6 ORBIT April 1989 BENTLY ROTOR DYNAMICS ‘ESEAROA CORPORATION Shait CenterLINES Fluid-generated Instabilities of Rotors By Dr. Agnes Muszynska Senior Research Scientist Bently Rotor Dynamics Research Corporation Donald E. Bently Chief Executive Officer, Bently Nevada Corporation President, Bently Rotor Dynamics Research Corporation 1, Introduction Bently Rotor Dynamics Research Corporation (BRDRC) thas been conducting research on uid flow generated roter instabilities in fui handling rotating machines for ever seven years. The resulls are reported in a series of publica~ tions (see References) In this article, summary of the results is presented in a, simplified form, Noted here ure the bottom line, qualitative doseriptions of physical phenomena, and appzoximate analytical expressions describing these phenomena. 2, What is rotor instability? “The situation whew the shaft of # rotating machine exhibits high Lateral vibrations which are not cormelated 1 unbalance or other exweial periodic forees or constant radial forces Guch as gravity) is informally referred co as “rotor insanity thse vibrates sal nave subsynchrones Frequencies ‘A more formal definition is that the rotor exhibits selfex- Cited vibrations induced by some internal mechanism which, in most cases, transfers rotational energy it shaft lateral vibrations. In particular, Nuid flow (including gas and sieamn) can play the role of such an energy convertor. Fluid circumferential flow — the main contributor to rotor instability “The physical phenomena can he brielly describe as follows A shaft outing in an enclosed fluid environment (Such as in Ihearings, seals, ova stator‘ease) drags the fluid into rotative motion, Usually the fluid flew is three-dimensional (spa~ tind. However, the circumferential component (most often shaft rotation generated) may appear quite significant, inde- pendently from the other componsets of Maid motion (dial and axial), The circumferential flow generates the dynamic cifect of fuid dynamic rotating force which, in tuen (or rather ina feedback loop), crags the rotor into lateral vibeations Main characteristics of circumferential flow in " earings and seals For the pucpose of analy:ring and predicting rotor instability the circumferential flow in bearings and seals is represented bby two main factors: the fluid circumferential average velocity ratio, \ (lauibdia), and uid fm call strtness, Ky, Both of these factors are functions of many parameters. ‘The most important arpong these parametersis, however, tbe shaft eccentricity, ie. shaft displacement from concentric, position closer to the wall of a bearing or seal, The radial stiffness Ky increases with shaft eecontricity (Fig. 1). The fluid average velocity ratio decreases (slightly) when the shaft operates at low eccentricity and decreases dramatically ‘when ccvenirieity becomes higher (Fig. 2). At high cecon- icity, the shaft appreaches the statienary wall and “cus off” the circumfereatial flow, While this flow situation mainly ecours in radial clearances, as in seals an bearings it may’ also oceur in an axial clearance area (such av asieei- aed with balance pistons).Apuil 1989 zx 3 BEARING RADIAL ‘STIFFNESS BEARING CENTERLINE BEARING WALL JOURNAL RADIAL DEFLECTION Figure 1 Fluid film radial stiffness as « function of shaft eccentricity: ¢ is bearing radial clearence. Similar reletionship holds trac for seals. ~ eur & gift SZ15 = 1. 5” Z 8 a = S & g = 2 = 2 53.0 Cc * SHAFT ECCENTRICITY Figure 2 ‘Typical fluid circumferential avorage velocity ratio as « fanc- tion of shaft eccentricity inside a bearing or seal. Fluid film radial stffiess Apa a nonlinear function of shaft ecoeniricity represents a well recognized characteristic of bearings and scals. The fluid circumferential average veloc: ity tatie \ is relatively new: It has been identified at BRDRC throughout extensive experimental esting [Ref. 1-6}. ‘The more formal definition is 2s follows: Fluid cireumferen: tial average velocity AO induced by shalt roiation with rorative speed @ is the angular velocity at which the Muid ow-generated force rotates. For any desing or seal. both funetions Aig and A can be obtained experimentally [Ref. 4-16] andior analytically from fluid