Service Summary

Customer Siemens Westinghouse/ Petronas Carigali

Customer Contact Mr. Qooshari
Job Location On board PLATFROM TEMBUNGO-A
Date of Service 07-10/01/03
Report Date 14/01/03
Machinery Gas engine generator
Workscope To carry out Vibration Analysis on the Alternator of Gas engine
generator which was running with high vibrations after generator
repair

Summary The maximm vibrations on the Generator bearing were

found in the range of 9 to 10 mm/sec which is well within the
acceptable range for this category of machines. However
further reduction is possible by replacing the damaged
coupling rubber , better alignment and reducing spread in
engine exhaust temperature and stabilize machine speed.

Job Done By Rashid Kadir

Report Done By Rashid Kadir

Report Approved By Rashid Kadir

1. INTRODUCTION AND WORKSCOPE

was requested by SIEMENS WESTINGHOUSE to carry out vibration analysis

on generator of Gas engine Generator G-500 to determine the cause of high
vibration and check for possibility to reduce the vibrations to acceptable level.

2. EQUIPMENT USED

2.1 The equipment used included:

i) CSI 2120 machinery analyzer Dual channel
ii) CSI accelerometers ( 100 mv/g )
iii) Photo tachometer
iv) Related cables & Magnetic Base.
v) Analyzer related software.
vi) Customers Optalign Laser alignment kit.

3. MACHINE HISTORY AND BACKGROUND

3.1 The sixteen cylinder Caterpillar engine drives the two bearing generator at 1200
rpm through a flexible coupling.

3.2 The generator was repaired and overhauled at SIEMENS WESTINGHOUSE

after casting new bearing housing and regular inspection / repair of the
generator.

3.3 The maximum no load vibrations at the test bench in workshop was 3.45 mm/sec
rms.

3.4 After carrying out dial gauge alignment the machine was loaded to the normal
maximum load of 300 KW. It was observed that the vibrations at the generator
bearings ( both drive end & non drive end ) was found reaching magnitudes upto
19.83 mm/sec .
3.5 As a trouble shooting measure the spark plugs of few cylinders were replaced
based on the electronic ignition CPU monitoring system readings. After this
change the vibration reduced to 11 mm/sec. Based on the reduction all the spark
plugs were replaced. After replacement the vibrations reduced to about 9.7
mm/sec. The machine was kept in operation.

3.6 Based on earlier analysis recommendations were made for replacement of

coupling rubber insert and inspect the crack on the base frame.

4. MEASUREMENT SETUP AND PROCEDURES.

4.1. The vibrations were recorded in the three principal directions at the Generator
and Engine Front ,rear bearing positions. Vibration amplitudes in velocity
mm/sec (rms) was used as the basis of measure and vibration readings were
recorded in the frequency range of 0-500 Hz.

4.2. In addition to spectrums, phase analysis & order tracking analysis was carried
out.

4.3. The vibration data was collected at idle speed, normal rated speed, 100 KW
load, 200 KW load and finally at 300 KW load. Vibration and operation data were
recorded during this process.

4.4. Finally hot alignment, cold alignment, soft foot checks and corrections were
made using the laser alignment system which adopts the reverse indicator
method.

5. OBSERVATIONS

5.1. The initial vibrations recorded on 08/01/03 showed a maximum reading of about
9.6 mm/sec at the generator bearings in the drive end as well as non drive end.
The spectrum at these locations showed a dominant component at 1x rpm. The
 tbgA - GAS GENERATOR-300 KW
G500-300 -A1A ALTERNATOR DE AXIAL
spectrum at the 7
Route Spectrum
08-JAN-03 17:17:00

engine and R
6 OVRALL= 7.34 V-DG
RMS = 7.33
M LOAD = 100.0
other locations S 5 RPM = 1210.
RPS = 20.17
Ve
loc
showed the ity
4
in
presence of m
m/
Se 3
sub harmonic c

2
(0.5x,1.5x…) and
their orders which 1

is typical pattern in 0
Ordr: 2.510
0 2 4 6 8 10 12 14 16 18 20 Freq: 50.63
engines . The Frequency in Order Spec: 5.283

generator bearing vibration spectrums especially the axial direction showed a

dominant 1.5x and 2.5 x component as shown in adjoining plot . The amplitudes
at these frequencies was found fluctuating with the same frequency as the
variation in the rpm observed.
5.2. The CPU showed almost a constant reading of CPVAG at 113 for all cylinders,
but the engine cylinder exhaust gas temperatures show most of the cylinders
with a exhaust gas temperature between 580 to 600 degree centigrade except
for L-10 at 500 degree centigrade and R-11 at 450 degree centigrade.
5.3. Phase analysis showed that the alternator bearings were in phase in the
horizontal direction and it was out of phase with the engine horizontal vibrations
by about 100 degrees. The alternator axial vibrations were also in phase and
about 130 degrees phase shift was observed between the generator and engine
axial vibrations. But due to the continuos fluctuation in machine speed the phase
readings and amplitudes were not steady.
5.4. During the load down and no load run of the generator the 1x rpm component at
the generator bearing was tracked. The vector was almost steady with only a
minor variation of 20 degrees from load to no load but the amplitude increased
from 3.2 mm/sec to about 9.0 mm/sec. The order tracked data during coast down
is as shown in figure above.
5.5. The graph below shows the variation of vibrations at the generator bearings in
the horizontal and axial directions from no load to full load of 300 kw. The final
point shows the reading after alignment on 09/01/03 .The Points represented by:
E1 Stands for engine non drive end bearing.
E2 stands for engine drive end bearing.
A1 stand for alternator drive end bearing position.
A2 stand for alternator non drive end bearing position.
and the suffix H ,V, A stand for horizontal, vertical and axial directions
respectively.
 12

