BALANCING OF ROTATING MACHINERY OVERVIEW

Pranabesh De Choudhury, Ph.D., P.E. Pran RDA Consulting Inc. Greensburg, PA 15601

EFFECTS OF UNBALANCE Unbalance in rotors causes rotor vibrations @ 1x Rotor Speed Transmits rotating forces to the bearings and to the foundations. Transmitted forces may cause damage to the machine parts and its foundation. Transmitted forces may affect neighboring machines and structures.

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CAUSES OF UNBALANCE Mass eccentricity Parts distortion Stacking errors Bent or bowed shaft Deposits on rotors Non-homogeneity of the material

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TYPES OF UNBALANCE Static unbalance Couple unbalance Quasi-static unbalance Dynamic unbalance

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Perfectly balanced rotor Principal Inertia Axis M-M coincides with the Shaft Axis

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Static unbalance Principal Inertia Axis M-M is displaced parallel to the Shaft Axis by the amount of the Mass Eccentricity

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Couple Unbalance Causes the Principal Inertia Axis M-M to be inclined by an angle relative to the Shaft Axis. The CG remains on the Shaft Axis

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Quasi-static Unbalance Causes the Principal Inertia Axis M-M to be inclined by an angle relative to the Shaft Axis. The axes intersect but not on the CG. Pran RDA Consulting Inc.

VERY STIFF ROTORS Insignificant rotor bending occurs through the operating speed range. Machines usually operate well below the first bending-type critical speed. May pass through one or two resonances governed largely by support stiffness. Rotors in this class can be balanced at low speed in two correction planes and retains quality of balance achieved when operated at service speed.

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VERY FLEXIBLE ROTORS Several changes in modal shape occur as speed is increased to the operating speed. Machines usually operate above two or more major bending-type critical speeds. Rotors in this class cannot retain, at service speed, the quality of balance achieved at low speeds. At-Speed balancing, preferably in the type of bearings which will be used in service, is required. Pran RDA Consulting Inc.

QUASI-RIGID ROTORS Modal shape in the operating speed range is a combination of significant rotor bending and rigid-onflexible-support response. Machines usually operate well above the first bending-type critical speed, but below the higher major bending critical speeds. Most multistage compressors and steam turbines belong to this class. Balancing techniques have been developed which permit adequate retention at service speeds the quality of balance achieved at low speed. Pran RDA Consulting Inc.

SINGLE PLANE BALANCING

The complex amplitude of motion of the single mass running at the balance speed = b, and has a bowed rotor is given by equation:
Z1 = Au Eu + Ar Er (1) Where, Au is the complex unbalance influence coefficient Ar is the complex shaft residual coefficient Eu is the unbalance eccentricity Er is the complex residual eccentricity

method. Add the trial balance of value Ut and run at the balance speed b. The disc response Zt is given by the equation
Zt = Au (Eu + Et ) + Ar Er (2)

Unbalance influence coefficient is by the trial weight

The difference in the responses Z1 and Zt provides the unbalance influence coefficient:
Au = (Zt Z1) / Et (3)

Proper balance correction eccentricity is:

Eb = (Z1 + Er) / Au

(4)

TWO PLANE BALANCING (Reference: Thomson, W. T., Vibration Theory with Applications, Prentice Hall, Inc. Englewood, N.J., 1965)
Refer to the two ends as near and far ends.

Rotor is first run as is and the amplitude vectors N and F relative to any reference mark on the end of the rotor are measured. N and F represent the effect of the actual unbalance in the rotor

 Pran RDA Consulting Inc. TWO PLANE BALANCING Add a trial known weight Wtn at any position on the near end. Amplitude vectors N2 and F2 are the effects of the original unbalance and the trial weight Wtn Vector difference N2-N and F2-F are the effect of Wtn alone on the near and far ends. N2-N and F2-F will vary directly with Wtn F2-F = (N2-N) = A, is a vector operator depending on the property of the machine and its

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TWO PLANE BALANCING Remove Wtn. Next add a known trial weight Wtf on the far end Repeat previous measurements and vector calculation. N3-N = (F3-F) = B

Proper balance weights at the near end Wbn and far end Wbf can be determined by changing the magnitude and direction of the trial weights Wtn and Wtf

Wbn = Wtn

Wbf = Wtf

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TWO PLANE BALANCING Operator will have the same effect on A and A as it has on Wtn Complete balance of the rotor can be expressed by A + ( B) = -N and B + ( A) = -F From the above two equations solve for and
= ( F N) / (1 - ) A = ( N F) / (1 - ) B

Knowing , , , and , the balance weights Wbn and Wbf can be determined. Pran RDA Consulting Inc.

