WBPDCL

WELCOMES YOU TO THE FIELD BALANCING TRAINING COURSE

AGENDA

INTRODUCTION TO BALANCING WHAT IS UNBALANCE ? CAUSES OF UNBALANCE BENEFITS OF BALANCING TYPES OF UNBALANCE RECOGNISING VIBRATION DUE TO UNBALANCE SINGLE PLANE BALANCING VECTOR

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SINGLE PLANE BALANCING WITHOUT PHASE SINGLE PLANE BALANCING WITH CHART TWO PLANE BALANCING

INTRODUCTION TO MULTI PLANE BALANCING

COMMON PROBLEMS

LEARNING OBJECTIVES

OBTAIN AND INTREPRET THE RANGE OF PARAMETERS CALCULATE THE FORCE RESPONSE FROM UNBALANCE IN ROTORS ASSESS THE CAUSES OF UNBALANCE BALANCE A ROTOR WITH AMPLITUDE ONLY

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BALANCE IDENTICAL ROTORS USING FLASH ANGLE USE A VARIETY OF METHODS FOR ADDITION OF CORRECTION WEIGHT CALCULATE THE ADDITION OF BALANCE WEIGHTS AND THE DIVISION OF CORRECTION WEIGHTS

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DIAGNOSE THE TYPE OF UNBALANCE MAKE 1 PLANE, 2 PLANE BALANCE CORRECTIION USING VECTOR SOLUTIONS AND USING BALANCING INSTRUMENT 246

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USE BALANCE TOLERANCES WITH REFERENCE TO ISO 1940 CALCULATE AND CORRECT THE EFFECT OF STATIC AND COUPLE UNBALANCE

TIME SCHEDULE

FIELD BALANCING TWO DAYS START - 09.00 HRS BREAK 10.30 - 10.45 HRS LUNCH - 12.15 - 13.15 HRS BREAK 15.00 - 15.15 HRS FINISH - 17.00 HRS

DEFINITION OF UNBALANCE

ISO DEFINITION

THAT CONDITION WHICH EXISTS IN A ROTOR WHEN VIBRATORY MOTION IS IMPARTED TO THE BEARINGS AS A RESULT OF CENTRIFUGAL FORCES

OTHER DEFINITIONS

UNEQUAL DISTRIBUTION OF WEIGHT OF THE ROTOR ABOUT ITS ROTATING CENTRE LINE

IT IS ALSO DEFINED AS MCD

GRAPHICAL REPRESENTATION

R = RADIUS IN CM W = UNBALANCE MASS IN GMS. UNBALANCE U = W X R GM CM

CAUSES FOR UNBALANCE

UNBALANCE IS GENERALLY CAUSED DUE TO

1. PRODUCTION PROCESS 2. SERVICE EFFECTS

PRODUCTION PROCESS

CASTING IMPELLER,PULLEY FABRICATION FAN FORGING CRANK SHAFT OTHERS ARMATURE

CASTINGS

BLOW HOLES OR SAND TRAPS RESULTING FROM CASTING PROCESS UNDETECTABLE BY VISUAL INSPECTION THE VOID REPRESENTS TRUE UNBALANCE

BLOW HOLE IN CASTING

ECCENTRICITY
THE GEOMETRIC CENTRE LINE DOES NOT COINCIDE WITH ROTATING CENTRE LINE - ECCENTRIC MACHINING - ECCENTRIC HOLE - OVERSIZE WEB

ECCENTRICITY

OVERSIZE WEB

ECCENTRIC HOLE LOCATION

OTHER CAUSES
KEYS AND KEYWAYS MOTOR BALANCED WITH OUT KEY PULLEY BALANCED WITH OUT KEY ASSEMBLY WILL RESULT IN UNBALANCE

UNBALANCE DUE TO KEYS

KEY

UNBALANCE DUE TO TOLERANCES

THIS IS ONE OF THE MOST COMMON CAUSE TOLERANCES FOR DIFFERENT PARTS GET ACCUMULATED TO PRODUCE UNBALANCE

PULLEY GEAR COUPLING

KEY

CLEARANCE TOLERANCE

SHAFT CENTRELINE

PULLEY CENTRELINE

OPERATIONS
DEPOSIT BUILD UP WATER BUILD UP CORROSION AND WEAR THERMAL DISTORTION OVER HAUL ROTOR STORAGE HYDRAULIC AND AERO DYNAMIC UNBALANCE

