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This paper outlines rotating machinery malfunction diagnostics using vibration data in correlation with operational process
data. The advantages of vibration monitoring systems as a part of preventive/predictive maintenance programs are
emphasized. After presenting basic principles of machinery diagnostics, several specific malfunction symptoms supported
by simple mathematical models are given. These malfunctions include unbalance, excessive radial load, rotor-to-stator
rubbing, fluid-induced vibrations, loose stationary and rotating parts, coupled torsional/lateral vibration excitation, and rotor
cracking. The experimental results and actual field data illustrate the rotor vibration responses for individual malfunctions.
Application of synchronous and nonsynchronous perturbation testing used for identification of basic dynamic characteristics
of rotors is presented. Future advancements in vibration monitoring and diagnostics of rotating machinery health are
discussed. In the Appendix, basic instrumentation for machine monitoring is outlined.
Rotor
the malfunctions.
The basic principles creating the foundation for machine malfunction diagnosis methodology applicable for
ompetitiveness
plants main goal of increased throughput of highquality products. This goal is often achieved by increased
machine speeds and reduced machinery outages, which,
in turn, put a great emphasis on machinery health.
Vibration monitoring as a part of preventive/predictive
maintenance programs assists in achieving the main goal,
and has proven to be highly cost effective. The benefits
from vibration monitoring include the following:
A. MUSZYNSKA
238
COMPUTEt:
DATA ACQUISITION
DATA STOIAGE
DATA PROCESSING
DATA FORMATTING
DATA DISPLAY
FIGURE
ANALYSIS
CORRECTIVE
ACTIONS
[1987]):
Analytical models of the machine dynamic behavior-particularly the models based on a modal approach--are
of tremendous value in future diagnostic procedures. On
large critical machines or machines that have had a
history of vibration problems, it is desirable to incorporate these analytical models into the machines database.
The analytical and testing baseline information is necessary for comparing the machines previous and present
condition when a machine malfunction occurs. It can
also be used after the problem is fixed to verify the
validity of the correction.
Most of the baseline data and process/operational
requirements, as well as a comprehensive prediction
profile of the machine, should be provided by the
machine manufacturer. Also, a monitoring system, or at
least the recommendation of transducer locations for
diagnostic purposes, should be included as a part of the
design for all rotating machines.
Monitoring of the machine operation and its process
variables should be cross-correlated with a simultaneous
monitoring of the machine vibrational behavior. The
operation of machines is a dynamic process, and the
process data, to be of significance, must include dynamic
components of the quantities monitored. Changes in
process or auxiliary variables (e.g., changes in bearing
temperature or changes in driving electric motor power
consumption) may represent the first warning signals of
impending vibration problems. Machine vibrations, being symptoms of malfunctions, occur in response to
either input forcing function changes or machine dynamic stiffness (transfer function) changes. Vibrations
also carry information about the character of, and possible source of, the malfunctions. Both process and
vibration data should be trended, ideally in cross-correlated formats using whichever cross-correlations that
yield pertinent information.
While fulfilling the main function of the rotating
machines, the machinery rotors are most prone to mechanical vibrations, and are the principal source of
vibrations. Most malfunctions originate from direct
transfer of rotor rotational energy into vibrational energy
of various modes. Among the latter, the lateral modes of
the rotor are of the highest concern. Most often they
represent the lowest modes of the machine structure.
Rotor vibrations are eventually transmitted to pedestals,
casing, and foundation. It is evident that measuring
vibrations "at the source" becomes vital for correct
evaluation of the machine health. That is why the
generally accepted practice is to utilize two noncontacting displacement transducers installed in orthogonal XY
configuration on or near each radial bearing to measure
lateral vibrations and static centerline position of the
rotor relative to the mounting fixture. Vibration measure-
239
function identification. Phase angles of vibration components with synchronous frequency, twice rotative
frequency, and of whirling and whipping frequencies
are especially meaningful.
Shaft centerline position for insight into the radial load
status, and into the specific location of the rotor with
respect to the stationary components of the machine.
vibration amplitudes, as
The ratio of overall to the
a signal for operators to get machinery diagnostics
assistance.
DIAGNOSIS OF PARTICULAR
MALFUNCTIONS OF ROTATING
MACHINES ILLUSTRATED BY BASIC
MATHEMATICAL MODELS OF THE
ROTOR
!n
A. MUSZYNSKA
240
M"
k.) + Kz
D(1
inertia
force
mr[-2eJ(t + 8), Z
+ jy,
d/dt, j
unbalanced
excitation force
tangential
force
=k//Z
(1)
Ae j(at + )
(2)
[K
MI) :z
+ jD(1
rotor synchronous
dynamic stiffness
X)
-1
Kt.] Ae jo mr2e j8
synchronous
response
vector
unbalance
vector
mr2
g- arctan
MI)
(4)
K.
