Suri Rotor Balancing
Suri Rotor Balancing
Suri Rotor Balancing
Topics
Introduction Definition and Concepts Sensors & Measurement One Plane Balancing Methods
Influence
Gyroscopic and Coriolis effects Speed-dependent bearing stiffness & damping Damping raises the critical speeds X and Y motions are coupled Rotor whirling can be self-excited at frequencies different from the forcing frequency Rotor damping can produce whirl instability
Courtesy of Prof. John Vance Texas A&M
Introductionsome facts
Mass Unbalance is the most common malfunction of
rotating machinery (50% or even more). It produces excessive synchronous forces on bearings and foundation, and also vibrations on the machine. Unbalance occurs due an unequal distribution of mass about the rotating centerline or shaft axis. Balancing is the process of attempting to improve the mass distribution of a body so that it rotates in its bearings within specified vibration level. Most balancing jobs are performed below the first critical. Balancing above the first critical may require several techniques and be even supported by a rotor model
Why Balancing?
Reliability-Increased bearing life Reliability-Decreased operating stresses that could lead to cracking and early failure Save energy (3 to 5% reduction is typical) Maintain optimum product quality Minimize operator fatigue Noise reduction to meet OSHA requirements Enhance Customer satisfaction
Unbalance
Center-hung Rotors Over-hung Rotor
WF Power
5.00E-03 1.00E-02 1.50E-02 2.00E-02 2.50E-02 0.00E+00
1 = R .B rg H sg Y R .B rg H sg Z 3 = G .B ox Y G .B ox -Z G .B ox X = Ba se Y
2 =
4 =
5 =
7 9 = L. Br g H sg Y L. Br gH sg X
Center hung
10 =
12 = M ot or Y ot or 14 15 = = M 16 M ot or =
Overhung
13 =
Z ot or C ur L. Br gH
re
nt sg
Before Balancing
Must establish that IX vibration is caused by mass unbalance
A variety of other mechanisms can produce synchronous rotational speed vibration. Some examples: Misalignment or Other Preload Excessive Bearing Clearance Bent Shaft or Rotor Cracked Shaft Soft Foot Gyroscopic Effects Load or Electrical Influence Gear Pitch Line Runout Locked Coupling Foundation
Although the process of balancing is relatively straight forward, there are six basic issues that must be checked to assure a satisfactory outcome: 1. Check machine maintenance history 2. Check the rotor for mechanical integrity and remove dirt/debris so that it resembles as closely as possible the original condition 3. Verify that all fasteners are tight 4. Verify that the bearings are in good condition so that rotor is properly constrained 5. Verify that the rotor is securely attached to the shaft so that it cannot slip or move from the original position 6. Verify that the source of unbalance is constant so that unexpected movement cannot occur 7. Verify that the balancing operation will not be performed close to a natural frequency
centrifugal forces.) 2. Heavy Spot (unbalance spot on the rotor) 3. High Spot (location of vibration peak) 4. Synchronous (rotor speed or 1X ) Vibration 5. Runout (Total radial displacement of the rotor) 6. Eccentricity (shaft radial displacement from the geometric axis, U = eM) 7. Units of Unbalance (mass times distance from shaft axis) 8. Centrifugal Force (operative force causing vibration) 9. Slow Roll and Slow Roll Compensation (slow shaft rotation to determine runout and subtracting it to balance the rotor)
Graphical Illustration
Eccentricity
The eccentricity is the amount of displacement between the center of gravity and the rotating axis
Graphical Illustration
Centrifugal Force
Rotating Shaft with an Eccentric Mass Moving in a circular path experiences centrifugal force
Types of Unbalance
1. Static Unbalance 2. Quasi-Static Unbalance 3. Couple Unbalance 4. Dynamic Unbalance
Graphical Illustration
Static Unbalance
Graphical Illustration
Quasi-static unbalance
Graphical Illustration
Couple Unbalance
Graphical Illustration
Dynamic Unbalance
Balancing Instrumentation/issues
Phase Measurement
1. Trigger Sensor Method 2. Strobe Method
Balancing Instrumentation
meter Single channel analyzer with phase trigger Dual channel analyzer with phase trigger Accurate phase measurement is essential for a success full balancing
Proximity Probe
Diagram of tip of proximity probe
Velocity Probe
Accelerometer
Cutaway drawing of accelerometer
Types of Balancing
Shop Balancing
Often use balancing small rigid rotor/components of at low speed Do not mimic real machine support and constraints High speed turbomachinery balancing is done in vacuum tight pits
Field Balancing
Balancing-Rotor Configurations
Center Hung Configuration (thin rigid rotors) Over Hung Configuration (Many fan), Vibration levels are much more severe and much harder to balance, usually due resonance and gyroscopic effects.
