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Vibration HistoryPulp & Bleach Area
0.19
0.170.16
0.25
0.21
0.16
0.17
0.18
0.19
0.2
0.21
0.22
0.23
0.24
0.25
0.26
1980 1981 1982 1983 1984
Year
Ave
rage
Am
plitu
de V
eloc
ityips
1 2 3 4 5
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1 2 3 4
•
•
•
•
44
42
40
38
36
34
32
30
28
26
24
44
32
2824
Dol
lars
/ To
n
Year
R&E Maintenance ExpensePulp & Bleach Area
1 2 3 4 5
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Vibration History
0.19
0.170.16
0.25
0.21
0.16
0.17
0.18
0.19
0.2
0.21
0.22
0.23
0.24
0.25
0.26
1980 1981 1982 1983 1984
Ave
rage
Am
plitu
de V
eloc
ityips
1 2 3 4
•
•
•
•
44
42
40
38
36
34
32
30
28
26
24
44
32
28
24
Dol
lars
/ To
n
Year
R&E Maintenance Expense
1 2 3 4 5
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Intellectuals solve problems; geniuses prevent them.
Albert Einstein
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What percentage of your machines are the highest HP?
…medium HP?…low HP?
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Average Maintenance Costs By Machine Size
500 hp 500 hp ……………………………………..............
150 hp 150 hp …………..……………………......$2x / hp / yr
$1x hp / yr
$4x / hp / yr
1 hp 1 hp ……..……......
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Vibration vs. Maintenance Costs1800 rpm pumps
Machine0
10
20
30
40
50
0
0.05
0.1
0.15
0.2
0.25
0.3Velocity, ipsDollars, Thousands
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< $4,000 0.03 in/sec
Velocity, ipsDollars, Thousands
Vibration vs. Maintenance Costs1800 rpm pumps
Machine0
10
20
30
40
50
0
0.05
0.1
0.15
0.2
0.25
0.3
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< $7,750 0.05 in/sec
Velocity, ipsDollars, Thousands
Vibration vs. Maintenance Costs1800 rpm pumps
Machine0
10
20
30
40
50
0
0.05
0.1
0.15
0.2
0.25
0.3
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0.08 in/sec
Velocity, ipsDollars, Thousands
Vibration vs. Maintenance Costs1800 rpm pumps
Machine0
10
20
30
40
50
0
0.05
0.1
0.15
0.2
0.25
0.3
< $15,000
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Fastest means to determine your own actual costs
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Maintenance Expense vs Vibration History
Machine type Highest Velocity, ips
Maintenance Cost, $
Lowest Velocity, ips
Maintenance Cost, $
Total Highest Lowest
Difference in maintenance costs for 3 machines with highest vibration vs 3 machines with lowest vibration:
Difference in 12 month maintenance costs = $
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Maintenance Expense vs Vibration History
Difference in maintenance costs for 3 machines with highest vibration vs 3 machines with lowest vibration:
Difference in same period maintenance costs =
Machine type Highest Velocity, ips
Maintenance Cost, $
Lowest Velocity, ips
Maintenance Cost, $
Pump - 1800 rpm 0.15 10298 0.012 2668
Pump - 3600 rpm 0.26 46383 0.021 2503
Fan 0.338 16793 0.052 226
Total Highest 73474 Lowest 5397
$$ 68,077
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Simplest, Easiest Procedures to Lower Amplitudes on Existing Plant Machinery
Eliminating Foot – Frame related Resonance
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1.0
0.8
0.6
0.4
0.2
00 200 400 600 800 1000
Frequency in Hz
Pk
Vel
ocity
in In
./Sec
1-A-REACTOR BLD. SPRAY MIH MOTOR INBOARD HORIZ.
SPECTRUM DISPLAY12-NOV-90 18:22PK=.7089LOAD=90.0RPM=3594RPS=59.91
2x RPM
1x RPM
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0.03
0.06
0.09
0.12
0.15
0.18
0.21
0.24
00 200 400 600 800 1000
Frequency in Hz
Pk
Vel
ocity
in In
./Sec
1-A-REACTOR BLD. SPRAY MIH MOTOR INBOARD HORIZ.
SPECTRUM DISPLAY15-NOV-90 18:32PK=.1970LOAD=90.0RPM=3585RPS=59.75
2x RPM
1x RPM
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1.0
0.8
0.6
0.4
0.2
00 200 400 600 800 1000
0.03
0.06
0.09
0.12
0.15
0.18
0.21
0.24
00 200 400 600 800 1000
Before After
Auto scaled
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1.0
0.8
0.6
0.4
0.2
00 200 400 600 800 1000
1.0
0.8
0.6
0.4
0.2
00 200 400 600 800 1000
Before After
Added 2‐3 mils of shimunder one flange bolt!
