Project Report Nikhil Chavan 0707

VIBRATION ANALYSIS OF ROTOR WITH DEFECTIVE BLADES
CHAPTER NO.01
INTRODUCATION
1.1 Introduction
Rotating Blades are considered as the most common cause of failures in rotating machinery.
The blade failure modes normally occur as a result of cracking due to unforeseen operating
condition and variable loads. There for the early detection damage in the blades is essential to
reduce the machine downtime and form the safety consideration. A number of research
studies including vibration- based method found in the literature are basically include the
vibration measurement on turbine casing, torsional shaft vibration and resent trended on the
blade tip time(BTT) method.
The resent study highlights the potential of the shaft torsion vibration of monitoring the blade
vibration behaviour. In the present research study. The dynamics of the blade both in the
healthy and cracked condition are studied on a small experimental rig using the un-bearing
vibration and shaft torsional vibration are which measured using the accelerometer and the
incremental shaft encoder.
The instrumentations needed for the onbearing and the shaft bearing vibration measurement
are simple and non-intrusive. The purpose of the present study is to compare this two
methods to bring out which of this method is more effective of the purpose of the (BHM).
The blade failure modes normally occur as a result of cracking, high cycle stresses , blade
rubbing, blade lossless, degradation from erosion and corrosion. There for, early fault
detection is important introducing blade related failure and hence there is a need of a reliable
and simple blade health monitoring (BHM) technique.
Sinha et al.[1] recently analyse the in-situ measured vibration data at the bearing pedestals
during the steady state and the transient operations in the steam turbine to understand the
machine dynamics, and to identify the root cause of the failure of the last stage blade in the
low pressure turbine.
K.P.C. Shelve, Pandharpur Page 1

Al-bedoor [2] gave the review of the different recharge method that has been attempted for
the blade vibration measurement till 2002.in-situ casing vibration near the last stage of a low
pressure (LP) turbine in steam turbo- generator. The shaft instantaneous angular speed (IAS)
signal from the encoder raw signal based on time-intervals changes between successive
pulses are noting but the repeating the shaft torsional vibration.
This method is generally non-intrusive and non-exorbitant method and now the topic of
research of different application. A few of them include the identification of faulty
combustion cylinder (s) in the disel engine [7,8] using the crank shaft IAS signal and the IAS
response of the shaft with fault (s) in rotating machine [9,10] it has also been reported in the
literature that transverse blade vibration in obtain related in the shaft bearing vibration fully
stop it was experimentally verified on small rigs, and the mistuning effect on the blade
natural frequency was also observed [11,12].
A series of experiments were conducted on a test ring with 6 blade disc for two different
condition ;-( 1) healthy with mistuned effect, (2) blade root looseness These condition are
often observed in practice for the rotating machine like steam turbine , gas turbine etc. And
hence the early and reliable detection of the faulty condition (2) . This is the overall of
project.

1.2 Literature review:-
A Ahmed A. Gubran et.al [1] In this project paper has submitted 19 December 2012
Accepted 3 February 2013 and Available online 26 March 2013. In that project paper he was
represent that the condition and observe turbine blade at various stage of cycle. . The blade
failure modes normally occur as a result of cracking, high cycle stresses, blade rubbing, blade
root looseness, degradation from erosion and corrosion. Therefore, early fault detection is
important in reducing blade related failures and hence there is a need of a reliable and simple
blade health monitoring (BHM) technique.
For that he was used the encoder, turbo- generator, analyser etc. is The use of the encoder in
rotating machines is seems to be a common practice to measure the shaft speed. The shaft
instantaneous angular speed (IAS) signal from the encoder raw signal based on time-intervals
change between successive pulses nothing but the representing the shaft torsional vibration.
The sensor simply measures the gap between each tooth on the gear during its rotation which
results in the pulse train of the measured gap voltage with time and the extraction of
instantaneous angular speed (IAS) signal using the pulse train.
The measured shaft torsional vibration shows a distinct difference between the healthy and
the faulty blade conditions. Hence, the observations are useful for the BHM in future. The
paper presents the experimental setup, simulation of blade faults, experiments conducted,
observations and results.
A Jyoti K. Sinha et.al [2] she was also submitted the project report on related vibration
analysis. These failures include blade cracking, high cycle stresses, blade rubbing and
blade root looseness. Therefore, early detection of damage in the blades is critical to reduce
machine down time, maintenance costs and to maintain overall safety. Earlier studies
indicate that the shaft instantaneous angular speed (IAS) representing the shaft torsional
vibration is a good approach for the blade vibration [2].
Different vibration-based methods found in the literature basically include the vibration

