Lateral Rotordynamic Analysis of a Large Alternator/Flywheel/Motor Train

Abstract

A large alternator/flywheel/motor train is employed as part of the power system for the ALCATOR C-MOD experiment at the MIT Plasma Fusion Center. The alternator is used to provide peak pulse power of 100 MW to the magnets employed in the fusion experiment. The flywheel diameter is 3.3m and the alternator is 1.8 m in diameter. After being driven up to full speed over a long period of time by a 1491 kW motor, the alternator is rapidly decelerated from approximately 1800 rpm to 1500 rpm during a 2 second interval. This sequence is repeated about six times per working day on average. A full lateral rotordynamic analysis of the including the rotors, fluid film bearings and unbalanced motor magnetic force was carried to assess the effects of rotor modifications in the alternator shaft bore. This paper provides a more detailed analysis of a complicated rotor train than is often performed for most rotors. Critical speeds, stability and unbalance response were evaluated to determine if lateral critical speeds might exist in the operating speed range in the existing or modified rotor train and if unbalance levels were within acceptable ranges. Critical speeds and rotor damping values determined for the rotor system with the existing and modified rotor. The first critical speed at 1069 rpm is an alternator mode below the operating speed range. The second critical speed is also an alternator mode but, at 1528 rpm, is in the rundown operating speed range. The third critical speed is a flywheel mode at 1538 rpm, also in the rundown operating speed range but well damped. The predicted highest rotor amplitude unbalance response level is at 1633 rpm, again in the operating speed range. Direct comparisons were made with measured bearing temperature values, with good agreement between calculations and measurements. Stress levels in the rotor were evaluated and found to be well below yield stress levels for the material for both original and modified rotors. Comparisons we carried out between standard vibration specifications and measured vibration levels which indicated that the third critical speed amplification factors were much higher than API standards indicate they should have been. Corrective actions to reduce unbalance were taken for the modified rotor.