PROCEDURE AND GUIDELINES

IN-SITU BALANCING WORKS

TNB REPAIR AND MAINTENANCE SDN. BHD.
(A wholly- owned subsidiar y of TENAGA NASIONAL BERHAD) (360318-P)

TNB REMACO

PROCEDURE AND GUIDELINE FOR

IN-SITU BALANCING WORKS
ON TURBOMACHINERIES (TURBINE – GENERATOR)

MECHANICAL DIAGNOSTICS
TNB REPAIR AND MAINTENANCE SDN. BHD.
LEVEL 23&23A, PJX-HM SHAH TOWER,
NO. 16A PERSIARAN BARAT,
46050 PETALING JAYA
SELANGOR
www.tnbremaco.com.my
TEL NO: +603 – 79642600
FAX NO: +603 – 79608028

Prepared By : ...............................................................
(WAN MOHD KHAIRUL WAN HUSSAIN)
ENGINEER,
MECHANICAL DIAGNOSTICS,
TNB REMACO

Reviewed By : .................................................
(KHAIRIL AHMAD MUHAJIR)
TECHNICAL MANAGER,
MECHANICAL DIAGNOSTICS,
TNB REMACO
 PROCEDURE AND GUIDELINES
IN-SITU BALANCING WORKS

1. Background

This document contains the basic guidelines of operating procedure to perform an in-situ
balancing to reduce vibration level of a rotating equipment.

2. Theory of Balancing

Unbalanced masses in the rotating parts create a centrifugal force that causes the unit to
vibrate. Field balancing consists of determining the amplitude (size) and location around the
shaft (phase angle) of the unbalance and placing weights on the rotor to counter the
unbalance.

2.1 As the rotor rotates (fig. 1), the unbalanced mass m tends to pull the rotor toward
the bearings on the side the unbalance is located creating an apparent high spot on
the shaft. At very low speeds, this high spot will be in phase with the unbalanced
(heavy) mass. As speed increases, the high spot begins to lag the heavy spot.

Figure 1: Illustration of rotor having unbalanced mass.

2.2 When balancing, the machine is assumed to be linear; i.e., vibration amplitudes are
in proportion to the forces causing them. For the purpose of this bulletin, the term
vibration amplitude is synonymous with shaft deflection which is a measure of the
unbalance present. The point that the vibration amplitude is maximum, called the
high spot. Consequently, to balance the unit, it is necessary to determine the
vibration amplitude and location of the shaft deflection caused by the unbalanced
condition. With this information known, a balance weight is determined and
positioned which gives a counter effect and balances the unit.
 PROCEDURE AND GUIDELINES
IN-SITU BALANCING WORKS

3 List of Equipments

3.1 Csi 2130/2140

3.2 Iotech Zonicbook (If Neccessary)
3.3 Accelerometer Seismic Transducer For Casing Vibration Measurement In Velocity
(Mm/S Rms)
3.4 Monarch Speed Sensor For Speed Measurement
3.5 Reflective Tape
3.6 Weight Scale
3.7 Angle Finder
3.8 Digital Camera
3.9 Laptop
3.10 Strobe Kit

4 Preparation and Requirement

4.1 The vibration readings will be measured using CSI 2140 portable analyzer on the
motor driven and non – driven end. Before measurement were taken, temporary
speed sensor will be installed directed to reflective tape which will be put on
exposed area of motor shaft. This will give speed reading of the motor which will be
used to identify the phase angle of heavy spot and high spot location for balancing
campaign.

4.2 Two seismic sensors will be mounted on the motor bearing driven and non – driven
end side.

4.3 Balancing weights and tools for weight installation need to be prepared prior to the
balancing works. Proper preparation is required to avoid delay on balancing works
schedule.

4. Balancing Procedure (Single plane)

The in-situ balancing on motor can be performed by following the steps listed below.