measurement using torsional shaft vibration [1-2]. Hence, the shaft IAS is extracted from the
measured encoder data during machine run-up to understand the blade vibration [1].
The use of the encoder in rotating machines seems to be a common practice to measure the
shaft speed [8]. The shaft instantaneous angular speed (IAS) signal from the encoder raw
signal based on time-intervals change between successive pulses is simple but
representative of the shaft torsional vibration.
This method is generally non-intrusive and non-exorbitant method and is now the topic of
research for different applications. Some of these include the identification of faulty
combustion cylinder(s) in diesel engines [3-4] using the crank shaft IAS signal and the IAS
response of the shaft with fault(s) in rotating machines.
Maynard et al. [5-6] have also demonstrated the field application of the use of the
torsional vibration for tracking cracks in the shaft and blades. Analytical simulations have
also shown the potential of the shaft torsional vibration it could be used as the condition
monitoring for turbine blades [9-10]. Hence, the shaft IAS has been extracted from the
measured encoder data during the machine transient operation to understand the dynamics of
the blades A recent study [1] highlights the potential of the shaft bearing vibration for
monitoring the blade vibration behavior using IAS signal. The measured vibration and
encoder data are analyzed by computing the responses
at different engine orders (EOs) related to the blade resonance frequencies and their higher
harmonics to understand the behavior of the blades under the fault conditions. A number of
experiments on an experimental rig with bladed discs were conducted using 2 types of 8-
bladed discs of (long and short blades) with healthy but mistuned, blades looseness and data
are recorded into a PC during the machine run-up using the shaft torsional vibration
measured using the incremental shaft.

1.3 OBJECTIVE OF VIBRATION ANALYSIS OF ROTOR WITH

DEFECTIVE BLADES:-
The following is the objective of vibration analysis of rotor with defective blade
1. To design and develop experimental test rig for bearing vibration

analysis of rotating shaft.
2. To analyse the vibration response characteristics for healthy blade and defective blade
with mistuned effect, blade root looseness.
3. To analyse vibration response characteristics of healthy and defective blade for

variable speed.
4. To determine the life of blade
5. To compare healthy and defective blade results with previous research
1.4 Proposed work:-
Phase 1 : LITERATURE REVIEW

Data collection phase involves the collection of reference material for project
concept; the idea is taken from vibration analysis and our guide teacher.

Phase 2: SYSTEM DESIGN

The system design also determine the system component and their shape and
overall dimension, the part are show in part list.
Phase 3: MECHANICAL STRUCTURE

The part mentioned above in the part list will be designed in such way that they will
be suitable for our project.
Phase 4 : PRODUCATION SKETCH PREPRATION
Production drawings of the part are prepared, with appropriate dimensions and
geometry tolerances. Raw material size for part is also determined.
Phase 5: MATERIAL PROCUREMENT AND PROCESS PLANING
Material is produced as per row material specification and part quantity. Part
process planning is done to decide the process of manufacture and appropriate
machine for the same.
Phase 6: COLLECATION OF PART

Parts are collected as per requirement also those parts are not to obtain which are
manufactured in the workshop
Phase 7 : ASSEMBLY- TEST AND TRIAL
Assembly of device is done as per assembly set up drawing, and test and trial is not
conducted on device for evaluating the performance. There are some queries are
present we will try to reduce it

1.5 Organization of the report
Chapter1:
This chapter involves the review of threshing method studies. It also involve
literature revive of threshing process and objective of vibration analysis. Also
include introduction of vibration analysis.
Chapter2:
It involves literature review, research problem and method of vibration analysis and
factor to be considered and theoretical background.

Chapter3:
This chapter involves selection of material, manufacturing process of part,
constructional details, and design of machine component, in the we design the
blade, rotor and selection of shaft and also calculate natural frequency and vibration
by the FFT analyzer.
Chapter 4:
This chapter involves the result, construction and working, advantage, disadvantage
and cost estimation of the project. And also include experimental setup
Chapter 5:
This chapter involves the conclusion and future scope of our project.

