www.testdevices.

com
571 Main Street, Hudson MA, 01749-3035 / Tel: 978-562-6017 / Fax: 978-562-7939

Spin Testing
By: Eric Sonnichsen of Test Devices, Inc.
From: Global Gas Turbine News, Vol 37, No1

Spin testing is an important step in the prevention of centrifugal burst disaster. Rotating
components used in modern, high-speed machinery operate under large centrifugal stresses
and can fail with explosive force; so all developers and manufacturers of turbomachinery com-
ponents need to test rotors for centrifugal strength. Developers need to calibrate and verify the
results of stress analysis, and to establish the fatigue life of high-performance rotors; and
manufacturers need to prove the strength of high speed disks before shipment and installation.
The vertical axis spin test that fills these various needs was originally developed to solve a
problem with military aircraft turbochargers during World War II, and has been in wide use ever
since. While there are other ways to test for centrifugal strength, the vertical axis, flexible shaft
spin test is most commonly used because it is the most versatile and general method available
to spin a high speed rotor without requiring a high cost, elaborate bearing system for each ro-
tor.
The most common way to con-
duct a spin test is to suspend a rotor
in a heavily armored vacuum cham-
ber from a flexible spindle and to
accelerate the rotor to high speed by
driving the spindle with a com-
pressed air turbine or electric motor.
The flexible shaft allows the rotor to
find its own balance axis, in much
the same way that a child's top spins
smoothly without any external sup-
port. The soft support eliminates the
need for extreme precision in mount-
ing or balancing, and limits the dam-
age to the drive system in the event
of a rotor burst. The armored cham-
ber is often called a "spin pit" for
historical reasons, but modern spin
chambers are designed with ade-
quate strength so they don't need to
be in a hole in the ground. Properly
designed spin pit armor is quite
massive. A high strength forged
steel cylinder with minimum thick-
ness equal to 1/3 of the radius of the
Figure 1 largest diameter test rotor is appro-
Typical Spin Test System Containment Diagram
priate for most common applications.
To reduce the magnitude of impact
shock, the steel armor is commonly
lined with a soft material like lead
(see Figure 1 for a diagram of a typi-
cal spin test system containment).
Spin tests are usually conducted in vacuum to eliminate the high air friction losses that
would make it difficult to drive most rotors at high speed, as well as to reduce the friction heat-
ing created if the test were conducted in air. The vacuum is an important safety feature since it
reduces the risk of explosion of metal dust or oil fog during a rotor failure. It is also important
in preventing unsteady aerodynamic forces from destabilizing the rotor. The necessary vac-

By: Eric Sonnichsen of Test Devices, Inc. From: Global Gas Turbine News, Vol 37, No1 1
 www.testdevices.com
571 Main Street, Hudson MA, 01749-3035 / Tel: 978-562-6017 / Fax: 978-562-7939

uum is of the order of 200 millitorr, or about 1/4000 of an atmosphere absolute pressure.
Although not considered a particularly high vacuum level, maintaining vacuum in this range
requires careful attention to chamber seals and imposes stringent requirements on the high
speed seal used where the spindle passes into the chamber.
Destruction of good rotors by bad spin tests has been a serious problem since the first
spin test was conducted more than 50 years ago. The original spin drive was brilliantly con-
ceived and manufactured in a matter of weeks, to solve a serious problem for the military. Un-
fortunately though, few significant improvements to the process were made for nearly forty
years afterward, and untold millions of dollars have been wasted as a result. The problems
are caused by the inherent weakness of traditional spin test spindles and the inadequate per-
formance of the vibration dampers intended to control the various resonant vibration modes of
the spindle. These dampers behave unpredictably and cause the failure of the drive spindle
and destruction of the test rotor. In one notable case, spindle failure destroyed half of all the
rotors tested in a production operation. In another case it proved impossible to conduct a low
cycle fatigue test on a critical jet engine rotor because the test assembly was always destroyed
by spindle failure within a few
hundred cycles of beginning
the test.
Fortunately, the problem has
been solved by the develop-
ment of substantially more
robust spindle/damper systems
not subject to the instability
and failure modes that plagued
users of the older drives. With
modern spindle/damper sys-
tems, the risk of damage to a
test rotor is virtually nil. With
properly engineered drives and
good vibration monitors, un-
balance and stability problems
which would otherwise have
destroyed a good rotor now
only result in test interruption
and problem resolution.
The low power of the tradi-
tional air turbine test drives has
been a handicap in the meas-
urement of cyclic fatigue life.
With the old drives, cycle
times measured in minutes
were common, and a 50,000
cycle life test required five
months of continuous test op-
eration. Modern high-
efficiency air turbines reduce
the cycle time to 10 - 30 sec-
onds for typical jet engine ro-
tors, reducing the total test
time to about 2 weeks. The
shorter test cycle allows
shorter time to market and
Figure 2 substantially reduces program
Ten Inch Compressed Air Turbine with Modern Damper System schedule slippage.
Mounted on Spin Pit