4.1 Reference Run

i. Run the motor and monitor the vibration reading until it is stable and in steady
state condition for 10 – 15 minutes.
ii. Records the operating condition i.e. machine speed, vibration data, process
state, load, temperature, pressure, etc.
iii. Stop the machine when all the required data are sufficient.
 PROCEDURE AND GUIDELINES
IN-SITU BALANCING WORKS

iv. Measure and record the original unbalance vector (amplitude and angle). Name it
vector O. Plot vector O on a polar graph paper. (also can extract polar plot from
ADRE data)

Figure 2: Polar Plot

v. Based on the polar plot, estimate the location (angle) for trial weight. Ideally, the
weight should be located 180º plus the lag angle - in the direction of rotation -
from the high spot to counter the unbalance. Experience indicates that the trial
weight should be approximately equal to the weight of the rotating parts divided
by 10,000.

Trial weight = weight of rotating parts

10,000

vi. Trial Weight installation.

- To mark the position for trial weight. Be careful on phase angle marking
direction either follow shaft rotation or against shaft rotation and 0° is referred
to the reflective tape location.
- Trial weight will be installed temporarily at balancing plane (if available) or
motor fan blade by using tack welding.
 PROCEDURE AND GUIDELINES
IN-SITU BALANCING WORKS

Figure 3: Example of trial weight installation

vii. After the trial weight installation completely done, prepare to start the machine to
capture the data for Trial Run.

4.2 Trial Run

i. Run the motor and monitor the vibration reading until it is stable and in steady
state condition for 10 – 15 minutes.
ii. If the vibration data are sufficient, stop the motor. If not, request run the motor for
1 - 2 hours or until reading stables (depends on vibration amplitude and phase)
and will be decided by Vibration Analyst/Balancer.
iii. Stop the motor when all the required data are sufficient.
iv. Measure and record the new unbalance vector. Name it vector O+T. This is the
vector response of the original unbalance and the trial weight together. Plot
vector O+T on a same polar graph paper.
v. Trial weight effect/response calculation
- Determine the effect of the trial weight alone by subtracting the original
unbalance vector (O) from the combination of original unbalance and trial
weight vector (O+T). Name it vector T.
- Mathematically, the process is as follows.
O + T = O+T
T = O+T – O
- Graphically, draw the T vector with a line connecting the head of the O vector
to the head of the O+T vector. The T vector must point to the head of the O+T
vector.
 PROCEDURE AND GUIDELINES
IN-SITU BALANCING WORKS

- Measure, record, and plot the T vector on the polar graph paper.
- Translate the T vector to the axis origin i.e. coordinate (0, 0).
vi. Correction Weight Calculation
- Calculate the correction weight size and location. Name it vector WC.
Assuming the rotor response is linear, the response vector of the calibration
weight alone should have equal in amplitude but opposite in direction to the
original unbalance vector, i.e. = –O.

WT is vector for trial weight

vii. Correction Weight Installation

- To mark the position for Correction Weight.
- To remove the trial weight.
- To install correction weight temporarily at motor fan blade by using tack
welding.
viii. After correction weight installation completely done, prepare to start the machine
to capture the data for Correction Run.

4.3 Correction Run

i. Run the motor and monitor the vibration reading until it is stable and in steady
state condition for 10 – 15 minutes.
ii. If the vibration data are sufficient, stop the motor. If not, request run the motor for
1 - 2 hours or until reading stables (depends on vibration amplitude and phase)
and will be decided by Vibration Analyst/Balancer.
iii. Stop the motor when all the required data are sufficient.
iv. If vibrations for all bearings are ok, Trim run is not required. If vibrations are still
high, Trim Weight calculation is necessary and additional balancing weight will
be installed.
 PROCEDURE AND GUIDELINES
IN-SITU BALANCING WORKS

4.4 Trim Run (Optional)

i. Perform step 4.2 and 4.3 again until vibration reading is satisfactory.

5. Record Keeping and Report Preparation

If vibration levels for all Bearings (TGB, GUB & GLB) are low and acceptable for long
term operation condition, balancing works is considered complete. Record final run
vibration reading, installed weight location for all steps until final run and prepare for
engineering report. All the balancing weights need to be secured by fully welds and paints
(as figure below). Perform housekeeping and remove the seismic sensors and speed
sensor.

Figure 4: Example of final balancing weight installation