Chapter No 02
2.1 Background History:-
Now a days we generate electrical power into lots of amount. The electricity generated with
the help of thermal power plant, Geo-thermal, Wind energy and lots of many way. The
electrical energy is generated on the principal of EMF generation. The main component of
generating electricity is turbine.
Type of failure of turbine :-
1 Corrosion Failure
A corrosion failure occurs when the metal wears away or dissolves or is oxidized due to
chemical reactions, mainly oxidation. It occurs whenever a gas or liquid chemically attacks
an exposed surface, often a metal. Corrosion is accelerated by warm temperatures and by
acids and salts.
Unacceptable failure rates of mostly blades and discs resulted in initiation of numerous
projects to investigate the root causes of the problems [1].Low-pressure blades of a steam
turbine are generally found to be more susceptible to failure than IP (Intermediate pressure)
and HP (High pressure) blades [2] as shown in figure 1.
The most common failure mechanisms which occur within low-pressure blade are Corrosion
fatigue (CF), Stress corrosion cracking (SCC), Pitting and Erosion-Corrosion in steam
turbines [3]. Hata et al [4] concluded that corrosion fatigue is the leading mechanism of
damage in low-pressure steam turbine and all fatigue cracking should be considered
corrosion fatigue

It is considered that the corrosive chemical enrichment in the wet/dry transient zone and the
corrosive environment have a strong relationship with blade corrosion fatigue damage [5].
From fractography result analysis many researchers have confirmed that corrosion
fatigue cracks often originate from pits by intergranular cracking and then proceeding as a
flat fatigue fracture with beach marks and striations
Fretting Fatigue Failure-
One common area for fretting failures to occur is blade/disk attachment at the fir tree
joint as shown in figure 2, in gas turbine engines is one of critical components which can fail
due to fretting fatigue [22]. Although this joint is nominally fixed, micro-scale relative
movement at the interface occurs between contacting bodies experience both centrifugal
and oscillatory tangential movement vibrations [23] resulting in damage and causes a
significant reduction in fatigue life [24]. This phenomenon is known as fretting fatigue and
often occurs in the blade and disk attachment region of gas turbines and jet engine.
The fretting cracks are initially quite small, but may eventually lead to severe
component damage. Eliminating or reducing slip at the interface is the only method for
preventing fretting fatigue, and it must be accomplished during the design process [26].
Fretting fatigue leading to crack nucleation, growth, and eventually failure faster than
that under the conventional fatigue condition without fretting (plain fatigue) [27]. A
complex interaction between high cycle and low-cycle fatigue leads to fretting-fatigue
induced failure in turbine disks.
Technical Details:-
Experimental setup consists of a shaft supported on two bearing and driven by a variable
speed motor. The test bearing is place to a non-drive end of shaft with radial load
arrangement shown in Fig.2, capable of changing load on test bearing.

The drive to test rig is provided with DC motor through muff coupling. A continuously
variable speed from 300 rpm to 3000 rpm from control panel of DC motor is expected. The
signatures of the vibration will be collected for various running parameters using the FFT
analyzer which is available at SKN COE, Korti, Pandharpur and has an accelerometer as a
sensor. The sensor will be directly attached to bearing outer race.
The readings will be obtained in the form of displacement, velocity and acceleration with
respect to time and frequency. The signatures obtained will be analyzed to formulate the
results. The results will then tabulated and will be presented in the form of graphs.
2.2 Component of vibration analysis:-
Motor:
The motor is used in project is 3 phase 1 H.P. DC motor. It produces 2813 rpm. It rotated the
shaft. The shaft consists of hub on which 6 blades is mount and produce on -bearing
vibration.
Dig.of Motor.

Selection criteria of motor:-
Sr.no Parameter Specification

1 Rpm 2813
2 Power Kw/Hp 0.75/1.0
3 Volts 415
4 Ampere 1.70
Shaft:
This type of shaft consists of pure stainless steel having grade is .
The detailed drawing of solid shaft is show in image below. It has provide to support the
turbine blade. Also it supported by two bearing

Dig.of solid shaft
Specification of sold shaft:-
Sr. Parameter Specification

No.
1 Outer diameter 20mm
2 Length 600 mm

Pedestal Bearing:-
This type of bearing consist of 1) a cast iron pedestal, 2) gun metal, or brass bush split into
halves called brasses, and 3) a cast iron gap and two mild steel bolts. The details drawing
drawing of pedestal bearing is showing in below. The rotation of bush in side the bearing
housing is arrested by a slug at the bottom of the lower brass. The cap is tightened on the
pedestal block by means of bolts and nuts. It can be adjusted by slot which is provided to it.
It having screws are provided to fix the shaft which is supported. The internal bearing is
adjusted as per our requirement. The opening is provided at top to greasing the bearing.
Dig.of pedestal Bearing.