)t)f
D(1
jK(12)z
stiffness
force
damping
force
rotor
(3)
241
.,
_-.-12
::"- 7_-.
-2.5
FIGURE 2 Bode and polar plots of a machine rotor 1x filtered
response measured by a vertical displacement transducer. These formats help to identify the first balance resonance frequency, and the
unbalance (heavy spot)location,
i: :i
2,y.r!!.75_ KE[_
2_1.- _::"
1
4
2 ltRad
s 2 x 104
K- M 2=
D(1- X)f- K,
{mrf2sin(8- oOJ/A
By plotting the results versus rotative speed, the observed modal stiffness, mass, and damping can .be
identified (Fig. 3). The procedure of synchronous perturbation is routinely used in the calibration weight
balancing methodology. The "influence vectors" (elements of the transfer function) represent elements of the
inverse of the dynamic stiffness (in the matrix sense).
During balancing, their meaningfulness is most often
underestimated. When stored and compared after consecutive balancing of the machine, they will reflect
changes in the rotor restraint characteristics through the
machine life span. They would assist in early detection of
such malfunctions as cracked shaft, rubs, and loose parts.
Easy to perform, the synchronous perturbation provides very useful, but usually insufficient, data for
appropriate identification of the machine system parameters, especially those which vary with the rotative
The term "observed" refers to the fact that the obtained parameters
usually differ from actual modal ones, due to specific axial locations of
measuring transducers, and controlled unbalances.
2In order to eliminate the effect of the rotor residual unbalance, the
controlled unbalance for the first run in inserted at the angular local &
for the second run at the location i + 180 then the synchronous
response vectors from these runs are vectorially subtracted, producing
net response to controlled unbalance (Muszynska et al. [1989a].
M+ D(1
z
X)
Fe j(t +
Ae j(t + oO
(K
8
Mw2) + [D(1
D(1
arctan
K,(Y)] 2
(5)
X)o- K(D,)
)t)to
M(o2
X//K/M
A. MUSZYNSKA
242
K-
M02 Fcos(81
oO/A
c)/A
was not included in the considered here rotor model. The nonsynchronous perturbation applied to an overhung rotor with a strong, gyro-
Gravitational load on horizontal rotors, thermal expansion load, offset, or cocked bearing-related load, and gear
mesh forces also belong to this category. Due to the
radial force, the rotor becomes displaced from the
original position, and moved to higher eccentricity
ranges inside the bearing and seals. It may also become
bowed, and rotate in a bow configuration. At these
conditions the nonlinear effects of the system become
active. A simple rotor model extended from Eq. (1)
describes this phenomenon:
M + Dx(1 Xx) Yc +
+ 8) + P cos T
Kx + K,(f)y
mr122 cos(Ot
(6)
243
M:+ D(1
(g2
v=
FIGURE 4 Excessive radial load/misalignment diagnosis: frequency
spectra, orbits, and centerline positions.
Rotor-to-Stator Rubbing
Rubbing between the rotor and stationary part of the
machine is a serious malfunction that may lead to a
catastrophic failure. Rubbing involves several physical
phenomena, such as friction, stiffening/coupling effect,
impacting, and may affect solid/fluid/thermal balance in
the machine system. Rubbing always occurs as a secondary effect of a primary malfunction, such as unbalance,
misalignment, or fluid-induced, self-excited vibrations,
which all result in high lateral vibration amplitudes
and/or changes in the shaft centerline position within
available clearances.
The first two rub-related phenomena mentioned above
are relatively easy to model. The original one-lateralmode model (Eq. (1)) is completed now with the second
equation representing the balance of forces at the rubbing
location (Fig. 5):
Zl
K2z + vg2(IZll c) (1 + j/z) i
+ K3)z
01 forfor IZlZll-<
0,
(7)
> c
K2Zl
Be jot + t),
zl
Be jogt
(8)
describes these self-excited circular vibrations with amplitudes B, B 1, frequency to and relative phase [3
(Muszynska [1984b]). The latter quantities can be calculated from four algebraic equations obtained after sub-
A. MUSZYNSKA
244
[K + K2K3/(K2 + K3)]/M (full rotor natural frequency). Finally the fourth algebraic equation provides
0 H
the amplitude B for each frequency to. If the stator (or
seal) is infinitely stiff, then B c. During dry whip, the
rotor rolls while sliding against the seal in the direction
opposite to the direction of rotation while the other
sections of the rotor vibrate at resonant conditions of the
backward mode, independently of rotative speed (Fig. 8).
