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Fourth Annual Introductory/Advanced RBSI-Ethos Energy

Two Short Course Program

Course 1. Rotor-Bearing Dynamics – Industrial Case Histories

Course 2. Magnetic Bearing Systems – Design and

Industrial Applications

Dates: October 17-21, 2016 Location: Ethos Energy, Houston, Texas

3100 South Sam Houston Parkway E. Houston, TX 77047

Sponsored By:

Rotor Bearing Solutions International (RBSI) EthosEnergy, Houston

Lots of New Material in Each Course

Attend Either One or Both at a Reasonable Cost

Second Attendee from Same Company at Half Price

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Course 1. Introductory/Advanced Rotor-Bearing Dynamics And Case Histories

Course 1. Industrial Machine Analysis and Fix Case Histories: Horizontal and Vertical Pumps

Single and Multistage Compressors Single and Multistage Steam Turbines

Motors, Generators, Alternators Geared Systems, Gas Turbines

Turbochargers

Course 1. Topics: Rotor Problems - Fixes and Repairs Rigid and Flexible Rotor Dynamics

New API Vibration Specifications and Automated Analysis Rotor Modeling for Industrial Machines

Fixed and Tilting Pad Bearing Properties and Damage Annular Gas and Water Seals

Rotor Unbalance, Cracks and Repair with Welding Stability Problems, Sub-synchronous Vibrations

Spur and Helical Gears, Pump Fluid Forces Squeeze Film Dampers, Substructure Effects

Rotor Unbalance Response

The Best and Most Comprehensive Rotor/Bearing/Seal Short Course This Year

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Course Description, Objectives, and Lecturers

This fundamental rotor bearing dynamics short course is intended for engineering staff of companies using, repairing or manufacturing rotating machinery of common types. These types include horizontal and vertical pumps, compressors, steam turbines, motors, generators, alternators, geared systems, and gas turbines. The emphasis is on the vibration phenomena exhibited by the machine undergoing high vibration. Numerous industrial machine case histories, high vibration characteristics, causes of the high vibration, and fixes are presented.

In each case history, the important individual components of the machines are described in detail and the influence of each component on the vibration is evaluated. Normally a computer model of the machine is developed by the analyst to better evaluate the cause and the machine fix. This process is described. The use of mathematics in this short course is minimized and, when discussed, is used primarily to indicate technical points of use in the solution.

The lecturers in this short course have extensive experience in the rotating machinery field. Paul Allaire and Tom Smith each have more than 40 years’ experience with diagnosing and fixing or repairing industrial rotating machinery problems. The other lecturers and contributing authors also have extensive experience in the field.

Lecturers:

1. Paul Allaire, ASME Fellow, Chief Technical Officer, Rotor Bearing Solutions International (RBSI) , Also, Mac Wade Chaired Professor, University of Virginia, Now Retired – Long Time Director of Rotating Machinery and Controls Laboratory

2. Tom Smith, EthosEnergy, Houston, Former General Manager Of Turbocare, Houston 3. Justin Fleming, EthosEnergy, Houston 4. Tim Dimond, P.E., President, Rotor Bearing Solutions International (RBSI), Formerly

Principal Scientist of University of Virginia Rotating Machinery and Controls Laboratory

Additional Contributors:

1. John Nicholas, Former Owner and Chief Engineer, Rotating Machinery Technology, Former Engineering Fellow, GE-Lufkin-RMT

2. Jianming Cao, Director of Rotor Dynamics, RBSI 3. Joy Brinkerhoff, Rotating Machinery Engineer, Solar Turbines 4. Saeid Dousti, Senior Fellow, RBSI

5. Brad Nichols, Senior Fellow, RBSI

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Course 1. Rotor Bearing Dynamics Short Course Agenda

Day 1- Monday, October 17, 2016

8:00-8:30 Registration (On Site) 8:30-8:45 Introduction to Short Course – Scott Hill, EthosEnergy

Session A1 – Introduction to Rotordynamics I

8:45-9:15 Talk A1 Introduction to Rotordynamics – Paul Allaire (Allaire’s Notes -Section 1.1) 9:15-9:45 Talk A2 Introduction to Rotor Dynamic (API) Vibration Specifications – Tim Dimond