Specification of pedestal bearing:
Sr.No. Parameter Speciation
1 inner diameter 20mm
2 Code UCP04
Blade:-
There are six blades mounted on the rotor shaft. All the defects which are observed during the
working of turbine are introduced on the blades like crack on the blades , blade root looseness
etc. are to be founded with the help of blades .the blades are more flexible. The detailed
drawing of Rectangular blades show in image below.
Dig .of Blade.

Specification of blade
Sr.No. Parameter Speciation
1 Material S.S.
2 Length 110mm
3 Width 20mm
4 Thickness 3mm

FFT Analyzer:-
Display Dig .of FFT analysis
The FFT spectrum analyzer invaluable tool for mechanical engg.in todays world
of measurement and analysis of mechanical system. FFT analyses are an essential
tool is such fields as vibration and shock data analyses, machinery monitoring and
analysis of complex waveforms. Use of the FFT analysis is required in many
industry , including military, transportation, aerospace, manufacturing and
customer products.
Many mechanical engineers to day make careers in the fields of vibration and
machinery analysis; the knowledge of principal and application of FFT analyses is
essential for these disciplines.

Chapter 3
METHODOLOGY
1. Selection of blade rotor:
A single row deep groove ball bearing is selected for the experimental study. The parameters
will be decided with respect to deep groove ball bearing. The maximum load capacity of the
overhang bearing will be evaluated with respect to its loading arrangement.
2. Preparing Defective sample blade:
The artificial defects are introduced separately on inner and outer race of single row deep
groove ball bearing using wire-cut machining method. The defects on the races are made with
varying sizes and defect locations.
3. Deciding the running situations:
The parameters like change in speed range of shaft, size of defect on defective
bearing, different defect locations in a bearing are decided which can be applied on the rotor-
bearing system during test.

3.1 Material
Sr.no Parameter Speciation
1 Shaft S.S. Grade 310
2 Blade S.S. Grade 310
3 Rotating Disc (Hub) S.S. Grade 310
3.2 Modal testing
Modal testing has been conducted on the test rig for the six blades in order to determine blade
natural frequencies by
using the Impulse-Response modal test [17]. Each blade was excited using an instrumented
hammer (type PCB-0860C03)
and the vibration responses were measured using a tiny accelerometer (Model 352C22, M/s
PCB) weighing just 0.5 g.
The blades natural frequencies were identified using the frequency response functions (FRF)
calculated from the measured.

Sr.No Natural Frequency Value
1 Blade 1 123.75
2 Blade 2 126.25
3 Blade 3 125.00
4 Blade 4 127.50
5 Blade 5 128.75
6 Blade 6 123.75
Mean Frequency 125.83

3.3 Machining operation on required parts:

Turning is a cutting operation in which the part is rotated as the tool is held against it
on a machine called a lathe. The raw stock that is used on a lathe is usually cylindrical, and
the parts that are machined on it are rotational parts mathematically, each surface machined
on a lathe is a surface of revolution .Machining is an essential process of finishing by which
work pieces are produced to the desired dimensions and surface finish by gradually removing
the excess material from the preformed blank in the form of chips with the help of cutting
tool(s) moved past the work surface(s).Most of the engineering components such as gears,
bearings, clutches, tools, screws and nuts etc need dimensional and form accuracy and good
surface finish for serving their purposes. Performing like casting, forging etc. generally
cannot provide the desired accuracy and finish. For that such preform departs, called blanks,
need semi-finishing and finishing and it is done by machining and grinding.
Grinding is also basically a machining process.
Machining to high accuracy and finish essentially enables a product:
Fulfill its functional requirements.
Improve its performance.
Prolong its service
1. Drilling the material as per dimension:
These four methods all produce holes of different types. Drilling produces round
holes of different types; reaming is used to improve the dimensional tolerance on a drilled
hole; boring uses a special machine operating like a lathe, to cut high precision holes; and
tapping creates screw-threads in drilled holes. Drilling: The geometry of the common twist
drill tool (called drill bit) is complex; it has straight cutting teeth at the bottom these teeth
do most of the metal cutting, and it has curved cutting teeth along its cylindrical surface. The
grooves created by the helical teeth are called flutes, and are useful in pushing the chips out
from the hole as it is being machined. Clearly, the velocity of the tip of the drill is zero, and
so this region of the tool cannot do much cutting. Therefore it is common to machine a small
hole in the material, called a center-hole, before utilizing the drill. Center-holes are made by
special drills called center-drills; they also provide a good way for the drill bit to get aligned
with the location of the center of the hole. There are hundreds of different types of drill
shapes and sizes; here, we will only restrict ourselves to some general facts about drills.