TYPES OF BALANCING MACHINES Soft bearing balancing machines Balancing machine having an operating speed above the 1st natural frequency of rotor-suspension system. Hard bearing balancing machines - Balancing machine having an operating speed below the 1st natural frequency of rotor-suspension system.

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THREE PLANE BALANCING Rotor is completely assembled using pre-balanced component. Utilizing two-plane technique amount of unbalance in planes at the outermost wheels is determined. This is resolved into a force component and a moment (couple). Single-plane (force) correction is made as near the center-of-gravity of the rotor as is physically practical.

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THREE PLANE BALANCING (continued)

planes through the end wheels, usually near onequarter points of the rotor span between bearings. Unbalance force correction near the center of the rotor span minimizes vibration response in the fundamental mode, especially through the first critical speed. Unbalance moment correction near the quarter planes minimizes vibration response in the second flexural mode for operation well above the first critical speed. Pran RDA Consulting Inc.

Residual unbalance moment is then corrected in two-

INCREMENTAL OR SEQUENTIAL BALANCING Wheels are assembled on the shaft singly or in pairs. Following each step, balancing corrections are made in two planes on the last wheel(s) assembled. This stepwise procedure is followed until all rotor parts are installed and balancing corrections made. Whenever possible the rotor should be stacked with pairs of wheels from the center outboard to each end. When rotor stacking must proceed from one end completed rotor should be check-balanced in the outermost planes. If the indicated unbalance exceeds specified tolerance, rotor should be stripped, and the whole process repeated. Pran RDA Consulting Inc.

HIGH SPEED BALANCE PROCEDURE Following a preliminary low-speed balance, attempt to run to over speed before final corrections are made. (If required, make temporary corrections). For required balance corrections, use trial weights at selected planes for influence coefficients needed by the balancing program. Adjust rotor by grinding or balance weight addition until tolerances are achieved, both for the peak at the first critical speed and at max. continuous speed.

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HIGH SPEED BALANCE TOLERANCES Requires consideration of pedestals selected to fit the bearings and meet pedestal natural frequency limits. For a 2000 lb. rotor at 12000 RPM, either pedestals with stiffness near 8 million or 3 million lb./in. could be selected. Velocity limit for more flexible (smaller) pedestals could be 1.0 mm/sec, but should be about 0.40 mm/sec for the larger, stiffer pedestals. Use rms of horizontal and vertical velocity measurements on bearing pedestals. Evaluate vibration at both first critical speed peak and at max. continuous speed Nmc. Knowing pedestal stiffness and displacement (integrating velocity) gives forces at bearings. Results should give force within 0.5 g at first critical peak and 0.2 g at Nmc. Pran RDA Consulting Inc.

HIGH SPEED BALANCE EXAMPLE 2000 lb. Rotor with Nmc=10000 RPM First critical speed at 7000 RPM Using pedestal K= 3.2 x 106 lb./in. Tolerance at first critical speed peak: Force/pedestal=.50 g = 500 lb. (peak) Displacement = 500/3.2 x 106=0.000156 in. Velocity = 2 (7000/60) x 0.000156 Velocity = 0.114 in./sec. (peak) Velrms = 0.114 x 25.4/1.414 = 2.0 mm/sec

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HIGH SPEED BALANCE EXAMPLE 2000 lb. Rotor with Nmc=10000 RPM Second critical speed at 16000 RPM Using pedestal K= 3.2 x 106 lb./in. Tolerance at Nmc <<< 2nd critical speed: Force/pedestal=.20 g = 200 lb. (peak) Displacement = 200/3.2 x 106=0.000063 in. Velocity = 2 (10000/60) x 0.000063 Velocity = 0.066 in./sec. (peak) Velrms = 0.066 x 25.4/1.414 = 1.2 mm/sec

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OPERATING SPEED BALANCING Main Advantages For flexible rotors above first critical, optimizes unbalance distribution for mode shape of rotor at full speed. Seasons rotor at over speed, e.g., removal of temporary bows, effect of shrink fits, blade seating. Provides rotor with a lower vibration baseline to accommodate changes, e.g., added unbalance during process operation.