DEFINITION OF UNBALANCE

ISO DEFINITION

THAT CONDITION WHICH EXISTS IN A ROTOR WHEN VIBRATORY MOTION IS IMPARTED TO THE BEARINGS AS A RESULT OF CENTRIFUGAL FORCES

OTHER DEFINITIONS

UNEQUAL DISTRIBUTION OF WEIGHT OF THE ROTOR ABOUT ITS ROTATING CENTRE LINE

IT IS ALSO DEFINED AS MCD

GRAPHICAL REPRESENTATION

R = RADIUS IN CM W = UNBALANCE MASS IN GMS. UNBALANCE U = W X R GM CM

WHAT IS BALANCING?

THESE CAUSES FOR UNBALANCE EXIST IN A ROTOR TO SOME EXTENT

THE VECTOR SUMMATION OF ALL THESE CAN BE CONSIDERED AS CONCENTRATED AT A SPOT KNOWN AS HEAVY SPOT

BALANCING THEREFORE IS A TECHNIQUE FOR DETERMINING THE AMOUNT AND LOCATION OF HEAVY SPOT AND APPLYING CORRECTION

WHY BALANCING IS REQUIRED?

F = 1.77 X (RPM/1000)2 X OUNCE INCHES F = 1/16 X (RPM/1000)2 X GRAM INCHES F = 0.01 X (RPM/1000)2 X GRAM CM

THE CENTRIFUGAL FORCE F VARIES AS THE SQUARE OF THE SPEED. IF THE SPEED IS DOUBLED THEN THE FORCE WILL BE FOUR TIMES MORE. THEREFORE IN HIGH SPEED MACHINES SMALL UNBALANCE CAN PRODUCE LARGE FORCES.

THE FORCES CREATED BY UNBALANCE ARE DETRIMENTAL TO THE LIFE OF BEARINGS,ROTOR AND SUPPORT STRUCTURE UNWANTED VIBRATION AND POOR PRODUCT QUALITY CAN RESULT FROM FORCES OF UNBALANCE e.g GRINDER

BENEFITS OF BALANCING
REDUCED VIBRATION REDUCED WEAR REDUCED STRESS/FATIGUE REDUCED NOISE INCREASED EFFICIENCY INCREASED ACCURACY TO SUM UP INCREASED MACHINE LIFE

TYPES OF UNBALANCE

STATIC UNBALANCE COUPLE UNBALANCE QUASI STATIC UNBALANCE DYNAMIC UNBALANCE

STATIC UNBALANCE

CENTRAL PRINCIPAL AXIS SHAFT AXIS

COUPLE UNBALANCE

C.P.A

QUASI STATIC UNBALANCE

IN - SITU BALANCING

THE PROCESS OF BALANCING A PART WITH OUT TAKING IT OUT OF THE MACHINE IS CALLED IN SITU OR FIELD BALANCING ELIMINATES COSTLY,TIME CONSUMING DISASSEMBLY AND PREVENTS THE POSSIBILITY OF DAMAGING THE ROTOR DURING ITS REMOVAL

WHY IS IN-SITU BALANCING NEEDED ?