Unbalance
Center-hung Rotors Over-hung Rotor
WF Power
5.00E-03 1.00E-02 1.50E-02 2.00E-02 2.50E-02 0.00E+00
1 = R .B rg H sg Y R .B rg H sg Z 3 = G .B ox Y G .B ox -Z G .B ox X = Ba se Y
2 =
4 =
5 =
7 9 = L. Br g H sg Y L. Br gH sg X
Center hung
10 =
12 = M ot or Y ot or 14 15 = = M 16 M ot or =
Overhung
13 =
Z ot or C ur L. Br gH
re
nt sg
b b FA = Fc me 2 = l l
Fs = a b me 2 + me 2 = me 2 l l
FB =
a a Fc me 2 = l l
Influence Coefficient
1. An influence coefficient or influence vector, is a complex number that describes how the 1X vibration of a machine will change when a balance weight is added to the machine. Or, how a balance weight will influence the amplitude and phase of the vibration of the rotating machine. 2. With a valid influence coefficient, the required correction weight can be calculated in one step. 3. When balancing, it is important to remember that a change in the machine since the last balancing operation may have changed the influence coefficient.
Procedure for Single - Plane Balancing Using Influence Coefficient Method Cont..
5. Start the rotor and record its vibration amplitude and phase measured at the same speed as step #3. 6. Determine the size of the correction mass and its position on the rotor. 7. Remove the trial weight and add the calculated correction mass. 8. Start the rotor and record its vibration amplitude and phase at the same speed 9. If the new vibration data is within an acceptable range, then the balancing job is complete; otherwise, either a trim balance is required (back to Step #4) or unbalance may not be the problem.
General Procedure of 4 Run Without Phase Balancing Method (Example Contd) 2nd Run
5. Start the rotor and let it reach typical operating speed. 6. Measure the new vibration amplitude. For the example, the vibration amplitude is 6.6 mils. 7. Draw a circle with radius equal to the new vibration amplitude (6.6 units) from the 0 location on the original circle as the center in Step #2.
Two-Plane Balancing Procedurewithout phase measurements [L. J. Everett, Texas A&M, 1987)
1. Run unbalanced rotor, measure vibration magnitudes at 2 planes(V1). 2. Locate a trial mass on plane 1, run and measure vibration magnitudes in two planes. 3. Change position of trial mass in plane 1, run and measure vibrations. 4. Perform step 3 again for a new position in plane 1, measure vibrations. 5. Perform steps 2-3-4 for plane 2. At this point the measured vibration magnitudes can be used to obtain unbalances graphically: 6. Draw three circles. Centers and radii of circles are based on measured vibration magnitudes in plane 1and angles. 7. Measure the distance (d) from the origin to the approximate intersection and angle () from the real axis to the line between the origin and intersection.
8. Divide d by trial mass magnitude (w) to obtain I 11. Subtr act from 180 deg to obtain the angle. 9. Draw three more circles as in step 6, using centers and radii vibration magnitudes in plane 2. Use the circles to compute I 21 and the angle as was done in step 7-8 10. Again draw three circles as in step 6 using centers and radii measured in plane 1 from 3 more unbalanced mass in plane 1. Again compute I 12 and the angle as was done in step 7-8 11. Repeat step 10 drawing circles with centers and radii from vibration magnitudes in plane 2 from 3 more unbalanced mass in plane 1. 12. Use obtained values for I s and vibration magnitudes to solve the equation for unbalance.
Balancing Standard
Shop Balancing Standards
1. ISO Standard No. 1940 on Balance Quality of Rotating Rigid Bodies provides an easy guide for determining recommended balance tolerances. 2. American National Standards Institute (ANSI) adopted this standard in 1989 with ANSI S2.19-1989. 3. API has different set of standards
Balance quality grades for various groups of representative rigid rotors Source: ISO 1940-/1
Maximum permissible residual specific unbalance value corresponding to various balance quality grades Source: ISO 1940/1 (SI Units)
Balancing Standard