Vibration Problem of The Steam Turbine of

Mae Moh Thermal Power Plant

Kiatisak Teowkul
Steam Turbine Maintenance Section , Mae Moh Power Plant Maintenance Division

Electricity Generating Authority of Thailand (EGAT) Tel 04-744-3440-1

800 Moo 6 Mae Moh District, Lampang, Thailand 52220
Abstract
Mae Moh power Plant,
which locates in Lampang is a
coal-fired power plant utilizing
lignite from the largest coal mine
in northern region of Thailand. It
consists of 10 power plants,
which generates a total capacity
of 2400 MW. As we are well
aware that significant system of
coal-fired power plant is run by
boiler to produce superheated
steam to roll a steam turbine for
generating electricity. Thus,
steam turbine is regarded as
important one in generating
process. Formerly steam turbine
of power plant unit 8 of 300
MW. used to face with vibration
problem caused by foundations
subsidence. The power plant
therefore must be shut down to
correct and EGAT certainly lost
opportunity to reliably distribute
electricity as well as large
revenue from such a problem.
In order to achieve
maximum load of unit 8, EGAT
studied several practical methods
for solution and it brought to
conclusion that bearings load of
steam turbine was a problem. As
a result, EGAT designed to
adjust level of steam turbines
deflection curve that directly
affected to all steam turbine
bearings load (number 1-7). It
revealed that there was a
relationship between values of
vibration and load of steam
turbines bearing i.e. after
adjusting bearings load to
designed
load,
vibration
consecutively decreased from
140 micrometers to below 125
micrometers without any effects.
This solution can be instant
answer to swiftly correct steam
turbine of coal-fired power plant
facing with the same vibration
problem in order to avoid any
shutting down. The result, if

analyzed
in
term
of
economics, could help to
reduce EGATs loss of
revenue from generating
electricity of 7 days or 57.75
million
baht
(1,446,281
USD).

Keywords
Vibration, Steam Turbine,
Steam turbine bearing load

1. Introduction
Mae Moh Power Plant
located in Lampang is a coalfired power plant utilizing
lignite from the largest coal
mine in the northern region of
Thailand. It consists of 10
power plants. The total
capacity is 2400 MW. The
significant system of Mae
Moh Coal-fired Power Plant
is run by boiler which has a
function
to
produce
superheated steam to spin a
steam turbine for generating
the electricity. Thus, steam
turbine is regarded as an
important
equipment
in
generating process.
The protection of power
plant
equipment
is
a
significant condition for all
power plants to keep safe of
equipment against serious
problems. As for turbine it
has many means to protect
from damages such as drum
level hi trip signal or bearing
temp hi trip signal. By the
way, the most essential means
is a release turbine from
system (Trip Turbine) by a
various signal but the
important one is vibration
signal. The

vibration signal is divided

into two level i.e. alarm signal
and trip signal. These signals
are in conformance with an

acceptable vibration value. If the

turbine shaft vibration is equal or
higher than 125 m, the alarm
signal will show on control panel
and if the turbine shaft vibration
is equal or higher than 250 m
which exceeds limitation, turbine
will automatically trip.
The turbine consists of three
casings, HP barrel type casing,
IP and LP split type casings
divided into upper and lower
halves. The three casings are
arranged like tandem compound
form.Fig.1
The individual shafts of the
cylinders and the generator rotor
shaft are coupled solidly
together.
All shafts are
machined from single forgings.
The critical speeds of the HP and
IP shafts are designed to be
above the normal rated speed.
Barrel-type H.P. turbine
The barrel-type cylinder
design permits flexible operation
rapid start up and high rates
of load change even when the
initial steam conditions are
extreme. The casing has neither
axial nor radial flanges and as a
result of the almost complete
rotational
symmetry,
mass
accumulations with thermal
stresses are avoided.
I.P Turbine
IP turbine is of the double
flow type construction. IP
turbine is fitted with 2 combined
reheat stop and intercept valves
to control the steam flow
between the reheated and the
turbine.
L.P turbine
The casings of the doubleflow LP turbines are connected
with the IP cylinder by two
crossovers, one on either side of
the machines and level with the
floor.
The arrangement of the casings
To
avoid
the
thermal
expansion, LP casing can free
expand to direction of generator
and that between HP and LP
casings can free expand to
opposite direction of generator.
IP casing is fixed on No.3
bearing pedestal and HP, IP
casings expand to the direction
of main oil pump. No.1 and No.2

bearing pedestals can slide to

axial direction by the guide
key on the soleplate.
Governing system
The turbine is governed by
a digital electronic governor.
Each
control
valve
is
positioned by and Electrohydraulic actuator, which is
controlled by an analogue
signal
from
a
digital
electronic governor with the
motive force provided by a
motive fluid supply system.
The electro hydraulic
governing
system has a
number of advantages not
only its high accuracy, high
operating
speed
and
sensitivity; it also permits
governed run-up to rated
speed allows only a small
value of temporary speed
deviation during a sudden loss
of load.
The HP turbine is provided
with two main stop valves
and four main steam control
valves, which are arranged
symmetrically at the right and
left sides of the turbine
casing. No.1 and No.2 main
steam control valves are
installed on the common
casing together with the main
stop valve. ,Fig.2

