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Estimating Influence of Inertial Resistance of Throttle for Hydraulic Balancing Device On Rotor Axial Vibration
A. Korczaka, V. Martsynkovskyyb, S. Gudkovc, c*
a
Silesian University of Technology, Faculty of Energy And Environmental Engineering, St. Konarski 18 Street, 44-100 Gliwice, Poland b,c Sumy State University, Department of General Mechanics and Dynamics of Machines, 2, Rimsky-Korsakov Street, Sumy 40007, Ukraine
Abstract There had been considered axial vibration of the rotor equipped with an automatic balancing system for axial forces. There were constructed amplitude and phase frequency characteristics, as well as evaluated influence of inertial resistance into throttling channels of auto discharge system. There were identified damping properties of resistance devices.
2011 Published by Elsevier Ltd. Selection and/or peer-review under responsibility of Sumy State University
Keywords: Rotor; dynamics; hydraulic balancing device; throttles; inertial resistance; vibration amplitude; critical frequency.
1. Introduction While operating, the centrifugal pumps with automatic balancing systems sometimes expose higher axial vibration of the rotor [1], which can be explained either by resonance in the system of rotor auto charge, or self-exciting oscillations due to loss of the system dynamic stability. The rotor axial vibration gives rise to the significant stress pulsations in the relief disk and in cross-section of the shaft, and may also cause the elevated transverse vibration of the rotor. In this regard, calculating the amplitude and phase frequency characteristics of the balancing system and testing its dynamic stability are essential to ensure the reliability of high-speed and high-pressure pumps.
262
cteristics, the rotor with the balancing device is con nsidered as a At calculating the dynamic charac ial uilibrium, for lumped-parameter system making axi oscillations relative to the position of static equ which the corresponding steady-state v values of pressure, face clearance and flow rate are d determined by the static calculation [1, 2]. 2. Equation of rotor axial vibration g. Based on Newton's 2nd Law, the equation of axial vibration can be written as follows (Fig 1):
mz + cz + kz = Fz T + k ,
(1)
iffness of the pressing-out device elastic elements; is a value of where: k is an adjusted (reduced) sti n their previous compression; T is an axial force being balanced while acting on the rotor; Fz = ( A2 + 0,5 Ac ) p 2 is a balancing pressure force acting on the balancing disk.
k* = 0 p n
There is performed dividing of all the terms of the equation by the conditional hydrostatic stiffness nsionless variables: 2 and go over to dimen
T12u + T2u + u = + ,
T12 = m 2 c 2 k 2 k T z , = , , T2 = , = ,= ,u= p 0 p 0 p 0 p 0 A0 pn H2
(2)
(3)
Fz = 2 , = A0 pn
+ 0,5
0
, 2 =
263
where: m - mass of the rotor; c - coefficient for damping the rotor axial vibration; , the dimensionless axial forces, the dimensionless previous stress of the pressing-out device; area of the impeller inlet funnel; - nominal pump discharge pressure.
0
- the
On introducing the operator of differentiation with respect to time, p = d dt , there is written equation of axial vibrations in the operator form:
D1 ( p )u = + ,
(4)
D1 ( p )
= T12 p 2
+ T2 p + ,
is an own operator of the rotor axial vibrations. 3. Equations of unsteady flow in throttles The equation of unsteady turbulent flow in the i-th throttle can be written as:
pi = R iQi2 + J i Qi =
where pi =
i
ia
+ pir ,
pi +1 - full pressure drop on the th throttle, pia = R i Qi2 , pir = J i Qi - pressure expenditures to overcome effective resistance and reactance, Qi - instantaneous flow rate, R i and J i - the coefficients of effective friction resistance and reactance (inertial resistance) of the fluid (i = 1, 2 ) .
Effective resistance at each instant of time is determined under the formulas for steady flow, neglecting its weak dependence on the frequency of the pressure pulsations [3]. For the turbulent flow, the effective resistance coefficients make R i = 1 / g i2 , where the conductivity of the ring and face throttles is computed under formulae [2]:
g1 = 2R1
[0,5 (1 + l1 / 2 1 )]0,5 ,
(5)
0,5
0,04, 2 0,06 - friction coefficients for self-field of the turbulent flow for the annular and face
clearances, respectively; 1 2 =1,01,15 coefficients of local (input) resistances; l 2 = R3 R2 . Reactance is determined in the accordance with the Law concerning rate of change of momentum K i :
dKi = Fi , K i = li f i vi = li Qi , Fi = f i pir , dt
264
f i pir = li Qi ,
ir
li
fi
Qi = J i Qi .
