TURBINE-GENERATOR SHAFT

TORSIONAL VIBRATIONS

SCHOOL OF ENGINEERING,IIT MANDI,MANDI

H P, I N D I A 1 7 5 0 0 1

TORSIONAL VIBRATIONS

The study of torsional vibration of rotors is very important especially in applications

where high power transmission and high speed are present. Torsional vibrations are
predominant whenever there are large discs on relatively thin shafts.

& c& k T sin t

I&
0

where

1
2
I mr , m mass, r radius
2
c damping
T0 Torque
also
T G
GJ

T
k
J
l
l
GJ
k
Torsional stiffness
l

TURBINE-GENERATOR
SYSTEM
Any turbine-generator system may have number of turbines to rotate the generator
to produce 50 Hz of three phase power.
Tg
T1

Turbine I

T2

T3

T4

Turbine II

Turbine III

Turbine IV

Torsional Vibration Damper

Generator

DAMPING IN TORSIONAL
VIBRATIONS

In any real rotor systems damping is always present. Torsional damping may come from several
sources, e.g. the shaft material, bearings, couplings, torsional vibration dampers, aerodynamic
damping at discs, rubbing of the rotor with the stator, loose components mounted on shaft, etc.
The torsional vibration damper is a device which may be used to join together two-shaft section. It
develops a damping torque, which depends upon the angular velocity on one shaft relative to the
other.
The disc aerodynamic (or rubbing) damping comes due to interaction of the disc with the working
fluid (like steam, gas, air, etc.), lubricant, and coolant; which results in dissipation of the energy in
the form of heat. This type of damping is proportional to the angular velocity of the disc itself.

MATHEMATICAL MODELLING
Torsional Damping
T1

T2
C23

C34

III

II
K12

C11

T4

T3

C12
I

Tg

IV

K23

C22

Aerodynamic Damping

C45

V
K45

K34

C33

C44

1
)

k12(2-1)

& T k ( ) c (& &) c &

I1&
1
1
12
2
1
12
2
1
11 1
& (c c )& c & k k T
I &
1 1

12

11

12 2

12 1

12 2

(1)

k23(3-2)

k12(2-1)

& T k ( ) c (& &) k ( ) c (& &) c &

I 2&
2
2
12
2
1
12
2
1
23
3
2
23
3
2
22 2
& c & (c c )& c & k (k k ) k T (2)
I &
2 2

12 1

12

23

23 3

12 1

12

23

23 3

k34(4-3)

k23(3-2)

& T k ( ) c (& &) k ( ) c (& &) c &

I 3&
3
3
23
3
2
23
3
2
34
4
3
34
4
3
33 3
& c & (c c )& c & k (k k ) k T (3)
I &
3 3

23 2

23

34

34 4

23 2

23

34

34 4

k45(5-4)

k34(4-3)

& T k ( ) c (& &) k ( ) c (& &) c &

I 4&
4
4
34
4
3
34
4
3
45
5
4
45
5
4
44 4
& c & (c c )& c & k (k k ) k T (4)
I &
4 4

34 3

34

45

45 5

34 3

34

45

45 5

5
)

k45(5-4)

& T k ( ) c (& &)

I 5&
5
g
45
5
4
45
5
4
& c & c & k k T
I1&
1
45 4
45 5
45 4
45 5
g

(5)

From equations (1), (2), (3), (4) and (5)

&
&
&
I

K T
Where,

I1
0

I 0

0
0

I2
0

0
I3

0
0

0
0

0
0

I4
0

0
0

0
I 5

T1
T
2
T T3
T
4
Tg

(6)

 k12
k
12

I 0

0
0

k12

( k12 k23 )
k23

k23
(k 23 k34 )

0
k34

k34

( k34 k45 )

k45

(c12 c11 )

c
12

0
C

c12
(c12 c23 )
c23
0

0
c23
(c23 c34 )
c34

0
0
c34
(c34 c45 )

c45

0
0
0

k45
k45
0
0
0

c45
c45

1
2
I mr , m mass, r radius
2
GJ
k
stiffness
l

Synchronous generator produce electricity whose frequency is synchronized with

mechanical rotational speed.

f e 60

rpm
np
2
f e freqency of electricity.
n p number of poles

At 50Hz

Number of
Individual Poles

12

24

36

48

Rotational Speed
(rpm)

3000

1500

750

500

250

167

125

Power
Torque

Pg
P3
P1
P2
Tg
, T1 , T2 , T3

T1 T2 T3 T4 Tg initially

SHAFT FAILURE

Various studies have been conducted to try to quantify the causes of shaft
failures. One industry study provided the results for rotating machines shown in
Table below. For rotating shafts, 90% of all failures can be placed into the
fatigue modes

A clear understanding of shaft loading is necessary before causes of shaft

failure can be determined. Two cases that provide the most common types of
turbine-generator shaft loading that can lead to fatigue-type failures are shown
below.

