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    Resolving Structural Vibration Issue On A Water Flood Pump

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    dachrydax
    This case study outlines how high vibration issues on two water flood pump modules were resolved. Detailed transient vibration data analysis and operating deflection shape modeling identified the problem as resonance between the power turbine's rotational speed and the stiffness of its drive end support system. The short term solution was to limit speed to avoid resonance, while the long term solution increased the support system's axial stiffness. This mitigated the vibrations and allowed maximum designed operation.

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    Resolving Structural Vibration Issue On A Water Flood Pump

    Uploaded by

    dachrydax
    122 views22 pages
    This case study outlines how high vibration issues on two water flood pump modules were resolved. Detailed transient vibration data analysis and operating deflection shape modeling identified the problem as resonance between the power turbine's rotational speed and the stiffness of its drive end support system. The short term solution was to limit speed to avoid resonance, while the long term solution increased the support system's axial stiffness. This mitigated the vibrations and allowed maximum designed operation.

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    Structural vibration description

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    Resolving Structural Vibration Issue On a Water Flood Pump

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    This case study outlines how high vibration issues on two water flood pump modules were resolved. Detailed transient vibration data analysis and operating deflection shape modeling identified the problem as resonance between the power turbine's rotational speed and the stiffness of its drive end support system. The short term solution was to limit speed to avoid resonance, while the long term solution increased the support system's axial stiffness. This mitigated the vibrations and allowed maximum designed operation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    122 views22 pages

    Resolving Structural Vibration Issue On A Water Flood Pump

    Uploaded by

    dachrydax
    This case study outlines how high vibration issues on two water flood pump modules were resolved. Detailed transient vibration data analysis and operating deflection shape modeling identified the problem as resonance between the power turbine's rotational speed and the stiffness of its drive end support system. The short term solution was to limit speed to avoid resonance, while the long term solution increased the support system's axial stiffness. This mitigated the vibrations and allowed maximum designed operation.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 22

    RESOLVING STRUCTURAL

    VIBRATION ISSUES ON
    A WATER FLOOD PUMP
    Nicolas Péton, Sergey Drygin,
    Dmitry Leonov
    Nicolas Péton
    Global Director – MDS services
    GE Oil & Gas- Bently Nevada
    Nantes, France
    Sergey Drygin, PhD
    MDS Technical Leader - Asia Pacific region
    GE Oil & Gas- Bently Nevada
    Moscow, Russia
    Dmitry Leonov
    Senior Rotating Equipment Engineer,
    Sakhalin Energy Investment Company Ltd
    Yuzhno-Sakhalinsk, Russia
    This case study is designed to outline how the high vibration
    issue of two Water flood modules was successfully diagnosed,
    the root cause for the high vibration and finally how it was
    mitigated using some structural analysis techniques.

    Detailed transient data analysis, steady state Operating


    Deflection Shape modeling allowed localization of the problem
    and recommend correction actions to change supporting system
    natural frequency by increasing the supporting system stiffness
    during planned overhaul.
    Travel time – 1 Day 11 hours. Minimum :?
    Actual was 2 days 23 hours – delays…
    Sakhalin Energy Investment Company Ltd. (Sakhalin Energy) is
    developing the Piltun-Astokhskoye oil field and the Lunskoye gas field
    off the north-eastern coast of Sakhalin. Its activities include production,
    transportation, processing, and marketing of oil and natural gas.
    Two identical water flood modules

