Proceedings of the ASME 2014 International Design Engineering Technical Conferences &

Computers and Information in Engineering Conference

IDETC/CIE 2014
August 17-20, 2014, Buffalo, New York, USA

DETC2014-34580

ROTOR DYNAMICS IN DESIGN OF A HIGH SPEED CRYOGENIC PUMP FOR GEO

STATIONARY LAUNCH VEHICLES

Srinivasa R Jammi Fellow

ASME
Kumaraguru College of
Technology
Coimbatore, India
and
Altair Engineering India
Bangalore, India

ABSTRACT satellite - Sputnik in 1957 and later the first man into space in
On January 5th 2014 the Indian Space Research 1961. President Eisenhower established the National
Organization successfully launched its Geo Stationary Launch Aeronautics and Space Administration (NASA) in 1958 in USA.
Vehicle with an indigenous Cryogenic engine. One of the main Indian Space program started in 1969 and its first launch
design aspects is in its rotor dynamics to predict the peak took place in 1980 with a SLV-3, followed by PSLV and GSLV
amplitude unbalance whirl and the speed at which it occurs. This for spacing satellites in a geostationary orbits. Geostationary
engine has several key technologies, one of them specifically is Launch vehicles use a Cryogenic Rocket in the final phase;
coupled rotors, viz., Turbine, Hydrogen Pump and Oxidizer United States developed first cryogenic rocket engines in 1963
supported on seven nonlinear rolling element bearings and with RL-10 engines on the Atlas V rocket, followed by Japanese
several seals all mounted in a flexible casing. The conventional LE-5 engine in 1977, French HM-7 in 1979, Chinese YF-73 in
beam model initially adopted failed to predict the speed at which 1984 and Soviet Union 1987. India began developing its own
peak unbalance response occurs. Cryogenic Engine in 1993 but could succeed in using it for the
The rotor system was first developed in a solid model to first time only in 2014, almost two decades later. One of the
determine the critical speeds of the rotor alone considering its main hurdles in developing Cryogenic engines is its high speed
40000 rpm centrifugal loads with bearings treated as linear. of operation, 40000 rpm and above. This paper is concerned
Then, unbalance whirl of this rotor system was developed by with the development of rotor dynamics technologies for this
codes specially developed for this purpose. The rolling element high speed engine.
bearings are found to be highly nonlinear with large bearing
radial forces at critical speeds. An iterative procedure was CRYOGENIC ENGINES
developed to match the bearing force and unbalance whirl to A schematic view of the Indian Geo stationary launch vehicle
determine peak amplitude response speeds. Subsequently, seals (GSLV) with its three stages is shown in Fig. 1 with the
and the influence of casing and internal pressures were Cryogenic Upper Stage (CUS). The Cryo stage is separately
accounted in the analysis. This paper describes the advanced shown in Fig.2 and Fig. 3 shows the Cryogenic engine with the
rotor dynamic design of this pump. nozzle.
. Oxygen liquefies at –1830C and Hydrogen at –2530C. The
INTRODUCTION propellants, at these low temperatures are pumped using turbo
The first recorded use of a rocket in battle is reported to be pumps running at around 40,000 rpm. During the flight, CUS
by the Chinese in 1232 against the Mongol hordes [1]. In 1780 fires for a nominal duration of 720 seconds. It is a very critical
Hyder Ali and his son Tipu Sultan effectively utilized Mysorean condition necessitating an accurate evaluation of the speed at
rockets and rocket artillery against the East India Company [2]. which peak whirl occurs and its magnitude to prevent seizure of
Modern rocketry [3] owes to Goddard with his launch of the the rotor in the expected 12 minute operation.
world's first liquid-fueled rocket in 1926. The current space
rocketry can be traced to R-7 [4] which launched the first

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 ROTOR DYNAMICS STATUS IN 20TH CENTURY was first formulated by Jeffcott [9] in 1919. He showed for the
It was a surprise in 1882 when de Laval built the first impulse first time that the shaft did not primarily rotate about its rest
turbine; see Rao [5] that it ran to 40000 rpm against the position, but about its own centerline. The whirl of the rotor
predictions of Rankine [6] in 1869. Rankine is a famous scientist corresponds to free or forced vibration of a stationary structure.
of 18th century and his statement on “Limit of Speed below This is a significant development in the understanding of rotor
which Centrifugal Whirling is impossible” is read by scientists of dynamic behavior.
the day as operation beyond this speed is not possible. From
simple equilibrium conditions, Laval derived a correct relation
for the whirl radius (though whirl and spin have not been clearly
differentiated) and showed that actually the rotor crosses the
natural frequency and operates smoothly.