Adjusted to same scale
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Electric motor
Two bolts loose
All bolts tight
10
0
2
4
68
DIS
PLA
CE
ME
NT
IN M
ILS
10
0
2
4
68
DIS
PLA
CE
ME
NT
IN M
ILS
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Primary production Machines(from company’s several mills)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2095
96
97
98
99
100
Ultimate Target
% Large pulp and paper company’s goals for additional production running time
Initial Target
Present production
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Primary production Machines(from company’s several mills)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2095
96
97
98
99
100% Goals for additional production running time
250,000 Tons / year ÷ 365 = 685 tons / dayAdditional
Initial Target250,000 Tons / yr
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Primary production Machines(from company’s several mills)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2095
96
97
98
99
100
Additional500,000 Tons / yr
% Goals for additional production running time
500,000 Tons / year ÷ 365 = 1370 tons / dayAdditional
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VP Production - major paper company:
“I can get an additional large papermill - not through the expenses and problems of building one - but by getting only 20 of our present machines to run just a little bit longer each day.
How?? Through our new very practical machinery improvement / precision maintenance efforts.”
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Large Aluminum manufacturing facility
Machinery
5000 pieces of rotating equipment
Maintenance PhilosophyBefore starting the program: run to failureAfter: machinery improvement / precision
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Average Vibration Levels for all Equipment
Year 10
0.05
0.1
0.15
0.2
0.25
0.3
0.35
Year 6
Inches/Second
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Unscheduled vs Scheduled Maintenance
Year 10
20
40
60
80
100Scheduled 15 %
Year 6
Unscheduled 85 %
Unscheduled 9 %
Scheduled 91 %
%
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1,500 Pumps (100 - 350 Hp)
• MTBF - 4 Years
• Average rebuild / replacement cost -$25,000 / pump
• Total pump maintenance cost -$9,375,000 / year
Annual Pump Maintenance (Run to Failure)
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• Same 1,500 Pumps (100 - 350 Hp)
• First four years• $4,687,500 / year
• Fifth year - present: • < $1,000,000
Annual Pump Maintenance Costs:
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Production Increase(through machinery improvement efforts)
Mill
ion
P oun
ds p
e r M
o nth
Year 1 Year 6
30 million pounds per month
0
10
20
30
40
50
60
70
60 million pounds per month
With no increase in expansion of capital machinery!
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ISO Balance Standards• G 100 Crankshaft -drives of fast diesel engines with six or
more cylinders, complete engines of cars, trucks and locomotives
• G 16 Propeller shafts, carden shafts, parts of crushing machinery, parts of agricultural machinery
• G 6.3 Parts of process plant machines, paper machinery rolls, fans, fly wheels, pump impellers, electric motor armatures
• G 2.5 Gas and steam turbines, Turbine driven machines, machine tool drives, motor armatures with special requirements
• G 1 Tape recorder and phonograph drives, grinding machines, small motor armatures with special requirements
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Page 225
G 6.3
G 2.5
G 1
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G 6.3
G 2.5
G 1 API
AmericanPetroleumInstitute
Shaft centerline orbit around center of massISO Rotor Balancing Standards: circa 1956
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Con
vert
ed to
inch
es
RPM1800
0.0011
1.1 mils radius = 2.2 mils orbit
2.2 mils @ 1800 RPM = approximately 0.22 in /sec
Not so good for long production life !
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Con
vert
ed to
inch
es
RPM2000500200
0.001
0.004
0.012centerline orbit radius of 12 mils
Total displacement 24 mils! How will this affect the gearmesh?
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Pitch circles
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AddendumDedendum
Addendum : Portion of tooth above the pitch circle
Dedendum : Portion of tooth below the pitch circle
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AddendumDedendum
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AddendumDedendum
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AddendumAddendum
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DedendumDedendum
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Gearmesh frequency12,498 cpm
Excessive barring on paper napkin machine
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Gearmesh frequency
Apply sideband cursor
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Gearmesh frequencySideband difference frequency 118 cpm
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Gear rpm = 117.9 cpm(closest data point at 120 cpm)
The peak in velocity is only 0.1 ips
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Gear rpm = 117.9 cpm
But the displacement is 16.6 mils!
The peak in velocity is only 0.1 ips
Indicates a large rotor imbalance
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The gear was balanced and the barring eliminated
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1200500200
0.001
0.004
0.012
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If the width of the rotor is less than ¼of the diameter, then it only requires a single plane balance.
False !
Balancing Narrow and Overhung Rotors
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Usually calls for single plane balance
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Usually calls for single plane balance
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Calls for two plane balance
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If the rotor is overhung (cantilevered), regardless of width, then it most often requires a single plane balance.
False !
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Vibratory motion of shaft centerline
Greatest amplitude at the top
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Cooling fan
what a convenient place for balancing at the top plane
False !
