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June 2012 | Volume 29, Number 2 For the Vibration Analyst Community
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2012
TRAINING SCHEDULE
As an organization with over 2,300 certified vibration analysts and members worldwide, we wanted to be sure that our administrative support was aligned to effectively respond to the needs of all our stakeholders. Improvements include: Upgrading our administrative resources, including office technology, the computer network, financial software, and the phone system to increase the efficiency and effectiveness of daily business operationsand better serve members. Reorganizing staff functions to better align roles, responsibilities, and accountabilities for certification, training membership, finance, and administration. Working closely with board officers and the board of directors to increase transparency through ongoing communication, quarterly conference calls, and two annual face-to-face meetings. The board has worked diligently and effectively to review and develop new programs that are of value to you and will support the next generation of vibration analysts (see page 23)
Since 1973, the Vibration Institutes mission has been the cornerstone for our growth and expansion. As a result, we have updated our look and interface with you to ensure that we remain vital to the profession we serve. Changes include launching the Institutes new website, www.vi-institute.org, in January 2012. It provides information in an intuitive and easy-to-use format in six verticals: About the Institute Membership Professional Development Certification Products and Services Chapters and Partners
The website also prominently features the annual Vibration Institute Training Conference and Online Store, two of the most widely used content areas of the site. The Members Only section, which will be available soon, will include a wealth of information and resources. Please stay tuned!
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More changes to increase the value of your Institute membership: In March 2012, we redesigned our flagship publication, Vibrations. The purpose of the redesign was to bring the look and feel of the publication into alignment with the Institutes new branding and website. Additionally, the publishing of Vibrations was brought in-house in January 2012 and every 2012 issue will be available online. We will continue to include the same outstanding technical content that you have come to expect over the years under the guiding hand of Dr. Ronald Eshleman, but we are providing new features like these: Letters from the president and executive director throughout the year Sections about certification, training, and academic programs From the Archivestimeless papers relevant to the profession no matter how much time has passed since they were written (beginning with the September 2012 issue) New advertisersto gain the attention of the vibration community, contact the Institute at (630) 654-2254 We will also be researching our options to publish Vibrations in an optional electronic format in 2013, to better serve our members and the vibration analyst community, so stay tuned.
Further extending our reach globally: We enhanced communications and now provide regular updates and information to our international representatives. Since 2010, we have increased the number of international representatives to 27, representing a 26 percent increase, with new representatives in China, India, Indonesia, Italy, and Mexico. Reducing turnaround time for certification examination results by 10 days, to that certification examination information is available quickly to candidates.
co MIng soon
The demonstrated success of these changes further deepens our commitment and drive to continue to align with our mission and nurture the next generation of professionals. In the coming months, you will hear more about: A membership database that will allow us to capture and store information more efficiently and provide up-to-the-date information on certification, training, members, products, and services, plus a new online membership directory. An enhanced strategic plan, developed by the board of directors, that will position the Institute for growth and opportunities, and will seek like-minded organizations to partner on projects that will further enhance the profession.
e n s u r
As a nearly 40-year-old organization, we feel there is an opportunity to examine how we can further strengthen the Institute and provide added value to all our stakeholders. Ideas were implementing include these: Revising the Corporate Sponsorship program to include three levels Platinum, Gold, and Silverand increase benefits and visibility through the new website. The number of corporate sponsors has increased from 40 in 2010 to 52 in 2012.
Of course, none of this would be possible without the commitment and hard work of so many, including our dedicated board of directors, committees, volunteers, and hardworking staff, all of whose candid and supportive feedback helped guide us. None of the changes throughout the past two years would have been possible without the hard work, dedication and involvement of manyand this is just the beginning. The best is yet to come.
c ontents
4 l etter from the e xecutive d irector By Karen A. Bresson, CAE f eature a rticle Rotordynamics of Pumps Part II: Between-Bearing Pumps By Malcolm Leader, P.E. 11 6 t echnical a rticle The Effect of Structural Asymmetry on the Vibration of Small Diameter Fan Rotors By Robert J. Sayer, PE c ase h istories Mechanical Looseness in a Fan System By Robert Jonas 21 Vibration of a Polyester Chip Crystallizer from an Electrical Source By Clyde Bridges a cademic c orner Establishing a Blueprint for the Future By Nancy L. Denton, P.E. a nnual l ist of c Individuals 23 19
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Vibrations | 5
f eature a rticle
Rotordynamics of Pumps
art I of this article, published in the March 2012 issue of Vibrations, concentrated on the rotordynamics of single-stage overhung pumps. Part II concentrates on the rotordynamics of between-bearing pumps.
Between-Bea
Some applications place a single impeller between bearings, usually employing a double-suction single-discharge arrangement. These designs will deliver more volume this way. With the impeller between bearings, the gyroscopic moment of the impeller cannot increase the critical speed of the rotor as with overhung machines (see reference 4). Typical applications are cooling tower pumps and boiler feed pumps. Such was the case with several problematic high speed (4,900 rpm) boiler feed pumps in a power plant. These pumps had a large pressure differential and two large eye wear rings, one on each side of the impeller. A portion of the complete train model is shown in Figure 1. This finite element model featured a complete case model with measured support characteristics. The orange bars represent two bushings with a 375 psi pressure differential and two eye seals with an 850 psi pressure differential. This pump experienced high vibration and bearing failures. The calculations showed that each impeller eye seal was almost 500,000 lb/in while the plain journal bearings were only 350,000 lb/in each. The seals were supporting the rotor
RIng Pu MPs
and did not have sufficient damping to control vibration. The bushings outboard of each eye seal were also unloading the bearings. Since modifying the seals was not an option that this user wanted to explore, highly preloaded tilting pad bearings were retrofitted. These bearings were designed with offset pivots so that significant stiffness and damping would be applied to the rotor even if the bearings did not have a significant gravity load. Although these pumps continued to have unexplained vibration excursions, believed to be caused by thermal effects, they run very well now that the bearings are supporting the rotor as well as the seals. f igure 1. d ouble-s uction Between-Bearing Boiler f eed Pump
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Take the previous example and add more stages and you get something like Figure 2. This is another boiler feed pump with a double-suction first stage and three additional single stage impellers. The water comes in, flows through the first and second stages, then crosses over to come back in the other side for the last two stages. This is done for hydraulic thrust balance. f igure 2. t ypical Multi-s tage Pump
This 1,800 hp pump has two plain bearings, two bushings, five eye seals and three hub seals. The seal pressure differential ranged from 40 psi to 160 psi and the speed was 3,585 rpm. As this was an audit of a new pump, a full API 610 analysis was conducted. This included an ANSYS model of the pump foundation conducted by Kelm Engineering. The bearing span is 70.562 inches. With all attachments except the coupling, the total wet rotor weight is calculated to be 617 pounds (7.9 pounds of water) and the coupling half-weight is 82 pounds. Because of the critical nature of the service, a full API 610, 10th Edition, Annex I analysis was required. The first required calculation is the first three dry critical speeds. In this case the first dry critical speed is below operating speed at 2,935 rpm and Figure 3 shows the mode shape. f igure 3. f irst c ritical s peed Mode s hape of Multis tage Pump
Next, the plain journal bearing coefficients supporting the rotor were calculated. This can be a challenge due to the hydraulic loads mentioned above. However, the specification designates that the static loading only be used. As it turns out, it makes virtually no difference in the end because the seals dominate the rotordynamic response in normal operation. Figures 4 and 5 are plots of the stiffness and damping values of the bearings versus rotor speed.