Payload fairing Satellite

Payload adaptor

Equipment bay

GS2, Liquid stage

(L37.5)
Vented Inter stage GS3, Cryo stage (C12)

Inter stage Fig. 3 Cryogenic Engine with the Nozzle

Hydrogen Pump Turbine Oxidizer Pump
Inter stage

Liquid strap on (L40), 4 Nos

Exhaust
Control
Valves
Fig. 1 Launch Vehicle and the Cryo Stage

Engine Oxygen
Tank
Hydrogen
Heat
Tank Exchanger

Nozzle
Fig. 4 Cryogenic Engine Operation
Though there were sigificant advances in stationary structures
taking Euler-Bernoulii beam theory to Sophie Grmain’s plates
and subsequrntly shells, rotor dynamics remained basically one
dimensional in nature until recent times. In the absence of
Fig. 2 Upper Cryo Stage with Liquid Hydrogen (Fuel) and number crunching as we know today, several ingenious
Oxygen (Oxidizer) Tanks, Engine and Nozzle numerical methods were developed, the last one of them being
Even before we understood the difference between a Transfer Matrix methods at the beginning of computer era, see
stationary shaft and a rotor in 1919, Stodola in 1910 [7] Rao [5]. Rotor Dynamics that is distinguished from Structural
extended the concept of rotary inertia of Rayleigh in 1877 [8] Dynamics was generalized from Jeffcott, by Lund [10] followed
and identified this as a gyroscopic effect that gives rise to split by several others, see [5]. The rotor dyamics is distinguished
natural frequencies and backward whirl between them. This has from structural dynamics, otherwise, by special considerations
become essential to improve a beam model by considering the such as gyroscopic effects, support characteristics, instabilities
disk effect of steam turbine rotors. The basic difference between amongst others. The speed entered into rotor dynamics only
a structure and rotor lies in the forced vibration analysis that through the introduction of gyroscopics to account for Stodola’s

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 invetigations. The classical effects of centrifugal loads of high Such a modeling allows the influence of speed directly enter
speed rotors were ignored until recently, because the beam into the Campbell diagram rather than through gyroscopic
assumption did not allow any centrifugal forces into the model. modeling in simplified one-dimensional beams. Further, the
Even the finite element method first introduced by Ruhl and rather tedious process of making an equivalent beam model of a
Booker [11] in 1972 and generalized by Nelson [12] in 1980 practical rotor is eliminated and instead, CAD and FE models
remained one dimensional in nature. can be directly accounted as in other analyses for stress or
In 1985, Bellamy et al [13] proposed the necessity of bringing thermo-mechanical analysis. The results of such an analysis are
the casing of an aero engine into the analysis and coupled a shell discussed in detail for aircraft engines by Rao [5].
model of the casing with the beam model of the rotor. Rao et al Transient analysis of these rotors is important as deduced in
[14] in 2002 have modeled the rotor with 3D beam elements for Space Shuttle Main Engine analysis. The exact solutions that
conventional rotor dynamic analysis with foundation modeled can be obtained Jeffcott type of rotors is first verified for
using solid elements and its dynamic stiffness is obtained from a equivalent Solid Rotor models by Rao and Sreenivas [18].
harmonic analysis with forces applied at the bearing locations to The CAD model of the cryogenic engine with the nozzle in
determine the combined rotor-bearing-foundation system Fig. 3 is shown in Fig. 5.
unbalance response.