(Allaire’s Notes – Section 1.3) 9:45-10:00 BREAK (Drinks and Snacks Provided During Breaks) 10:00-10:30 Talk A3 Single Mass Flexible Rotor (Jeffcott Rotor) on Rigid Bearings – Paul Allaire

(Allaire’s Notes – Section 2.1) 10:30-11:10 Talk A4 Rotor Modeling, Critical Speeds, Mode Shapes, Campbell Diagrams and

Unbalance Response of Compressor Rotor – Automated API Analysis with ROTORAUDIT -Tim Dimond with Jianming Cao

Session A2 – Fixed Pad Bearings I

11:10-12:00 Talk A5 Properties of Fixed Fluid Pad Bearings – Paul Allaire (Allaire’s Notes –Section 4.10)

12:00-1:00 LUNCH (Provided)

Session A3 – Fixed Pad Bearings II and Case History

1:00-1:45 Talk A6 Dynamics of Fixed Pad Fluid Bearings/Plain, Axial Groove, Multilobe, Offset Half – Paul Allaire (Allaire’s Notes – Section 4.11, Part 1)

1:45-2:30 Talk A7 Dynamics of Fixed Pad Fluid Bearings/Pressure Dam – Paul Allaire (Allaire’s Notes – Section 4.11, Part 2)

2:30-3:15 Talk A8 Rotordynamics of High Speed Turbochargers in Fixed Pad Bearings – Tim Dimond with Saeid Dousti

3:15-3:30 BREAK

Session A4 – Fixed Pad Bearing Case Histories 3:30-4:15 Talk A9 Steam Turbine/Gearbox/Generator Bearing Case History of Instability in

Fixed Pad Bearings and Repair with Pressure Dam Bearings – Tim Dimond

4:15-5:00 Talk A10 Case History and Lateral Rotordynamic Assessment of Large Alternator/Flywheel Rotor – Tim Dimond

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Day 2 – Tuesday, October 18, 2015

Session A5 – Horizontal and Vertical Pumps/Case Histories 8:00-8:45 Talk A11 Practical Rotor Dynamics for Pumps/Stiff vs Flexible Rotors/Wet and

Dry Critical Speeds and Nuclear Pressure Injection Pump Case History (Allaire’s Notes – Section 7.1) – Paul Allaire

8:45-9:40 Talk A12 Vertical Pump Rotor Vibration Problems and Case Histories – Submersible Pumps, Nuclear Main Coolant Pumps (Allaire’s Notes – Section 7.2) – Tim Dimond

9:40-10:00 Talk A13 Horizontal Pump Vibrations/API 610 Specifications, Sulzer Pump Examples, Boiler Feed Pump Vibration Case History (Allaire’s Notes – Section 7.3) – Paul Allaire

10:00-10:15 BREAK

Session A6 – Tilting Pad Bearing Static and Dynamic Properties I

10:15-11:00 Talk A14 Tilting Pad Bearing Static Properties (Allaire’s Notes – Section 4.12, Part 1) – Paul Allaire

11:00-11:30 Talk A15 Tilting Pad Bearing Dynamic Properties (Allaire’s Notes – Section 4.12, Parts 2&3) – Tim Dimond

11:30-12:00 Talk A16 Tilting Pad Bearing Selection for Best Bearing Design (Allaire’s Notes – Section 4.12, Part 4) – Paul Allaire

12-00-1:00 LUNCH (Provided)

Session A7 – Compressor/Steam Turbine Instability Issues 1:00-1:45 Talk A17 Stability of Jeffcott Rotor with Cross Coupled Effects - Steam Whirl,

Alford Forces, Aerodynamic Excitation – Paul Allaire (Allaire’s Notes – Section 2.4)

1:45-2:20 Talk A18 Stability of Six Stage Compressor with Seal Cross Coupling and Optimized Tilting Pad Bearings with Pivot Flexibility – Automated API Analysis with ROTORAUDIT - Tim Dimond with Jianming Cao

2:20-3:00 Talk A19 Unbalance Response of Six Stage Compressor and Optimized Tilting Pad Bearings with Pivot Flexibility – Automated API Analysis with ROTORAUDIT - Tim Dimond with Jianming Cao

3:00-3:15 BREAK

Session A8 – Compressor/Steam Turbine Instability 3:15-4:20 Talk A20 Rotordynamic Design of Centrifugal Compressors in Accordance with