An ANSYS finite element model of the case was constructed from very detailed case and support base drawings by Kelm Engineering. Once the natural frequencies were determined, the dynamic stiffness in each direction (see Figure 6) was
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Vibrations | 7
calculated at the centerline of each bearing by applying an alternating force at the center of the bearing and then viewing the dynamic response at the bearing where the load is applied. The applied force and the calculated response were then used to determine the dynamic stiffness as shown in this equation:
This method of calculating the dynamic stiffness is similar to the method used to measure dynamic stiffness using a field test where a point compliance method is employed by applying a force and measuring the response at the same location. Finally, the seal coefficients at all 10 locations were calculated. Instead of endless plots let it be said that the principal stiffness of these seals ranged from 20,000 to 50,000 lb/in at each location. The cross-coupled stiffness at each seal was about 200 to 1500 lb/in and the damping ranged from 3 to 30 lb-s/ in. Seal coefficients were determined at design clearance and twice design clearance to account for wear. Rather than a traditional stability analysis, the API requirement is to calculate damping factors for all potential eigenvalues up to twice operating speed. API publishes an acceptability range for these factors depending upon how close they are to operating speed. All calculated values must be in the acceptance area as shown in Figure 7. f igure 7. Multi-s tage Pump a cceptance c hart
imbalance. With twice design seal clearance the predicted vibration increased by about ten percent. The overall conclusion is that the seals control the rotordynamics of most centrifugal pumps and that dry operation would be a very bad thing. If the seals become excessively worn, problems could also occur. In one particular case, the author looked at a 10-stage deep well injection pump that was periodically used to flush a sand filter. Large amounts of abrasive sand would erode all the seals and bushings each flush, the critical speed would eventually drop into operating speed and the vibration would become high enough to trip the turbine driver. In these cases the clearances would typically be 10 to 20 times normal clearance. This problem was solved by designing and building a clean water injection system. The case was drilled and tapped at each seal and bushing location and high pressure clean water was injected whenever the sand filter flush was activated.
1. Nicholas, J.C., and Barrett, L.E., The Effects of Bearing Support Flexibility on Critical Speed Prediction, ASLE Transactions, 29 (3), July 1986 2. Leader, M.E., Practical Rotor Dynamics, Proceedings of the Vibration Institute 26th Annual Meeting, June 2002 3. Leader, M.E., Rotor Dynamics as a Tool for Solving Vibration Problems, Proceedings of the 27th Vibration Institute Annual Meeting, July 2003 4. Leader, M.E., Rotordynamics of Semi-Rigid and Overhung Turbomachinery, Proceedings of the 28th Vibration Institute Annual Meeting, July, 2004 5. Kirk, R.G. and Gunter, E.J., The Effect of Support Flexibility and Damping on the Synchronous Response of a Single Mass Flexible Rotor, ASME Journal of Engineering for Industry, 94(1), February 1972 6. Nicholas, J.C., Whalen, J.K., and Franklin, S.D., Improving Critical Speed Calculations Using Flexible Bearing Support FRF Compliance Data, Proceedings of the 15th Turbomachinery Symposium, Texas A&M University, pp. 69-80, 1986
Refe Rence lI st
The unbalance response of this typical multistage pump is relatively uninteresting because all the seals wont allow a traditional critical speed to show up. The biggest concern is the operating speed amplitude at the tightest seal clearance location. This is done for design seal clearance and twice design clearance. Figure 8 is the predicted center-of-rotor relative shaft to stationary part vibration as a function of speed with 16W/N imbalance at the rotor center. Since the nominal radial clearance is 5 mils and the predicted peak-to-peak vibration at operating speed is 0.46 mils, there should be no danger of rubs even with this high level of
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7. Leader, M. E., A Solution for Variable Speed Vertical Pump Vibration Problems, Proceedings of the 2nd International Pump Symposium, Texas A&M University, 1985 8. Rotordynamics Tutorial: Lateral Critical Speeds, Unbalance Response, Stability, Train Torsionals, and Rotor Balancing, API RP684, American Petroleum Institute, August 2005 9. Chen, W. J., and Gunter, E. J.,Introduction to Dynamics of Rotor Bearing Systems, Trafford Publishing, 2005 10. Lomakin, A.A., Calculation of the critical speed and the conditions to ensure dynamic stability of the rotors in high pressure hydraulic machines, taking account of the forces in the seals (in Russian). Energomashinostroenie, 14, No.4, pp 1-5, 1958 11. Black, H. F. and Jenssen, D. N., Dynamic Hybrid Bearing Characteristics of Annular Controlled Leakage Seals, Proc Instn Mech Engrs, Vol. 184, pp. 92-100, 1970 12. Childs, D. W., Dynamic Analysis of Turbulent Annular Seals Based On Hirs Lubrication.Equation, ASME Journal of Lubrication Technology, Vol. 105, pp.429-436, 1983 13. Corbo, M.A., Malanoski, S. B., Pump Rotordynamics Made Simple, Proceedings of the 15th International Pump Symposium, Texas A&M University, 1998
14. Leader, M. E., Introduction to Rotordynamics of Pumps without Fluid Forces, Proceedings of the 1st International Pump Symposium, Texas A&M University, 1984
Malcolm Leader, P.E. owner of Applied Machinery Dynamics Company in Durango, CO, has been a turbomachinery consultant for 25 years. Focusing on providing practical solutions, he specializes in lateral rotordynamics including bearing and seal optimizations and steady-state and transient torsional analyses. Leader holds BSME and MSME degrees from the University of Virginia. He is a Certified Vibration Analyst Category IV by the Vibration Institute and is a member of the Institutes board of directors. He has more than 28 publications in the machinery and rotordynamics fields and holds one patent. He is an ASME Fellow and a registered Professional Engineer in Texas. He can be reached at mleader@rotorbearingdynamics.com
Commtest Instruments has been acquired by General Electric and is operating within the Measurement and Control business unit, specifically aligned with the Bently Nevada branded product portfolio. This acquisition highlights the complimentary condition monitoring portfolios of each business. As a business, we remain passionate about creating simple, intelligent systems that give our customers access to the asset health information they need to keep their machinery operating in optimum condition and meet corporate goals. Our product line-up includes portable vibration data collectors, portable vibration analyzers, portable dedicated balancers, and permanent machinery surveillance systems, all sharing intelligent user-friendly software interface.