J i = li / f i ,
(6)
where; - momentum coefficient taking into account the uneven distribution of the fluid velocity over the channel cross section; f i , li - cross-sectional area and length of the i-th channel; for laminar flow in a circular channel = 1,2, and for the turbulent flow 1 ; Q = fv ; inertia of the fluid take the form:
With the account of the flow rate expression Qi = g i pia the pressure losses to overcome the
pir = J i
where
pi = pi ` pir = pi J i
= 0, pi* = pi . The last expressions are nonlinear differential equations of the first order concerning pressure pi .
Henceforth we herein restrict ourselves to consideration of small deviations of variables in comparison with their steady-state values, which fact allows passing to the linearized equations (to the equations in variations):
pi = pi J i
pi pi +1 d g i ( pi pi +1 ) 0 + g i 0 . dt 2 ( pi pi +1 ) 0
pir = 0 pi0 = pi 0 , therefore:
Subscript "0" indicates the values of the variables in the steady (equilibrium) state defined by a static calculation. In the steady state Q = 0 ,
pi = pi J i
pi 0 = pi 0 p(i +1) 0 , Q0 = g i 0 pi 0 = g e 0 p0 .
265
The conductivity of the cylindrical throttle at a constant eccentricity (the rotor radial vibrations are not taken into account) is independent of the axial displacement of the rotor and keeps the constant value, so g1 = 0. The conductivity of the face throttle is determined by the second formula (5) and taking into account that under the steady condition g1 = 0. , the variation of its time derivative is reduced to the form:
0 g 2 = 1,5 g 2 nu 0,5u , g 2 = 1,5 g 2 n u0 ,5u = 1,5
g 20 u. u0
Further, to shorten the description, the signs of variations are omitted. After passing to dimensionless pressures i = pi / p and clearances u = z / 2 , the equations (6) are reduced to the form:
(8)
T1i =
3 i0 3 p J i Q0 pi 0 p , = i0 , ik = 1 = io . = i 0 , i = i , i = 2 p i 0 p p u0 k pko 0
(9)
Provided that inertial resistance is not taken into account, Ji = T1i = 0, D1i =1, pi* = pi . 4. Flow rate balance equation Equations (8) contain unknown pressure i and pressure 2 into the hydraulic balancing device chamber. To calculate these pressures, there is used the flow rate balance equation, which in contrast to the static equations Q10 = Q20 = Q0 must take into account the flow rate values for displacement
Q1 = Q2 + Qv 2 + Q p 2 or g1 p1 p2 = g 2
p2 + z + p2V2 / E .
(10)
The last equation is nonlinear (the flow rates Q1 , Q2 , Q3 are nonlinear), so it is necessary to linearize them, transiting to the equations in variations. Taking into account that in equilibrium position p10 = p10 , 2*0 = 20 , we herein omit the signs of variations:
2*
+ znu +
V2 p2 . E
266
Having multiplied this equation by 2 10 Q0 and after transition to dimensionless pressures taking into account designations (9), we herein obtain:
1* 2 =
T22 =
D22 ( p ) = T22 p + 1, M 22 ( p ) = 22 p + 1 ,
and we reduce the flow rate balance equation to the following form:
D22 ( p ) 2 = 1 12 2 1M 22 ( p )u .
From equations (8), it follows:
(12)
1 =
1 ( 1 + T11 p 2 ), D11
2 =
1 ( 2 2T12 pu ). D12
Having Substituted these expressions into (12), we herein obtain an equation concerning 2 :
D22 2 =
12 D11
= D12
1 D11
(13)
Based on (3) = 2 , therefore, having lettered the operators of a controller and a device detecting influence by mistake
12 D11;
(14)
D2 ( p ) = D12 ( p ) 1 1M 2 ( p )u .