dynamic theory equations [Ref. 231 ORBIT 7 5. Whirl ond whip Fluid motion-induced sel-excited lateral vibrations of shafts are known as “oil whirlwhip,” “steam whip,” “aerody- amie whip.” or simply “rotor instability”. AlL ese vibra- tions actually belong in the sume category. They are characterized by forward orbital motion (in the direction of shall rotation) and subsynchronous frequency, which is ci ther nearly constant (independent of rolative speed) or is 2 fraction of the rotative frequency, maintaining this Fraction constant a§ the rotor speed varies, and winen other parame- teisof the system are constant. This fraction iy very close in value to the fluid eireurnferential average velocity ratio dis- ceussed above, The first situation ischaracteristie for “whip. the second for “whirl”. The constant Frequency’ of whip is Usually close to the rotor natural frequency, most often cor responding to the first Isteral mode it could also be of @ higher rotor mode) (Ref. 25) There is a very smooth transition from whirl to whip with ‘increasing rotative speed (Fig. 3a). Sometimes, when is close 10.0.5 snd the chreshold ef stability is higher than dea ble the first natural frequency of the rotor first lateral f SPEED (kreHl roraey requaxer (erm) Figure 2 [q) Spectrum cascade of the vibrational response during startup of a rotor supported in one rigid and one oll-ubricated becrring. (b) Spectrum ccscade of the vibrational response during startap of a rigidly supported rotor with a mid-span seal.8 ORBIT taode, he whip cccurs without being precsded by whirl Fig, 3b). Achigher rotstive speed. the whip may disappear anil the rior stabilizes. Sometimes whip "jumps" into a ‘hid ofthe second snode jump” relates to amplitude and frequency) (Fig. 4). Sometimes whip and whirl of the se2- ‘ond mode exist simultaneously (Fig. 5) 6, Threshold of stability ‘Threshold of stability isthe rotor speed at which self excited vibrations start (Pigs. 3, 4, and 5). Very informally speak- ing, at the threshold of stebility, damping-type forees disup E Fapguency (hod Figure Spectrum cascade of the vibrational response during startup of @ rotor supported ia an oil-lubriceted heating indicating the “jump” of self-excited vibrations from whip to the second mode whirl, The sketch indicates where measurements were taken. The oscilloscope in orbital mode shows that shaft in whic] at lower rotctive speeds vibrates in phase: at higher rotative speeds. shaft right-hond side is 180° out of phase from left-hand side. FREQUENCY [XCEM] Figure § Spectrum cascade of the vibrational response of a rotor indi- cating coexisionce of selfexcited vibrations of the whip and second mode whiel types. April 1989 pear, then Hecume “negative”, More precisely, the actual daroping forces do not change at all, but there are emerging, forves which act opposite to damping, fist nubitying it then becoming dominat. ‘The “stable” rotor at rotative specds below the threshold of stability rotates smoothly, and usually, due to residual untal- ance, il exhibits some Synchronous lateral vibrations (and possibly higher order harmonics). At the threshold of stabil- ity, the rotor starts vibrating with # subsynchronous.tre- quency and increasing amplivude, finishing up in a limit cycle self-excited vibration of the whirl or whip category (Fig. 6). While this new subsynchronous component appears in the vibrational spectrum, the synchronous com ponent does not exhibit any significant change Figure 6 Oil whirl limit-cycle inception, Numbers on the orbit indicate consecutive rotations, Picture taken from oscilloscope display “with expesure 18 second; shaft rotative speed was $180 rpm. The threshold of stability ean be easily predicted by « linear ‘mathematical model ofthe rotor system (such as represented by bearing or scal coefficients). However, the self-cxeited vibrations can only be described hy nonlinear model The nonlinear terms in dhe model determine the values of vibration amplitudes, ie. the size of the whiel andlor whip Limit eyele orbits, 7. How to prodict the threshold of stecility ‘The threshold of stability does not depond exelusively om the bearing/seal characteristies; itis definitely an entire rotor! bearing/seal system