Most often observed frequency of the dry whip is
"/(K + K2)/M. High radial (normal) and corre12
I0
Frequency (cpm)
sponding friction (tangential) forces at the contacting
FIGURE 6 Rub diagnosis in a turboenerator: shaft center]ine as surfaces may lead to extremely severe damage of the seal
function of load; orbit, timebase wavefo, and spectrum at
and rotor surfaces in a very short time. In addition, due
and 3600 m. The presence of rub-induced ]12x subsynchronous to
the backward mode of vibrations, the rotor operates
vibrations (BN DS Repots).
under severe alternating stress with relatively high fre+ to. The rub-related failures of machines
quency
often (Muszynska [1989b]).
occur
quite
stituting Eqs. (8) into Eqs. (7). The rotor disk vibration
model
Since
(7) includes the rub-generated nonlinear
relative phase depends on the rotor characteristics. The
besides the fundamental comthe
rotor
term,
responses,
disk amplitude is a function of the latter, and the rotor
of higher harmonics. The
contain
a
ponents,
spectrum
amplitude at the seal:
impacting, as another nonlinear mechanism of rubbing
(not included in the model (7)), increases the strength of
-toD(1 XR)
this
spectrum even more. Rotor-to-stationary element
arctan
13
K + K- Mto 2
robbing is actually a very rich phenomenon resulting in
(9) rapidly changing system parameters with a tendency to
KzB1
chaotic motions, thus the model (7) represents only the
+ K2 -Moj2) 2 -I-[D(1 .R)to] 2
simplest first approach, which includes the basics. (The
effects of rub on the torsional load, thermal, and fluid
The frequency equation yields four self-excited frequen- flow-related effects were neither included here.)
cies to with approximate values: +_ ,/(KI + K2)/M
and
"short"
rotor
natural
frequency)
(a
cw Rotation
"/
..
..
..."
V(KI
1X
0.5X
FIRST
BALANCE
1/3x
l/5x l/4x
O)res 2
FREQUENCY, kcpm
FIGURE 7 Spectrum cascade of rotor vibrations and corresponding
orbits. Rotor is lightly rubbing on the upper surface of a seal
(Muszynska 1984a]).
FIGURE 9
M:+ D(1
K2Zl
K2z + Db (l -jhDZl) +
(K2 + K3)Zl
(10)
tangential force
gb
gnblZ112 /...)Z
[K2 + K
[K K
/
ROTATTVE SPEED,
245
+ Kb + Dbj(to- 2) + KnbB2]
Moo2
jO(1
)tlOOO
] K@
(11)
A. MUSZYNSKA
246
/
e3:se:7
e3:58:32
o3:54:47
83:68:27
ea: 521 a7
12
e3:62:57
..3:
31:3
a7
3687
e3:1:47
32
o
Scale
Steady-State x Filtered Uncompensated Rub Occurred at an Oil
3 rail pp Full
0a Y
towhir/
KD(1 X)
)k-
Ob[(K, + K2
X f and towhip
MX21)2) + [D(1
+K
M
A,)A 1)]
(12)
The relationship 09
to(O) is an inclined hyperbola;
around f
+ K2 / Mthe values (12) are
/
least accurate. Without the nonlinear term (Knb 0), Eq.
(11) represents the system characteristic equation for
calculation of the eigenvalues. The imaginary parts of the
eigenvalues are almost the same as frequencies in Eqs.
(12) (additionally, there exists the negative "whip" frequency). It has been well known in vibration theory that
the self-excited vibrations exhibit frequencies close to
natural frequencies of the linearized system. Small differences occur due to system nonlinearities, active at
higher deflections of the elastic members. The "whip"
frequency (12) asymptotically approaches the rotor lateral mode natural frequency corresponding to rotor high
(1 X) "K
AVERAGE
FLUID
VELOCITY
FLUID VEL
PROFILE
SHAFT
Model of a shaft rotating inside a bearing or seal. The
circumferential flow-induced force rotates at angular velocity h
(Muszynska 1988a]).