Our tiered instrument range allows you to select an appropriate set of features at a cost effective price. Choose a model tailored to your requirements with the added peace of mind provided by our rock-solid 5 year warranty. Commtest, Inc. 6700 Baum Drive, Suite 12 Knoxville, TN 37919 1-877-582-2946
JUNE 2012
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ARMD
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Field Vibration Measurement and Analysis Torsional Critical Speeds, Mode Shapes and Response of Drive Trains Including Reciprocating Machinery, Synchronous and Variable Speed Drive Motors
Rotor Dynamics (Natural Frequencies, Stability, Critical Speeds & Response) Bearings, Bearing Systems, and Seals Failure Analysis Design Audit
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Tel: (610) 415-0412 Fax: (610) 415-0413 www.rbts.com JUNE 2012 info@rbts.com
t echnical a rticle
The Effect of Structural Asymmetry on the Vibration of Small Diameter Fan Rotors
Robert J. s ayer, Pe Applied Structural Dynamics
mpellers for many small to medium-sized commercial fan rotors are installed on the shaft using keys and set screws. Because of the lower service requirements of the these fans, the diameter of the shaft is relatively small. The proportion of material removed from the shaft when machining the key-way can be significant. In the case of a double-wide, double-inlet (DWDI) fan, the impeller is located near mid-span of the shaft, which is also the location of maximum flexural deformation. The key-way reduces the flexural stiffness of the shaft. The degree of stiffness depends on the orientation of the key. Figure 1 shows a cross section of a fan shaft with the keyway oriented at the top center position. The flexural stiffness is directly related to the moment-of-inertia, which is larger about the x-axis than the y-axis. When the shaft is rotated 90 degrees, as shown in Figure 2, the flexural stiffness increases about the x-axis and decreases about the y-axis. During operation, the fan is continually rotating about its centerline, resulting in an excursion in flexural stiffness twice per revolution. Since the key-way is concentrated at the impeller and does not extend the length of the shaft, this change in flexural stiffness is small. Gravity, a force that is constantly and statically applied to all objects on the Earth, is not a dynamic force. However, when gravity is applied to the fan rotor that has a rotating flexural stiffness, the magnitude of rotor deformation changes twice per revolution. Normally, the amount of this change in flexural deformation is extremely small since the change in stiffness is small. For most fans, it does not present a problem. It becomes an issue only when the natural frequency associated with the flexural mode of the fan rotor is close to twice the operating speed. Most small commercial DWDI fan rotors are designed to have the natural frequency of the flexural mode greater than the operating speed. If the natural frequency of the rotor coincides with twice operating speed, resonance will occur.
The amplified response of the rotor will usually result in noticeable vibration levels at 2X fan speed measured at the bearings. Although not common in SWSI fans, the effects of structural asymmetry can occur (see Case History 3 at the end of this article).