Bending fatigue

Torsional fatigue

TURBINE-GENERATOR SHAFT LITERATURE REVIEW

Reference

Investigation/Research

J.C. Wachel et al Give the basic overview of vibration in rotating machinery. Different
[1]
cause of failure in rotating shafts has been discussed. Theory of torsional
vibration and stress analysis criterion is explained in detail.
Niculai PASCA Presented failure analysis of a shaft, from a double suction hydraulic pump
et al [2]
in operation of approximately 30 years, in a storage station. The finite
element analysis of the pump shaft and an analytical failure analysis for a
circumferential crack type, using the failure assessment diagram is
presented
Stuart
H. Summarize design methods, based on strength considerations, for sizing
shafts and axles to withstand both steady and fluctuating loads. The effects
Loewenthal [3]
of combined bending, torsional, and axial loads are considered along with
many application factors that are known to influence the fatigue strength
of shafting materials.
V. S. Khangar et Methodologies used for the failure analysis of shaft used in different
al [4]
application by various authors are reviewed in this paper
Osman Asi [5]

Conclusion
Basic criterion for stress analysis of a rotating shaft
is explained .
This study presents an opportunity related to safe
operation condition and remaining life estimation for
a storage pump.
Methods are presented to account for variable
amplitude loading and their influence on limited-life
designs.
Review paper

Described the failure analysis of rear axle shaft used in an automobile. Observation crack was initiated at stress
Shaft is subjected to bending and torsional stress.
concentration point leading to fracturing of axle
shaft
M. J. Reid et al Analysed 93 roll shaft breakages which have occurred at eight selected Theoretical analyses of shaft stresses and fatigue
[6]
sugar mills in Natal since 1979 to 1988 in eight sugar mills have been stress concentration factors have been carried out to
collected and analyzed to determine the most likely causes of failure.
determine whether present shaft design, machining
practices, material specifications and shell assembly
techniques are satisfactory and whether they can be
improved.

Reference

Investigation/Research

Conclusion

D. Stojanovic et al Mathematical model for calculating and analysing the torsional It is proved that in certain cases the torsional torques on the shaft become
[7]
torque of big turbine-generator is described.
several times higher than the rated torque.
C.J. Cudworth et al Simulation results are presented in the paper for two different Comparisons of these computer predictions and actual measured test results
[8]
operating conditions: malsynchronisation and load rejection for are made for the torque transients on two shafts of the turbine generator.
turbine-generator system.
Good correlation is obtained if electrical and mechanical damping data is
chosen carefully.
C.Chyn et al [9]
Studied the effect of system faults on fatigue life of turbine- Effect of various parameters are simulated to analyse the fatigue life
generator shaft system.
expenditure in case of different system faults.
M.C. Jackson et al Studied the effects of power system disturbances and operating
[10]
practices upon turbine-generator shafts. The paper presents
techniques for the analysis of shaft fatigue damage due to
torsional oscillations.
M.C. Jackson et al Refinements to the previous models and procedures for the
[11]
calculation of torsional fatigue damage to turbo-generator shafts
are presented
F.R Snezasi et al Analysed the optimum location of torsional critical speeds which
[12]
will be excited by the transient start-up.

The detailed development of a fatigue model is presented. An example

illustrates the use of the techniques for calculation of the loss of life of a
turbine-generator shaft due to high speed reclosing of a close-in three phase
fault.
The fatigue model has been improved by the addition of stress concentration
effects and a rain-flow cycle counting technique has been implemented.

Tomasz Szolc et al Investigated the rotor shaft systems by means of the discrete[13]
continuous mechanical models. In these models the rotor shaft
segments are represented by the rotating cylindrical flexurally and
torsionally deformable continuous viscoelastic elements.
Hamdi Taplak et al In this paper a gas turbine rotor with certain geo- metrical and
[14]
mechanical properties is modeled and its dynamic analysis is
performed using finite element method.

The proposed model enables us to investigate coupled linear or non-linear

lateral torsional Vibrations of the rotating systems in steady-state and
transient operating conditions.

Shigeru
SAKAMOTO
Et al [15]

Result are shown graphically.

Reasonable results are obtained from the rotor system modelled.

Calculated vibration due to electromagnetic forces for rotating The usefulness of this method is verified through the agreement between
electric machines.
calculated and measured results for a three-phase/four-pole induction motor.

Reference

Investigation/Research

Qing He et al [16]

A new method of response calculation of torsional vibration of

turbine-generator shafts, the Increment Transfer Matrix method
(ITM), which combines the Riccati transfer matrix method with
the Newmark step-by-step integral method, is presented.