FIGURE 11
K1 +
1)st
(K + K Mw2)K22
(K, + K Moe) e + [D(I ))o]
;2-/3
}-
/2
lx
0.4x0.5x
2x
.3x
-.-
to
Rotation-ccw
_5056
rpmz_.._
247
(14)
where
are the whirl or whip frequencies which are
calculated from the remaining paa of Eq. (11) (Eqs. (12)
present approximated values only).
For well-balanced rotors the whirl vibrations are quite
persistent (Fig. 12). At the beginning of fluid whirl, the
rotor vibrates as a rigid body. When the rotative speed
approaches the 1/A value of the first balance resonance
frequency, the rotor self-excited whirl vibrations get
smoothly transformed into the whip, with a frequency
_---Y._--_--_----..0.3- il-p/div
O0
iz
18
;7.
ms/div-----
9.6
12
FREQUENCY, kcpm
FIGURE 12 Orbit, timebase wave at 5056 rpm, and spectrum cascade
of a start-up of an electric motor-driven compressor rotor supported in
oil-lubricated bearings. Fluid whirl vibrations with frequency 0.4 are
present (BN MDS Reports).
248
A. MUSZYNSKA
B
Mp" +
D (1
KlC
X)9 +
K y + v[Dfp + Kf(y
c)
0 for lyl-< c
for lyl > c
(15)
...
I";,
I;i
..,..i
.,
I,
I":,
,.",
l,.,t,
/.. ,,"
,:,
.2
",/
--4".
#" v ----;.,":.-."--.
;,,
(t.. ,",,"
-----.,"
. . . . ...... . . . . . . . . . . "
t.,
,iei.,,,
I ,:,,
lllfF,
./
T,
,:
:.,
,".-
y,i
ll
-------I":
.,,,
!il,,,.
::,
,%11, "":"";5",:/",
"5
"i
-__..i:
3x
":
..
,,,,..
7,:
;"", I",, .!..,:7" ;:.,L,
:,;:;:i;,,
:,i.-,/,:,,,,,".),",:;
/-.-,,".,( -.--V,,.
q.,.,-.
l ;." ,.,, ",".
"
e, /..-
.."...:,..",.il ;!
,"
"\.,
i"":
/:
!,",
,,...,.
16""i
,,/
:....
/"-
./,."
--,l
."
., ,
249
./
/
,."
2i
FREQUENCY,
A. MUSZYNSKA
250
::i:!::::
1!
Orbit Scale=5milpp/div
3360
l:::::::::1,
tio "v"
I:
:.. r
LOt./ I/I
4: .,o
I:::::::::/
2,,
3210
lm
,OIV !/]/
t /,
69
.oo
"
ooo
v...,
/:::::::::
PPiO
...i
/x
351e
FIGURE 15 Centerline position during start-up and selected orbits of a journal rotating in an oversize poorly lubricated bearing (unbalanced rotor
supported in one 5-mil and one 50-mil radial clearance brass bearing bushing) (Muszynska [1990b]).
(16)
where the subscripts "R" and "f" refer to the rotor and
loose rotating part respectively. The loose part rotative
frequency m e is a function of the shaft/loose part clearance, surface friction, and the tangential drag coefficient
O, provided by the fluid environment. Depending on a
particular machine, the latter can drive the loose part at
higher frequency than f (e.g., a loose turbine disk) or
slow down the loose part, relatively to the rotor. In both
situations p and O act in opposite directions. At steadystate conditions the friction and fluid drag may balance
each other, and 0 e becomes constant. If it does not differ
very much from the rotative speed, the resulting vibrations exhibit the characteristic pattern of beat (Fig. 17).
Most often, however, the looseness of a rotating part
leads to transient conditions. The loose-part-related vibrations have most often a subsynchronous frequency
tending to the natural frequency of the rotor. These
vibrations look somewhat similar to fluid whirl/whip
251
0.5x
1X
9690 rpm-
8310 rpm
7710 rpm,
3x
5910
3510 rpm
----f---"
Orbit Scale
pp/div
3 mil rpml
----!
171
FREQUENCY, kcpm
FIGURE 16 Spectrum cascade of the journal horizontal response and selected orbits from the same run as in Figure 15. Subsynchronous
vibrations of 1/2 and 1/3, as well as self-excited vibrations, are present (Muszynska [1990b]).
Cracked Shafts
Cracked shafts represent a severe malfunction in rotating
machinery, and always should be considered as a potential event. A shaft crack causes two major results: a
stiffness reduction resulting in rotor anisotropy, and a
shift of the elasticity axis (the rotor bows) which affects
the balance state.