1. UNBALANCE INTRODUCED WHEN STRIPPED AND DURING REASSEMBLY 2. ROTORS RUNNING ABOVE CRITICAL SPEED - MAY NEED TRIM 3. DIRTY PROCESS 4. HEAT DISTORTION 5. TO COMPENSATE FOR WEAR

CONDITIONS FOR IN-SITU BALANCING

THERE MUST BE PROVISION FOR MAKING WEIGHT CORRECTION THERE MUST BE PROVISION FOR OBTAINING VIBRATION AMPLITUDE AND PHASE ANGLE IT MUST BE POSSIBLE TO START AND STOP THE MACHINE FOR MAKING WEIGHT CORRECTIONS AND FINALLY

THE VIBRATION PROBLEM MUST BE DUE TO UNBALANCE

RECOGNISING VIBRATION DUE TO UNBALANCE

UNBALANCE WILL ALWAYS PRODUCE VIBRATION AT ROTATIONAL SPEED

VIB. AMPLITUDE IS DIRECTLY PROPORTIONAL TO UNBALANCE VIBRATION IS RADIAL IN NATURE. FOR OVERHUNG ROTORS IN AXIAL DIRECTION ALSO. STEADY PHASE READINGS SHIFTING THE VIB. PICKUP BY 900 WILL RESULT IN SHIFT IN PHASE ANGLE BY 90 0

WHAT LOOKS LIKE UNBALANCE BUT IS NOT

MISALIGNMENT RESONANCE LOOSENESS ECCENTRICITY DISTORTION RECIPROCATING FORCES ELECTRICAL PROBLEMS AERODYNAMIC FORCES RUN OUT ON NC PICKUP

THESE PROBLEMS CANNOT BE CORRECTED BY BALANCING AND ATTEMPTING TO BALANCE CAN RESULT IN WASTE OF TIME AND EFFORT

THEREFORE THOROUGH ANALYSIS OF VIBRATION MUST BE CARRIED OUT FIRST TO CONFIRM THAT THE PROBLEM ACTUALLY IS UNBALANCE

APPROACH TO FIELD BALANCING

EVALUATE CIRCUMSTANCES LEADING TO CURRENT SITUATION IS THERE A SUDDEN INCREASE IN VIBRATION ? REVIEW HISTORY REVIEW MAINT. RECORDS e.g A COUPLING MIGHT HAVE BEEN CHANGED. STRUCTURAL CHANGES HAVE BEEN MADE

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STUDY THE DRAWINGS KNOW AND UNDERSTAND THE OPERATION PERFORM INSPECTION INTERNALLY IF POSSIBLE ? (CRACKS,BOW,MISSING PARTS) CHECK BACKGROUND VIB. ALLOW EQUIP. TO STABILISE PERFORM ANALYSIS

DISTINGUISHING UNBALANCE FROM OTHER PROBLEMS

ECCENTRICITY 1 PRODUCE REACTION FORCES 2 VIB. FREQ. 1 X RPM 3 VIB. IN RADIAL DIRECTION - APPEARS TO BE UNBALANCE THE DIFFERENCE IS REACTION FORCES DUE TO ECCENTRICITY ARE HIGHLY DIRECTIONAL - BALANCING IN HORI. DIRECTION INCREASES VERT. VIBRATION & VICE VERSA

MORE ON ECCENTRICITYPHASE COMPARE HORI. AND VERT.

READINGS DIRECTIONAL FORCES WILL USUALLY REVEAL PHASE READINGS WHICH ARE SAME OR DIFFER BY 1800 WORK OUT BALANCING SOLUTIONS SIMULTANEOUSLY FOR HORI. AND VERT. MEASUREMENTS. IF THE BALANCE CORRECTION IS SAME THEN IT IS UNBALANCE. IF THE SOLNS. DIFFER CONSIDERABLY THEN CHECK FOR OTHER PROBLEMS

RESONANCE

MACHINES WITH SUPPORTING STRUCTURES ARE COMPLEX SYSTEMS REPRESENTING MANY SPRING MASS SYSTEM HAVING SEVERAL DEGREES OF FREEDOM THEREFORE RADIAL RESONANCE CAN EXCITE UNBALANCE RESONANCE ACTS AS AMPLIFIER AND CAN BE HIGH DANGEROUSLY ALTHOUGH UNBALANCE FORCE IS ACCEPTABLE *