Common drill bit materials include hardened steel (High Speed Steel, Titanium
Nitride coated steel); for cutting harder materials, drills with hard inserts, e.g. carbide
or CBN inserts, are used;
In general, drills for cutting softer materials have smaller point angle, while those for
cutting hard and brittle materials have larger point angle;
If the Length/Diameter ratio of the hole to be machined is large, then we need a
special guiding support for the drill, which itself has to be very long; such operations
are called gun-drilling. This process is used for holes with diameter of few mm or
more, and L/D ratio up to 300. These are used for making barrels of guns;
Drilling is not useful for very small diameter holes (e.g. < 0.5 mm), since the tool may
break and get stuck in the work pieces;
Usually, the size of the hole made by a drill is slightly larger than the measured
diameter of the drill this is mainly because of vibration of the tool spindle as it
rotates, possible misalignment of the drill with the spindle axis, and some other
factors;
For tight dimension control on hole diameter, we first drill a hole that is slightly
smaller than required size (e.g. 0.25 mm smaller), and then use a special type of drill
called a reamer. Reaming has very low material removal rate, low depth of cut, but
gives good dimension accuracy;
large and deep holes are made by spade drills;
Countersink/counter bore drills have multiple diameters they make a
chamfered/stepped hole, which is useful for inserting screws/bolts the larger
diameter part of the hole accommodates the screw/bolt head;
Internal threads can be cut into holes that mate with screws/bolts. These are cut by
using tapping tools.
2. Welding the material as per dimension:
Welding is a process for joining two similar or dissimilar metals by fusion. It joins
different metals/alloys, with or without the application of pressure and with or without the
use of filler metal. The fusion of metal takes place by means of heat. The heat may be
generated either from combustion of gases, electric arc, electric resistance or by chemical
reaction. During some type of welding processes, pressure may also be employed, but this is
not an essential requirement for all welding processes. Welding provides a permanent joint
but it normally affects the metallurgy of the components. It is therefore usually accompanied
by post weld heat treatment for most of the critical components. The welding is widely used

as a fabrication and repairing process in industries. Some of the typical applications of

welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore
platform, bridges, welded pipes, sealing of nuclear fuel and explosives, etc. Most of the
metals and alloys can be welded by one type of welding process or the other.
However, some are easier to weld than others. To compare this ease in welding term
Weld ability is often used. The weld ability may be defined as property of a metal
which indicates the ease with which it can be welded with other similar or dissimilar
metals.
Weld ability of a material depends upon various factors like the metallurgical changes
that occur due to welding, changes in hardness in and around the weld, gas evolution
and absorption, extent of oxidation, and the effect on cracking tendency of the joint.
Plain low carbon steel has the best weld ability amongst metals. Generally it is seen
that the materials with high cast ability usually have low weld ability.
3. Grinding the project welding joints:
There are several types of grinding machines. The main ones are surface grinders,
grinding wheels, cylindrical grinders and center less grinders. The figure below shows
examples of a few of these. Surface grinders produce flat surfaces. The part is held on the flat
table (steel parts can be held by a magnetic force The table moves in a reciprocating motion,
and the rotating wheel is lowered so that it just scrapes along the surface.
To improve dimension control on cylindrical parts, center less grinders, which use
long cylindrical wheels, are employed. The axis of the regulating wheel and grinding wheel
are slightly misaligned, causing the part to travel slowly in the axial direction, and after some
time, the part automatically moves beyond the length of the wheel. Controlling the angle of
misalignment can control the time that the part is subjected to grinding. If a turned part of
complex shape (e.g. stepped shafts) are to be ground, then cylindrical grinding is used, which
employs specially made grinding wheels, whose profile fits the profile of the part to be
ground
3.4 Operations Involved
1. Cutting:
In this project it is used to cut some raw materials like square bar, PVC, PU Rubber,
Hollow rod. The abrasive cutter is used to cut the square bars and hollow rod Cutting of
hollow square bar to making the frame for the project into sixteen pieces as per the required
dimensions given in design.