CRYOGENIC ENGINE ROTOR DYNAMICS

Space shuttle main engine (SSME) RS-25 had its first flight
on April 12, 1981. This engine was manufactured by
Rocketdyne, a division of Rockwell International. Rocketdyne
developed a lumped parameter structural-dynamic model,
consisting of 13 rigid bodies connected to each other by
massless beam elements. After the design was fixed a rotor
dynamic analysis was carried out by Childs [15], NASA and
Rocketdyne engineers. Speed dependent radial stiffness
coefficients for the ball bearings were calculated and rotor
imbalance distribution was employed at the boost stage impeller,
main impeller, and turbine wheels. Together with forward and
rear bearings damping and internal damping, the modal damping
factor for the first mode 13000 rpm is taken as 3.5%. The Fig. 5 Cryogenic Engine with the Nozzle
critical speed 13000 rpm was away operating speeds 20,890, The CAD model of the pump alone is shown in Fig. 6. The
29250 and 31,160 rpm. The rotor transits through the critical rotor and the casing are meshed with 8 noded brick elements,
speed at 13000 rpm. No problems were indicated at steady state see Fig. 7. Bearings and seals, see Fig. 8, are simulated by 12 by
operations; however, a rubbing condition was predicted at the 12 Matrix elements accounting for all degrees of freedom
turbine floating-ring seals during critical speed transition. With between two nodes. Total number of elements is 379,779 and
this general background from Childs [15], a detailed cryogenic the total number of nodes is 534,115.
pump of ISRO was carried out with solid models for the rotor
rather than beam models. ROTOR ALONE ANALYSIS
Solid model rotor dynamics was first established by Rao [16]. 3-D FE Model of Turbine and First Stage Impeller is shown
This was done by considering an equivalent solid rotor model in in Fig. 8. This FE model has 14890 nodes with 53608 linear
place of a two-spool beam model of Rajan et al [17]. The solid tetrahedral elements. Fig. 9 shows the 3-D FE Model of Second
model is constructed using SOLID-45 elements with eight nodes Stage Impeller and Inducer which has 11491 nodes with 40465
each having three degrees of freedom of translation. The linear tetrahedral elements. Likewise Fig. 10 shows the 3-D FE
bearings are simulated by COMBIN-14 elements. Both the Model of Oxidizer Stage having 13190 nodes with 45303 linear
rotors are subjected to spin. There are two basic advantages in tetrahedral elements.
this modeling, viz., 1. There is no necessity of separate The bearings (deep groove ball) are taken linear for first cut
gyroscopic modeling as the kinetic energy of the discs in analysis and stiffnesses taken as 6, 5.6, 5.6, 5.04, 5.04 and 3.27
translation and rotation about the transverse axis are included by E+04 N/mm for bearing numbers 1 to 6 respectively based on
virtue of three translational degrees of freedom of all the static bearing reactions. (The stiffness is subsequently
elements in the disks, 2. The centrifugal stiffening and spin considered nonlinear depending on the reaction forces.)
softening are brought in by spinning the rotors at their
respective speeds, including the casing and foundation which
rotate at 0 rpm.

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 Bulk Flow Model for Seals:
There are eight seals and their properties are determined
using bulk flow models, see [19]. This model is briefly explained
here by considering a plain seal with length L, radius R and
clearance C, with pressure difference across given by p. Let
the average flow velocity in the seal be V given by
2p
V
 1    2 
Resistance to flow is represented by  with the resistance
coefficient  which depends on Reynolds number Ra  V C .

Fig. 6 CAD Model of the Pump L
 
C
0.375
 1 
  0.066 Ra0.25 1 
2 
 4b 
V
b
R
Here,  is density,  is kinematic viscosity and  is entrance
loss coefficient, which can be taken as 0.5.
The coefficient 0.066 and the exponents -0.25 and 0.375 are
Hir’s coefficients. The rotational speed is  rad/s. With
Fig. 7 FE Model of the Turbo Pump characteristic time for the seal T  L , the direct and cross-
V
coupled stiffness and damping coefficients are expressed as
 1 
K d   a0  a2 2T 2  K *
 4 
1
K c  a1TK *
2
Cd  a1C *
Cc  a2TC *
where
LR
K *  p
Fig. 8 3-D FE Model of Turbine and First Stage Impeller c
C K T
* *