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Vibrations | 11
The magnitude of the 2X vibration component varies depending upon the stiffness of the bearing support. It can be significantly larger than the vibration at rotating speed, especially for typically very flexible bearing support structures of many commercial fan units. The high 2X response in the frequency spectrum of vibration, without any other harmonics, is often misdiagnosed as misalignment. Disk-skew also presents many of the same symptoms as structural asymmetry. If the center plate of a fan is not perpendicular to the centerline of the shaft, the disk-skew can produce dynamic forces at twice the rotational speed of the shaft without any other significant harmonic multiples. One distinguishing indication of structural asymmetry instead is that the vibrations in the direction of gravity (vertical) are usually significantly larger than in the horizontal direction. An exception to this would be fans mounted on structural supporting conditions with strong cross-coupling of horizontal and vertical stiffness. One method of diagnosing structural asymmetry is to perform two impact tests of the fan shaft, one with the key-way in the top-center (12 oclock) location and another with the key-way in the horizontal (3 oclock) location. The natural frequency in one direction should be slightly different from the natural frequency in the other direction. Also, for DWDI fans, the natural frequency should be very close to twice rotational speed. Since problems associated with structural asymmetry involve resonant excitation of the rotor, corrective actions include removing the dynamic force or changing the natural frequency. The following case histories illustrate the diagnosis and correction of the problem. All of these fans were mounted on a vibration isolation base similar to the sketch in Figure 3. f igure 3. t ypical f an a rrangement on an Isolator Base
failures result in total loss of product. The shaft and bearings of this unit failed. The bearing race that was fixed to the shaft loosened allowing it to rotate independent of the shaft. The relative motion between the race and shaft machined the outer diameter of the shaft almost as if it were done in a lathe. The fan wheel had a diameter of 48 inches and weighed 470 pounds. It was mounted on a shaft with a diameter of 3 15/16 inches. The fan was belt-driven by a 100 hp motor. The operating speed of the fan was 1620 rpm (27 Hz). Figure 4 shows the results of an impact test performed with the key-way in the bottom-center (six oclock) position. The natural frequency of the rotor was 53.8 Hz. Figure 5 shows the results of an impact test performed with the shaft rotated 90 degrees so that the key-way is in the horizontal position. The natural frequency of the rotor increased to 54.5 Hz. Both natural frequencies are almost coincident with twice the operating speed of the fan. The bearing vibration at twice operating speed of the fan was 0.03 ips in the horizontal direction and 0.22 ips in the vertical direction. This verticalto-horizontal vibration ratio of nearly 3:1, together with the natural frequency results, supported a diagnosis of structural asymmetry as the probable root cause of the failure. f igure 4. Impact t est Result-Key at 6 o clock Position (f an Rotor c ase 1)
53.8 Hz
54.5 Hz
case h Is to Ry 1
A sterile air handling unit at a pharmaceutical plant incorporated a small belt-driven commercial DWDI fan. Sterile air handlers must operate continuously; mechanical
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t echnical a rticle
The Effect of Structural Asymmetry on the Vibration of Small Diameter Fan Rotors
The corrective procedure used for this case was to remove the dynamic force. A new rotor was supplied that had a shaft without a key-way. The fan wheel was installed on the shaft using taper-lock hubs. Since the key-way was removed, so was the source of the dynamic force that excited the rotor resonance. f igure 7. Impact t est Result (f an Rotor c ase 2)
13.75 Hz
case h Is to Ry 2
A new air handling unit that used a DWDI fan was installed for several paint booths at an automotive plant. Excessive vibration during commissioning led the end user to reject the unit. The fan wheel had a diameter of 80 inches and weighed nearly 850 pounds. It was mounted on a shaft with a diameter of 4 15/16 inches. The fan was belt-driven by a 200 hp motor. The fan operated with a variable frequency drive (VFD). Figure 6 shows the frequency spectrum of vibration data measured at the bearing in the vertical direction with a VFD setting of 80 percent. Vibration levels exceeded 1.2 ips! Although the fan speed was 409 rpm (6.8 Hz), almost the entire vibration was concentrated at twice fan speed (13.6 Hz). At full speed, the bearing vibration reduced to 0.40 ips, which was still considered unacceptable. Blanking out the operating range of the VFD from below 80 percent to full speed was not considered a viable solution to the problem. f igure 6. f requency s pectrum of Bearing Vibration (Vertical d irection)
case h Is to Ry 3
A roof-top air-handling unit at a food processing plant used a single-wide, single-inlet (SWSI) plenum fan. The fan wheel had a diameter of 54 inches and weighed 500 pounds. The diameter of the shaft was only 2 7/16 inches. The fan was beltdriven by a 25 hp motor and operated at 700 rpm (11.7 Hz). Frequency spectra of bearing vibration contained an elevated component at 2X operating speed in the vertical direction. Figure 8 shows the results of an impact test of the fan rotor that identified the natural frequency of the flexural mode at 19.5 Hz. In this case, the natural frequency did not equal the second harmonic multiple of fan speed. Unlike a DWDI fan rotor, the natural frequency of a SWSI fan rotor will increase during operation [1][2] because of centrifugal stress and gyroscopic effects. In this case, the natural frequency increased from the at-rest value of 19.5 Hz to almost 23.5 Hz, making it very sensitive to the dynamic force developed as a result of structural asymmetry. f igure 8. Impact t est Result (f an Rotor c ase 3)
Figure 7 shows the results of an impact test that identified the natural frequency of the fan rotor at 13.75 Hz. At 80 percent of full speed, the natural frequency of the rotor matched the frequency of the dynamic forces developed as a result of asymmetry. The solution was to replace the rotor with one that had a shaft large enough not only to remove the natural frequency at 80 percent of full speed, but also to increase it beyond the excitation range of the 2X dynamic force at full speed.
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The cyclic change in flexural stress, combined with the local stress concentration at the key-way, initiated a fatigue crack. The fatigue crack propagated until the shaft experienced a catastrophic failure, splitting into two pieces. The failed rotor penetrated the sidewalls of the air-handling unit and damaged the roofing that protected the food processing operation from the elements. The failure of the fan caused the shutdown of the process. The corrective action taken for this fan was to increase the natural frequency of the rotor by decreasing the mass of the fan wheel. The original fan wheel was constructed from carbon steel. The replacement fan wheel was constructed from aluminum.
1. Sayer, R. J., Modal Characteristics of Single-Wide Fan Wheels, Engineering Paper 5207-03, AMCA International Engineering Conference, Schaumburg, IL, December 2003. 2. Sayer, R. J., Flexural Critical Speed of Single-Wide Fan Rotors, Proceedings of the National Technical Training Symposium of the Vibration Institute, New Orleans, LA 2003.
Robert Sayer, P.E., owner of Applied Structural Dynamics in Medina, OH, has over 35 years experience with condition-based maintenance technologies, specializing in modal analysis, finite element analysis and structural dynamic studies. Sayer holds a BSCE degree from Ohio University, a MSCE degree from Purdue University and a MSIE degree from Cleveland State University. He is Chairman of the Central Indiana Chapter of the Vibration Institute, a member of the Board of Directors of the Vibration Institute, and a registered Professional Engineer in the State of Ohio. He can be reached at sayerinc@bright.net.
c ertification s urveillance
In order to protect the Institute members who have justly earned certification as a Vibration Analyst, the Vibration Institute wants to pursue individuals who falsify Institute certification in any manner. If you are aware of any instance in which you believe an individual is falsifying his/her certification status, please call or contact the Vibration Institute immediately. If you are aware of any individual who you believe is violating basic ethics, please contact the Institute as soon as possible. Failure to do so degrades the reputation of your certification and the Vibration Institute. (630) 654-2254 information@vi-institute.org
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case study
uring a routine monthly vibration survey of a fan for a dust collection system in the food processing industry, a large increase in overall energy was noted to be coming from the fans bearings. Figure 1 is a sketch of the equipment arrangement, with data acquisition positions identified as numbers 1 through 4. Positions 1 and 2 were located on the motor. Positions 3 and 4 were located at the drive-side and fanside ends of the fan, respectively. New bearings had recently been installed at positions 3 and 4.