In order to present a simple model of a rotor with the
cracked shaft, first transform Eq. (1) of an unbalanced
rotor into coordinates Zr Xr + JYr-" ze-Jft attached to the
rotor, and rotating at the angular speed 12 (assuming
further that the axis Yr passes through the crack):
(17)
(Muszynska, 1982)"
A. MUSZYNSKA
252
t=t 5
t=t 4
t=t 3
t=t 2
t=t
I
SMALL
EXCURSION
KEYPHASOR
SMALL
AMPLITUDE VARIATION
HIGH RATIO OF UNBALANCES
0.5x
forward).
The crack-related weakening of the rotor in a constant
and 2
operation may be diagnosed by analyzing the
vector trend data. A shift in the natural frequency can be
detected when at a constant rotative speed, at certain
or 2 vectors exhibit resonant
moment of time, the
features (Fig. 21). With an assumed rate of crack
propagation, the timing of the total shaft breakage can be
estimated.
Torsional/Lateral Coupled Vibrations
,MI2
4
0
2.4
4.8
7.2
9.6
12
253
..INCONCLUSIVE
..
EC: 40
TYPICAL ORBITS
"
r 30
2.5
(C)
.5
2.0
RES-0.0
0
.5 RES
RES
FREQUENCY [kcprn]
FIGURE 19 Spectrum cascade and selected orbits of a cracked shaft vibrational response. High
resonances at "half resonance" speeds of (Bently et al. [1986]).
.
.
"
..
. .- -
9O
i--"-"-------"---.
."=
----._
",
HORIZONTAL
RUNUP
-,
...,."t?::.,,iee
,..
.."-
. ..
:X
\,
_....;
"
/DATE: IINE
-=i
_. gg7
:L
.. . .
.:t I;
,:t,;,.
."...t..."
t
%..,.,,!-
7,,\ ".
-r.."e
".
.
123.,
,,o Y. k
,_-,
.
t..
...i... ;,,,:
t
1
7.._2_!-_,r-1 I_._L t-_.C_-r-r-I 177-! i-i-.U.,..!L.i7; .--r-I
-. -.
./.te,,FIL
.ill
i--bi-i--i--:i_-.I ,-:"
UNFILTEREDtI-r--I
I-i-i-FVI ITi._7.[2[LI i-i-;-Tr:qi-L7{_2].L-I
T--
"-
-F-l-i-,
Ii"-C,=::-:1
i ^-.==,-r-.
k].7-r--..L..-25.7_7.1
FIGURE 20 Shaft crack diagnosis: abnormal 2 response vector polar plot taken 9 days after the first one. Amplitudes considerably increased,
and phase is leading in the low speed range. At 3550 rpm 2 orbit is backward (BN MDS Reports).
254
P tcos(t + 8- T)
P sin(l-It +
-.
/)]
(20)
One classical machinery rotor malfunction, namely internal and structural friction, has not yet been mentioned.
Internal/structural friction in rotating elements is known
to cause self-excited lateral vibrations with frequencies
close to rotor natural frequencies (the model (10) with
and Db equal to the internal/structural friction
damping may be used as a first approach in modeling
these phenomena). Since internal/structural friction-induced, self-excited vibration exhibit the whip type (as the
onset of stability is high enough with ) 1), it is usually
difficult to identify a real cause of these vibrations. (Most
often the whip is caused by fluid interactions, as much
stronger agents.) One aspect of the internal/structural
friction should, however, be mentioned here: The internal friction force acts in phase with the external damping,
i.e., it intensifies the effective damping only for super
synchronous frequencies. For subsynchronous frequencies, it opposes the external damping, reducing its
stabilizing effect. That is why all subsynchronous vibra-
FIGURE 21 Shaft crack diagnosis: amplitude-phase-time (APHT) plot and polar trend of a cracking rotor 2 vibration component, at a constant
speed. The plots exhibit the characteristics of the lateral second mode resonance response, due to the propagating crack-related shaft weakening
(BN MDS Reports).
180
,I
I..,, ,..,I
I,,
360
f7""-
= I I l I
4
2
KOTATI SPEED, krpm
255
256
A. MUSZYNSKA
instruments and computer systems to collect, record, and cost-effective, and reliable operation of the machinery
process the data has become a routine. Expert systems used to produce required products.
are natural extensions of this trend. About ten years ago,
aspirations in the area of expert systems were being
discussed. Today attempts of their designs are being References
published (Lu et al. [1986], Gross et al. [1989]). Several Bently, D. E., and Muszynska, A., 1986. Detection of Rotor Cracks,
Proceedings of the Texas A&M University 15th Turbomachinery
years from now, accomplishments will be summarized,
Symposium and Short Courses, Corpus Christi, Texas, pp. 129-139.
followed by their routine implementations.