The coefficients a0, a1, and a2 are given by

a0  2.5 AE
E 1  1 
a1  24  B E  
 2  6 
A 1
a2   E  
 6
where A, B and E are obtained from
Fig. 9 3-D FE Model of Second Stage Impeller and Inducer

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  Free vibration analysis was carried out at different speeds
A within the operating region. Stress stiffening and spin softening
1    2 effects are included. The results are post processed and the
1  7b 2 different forward and backward modes are identified, see [20] at
B different speeds. Eigen values are extracted using Block
1  4b 2 Lanczos method and the Campbell diagrams obtained thus are
1  given in Figs. 13 and 14 for the rotor alone and rotor + casing
E
21    B  respectively. Here, bending modes are only considered while
plotting the Campbell diagrams, torsional and axial modes are
The stiffness and damping values are curve fitted; typically excluded.
the properties of first seal are given by 1400

K xxlb1  4.738452E - 12  rpm3  2.261960E - 06  rpm2  1200

2.659990E - 03  rpm  2.958842E  02 N/mm 1000 1xx

T urbine_Bending Mode_backward
800 T urbine_Bending Mode_forward

Hz
600 Mid_span_ Bending_backward
Mid_span_Bending _forward
400
Inducer_Bending_ Mode_backward
200 Inducer_Bending Mode_forward

0
0 10000 20000 30000 40000 50000 60000
rpm

Fig. 13 Rotor Alone Case Campbell Diagram

1400 Turbine_Bending Mode_backward

1200 Turbine_Bending Mode_forward

1000 Mid_span_ Bending_backward
800 Mid_span_Bending _forward
Hz

600 Inducer_Bending_ Mode_backwad

Fig. 10 3-D FE Model of Oxidizer Stage
400 Inducer_Bending Mode_backward
200
1xx
0
0 10000 20000 30000 40000 50000 60000
rpm
Fig. 14 Rotor-Casing Campbell Diagram
It is observed that the first forward critical speed of the rotor
Fig. 11 Boundary Conditions for Rotor – Bearing Locations is at 28000 rpm and the second forward critical speed is at
1 to 6 are as marked – the rest 8 are Seal Locations 55000 rpm. The first and second backward critical speeds are
observed at 20000 and 44000 rpm respectively. The critical
The other end of the bearing and the seal free nodes are speeds dropped significantly to 23500 rpm and 39000 rpm when
constrained in all degrees of freedom. All the inlets and the the casing effect is included.
outlets of the turbo-pump are constrained in all degrees of
freedom as shown in Fig. 12 for combined rotor-casing analysis. UNBALANCE RESPONSE
The unbalances at Turbine, First Stage Impeller, Second
Stage Impeller and Oxidizer in gm-mm are taken as given in Fig.
11. Macros are written to apply the unbalance load in
accordance to the following relation [21].
Fx  u 2 cos  cos t  iu 2 sin  sin t
Fy  u 2 sin  cos t  iu 2 cos  sin t
where u is the unbalance and  is phase angle.
Bearing reaction forces obtained for the rotor alone case in Y
direction are given in Fig. 15.

Fig. 12 Boundary conditions for Rotor Casing

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 Bearing Reaction FY
Bearing Reaction FY
2500
EFFECT OF PRESSURE ON THE CASING
Bearing 1
Bearing 2 Bearing 1 The casing is subjected to internal pressure as given in Fig. 17
2000
Bearing 3 and
Bearing 2 pre-stressed. This influences the effective stiffness at the
Reaction Force FY (N)

Bearing 4 bearings.
Bearing 3 The resulting Campbell diagram with nominal stiffness
1500 Bearing 4
Bearing 5 of the bearings given earlier is given in Fig. 18.
Bearing 6 Bearing 5
1000 Bearing 6
The effect of pressure on the rotor-casing system is to
increase the critical speeds, the increase in I critical speed is
500 about 3000 (26500-23500) rpm as can be seen from Fig. 18.