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OPERATING SPEED BALANCING Main Precautions Bearing pedestals low mass and stiffness affect criticals, especially the 2nd and 3rd. Mode shapes at speed to be similar to actual operation; thus bearings with characteristics similar to those for actual machine are needed. Both pedestal and rotor/bearing natural frequencies can give a much more sensitive system (vibration limits should be adjusted). Pran RDA Consulting Inc.

Verification of Unbalance Response Predictions at an At Speed Balance Bunker

This section does not address the balancing of a rotor, but a requirement per API 612 and API 617. This section relates to the possibility of verification of unbalance response predictions at an at speed balance bunker, instead of on the test floor which has few restrictions. Generally, during the unbalance response verification on the test floor, the unbalance can only be put on the coupling hub. In order to more accurately verify the location of first critical speed, the more appropriate location would be at a location between the bearings for non-overhung rotors. This would generally be difficult without opening the casing. The same is true for verification of the location of second critical speed, where one needs to put the unbalances at quarter span. However, if these verification tests are conducted on an at speed balance speed bunker the above two difficulties will not arise. If it is mutually agreed upon between the manufacturer and the user to conduct such a test where at speed balance facility is available and used for such a purpose, the following steps need to be taken. 1. The subject rotor has to be balanced first with simulated half coupling weight.

2. For such a test it is recommended that the job bearings be used. 3. The rotor assembly is balanced first. 4. Analyses should be conducted using the expected pedestal flexibility, mass, and damping data. 5. Record vibration data up to over speed and coast down of the balanced rotor. Obtain bode plots, run out subtracted. 6. Put unbalance at the rotor mid span. Amount and location to be mutually agreed upon with the customer. Run up to over speed and coast down. Record vibration data. Obtain bode plots run out subtracted. Correlate location of peak response, and amplitude, at probe locations, using vector change between 5 and 6. Correlate amplification factors at peak response. 7. Take out the mid span unbalance. Put out of phase unbalances at the rotor quarter spans (end impellers, or, disks). Amount and locations to be mutually agreed upon with the customer. Run up to over speed and coast down. Record vibration data. Obtain bode plots, run out subtracted. Correlate location of peak response, and amplitude, at probe locations, using vector change between 5 and 7. Correlate amplification factors at peak response. 8. Location of peak responses, amplitudes and amplification factors are expected to be within percentages mutually agreed upon, or, per API.

Minimum Achievable Residual Unbalance (Umar)

(Hatto Schneider, Balancing Technology) Residual unbalance which can be achieved on a balancing machine Expressed in g mm/kg. Specific unbalance corresponding to readout instrument for this value. In hard bearing balancing machines, the Umar may be given in g mm instead of specific unbalance. Parameters are valid for the whole working range of the balancing machine, defined by a combination of rotor weight and speed limits Umar is influenced by the type of instrumentation,

amount and angle indication, plane separation, sensitivity, drive, bearing etc. Umar can be checked by a traverse test carried out with a special proving rotor

Test for Umar This is the Residual Unbalance in the Proving Rotor Test comprises of the following steps
(Hatto Schneider, Balancing Technology) Choose the proving rotor. Residual unbalance of the rotor must not exceed five times the specified Umar Two test weights are applied which correspond to 10

Rotor is balanced in 2 planes. A maximum of 4 balancing runs are permitted. The angle reference mark is changed by 60 or 90 e.g., turn the end-drive shaft with respect to the rotor.

to 20 times Umar. Care must be taken that they are not applied 1. In the same plane. 2. In one correction plane. 3. At the same angular position or 180 apart.