propesty For a laterally isouopie rowr supposted in one rigid bezring. and one oil-lubricated betting (Fig. 7), the threshold of six biliy, yr, can be approximated [Ref 15} as 1 [RGR ERO RK. sr a «fein 1sApril 1989 where Ky and Kars the partial stiffnesses of the rotor frst lateral mode, 7 is the modal mass, Ko is Muid film racial stiflness at zero eccentricity, and) isthe Hluid eiecum ere tial average velocity rao, Since the stiffnesses Kiy and Ko act in series, their equivalent stiffness is smaller than either of them, Therefore. when either Ky or Kp is small, their ‘equivalent stiffness becomes insignificant in comparison © Kj, and can be neglected. This yields the Final approxima tion in Equation (7). In the case oF rotor with a close to mid-span seal and 10 rigid supports (Fig. 8), dhe threshold of stability is relatively higher than (1 1 = (VR Ron @ where Kj, Kp and M are the corresponding partial stilt nesses and mass of the shaft firs lateral moda. Im both of these simple eases, the threshold of stability is in versely proportional to the uid circumferential average velecity ratio, ', and to the square root of rotor model mass, Since A deereases with shaft eoceatriety inside the bearing ‘or seal, the threshold of stability increases with ccventric: ‘ty. [Liswell known that when high radial load is applied 10 the shaft (such as gravity for horizontal smchines), it results in shaft displacement to higher eecentrivity inside the hear- ings. This stabilizes the rotor: oil whit! ot whip disappear Determined by the roior actual mass, the modal mass Fin the denominator of the threshold of siability is also signifi cant: heavier rofor usally results in lowering the thresh- ‘kd of stability. This sounds contradictory © the common beliefs, Nove, hemever, chat we are talking about the “mass” Figure 7 Model of a rotor supported in one rigid andl one oil-lubricated, hoatting: X).%2 and 72 aro shaft horizontal ond vertical deflections respectively. Floxble Shaft « w oe —- = 4 7 a \ Bearing Seal Rigid Boaring Figure ¢ Model of « zoter/secl system. ORBIT 9 not the “weight” (av lore) and we do not specify whether the rotor is horizontal or vertical, [Cis assumed thatthe stu rotates at the seame original cecontricity, ic., Xremains the same fbr the rotor with lower or tigher mass. Interesting also is the influence of rotor silliness on the stax bility threshold. Irat the cigid bearing side in the first wodel (Fig. 7) the roxor is stiff (Ky higher). the threshold af stahi ig increases, (Fits stiff al the fluid lubricated bearing side Ge. the rotor mass center ic closer to the fluid bearing}, the stability threshold decreases, i.e., the roior is Hess stable (Figs. 9 and 10), What are self-excited vibrations? Vibrations in mechanical systems are usually classified into three categories: free vibrations, forced vibrations, and self excited vibrations (Fig. 1). ‘The differences between 1 exist in the mechanism of energy supply 10 susesin the vibeation, ROTATIVE SPEED [kRPM] FREQUENCY [kCPM] Figure 9 Spectrum cascade of the rotor vibrationel response daring startup. Heavy disk close tothe rigid bearing. Ky high. thresh old of stabinty high. ROTATIVE SPEED [kRPM] FREQUENCY [KCPM] Figure 10 Spectrum cascade of the rotor vibrotioncl response during Startup. Disk closa to the oil-hubricated hearing. Ky low. Ureshold of stebility low.10 ORBIT aR ome °) Enver a oureuT mort ic) ¥ Figure 11 Free vibrations, forced vibrations, and self-excited vibrations in mechanical aysteme. Free vibrations are of the transient type and they fallow an instantancous enorgy impulse. For lightly damped systems, the dominant frequency of free vibrations corresponds wo the Towest ratural frequency of the system, In onder to excite forced vibrations, the applied external force ithus the energy input) is usually periodic: the exiernal forced vibration Gequency is equal to that of the exciting force [Note that both of these vibration types ean exist in rotating or owolating structures. In general, dhe input force is inde- pendent from rotative motion, The resultive vibrational motion does not affect the input force. Self-excited vibrations are induced by a constant force, Sustained by & constant energy