Fig.1 Steam Turbine

Main steam comes in
through each of two main
steam pipes; first, it passes
through the main stop valves
and then through the main
steam control valves. Further,
main steam passes through
the connecting pipes and

enters into the barrel type

casing from the right and left
sides and then reaches the blade
groups.
Over load steam passes
through the over load steam
control valves (No.3, 4) , Fig.3
and HP connecting pipes and
flows into the middle part of the
blade groups from the inlet
connections of right and left
sides of barrel type casings. The
distance between the main steam
control valves and turbine casing
is short , the steam volume at this
part becomes very small.
Because of the matter, it is
possible to lower the rapid
acceleration of turbine rotor after
full load shedding. The main
stop valves and main steam
control valves are all provided
with respective E/H actuators,
which are installed on the floor
to facilitate inspection and
maintenance. Since these E/H
actuators are arranged so that
they may not be affected directly
by the heat of the HP turbine
part, a possibility of fire can be
minimized.

No.
1.
2.
3.
4.
5.
6.

7.
8.

Name
Barrel type casing
Combined valve casing
Control valve casing
(over load)
E/H Actuator for main
stop valve
E/H Actuator for main
steam control valve
E/H Actuator for main
steam control valve
(over load)
Main steam pipe
HP Connecting pipe

Fig.2
Steam Stop Valves

Main

Fig.3 Main Steam

Control Valves.

2.Theory
2.1. Vibration of Steam
Turbine
The vibration measuring
device for pedestal vibration
and shaft vibration is mounted
on each pedestal and bearing
in this turbine set. Since
vibrations play an important
role as an index for
determining the behaviors of
the turbine, they must be
monitored strictly at all times.
The
tolerance
for
vibrations of the pedestal is
given in Various Limit
Values. However, be careful
since these limit values do not
always mean that vibrations
may
be
left
out
of
consideration
if
their
measured values lie within
these values. Accordingly, its
cause must be located in such

a case.

The vibration values may change

in the following cases;
1.
2.
3.
4.

When the load has changed;

When
the
steam
temperature has changed;
When the revolutions have
changed;
When the gland sealing
stream temperature has
changed ;

If the vibration value reaches the

tolerance, operator should check
the following items first.
1.

Amount
of
vibrations
increased from that in
normal operating;
2. Vibration measuring device
for accuracy (Check it
by
another
measuring
instrument);
3. If cause of vibration change
has been clearly
located; If it is impossible to
restore the machine
to its normal condition as
before;
4. If
vibrations trend to
increase;
5.
If
abnormal
noises
happen;
6. Temperature
difference
between upper and lower
walls of casing;
The
following
countermeasures
should be
taken immediately according to
the above checked results.
1.

Return
the
operating
condition to the previous
state before the vibration
value has not been
changed.
2. Trip the turbine if it
seems to be dangerous to
continue
operating
the
machine since vibrations
do not decrease after step
(1) above.
3. Trip
the
turbine
immediately
if abnormal
noises
are detected.

2.2 Synchronous Response

The synchronous, or running
speed, or fundamental, or 1X

motion of a rotating element

is an inherent characteristic of
every machine. It should be
recognized that all machines
functions with some level of
residual
unbalance.
All
machines must operate with
some finite clearance between
stationary and
rotating
elements.
Since
it
is
physically impossible to
produce a perfectly straight
and concentric rotor, another
source of synchronous motion
is apparent. In addition, all
machines are supported by
various compliant structures
and foundations.
Vibration
response
measurements
on
any
machine with virtually any
transducer will reveal a
component
at
rotational
frequency. Not surprisingly,
this universally common
excitation accounts for the
majority of the machinery
malfunction
mechanisms.
Unfortunately, the analysis of
1X vibration is significantly
complicated by the fact that
many different mechanical
malfunctions
appear
as
changes in the rotational
motion. Hence, the machinery
diagnostician is faced with the
real dilemma of observing a
single
frequency,
and
attempting to diagnose the
origin of observing a single
frequency, and attempting to
diagnose the origin of an
increased
vibration
amplitude.
The first line of attack
resides in reviewing the
traditional
relationship
discussed earlier in the text
as:

