MECHANICAL DYNAMICS & ANALYSIS

CCUG High Speed Balance

Presenter: Keith Collins General Manager - Balance
August 28, 2019
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Presentation Overview
High Speed Balancing
 Balancing other equipment (BOP equipment), not just turbine

 Mistakes made with balancing

 Why is it beneficial to do High Speed Balancing vs Low speed balancing

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Balance
What is Balance?

Balancing
 The act of identifying inequities in the distribution of mass in a
rotating object and the correction of that mass distribution to
bring the centerline of mass into harmony with the geometric
and rotation centerline.

The Goal of Balancing

 Reduce vibration, specifically 1x vibration

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Balance?
Why Do We Balance?

To Reduce Vibration
 Rotor runs better
 Mating parts last longer
 Fewer operational issues
 CTQ

To Conduct Testing or Verification

 Overspeed – Proof Testing
 Vibration Analysis
 Electrical Testing

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Balance
Options for Balancing a Rotor

 Low Speed Balance

 High Speed Balance

 On-Site Balance

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Low-Speed Balance
When to Choose a Low-Speed Balance

Steam Turbine or Gas Turbine Rotors

 When the rotor is at a location without HSB
capability:
◦ Time is a factor and shipment to a HSB facility
will impact critical path
◦ Cost is a factor and cost of HSB has not been
budgeted
 When the rotor is in a shop with HSB capability:
◦ Time is a factor and additional 1-2 day cycle is
critical path
◦ Cost is a factor and cost of HSB has not been
budgeted
◦ Scope of repairs is minor and easily quantified
For Generator Rotors
 Never*

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High-Speed Balance
When to Choose a High-Speed Balance

Steam Turbine or Gas Turbine Rotors

 Scope of repairs is extensive and/or complex
◦ Journal Machining
◦ Rotor heat straightening
◦ Rotor weld repair

 Schedule and Budget Allow

◦ Cheap insurance
◦ Shorter cycle back at plant
◦ Fewer variables on site
◦ Assurance that the rotor has been run to speed
post-repair
◦ Lower vibration

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High-Speed Balance
When to Choose a High-Speed Balance

Generator Rotors
 After rewind with new or existing copper
 After machining repairs
 After rings off inspection
 For diagnostic purposes

Additional Generator Benefits

 All benefits similar to steam turbine
◦ Low vibration, etc
 At-speed electrical testing
◦ Flux probe
◦ Insulation resistance
◦ AC Impedance

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The Flux Probe

Major Benefit of High-Speed Balance on a Generator Rotor – No Shorts at Speed

At Speed Shorted Turn Detection

 Only way to guarantee no shorts at start-up
 Turn-to-turn testing in shop cannot detect speed-sensitive shorts
 Flux prove is the “acid test”

Timing of Test
 After overspeed
 Prior to final balance

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Balance of Plant Equipment

Other equipment
BFPT
Mechanical Drive turbine
Motors
Pumps
Fans
Gears

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High Speed VS. Low Speed

What’s the Advantage?

Over-Speed Testing
 Proof testing of all major components
 Setting of shrunk-on or fitted parts
◦ Buckets
◦ Rings
◦ Coils

High Speed Balance

 Modal Balance
◦ 1st Critical
◦ 2nd Critical
◦ 3rd Critical
◦ Extensions
◦ 4th Critical

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Balance Standards
How Do We Define a Good Balance?

What specifications are Available and Appropriate

 ISO 21940-12:2016
 API-612
 ISO 1940-1:2003
◦ Grade 2.5
◦ Grade 1.0
 OEM Specifications

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Measurement of Vibration
Types of Measurement

 Displacement

 Velocity

 Acceleration

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Measurement of Vibration
Probes and Systems

Displacement Probes
 Non-Contacting Eddy Current Probes
Velocity Probes
 Velometers
Acceleration
 Accelerometers
Systems
 Cablex++
 CAB920
 ADRE 208/408
 Clones

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Critical Speeds
Probes and Systems

All rotating shafts, even in the absence of external load, will

deflect during rotation. The unbalanced mass of the rotating
object causes deflection that will create resonant vibration at
certain speeds, known as the critical speeds.

The magnitude of deflection depends upon the following:

 Stiffness of the shaft and its support

 Total mass of shaft and attached parts
 Unbalance of the mass with respect to the axis of rotation
 The amount of damping in the system

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Methods of Balance
How Shots are Called

 Influence Coefficient

 Measure Effect

 Modal Balance

 Balance Software

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Modal Balance
Understanding Criticals and Mode Shapes

 Understand Criticals
 Understand the Rotor
 Learn from Trial Shots
 Use Software as an Aide to run Virtual Shots
 Refine the Modal
 Use Software as an Aide to run Virtual Shots

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Advantages of HSB
 Simply put one test is worth 1000 expert opinions

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Error Traps for HSB

Mating part error
 Adapter plate Run Out
 Stub Shaft Run Out
 Drive shaft imbalance
 Hardware not equal

Unknowns
Overhang imbalance
◦ Drive coupling holes
◦ Extension run outs

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MD&A’s Turbine-Generator Repair Facility

High Speed Balance Presentation

Speaker Contact Info:

Keith Collins
General Manager- Balance
(314) 880-3058
[email protected]
Connect on LinkedIn

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