Machinery Malfunction

Diagnosis and Correction

Vibration Analysis and Troubleshooting

for the Process Industries

Robert C. Eisenmann, Sr., P.E.

Principal Mechanical
President — MACHINERYEngineer - Sulzer Hickham
DIAGNOSTICS, Inc.
Inc. — - La Porte,
Minden, NevadaTexas

and

Robert C. Eisenmann, Jr.

Manager of Rotating Equipment — HAHN & CLAY — Houston, Texas
Rotating Equipment Technical Authority - BP Products North America - Houston, Texas

PTR
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Eisenmann, Robert C. 1943-

Machinery malfunction diagnosis and correction: vibration analysis and troubleshooting for
the process industries / Robert C. Eisenmann, Sr., and Robert C. Eisenmann, Jr.
Acquisitionsp. cm -- (Hewlett- Packard professional
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1. Machinery -- Monitoring. 2. Machinery
Manufacturing Manager: Alexis R. Heydt -- Vibration.
Illustrations I. Eisenmann,
by: Robert C. Eisenmann,Robert
Sr. C., 1970-
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.
 To Mary Rawson Eisenmann,
Wife and Mother
Who Always Kept The Home Fires Burning
While The Boys Went Off To Play With Their Machines
Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Chapter 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machinery Categories 4
Chapter Descriptions 5
Bibliography 8

Chapter 2 - Dynamic Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Malfunction Considerations and Classifications 9
Fundamental Concepts 10
Vector Manipulation 21
Undamped Free Vibration 28
Case History 1: Piping System Dynamic Absorber 31
Free Vibration with Damping 37
Forced Vibration 45
Case History 2: Steam Turbine End Cover Resonance 55
Torsional Vibration 58
Bibliography 66

Chapter 3 - Rotor Mode Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Mass and Support Distribution 67
Case History 3: Two Stage Compressor Rotor Weight Distribution 72
Inertia Considerations and Calculations 74
Damping Influence 96
Stiffness Influence 105
Critical Speed Transition 120
Mode Shape Measurement 130
Case History 4: Vertical Generator Mode Shape 137
Analytical Results 142
Case History 5: Eight Stage Compressor Mode Shape Change 143
Bibliography 148

Chapter 4 - Bearings and Supports . . . . . . . . . . . . . . . . . . . . . . . . 149

Fluid Film Radial Journal Bearings 150
Case History 6: Shaft Position In Gas Turbine Elliptical Bearings 161
Fluid Film Radial Bearing Clearance Measurements 165
Case History 7: Expander Journal Bearing Clearance 174

iv
v

Bearing Supports — Measurements and Calculations 179

Case History 8: Measured Steam Turbine Bearing Housing Stiffness 181
Case History 9: Measured Gas Turbine Bearing Housing Stiffness 185
Bearing Housing Damping 187
Fluid Film Thrust Bearings 188
Rolling Element Bearings 193
Before Considering Bearing Redesign 196
Bibliography 198

Chapter 5 - Analytical Rotor Modeling . . . . . . . . . . . . . . . . . . . . 199

Modeling Overview 199
Undamped Critical Speed 201
Case History 10: Mode Shapes for Turbine Generator Set 206
Case History 11: Torsional Analysis of Power Turbine and Pump 208
Stability and Damped Critical Speed Calculations 213
Case History 12: Complex Rotor Damped Analysis 217
Forced Response Calculations 222
Case History 13: Gas Turbine Response Correlation 226
Case History 14: Charge Gas Compressor with Internal Fouling 230
Case History 15: Hybrid Approach To A Vertical Mixer 236
Bibliography 242

Chapter 6 - Transducer Characteristics . . . . . . . . . . . . . . . . . . . 243

Basic Signal Attributes 244
Proximity Displacement Probes 253
Velocity Coils 272
Piezoelectric Accelerometers 278
Pressure Pulsation Transducers 285
Specialized Transducers 288
Aspects of Vibration Severity 294
Bibliography 302

Chapter 7 - Dynamic Signal Characteristics . . . . . . . . . . . . . . . 303

Electronic Filters 303
Time and Orbital Domain 316
Time and Frequency Domain 333
Case History 16: Steam Turbine Exhaust End Bearing Dilemma 343
Signal Summation 347
Case History 17: Opposed Induced Draft Fans 349
Amplitude Modulation 353
Case History 18: Loose and Unbalanced Compressor Wheel 356
Frequency Modulation 359
Case History 19: Gear Box with Excessive Backlash 362
Bibliography 364
 vi

Chapter 8 - Data Acquisition and Processing . . . . . . . . . . . . . . . 365

Vibration Transducer Suite 365
Recording Instrumentation 369
Data Processing Instrumentation 379
Data Presentation Formats 383
Bibliography 394

Chapter 9 - Common Malfunctions . . . . . . . . . . . . . . . . . . . . . . . 395