API Specifications – Comparison of Historic (Kaybob and Ekofisk) and Modern Compressors – Paul Allaire with John Kocur and John Nicholas

4:20-5:00 Talk A21 Compressor Instability Due to Internal Seals and Tilting Pad Bearing Solution – Paul Allaire with Joy Brinkerhoff and Chester Lee of Solar Turbines

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Day 3 – Wednesday, October 19, 2015

Session A9 – Motor, Generator and Alternator Case Histories 8:00-8:45 Talk A22 Torsional Analysis of Large Alternator/Flywheel Rotor with Motor

Excitation and Fatigue Life - Tim Dimond 8:45-9:15 Talk A23 Modeling of Geared Systems Including Bearings and Shaft Dynamics –

Tim Dimond 9:15-10:00 Talk A24 Motor/Compressor Train Excitation of Structural Vibration Problem

and Fix –Paul Allaire

10:00-10:15 BREAK

Session A10 – Bearing Problems and Repairs I

10:15-10:45 Talk A25 Bearing Redesign – Tom Smith 10:45-11:15 Talk A26 Morton Effect in Overhung Compressor Instability – Paul Allaire with

Saeid Dousti 11:15-12:00 Talk A27 Tilting Pad Journal Bearing to Solve a High Speed Pinion Vibration

Problem – Case History – Paul Allaire with John Nicholas

12:00-1:00 LUNCH

Session A11 – Rotor Problems and Repairs - Case Histories 1:00-1:30 Talk A28 Characteristics and Repair of Rotor Cracks, Tom Smith 1:30-2:15 Talk A29 Rotor Repair with Welding and Coatings – Performance Improvements

– Tom Smith 2:15-3:00 Talk A30 Better Rotor Balancing – Principles and Repairs – Justin Fleming 3:00-3:15 BREAK

Session A12 – Rotor Problems and Repairs II 3:15-3:30 Talk A31 Rotor Reverse Engineering – Tom Smith

3:30 - Tour of Ethos Energy Facility

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Day 4 – Thursday, October 20, 2016

Session A13 – Steam Turbine High Vibrations and Squeeze Film Dampers I

8:00-8:40 Talk A32 Retrofitting a Large Steam Turbine with a Mechanically Centered Squeeze Film Damper – Paul Allaire (with John Nicholas)

8:40-9:20 Talk A33 Eliminating a Rub Induced Start-Up Vibration Problem in an Ethylene Drive Steam Turbine with Squeeze Film Damper – Case History – Paul Allaire (with John Nicholas)

Session A14&B1 – Magnetic Bearings – Introduction/Industrial Apps I

9:20–10:00 Talk A34&B1 Introduction to Magnetic Bearings – Paul Allaire

10:00-10:15 BREAK

Session A15&B2 – Magnetic Bearings – Introduction/Industrial Apps II 10:15-11:00 Talk A35&B2 Initial Levitation Testing and Design of Magnetic Bearings

for High Speed Turbo Aerator – Paul Allaire (with Simon Mushi, Brad Nichols, et al, Kinetic Traction Personnel)

11:00-12:00 Talk A36&B3 Design of Active Magnetic Radial and Thrust Bearings for High Speed Turbo Aerator – Tim Dimond (with Paul Allaire, Brad Nichols, et al, Kinetic Traction Personnel)

12:00-1:00 LUNCH

12:00 - End of Short Course I

Small Agenda Changes May Occur In the Final Short Course Talks and Notes

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Course 2. Magnetic Bearing Systems – Design and Industrial Applications

Industrial Applications

Compressors, Turbines, Motors, Generators Energy Storage Flywheels, Turbo Aerators,

Refrigeration Motor-Compressors Waste Heat Turbine Generators

Turbomolecular Vacuum Pumps, Artificial Hearts

Topics Magnetic Bearing Operating Principles

AMB Design, Magnetic Circuits, Magnetomotive Force Airgaps, Magnetic Materials, Wire Sizing

Load Capacity. Number of Poles Amplifiers, Simple Tilt Translate Controls,

Know Your AMB System Digital Controller Specifications, Modern Controls,

Sensitivity Functions, API/ISO Standards Auxiliary Bearing Design, Rotor Drop Modeling

Surge Control, Rotor Identification

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Course Description, Objectives, and Lecturers