 Two test weights each equivalent to 5 times Umar are applied in the two correction planes. Both test weights at the same angular position. In subsequent test runs the test weights are moved to positions in arbitrary sequence. The amount indication for each angular position is noted for each correction plane. The amount readouts are plotted against angular position. The points connected by mean sine curve. If all amounts lie within these two straight lines the claimed residual unbalance has been achieved. If amount indication is not stable, the maximum and minimum values must be taken and plotted for each angular position. All points must lie within the straight lines.

Diagram Showing Residual Unbalance

Scale Indicator in Divisions

Arithmetic Mean

50

100

150

200

250

300

350

Angle of Test Mass

Balancing Softwares mainly for Field Balancing Two softwares are included in this write up: Single Plane Balancing Two Plane Balancing
Waiver of Warranties and Limitations of Liability its use, or the results obtained from the use thereof. Users hereby waive all warranties, expressed, implied, or statutory, including but not limited to, any warranty of merchantability of fitness for a particular purpose. In no event Pran RDA Consulting Inc. be liable for any damage, whether special, consequential or otherwise, resulting from the use of the softwares hereunder even if Pran Rda Consulting Inc. has been advised of the proposed use of the results of said services and the possibility of such damage. In addition the user agrees that Pran RDA Consulting Inc. will not be liable for any lost profits, nor for any claim of demand against the user by any other party. The results specified herein are exclusive.
. Pran RDA Consulting Inc. makes no warranties of any kind related to the softwares or

Sample Run using Single Plane Balancing Software

SINGLE PLANE BALANCING PROGRAM. BE SURE TO ENTER IN FREE FORMAT INFORMATION IS REQUESTED.

ENTER "0.5" IF 200 MV/MIL PROXIMITOR PROBES ARE USED "1.0" IF 100 MV/MIL PROXIMITOR PROBES WERE USED "3.0" IF NEITHER 100 MV/MIL NOR 200 MV/MIL PROXIMITORS WERE USED. .5 ENTER "1.0" TO SUBMIT DIRECT DIRECT DEFLECTIONS, "0.0" TO SUBMIT OSCILLOSCOPE TRACES. 1. ENTER "1.0" IF ANGLES ARE FROM KEYER TO ACTUAL HIGH SPOT. (ARE ABSOLUTE). OTHERWISE ENTER "0.0". 1.

ENTER ANGLE IN DEGREES FROM KEYER TO BALANCE PROBE "+" IN DIRECTION OF ROTOATION.

0. ENTER RESIDUAL UNBALANCE AND ANGLE RUNNING SPEED UNBALANCE AND ANGLE TRIAL WEIGHT UNBALANCE AND ANGLE -----------!!!!!!!!EXPRESS ALL ANGLES IN DEGREES. 1. -90. 4.69 -72.9 6.73 -53.5

ENTER TRIAL WEIGHT AND THE ANGLE FROM THE KEYER TO THE TRIAL WEIGHT "+" IN THE DIRECTION OF ROTOATION.

1. 360.

RESIDUAL BOW UNBALANCE : RUNNING SPEED HIGH SPOT:

1.0000 AT 4.69000 AT

-90.000 DEGREES. -72.900 DEGREES.

TRIAL WEIGHT OF 1.00000 AT WITH RESPECT TO THE KEYER.

360.00000 DEGREES

ANGLE FROM KEYER TO BALANCE PROBE: TRIAL WEIGHT HIGH SPOT: 6.73000 AT

0.00000 -53.500 DEGREES.

PLACE A BALANCE WEIGHT OF, 1.34588 AT , 0.1310643E 03 FROM THE KEYER TO BALANCE THE ROTOR. POSITIVE IS IN THE DIRECTION OF SHAFT ROTATION. BALANCE WEIGHT : 1.25033 AT 135.00000 DEGREES WITH 0.13064 AT DEGREES WILL PROVIDE ABOVE BALANCE.

