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Vibration Spike During Start-Up of An Integrally Geared Compressor

During testing of a new 3-stage air compressor, abnormally high vibrations were detected at the first two stages during start-up that prevented the machine from reaching full speed. An investigation found the root cause was the upward-driven low-stage rotor experiencing momentary high displacement in the bearing during start-up due to low aerodynamic loads. Replacing the four-pad bearings with five-pad bearings reduced displacement and allowed smooth start-up. The lesson learned is upward-driven pinions in light-weight rotors can experience high transient vibrations during start-up due to bearing displacement.

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Mohammadreza Galeban
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131 views18 pages

Vibration Spike During Start-Up of An Integrally Geared Compressor

During testing of a new 3-stage air compressor, abnormally high vibrations were detected at the first two stages during start-up that prevented the machine from reaching full speed. An investigation found the root cause was the upward-driven low-stage rotor experiencing momentary high displacement in the bearing during start-up due to low aerodynamic loads. Replacing the four-pad bearings with five-pad bearings reduced displacement and allowed smooth start-up. The lesson learned is upward-driven pinions in light-weight rotors can experience high transient vibrations during start-up due to bearing displacement.

Uploaded by

Mohammadreza Galeban
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Vibration Spike During

Start-up of an Integrally
Geared Compressor

Qinling Shen
Patrick J. Smith
DECEMBER 14-16, 2021
Presenters
Qinling Shen is a Machinery Engineer at Air Products and Chemicals, Inc. based in
Detroit, MI. She started her career with Air Products and Chemicals, Inc. in 2009
after graduating from Drexel University with a Master Degree of Mechanical
Engineering.

Patrick Smith is a Principal Engineering Associate of Machinery in the Operational


Excellence Technical Team at Air Products and Chemicals, Inc. He is based in
Allentown, PA, and his position includes being the Machinery Technology
Manager. Patrick started his career with Ingersoll-Rand in the Pump Division in
1982 after graduating from Villanova University with a Bachelor of Mechanical
Engineering degree. He joined Air Products and Chemicals, Inc. in 1986 working as
a rotating machinery specialist.
Abstract

During workshop testing of a new 3-stage main air compressor,


higher than expected vibration levels were detected at stage 1 and
2 at start up. They are high enough that the machine could not be
brought to the full speed. This case study will cover the basic design
of the compressor, the history of the problem, the root cause
analysis, conclusions and corrective action.
Outline

1. Background – Machine Configuration

2. The Problem

3. Investigation

4. Root Cause & Solutions


Background – The Compressor
New Main Air Compressor for a middle size Air Separation Unit (ASU).

Main Air Compressor brings air flow into the system for feeding the
downstream process.
* 3-stage, 2-pinion, integrally geared centrifugal compressor
* Atmospheric air suction pressure and 6 bara (87 psia) at final discharge
* Driven by 5500 HP, 1800 rpm induction motor, no VFD

Pinion Speeds:
* Stage 1&2 14,135 rpm
* Stage 3 20,062 rpm
Background – The Compressor
Single vibration probe adjacent to
each impeller

Thrust collars on the LS and HS


pinions and thrust bearings on the
BG.

Stationary labyrinth air-seal and


oil-seal on each stage
The Problem
The machine was initially set in the new testing bed at the supplier’s newly
established workshop. It was a packaged type compressor testing with the
workshop coupling and motor. The motor was driven by a VFD.

When the machine was in cold condition, the 1st and 2nd vibration exceeded
the vibration transmitter range (0~5 mils) during the startup, and it tripped
the machine.

The API vibration level for a new machine at the operating speed
* Stage 1&2 0.9 mil
* Stage 3 0.8 mil
12000
In U.S. Customary units, mils: A= 𝑁
A = amplitude of unfiltered vibration, (mil) true peak-to-peak
N = maximum continuous speed, rpm
The Problem

The VFD ramping speed was changed from 50 rpm per second to 5 rpm per
second which helped in starting the machine successfully during the 3rd
attempt.

The performance test was done and during that period the vibration for all 3
stages was below the API limits. Oil supply temperature was stable at 46 deg C
(115 deg F).

The machine was tripped after the 110% overspeed test and it couldn’t be re-
started when the machine was in warm condition due to high 1st and 2nd stage
vibrations.
The Problem

The large compressor vibration spike during the compressor start-up was not
expected and the compressor OEM could not explain it nor the difference in
behavior with cold versus warm oil. The compressor supplier was concerned
there was possible mechanical issue.
Investigation – Fishbone Diagram
Investigation
Potential Root Causes Considered:
Bearing was mounted loose or bearing clearance was not set properly
✓ Bearing clearance was checked and all was within the design tolerance

Instrumentation noise
✓ Instrument probe and cabling installation was inspected. Everything was fine.

Test Stand and its VFD were not set properly


✓ Test Stand and VFD settings were verified. Nothing was found.

Longer than usual flexible coupling was used on the new test bed
✓ Used a shorter coupling with a rigid steel spool piece for replacing the original long
coupling. Machine could be started smoothly at cold condition while it still couldn’t
be started at warm condition.
Investigation
Potential Root Causes Considered:
It was decided to send the machine to a different facility for more in depth
testing. The initial test showed the same behavior as the previous shop tests.

The collected data and Fishbone Diagram were reviewed.


The Solution
Root Cause:
The LS rotor for the 1st and 2nd stages in the compressor is up driven. For up
driven pinions during start-up, the initial torque can push the rotor upward.
With the low aero load at start-up, the rotor can instantaneously move upward
in the pinion bearings.

Besides, the LS rotor on this machine is installed with smaller impellers and it’s
the lightest weight LS pinion assembly being installed in this compressor frame
size.

Bull Gear
HS rotor for Stg 3 LS rotor for Stg 1 and 2
The Solution
Root Cause:
The 4-pad, load between pad tilting pad pinion bearings were replaced
with a 5-pad, load on pad tilting pad bearings.

With the same clearance (7 mils), the 4-pad design will lead to more
displacement than the 5-pad one due to the geometric arrangement.

Before After
The Solution
Root Cause:
Brg Clearance = Factor x Lift → Lift = Brg Clearance ÷ Factor

Vibration Probe is detecting the Lift Displacement

Bearing Clearance, Lift and Factor Table*

* By Robert C. Eisenmann Sr.


Tilt-Pad Bearing Preload, Sulzer Technical Review 2/2004
The Solution
The 5-pad design results in less shaft displacement in the bearing. On
start-up with the new bearings, the vibration spike was much lower and
the test results were accepted.

The machine was able to be started smoothly in both cold and warm
conditions.
Lessons Learned
Upward driven pinions can be driven to full bearing displacement during
start-up when the gear reaction forces exceed the static load due to the
pinion weight. This cause momentary high vibrations. And, if the
displacement exceeds the range of the vibration transmitter this can lead
to a bad quality signal from the vibration probe until the pinion vibration
settles down. This will trip the machine if the vibration protection system
is configured to trip on bad quality with no time delay.

Different bearing designs can help reduce the effect, but if it is desired to
not incorporate a time delay, the maximum shaft displacement for light
weight upward driven pinions should be considered when selecting the
vibration transmitter range.
Questions?

Thanks!

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