This magnetic bearing systems short course is intended for engineering staff of companies interested in understanding or using magnetic bearings. The use of magnetic bearings is increasing in industrial applications but they are often not well understood by mechanical engineers. This course will provide the basic background in electro-magnetic systems and controls. Details of industrial applications of magnetic bearing industrial machines are presented in the course. A number of basic and advanced topics on magnetic bearing design and feedback control are provided but it is not expected that attendees are experts in controls technology. Finally, a few additional topics on modern control for flexible shaft-AMB machines such as high pressure compressors and surge control in compressors using magnetic bearings is presented. API/ISO specifications for magnetic bearing supported rotating machines are presented. The details of rotor dynamic analysis of rotor drops on auxiliary bearings are presented for various examples. The use of mathematics in this short course is minimized and, when discussed, is used primarily to indicate technical points of use in the solution.

Lecturers:

1. Paul Allaire, Chief Technical Officer, Rotor Bearing Solutions International Also, Professor, University of Virginia, Retired – Long Time Director of Rotating Machinery and Controls Laboratory, Ph. D. Northwestern University

2. Tim Dimond, P.E., President, Rotor Bearing Solutions International, Ph. D. University of Virginia, Formerly Principal Scientist, Rotating Machinery and Controls Laboratory, University of Virginia

Additional Contributors:

1. Simon Mushi, Director of Magnetic Bearings and Controls, Rotor Bearing Solutions International, Ph. D. University of Virginia

2. Jianming Cao, Director of Rotor Dynamics, Rotor Bearing Solutions International, Ph. D. University of Virginia

3. Pablo Yoon, Assistant Professor, University of New Hampshire, Ph. D. University of Virginia

4. Arun Kailasan, Magnetic Bearing Specialist, Gardner Denver, Ph. D. University of Virginia

5. Christian Klatt, Cerobear 6. Weimin Wang, Professor, Beijing University of Chemical Technology

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The course lecturers and contributors have the combined experience and ability to explain rotor-AMB systems making this short course unlike any other short course found in today’s world. Paul Allaire has 42 years’ experience in research and teaching rotor dynamics and magnetic bearings. He has taught more short courses on magnetic bearings to engineers in industry than anyone else. He has refined the basic lectures on magnetic bearings over the past 30 years as well as built the largest academic AMB laboratory in existence. Tim Dimond is the President of RBSI and formerly was the Principal Scientist of the ROMAC Laboratory. He also worked for 9 years as a design engineer at Newport News Shipbuilding. He has now been in magnetic bearings research over the past 10 years and participated in numerous AMB short courses. Simon Mushi is the Director of Magnetic Bearings and Controls for RBSI. He has been working on magnetic bearings and high speed rotors for the past 9 years. Jianming Cao is the Director of Rotor Dynamics and has worked on nonlinear transient rotor dynamics for the past 9 years.

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Day 4 – Thursday, October 20, 2016

Session B1&A14 – Magnetic Bearings – Introduction/Industrial Apps I 9:20–10:00 Talk B1&A34 Introduction to Magnetic Bearings – Paul Allaire

10:00-10:15 BREAK

Session B2&A15 – Magnetic Bearings – Introduction/Industrial Apps II 10:15-11:00 Talk B2&A35 Initial Levitation Testing and Design of Magnetic

Bearings for High Speed Turbo Aerator – Paul Allaire (with Simon Mushi, Brad Nichols, et al, Kinetic Traction Personnel)

11:00-12:00 Talk B3&A36 Design of Active Magnetic Radial and Thrust Bearings for High Speed Turbo Aerator – Tim Dimond (with Paul Allaire, Brad Nichols, et al, Kinetic Traction Personnel)

12:00-1:00 LUNCH (Note: These three talks are covered in both Short Course 1 and Short Course 2)

Session B3 –Basic Concepts and Design 1:00-1:30 Talk B4 Electromagnetic Fields, Flux, and Material Properties –

Paul Allaire 1:30-2:00 Talk B5 Magnetic Actuator Properties - Paul Allaire

2:00-2:30 Talk B6 Magnetic Bearing Materials and Design - Tim Dimond 2:30-3:00 Talk B7 Design of High Load Capacity Magnetic Bearing – Tim

Dimond 3:00-3:15 BREAK

Session B4– Control of Magnetic Bearings and Standards 3:15-3:50 Talk B8 Design and Tilt-Translate PID Control of Magnetic Bearings

in a High Speed Industrial Motor – Paul Allaire (with Simon Mushi)

