Machinery Malfunction Diagnosis and Correction

Vibration Analysis and Troubleshooting for the Process Industries

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

President MACHINERY DIAGNOSTICS, Inc. Minden, Electric Nevada Energy - Sugar Land, Texas Global Machinery Diagnostics Services Manager - General and

Robert C. Eisenmann, Jr.

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

PTR Hall, Cliffs, New by: Jersey 07632 The original HardPrentice Copy format of this Englewood book was previously published Pearson Education, Inc.
Copyright Assigned to Robert C. Eisenmann, Sr. by Hewlett-Packard effective June 6, 2005.

Library of Congress Cataloging-in-Publication Data

Author: This space is reserved for Library of Congress Cataloging-in-Publication Data, which PTR will insert.

Original Library of Congress Cataloging in Publication Data Eisenmann, Robert C. 1943Machinery malfunction diagnosis and correction: vibration analysis and troubleshooting for the process industries / Robert C. Eisenmann, Sr., and Robert C. Eisenmann, Jr. cm -- (Hewlett- Packard professional books) Acquisitionsp. editor: Editorial assistant: Includes index. Cover design: bibliographical references andCover design director: Eloise Starkweather-Muller Copy Editor: Art production manager: Gail Cocker-Bogusz ISBN 0-13-240946-1 Manufacturing Manager: Alexis R. Heydt Illustrations by: Robert C. Eisenmann,Robert Sr. 1. Machinery -- Monitoring. 2. Machinery -- Vibration. I. Eisenmann, C., 1970Production team: Sophie Papanikolaou, Jane Bonnell, Lisa Iarkowski, John Morgan, Dit Mosco, II. Title. III. Series. Mary Rottino, Ann Sullivan, Harriet Tellem, and Camille Trentacoste. TJ153.E355 1997 Proofreaders: 621.8'16-dc21 97-31974 This book was composed with FrameMaker. CIP

1997 PTR Prentice Hall Prentice-Hall, Inc. A Paramount Communications Company Englewood Cliffs, New Jersey 07632 The publisher offers discounts on this book when ordered in bulk quantities. For more information, contact Corporate Sales Department, PTR Prentice Hall, 113 Sylvan Avenue, Englewood Cliffs, NJ 07632. Phone: 201-592-2863; FAX: 201- 592-2249. All rights reserved. No part of these templates may be reproduced, in any form or by any means, without permission in writing from the publisher. Printed in the United States of America 10 9 8 7 6 5 4 3 2 1
Author: This space reserved for OCR ISBN to be inserted by PTR.

Prentice-Hall International (UK) Limited, London Prentice-Hall of Australia Pty. Limited, Sydney Prentice-Hall Canada Inc., Toronto Prentice-Hall Hispanoamericana, S.A., Mexico Prentice-Hall of India Private Limited, New Delhi Prentice-Hall of Japan, Inc., Tokyo Simon & Schuster Asia Pte. Ltd., Singapore Editora Prentice-Hall do Brasil, Ltda., Rio de Janeiro

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 Fluid Film Radial Bearing Clearance Measurements 165 Case History 7: Expander Journal Bearing Clearance 174 161

iv

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 B Physical Properties 795 C Conversion Factors 797 D Index 801 781

Preface

hen my son graduated from Texas A&M University, he was understandably eager to start working, and begin earning a livable salary. He accepted a maintenance engineering position at a large chemical complex, and embarked upon learning about process machinery. In the months and years that followed, he and his colleagues had many questions concerning a variety of machinery problems. From my perspective, most of these problems had been solved twenty or thirty years ago. However, it was clear that the new engineering graduates were devoting considerable effort attempting to unravel mysteries that had already been solved. The obvious question that arises might be stated as: How come the new engineers cannot refer to the history les instead of reworking these issues? A partial answer to this question is that the equipment les often do not provide any meaningful historical technical data. Major corporations are reluctant to spend money for documentation of engineering events and achievements. Unless the young engineers can nd someone with previous experience with a specic malfunction, they are often destined to rework the entire scenario. Although numerous volumes have been published on machinery malfunctions, there are very few technical references that address the reality of solving eld machinery problems. This general lack of usable and easily accessible information was a primary force in the development of this text. The other signicant driving force behind this book was the desire to coalesce over thirty-three years of experience and numerous technical notes into some type of structured order that my son, and others could use for solving machinery problems. This is a book about the application of engineering principles towards the diagnosis and correction of machinery malfunctions. The machinery under discussion operates within the heavy process industries such as oil reneries, chemxi

xii

ical plants, power plants, and paper mills. This machinery consists of steam, gas and hydro turbines, motors, expanders, pumps, compressors, and generators, plus various gear box congurations. This mechanical equipment covers a wide variety of physical characteristics. The transmitted power varies from 50 horsepower, to units in excess of 150,000 horsepower. Rotational speeds range from 128 to more than 60,000 revolutions per minute. There is a corresponding wide range of operating conditions. Fluid temperatures vary from cryogenic levels of minus 150F, to values in excess of plus 1,200F. The operating pressures range from nearly perfect vacuums to levels greater than 40,000 pounds per square inch. Physically, the moving elements may be only a few feet long, and weigh less than 100 pounds or they may exceed 200,000 pounds, and cover the length of a football eld. In virtually all cases, these process machines are assembled with precision ts and tolerances. It is meaningful to note that the vibration severity criteria for many of these machines are less than the thickness of a human hair. In some respects, it is amazing that this equipment can operate at all. When the number of individual mechanical components are considered, and the potential failure mechanisms are listed, the probabilities for failures are staggering. Considerable credit must be given to the designers, builders, and innovators of this equipment. They have consistently produced machines that are constantly evolving towards units of improved efciency, and extended reliability. The majority of machinery problems that do occur fall into what I call the ABC category. These common problems are generally related to Alignment, Balance, and incorrect Clearances (typically on bearings). Due to the continual appearance of these malfunctions, an entire chapter within this text has been devoted to each of these subjects. Machines also exhibit other types of failures, and a sampling of common plus unique problems are described within this book. Some people might view this document as a textbook. Others might consider this to be a reference manual, and still other individuals might use this book for troubleshooting. It has also been suggested that this book be categorized as a how to do it manual. Since 52 detailed case histories are combined with numerous sample calculations and examples, each of these descriptions are accurate and applicable. In the overview, the contents of this book cover a variety of machinery malfunctions, and it engages the multiple engineering disciplines that are required to solve real world problems. Regardless of the perception, or the nal application, this is a book about the mechanics, measurements, calculations, and diagnosis of machinery malfunctions. I sincerely hope that this text will provide some meaningful help for students, for new graduates entering this eld, as well as provide a usable reference for seasoned professionals. Finally, I would like to extend my deepest personal thanks to John Jensen of Hewlett Packard for the inspiration, encouragement, and opportunity to write this book. I am further indebted to John for his detailed and thorough review of much of the enclosed material. I would also like to thank Ron Bosmans, Dana Salamone, and Pamela Puckett for their constructive comments and corrections. Robert C. Eisenmann, Sr., P.E. October 1997