D. E., and Bosmans, R. F., 1990. A Method to Locate the
Bently,
Contemporary expert systems are cost effective only
Source of a Rotor Fluid-Induced Instability Along the Rotor, The
when applied to specific classes of machines which
Third International Symposium on Transport Phenomena and Dyoperate in large numbers. High complexity and resulting
namics of Rotating Machinery, Honolulu, Hawaii.
high development costs of the expert systems are realis- Bently Nevada Mechanical Diagnostic Services Reports, 1987-1990.
tic only if they can be amortized over a large number of Diewald, W., and Nordmann, R., 1990. Parameter Optimization for the
Dynamics of Rotating Machinery, Proceedings of the Third IFToMM
sales. The individual specific solutions for expert sysInternational Conference on Rotordynamics, Lyon, France.
tems are necessary, because the general solution for the Goldman, P., and Muszynska, A., 1991. Analytical and Experimental
vibration pattern recognition problem for a wide variety
Simulation of Loose Pedestal Dynamic Effects on a Rotating Machine Vibrational Response, Rotating Machinery Dynamics, DE-vol.
of rotating machines operating in a large multitude of
35, The Thirteenth Biennial ASME Conference on Mechanical
processes is still imperfect at the present time. A second
Vibration and Noise, Miami, Florida.
that
is
with
major problem
contemporary expert systems
Gross, K. C., and Humenik, K. E., 1989. Nuclear Plant Component
the responses and recommendations are stated only as
Surveillance Implemented in SAS Software, SAS Users Group
probabilities, thus expert human judgments are still
International Conference, San Francisco.
required to assess these probabilities. In a few years, Laws, W. C., and Muszynska, A., 1987. Periodic and Continuous
Vibration Monitoring for Preventive/Predictive Maintenance of Roexpert systems will evolve from tools that assist experts
tating Machinery, Trans. of the ASME, Journal of Engineering for
will
be able to help knowledgeable users
into tools that
Gas 7urbines and Power, vol. 109, pp. 159-167.
who are not experts. Only in the distant future will expert Loewy, R. G., and Piarulli, V. J., 1969. Dynamics of Rotating Shafts,
systems be able to help general users. (Advances in the
The Shock and Vibration Information Center.
neural network computing and fuzzy logic may speed up, Lu, S. C-Y, and Komanduri, R. (Eds.), 1986. Knowledge-Based Expert
Systems for Manufacturing, ASME Publication PED-v. 24, H00371.
however, this process.)
Detection, Proc. of the Seventh
A true expert system must be capable of totally Muszynska, A., 1982. Shaft Crack
Machinery Dynamics Seminar, National Research Council, Edmonreplacing a human expert in the machine operation
ton, Alberta, Canada.
control, diagnosis, and corrective actions. In the machin- Muszynska, A., 1984a. Partial Lateral Rotor-to-Stator Rubs, The Third
International Conference on Vibrations in Rotating Machinery,
ery diagnostics field, a true expert system would have to
IMechE, C 281/84, York, New United Kingdom, pp. 227-236.
be able to recognize early signs of any potential problem
A., 1984b. Synchronous and Self-Excited Rotor Vibrations
Muszynska,
from
the
real-time
data
vibration
monitorby analyzing
Caused by a Full Annular Rub, Proceedings of the Eighth Machinery
ing and process control systems, hypothesize all possible
Dynamics Seminar, NRC No. 23619, Halifax, Nova Scotia, Canada,
causes of the problem, construct a series of parametric or
pp. 22.1-22.21.
process perturbation tests, and develop a data acquisition Muszynska, A., 1986a. Modal Testing of Rotor/Bearing Systems,
International Journal of Analytical and Experimental Modal Analystrategy to gather the required additional information to
sis, vol. 1, no. 3, pp. 15-34.
each
the
or
conduct
tests,
prove
disprove
hypothesis,
Muszynska, A., 1986b. Whirl and Whip--Rotor/Beating Stability
gather the data, analyze the results with respect to the
Problems, Journal of Sound and Vibration, vol. 110, no. 3, pp.
particular machinery, process them, form a reliable
443-462.