By: Eric Sonnichsen of Test Devices, Inc. From: Global Gas Turbine News, Vol 37, No1 2
 www.testdevices.com
571 Main Street, Hudson MA, 01749-3035 / Tel: 978-562-6017 / Fax: 978-562-7939

Advanced Test Technology

Properly equipped spin facilities give devel-
opers the tools to perform important tests in
addition to the conventional proof, burst, and
Low Cycle Fatigue (LCF) protocols:
Hot Testing: Turbines and high pressure
compressor rotors operate at high tempera-
tures and need to be tested at those tempera-
ture levels, particularly when LCF life is being
evaluated. Hot testing to 2000 °F is practical
with proper selection of spindle material, instal-
lation of high performance spindle seals, and
appropriate measures to control damper tem-
perature. Although the vacuum eliminates
Figure 3 most convective heat transfer, rotors can be
Modern Spin Test Console with Vibration Moni- heated by infrared radiation from resistive heat-
tor, Heated Test Capability, Tachometer, PC ing elements. Radio Frequency (RF) induction
Computer Interface, Slip Ring System and Ra- heating works well also, but is more costly and
dio Telemetry for Strain Measurenent and High difficult to set up because of the need for spe-
Speed Camera Control cial induction coils for each rotor configuration.
Controlled Atmosphere Testing: Inserted
blade turbines often show shorter life in a
heated vacuum spin test than they do in engine
operation. The source of the problem is accelerated fretting at the fir tree caused by the lack
of air. This problem can be eliminated by operating the spin pit at absolute pressures signifi-
cantly above the conventional 100 - 300 millitorr level. High power drives, careful control of
aerodynamic losses by baffle and shroud design, and special temperature controls are neces-
sary, but a properly engineered system is capable of running a heated spin test at any pres-
sure up to and including one atmosphere. (It should be emphasized that running heated tests
with an air atmosphere carries the serious risk of oil fog or metal dust explosion, and must not
be done without critical safety measures).
Blade Vibration Testing: High frequency fatigue of blades has become a serious problem
in the operation of advanced performance jet engines. These problems can be explored and
resolved quickly with a well equipped spin pit. Use of special high power drives makes it pos-
sible to set up and run a bladed rotor in the spin pit without vacuum, again using well designed
baffles and shrouds to reduce pumping losses. Using a high speed slip ring and hollow spin-
dle to conduct strain signals to external instrumentation, blade modes are explored by exciting
vibrations with external air jets or electromagnetic fields. These tests allow rapid measurement
of blade vibration response and rapid evaluation of the effectiveness of proposed changes
when a problem needs to be solved. If blade mode mapping were done this way as a routine
part of rotor qualification, it could reduce the number of blade vibration problems discovered in
the field.
Scale Model Testing: A very limited number of spin facilities are available for testing large
gas turbine engine rotors. With the trend toward very large turbines for power generation, and
large fans for jet engines, the size of the rotor assemblies to be tested now exceeds the size of
the available spin pits. Until new facilities are constructed, it will be necessary to do develop-
ment testing with scale models. Fortunately, the scaling laws for centrifugal strength are quite
simple and scale model testing can produce reliable results. To perform a scale model test,
the model must be an exact scale replica of the full size assembly, including all bolt holes, fit-
tings, and fasteners. The scaling law requires that the model must be run at a speed equal to
the running speed of the full size rotor divided by the scaling ratio, so a ¼ scale model needs
to be run at four times the speed of the full size rotor.