3:50-4:20 Talk B9 Control and Sensitivity Functions for Magnetic Bearings - API/ISO Vibration Standards for Magnetic Bearing Systems, Allaire (with Simon Mushi)

Session B5 – Digital Electronic Control Hardware 4:20-5:00 Talk B10 Principles of Digital Electronic Control Hardware – Paul

Allaire (with Simon Mushi)

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Day 5 – Friday, October 21, 2016

Session B5 – Auxiliary Bearings 8:00-8:40 Talk B11 Rotor Drop Analysis and Auxiliary Bearing System

Optimization: Part I – Tim Dimond (with Jianming Cao)

8:40-9:20 Talk B12 Rotor Drop Analysis and Auxiliary Bearing System Optimization: Part II – Tim Dimond (with Jianming Cao)

Session B6 – Low Cost Magnetic Bearings

9:20-10:00 Talk B13 Design of Low Cost Magnetic Bearing Systems – Paul Allaire

10:00-10:15 BREAK

Session B7 – Understanding Your AMB System

10:15-10:50 Talk B14 Design and Characterization of Flexible Rotor on Active Magnetic Bearings – Paul Allaire (with Simon Mushi)

10:50-11:20 Talk B15 Modal Rotor Dynamics & State Space Modeling of Rotor/AMB System – Tim Dimond (with Simon Mushi)

11:20-12:00 Talk B16 Determination of Compressor Rotor/Tilting Pad Bearing Stability Using a Magnetic Exciter – Tim Dimond (with Weimin Wang)

12:00-1:00

LUNCH

Session B8 – Energy Storage Flywheel Design

1:00-1:40 Talk B17 High Speed Energy Storage Flywheel Design – Composite Rotor, AMB Support System, Motor-Flywheel-AMB System Design – Tim Dimond (with Arun Kailsan)

Session B9 – AMB System Control

1:40-2:40 Talk B18 Modern Control of Flexible Rotor on Magnetic Bearings – Paul Allaire (with Simon Mushi)

2:40-3:00 Talk B19 Advanced Control of Flexible Rotor with Aerodynamic Cross Coupled Stiffness Effects and Uncertainty – Paul Allaire (with Simon Mushi)

3:00-3:15 BREAK

Session B10 – Compressor Surge Control

3:15-3:40 Talk B20 Surge Control Test Rig with Magnetic Bearings in Centrifugal Compressor Paul Allaire (with Pablo Yoon)

3:40-4:00 Talk B21 Surge Control with Magnetic Bearings in Centrifugal Compressor – Paul Allaire (with Pablo Yoon)

4:00-4:30 Talk B22 Magnetically Suspended Artificial Hearts – Tim Dimond

End of Course 2.

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Registration Advanced registration for the short course is available at: Dr. Tim Dimond Rotor Bearing Solutions International tim.dimond@rotorsolution.com 434-632-8469 434-284-1850 (cell) Registration can also be sent by mail to: Dr. Tim Dimond Rotor Bearing Solutions International 3277 Arbor Trace Charlottesville, VA 22911 tim.dimond@rotorsolution.com 434-632-8469 434-284-1850 (cell) The EthosEnergy point of contact for facility questions is Scott Hill. He can be reached at 713-203-7236. Fees Advance

First Person From a Company

Additional people from the same company

One Course $900 $500 Both Courses $1,500 $750

On-site

First Person From a Company

Additional people from the same company

One Course $1,000 $550 Both Courses

$1,600 $800

Seating for the short course at Etho Energy is limited so early registration is

recommended. On-site registration payments can be made with cash or credit card. If requested in advance via a purchase order, billing to an individual company will be accepted.

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Lecture Materials and Continuing Education Credit The material for all talks will be provided to attendees on a memory stick. Detailed

questions on the course topics in particular and magnetic bearings in general will be answered.

Certificates (PDHs) will be provided for attendees of the short course upon request.

Course 1. 26 PDH Course 2. 12 PDH Both courses: 36 PDH

Short Course Hotels Hotels near the Ethos Energy, Houston site will be recommended soon. The lectures will be held in the Ethos Energy conference room. The attendees are responsible for registering at the hotel of their choice on their own. More detailed information about the hotels and room reservation information will be available soon on the RBSI website.