conclusion, and undertake corrective actions. An expert Muszynska, A., 1988a. Improvements in Lightly Loaded Rotor/Bearing
and Rotor/Seal Models, Trans. of the ASME, Journal of Vibration,
system capable of performing all of these functions
Acoustics, Stress and Reliability in Design, vol. 110, no. 2, pp.
should be able to handle most typical problems with
129-136.
well-behaved symptoms on traditional machinery. Hu- Muszynska, A., 1988b. Multi-Mode Whirl and Whip in Rotor/Bearing
man experts, with their intuitive abilities, will probably
Systems, Dynamics of Rotating Machinery, The Second International
always be required to provide solutions for most infreSymposium on Transport Phenomena, Dynamics, and Design of
Rotating Machinery, vol. 2, Hemisphere Publishing Corp., Honolulu,
quently encountered problems, or almost all malfuncHawaii, pp. 326-340.
tions which exhibit any asymptomatical characteristics.
Muszynska, A., 1988c. Effects of Loose Rotating Parts on Rotor
Expert systems must always be considered, however,
Dynamics, The Fourth International Conference on Vibrations in
as useful tools to assist in the machinery health diagnoRotating Machinery, IMechE, C241/88, Edinburgh, Scotland, pp.
573-578.
sis, not as main goals. The latter is still the safe, efficient,
Nomenclature
A,c
B, BI(
c
D,K,M
unbalance
Shaft/bearing normal force
Radial force amplitude and its angular
orientation
Time
Torque
Rotor lateral displacements in two orthogonal
directions (conventionally x horizontal, y
z,z
A,e
vertical)
Rotor lateral displacement coordinates
Crack-related stiffness-reducing coefficient and
elasticity axis shift respectively
Fluid-related tangential drag coefficient
Fluid circumferential average velocity ratio, a
measure of the strength of circumferential flow
in bearings, seals, and/or rotor/stator periphery
frequency
Rotative speed
Subscripts
b
f
/
n
r
257
s
st
Rotor
Stator
Stability
t,x,y
"r
Tangential
APPENDIX
Vibration Transducers
258
A. MUSZYNSKA
CASE
BOBBIN
SPRINGS
BOBBIN
POLE PIECE
PROBE GAP
MAGNET./
259
Amplifier
Preload Bolt
Mica
Reference Mass
Con du ctive
"Jl//,,//l
Plate
PiezoelectriCcrystal
Electrical
Insulator__...
A. MUSZYNSKA
260
-270
-300
3,750 rpm
4 rnil=
UNCOMPENSATED
COMPENSATED
,mils
330
2 mils
4,000 rpm
3.200 rprn
rail
2,900 r
-180
6,000 rpm
7,000 rpm
10.,000 rprn
_150
-120
-60
-90 o
FULL SCALE
-30
5 mils pp
FIGURE A5 Polar plots of rotor uncompensated and compensated (slow roll vector subtracted) synchronous (1 ) vibration data measured by
a horizontally mounted displacement transducer.
3,600 rpm
/ / ,20o
m,,
b X probes
and
261
UNFILTERED
.4 MILSmIV
10 MSECIV
3604
3606
PLANT ID:
TRAIN ID:
MACHINE ID:
XYZ UTILITIES
TURBINE GENERATOR
TURBINE #2 BRG
RUN:
DATE:
TIME:
PROBE #1 ID:
ORIENTATIONMAX AMPPROBE #2 ID:
ORIENTATIONMAX AMP-
5
21 MAY 81
1206 Hour
#2 BRG VERTICAL
135 DEG
1.35 MILS PK-PK
#2 BRG HORIZONTAL
45 DEG
1.07 MILS PK-PK
X FILTERED
RUN:
DATE:
TIME:
PROBE #1 ID:
ORIENTATION1X VECTOR-
N
MMP SCALE- .4 MILS/DIV
AMP SCALE
TIME SCALE
RPM (START)-
/"
PROBE #2 ID:
ORIENTATIONIX VECTOR-
5
21 MAY 81
1208 Hour
#2 BRG VERTICAL
135 DEG
1.05 MILS PK-PK
0 201
#2 BRG HORIZONTAL
45 DEG
.83 MILS PK-PK
0 356
.4 MILS/DIV
o MSEC/DIV
3606
RPM( END)- 3605
A. MUSZYNSKA
262
TUIRB-CEN
[GIN:
-POINT
gRG
--I
--7
HP TUIBIPIE
22 -NOV-El4
IZt, lO:
1: 4El
-S
TRENFI
2t:j-NOV-fl4
-3
-4
113:413
-2
121
-2
t2t
OR Y
g HORIZ
TYPF_
-S
-3
-4
Ol:l Y
UP
.ei-.:"": :;: :: ;
New Beoring
Bad Beorlng
=.