Response =

Force
Restraint

It is clear that the

vibration response is directly
proportional to the applied
force when the restraint or
stiffness is held constant. As
force increases, the resultant

vibration response will also

increase.
This
type
of
relationship is intrinsic with the
fundamental concepts associated
with activities such as rotor
balancing. It is also clear that
vibration response is inversely.
In this condition, as the restraint
decreases, the resultant vibration
response will increase. For
instance,
a
bearing
with
increasing
clearances
will
typically exhibit a reduction in
support stiffness (i.e., restraint).
Assuming a constant unbalance
force, the rotor will vibrate at a
higher response level.
The third possibility for the
changes in vibration response
amplitudes
must
consider
variations in both the force and
the restraint, as stated by Donald
E. Bently in an issue of Orbit
magazine:
Vibration is usually either the
result of a bowed rotor or the
result of a force or moment
acting on the stiffness of the
machine to that force or moment.
As such, vibration is actually a
ratio and frequently not an end
objective measurement in itself.
Remember that forces and
moments flow through, moments
are measured across, and:

Gravity excitation

Orders

Orders; cannot be

2X

Balanced 1/2 critical

Reduce eccentricity by

Speed appears on
Bode plot (unfiltered)

Balancing

1/2 critical speed appears on

Vibration patterns
1X has varying phase angle
And amplitude

Eliminate asymmetry

Asymmetric rotor

2X

Thermal instability

1X

Give terms of operating speed; 1X=

one time operating speed.

4. Vibration
Investigation
After unit 8 was starting
up on December ,2004
.The vibration of shaft no.1
and no. 2 were very high
(See fig.4 below).Normally
there are several causes of
this vibration problem .We
,EGAT
Engineer,
had
discussed for finding out
the root cause . However
we need more vibration
information for analysis.
Fig.4 The vibration trend
of shaft no.1-4

Dynamic Motion (Vibration) = Dynamic forces or Moments

Dynamic Stiffness

TABLE 1. Identification and Correction of Malfunctions of

Rotating Machinery Operating Speed Effects

Fault

Frequency

Mass
Unbalance

1X

Misalignment

1X.
2X,etc

Spectrum, time,
domain,
Orbit shape
Distinct 1X with much
lower values of 2X. 3X.ect.,
Elliptical and circular orbits.

Shaft bow

1X

Steam
Loading

1X

Distinct 1X with equal or

Higher values of 2X, 3X.
etc., figure-eight orbit
Dropout of vibration around
Critical speed in Bode plot
Load-sensitive 1X

Bearing
Wear

1X,
Subharmonics,

High 1X, high 1/2X,

Sometimes 1 1/2 or

Correction
Field or shop
balancing
Perform hot and/or
coldThe
alignment
bearing

load of all
steam turbine and generator ,
Heating or peening
to
tandem
compound
type, was
straighten rotor for
designed
all steam
Modify admission
turbine
weight and external
sequence;
repair
force .The
adjustment of
diaphragms;
install was effected the
rotor
position
nozzle blocks properly
steam
turbine
deflection
Replace bearing
curve( Table 2 and fig.5 )
then effected to the bearing

Compromise balance or
remove problem

vibration trend ,the orbit plot

,the shaft average centerline
plot, were considered
in
problem solving.

load distribution respectively.

Steam turbine unit 8 was faced
with the subsidence of turbine
foundation ,this problem should
be considered as an important
factor that caused out of design
load distribution. However we
had the manufacturers software
for re-adjustment of all steam
turbine bearing load during
maintenance work.The bearing
load of steam turbine bearing
no.1-7 was directly distributed
on their pedestal no.1-7.
Table. 2
The relationship
between the steam turbine
deflection curve and the actual
bearing load compared with
the design bearing load
brg.No
1
2
3
4
5
6
7
brg.No.
1
2
3
4
5
6
7
brg.No.
1
2
3
4
5
6
7

dev.
mm
3.487
1.970
0.590
0.000
-0.203
-0.395
0.342

Load
N
31623
122880
436781
414788
193340
220388
15664

Press
MPa
0.807
1.345
1.941
1.844
1.284
1.464
0.490

span rotation vertical

mm
mm
mm
15465
0
0
11940
0
0
7450
0
0
0
0
0
-1650
0
0
-10340
0
0
-12840
0
0

1
0.302
-0.247
0.052
-0.006
0.003
0.000
0.000

2
-0.575
0.724
-0.271
0.115
-0.058
0.001
-0.001

rot.angl align.
deg(CCW) dev.
0
0
vertical
0
mm
0
0
0
0
0
0

Influence Coef(MPa/mm)
3
4
5
0.298 -0.036
0.012
-0.667
0.283 -0.096
0.384 -0.453
0.293
-0.453
2.062 -1.806
0.438 -2.699
2.466
-0.009
0.154 -0.198
0.006 -0.100
0.220
design
2.853
2.360
1.490
0.000
-0.007
5.515
8.758

6
0.000
0.002
-0.006
0.103
-0.198
0.161
-0.512

alignment
measure delta
6.340
3.487
4.330
1.970
2.080
0.590
0.000
0.000
-0.210 -0.203
5.120 -0.395
9.100
0.342