By: Eric Sonnichsen of Test Devices, Inc. From: Global Gas Turbine News, Vol 37, No1 3
 www.testdevices.com
571 Main Street, Hudson MA, 01749-3035 / Tel: 978-562-6017 / Fax: 978-562-7939

It should be emphasized, that even though scale model testing can provide valid informa-
tion about the centrifugal strength of a new design, testing a model does not satisfy the cardi-
nal rule of testing: always test what you will ship, including the smallest, apparently insignifi-
cant detail. Scale model testing is only valid if the test assembly is an accurate model of the
full size article.
Containment Testing: Recent accidents in commercial airline service have renewed in-
terest in the problem of jet engine rotor burst. The FAA Aircraft Catastrophic Failure Preven-
tion Program is addressing the problem by working toward development of fragment barriers
and debris mitigation techniques. Spin pit burst testing of individual rotors and candidate con-
tainment structures allows rapid evaluation of new designs at reasonable cost. Advances in
video recording technology allow the test engineer to study the interaction between the burst-
ing rotor and the containment structure, validating dynamic models and pointing to improve-
ments in containment design.
Strain Survey Tests: Despite continued advances in Finite Element Analysis (FEA) tech-
nology, computer models need both verification and initial physical parameters that sometimes
only testing can supply. In particular, new kinds of non-isotropic materials including organic
and metallic matrix composites are difficult to model in the three-dimensional centrifugal stress
field that exists in a high speed rotor. A spin test with strain gauges placed on critical locations
is very important for validating the model and understanding the performance of complex
structures. Modern, advanced performance slip-rings
are available for speeds up to about 90,000 rpm, and
with capacity of 100 channels of strain data or more, so
multiple gauges can be monitored in a single run. High
temperature gauges are expensive but available, so it
is even possible to evaluate the effects of temperature
on the strain field.
Real-Time Detection of Cracks: During a Low
Cycle Fatigue test it is important to monitor the health
of the accelerating and decelerating rotor in real time to
prevent bursts. Classical spin test protocols require
removing the rotor for inspection at fixed intervals, with
no insight into the health of the rotor during the actual
test. Without this instrumentation a spin test engineer
is “flying blind”, and relies only upon experience and
luck to select the correct time to remove a part for in-
spection. Much the same thing happens in the field
with a high-performance rotor. Components are re-
moved at fixed intervals and are inspected, but there is
rarely an on-line indication of a potential problem, ex-
cept for perhaps an indication of raw vibration.
Figure 2 A method has recently been developed to monitor and
This 36" spin test system was used by
Test Devices Inc. to burst a rotor and evaluate the integrity of a spinning assembly continu-
demonstrate that the containment ously throughout a test. The method uses a non-
structure would satisfactorily support contact eddy-current probe to measure the vibration
the event (see "Anatomy of an Acci- vector of the part, then compares the amplitude and
dent"). However, the system, which phase of this vibration to a baseline that has been pre-
included a spin chamber, turbine - atop viously established. Any distortion in the strain field of
the pit with two blue hoses entering the the disk, or any relative movement of the components
side - and vacuum and oil pumps, was that make up the assembly will cause a minute unbal-
later destroyed in an accident. ance and will appear as a distinct amplitude and phase
change. The vibration vector change usually indicates
that a disk crack has developed, but sometimes dis-
closes some other important change in the assembly
such as a loose tie bolt, etc. (see Figure 4 for a dia-
gram of the elements of a Crack Detection System).

By: Eric Sonnichsen of Test Devices, Inc. From: Global Gas Turbine News, Vol 37, No1 4
 www.testdevices.com
571 Main Street, Hudson MA, 01749-3035 / Tel: 978-562-6017 / Fax: 978-562-7939

In the spin pit this signal is used as an early warning of a crack to determine when the part
should be taken out for inspection, or as a diagnostic tool to determine if there has been some
slipping, fretting or movement between the pieces of the assembly. Monitoring simple vibration
amplitude is not helpful in detecting signals of interest here, since the relevant changes in vi-
bration are very small vector quantities and often have no observable effect on the overall vi-
bration level of a rotor.