P:
,.,,,.,#--_i-<:
/" /" /
/
/,: , ,/ /"/,,,
/ i / /
/ /"
..,>J--t.-_i-x ,.:..--:.(-::-. 7
I,i I i i i I i
!
./
it ,!
/lo
ll
t,
FREOUFNGY (kcpm)
.o
.,o
+ i
^IF e?:zg:ts
4-.=4
,,,,,,/-s
oo
. .!.! !!
.o
:rO :17{1S} :
:.,. O?:.,S:,,.; :/2
[:: :":..t,::::t::::
TRAIN: 115 MW Turbogenerator
POINT ID: BRG #1 VERT 45 deg
POINT 1D: BRG #1 HORIZ 315 deg
FIGURE A11 Shaft centerline position trend plot measured by X
displacement transducers.
263
Vertical
KEYPHASOR
PROBE
Horizontal
oEc.zS--ROTATION
160 ORB
360 OF ROTATION
180 OF ORBITING
360 ROT
S60O0F ROTATION
120 ORB
120 OF ORBITING
3t30 ROT
24O ORB
360 ROT
<
B
RG 1-7
--X
3
0F ROTATION
OF ORBITING
FIGURE A 13 Vibration frequency estimation using Keyphasor marks
on the orbits.
Machine).
FIGURE A15 Turbogenerator diagram with lateral vibration displacement transducer orientation.
A. MUSZYNSKA
264
"-L-J
_1_
12" Max
E]GURE ]6
xJa] (thst)
posJtJovJbratJon measurements.
II ILII
--"
,,,._..,
/7..,
tlORIZ
K,
-,L
,,<....,
x.._/
glll
,._.---.
i-ili
""
lJll
-_--_--_--_--_--_--_.JL
I"tii
"
rlr3k
I"t)"
Time Base
L.ILJI
j_=__.._._=_=___jj
E[GURE ]8
probes.)
Two temperature sensors located in each radial bearing
for short bearings (with length-to-diameter ratio less
than 1/2) one sensor will be sufficient.
Two temperature sensors mounted in active and inactive faces of the thrust bearing.
BE
"
MASS
MODE SHAPE
#1
The tracking filter can thus provide the filtered synchronous vibration (1 ), as well as vibration signal components being fractions or multiples of the rotative speed
(1/3, 1/2, 2, 3, etc.).
If the bandpass filter is swept across the frequency
range (sweep filter), a spectrum will be generated. It
serves for identification of significant frequency components of a vibration signal.
4. FFT Spectrum Analyzer. This instrument is widely
used (and often misused) in vibration analysis. It provides the Fourier spectrum of the vibration signal. In
rotating machine diagnostics the most often used are
steady-state spectra, spectrum waterfalls versus time, or
versus some other monitored parameter, and spectrum
cascade plots versus rotative speed from the machine
start-up or shutdown. For rolling element beating and
gear train diagnostics, however, the spectrum analyzer is
often the primary measuring instrument. The spectrum
analyzer is also used for identification of the instability
source location along the rotor of a machine train (phase
measurement of cross-correlated signals, such as fluid
whip, from two ends of the rotor).
A#R21N G
l.,, k7 IEYPHASOR
,"
" " OF
F:
"BEARING
265
ROTOR
FIGURE A19 Shaft mode shape determined from orbit and Keyphasor mark information.
Systems
Vibration and process data from machines can be visually monitored, and/or manually acquired and reduced
"-Auand,- om-,i""
Da- -ta-cq- isi ," o""
Storage System for
r"
II
-"l
Machinery Protection
INPUT
DATA
"-
/Trend
Monitor/Alarm
System
Human
Expertise
Problem Determination and
Correction
Actions
_Long Term
torage
Uomputer
Data Correlation
Data Compression
Plotting Capability
II
ii
Automatic
Shut Down
the Machine
...,m Il--.o..,n.
__kj Sto
lS"" /
-1
age
-__-__-__-__-__
j
/
_I
A. MUSZYNSKA
266
OUTPUT
-Z
INPUT
CUT-OFF/CENTER
QUENCY
FIGURE A21
Filter types.
cal" data.
(F----I
li i[3,, ii[] @
TRANSDUCER SYSTEMS
STORE AND
RETRIEVE DATA
PRIN TER
PLOTTER
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