supply. The system hits an in tamal energy traasier mechanism which delivers the energy Jn periodic manner. The frequeney at which the energy is provided usually corresponds to a natural frequency of the system A stable system responds to an impulse force with decaying, Vibrations: an unstable systent responds with increasing, Vi bration amplitude. Theoretically for unstable linear sysiems, {his amplitude grows 10 infinity. Practically, the amplitude increase is aecompanied by a significant increase of system nonlinearities which. in turn, slows down the amplitude growth. Most often, the final result isa “limit eyele” selfex- Gited vibration. ‘The amplitude of the selF-cxcited vibration is, therefore, limited, and determined by nonfinearitiesin the system. The frequency of slf-excited vibrations is very. close to the Linear systera natural frequency atthe threshold ‘of stability, as itis usually insensitive wo noalinearities, ‘April 1989 In rotoribearing/seal systems, the constant energy input is represented by rotation. Fluid dynamic forces gesterated by Shaft mtation in bearings and seals act as energy convertors from rotation (o lateral motion and cause rotor self-excited vibrations of the whislwhip type. Following all classical features of self-excitation in mechanical systems, these sell ‘oxcitod vibrations have « frequency lose o ano of the sy tem natural Frequencies, and the zmplitude is determined by the system nonlinearities. The most dominant and signiti- cant among these nonlinearities are fluid film radial stifiness, and fluid circumfereatial average velocity ratio as eonlinesr functians of shafi ecceatricity. Example: Natural frequencies and whirl/whip ‘amplitudes of the rotor supported in one rigid and one oil-lubricated bearing Ina very simplificd form, the characteristic equation for nat ural frequencies and stability chaeshold of the liner rotor! hearing system astrated in Fig. 7 is as follows (the formal analysis given in [Ref. 15): (Ki Ky Ma®) [Kp 4 Ky A/D AD] — KI = 0 (8) where w is the complies eigenvalue, Ky is the Linear part of the fluid film radial stiffaess, D is uid film esdial damping, and @ is 1ouaive speed, This equation tas three roots oF ‘which the real parts representing the system natural frequen, cies are approximately equal to the following valves: os VR ” w= 8) The natural frequency (4) corresponds to the rotor Hirst lateral mode (“whip frequency”). The natural irequency (5) §s due to the flaidisolid interaction and is called “shir! Srequency”™ The equation to calculate the frequency of the selFexcited vibnations differs very Title from equation (3): (Ry +R) - Me) [Kot Kot V(AVHID (e-AO)) 6) where = Ky ~ Kq is a noslinear part of the Aluid file raclial stiffness versus cocentricity (¥(0) =D, Fig. 1) and A is the journal selfexcited vibration ampliaue (a rotating eccentricity” in this case). The self-excited vibration fre quencies will differ, therefore, very litte from the natural frequencies (4) and (5). In this example, the fluid cireumfer ential average velocity ratio A is assumed (0 be constant Phe equation resulting fiom (6) for journal selFexcited vi- bration amplitude estimation is as follows: - Mar-K, Ky = KytWid) = Ky ———_ sy Ky Ky Ms*April 1989 In equation (7), A and are journal amplitude and fre. quency of the self-excited vibration correspondingly ‘The whirl amplitude can be estimated when the self-excited frequency is a = AQ, oblained from the linear analysis ids, therefore, (Fig. 12) MN Ky+ WA yiut) = Kz ————— _ 8) Ky + Keane Note that for a rotative speed lower than the threshold of sta bility, ie., when oct f x, K " M "MIKo#K: the right-hand side funetion of (8) is smaller than Kot %, and the two funetions co not intersect (Fig. 13). This per” tectly corresponds to the previously estimated stable rotor behuvior below the threshold of stability For >Qsr both fianetions of Equation (7) cross, and at the neisection, yield the whirl or whip amplitude ig. 13). ‘When particular numerical values of the functions ¥ and >. are given, A yyy can be calculated numerically. Usually the nonlinearity of A al low and medium eccentricities intro uces only a slight numerical adjustment, without modify ing the qualitative pieture