UTP Adjunct Lecture 2016

Mechanical Vibration
Title : Fundamental of Casing
Vibration Analysis
Khairul Fata b Ahmad Asnawi,
Staff Engineer (Turbomachinery),
PETRONAS Carigali Sdn. Bhd.,
Sarawak Gas Operation, Miri.
20 July 2016

About Lecturer
Khairul Fata b Ahmad Asnawi
11 years with PETRONAS. Currently, Staff Engineer (Rotating Equipment) in Sarawak Gas Operations,
PCSB since 1st April 2016.
Previous job functions: 2005 2008 : Mechanical Rotating Engr, PP(T)SB
2008 2009 : Maintenance Planner (Aromatics Plant), PP(T)SB
2010 2011 : Senior Engineer Turbomachinery, PP(T)SB; and, Head Turbomachinery Group for
Plant Major Turnaround 2011
2012 2013 : Terminal Maintenance Manager, Oil Movement & Shipping Facilities, PP(T)SB
2013 2016 : Staff Engineer (Rotating Equipment), Sarawak Operations, PCSB
Had BE (Hons) Mechanical from University Technology PETRONAS, Tronoh, Perak in 2004
Board of Engineer Malaysia, Graduate Engineer
Married with 2 kids
Hobby: Travel (Overland), Running, Cycling and Land Rover

Introduction

In industry, vibration monitoring is a part of Condition Based Monitoring (CBM) Program.

Vibration monitoring with good analysis can prevent catastrophic failure to the equipment.

Early detection of
equipment failure can be
detected by Vibration
Analysis

There a few vibration monitoring technique such as rotor vibration and casing vibration. In this
lecture, focus is on the casing vibration. Casing vibration is off-line method gathering machine
vibration data and analyzed the data at workstation.

Vibration data gathering at site

Vibration analysis plots

Rotor assembly can be simplified as a spring-mass system. Rotor is the mass, bearings is the
springs with stiffness and casing is the fixed based or reference.

Foundation/ casing
[Fixed base]

Spring [Stiffness]

Mass
Spring- mass system

Rotor assembly

There are two types of bearing in industry, one is anti-friction and another one is hydrodynamic
bearing. Anti-friction bearing vibration is more suitable to be monitored by casing vibration
method.

Anti-friction bearing (low-moderate speed

and load)

Hydrodynamic bearing (high speed and load)

Equipment produces various sinusoidal vibration at various frequency. These vibration merge to
become complex wave form measured by the vibration instrument. Then the instrument isolate
vibration according to each frequency to create frequency domain spectrum.

Vibration data gathering

FFT

Complex Wave form

Frequency domain

Analysis is done by determine the dominant peak. Dominant peak contain the frequency (fault)
and amplitude (severity).

Amplitude (mm/s)

Dominant peak

Frequency (Hz)

Common fault to be discussed (80% fault

observed in industry):
1. Unbalance
2. Misalignment

UNBALANCE occur when the rotor become non-homogeneous where the mass distribution is not
even. This mass generate unbalance force and create vibration. Unbalance force depend on the
unbalance mass and speed of the rotor.

Rotor material shall be near-homogenous so that

unbalance mass is reduces.
In case of mass is removed or add that change the
near-homogenous condition, it become unbalance.

Example: Impeller damaged due to chemical

attack. Material is removed and become nonhomogenous. Unbalance happened.

When the unbalance rotor in operation, it create sinusoidal force equal to 1x running frequency.
When translated to frequency domain, the 1x (read : one-time)peak appear.

If the rotor running speed is 3,000 RPM, the

running frequency is 50 Hz.
The unbalance create vibration also at 50 Hz. It is
also called as 1x running frequency

To correct unbalance, one shall determine amount and angle of the unbalance mass. Then the
unbalance mass shall be removed or add counter mass in opposite direction to cancel the
centrifugal force.

Adding counter mass

Removing unbalance mass

Note:
Industry standard for balancing are ISO 1940, API 617.

MISALIGNMENT occur when driver and driven shaft centerline not coincide to each other. Three
type of misalignment as below.

Most of the case in

industry

Misalignment mostly caused by improper installation and at stationary part such as casing,
foundation, piping and nozzle.

Cause of misalignment:
Human error during alignment
Soft foot
Pipe strain
Bearing wear
Loose foundation bolts
Incorrect levelling
Misalignment shaft may cause:
Increased bearing load
Reduction of bearing life
Increased noise
Increased vibration
Increased wear of seals
Increased energy consumption
Good alignment

Angular misalignment is clearly observed at axial direction where 1x and 2x peak are high and 1x
is higher than 2x.

Characterized by high axial vibration

1800 phase change across the coupling
Typically high 1 and 2 times axial vibration
Not unusual for 1, 2 or 3X RPM to dominate
Symptoms could indicate coupling problems

Parallel misalignment clearly indicated from vertical and horizontal direction where peak 1x and
2x appear where 1x is lower than 2x.

High radial vibration 1800 out of phase

Severe conditions give higher harmonics
2X RPM often larger than 1X RPM

Similar symptoms to angular misalignment

Coupling design can influence spectrum shape and amplitude

To correct misalignment, proper alignment shall be done using various method such as reverse
dial, face and rim or laser alignment method.

Laser Alignment

Dial Gauge

Other than unbalance and misalignment, there are a lot more cause problem to the equipment.
These problems were able to detect potential failure by identifying the vibration signature.

Conclusion

Vibration is one among the technique use to determine equipment health.

Vibration analysis can provide indication of what kind of fault on the equipment.
It is the most established method that can cover huge category of rotating machinery (in
some extend to static equipment).

There are two types of vibration monitoring techniques i) casing vibration ii) rotor vibration.
The selection of the method commonly reasoned by the type of bearings use.

End