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大型汽轮发电机螺旋振动热输入模型及工程治理研究

Study on Heat-Input Models and Engineering Mitigation of Spiral Vibration in Large Turbogenerators

  • 摘要: 螺旋振动是大型汽轮发电机、压缩机及汽轮机等旋转机械中较为典型的不稳定振动现象,其本质是转轴与静止部件之间发生软摩擦后形成局部热点,局部热输入诱发转子热弯曲,进而使不平衡矢量和振动矢量产生缓慢旋转。针对一台450 MVA、3000 r/min氢冷汽轮发电机在工厂运行试验中出现的正向螺旋振动问题,本文结合现场试验、热点定位、转子动力学分析和热输入模型对其形成机理与治理措施进行研究。通过“带刷”和“无刷”对比试验,确认振动热点主要来源于碳刷与集电环之间的摩擦接触。基于Kellenberger热模型,建立热输入分别与轴位移、轴速度和轴加速度相关的三类模型,并通过稳定性特征值分析对不同模型的适用性进行比较。研究表明,碳刷接触压力和摩擦方向与轴振动速度具有更强的相关性,速度型热输入模型能够较好解释试验中观测到的正向旋转、周期约60~75 min以及3000 r/min额定转速定速运行下振动幅值随时间增大的螺旋振动特征。在此基础上,提出通过提高水平方向临界转速、优化轴承支承刚度和采用可倾瓦轴承等工程措施抑制螺旋振动。现场验证表明,改进后机组额定转速下振动稳定性显著提高。研究结果可为大型汽轮发电机螺旋振动诊断、热输入建模和结构治理提供参考。

     

    Abstract: Spiral vibration is a typical form of unstable vibration observed in large turbogenerators, compressors, turbines, and other rotating machinery. It originates from a local hot spot produced by soft rubbing between the rotor and stationary components. The resulting localized heat input causes thermal bowing of the rotor and, consequently, a slow rotation of the unbalance and vibration vectors. This paper investigates the forward spiral vibration observed during factory running tests of a 450 MVA, 3000 r/min hydrogen-cooled turbogenerator by combining field tests, hot-spot localization, rotordynamic analysis, and heat-input modeling. Brush-on/brush-off comparative tests confirm that the dominant hot spot is generated by frictional contact between the carbon brushes and collector rings. Based on the Kellenberger thermal model, three types of heat-input models—displacement-, velocity-, and acceleration-dependent models—are established, and their applicability is evaluated through eigenvalue-based stability analysis. The results show that carbon-brush contact pressure and friction direction are more strongly correlated with shaft vibration velocity; accordingly, the velocity-dependent heat-input model best reproduces the measured characteristics, including forward precession, a spiral period of approximately 60–75 min, and divergence during constant-speed operation at the rated speed of 3000 r/min. Engineering measures are therefore proposed to suppress spiral vibration by increasing the horizontal critical speed, optimizing bearing-support stiffness, and applying tilting-pad bearings. Field verification demonstrates a marked improvement in vibration stability at rated speed after the modification. The results provide a technical reference for the diagnosis, heat-input modeling, and structural mitigation of spiral vibration in large turbogenerators.

     

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