30000 35000 40000 045000 50000 55000 60000

rpm 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000
rpm

Fig. 15 Bearing Reactions Forces in Y Direction

It is observed that peak responses occur at the critical speeds
as predicted in the rotor alone case Campbell diagram Fig. 13.
Bearing 1 suffers maximum reaction force 2150 N at the first
forward critical speed. The response in this region is not correct
because the bearing stiffness is significantly affected by the
response. In reality the bearing stiffness is nonlinear and given
by [19]

k  1.289nz d 0.333F 0.333N/m

0.666

where
nz = number of balls in the ball bearing = 9 Fig. 17 Internal Pressure Campbellindiagram (Rotor-casing)
the Casing
d = diameter of the ball = 11.12 mm 1400 1xx

F = Reaction force at the desired frequency = 2150 N 1200 Turbine_Bending

Substituting these values, we get k  16.363 10 N/m which

7
1000 Turbine_Bending

is 2.727 times more than the stiffness used earlier. An iterative 800 Midspan-Bending
Hz

process is adopted to determine the response in the critical 600 Midspan-Bending

speed region to match the starting value of stiffness and the 400 Inducer_Bending
bearing reaction force with the results in the final step. The 200 Inducer_Bending
casing stiffness, internal pressure amongst other parameters will
Campbell diagram (Rotor-casing) 0 Midspan-Bending
influence the end result, for the present it is assumed that the 10000 20000 30000 40000 50000 60000
7
14006×10 N/m and the evaluated
average value of starting stiffness 1xx
rpm
stiffness 16.36×107 N/m, viz., 12×10
1200 7N/m will be applicable to Turbine_Bending_Backward

assess the influence of nonlinearity

1000 of the bearing. With this, the Turbine_Bending_Forward

Campbell diagram obtained is shown 800 in Fig. 16. Midspan-Bending_Forward

Hz

600 Midspan-Bending_Backward
1400 400 1xx Inducer_Bending_Backward

1200 200 Inducer_Bending__Forward

Turbine_Bending Mode_backward
1000
0 Midspan-Bending_Forward

10000 Turbine_Bending
20000 30000 Mode_forward
40000 50000 60000
Fig. 18 Campbell Diagram of Rotor-Casing Considering Internal
800 rpm
Mid_span_ Bending_backwad Pressure
Hz

600
Mid_span_Bending _forward STABILITY ANALYSIS
400 Stability analysis of solid model rotors calls for a
Inducer_Bending_ Mode_backward
determination of complex Eigen values of large size
200
Inducer_Bending Mode_forward unsymmetrical matrices including damping coefficients. Here the
0 seal stiffness and damping properties are simulated at 30,000
0 10000 20000 30000 40000 50000 60000 rpm. However the spin speed of the rotor is kept zero, i.e., the
rpm influence of centrifugal stiffening and spin softening is
Fig. 16 Rotor Alone Campbell Diagram with Revised Stiffness unaccounted as in beam model studies. Complex Lanczos
for Bearing 1 method was adopted to extract the Eigen values and the results
obtained are given in Table 1.