7
0.000
0.000
0.001
-0.014
0.047
-0.109
0.387

des.pres
MPa
0.713
1.155
2.124
1.584
1.536
1.528
0.198

Hot alignment
coorrec sum-delt
0.000
3.487
0.000
1.970
0.000
0.590
0.000
0.000
0.000 -0.203
0.000 -0.395
0.000
0.342

Width
mm
140
290
450
450
386
386
160
offset
0.000
0.000
0.000
0.000
0.000
0.000
0.000

Dia.
mm
280
315
500
500
390
390
200
tot-delt
3.487
1.970
0.590
0.000
-0.203
-0.395
0.342

Load des.Load ratio

N
N
33822
0.93
31623
122880 117494
1.05
436781 445073
0.98
414788 378090
1.10
193340 225705
0.86
220388 225253
0.98
15664
10019
1.56
?
after offset

Fig.6 Vibration trend of

Fig.5 The adjustment of steam
turbine rotor position ( Design,
0-0 alignment , Actual after offset ) in
mm.

Table 3 Deflection curve and

design load
DEFLECTION
BEARING LOAD
Bearing
CURVE
( From cal.)
Position
(mm.)
1
4.46
39,258 N
2
2.34
106,110 N
3
0.76
483,072 N
4
0
159,301 N
5
0.76
424,870 N
6
7.87
204,153 N
7
12.48
19,105 N
For more analysis. Mae
shaft no.1-4 of unit 9
Moh power plant unit 9 was
Fig.7-8 show the orbit plot
discriminated . Unit9s steam
of shaft vibration no.1-7
turbine was the same capacity ,
same design and same age . the

Second,

First,compared with the orbit

plot of shaft vibration of unit 9
and Unit 8 we found some
important relationship ,when we
lined the linear line between the
key phaser (black point) of each
shaft position we could explain
that the unit 8 rotor movement
was not in good position and not
conform with the design (straight
line.)

Fig.9-10 show the shaft

average centerline plot of shaft
vibration no.1-7

the

shaft

centerline of unit 8 was also

not to be appropriate position
because
rotor position of
shaft no.1-3 was seem to be
higher than design position,
the vibration could be
occurred because of this
unstable state.
So the adjustment of
steam turbine deflection curve
was implemented during the
steam turbine alignment.
Finally, we had adjusted the
deflection curve by shim up
the turbine support(pedestal

no.1) about 1.55 mm. The

vibration result was favorable,
the vibration of the shaft no.1
and no.2 were decreased under
the vibration alarm set point (
125 micron) ,see in table 4
below, so unit 8 can be operated
in order to achieve maximum
capacity 300 MW ( fig.11) .
Table 4. Vibration amplitude
before and after adjustment of
the steam turbine
pedestal/leveling
VIBRATION
BEARING
BEFORE
ADJUST.
POSITION

1
2
3
4
5
6
7

155.26
132.5
89.99
40.45
36.84
28.93
26.62

Fig.11 the vibration trend

of unit 8 after
adjustment

vibration. Apart from that, it

could help ease
critical
problem so that the power
plants do not have to stop the
operation and the inspection
of internal part or preparing
spare parts could be done in
time.
Consequently, if
analyzed
in
terms
of
economics, this could help
reduce
EGATs loss of
revenue from generating
electricity of 7 days or 57.75
million
baht
(1,446,281
VIBRATION
USD).
AFTER ADJUST.

80.97
107.24
6. Acknowledgments
58.01
32.44
The study would not have
35.35
been
completed without the
contribution
of EGAT staff,
35.55
Fuji
staff,
Mr.Watcharapol
32.14
Homnan, , friends and my
family, to whom the author
sincerely indebted. The author
wish to thank Mr.Somyos
Theravongsakul
for
his
valuable professional advice
and help.

7. Reference

5. Conclusion
After the correction of all
bearing load by adjustment of
steam turbine deflection curve,
the vibration
of shaft no.1
decreased from 155 microns to
81 microns and the vibration of
shaft no.2 decreased from 133
microns to 107 microns without
any effects. Now Mae Moh
power plant unit 8 could be
operated at normal condition
without vibration problem.
The result of the study can be
applied to steam turbine of coalfired power plants especially
facing the same problem of

[1] Eisenmann C.R. and

Eisenmann. C.R.
Machinery
Malfunction Diagnosis and
Correction , Prentice
Hall Inc, 1988.
[2] Sakae Izumi
Investigation and
Adjustment
Report for High Shaft
Vibration at No.1
Bearing, Fuji Electric
Co,Ltd, 2001
[3] Fuji Electric Co,Ltd
Maintenance instruction
Manual of Mae Moh
Power Plant Unit 10 ,
Japan, 1997