Figure 4
Crack Detection System Block Diagram

With this technology it is possible to terminate tests just prior to disk burst, preserving the
entire assembly for analysis. Preventing a burst allows the metallurgist an opportunity to view
the disk with no collateral damage and to determine the crack initiation site with complete cer-
tainty. Preventing a burst also reduces the cost of the test by eliminating the high costs asso-
ciated with facility repair after a failure; and further savings are realized by preserving arbors,
blade sets, and other associated tooling and attachments.

Safety
Spin testing is potentially dangerous. The kinetic energy of typical turbomachinery com-
ponents is very high at burst speed, and the fragments of a disk can do serious damage to
structures and people if containment is inadequate. For example, a 200 lb steel disk spinning
at 18,000 rpm has a kinetic energy of approximately 5.2 million lb-ft, the equivalent of a 22 ton
truck traveling at 60 miles per hour. A recent fatal spin test accident in Europe underscores the
need for careful consideration of the potential hazards inherent in operating spin pits. A large
number of the spin test facilities in the United States are home-made, designed by engineers
who may have been unaware of some of the more subtle hazards of spin test operations.
Many of them are unsafe. Some of the commercially manufactured spin pits were designed

By: Eric Sonnichsen of Test Devices, Inc. From: Global Gas Turbine News, Vol 37, No1 5
 www.testdevices.com
571 Main Street, Hudson MA, 01749-3035 / Tel: 978-562-6017 / Fax: 978-562-7939

during a time when rotor fragment energies were lower than those of advanced performance,
modern turbomachinery equipment, and are inadequate in several important areas. Some of
these old designs are still being offered on the market. A well designed test facility has the
following important features:
1. Strong Lid/Cover Retention. Nearly all of the serious spin testing accidents have
been the result of axial containment failure. Aluminum or titanium dust can produce pressures
in excess of 100 psi, with a very rapid rise time. Lubricants, including “fire resistant” hydraulic
fluids are nearly as hazardous. The chamber must be designed for explosive pressure rise of
this magnitude and the cover must be held with substantial clamps or bolts or lid dogs, ade-
quate to contain the explosion. Vacuum force is not sufficient by itself to safely retain the
cover, and explosion ports cannot vent the chamber rapidly enough to prevent overpressure.
2.Strong Radial Containment. The containment should be a single steel cylinder to pre-
vent multiple sequential shear penetration failure, and it must be free to rotate with respect to
the vacuum chamber as a bursting rotor transfers its angular momentum to the liner during a
burst. Spectacular accidents have occurred when the burst liner was constrained from rotation
and the bursting rotor had enough energy to tear the spin pit from its mountings and cartwheel
it around the room.
3. Secondary Protective
Barriers. Operators and bystanders should NEVER be directly exposed to an operating spin
pit. Despite all the efforts of safety engineers, the high rate of energy release by bursting ro-
tors can cause unpredictable results, endangering people and equipment. The spin chamber
needs to be located in a reinforced concrete test cell, with the operator station located outside.
No one must be allowed in the test cell when the machine is running, and safety interlocks
must be in place to prevent the pit from being opened under unsafe conditions.

Figure 5
Top of Spin Pit with Air Turbine Mounted in Center Showing Lid
Dogs Used for Axial Lid Retention

By: Eric Sonnichsen of Test Devices, Inc. From: Global Gas Turbine News, Vol 37, No1 6
 www.testdevices.com
571 Main Street, Hudson MA, 01749-3035 / Tel: 978-562-6017 / Fax: 978-562-7939

Summary
Spin testing is the most cost-effective and reliable way to evaluate centrifugal stress.
Many problems with spin testing in the past have been solved with advanced high technology
developments in damping systems, high-performance turbines, hot testing, reduced vacuum
testing, and non-destructive methods to detect cracks in real-time. Spin testing can be a dan-
gerous activity and the equipment must be designed and installed appropriately to minimize
the risks inherent in the rapid energy release of a rotor burst. Advanced technology rotors
made of new materials present special challenges to existing spin test systems, and these
need to be examined on a case by case basis.

—END

Copyright® 2003, 2004, 2005, 2006, 2007 Test Devices Inc

EMAIL: [email protected]

By: Eric Sonnichsen of Test Devices, Inc. From: Global Gas Turbine News, Vol 37, No1 7