10

8
A1H
A2H
6
A1A
A2A
4

0
ZERO LOAD 100 KW 200 KW 300 KW FULL LOAD
AFTER
ALIGNMENT

5.6. The table below provides the data observed from no load to full load condition.
Point Location Zero load 100 KW load 200 KW 300 KW load After alignment (
Load 300 KW load)
E1V 5.765 10.44 7.339 7.8 6.045
E1H 2.526 2.389 3.003 3.297 3.249
E1A 2.706 1.999 3.403 4.56 4.746
E2V 5.528 3.403 3.776 4.162 4.086
E2H 5.082 4.56 4.028 4.428 6.032
E2A 2.764 2.146 3.212 4.076 3.659
A1V 3.379 2.633 3.583 4.679 4.028
A1H 4.419 6.399 8.677 10.29 9.656
A1A 3.055 2.95 4.181 6.942 6.399
A2V 2.778 2.009 3.285 4.481 2.813
A2H 4.274 5.369 8.306 9.119 9.05
A2A 3.022 2.937 4.124 7.467 6.712

5.7. The graph below shows the same data in graph format.
 12
ZERO LOAD
10

8 100 KW

6
200 KW
4

2 300 KW

0
FULL LOAD AFTER

E1V E1H E1A E2V E2H E2A AI

V
A1H 1A A2V A2H A2A ALIGNMENT
A

5.8. The alignment readings were taken in hot as well as cold condition . The hot
alignment readings were :

Vertical offset -0.0084”

Vertical face gap 0.0067 “
Horizontal Offset 0.0020”
Horizontal Gap 0.0046”

The offset reading was decreasing with decrease in temperature indicating the cold
alignment offset was not present. The cold alignment reading before correction was:
Vertical offset -0.0011”
Vertical face gap 0.0014“
Horizontal Offset 0.0006”
Horizontal Gap 0.0043”

5.9. Soft foot check showed that the maximum deflection was 0.06 mm at the front
left foot, as it was 0.02 mm at other feet.
5.10. Based on the desired offset 0.012” shims were added in the front foots and
0.021” shims were added at the rear foot.

5.11. The final alignment readings were

Vertical offset 0.007”
Vertical face gap -0.0034“
Horizontal Offset 0.0006”
Horizontal Gap 0.0001”

5.12. The machine was put on load and there was no major improvement in vibrations
observed so the unit was stopped and the hot alignment rechecked. The
readings observed were
Vertical offset -0.0041”
Vertical face gap -0.0053“
Horizontal Offset 0.0008”
Horizontal Gap 0.0006”

5.13. Cold alignment readings taken after a duration of 20 minutes were

Vertical offset -0.0007”
Vertical face gap -0.000“
Horizontal Offset 0.0005”
Horizontal Gap 0.0018”
CONCLUSION & RECOMMENDATIONS

 The absence of any high frequency components in the spectrum at the alternator
indicates absence of any bearing faults. The normal vibrations level at 1200 rpm
no load condition and steady phase during loading indicate absence of lateral
resonance condition. At no load condition indicates that unbalance in the rotor is
not a cause of high vibration. The in phase readings between drive end and non
drive end bearing rules out the possibility of casing distortion or bent rotor .

 The high horizontal vibrations with dominant 1x and a minor 4x coupled with the
phase difference between engine and alternator, indicates possibility of
misalignment. This was confirmed by the offset observed during the hot
alignment check the first and second time. This coupled with the damage of the
rubber insert could escalate the problem. The damage in the rubber could be the
cause of the abnormal alignment readings observed.The other major source of
the problem could the speed fluctuation and unbalanced firing in the cylinder
which can create torsional pulsation’s having a cross effect in lateral vibrations.
This has been proved by the fact that by changing the spark plugs the vibration
levels reduced.

 However the present vibrations are well within the normal acceptable range for
this category of machines which permit levels as high as 20 mm/sec at the
alternator bearings. So steady state operation at this level should not a cause of
concern. Kindly refer to attachment 2 for the standards on vibration limits. Further
improvement could be achieved by replacing the coupling rubber and providing
the right cold offset so that we can achieve good hot alignment
readings.Improvement in engine operating conditions would also provide more
stable vibration levels, which are fluctuating now.