Further we perform the multiplication in expression (14) and group the addends in powers of p:
(15)
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D2 ( p) =
where
0
3 0
2 1
+ 3;
( ) = b0 p3 + b1 p2 + b2 p + b3 ,.
+
22 ,
= T11T12T22 ,
= 12T11 +
12
= 1 + 12 ;
(16)
5. Controller transfer function From equation (15), it is possible to determine the transfer function with the error, that is, with the deviation of the clearance (of the controlled variable) from its steady-state value. With due account of the expressions of the operators (15), the controller transfer function with the error takes the form
Wu ( p ) =
= 1
( ) = 1 D2 ( p )
2
b0 p 3 + b1 p 2 + b2 p + b3 . 3 + 1 2+ 2 + 3 0
(17)
In the case of the harmonic effects, it represents the frequency transfer function or dynamic stiffness of the controller, which allows at the first approximation to estimate the natural frequency of axial vibrations of the rotor and the stability of the system as well. For the steady-state condition, p = d dt = 0 and the transfer function of the controller become the coefficient of the hydraulic balancing device static stiffness:
Wu (0) = s = 1
b3 1 . = 1 a3 1 + 12
(18)
The dynamic stiffness possesses important informative features: it allows setting the range of variations for the natural frequencies of the rotor axial vibrations and at the first approximation, to evaluate the system stability. As for the harmonic signals, which are considered in the frequency transfer functions, the differentiation operator p = i . On introducing such a change, we herein obtain the frequency transfer function of the controller or a complex dynamic stiffness of the system:
Wu (i ) =
= 1
M 2 (i ) b 2b1 + i b2 2b0 . = 1 3 D2 (i ) a3 2 a1 + i a2 2 a0
( (
) )
(19)
At = 0 the last expression represents the controller dimensionless static stiffness: Wu (0) = s . At
Wu (i) = = 1
b0 = 1 22 . a0 T22
(20)
268
We herein obtain the maximum modulus value corresponding to the stiffness of conventionally nonflowing part, the stiffness of which is only caused by the compressibility of the fluid in the chambers of the hydraulic balancing device. Further, we herein disjoint real and imaginary parts in (19).
= Wu (i ) = 1 [U u ( ) + iVu ( )] ,
where
(21)
Uu =
(a (a
2 a1 b3 2b1 + 2 a2 2 a0 b2 2b0
2 2 2 2 2 3 1 2 0
( (a a ) + (a )(
2
)(
)( a )
2 2 2 0
),
(22)
Vu =
a1 b2 b0 a2 a0 b3 b1
2 2
(a
2 a1 + 2
) (
)( (a a )
2
).
If the real and imaginary parts are positive U u > 0, Vu > 0 , they respectively represent the positive additions to the dimensionless stiffness damping
2
. The negative values U u and Vu destabilize the system, and while Vu = T2 , the system is
at the oscillatory boundary and while U u = n , the system is at the aperiodic stability boundary. In the absence of the external damping
(a
)(
) (
)(
which can be used for preliminary (with some allowance) assessing the stability of the system. In particular, for the pivot without additional external throttle and not taking into consideration the fluid inertia, the condition Vu > 0 is reduced to form [1]
22 > T22
2 1 + 2
or
(23)
The first inequality discloses that the displacement flow rate (time constant 22 ) possesses the property of damping and stabilizes the system. The compression flow rate (time constant
22
destabilizes the system, so increasing chamber volume V2 and decreasing fluid bulk modulus E augment the risk of the stability loss. Dimensional values of the real and imaginary parts of the dynamic stiffness are calculated taking into account designations (3) and multiplying the both sides of (21) by 0 2 :
2 +
0
2
Vu i + k +
0
2
U u z = T + k.
269
ku ( ) =
p 0
2
U ( ),
( ) =
p 0
2
V ( ) .