The fan system consisted of an overhung single-wide, singleinlet fan, belt-driven by a 50 hp, 1770 rpm motor. The fan speed was around 1109 rpm. Figure 2 shows five spectra of data acquired between December 2008 and January 2010. The spectrum for data acquired in January 2010 showed multiple harmonics of the fans running speed that were not evident in the previous spectra. A slight knocking could be heard coming from the fans driveside bearing area (position 3). The bearing support frame and shroud were inspected for any indications of mechanical looseness. No relative motion was found between the mating surfaces. Next, the bearings and shaft were visually inspected with a strobe light. The strobe light revealed indications that
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Vibrations | 19
f igure 4. f requency s pectra of f an Bearing Vibration (Before and after shaft replacement)
In conclusion, an increase in the operating speed harmonics of the fan indicated possible mechanical looseness. The time waveform and a strobe light were the key tools in determining where the looseness was located. The modulation helped to support the diagnosis of looseness. Allowing this fan to run to failure would have resulted in a costly unscheduled shutdown. Robert Jonas, a Certified Vibration Analyst II, has worked for Integrated Maintenance Technologies, Inc., in Kalamazoo, MI, for the past 16 years. In his 20-plus years in the vibration field, he has served in several industries, including paper, plastics, and the food industry. Jonas is an active member of the Vibration Institute and a Vibrations journal contributor who has published numerous local and national peer-reviewed articles. Send questions to him at robertjimt@aol.com.
impact occurring every 0.0541 seconds, with a strong modulation at the drive-side bearing. Once-per-revolution impacting with a modulated signal is a very good indicator of mechanical looseness. Since the energy was the greatest at the fans drive-side bearing, it was then confirmed that the drive-side bearing was loose on the shaft. The fan was shut down to avoid damage of the new bearings. A new shaft was installed because the old one was found to be undersized at the drive-side bearing. Vibration readings were taken following the shaft replacement. Figure 4 shows spectra of vibration data acquired before and after the installation of the new shaft. A comparison of the spectra showed that the vibration at harmonic multiples of fan speed had improved significantly. The mechanical looseness problem had been corrected.
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case study
his case study involves the drive motor for a chip crystallizer that is proprietary process equipment used in the making of polyester film and chips. The drive train of the crystallizer consists of a 200 hp motor, gearbox, and rotor. An unusual noise was reported, as well as a noticeable vibration. High motor current was also indicated on the operator control panel.
The panel meter indicated current on only one leg of the threephase power going to the motor. The vibration was present on the entire drive train. When vibration data were collected, amplitudes obviously were higher than normal, and they were higher on the motor than anywhere else on the drive train. Figure 1 shows a frequency spectrum of vibration data acquired from the motor. The spectrum was dominated by vibration at exactly 120 Hz (2X electrical line frequency). The vibration data did not indicate any change from the trend other than a 700 percent increase in amplitude at 120 Hz. Vibration at 2X line frequency often indicates an uneven air gap between the rotor and stator. However, since noise was present and the increase in amplitude was so sudden and dramatic, it was decided to perform a thorough electrical check. The motor current on all three legs could not be safely checked without first shutting the motor down and restarting. As an alternative to the motor current test, the motor was shut down, the power supply was locked out, and a phase-to-phase resistance check of the motor windings was done from the motor starter. The resistance check indicated an open leg in the motor. Plans were made to replace the motor.
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Before calling in a crane to lift out the motor, one of the technicians decided to double check the wiring from the motor starter to the motor. Further investigation revealed the open circuit was in a local 3-pole switch (lock-out device) located near the motor. Evidently the switch had failed while the motor was running and allowed the motor to continue running single-phase. The switch was replaced and the motor was restarted. f igure 2. f requency s pectra of Motor Vibration
Recertification Requirements
Certification as a Vibration Analyst is valid for five years from the date of current certification level. After five years, and in compliance with ISO 18436: Part I, certified Vibration Analysts are required to recertify. Re-certification at the current level of certification can be achieved in one of two ways: Renewal. You may provide evidence of continuing education experience, training and/or technical activity. Points for renewal can be earned for vibration-related activities including work experience, professional development, attending industry, association or chapter meetings, and vibration-related presentations and published articles. Re-examination. You may take the certification exam at the level you are currently certified. This requires scheduling an examination and securing a proctor per established Vibration Institute protocol. Vibration Analysts are certified on the basis of ability to function at a specified level. The motivation for recertification is to ensure that the Vibration Analyst maintains the capability to function at the level certified. Points toward recertification can be earned in various ways. The Vibration Institute Certification Committee has approved renewal requirements as follows: Category I: Category II: Category III: Category IV: 24 points (beginning January 2011) 28 points (beginning January 2011) 32 points (beginning January 2013) 36 points (beginning January 2014)
Figure 2 shows multiple spectra of motor vibration acquired before and during the electrical problem and after replacement of the local 3-pole switch. Vibration levels returned to normal. It is important to note that not all vibration is caused from mechanical problems, and the motor is not always the culprit when there is a so-called motor problem. Clyde Bridges, a licensed master electrician with 40 years of experience, has level 4 Vibration Institute certification and is also certified by the Municipal Association of South Carolina. Since 1994, he has worked as a machinery vibration analyst in the predictive maintenance department at Mitsubishi Polyester Film in Greer, S.C. He can be reached at clyde_bridges@bellsouth.net.
Visit www.vi-institute.org and click on Certification to learn more about earning points for re-certification!