Synchronous Response 395
Mass Unbalance 398
Bent or Bowed Shaft 400
Case History 20: Repetitive Steam Turbine Rotor Bow 402
Eccentricity 406
Case History 21: Seven Element Gear Box Coupling Bore 407
Shaft Preloads 410
Resonant Response 416
Case History 22: Re-Excitation of Compressor Resonance 419
Machinery Stability 422
Case History 23: Warehouse Induced Steam Turbine Instability 429
Case History 24: Pinion Whirl During Coastdown 432
Mechanical Looseness 435
Case History 25: Loose Steam Turbine Bearing 438
Rotor Rubs 440
Cracked Shaft Behavior 443
Case History 26: Syngas Compressor with Cracked Shaft 446
Foundation Considerations 449
Case History 27: Floating Induced Draft Fan 451
Case History 28: Structural Influence of Insufficient Grout 454
Bibliography 458

Chapter 10 - Unique Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

Parallel Shaft - Two Element Gear Boxes 459
Case History 29: Herringbone Gear Box Tooth Failure 466
Epicyclic Gear Boxes 470
Case History 30: Star Gear Box Subsynchronous Motion 477
Process Fluid Excitations 483
Case History 31: Boiler Feed Water Pump Splitter Vane Failures 496
Case History 32: Hydro Turbine Draft Tube Vortex 499
Electrical Excitations 507
Case History 33: Motor With Unsupported Stator Midspan 515
Case History 34: Torsional Excitation From Synchronous Motor 519
Reciprocating Machines 522
Case History 35: Hyper Compressor Plunger Failures 526
Bibliography 534
vii

Chapter 11 - Rotor Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535

Before Balancing 536
Standardized Measurements and Conventions 539
Combined Balancing Techniques 545
Linearity Requirements 547
Case History 36: Complex Rotor Non-Linearities 548
Single Plane Balance 552
Case History 37: Forced Draft Fan Field Balance 560
Two Plane Balance 564
Case History 38: Five Bearing, 120 MW Turbine Generator Set 575
Weight Sequence Variation 586
Case History 39: Three Bearing Turbine Generator at 3,600 RPM 588
Case History 40: Balancing A 36,330 RPM Pinion Assembly 597
Three Plane Balance 606
Static-Couple Corrections 616
Multiple Speed Calculations 618
Response Prediction 619
Trim Calculations 622
Balancing Force Calculations 623
Balance Weight Splitting 626
Weight Removal 628
Shop Balancing 629
Bibliography 636

Chapter 12 - Machinery Alignment . . . . . . . . . . . . . . . . . . . . . . . . 637

Pre-Alignment Considerations 638
Optical Position Alignment 649
Case History 41: Hyper Compressor Position Alignment 654
Laser Position Alignment 658
Optical and Laser Bore Alignment 660
Wire Bore Alignment 663
Case History 42: Hyper Compressor Bore Alignment 667
Shaft Alignment Concepts 669
Rim and Face Shaft Alignment 673
Reverse Indicator Shaft Alignment 681
Optics, Lasers, and Wires for Shaft Alignment 691
Hot Alignment Techniques 692
Case History 43: Motor to Hot Process Pump Alignment 697
Bibliography 702
 viii

Chapter 13 - Applied Condition Monitoring . . . . . . . . . . . . . . . . 703

Maintenance Philosophies 703
Condition Monitoring 705
Machinery Performance 706
Vibration Response Data 708
Bearing Temperature Data 711
Data Trending 712
Case History 44: Four Pole Induction Motor Bearing Failure 714
Case History 45: Cracked Gas Compressor Intermittent Instability 718
Case History 46: High Stage Compressor Loose Thrust Collar 721
Pre-Startup Inspection and Testing 724
Startup Inspection and Testing 732
Case History 47: Turbine Solo Operation with Tapered Journal 735
Case History 48: Coupled Turbine Generator Startup 736
Case History 49: Heat Soak and Load Stabilization 739
Bibliography 742

Chapter 14 - Machinery Diagnostic Methodology . . . . . . . . . . . 743

Diagnostic Objectives 744
Mechanical Inspection 744
Test Plan Development 745
Data Acquisition and Processing 746
Data Interpretation 749
Conclusions and Recommendations 750
Corrective Action Plan 750
Case History 50: Steam Turbine Electrostatic Voltage Discharge 751
Case History 51: Barrel Compressor Fluidic Excitation 758
Case History 52: High Speed Pinion Instability 766
Conclusions on Diagnostic Methodology 770
Bibliography 770

Chapter 15 - Closing Thoughts and Comments . . . . . . . . . . . . . 771

Economic Reality 772
Corporate Considerations 773
Presentation of Results 778
Silver Bullets 780

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781
A — Machinery Diagnostic Glossary 781
B — Physical Properties 795
C — Conversion Factors 797
D — Index 801