20 - Sample Machinery Vibration Analysis Report

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Machinery Vibration Analysis
&
Diagnostic Studies Report

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
Page 2 of 12

Table of Contents

Table of Contents..02

1. Executive Summary..03
2. Introduction.....04
3. Equipment Details....04
4. Equipment Sketch....05
5. Allowable Vibration Limits.....05
6. Vibration Analysis.....05-10
7. Interference Diagram Analysis....11
8. Solutions..........................................................................11-12
9. Recommendation..12
10. Conclusion..12

Page 3 of 12

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/cm
2

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 < f
w
< 0.6 x order) will not interfere or re-excite the 1
st
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.

Page 4 of 12

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 : Multistage XXXXXXX Pump
Pump Entity Number : XXXXXXXXXXX
Rated Power : 7.0 MW
Rated Speed : 7220 rpm
Rated Capacity : 400 m
3
/hr
Suction Pressure : 74 Kg/cm
2
Discharge Pressure : 300 Kg/cm
2
Lub oil Pressure : 2.0 Kg/cm
2

Lub Oil Flow : N/A
Lub Oil Temperature : N/A
Bearing Clearance : 200 microns - diametrical

Page 5 of 12

Equipment Sketch

Allowable Vibration Limits

Acceptable limit : < 50 microns Pk-Pk
1
st
Alarm limit : 75 microns Pk-Pk
Trip limit : 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

Page 6 of 12

The start-up and coast down polar plot
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

Page 7 of 12

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 cascade shows the dominant
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

Page 8 of 12

Pump Outboard Bearing Interpretation

The start-up and coast down bode plot
4047 CPM
The start-up and coast down polar plot
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

Page 9 of 12

The waterfall shows the dominant
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

The cascade shows the dominant
microns PK-PK

Page 10 of 12

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.

The average shaft centreline of coast
down of the pump shows very small
eccentric ratio and attitude angle is 90
degree at 7227 rpm

Page 11 of 12

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 < f
w
< 0.6 x order) will not interfere or re-excite the 1
st
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.

Page 12 of 12

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 2
nd
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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