Chao Liu et al [19]

To estimate influences of grid disturbance, coupled torsional

vibration and fatigue damage of turbine generator shafts are
analysed in this work. Coupled system is established with
generator model and finite element method (FEM)-based shafts
model, where the grid disturbance is signified by fluctuation of
generator outputs and the shafts model is formed with lumped
mass model (LMM) and continuous mass model
(CMM), respectively

Conclusion

The responses of torsional vibration of 200MW turbine- generator shafts due

to the generator at non-all-phase operation are calculated and analysed. The
natural characteristics and responses of torsional vibration of shafts of
200MW turbine-generator are simulated and analysed under the catastrophic
accident condition. The results are identical with the data recorded in field.
Dennis S.H. Chan Transient torsional vibration due to generator short circuit is Flexible couplings affect the transient torsional response and they must be
investigated in this paper. Typical short circuit excitation included in the system vibration analysis. Their influence on the peak
[17]
functions are discussed. A modem gas turbine / generator / steam transmitted torque has been examined
turbine system is used to illustrate the effects of modelling
inaccuracies and parameter variations.
A. Vaziri et al [18]
Studied the generation and propagation of circumferential cracks The fracture surface roughness depends on the material microstructure, the
on turbo-generator shafts that are subjected to complex dynamic material yield strength, and the applied cyclic torque amplitude. This crack
torsional loadings.
pattern can severely affect the vibration characteristics of the shafts. The two
most common sources of the energy loss are the local energy loss due to the
plasticity at the crack tip and frictional energy loss due to interaction of
mutual crack surfaces. A theoretical procedure for evaluating the values of
the system loss factors corresponding to these sources of energy loss is
presented.
The results indicate that the proposed scheme with continuous mass model
can acquire more detailed and accurate local responses throughout the shafts
compared with the scheme without coupled effects or the scheme using
lumped mass model.

Reference

Investigation/Research

Conclusion

R. Oliquino et al Presented the results on the experiment conducted regarding the The effect of 3-phase fault (3PF), line-to-line fault (LLF), line-to-ground fault
[20]
effects of selected types of electrical faults on generators (LLGF) and line-to-ground fault (LGF) on the 5KVA model generator
vibration signatures.
vibration signature is evidently seen particularly on the time and XY plots.
Jong-Ian Tsai et al Long-term effect of noncharacteristic subharmonic currents in a To completely investigate the long-term effects of inevitable asynchronous
HVDC link on the fatigue life loss in turbine-generator shafts is operation, a systematic scheme is motivated to examine the concerned fatigue
[21]
analysed
life expenditure level. The simulation results show the influences under
various operating conditions and prove the potential long-term failure of
shafts due to such electrical disturbances
Kwai S. Chan et al a methodology is presented to assess the influences of high cycle The methodology is based on an integration of a global finite element
fatigue loading on the fracture risk of gas turbine engine analysis of the disk-blade assembly, numerical solution of the singular
[22]
components subjected to fretting fatigue.
integral equations using the CAPRI (Contact Analysis for Profiles of Random
Indenters) and Worst Case Fret methods, and risk assessment using the
DARWIN (Design Assessment of Reliability with Inspection) probabilistic
fracture mechanics code. The methodology is illustrated for an actual military
engine disk under real life loading conditions.

SHAFT STRESS
The objective of performing a forced vibration analysis is to evaluate the torsional amplitudes at
each turbine and resulting stress in each shaft. The resulting stress then compared to the endurance
limit stress of the shaft material to evaluate the probability of fatigue failure.

Bending fatigue
M e rshaft
SCF
I shaft
where
Bending stress in shaft
SCF stress concentration factor due
to discontinuty in shaft
I shaft Moment of inertia of shaft
rshaft shaft radius

For safe design endurance

FOS
FOS factor of safety
Adapted from J.C. Wachel et. al. [1]

Torsional fatigue
G rshaft
SCF
l
where
shear stress in shaft
SCF stress concentration factor due
to discontinuty in shaft
twist between adjacent turbines
rshaft shaft radius

endurance
For safe design
FOS
FOS factor of safety

Another formula to find the diameter of shaft for safe conditions is given by Stuart H. Loewenthal [3]
can be used to size solid or hollow shafts under reversed bending M r and torsional T m

32 FOS
d3

M
3 T m
r

4
f

where

f fatigue stregth
y yield strength
M r Bending moment
Tm torsion moment

1
2

REQUIRED INPUT PARAMETERS

S.No
1
2
3
4
5

Turbine Parameter/Property
Mass of each turbine
Radius of gyration of each turbine
Torsional damping in each turbine
Aerodynamic damping in each turbine
Turbine power

Value

S.No

Shaft Parameter/Property

Shaft material and properties E, G,

Yield strength, Ultimate strength,
Endurance strength,

Shaft length

Shaft drawing with dimensions

Number of poles in generator

Generator Power

S.No Generator Parameter/Property

1 Number of poles in generator
2 Generator Power

Value

Value

REFERENCE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

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Dallas, TX, Sept, pp. 14-16. 1993.
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PUMP SHAFT." (2012).
Shafts, Transmitting. "Design of Power-Transmitting Shafts." (1984).
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Asi, Osman. "Fatigue failure of a rear axle shaft of an automobile." Engineering failure analysis 13, no. 8 (2006): 1293-1302.
Reid, M. J. "Analysis of the causes of recent roll shaft failures in natal sugar mills." In Proceedings of the annual congress-South
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Mitrovic, D. Stojanovic D. Petrovic N. "Analysis of Torsional Torques of Big Turbine-Generator Shafts."
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