of the phenomena, ‘The right-hand side Function in Equation (8) inereases to in- Finity when @ approaches the value Vik) +KayiMI. The Jaiter value corresponds to the transition between “whit!” and “whip” natural frequencies (5) and (2) respectively. = Mor BEARING CENTERLINE, TOK | sown RL/WOEP, SHAFT ECCENTRICITY Figure 12 Estimetion of whirl or whip cmplitude based on Equation (7). q+ ¥(A) is fluid rodicl stiffness as a function of eccen: boating clearance. ORBIT FOR 2 < gy Pusame TT ‘wurea, Syne Figure 1o Estimation of the whirl ond whip amplitudes (1) for vatious rolative speeds {0} and system natural frequencies Ww, based on Equation (71. From Equation (7), it follows also that when « equals the whip frequency (4), the right hand side function (7) tends 1 infinity. Sinoe the bearing eadial stiffness Ky tends to infin ity when the shaft appecaches the bearing or seal wall, the journal whip amplitude also approaches the beuring wall Thus the journal amplitude is limited by the Dearingyseal clearance, ¢, ard A ship. = © ‘More important in che whip case is, however, to analyze the value of the rotor amplitude at mid-span, 3s the rotor vibrates at iis resonant frequency. For beth whirl and whip, this amplitude con be caleulated from the following, equation: Ay Avvo = Apia —————$—$— K+; Mw? + Dj! with the relative phase between journal and rotor vibrations Dso 8 Sarctan ————— ao’ Mih-K Ky whore Ds is rotor moda damping, @ Por whirl, je. when oe = AO: Aeator = Ajoarea\ (KK: the amplitude AygeoeiS 286 than Apart SSL 2 >VK MN The phase fis close to zero, The whirl made has a" ceal” shape (Fig. M4) For whip, when o = VOR FAS FA and Ajoyeget = 60 follows fran (©) ane (10) that K W Aww = (—\/——}. aa Ds Vi Ky+Ky 90° 413)12 ORBIT thus, the rotor amplitude can be very high as its controlled only by he rotor damping Ds. Now thattbe bearing damping Das no influence on the whip amplinude. The roto vihrat ing at whip frequency isin esonance and, hevetorc is in a highly dangerous condition. This condition is similas to pro- longed rotor operation a the frst balance resonance speed. But this time this jeopundizing condition is rowtive specd indeperdext. “Passing through.” lke the hist balance 1es0- nance critical speed, is not possible, There exist. however, some other measures to correet the problem. ae CONICAL Mops ESSENTIALLY IN PHASE BENDING MODE wor Pens ore s—-# i MODES OF ROTOR/BEARING SYSTEM COMPARE WIT TWD-WASS ROTOR SECOND MODE: «OU Whirl and whip modes of the rotor supported in one rigid and one oil-lubrieated bearing. 10. Whirl and whip cures Analyzing the threshold of stability (1) and @) and whisk ‘whip amplitude evaluation (Equation (7) and Fig. 13), is, easily seen thal there exist two major possibilities 6 im prove the rotor stability. independently of rotor parameters: Deciease of ) and increase of Kp. A decrease oF the uid circumlerential awerage velocity x tio, A, can he achieved by a perturbation of the cireumteren. tial How regular pattern, Or prevention ofthe cireurale How cecurrence in the bearing for seal). In bearing: can be siccesstully saceamplished by noneircular geometries (e.x., elliptical, two or three lobe) andor the presence of moving parts inside hearings tilting pads, Moating rings). In such bearings, the cincumferential ow is significantly reduced in ccmparison to eireular bearings. 180° PHASE DIFFERENCE In seals, 2 decrease of ) can be accomplished by injections of the fluid tangentially in the direction opposite to rotatian, in onder 4o perturb the roration-generoted cireumferential flow. This technique is Known as “anti-swirl” control [Ret. 18,19] and is currently widely used in compressors, wurbines, sand pumps. Moving the shaft to higher eccentrivity affects the bearing! seal radial stiffness Kp. At higher eecentricity, the radial sMifTness is much larger and this improves voter stability April 1989 Higher eccentricities also lower the ratio which farther improves stability, 1 reqaires an increase in the radial Force applied to the shall. tt can be eweated either by a “Friendly” Misalignment, andor by a teavier shat in horizontal ‘machines and/or by main flow distortion in fluid handling Machines, so that the How generates a