(24)
Natural frequency of non-damped axial vibrations of the rotor without controller (Wu = 0) is equal to
The natural frequency for the hydraulic balancing device without a pressing out device ( k = 0) is determined only by stiffness of the controller:
D ( p )u = D2 ( p )( ) + D12 ( p ) 1 ,
where the system operator of its own
(26)
D ( p ) = D1 D2 + 1M 2 ,
and taking into account (4) and (15)
D( p ) = c0 p 5 + c1 p 4 + c2 p 3 + c3 p 2 + c4 p + c5 ,
where
(27)
270
Thus, having introduced the constraints for building the mathematical model, the balancing device represents an automatic control system of the fifth order. While providing for the change = = n is and equating the operator of its own (27) to zero, we herein obtain the characteristic equation, the root imaginary parts of which are the natural frequencies of the rotor axial vibrations. In summary, we herein consider the case when pressure p1 and axial force T are proportional to square of rotational speed of the rotor
= 2,
= 2, 1 =
2 2 . ; = 2, = 2, = 2 2
(29)
1 =
2 = 2
( )
0 , = 2 0 . 2 2
(30)
Having substituted these expressions into equation (26) and omitting the signs of variations, we herein obtain:
D ( p )u = (D12 - n D2 )2
0 + D2 . 2 n
(31)
In this case, the frequency of the rotor rotation performs as an external influence rather than the force
7. Calculation of amplitude-frequency and phase-frequency characteristics of system The necessary step in the process of designing reliable balance systems is to construct frequency characteristics, as they represent a fairly complete picture of the dynamic properties of such systems, in particular, of their responses to harmonic disturbances of different frequencies. A number of disturbances influences on the rotor in the axial direction, among which there dominate the harmonic disturbances with frequencies values that are equal to and divisible by the rotor rotational speed value. Within the limits of the analyzed linear model of the balance system, which includes the rotor as an object to be controlled, the superposition principle holds, i.e. the rotor resulting response is the sum of the harmonic responses to the individual elementary harmonic disturbances. Therefore, the analysis of the axial harmonic vibrations of the rotor u = u e i (t + ) (i = 1). is of practical importance. In this case, the differentiation operator with respect to time is replaced by the imaginary operator p i. In the sequel, we herein assume that the external factors , 1 of influence harmonically vary with the frequency value being divisible by the rotor rotational speed value f = k f , ( k f is multiplicity factor): . Setting influence (control input) and rotational speed, as a rule, have the form of a step or linear function of time, and responses to them are characterized by transition processes. The most intense oscillations occur with the reverse frequency f = , so we herein restrict the analysis of the forced oscillations by this frequency k f = 1 . The linear system response to the harmonic actions:
= ae
ik f t
, 1 = 1a e
ik f t
271
, is the amplitude of the response, is the response phase shift with respect to the phase of the influence. The system frequency transfer functions as per the individual external influences are obtained from the system dynamics equation (26), introducing the substitution = i :
ae
i (t + )
W (i ) =
D2 (i ) u D (i ) , W (i ) = = 12 . D(i ) 1 D(i )
(32)
u W (i) = =
()ei
, W (i) =
()ei
(33)
To determine the amplitude and phase frequency characteristics, we herein separate the real and imaginary parts:
D(i ) = U + iV , U = c1 4 c3 2 + c5 , V = co 4 c2 2 + c4 ;
(34)
W (i ) = U + iV , W (i ) = U + iV ;
U = UU2 + 2VV2 UV VU U + 2VT UT V 12 , V = 22 2 2 ; U = 2 ,V = 2 12 2 . 2 2 2 U + V U + V U + V U + V
(35)
(36)
The amplitude frequency characteristics for the modules of the frequency transfer functions are represented by:
() =
(37)
The corresponding phase frequency characteristics are represented in the following form:
( ) = arctg
V V . , () = arctg U U
(38)
The absolute values for the amplitudes of the forced axial vibrations generated by various external harmonic actions can be expressed from formulae (37):
z a =
Ta H 2 A ( ), 0 pn
z a =
p1a H 2 A ( ). pn
(39)
The amplitude and phase frequency characteristics of the system are to be constructed in the frequency band that is two decades higher than the frequency spectrum of the input influences. Since the fundamental harmonic frequency of the forced axial oscillations of the rotor is usually equal to its rotational speed n , the frequencies under investigation can be limited to the range 0 max 10 2.