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Academic Corner
Academic authors, the majority of whom are students, will give their 20-minute presentations on Thursday, June 21, during the Training Conference in Williamsburg. The eight selected presentations for the academic track program are thoughtprovoking and represent a variety of areas within the industry: Vibration Data Acquisition and Analysis for a Small Residential Wind Turbine Shannon Sweeney, Penn State Erie, The Behrend College Robert Michael, Penn State Erie, The Behrend College Design and Analysis of Non-Linear Spring Based Passive Suspension Using B-Spline Collocation Method Rahul A Jhaveri, Rochester Institute of Technology Hany Ghoneim, Rochester Institute of Technology Design and Implementation of Passive and Multichannel Active Noise Treatment of a 2kw Diesel Generator Cory M. Papenfuss, Virginia Polytechnic Institute and State University Tom-Davy W. Saux, Virginia Polytechnic Institute and State University Chris R. Fuller, Virginia Polytechnic Institute and State University A Study on Effect of Foam on the Vibration Quality of Aluminum Structure Under Combined Loading Masud Nawaz, Georgia Southern University Aniruddha Mitra, Georgia Southern University An Experimental Study of the Curve-Veering Phenomenon Phillip D. Rodenbeck, Rose-Hulman Institute of Technology Stephen S. Sakai, University of Wisconsin-Madison Compensation for Boundary Condition Effects of a Helicopter Blade Droop Stop Using Frequency Domain Impedance Modeling Douglas Adams, Ph.D., Purdue University Blake Hylton, Purdue University Andrew Crandall, Purdue University
Initially, weve taken a two-phase approach to develop programs that bring college students and academics to the 2012 Vibration Institute Training Conference on June 1922, 2012, in Williamsburg, VA: Phase 1Establishing academic track conference sessions dedicated to university research, student projects, and instructional practices, while meeting the academic requirements for refereed publications. Phase 2Sponsoring the conference attendance of a select group of students who have expressed an interest in our profession.
The academic track program will invite future industry professionals and the faculty who prepare them to present their vibration-related papers at the conference and their papers will be published in the Conference Proceedings. The program funding will heavily subsidize conference registration for the presenters. My academic committee colleague, Bob Sayer, and I quickly reached out to various universities with a Call for Papers, requesting abstracts by November 18. Interested candidates submitted draft papers by January 27 and final papers by April 13. Each manuscript submission was reviewed by at least two peer reviewers.
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The Effect of the Contact Model on ImpactVibration Response Matthew R. Brake, Sandia National Laboratories Static and Dynamic Behavior of Open Cell Metallic Foam Structures Swaminadham Midturi, Ph.D., University of Arkansas at Little Rock These eight papers will be published in the Conference Proceedings and will be available online from the Vibration Institute: www.vi-institute.org.
Mo VIng fo Rwa Rd
The Vibration Institutes Board is committed to supporting the future generation of our profession. The success of the 2012 academic Track and academic sponsorship program will most certainly result in offering the track and program again at the Vibration Institute Training Conference in Jacksonville, FL, on June 1821, 2013, at the Wyndham Jacksonville Riverwalk. Information about the Call for Papers will be available in the fall on the Vibration Institutes website: www.vi-institute.org. A number of our chapters already offer educational scholarships. The Board is grateful to them for their efforts to ensure that we have a next generation of vibration professionals. Beginning with discussions at the June conference, we will be gathering suggestions for ways to collaborate locally and nationally to strengthen our efforts to encourage our future colleagues. Nancy L. Denton, P.E., is professor and associate department head for mechanical engineering technology at Purdue University, where her primary teaching and research interests are machinery health-monitoring and data acquisition. Her industrial experience includes design engineering for the Naval Avionics Center and acoustical engineering for Digital Equipment Corporation. A member of the Vibration Institutes board of directors, she chairs the academic committee and serves on the certification committee. She is also a member of ASME and an ASEE fellow. She can be reached at dentonnl@purdue.edu.
Some of us show up for our first conference when we are presenting our work, but for most of us, participation is the starting point on our professional growth journey. To that end, we set up our student sponsorships to benefit both authors and non-authors. With the help of key vibration and monitoring faculty, we identified eight students from four institutions. Their transportation, hotel, and conference registration costs are provided by the academic sponsorship program. By attending the conference, students will obtain valuable experience networking with other professionals, exchanging technical knowledge, and beginning their lifelong professional journey of sharing information and findings within the industry.