Fig. Cutting Operation
2 Welding
It is the process which is used to joining of two or more similar or dissimilar metallic
rod and other material. Arc welding is a process utilizing the concentrated heat of an electric
arc to join metal by fusion of the parent metal and the addition of metal to joint usually
provided by consumable electrode. Either direct or alternating current may be used for the
arc, depending upon the on the material to be welded and the electrode used.
Fig. Welding Operation

3 Grinding
Sharp edges of the different part of the machine removed by using grinding machine. It also
improves the external look of the system and gives shine to it. Grinding operation is very
necessary for the safety of the operator.
Grinding is used to finish the work piece that must show high surface quality and high
accuracy of shape and dimension. However, there are some roughing application in which
grinding removes high volume of the metal quite rapidly.
Fig. Grinding Operation

4 Drilling
Drilling is the cutting process that uses a drill bit to cut or enlarge a hole of circular cross
section in solid material. The drill bit is a rotary cutting tool, often multipoint. The bit is
pressed against the work piece and rotated at rates from 100 to 1000 of revolution per minute
Fig. Drilling Operation

3.5 Experimentation
The fig. shows experimental set up of the opration.

3.6 Data analysis :-
Healthy blade with mistuned effect
The healthy blade with mistuned case (Case 1 as per Table) for the blades is tested initially
where the variation in the 1st natural frequencies is listed in Table. It is the most likely
condition of the healthy blades in any rotating machines like the steam turbines, gas turbines,
etc.
Blade root looseness
If the blades are not properly mounted and assembled on the shaft disc then the blades root
may be loose that could result in rubbing during machine operation which may lead to the
failure. Hence this root looseness fault is simulated by putting 2 free loose washers on the
root of Blades 1 and 5 separately as per the Case 2(i) and Case 2(ii) in Table 3. Fig. 9 shows
the root looseness simulation.

3.7 Design/ Graph analysis :-
For Healthy Blade:-
Fig. of FFT Ansys. (A)
Fig. of FFT Ansys (B)

Blade with rootlessness:-
Fig of FFT Anysis (A)
Fig of FFT Anysis (B)

Chapter NO 4
RESULT AND DISCUSSION
4.1 Experimental setup of vibration analysis:-
Fig.of vibration analysis
4.1.1 Working of vibration analysis:-
Vibration:- A body said to vibrate when it decribes an oscillating motion about a

refrancce position. The number of time a compited motion cycle take palce during
the period one secound is called as vibration.
Vibration created due to action of acceration,Displacement and velocity
Vibration measured in applituded.
It univasally measured in Metric unit with ISO system coherent Units.

4.2 Experiment Counduct
The vibration experiments have been carried out for all cases listed in Table (i.e., Healthy,
Root looseness). Initially the experiments were conducted at different constant shaft speeds
but the excitation of the onbearing vibration was not observed to be significant, hence the
further experiments were conduced during the machine run-up from 600 rpm (10 Hz) to 1800
rpm (30 Hz). The run-up rate was kept equal to 40 rpm/s. The measured analogue signals by
the accormeter sensors were then collected at 50,000 Samples/s and stored into the PC for the
further signal processing.
The dia.of experiment showes below.
Different view of hub, blade.
4.3 Cost estimation:-

Sr.no. Component Quantity Price

RS.
1 Shaft 1 200
2 Blade 6 500
3 Hub 1 500
4 Motor 1 1700
Total Material Cost =2900
4.4 Advantages:-
1) Down time of machine is reduced by 50-80%.
2) It is non-destructive technique which helps early detection of machine problems by

measuring vibration.
3) Lower expenses of over pay may same as much as 30%.
4) Increases the equipment life expectancy.
5) Reduces the maintenance cost by reducing the capital spending by 10-20%, labor cost
by 10%, material cost by 30%.
6) Improve the employees safety.
7) Preventive maintenance results in a catastrophic failure and down time are required to
complete all scheduled maintenance costs.
8) Damage to machine is less.

4.5 Disadvantages:-
1) High installation costs, for minor equipment items more than value of equipment.
2) Unpredictable maintenance periods are causing costs to be divide un equally.
3) Increased number of parts(CBM installation ) that need maintenance and checking.
4.6 Machining cost:-
1) Welding = 500/-
2) Grinding = 300/-
3) Drilling = 300/-
Total Machining cost = 1,100/-
Transportation Cost =1000/-
Total Project Cost = Material cost + Machining cost + Transportation Cost
= 2900 + 1,100 + 1,000
= 5,000

4.7 Instruction for Operating the System :-
Use a proper distance when operating instrument.

Does not run at high speed at starting.
Make sure that you have to knowledge about that.
Use under the giddiness of experience people.

