20 - Sample Machinery Vibration Analysis Report

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Machinery Vibration Analysis
Diagnostic Studies Report
Table of Contents
Table of Contents..02 1. 2. 3. 4. 5. 6. 7. 8. 9. Executive Summary..03 Introduction.....04 Equipment Details....04 Equipment Sketch....05 Allowable Vibration Limits.....05 Vibration Analysis.....05-10 Interference Diagram Analysis....11 Solutions..........................................................................11-12 Recommendation..12
10. Conclusion..12
B-22, Aspen Block, Citilights Meadows, No.82, Andal Ammal Street, Nolambur,Chennai 600 095, India, Phone: +91-9840372209 (India), +974-66279565 (Middle East & International) Email : info@evibrationconsultancy.com, www.evibrationconsultancy.com
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Executive Summary The machinery vibration analysis and diagnostics studies for 7.0 MW XXXXXXX Pump have been requested by XXXXXXX Company Ltd China on 20-Jan-2010. The following details were informed during the discussion with Technical Services Department Engineer. The pump was installed newly and commissioned on 03 Oct 2010. During the start-up; the pump is tripping at high vibration of 100 microns. The trip set value is 100 microns. The pump is 9 stage high pressures type and make is XXXXXXXX. The driver is a 2-pole motor and coupling the pump with speed increasing gearbox. The speed of the motor is 3000 rpm and pump is 7220 rpm. The rated power is 7.0 MW. The bearing type is pressure dam and inspected found normal. The bearing radial clearance is 0.1 mm. The pump is installed with Bently machinery monitoring system and have an eddy current displacement probes to measure vibration amplitudes. The lubrication is forced type and lubrication oil is ISO grade 32. The lub oil pressure is 2.0 kg/cm2
Through remote access of machinery monitoring system desktop, the vibration data were reviewed along with the Technical Engineer. Based on review of submitted data and remote analysis of the machine, the reason for high vibration is identified as FLUID INDUCED INSTABILITY of the pump system. The fluid instability can happen by the bearings, wear rings, impellers, balance pistons or seals of the pump system. To resolve the fluid induced stability, the solutions are 1. Change or tune the rotor-bearing system natural frequency such way that fluid whirl frequency (0.3 x order < fw< 0.6 x order) will not interfere or re-excite the 1st natural frequency. 2. Eliminate the sub synchronous fluid whirl frequency by modification of the bearing design, increase the eccentric ratio and reduce the attitude angle towards zero degree. 3. Reduce the operating speed to 6900 rpm. Out of the above solutions the best option and recommended is re-design or change the existing bearing design to tilting pad type. The modification of tilting pad type bearing will eliminate the fluid whirl frequency. The bearing will create large eccentric ratio and keep the attitude angle towards zero degree. The more details of the analysis please refer the report below.
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Introduction
The machinery vibration analysis and diagnostics studies for 7.0 MW XXXXXXX Pump was requested by XXXXXXX Company Ltd China on 20-Jan-2010. The following data have been received and analysed. Polar and Bode Plot of start-up and coast down Waterfall and cascade of pump start-up/coast down Vibration Full Spectrum at operating speed Orbit and Time Waveform at operating speed Equipment Data Sheet Pump P & ID Lub Oil P & ID Pump Cross Section Drawing Pump Operation and Maintenance History/Background
Equipment Details
Pump Description Pump Entity Number Rated Power Rated Speed Rated Capacity Suction Pressure Discharge Pressure Lub oil Pressure Lub Oil Flow Lub Oil Temperature Bearing Clearance : Multistage XXXXXXX Pump : XXXXXXXXXXX : 7.0 MW : 7220 rpm : 400 m3/hr : 74 Kg/cm2 : 300 Kg/cm2 : 2.0 Kg/cm2 : N/A : N/A : 200 microns - diametrical
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Equipment Sketch
Allowable Vibration Limits Acceptable limit 1st Alarm limit Trip limit : < 50 microns Pk-Pk : 75 microns Pk-Pk : 100 microns Pk-Pk
Vibration Analysis
Pump Inboard Bearing data Interpretation
The start-up and coast down bode plot indicates the first natural frequency is at 4047 CPM
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The start-up and coast down polar plot indicates the first natural frequency is at 4025 CPM
The orbit and time base shows 2:1 ratio (1/2 X Order) forward whirl with maximum amplitude of 90 microns Pk-Pk
The waterfall shows the dominant frequency is at 72.5 Hz (4350 CPM) at 7223 rpm with vibration amplitude of 52 microns PK-PK
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The cascade shows the dominant frequency is at 72.5 Hz (4350 CPM) at 7223 rpm with vibration amplitude of 66 microns PK-PK
The Full Spectrum shows the dominant frequency is 72.5 Hz (4350 CPM) at 7217 rpm with vibration amplitude of 67 microns PK-PK
The average shaft centreline of start-up of the pump shows very small eccentric ratio and attitude angle is approached 90 degree at 7200 rpm
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Pump Outboard Bearing Interpretation
The start-up and coast down bode plot indicates the first natural frequency is at 4047 CPM
The start-up and coast down polar plot indicates the first natural frequency is at 4001 CPM
The orbit and time base shows 2:1 ratio (1/2 X Order) forward whirl with maximum amplitude of 100 microns Pk-Pk