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Certications
Certied Institute Members Vibration Analyst ca tego Ry II*
Denni Khusuma Stephen R. Kiefer David King Kerry Herman Knapp Francis A. Knight Matthew J. Knuth Chee Wee Koay David C. Koehler Lingjun Kong James S. Kosinski Edward N. Kriner Balasubramanian Krishnakumar Arunkumar Krishnan S. Murali Krishnan Sujit Kshatri Meaghan L. Kubisa Pasit Kulkitdecharat Nicholas H. Kulupka Rishikesh Kumar Iman Parta Kusuma Prakash Kutagolla Maano Archibald Kwinda William A. Lackey Thomas Lagarde Luis Torres Lagos Errol J. Lain Steven A. Lake Praveen Lakshmanan Craig Scott Landry Jim R. Landry Louie J. Langford Mark A. Lanius George Lankford Alain Laporte Shanmugam Latchaman Louis P. Lavallee Johnny H. Lawson James G. Laxson Glyn S. Learmonth Jerome R. LeBlanc Cherk Koon Lee David H. Lee Fook Mun Lee Jung-Chieh Lee Kim Yang Lee Kit Lee Ramiro M. Leon Francois Leonard William R. Lewis Lihong Li Zhen Dong Liang Ari Dinata Lidera Sergey Likhachev Jirapong Lim Thomas R. Lippincott Jing Feng Liu Zheng Liu Poongkunran Llangovan John Lombardozzi Gary G. Long Godofredo Lopez Sergio Lopez Chora Angel Ramon Lopez Zugasti Asle Lotveit Jerold Luby Tom Lumadue Michael F Mac Kinnon, Jr. James G. Maddrey, Jr. Marvin Madriz Barrantes Carlos R. Magana Javier Domenico Maggio Mohamed S. Mahmoud Hilal Mark A. Malanya Paul T. Malek Lucy Malone Amr Yousrey Manisy Robert A. Marcel Manuel A. Marin Jorge Arturo Marin Castillo Richard B. Marks, Jr. Charles W. Martin Rodney W. Martin Cosme Martinez Eloy Martinez Martinez J. Jesus Martinez Rodriguez Scott E. Mason Walter Keith Matherne Roshan Elias Mathew Peter R. Mattes Steve Matthews Grant D. Mayers Edgar Manuel Mayo Filio Matthew A. McDonald Philip Glenn McDugle Robert A. McEvoy Tammy McGath Mark T. McGown Mike McGregor Raymond F. McKinney Michael R. McMahan Richard McMullen Michael R. McNulty Khairil Safuandy Md Salleh Keith L. Mead, Jr. Alejandro Medina Gonzalez Alok Mehrotra Kenny A. Melendres Quispe Ted Melnyk Fabio A. Mendoza Gomez Hecner Merino Berrocal Stephen F. Merkel Kevin Meyermann John J. Meyers John J. Michael Richard Miedema Youssef Ibrahim Mikhail Stephen W. Mireles Brian Miska David R. Mitchell Michael Mizell Sascha Moebus Tony J. Moeller Darrell W. Moerbe Khavi Fazal Mohamed Meeran Mohideen M. Abel Ortega Mollar Peter I. Moncrieff Pablo B. Monteverde Donald J. Montry William Jeff Moran Tino G. Morassut Bernardo Moreno Lozano Richard A. Morris David E. Morrison Jerry Morrison Scott Morrison Mark Mosher Brian Mroozian Phillip Munoz Srinivasan Murali James P. Murphy Bevan Scott Murray Kit Chandler (Casey) Murray Stephen M. Murray Muhamad Saiin Mustofa Thangavelu Muthukumaran Halvard Myrvang Mohan Nachiappan Muhammad Naeem Akhter Ravi Naidoo Juan Manuel Najera Perez Venkatesan Narayanan Claude G. Nasse Ravi L. Natarajan Navapun Navasearttavisootr Deepak G. Nayak Joel Negreros Zamora Christopher P. Nemarich Michael P. Nero Cameron Newton Tze Shen Ng Yen Yee Ng Wong Fook Ngian Thanh Ngo Duy Raymond R. Nichol Jiramit Noothong Mark A. Nowakowski Peter A. Oakes Timothy R. Okerson Fred G. Oliva Brett C. Oliver Tracy ONeal Randy Paul ORosco Thomas Orr David P. Osis Nicholas P. Oslowski Luis F. Ovalle Josue Rosemberg C. Ozuna Alex Pachas Sulca Luis Alberto Padron Rojas Pradeep Raghoba Parab Glen W. Parker Jacquelyn G. Parker Robert Aaron Parker Daniel J. Parry Darrin K.J. Parsons Piyush Patel Pratap Ramrao Patil Pasakorn Patisonthi Ranganayakulu Patnala Craig D. Patterson Andrew M. Pauken Denis Paulet Gary M. Payne David Peck Christopher D. Pekrul William J. Pelletier Joseph M. (Mike) Penkin Harish S. Pera Ivan Jorge Perez Gutierrez Rosalio Perez Martinez Marco Antonio Perez Perez Joseph M. Perkins Dedi Permana Richard K. Pernich Richard S. Peterson Kevin Pettinelli Mark K. Phillips James J. Phillips, II Eduardo F. Piatti Mike Picou Salvador A. Pineda Ibanez Lee Han Ping Willman R. Pinto Flores Gasper Pizzolato John C. Plott Thomas J. Pluskat Greg Poirier Michael Polk Brandon M. Pollet Ernest E. Polmateer, III Bopanna P. Ponnanna Ross Porter Scott Porter Randell L. Powers Doug J. Prasek Alberto Prieto Hernandez Widhya Putra Propatria Michael A. Pytlinski Brian J. Quirk Alex Quispe Quispe Ross Kendrick Rabun Michael D. Raffetto Alaa Eldin M. Ragab Daniel Rains Sudhar Rajagopalan Abdoh Ahmad Rajhi Alexi S. Rakow Chandran Ramalingam Jose A. Ramirez Escobar Amrit A. Ramnanan Amaresh Rath Jose Luis Rattia Palanisamy Ravi David R. Rayle Imanel Kostanv Rebello Pathakota Sudheer K. Reddy Jonathan Reed Jeffrey L. Reeves Juan Carlos Reich Sheldon Reid Jon Reisner Neva J. Rhoe Franco Matias Ricci Carlos Jorge Riera William A. Rinehart Adrian Rios Alvaro Marcelo Rivero Alen Antony Robert Phil Robinson Wilmers Cruz Rodriguez Janio J. Rodriguez Martinez Arquimedes Rodriguez Mata Dennis O. Rogers Fernando Rojas Carreon Danuta Romanowski Gustavo Romero Pradilla Luis Carlos Romero Roa Ruben Jose Rosales Mohd Kazzlan Bin Rosalie Steven A. Rosenau Pablo Enrique Rossi Dale A. Rountree Michael T. Rouse Rafael R. Rozo Andy Ruehs Abraham L. Ruper Matthew Rush Anthony D. Russell Rick