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 Table 1 acceleration of 600 rad/s2, the resonance is further shifted
Complex Eigen Values of Rotor-alone and Rotor-Casing System to 87.6 Hz.
at 30,000 rpm 2. The resonant amplitude due to acceleration of the rotor is
much lower, when the rotor is accelerated, From steady
Mode Rotor-alone Rotor-Casing state values, the amplitudes are lower by as much as half at
Hz Damping Hz Damping 60 rad/s2
Coefficient Coefficient 3. There is only a marginal reduction in amplitude as the
1 73.7 1.4382E-02 70.99 1.4120E-02 acceleration rate increases, though the frequency shift is
2 468.9 1.8456E-02 395.1 3.7446E-02 significant. The peak amplitude for an acceleration rate of
3 513.3 3.2998E-02 522.6 8.9713E-03 600 rad/s2 is lower than the peak amplitude for an
4 599.6 2.0165E-02 586.5 7.1332E-03 acceleration rate of 60 rad/s2. This can be attributed to the
5 768.1 9.1013E-03 682.4 6.3391E-03 fact that for a lower acceleration rate, the system has
relatively more time to dwell in the resonance region, when
The rotor is found to be stable at all the natural frequencies. compared with a higher acceleration rate.
This is advantageous in fixing the acceleration of the rotor
that ensures no rubbing takes place. The analysis of the pump
TRANSIENT ANALYSIS THROUGH CRITICAL SPEED
rotor under acceleration is not presented here.
All steady state calculations performed at critical speeds take
time to build resonance or large amplitude of whirl. Fortunately,
in real cases of rotors coasting through critical speeds do not ONE DIMENSIONAL BEAM VS SOLID MODELS
The drawbacks of traditional beam models are:
operate steadily at a critical speed. They are accelerated through
 Real life rotors are not one-dimensional
the critical speed with an acceleration  and therefore their
excitation frequency depends on instantaneous conditions and  Considerable time and effort in deriving a good
the frequency excitation rapidly grows with the speed. The approximation of one-dimensional model from actual
drawings
1 2
frequency of excitation can then be expressed as 0t  t .  Influence of disks on shafts, vice versa not possible
2  Centrifugal effects cannot be accounted
Rao and Sreenivas gave such an analysis [22] using a Jeffcott  Gyroscopic effects calculated as separate elements of
rotor model with stiffness = 1.387E07 N/m, mass = 54.432 Kg. equivalent disks; speed otherwise does not enter into
A beam based finite element model of the rotor system has been Campbell diagrams
adopted. The coast up time domain excitation of the rotor is  Foundation and casing effects are to be determined by sub-
generated and input as an array. A time step of 0.0005 seconds is structuring analysis to determine their stiffness and damping
used with an acceleration 60 rad/s2 and 600 rad/s2 are selected. effects and included in the beam models
The natural frequency is 80.54 Hz.
Solid models provide:
 Accurate rotor dynamic analysis needs solid models
 / p 2  0.000234  Modern designs, all components are CAD modeled
 Auto-meshing features makes meshing accurate and
 / p 2  0.0023
y /  st accomplished in very little time compared to procedures in
beam modeling
 Disadvantages of beam models are automatically taken care
of in solid rotor dynamics
 However, CPU time, RAM and hard disk requirements go
t / p up considerably
 With recent advances in computers, these limitations are
gradually diminishing, thus making solid rotor dynamics
Fig. 19 Damped coast up response of the rotor (600 rad/s2)
more attractive
Fig. 19 shows the results obtained in non-dimensional form in
terms of the static deflection of the simply supported rotor =
CLOSURE
3.849E-05 m. The following observations can be made.
We now have technologies using actual three dimensional
1. There is a significant increase of the resonant frequency
rotor for the unbalance whirl for an effective rotor dynamics
with increasing values of acceleration rates. In case of the
analysis of complex rotor systems without taking recourse to
rotor, for an acceleration rate of 60 rad/s2, the resonance is
simplified one dimensional models.
observed at 81.29 Hz as against 80.54 Hz. For a higher

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 ACKNOWLEDGMENTS 16. Rao, J. S., (2002) Rotor Dynamics Comes of Age,
Several students of mine have developed the technologies for Keynote address, Proceedings 6th IFToMM International
solid rotor dynamics since 1970’a in IIT Delhi; BHEL, New Congress Rotor Dynamics, Sydney, September 30 – October 3,
Delhi; QuEST, Bangalore; Altair, Bangalore; I am grateful to 2002, vol. 1.
them in participating and advancing rotor dynamics work. I am 17. Rajan, M., Nelson, H. D. and Chen, W. J., (1986)
also thankful to ISRO, Liquid Propulsion Division, Valiamala for Parameters Sensitivity in the Dynamics of Rotor-Bearing
their support, to whom this cryogenic rotor dynamics work was Systems, Journal of Vibration Acoustic Stress Rel. design,
developed in having the high speed pump that successfully ASME, vol. 108, p. 197
operated on Geo Stationary Launch Vehicle. Lastly I am grateful 18. Rao, J. S. and Sreenivas, R., (2003), Dynamics of
to Dr. Mahalingam, Chairman of Kumaraguru College for his Asymmetric Rotors using Solid Models, IGTC2003, Tokyo TS-
encouragement. 016
19. Rao, J. S., (2000) Vibratory Condition Monitoring of
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