4.8 Result:-
It is observed from Fig. 15(a) that the amplification of the BR region seems to be in a
banded form for Case 1 blade healthy condition. The mistuned effect in the blades
natural frequencies is possibly resulted into a band response.
A small amplification in the BR region at higher harmonics of 1 BR is also observed
for the healthy case.
A typical EO10 response in 2 BR region for the healthy case is shown in Fig. 16(a).
The presence of higher harmonics of the BR for the healthy
blades or higher harmonics of the shaft speed even for the healthy machine is often
observed in the experimental rigs and rotating machines. It is often due to some
misalignment in the rotor at coupling during the machine assembly [18]
However it is important to observe the dynamic behavior and changes in case of the
faulty blade conditions.
Cases 2(i) and 2(ii) are the root looseness cases at Blades 1 and 5 respectively. The
addition of 2 loosely held washers at the root has not affected the natural frequency of
Blades 1 and 5 significantly but their EO5 and EO10 responses in Figs. and 16 show
significantly different behavior compared to Case 1.
It was observed that the 1 BR and 2 BR show 2 or more distinct peaks instead of a
single banded peak for Case 1 healthy condition. These features are nearly common
for both blade looseness casesBlade 1 (Case 2(i)) and Blade 5 (Case 2(ii))
compared to Case 1 (healthy blades).
The observations are close to the Case 2 for the blade root looseness. Case 3(iv) was
basically the repetition of the Case 3(iii) after the period of 100 min rig operation. The
identical observations in the Case 3(iii) and 3(iv) also confirm the repeatability of the
dynamics behaviour of the rig the interaction due to the root looseness in the blades
seem to be responsible for the multiple peaks in the BR region and its higher
harmonics.
Further investigation is also done on a simple mathematical model to understand the
banded peak and multiple peaks in the BR region for the healthy and faulty blade
cases respectively.

4.9 Photograph of Setup:-

Chapter No 5
CONCLUSION
In this paper the measured shaft IAS signal during machine transient operation was used to
understand the dynamics of the rotor blades with and without faults. Experiments were
conducted for the 3 different blade conditions: (a) Case 1: Healthy with mistuned effects, (b)
Case 2: Blade root looseness and (c) Case 3: Blade crack.
The IAS signal when order tracked with the EO5 and its higher multiples shows the existence
of the BR and its higher harmonics for all the 3 cases. It was observed that the one banded
peak for healthy blades (Case 1) in the 1 BR changes to the two or more peaks in1 BR
and its higher harmonics for both faults conditionsthe blade root looseness (Case 2). These
features are nearly common for all faulty cases. A simple mathematical model and analysis
also support the feature of a banded peak and the multiple peaks for the healthy and the
cracked blade cases respectively. Hence the present observations are definitely encouraging
and can be extended further for the BHM.
The instrumentation cost and the signal processing are also not exorbitant and can be easily
extended to any industrial applications. More experiments are also underway with multistage
bladed discs to enhance confidence levels of the present observations.

5.1 Future Scope:-
wide range of study scope.

Breakdown of turbine is stopped
It reduce the maintance cost of turbine
For long period of turbine it gives useful information about turbine.