significant radial force component An increase of Mluid fin radial stiffness, Kp, can also be achieved by increasing fluid pressure, Hydrostatic hearings, (or more properly called “externally pressurized” beatings) are well recognized for their high stability features © cures which prevent rotor whirl and whip are illustrated in Figs. 15 to 18. The relationships are decuced from Equation (7) eae og TURESHOL SBAPT ECCENTRICITY Figure is Instability care: threshold of stability increases for shetts with Did antiawirl injections: A qj isthe fluid average veloc: ity atic due to ont-swil Bho 1/E gk g bp y \ a5 2B 3 2 ee BE | 8 gs lp 2 & aeauine 18 CENTERLINE BE foRtoINnL ‘THRESHOLD i Ow | af . AIGHER ECCENTRICITY a OBERATTON SHAFT ECCENTRICITY Figure 16 Inetubility cure: threshold of stability increases for ehafte ro- tating ot higher eccentricity: Ng is the fluid average velocity. ratio at higher eccentricity.April 1989 ORBIT | A ss, ron sanomnin ff) ensecunzano suantves /f | | 5 Ajournat = Arotor seaxin 4 CeNnERLWE she Anis ew : D ORIGINAL K, I \ ert D, 5 TN . itn wKP i ‘ ke snare pocuwasrexsy K Figure 17 . Improvements of rotor stability wits externally pressured . bearings: Kg reaches a higher value than the threshold of stc- Ki Ry Ban. M CRNTERLENE NEW POSITION OF SHAFT. CENTERLINE BEARING ORIGINAL me , ° WHERE /WHIE SHAPT ECCENTRICITY Figure 18 Instebilty cuce: whisVhip occurs when the shat is concen- tic in tho bocring or sol, improvement of rotor stability fe chieved when shalt operates at higher eccentricity: Func- tion KyMa"-ky) 1 (Ky tp M19) from equation (7) appears below the new Kp and does not cross with Kt Ne whi whip exist. ll. Closing remarks This article presents new results regording (low-inilveed Instabilities of r1or/beating’scal_ sysicms. Experimentally identified models of flad forces allow for betier understand ing of vibrational phenomena occurring in rotating machines. and Jead_to rational prevention of undesizable flow-inuced selFexcited ror vibrations. 13 Notation Amplitude of rotor self excited vibration of whirl or whip type. Amplitude of journsl whirl or whip, Amplitude of rotor mid-span whisl or whip, Amplitude of journal whip. Amplitude of journal whirl Bearing or seal radial clearance. Bearing or seal radial damping coefficient. Rotor first lateral mode damping coefficient. wt Bearing or seal Avid film nadia stiftiness, 2s fume sion of shalt eccentricity Bearing or seal sluid film radial stiffness at 7er0 eccentricity. Rotor first lateral mode partial stifTnesses, Rotor first lateral mode generalized mass. Time. Rotor lateral deflection (x — horizontal, y —~ vertical) Relative phase between rotor and journal self-ex- cited vibrations, Fluid ciroumferential average velocity ratio Pluid cirovmferential average velocity ratio for cancenirie shat Anti-cwirl-related fluid circumferential average velocity ratio. Bearing or seal Muid film radial stiffoess. « wonlin= car Function of shal eecenieity Rocor/bearing/seal system natural frequency, also Frequency of self-excited vibrations. Rotative speed Threshold of ye14 ORBIT References 1. Bonily, D. E., Bosmans, RE, Oil Whiel Resonance. Fundamen I tals of de Design of Paid Mies Besrings, Published by ASME, lo 2. Rortly, D. E., Dynamic Insability of us and Bearings. A Brief (Outline ofa Speech Presented atthe EPRI Purp Syrnposiumn, 2-48 Tune 1982, Cleny Hil, New Jersey 3. Bortly. D.E.. Muszynsia, A. Stibility Evaluaion of Rolor!Bear= 1. ing System by Peuturhation Tests. Rotor Dynami Insability Probe leins in High Pertormuace Tusborrachinery, Proceedings of 4 Workshop, Texas: ABM University, Callege Station, Tevas, NASA Conference Publications CF2250, 1982, 1 4. Benily, D-E., Muszynske, A, Of Whirl Weatificetion by Pestar- ation Test. Advances in’ Computer Aided) Bearing Design, §2- 72078, ASMEVASLE Lahrisation Conforonece, Washington, D.C. October 1982, 1s. 5. Bently, E., Mussyaska, A. Perurhation Tests of Bearing! for Evaluation of Domamis Coefficients, Syposivny an Recor Dynamical escabilty, Sunoer Anaual CoaLeretee of the ASME, Appliod Mechanies Division. AMD, Volume 53, Hoasin. Texas, ens 1983, 6. Bortly, D_E., What Happonod to the Damping? 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