Normal Operation

Normal operation is indicated by acceptable vibration at all measurement positions. Critical speeds may be
excited during speed transients; but the amplitude will be acceptable. Trend plots show constant amplitude with
little or no variation with load. The dominant vibration frequency is 1X with little or no vibration at any other
frequencies.

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Sudden Mechanical Imbalance (Blade Loss)
A sudden imbalance may be caused by a blade loss, loss of balance weight, or another component normally attached to the
rotor. This may occur during normal operation or during a load or speed transient. It can be differentiated from an electrically
induced imbalance because the changes in vibration characteristics (amplitude/phase) are not reversible by changing load or
speed.

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Misalignment
Misalignment will generally result in elevated vibration amplitude due to load transfer from one bearing to an
adjacent bearing. The increase will show up as higher amplitude at 1X and 2X in spectrum plots, with 2X
amplitude reaching or exceeding 1X amplitude as the severity of the misalignment increases. The misalignment
may be coupling, or internal misalignment caused by improper bearing elevations.

3
Shaft Crack
A cracked shaft will result in elevated vibration at 1X and 2X with a trend that increases with time as the crack
develops. Because of the reduction in shaft stiffness from the crack, the rotor will tend to bow which will influence
rotor behavior. The decreased shaft stiffness from the crack may result in a decrease in critical speed observed.

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Static Rotor Bow
A rotor may bow if it remains stationary for a long period of time, or if the rotor is damaged. The bow is considered
static if the severity of the bow cannot be reduced by operating the rotor on turning gear. A rotor bow is generally
most traumatic if a machine is stopped under load and not placed on turning gear.

5
Temporary Rotor Bow
A temporary bow may occur if the turbine generator is left stationary while the rotor is at elevated temperature,
such as the case where a turning gear malfunctions. Unlike a Static Rotor Bow, a temporary rotor bow typically
relieves itself after a period of operation at lower speeds or at full speed.

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Thermal Bow
A thermal bow may occur during operation when a rotor-to-stationary-component rub produces a hot spot at the
rub location on the rotor. This results in a temperature gradient across the rotor and uneven expansion. This may
also be known as spiral vibration due to the presence of loops in polar plots at constant speed caused by the
continuous change in the rotor balance condition.

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Partial Rub
Rubs typically occur at locations with limited radial (or axial) clearance. A partial rub occurs when the rotor
occasionally contacts a stationary surface while travelling through its normal precession. This produces elevated
1X vibration and may produce vibration at fractional frequencies (1/2X, 1/3X, etc.).

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Full Annular Rub
A full annular rub occurs when the rotor contacts and remains in contact with a stationary component as it precesses. Vibration
amplitudes are generally higher than for a partial rub, and the dominant vibration frequency is at 1X with no fractional frequency
vibration. Rubs that occur during transients may show excessive vibration even after passing through a critical speed. This is often
unsustainable due to excessive dynamic bearing loads developed during these events.

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Oil Whirl
Oil whirl is normally caused by improper design of the rotor-bearing system. The presence of vibration components
at frequencies slightly less than 1/2X with varying amplitude are indications of oil whirl. Oil whirl can be aggravated
by higher speed, higher oil viscosity, and lighter bearing loading.

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Oil Whip
Oil Whirl will transition to Oil Whip when the whirl frequency reaches the first natural frequency. The sub
synchronous vibration will lock onto the unstable natural frequency and will not continue to increase with the
rotor speed. The sub synchronous vibration will increase and can be damaging.

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Mechanical Looseness
Mechanical looseness may come from excessive bearing liner, retainer to pedestal clearance, or pedestal to
foundation looseness. Looseness of rotating components may also result in elevated harmonics of running speeds
and/or 1X amplitude and phase changes over time.

12
Excessive Bearing Clearance
Excessive bearing clearance may be caused by design or maintenance issues. Other causes could be a loss of
Babbitt material on the bearing liner or pads. This can increase the vibration amplitude if the clearance is due to
wear during operation from the change in the bearing stiffness and damping coefficients.

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Electrostatic Discharge
Electrostatic discharge at the bearings occurs when there is a problem with the rotor grounding system. Any residual electric
charge in the rotor or electric charge induced by saturated steam will be discharged through the bearing oil film and will damage
the bearing. This can often be misdiagnosed as an instrumentation fault. If left uncorrected, this will lead to excessive bearing
clearance and vibration and bearing temperature problems.

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Labyrinth Seal Instability
Labyrinth seal instability, or steam whirl, is a generic term used to describe the condition in which the combination of
destabilizing forces from circulating steam flow in labyrinth seals and from steam forces at the blade tips results in sub
synchronous vibration. The condition may be benign with the sub synchronous frequency and amplitude varying over time but
never reaching damaging levels.

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Operation on Resonance
Operating a turbine generator on a critical speed or a structural resonance will result in elevated 1X vibration
amplitude. This is normally the result of a design deficiency but can also be caused by changes to the system that
cause shaft critical speeds to shift, or structural issues, such as foundation degradation, that result in changes to
structural natural frequencies.

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Bearing Loose in Housing
Bearings are typically installed into housings or bearing retainers with a slight interference. This is often referred to
as "bearing crush". If there is inadequate crush, the bearing may be loose in the housing. This can produce high 2X
vibration that is difficult to differentiate from 2X electrical line frequency vibration until the generator is de-
energized.

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Glitch
Glitch is a term used to describe damage such as corrosion or scratches on the proximity probe target area. This will
result in spikes in the time waveform plots and elevated 1X amplitude. The location of the spikes will be at a fixed
location when compared to the phase timing marker on time waveform or direct orbit plots. This does not affect the
health or reliability of a turbine generator but will make detecting or diagnosing other faults difficult.

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 Diagnostic Process Flow Chart

1. Data Validation 2. Collect Machine History Data

Abnormal Personal error Provide

Vibration Yes D. C. Recent
in identifying additional B. Data from A. Recent
detected Historical transient Adjust Alarm
the faulty data training support Maintenance
vibration vibration set points
instrumentation history
No data data
Validate
Existing Incorrect Adjust
Yes
data alarm set alarm set
points points Result of Results of Vibration Yes
Previously No No Yes
No operational maintenance acceptable
identified ?
Repair or changes ? activity ? ?
Yes Faulty No
replace faulty Yes Yes No No
instrumentation
instrumentation
Adjust
Investigate
Operation to
previous
correct the
resolution
condition
Valid data available
Yes for diagnosis
Compare data to fault
matrix
No
Instrumentation 4. Data Steady State Data
data • 1X amplitude
Identify Assessment trend Collect additional
Corrective • 1X phase trend vibration or support
• Thrust position
Actions based on • 2X amplitude instrumentation data
• Rotor eccentricity
fault analysis Transient Data trend
• DE (Diff.
(Maintenance • Time domain
Expansion)
actions – • Spectrum plots
• Temperature • Shaft center line
Operation change • Full spectrum plot
• Pressure plots
– Design change ) • Direct orbit 3. Collect
• flow • Bode plot
• Load • Polar plot • 1X filter orbit Additional data
• Cascade plot • Shaft centre line
5. Fault Diagnosis
• Waterfall plots

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