272
The resonant frequencies of the balance systems for the actual multistage pumps are located within the range of 500 to 2000 s-1. Such frequencies are not dangerous for the low-speed ( n 3000 rpm) pumps. 8. Numerical example To assess the influence of the inertial resistance on the dynamics of the rotor, as a numerical example there is considered a balancing device without an additional cylindrical throttle having the following parameters: =16 MPa, p3=0,8MPa, =80kN, Tmax =90 kN, r0=R1=R4=4,75 10-2m, r1 = 5,75 10 2 m,
=981kg/m3, Q n =70 m3/h, n = 850 s 1 , min = 300 s 1 , l2 0,4R2 = 0,0225, R3 = R2 + l 2 = 0,085 m , z n = 2 =10-4m.
R2 = (1,05...1,15)r1 = 0,0625 m ,
The amplitudes of the external disturbances pulsations are assumed as 1 = 1MPa , = 5kN that makes approximately 6% of their nominal values. According to formulae (37) and (38), there had been constructed the amplitude and phase frequency characteristics of the balancing device as the responses to the harmonic external forces taking into account the inertia forces and not taking into consideration the inertia forces. Curves 1, 2, 3 represent the results obtained not taking into account the inertia for the relative discharge pressure values 1 = 0,63; 1,0; 1,13 (p1 = 10, 16, 18 MPa), respectively; curves 4, 5, 6 are received at the same pressure values and taking into consideration the fluid inertia.
1
1
b)
c)
d)
1
Fig. 2. The amplitude and phase frequency characteristics of the rotor as per discharge pressure
= 1.52
273
1 1
b)
c)
d)
1
Fig. 3. The amplitude and phase frequency characteristics of the rotor as per discharge pressure
=1
The amplitude frequency characteristics demonstrate that the inertial resistance of fluid in the throttling channels of the balancing devices has a damping influence reducing the natural frequencies and amplitudes of the resonant vibrations. The resonant frequency amplitudes at the relative discharge pressure values 1 = 0.63; 1; 1.13 decrease, respectively, by (67.2, 51.5, 46) %, and the critical frequency values decrease by (46.9, 3.2, 2.4) %. Similarly, there is changed the system response to the oscillations of the external force . Table 1 shows the critical speed values (at which the amplitude of the forced oscillations achieves their maximum), as well as the values of the dimensionless and dimensional maximum amplitudes. The results obtained taking into account the inertia of the fluid are given in the numerator, and not taking into account the inertia - in the denominator.
Table 1.
1 = 0,63
1 = 1,0
2380/2460 1.4/2.87
-5
1 = 1,13
2450/2510 1.39/2.84
-5
* , s 1
1
z a 1 ,m
(1.4/2.88) 10 0.89/1.84
(1.56/2.88).10-5 1.0/1.84
A z a ,m
(0.83/1.75) 10
-5
(0.95/1.75).10-5
274
As the Table shows, the amplitudes of the forced axial oscillations are of the order of 0.01 mm, i.e. about 0.1 z n if the disturbance amplitudes are within 0.06 ( 1 , ) . The rotor axial vibrations are conditioned by the variable axial force, which is received by the relief disk. Thus, both the disk and the shaft, particularly at the points of fixing the disk, are at risk of fatigue failures. This fact must be taken into account when calculating the strength of the pump component parts and assembly units. The influence of the fluid inertial forces increases with decreasing the discharge pressure. Therefore, taking into account this effect in predicting the dynamic characteristics of the rotors is especially important for the centrifugal pumps operating in a wide range of pressures. 9. Conclusions The inertia of the fluid at its unsteady flowing in the throttling channels of the automatic balancing devices is of a damping influence on the rotor axial vibration: it reduces the amplitudes of resonant oscillations and diminishes the critical frequencies. The inertia influence increases with decreasing the discharge pressure. In this regard, taking into account the inertia while performing the determination of the critical frequencies is particularly important for high-speed pumps and pumps working at a wide range of discharge pressures. Due to the small values of the face clearances and the high pressure values, the balance system possesses a great hydrodynamic axial stiffness, which determines the relatively high values of the critical frequencies. However, for high-speed pumps, there is a real danger of resonant axial oscillations, which could affect the overall vibration state of the machine. Being a subject of consideration, the discrete model of the rotor equipped with the automatic balancing device is only the first approximation of real designs and requires further clarification.
References
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