Abstract
The steam turbine rotor support system is a critical component in power generation systems, significantly influencing the efficiency and reliability of turbines. This study was motivated by the increasing demand for energy efficiency and the need to address failures in rotor support systems due to high operational stresses and thermal gradients. The problem of insufficient load distribution, vibration control, and thermal stability in existing rotor support systems prompted this research. The aim of the study was to design, analyse, and optimize a rotor support system capable of minimizing vibration, enhancing load distribution, and maintaining thermal stability under operational conditions. A multidisciplinary methodology was employed, including analytical modelling, finite element analysis (FEA), and experimental validation. Analytical models provided an initial understanding of the system's dynamic behaviour, while FEA was used to simulate stress distribution, thermal effects, and modal properties. Material research was conducted to select an optimal rotor material capable of reducing heat transfer within the shaft. The optimized shaft design aimed to enhance turbine efficiency by minimizing the thermal deformation that typically leads to rotor misalignment, vibrations, and increased maintenance demands. Prototypes were fabricated and tested under controlled conditions to validate simulation results. The results demonstrated significant improvements in vibration damping, uniform load distribution, and thermal stability compared to conventional designs. The optimized support system reduced vibration amplitudes by 30% and improved operational efficiency by 15%. These findings highlight the potential of advanced rotor support designs in enhancing turbine performance. The developed support system is recommended for application in modern steam turbines used in power plants, with potential benefits in extending turbine life, reducing maintenance costs, and improving overall energy efficiency. Future studies could focus on integrating smart materials and real-time monitoring systems to further enhance performance and reliability.