References
From internet :
- www.elsevier.com/locate/ymssp
- http://www.researchgate.net/publication/268687468
- www. FFT analyzer.com
- www. Pedestal Bearing.com
From Reference Paper:-
[1] K. Sinha, W. Hahn, K. Elbhbah, G. Tasker, I. Ullah, Vibration investigation for low
pressure turbine last stage blade failure in steam turbines of a power plant, GT2012-70129,
in: Proceedings of the International Conference on Turbine Technical Conference and
Exposition ASME TURBO EXPO, June 11-15, 2012, Copenhagen, Denmark.
[2] B.O. Al-Bedoor, Blade vibration measurement in turbo-machinery: current status, Shock
Vib. Dig. 34 (6) (2002) 455-461.
[3] A.R. Rao, R.K. Sinha, Insitu measurement on turbo-generators for detection of blade
vibrations, in: Proceedings of the VETOMAC-1, October 2000,Bangalore, India.
[4] D. Knappett, J. Garcia, Blade tip timing and strain gauge correlation on compressor
blades, Proc. Inst. Mech. Eng. Part G: J. Aerosp. Eng. 222 (2008) 497-506.
[5] J.S. Rao, A. Pathak, A. Chawla, Blade life: a comparison by cumulative damage theories,
Trans. ASMEJ. Eng. Gas Turbine Power 123 (2001) 886-892. [6] G. Dimitriadis, I.B.
Carrington, J.R. Wright, J.E. Cooper, Blade-tip timing measurement of synchronous
vibrations of rotating bladed assemblies, Mech. Syst. Signal Process. 16 (4) (2002) 599-622.
[7] P. Charles, J.K. Sinha, F. Gu, L. Lidstone, A.D. Ball, Detecting the crankshaft torsional
vibration of diesel engines for combustion related diagnosis, J. Sound Vib. 321 (3-5) (2009)
1171-1185.

[8] P. Charles, J.K. Sinha, F. Gu, A.D. Ball, Application of novel polar representation method
for monitoring minor engine condition variations, Mech. Syst. Signal Process. 24 (3) (2010)
841-843.
[9] L. Arebi, F. Gu, A. Ball, Rotor misalignment detection using a wireless sensor and a shaft
encoder, in: Proceedings of the Computing and Engineering Annual Researchers Conference
2010: CEARC10. University of Huddersfield, Huddersfield, 2010, pp. 6-13.

Project Report Nikhil Chavan 0707

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VIBRATION ANALYSIS OF ROTOR WITH DEFECTIVE BLADES

K.P.C. Shelve, Pandharpur Page 1

K.P.C. Shelve, Pandharpur Page 2

1.2 Literature review:-

K.P.C. Shelve, Pandharpur Page 3

K.P.C. Shelve, Pandharpur Page 4

1.3 OBJECTIVE OF VIBRATION ANALYSIS OF ROTOR WITH

1. To design and develop experimental test rig for bearing vibration

3. To analyse vibration response characteristics of healthy and defective blade for

4. To determine the life of blade

5. To compare healthy and defective blade results with previous research

1.4 Proposed work:-

Phase 1 : LITERATURE REVIEW

K.P.C. Shelve, Pandharpur Page 5

Phase 2: SYSTEM DESIGN

Phase 3: MECHANICAL STRUCTURE

Phase 6: COLLECATION OF PART

K.P.C. Shelve, Pandharpur Page 6

1.5 Organization of the report

K.P.C. Shelve, Pandharpur Page 7

2.1 Background History:-

Type of failure of turbine :-

K.P.C. Shelve, Pandharpur Page 8

Fretting Fatigue Failure-

K.P.C. Shelve, Pandharpur Page 9

2.2 Component of vibration analysis:-

K.P.C. Shelve, Pandharpur Page 10

Selection criteria of motor:-

Sr.no Parameter Specification

2 Power Kw/Hp 0.75/1.0

This type of shaft consists of pure stainless steel having grade is .

K.P.C. Shelve, Pandharpur Page 11

Dig.of solid shaft

Specification of sold shaft:-

Sr. Parameter Specification

K.P.C. Shelve, Pandharpur Page 12

Dig.of pedestal Bearing.

K.P.C. Shelve, Pandharpur Page 13

Specification of pedestal bearing:

Sr.No. Parameter Speciation

1 inner diameter 20mm

Dig .of Blade.

K.P.C. Shelve, Pandharpur Page 14

Sr.No. Parameter Speciation

K.P.C. Shelve, Pandharpur Page 15

Display Dig .of FFT analysis

K.P.C. Shelve, Pandharpur Page 16

1. Selection of blade rotor:

2. Preparing Defective sample blade:

3. Deciding the running situations:

K.P.C. Shelve, Pandharpur Page 17

Sr.no Parameter Speciation

1 Shaft S.S. Grade 310

2 Blade S.S. Grade 310

3 Rotating Disc (Hub) S.S. Grade 310

3.2 Modal testing

K.P.C. Shelve, Pandharpur Page 18

Sr.No Natural Frequency Value

Mean Frequency 125.83

K.P.C. Shelve, Pandharpur Page 19

3.3 Machining operation on required parts:

K.P.C. Shelve, Pandharpur Page 20

K.P.C. Shelve, Pandharpur Page 21

as a fabrication and repairing process in industries. Some of the typical applications of