Russell Majed Hassan Saimaldahr Asif Ramzan Ali Sajwani Mohamed Salahudeen K.H. Luis A. Salcedo Cabezas Mohamed Ibrahim Salem Israel Salinas Leandro Salvatore Pathiri Narayanan Sampath Kenneth F. Sanchez Mario Sandoval Tolentino Worasak Sansri Joseph Santillo Ghilmar J. Santos Chauca Robert L. Sardo Andri Sasongko Arturo Sastre Noble Jerl W. Savage Chuck Saverline Michael A. Sayre Jason W. Schley Kenneth W. Schoenbauer Jeffrey S. Schwartz Charles R. Scott Charles S. Scott Michael R. Scott Dale E. Sedam Lawrence V. Seger Jeremy Scott Self Le Roy M. Sell Murugesan Sellapillai Joe Sendejo Ramasamy Senthil Kumar Paul Settles Irvin Jean Sewell, Jr. Essam Ewis Shaban Rakeshkumar N. Shah Abdulrahman N. Shamsudeen Scott L. Shapiro Jed Cameron Shaw Jainul O. Sheik Mohamed George Sheppard Elvin B. Shields Thomas L. Shirley Andrew J. Shoaf Ilya Shulkin Robert Shumate, Jr. Robert E. Siebert Theodore C. Sill John S. Simmons, III Robert B. Simpson Glenn E. Sims Rajeev Rajkumar Singhai Matthew W. Singkofer Dale Skinner Joseph L. Sklepik, III Christopher Slaton James J. Slawson Philip C. Slifkin Kevin J. Small Dan Smith Martin L. Smith Michael Nathan Smith Ronald H. Smith Timothy J. Smith Kjetil Solberg Jose Saul Sosa Baltazar Francisco Gerardo Sosa De Los Santos John David Spann John M. Sperrazza Kenneth E. Squires Rajendra Kumar Sridhar Gudipudi Srinivasulu Jonathan L. Stan Joseph A. Stilwell Mark V. Stokley Martin Strade Scott A. Stranford Katie Ann Strautman Tom Strawley E.J. Stringer, Jr. Ray Studdard Baoding Su Shitiz Sud Troy A. Sulliman Junqiang Sun Ahmed Abdullah Suqait Eric Suseno Virgil E. Sutton Rick Svendsen, Jr. Greg Svicarovich Kedrick W. Swain Kyle K. Swartley Michael R. Tallman Fernando Tapia Arteaga Christopher J. Taylor Gordon K.L. Templeton Tenzin Semjon Terehhov Sukham Thanapaisarnkit Kenneth L. Theimer Corey Scott Thoe David J. Thompson Victor E. Thompson Ted A. Thull Chaiyan Tibdee Andrew G. Tierney Irappa S. Tikkundi Brian Tjelle Edwin E. Todd, Jr. Watson Tomlinson Marcel B. Torrejon Torrico Ronnie Valenzuela Torres Alejandro Torres Aleman Juan H. Torres Guevara Jose Torres Mejia Helge Torvi Jim Townsend Robert Trahan Gustavo Trinidad Ventura Vimalendu Bhushan Tripathi Mark A. Trosclair Michelle Lobben Tveit Richard Tym Williams E. Udoa Larry A. Ulschmid Keith Ulyatt Albert Ike Umunna Juan Carlos Ustiola Subramanian K. Vaidyanathan Javier Marcelino Valderrama Segura Alfonso Valdez Ronald R. Van Cleave Marc Van Dyk Joe Van Dyke Eric Shawn Van Leuven Steve Vandagriff Nicolas Vasena Francis S. Vass Girish Padinhare Veetil Vijayakrishnan Venugopal Jorge Luis Vera Mechan David E. Verbanick Oscar Beja Vieira Palani Vijayaraghavan Jose Noel Villamizar Edgar Villavicencio Mattos Greg Vokovan Mukesh Vyas Manojkumar B. Wagh
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Certications
Certied Institute Members Vibration Analyst ca tego Ry III*
Gary J. Roesner Dennis H. Roinick Malla Guna Sagar Justo Jesus A. Salgado Razo Art Salter Sean M. Sampson Tareq Essam Saqr Manish Kumar Saxena Alberto G. Schirmer Jacob Schlottman Michael T. Schunk Michael G. Schutze Gregg Schwartz Jeff Eric Scott Terry Scroggins Karl Seguin Robert F. Seibert Ramesh Seshan Kenneth Sharp Barry L. Shaw Kenneth R. Shifett David W. Shook A. Keith Smith Adrian M. Smith Allen L. Smith John N. Smith Michael Smith Mohd. Abd Elkreem Soltan Timothy Sorensen Somkhuan Sornpetch Broc A. Sparks John R. Speer Kevin A. Spencer Jason T. Spettel Dino Spina Gary M. Stamper Bruce C. Stanley Keith Stanton Charles Stevens Todd Stevens Octavian Ion Stirbu Steven E. Stivers Michael S. Stives Brian K. Strampe Terry Q. Sudduth James Sullivan Michael Supplee Deren Swartz Michael A. Szurkowski Mozaid Bin Tajuddin Robert Tapia Peggy Tarnowieckyi Ivan Lee Taylor James L. Thomas Mark R. Thomas James Thompson Robert E. Thompson Michael E. Thornton Tim Threatt Scott Tilley Luther B. Tilley, Jr. Jeffrey C. Tipps Stephen J. Toomey Kiran K. Toram John Trulli Mikhail Tsypkin Roger W. Tucker Iosefa Tuimaualuga Gino Uliana Mario P. Urquizo Calderon Muthusamy Vaikundam William Van Heyningen Blake W. Van Hoy John Adriaan Van Zwienen Earl Randall Vaughan Dennis K. Vaughn Orlando L. Venegas Christopher J. Verink Luis Fabian Villacres Eugene T. Vogel Mark F. Vowell Robby D. Wallace Zhiping Wang Stephen L. Wareham Ray Warpehoski C. Nelson Watson Nelson Gregory Watson Bruce Weathersby Timothy C. Wechsler Marc E. Williams Shawn A. Williams Christopher P. Wills David Ray Wilson Anthony T. Wofford Stanley M. Wolczyk Vincent F. Woodkotch Rick R. Woodward Prasada Rao Yaramatti Peera Yongsuwan Michael A. Yucatonis David Zambrana Fonseca Molly A. Ziergiebel
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*Current Vibration Institute certied Vibration Analysts according to ISO 18436 Vibration Analysts (certication fees paid and ISO form on le as of May 18, 2012). **Certication current and fees paid as of May 18, 2012. ***Current CMVA certied Vibration Analysts according to ISO 18436 Vibration Analysts (certication fees paid and ISO form on le as of May 1, 2012).
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