replace with new. Internal clearances were restored back to within OEM design limits. Turbine vibration was healthy
and stable during commissioning.

• After about 1.5 years of operation, the turbine started to experience intermittent vibration spikes. The amplitude of spikes on steam end were
consistently observed to be higher than exhaust end.

• The increase in vibration amplitude was observed to be gradual, and return to ‘normal’ level every time the vibration peaks.

Vibration peaks

Gradual vibration increase


Vibration
normalized
Analysis
1. ADRE 408 external data acquisition and diagnostic system was used to collect the steady state vibration data for further troubleshooting.

2. Dominant 1x peak during vibration spike , with clear reverse component observed on full spectrum.

Fig. 2: Full spectrum during vibration spike


Analysis
3
3. Significant phase angle change observed during
vibration spike indicating a shift of rotor heavy spot.
Reverse precession (vs. direction of shaft rotation) was
observed on orbit plot.

4. Polar plot shows random shift of phase angle during


vibration spike event.

4
Fig. 3: Phase angle change in Bode and reverse precession
in orbit observed

Fig. 4: Polar plot with phase shift during vibration spike


Analysis
• Base on vibration data analysis, it is highly suspected
the cause of intermittent vibration spike is due to
light or partial rubbing of rotor.

• Rubbing is not a machinery malfunction; but rather a


secondary indicator that there are other primary
cause(s) that led to the rub.

• Last overhaul QA/QC record indicates the location of


tightest clearances is at the bearing housing oil baffle
(A, B and C with design clearance of 0.001” – 0.003”)

• Site check revealed that the sealing air supply to oil


baffle was not commissioned post turbine restart in
2019.

• Lack of sealing air => Oil migration to oil IMMEDIATE ACTION:


baffle => Oil carbonization (high temp.) To reduce the probability of tripping,
=> Smaller clearances => Rotor rubbing 1. Recommission the sealing air supply to air baffle
2. Review and increase vibration alarm set point

Unfortunately, it was too late and the turbine eventually tripped on NDE (Steam end)
VAHH in Feb 2021
Open
Findings & Mitigation
1. After the trip event, the turbine bearing housing was opened for inspection.
4
2. Steam end bearing housing oil baffle was badly clogged with carbonized oil. Clear
rubbing sign on turbine shaft.
3. The sealing air injection port was also fully plugged which explain the reason why
recommissioning of sealing air does not help to prevent the trip.
4. Exhaust end bearing housing oil baffles were significantly cleaner as they were exposed
to much lower temperature; hence no carbonized oil.
5. All oil baffle were cleaned before reassembling of the bearing housing.

DE oil baffle – coupling end DE oil baffle – exhaust end


2

Steam end (NDE) oil baffle post cleaning


Open
Mitigation & Results
• As the vibration analysis and troubleshooting was completed prior to the trip event, the total downtime was significantly reduced to only 2
days (including unit restart). Targeted rectification work can be performed immediately after the trip.
• Post restart, the vibration trend was healthy and stable. No vibration spikes observed.
• Site visual cue / signage was put up to remind operators the importance of commissioning the sealing air to the bearing housing oil baffle.
• Similar “Caution” remarks was updated into the turbine start-up procedure for long term sustainability.
Key Learnings
1. Vibration data collection and diagnostic is an important tools for machinery troubleshooting.
2. In this case, it has helped to reduce equipment downtime by identify the risk and required rectification
scope in advance prior to the trip. In many other cases, it can even prevent an unplanned shutdown.
3. The importance of sealing air was not fully understood and underestimated. It is crucial in preventing oil
leakage through the oil baffle, forming carbonized oil when exposed to the radiant heat from steam
turbine casing. Besides, the continuous flow of air will directionally cool down the surround temperature
of the oil baffle.
End of Presentation
Questions?

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