Shaft alignment is a key factor for the safe and reliable operation of a turbine unit. This paper presents an approach to estimate the turbo-generator shaft alignment using strain gauge technique with two measuring sections nearby each coupling. The change of shaft bending moment is linearly proportional to the change of bearing elevation and reaction force. So the bearing load distribution can be identified from the strain values and bending moments which are measured using strain gauge. The transfer matrix method is used to calculate the detailed shaft alignment data including deflection, slopes, bearing reaction forces, influence coefficients, sag/gap values. Experiments were carried out on a test rig with 3 rotors, 2 couplings and 6 bearings. It was shown that the strain gauge identification results agree well with the results using the jack-up method. The maximum relative error of each bearing loads is almost 8.7%. The sag/gap values using the strain gauge method are close to those using the laser alignment method. The maximum relative error is less than 7.5%. Results also show that the strain gauge method is sensitive to possible disturbances in the bearing elevation. In the end, strain gauge alignment technique with two measuring sections nearby each coupling was applied on the shaft alignment estimation of a 600 MW turbine unit successfully. The bearing loads and shaft deflection were obtained accurately.

The identification method using infinitesimal theory is proposed to predict rotordynamic coefficients of annular gas seals. The transient solution combined with moving grid method was unitized to obtain the fluid reaction force at a specific position under different whirling frequencies. The infinitesimal method is then applied to obtain the rotordynamic coefficients, which agrees well with published experimental results for both labyrinth seals and eccentric smooth annular seals. Particularly, the stability parameter of the effective damping coefficient can be solved precisely. Results show that the whirling frequency has little influence on direct damping coefficient, effective damping coefficient, and cross-coupled stiffness coefficient for the labyrinth seal. And the effective damping coefficients decrease as the eccentricity ratio increases. A higher eccentricity ratio tends to destabilize the seal system, especially at a low whirling frequency. Results also show that the fluid velocity in the maximum clearance in the seal leakage path is less than that in the minimum clearance. The inertial effect dominates the flow field. Then it results in higher pressure appearing in maximum clearances. The pressure difference aggravates the eccentricity of rotor and results in static instabilities of the seal system.

This article proposes a rotordynamic identification method using the accelerating sweep frequency excitation method. The computational fluid dynamics transient solution combined with the moving grid method is utilized to obtain the transient flow field of the seal excited by the whirling rotor with an accelerating frequency. Rotordynamic coefficients at swept frequencies are obtained by analyzing the transient response force acting on the rotor. Rotordynamic coefficients of three published experimental seals including a labyrinth seal, a fully partitioned pocket damper seal and a honeycomb seal are identified to validate the proposed method. The results show that the predicted rotordynamic coefficients are all well agreement with the trend of experimental data. Compared with the existing numerical models based on transient solutions, the central processing unit consumption of the proposed method is substantially reduced by 98% when achieving the same frequency resolution. In addition, the impact of the exciting acceleration on the identification accuracy is also illustrated.

Numerical analysis model of an interlocking labyrinth seal (ILS) is established for studying the effect of tilting rotor on its rotordynamic characteristics. The dynamic characteristic identification method based on infinitesimal theory is applied to solve the dynamic force coefficient of the seal with arbitrary elliptical orbits and eccentric positions under field conditions. The paper investigated the dynamic characteristics of the interlocking labyrinth seal with various misalignment angles (θ = 0, 0.1 deg, 0.2 deg, 0.3 deg, 0.4 deg, 0.5 deg, 0.6 deg), different pressure ratios (Pin = 6.9 bar, PR = 0.5, 0.8), locations of misalignment center (Loc = 0, L/2, L). Results show that the tilting rotor could minimize the leakage flow rate of the ILS. When the misalignment angle θ = 0.6 deg, the mass flow rate can be reduced about 2.5%. The effect of each cavity in the ILS on the stability of the system is different. The cavity with the inlet close to the rotor and the outlet away from the rotor helps to improve the system stability due to its locally antirotational flow. The effective damping of the entire ILS increases as the misalignment angle increases. The system shows the best stability when the misalignment center is close to the seal inlet. The tilting rotor has a positive effect on the stability of the ILS only except for high whirling frequency (>100 Hz) under Loc = L.

The paper proposed an experimental measurement to identify the fluid-induced force and static stiffness coefficients. A three-dimensional fluid model of the labyrinth seals was also established. And the static characteristics under different eccentricities and inlet pressure were studied. Theoretical results show a good agreement with the experiment results. The labyrinth seal with different eccentricity ratios produces a de-centered fluid-induced force and a negative direct static stiffness, which cause the rotor deviating from the geometric center of the stator. Both the fluid-induced force and negative direct static stiffness coefficient with a value of −13.5 kN/m to −72 kN/m increase with increasing eccentricity and inlet pressure. Particularly, the direct static stiffness coefficient shows a relatively significant increase with a high eccentricity ratio (∼>40%). The static instability is mainly due to the fact that the fluid velocity in the small clearance increases more rapidly along the leakage path. The inertial force is increased significantly and the pressure decreases. This results in a greater pressure distribution in the larger clearance. The fluid force and direct static stiffness coefficient that tend to push the rotor away from the stator center are produced, and eventually lead to the static instability of the labyrinth seal.