90.00000

ENTER "1.0" TO REEXECUTE, "0.0", TO END PROGRAM. 0.0

Sample Run using Two Plane Balancing Software

**********TWO PLANE BALANCING METHOD********** BE SURE TO INCLUDE A DECIMAL POINT WITH ALL ENTRIES IN THIS PROGRAM. ENTER IN FREE FORMAT THE INFORMATION REQUESTED

ENTER "1.0" TO SUBMIT DIRECT DEFLECTIONS, "0.0", TO SUBMIT OSCILLOSCOPE TRACES. 1. ENTER "0.5" IF 200 MV/MIL PROXIMITOR PROBES WERE USED "1.0" IF 100 MV/MIL PROXIMITOR PROBES WERE USED "3.0" IF NEITHER 100 MV/MIL NOR 200 MV/MIL PROXIMITORS WERE USED. 3. ENTER 30. ENTER SPOT. 1. ENTER NUMBER OF MILS DISTANCE CHANGE REQUIRED FOR PROBE TO PRODUCE 1.0 VOLT. "1.0" IF ANGLES ARE FROM KEYER TO ACTUAL HIGH (ARE ABSOLUTE). OTHERWISE ENTER "0.0".

NEAR END AMPLITUDE NEAR END ANGLE (DEGREES) FAR END AMPLITUDE FAR END ANGLE (DEGREES) MAY BE ENTERED ON ONE LINE OR ONE DATUM PER LINE.

1.3 7. 1.6 52. WITH A TRIAL WEIGHT ADDED AT THE NEAR END ENTER NEAR END AMPLITUDE NEAR END ANGLE (DEGREES) FAR END AMPLITUDE FAR END ANGLE (DEGREES) MAY BE ENTERED ON ONE LINE OR ONE DATUM PER LINE.

1.5 65. 1.2 76. WITH A TRIAL WEIGHT ADDED AT THE FAR END ENTER NEAR END AMPLITUDE NEAR END ANGLE (DEGREES) FAR END AMPLITUDE FAR END ANGLE (DEGREES)

MAY BE ENTERED ON ONE LINE OR ONE DATUM PER LINE.

1.1 -15. .9 162. ENTER NEAR END TRIAL WEIGHT AND ANGLE FROM THE TRIAL WEIGHT TO THE KEYER. "+" IN THE DIRECTION OF ROTATION. 2. 90. ENTER FAR END TRIAL WEIGHT AND ANGLE FROM THE TRIAL WEIGHT TO THE KEYER. "+" IN THE DIRECTION OF ROTATION. .5 180. NEAR END RESIDUAL UNBALANCE: FAR END RESIDUAL UNBALANCE: NEAR END N2 UNBALANCE: FAR END F2 UNBALANCE: NEAR END N3 UNBALANCE: FAR END F3 UNBALANCE: NEAR END TRIAL WEIGHT: FAR END TRIAL WEIGHT: ALL VALUES ARE WITH RESPECT TO THE 1.30000 1.60000 1.50000 1.20000 1.10000 0.90000 2.00000 0.50000 KEYER. AT: 7.00000 DEGREES. AT: 52.00000 DEGREES. AT: 65.00000 DEGREES AT: 76.00000 DEGREES AT: -15.00000 DEGREES AT: 162.00000 DEGREES AT: 90.00000 DEGREES AT: 180.00000 DEGREES.

NEAR END BALANCE WEIGHT: 1.81581 FAR END BALANCE WEIGHT: 0.23803 WITH RESPECT TO THE KEYER.

AT AT

147.95294 -164.92392

DEGREES. DEGREES.

RESOLUTION OF BALANCE WEIGHTS YIELDS: NEAR END COMPONENTS ARE: 0.57561 AT 180.00000 DEGREES AND

1.36259 AT 135.00000 DEGREES.

FAR END COMPONENTS ARE: 0.08756 AT 225.00000 DEGREES AND

0.16793 AT 180.00000 DEGREES

ENTER "1.0" TO REEXECUTE, "0.0," TO END PROGRAM. 0.

References 1.

Thomson, W. T., Vibration Theory with Applications, Prentice Hall, Inc. Englewood, N.J., 1965.

2. Hatto Schneider, Balancing Technology , Schenk Trebel, 1977, pp 107-109. 3. Douglas G. Schneider, Fundamentals of Balancing, Schenk Trebel, 1983. 4. Edgar J. Gunter, Jr. et. al. , RODYN SHORT COURSE NOTES, May, 1977.