MORE ON RESONANCE

BALANCING NEAR RESONANCE WILL BE FRUSTRATING MINOR VARIATION IN SPEED WILL PRODUCE ERRORS IN UNBALANCE AMPLITUDE & PHASE MEASUREMENTS SINCE PHASE IS SHIFTING 3 TO 4 RPM CHANGE CAN PRODUCE A 500 OR 600 SHIFT IN PHASE ANGLE AT RESONANCE THE SYSTEMS ARE VERY SENSITIVE TO MINOR UNBALANCE

MORE ON RESONANCE

EVEN IF IT IS POSSIBLE TO REDUCE RESONANT VIB. BY CAREFUL BALANCING IT WILL BE A TEMPORARY SOLUTION MINOR DEPOSIT OR SMALL AMOUNT OF WEAR OR THERMAL DISTORTION MAY CAUSE THE PROBLEM TO REAPPEAR

DETECTION OF RESONANCE

BY RUN UP RUN DOWN PLOTS FROM SPECTRUM ANALYSIS VIBRATION AMPLITUDE AT ROTATIONAL FREQ. VERY HIGH. AMPLITUDE RATIOS OF 5 ; 1 OR GREATER SUGGESTS RESONANCE WITH THE MACHINE SHUT DOWN BUMP THE MACHINE AND DO FREQ. ANALYSIS

LOOSENESS
WHEN THERE IS EXCESSIVE CLEARANCE OR LOOSENESS, RELATIVELY SMALL UNBALANCE CAN PRODUCE LARGE VIBRATION AMPLITUDE COMMON SOURCES OF LOOSENESS LOOSE MOUNTING BOLTS EXCESSIVE CLEARANCE SLEEVE BEARINGS ROLLING ELEMENT BEARINGS LOOSE IN THE HOUSING STRUCTURAL BREAKS

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WEAK SOLE PLATES ROTOR LOOSE ON SHAFT BALANCING BY CONVENTIONAL TECHNIQUES WILL BE EXTREMELY DIFFICULT THE SYSTEM REVEALS NON-LINEAR RELATIONSHIP BETWEEN AMOUNT OF UNBALANCE & AMPLITUDE LOOSENESS WILL REVEAL VIBRATION AT FREQ. WHICH ARE MULTIPLES OF ROTOR SPEED LOOSENESS CAN BE SUSPECTED IF HIGH FREQ. VIB. IS MORE THAN ONE HALF OF 1 X RPM VIBRATION

DISTORTION OR TWISTING OF M/C DUE TO SOFT FOOT WILL REVEAL VIB. SIMILAR TO UNBALANCE. VIBRATION DUE TO DISTORTION IS DIRECTIONAL AND PHASE READING OF HORI. AND VERT. WILL BE SAME OR 1800 OPPOSITE. CAN BE CONFIRMED BY TAKING READINGS VERTICALLY AT EACH MOUNTING FOOT. DISTORTION DUE TO PIPING STRESS IS DIFFICULT TO PINPOINT BY SIMPLE MEASUREMENT AND IS DETECTED BY MODE-SHAPE ANALYSIS

DISTORTION

MISALIGNMENT

COMMON CAUSE OF VIBRATION AT A FREQ. 1 X RPM CAN BE MISTAKEN FOR UNBALANCE MISALIGNMENT ALSO GENERATES AXIAL VIBRATION IF THE AXIAL VIBRATION AMP. IS MORE THAN ONE HALF OF HIGHEST RADIAL VIBRATION THEN MISALIGNMENT IS TO BE SUSPECTED AXIAL PHASE MEASUREMENT AT THE TWO ENDS OF COUPLING WILL BE OUT OF PHASE