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The waterfall shows the dominant frequency is at 72.5 Hz (4350 CPM) at 7228 rpm with vibration amplitude of 52 microns PK-PK
The cascade shows the dominant frequency is at 72.5 Hz (4350 CPM) at 7223 rpm with vibration amplitude of 85 microns PK-PK
The Full Spectrum shows the dominant frequency is 72.5 Hz (4350 CPM) at 7240 rpm with vibration amplitude of 86 microns PK-PK
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The average shaft centreline of coast down of the pump shows very small eccentric ratio and attitude angle is 90 degree at 7227 rpm
The following are the observations of the vibration data of inboard and outboard bearing of the pump The maximum overall amplitude of 82 microns in inboard and 101 microns in outboard bearings at dominant sub synchronous frequency of 72.5 Hz (4350 CPM). The orbit, time base, full spectrum, waterfall and cascade are clearly shows forward precision order (forward whirl) sub synchronous vibration. The polar and bode plot of start-up and coast down data are confirms the first natural frequency of the pump system is 4000 CPM (Range 2400 5200 CPM) The amplification factor (AF) is calculated from the bode plot of inboard and outboard bearings. The values are 3.2 & 2.5 respectively. The separation margins of critical speed for this amplification factors are well away. The critical damping ratios are 0.15625 (inboard) and 0.2 (outboard). The damping is greater than recommended damping value (> 0.0625) The frequency ratio of operating speed to natural frequency is 1.8. The ratio is well above and the system is in isolation. The average shaft centreline of the both bearings are indicates shaft, bearing and fluid are in concentric. The eccentric ratio of shaft vibration to bearing clearance is very small. The attitude angle of both bearing is approached 90 degree at operating speed.
The above analysis on pump is clearly shows that the pump is under fluid induced instability. The fluid instability can be happen by the bearings, wear rings, impellers, balance pistons or seals of the pump system.
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Interference Diagram Analysis The interference diagram was plotted and it clearly shows that the first natural frequency is re-excited at about 7200 rpm by whirl frequency. This is the reason vibration was amplifying while approaching the operating speed of 7220 rpm.
Solutions Based on the interpretation of the vibration data it is clear fluid induced instability is the cause for the high vibration while approaching operating speed. The following are solutions to resolve this vibration issue 1. Change or tune the rotor-bearing system natural frequency such way that fluid whirl frequency (0.3 x order < fw< 0.6 x order) will not interfere or re-excite the 1st natural frequency. 2. Eliminate the sub synchronous fluid whirl frequency by modification of the bearing design, increase the eccentric ratio and reduce the attitude angle towards zero degree. 3. Reduce the operating speed to 6900 rpm.
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Increasing the natural frequency of the system
Tune the frequency to 5220 CPM by increasing rotor and bearing stiffness however this is not advisable due to separation margin of natural frequency will be very close to operating speed and it may affect balance response. Decreasing the natural frequency of the system
Tune the natural frequency of the pump lower than 2166 CPM (< 0.3 x order) by reducing stiffness or increasing of the rotor-bearing system. However this may be difficult task and involve more modification of the pump shaft, impeller or diffusers or bearing. Therefore reduction of the natural frequency is also not advised. By small modification (impeller wear rings or balance piston or seal or bearing) if natural frequency of the pump system is reduces below 2166 CPM means this option can be considered; however while redesigning should not lower the second critical speed and close to operating speed. The separation margin of 2nd critical speed should maintain 20% well above the operating speed. Practically reduction of existing natural frequency from 4000 CPM to less than 2166 CPM will be difficult task and may not achieve. Reduce the operating speed to 6900 rpm
The lower the speed of the pump needs change of gearbox design; the speed reduction will lower the pump operating performance. So this modification is not recommended. If customer prefers and lower the performance of the pump is not a concern then this modification can be considered. Recommendation From the analysis of the above it is recommend re-design or change the bearing to tilting pad type. The modification of tilting pad type bearing will eliminate the fluid whirl frequency. The bearing will create large eccentric ratio and keep the attitude angle towards zero degree. The bearing design change will be the best option to resolve this fluid induced vibration issue for this pump. Conclusion Our above recommendation is required design change and in-house modification is not practically applicable, so it is suggested consult the pump OEM or bearing manufacturer for the bearing design change. If the design data of the pump and bearings are provided; the rotor dynamic calculation shall be reviewed and provide you the best solutions to re-design rotor-bearing system.
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20 - Sample Machinery Vibration Analysis Report

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