    1. Gas turbine and 5 4 3 2 1


    enclosure
    2. Main gearbox
    3. Pump
    4. Booster gearbox
    5. Booster pump
    Problem statement
    • Based on Operations request, to provide maximum designed water
    flow, the Unit’s speed was increased up to maximum allowed stare
    value.
    • While units were operated at increased speed, Power Turbine Shaft
    relative vibration was exceeding Manufacturer defined Alarm,
    close to Trip state levels.
    • This was repeated each time when Units were operating at speed
    close to maximum allowed speed.
    • It had not been noticed earlier because both units did not reached
    that speed during previous operation, based on less flow needs.
    Summary of vibration tests data:
    - Vibration data was recorded for few operation modes:
    - stopped Unit
    - 7500 rpm (minimum flow),
    - 10500 rpm (55% flow),
    - 12500 rpm (91% flow– maximum level before Unit trip)
    - Unit shutdown,
    - high Power turbine shaft vibration level – 90um pp (3.5 mils pp)
    detected @ 12500 rpm,
    - high Main Gearbox casing vibration level 12-16 mm/s RMS (0.47
    – 0.63 in/s) detected @ 12500 rpm.
    Some details… Main Gearbox Booster Booster
    Pump Gearbox Pump

    Gas Power
    Generator turbine

    Power Turbine
    High level of Shaft
    relative vibration
    > 90 um pp (3,5 mils)

    GG PT Main Gearbox Pump


    Casing vibration data collection Booster Booster
    Gas Generator PT Main Gearbox Pump Gearbox Pump
    Synchronous rotor response

    Green line - well below resonance, red line - on resonance,


    blue line – well above resonance.
    Casing vibration transient data collection

    Over 160° phase shift -


    well above resonance

    Close to 90° phase shift – on resonance


    Vibration data analysis:
    - the dominating frequency component for the Main Gearbox
    Shaft relative and casing vibration was the 1X rotational speed
    of low speed shaft,
    - the Power Turbine Support Casing vibration Polar plots shows
    vibration amplitude grows, starting at speed 12000 rpm and
    approx. 90° phase shift from low speed to 12500 rpm,
    - this indicates rotor is operating on or close to the Power Turbine
    supporting system resonance frequency.
    It is time for ODS
    To visualize Power Turbine movement, demonstrate consequences of
    detected resonance phenomena, Operational Deflection Shape (ODS)
    animations were done for different Unit operation conditions:
    - stopped Unit
    - 7500 RPM (minimum flow),
    - 10500 RPM (55% flow),
    - 12500 RPM (91% flow– maximum level before Unit trip)
    Measurements done by roving three axis accelerometer in orthogonal
    directions – vertical, horizontal and axial and reference accelerometer,
    installed in vertical direction at the Non-drive end (NDE) Gas Turbine
    support.
    It is time for ODS

    Roved Triaxis
    accelerometer
    (points 1-35)

    Reference probe (point 5)


    It is time for ODS
    12500 RPM mode
    shows clear picture of
    Power turbine Drive end
    side supporting system
    resonance.
    This PT Drive end side
    supporting system
    movement can be the result
    of supporting system
    stiffness degradation, or
    lack of supporting system or
    frame design.
    Problem and short term solution

    The short term solution


    was to limit operation
    speed up to 12000 rpm,
    to avoid Units operation
    at resonance.
    Problem and long term solution

    The long term solution was


    to increase Power turbine
    Drive end side supporting
    system stiffness in the axial
    direction .
    Problem and long term Solution
    Increase supports
    stiffness in the axial New design of Unit A Power turbine Drive end
    direction supports was implemented by Customer
    during next planned overhaul.
    The stiffens of supporting system was
    increased in axial direction, U beam was
    removed and Power turbine legs supports
    were replaced by new, more stiffer design.
    This modification was done by Customer and
    new supports design wasn’t scope of this job.
    Problem and long term Solution

    Original design of PT support after


    PT support modification
    Outcome
    After supporting system
    modification it was possible
    for Unit A to reach maximum
    designed speed, maximum
    flow with acceptable
    vibration level.
    Unit B modification done
    during next planned
    overhaul.
    Lesson learned
    • There was no onsite Acceptance Test data.
    • A Factory Acceptance Test done separately for the
    different parts of the unit can not give information about
    assembled Unit operation.
    • Site acceptance test is required to confirm Units ability to
    run for whole designed operation range.

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