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Static imbalance (overhung) creates large couple
Couple (rocking motion) pivot point
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If Resonant in the rocking mode, bracing usually does not work
Instead, use a tuned dynamic absorber (works only on a resonant system)
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Page 234
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G 1 Parts of process plant machines, paper machinery rolls, fans, fly wheels, pump impellers, electric motor armatures
Develop your own company standards for precision balancing
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Balancing time, from G 2.5 to G 1 (or API) another ½ hour
Balancing time, from G 6.3 to G 2.5, ½ hour
Balancing time, including cleaning the rotor, removing burrs, adding proper key, mounting on balancing machine, adjusting drive unit and positioning end stops.
Balance to G 6.3 Time: 1 to 1½ hours
Total extra time for balancing from G 6.3 to G 1, One hour
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Total for true precision balance 1 hour
Motor solo test and touchup ½ hour
Extra for true precision alignment 1 hour
Foot related resonance test ½ hour
Additional resonance improvement 1 hour
Total 4 hours
At $100/hour = $400
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Eccentricity at 200 RPM = 12 mils
Vibration amplitude in displacement :12 x 2 = 24 mils
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Most common places where alignment goes wrong
Actual thermal growth situations
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From Update International SurveysFrom Update International Surveys
Typical responses from Supervisors and Managers
“My plant already has modern alignment instruments (laser and/or reverse indicator).”
“My people have received a good training from:
instrument manufacturer
alignment seminar specialists
internal training staff
Update International……..etc”
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Responses from those who perform alignmentResponses from those who perform alignment• “Nobody has ever complained about my work”
• “I can get the job done with one indicator, faster than setting up the fixtures.”
• “I love using the laser system. I use it all the time.”
• Question: “How do you know when to quit?”Typical answer: “I have a lot of experience. I just know it.”
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“Almost never”
“When it is a brand new machine, with manufacturer’s representative present.”
“Nobody tells me when. I don’t believe they’re hot enough!”
“It’s not my job to figure it out.”
“When in doubt, I ask my supervisor / maintenance planner.”
Responses on:Responses on:““WWhen do you offset for thermal growth?hen do you offset for thermal growth?””
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Fan (very hot)
History:• 10 years of vibration amplitudes from 1.0 to 1.5 in / sec• Replaced worn bearings, every 4 to 6 months• Each shutdown resulted in an outage of half the plant• Repeatedly balanced in-place• Repeatedly realigned, (including offsets for thermal
growth)• Thermal growth offsets supplied by fan manufacturer• Manufacturer’s calculations based on one motor / fan
assembly
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Fan (very hot) Fan (very hot)
Actually there were two fans back-to-back
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Fan (very hot) Fan (very hot)
notice the exceptionallyhot area for each
outboard pedestal.
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Generator
3000 rpm
HotSteam
Turbine
A B
Noise enclosure
History:• 4 years of high vibration amplitudes• 4 different consultants (with no solutions)• thermal offsets estimated for generators internal
temperatures (same for each end) - - - - - - no actual temperatures measured
• consider temperature pedestal A relative to pedestal B
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Now, what else can magnify these vibrations?
Resonance at new operating speed
How can we tell ahead of time?
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½ HP variable speed vibration shakerRange 0 to 6,000 RPM
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Shaker large enough to shake a whole section of a paper machine
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(36) i
Not resonant
1st Resonance Frequency
2nd Resonance Frequency
Not resonant
1st Resonance Frequency
2nd Resonance Frequency
3rd Resonance Frequency
3rd Resonance Frequency
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A F G H IC D EB
ON
0.08
Testing for resonance with a shaker using a 10 division modal shape plot
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(38)mdsh ai
First resonance excited by shaker
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0.050.23 0.27 0.240.04 0.18 0.24 0.16 0.05 0.07 0.15
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5
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7
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8
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9
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Dynamic imbalance:Composed of static and couple
To counterbalance first resonance “whip” remove static imbalance
To counterbalance second resonance “whip” remove couple imbalance
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Notice: no balance weights or holes, no tough point indicated between shaft and bore
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This did not start with bad gearteeth.It started with no dynamic balance and poor assembly fitsFinally magnified by resonance with cracks forming at the node
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Distance (feet)Number of bars
Surface speed: feet/minute
Bars FtFt Minute
X = Bars/Minute
First determine what is not causing the problem
Frequency causing the barring
=
Often involves a resonance
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Barring on a roll: number of bars X roll RPM
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Equal angles
Aligned
Unequal angles
Misaligned
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Before
After alignment
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Lum
ens
Frequency CPM
Coupling bindingand resonant pipe
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Lum
ens
Fans
Frequency CPM
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Out of balance fans 30’ away from resonant headbox
Resonated section of headbox above the slice
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Lum
ens
Frequency CPM
Centri-screen drive motor
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Lum
ens
Frequency CPM
Centri-screen drive motor
Coupling bindingand resonant pipe
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Headbox
Pipe resonant to 2x RPM of pump below
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Normal
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Resonant
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Resonant
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