ELECTRICAL PROBLEMS ELECTRICAL PROBLEMS THAT CAUSE VIBRATION IN MOTORS, GENERATORS & ALTERNATORS ARE 1.BROKEN ROTOR BARS 2. UNEQUAL AIR GAP BETWEEN ROTOR AND STATOR 3. OUT OF ROUND ROTOR 4. SHORTED STATOR LAMINATION 5. UNBALANCED PHASES 6. ECCENTRIC OR BOWED ROTOR 7. SHORTED ROTOR BARS

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DIAMETRICALLY UNEQUAL MAGNETIC FORCES BETWEEN ROTOR AND STATOR CAUSE VIB. THESE FORCES VARY WITH LOAD VIB. AMPLITUDE ALSO IS DEPENDENT ON LOAD SYNCHRONOUS MOTOR ELEC. PROBLEM VIB. FREQ. WILL BE SAME AS THAT OF ROTOR SPEED CHECK CHANGES IN VIB. AMP. UNDER VARIOUS LOADS OBSERVE CHANGE IN VIB. AMP. THE INSTANT POWER IS SHUT OFF.

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IN THE CASE OF INDUCTION MOTOR VIBRATION AMPITUDE PULSATES IN CYCLIC MANNER PULSATION IS DUE TO THE RPM OF THE ROTOR AND THE ROTATING SPEED OF THE MAGNETIC FIELD BEING NOT THE SAME e.g 4 POLE INDUCTION MOTOR WITH 50 HZ POWER. ARMATURE MAY ROTATE AT 1440 RPM WHEREAS THE MAGNETIC FIELD OF STATOR ROTATES AT 1500 CPM. IN CASE OF ROTOR PROBLEMS LIKE BROKEN OR SHORTED BARS THIS DIFF. IN SPEEDS CAUSE MODULATION IN AMP. & WILL BE 2 X SLIP FREQ.

SIX POINTS - UNBALANCE

UNITS ARE IN G.MM OR OZ.IN VIBRATION AMPLITUDE IS PROPORTIONAL TO THE AMOUNT OF UNBALANCE THE PHASE SHIFTS BY AN ANGLE AND DIRECTION EQUAL AND OPPOSITE TO THE SHIFT OF THE HEAVY SPOT THE FORCE GENERATED INCREASES AS SQUARE OF THE SPEED UNBALANCE WILL ALWAYS PRODUCE VIBRATION AT 1 X RPM FOR BEST SENSITIVITY USE DISPLACEMENT UPTO 15000 RPM

REQUIREMENTS FOR IN-SITU BALANCING

VIBRATION MUST BE DUE TO UNBALANCE THERE SHOULD BE ACCESS TO ROTOR TO ADD OR REMOVE WEIGHTS FACILITY TO OBTAIN PHASE REF. STEADY PHASE 71/2 DEG - 8 : 1 15 DEG - 4 : 1 SAME ROTOR SPEED FOR EACH RUN STABLE MACHINE OPERATING CONDITIONS LIKE SPEED, LOAD, TEMP. ETC.

OTHER IMPORTANT POINTS

OBSERVE PHASE FROM THE SAME END TUNE FILTER PROPERLY SAME MEASUREMENT PARAMETER SHOULD BE USED SAME SPEED TO BE MAINTAINED PICK UP DIRECTION SHOULD NOT BE CHANGED

TYPES OF BALANCE PROBLEMS

L/D RATIO
LESS THAN O.5 GT. 0.5 UPTO 2 MORE THAN 2 BALANCE CORRECTION 1P 2P GT.2P N.A ABOVE 2000 RPM * * 0-1000 ABOVE 1000 RPM RPM 0-150 150 2000 RPM RPM * 0-100 RPM ABOVE 100 RPM *

* ABOVE 70% OF 1ST CRITICAL

SINGLE PLANE BALANCING

THE LOCATION AND THE AMOUNT OF UNBALANCE IS UNKNOWN THE VIBRATION READINGS REPRESENT ORIGINAL UNBALANCE A TRIAL WEIGHT NEED TO BE ADDED TO KNOW THE SYSTEM RESPONSE TO UNBALANCE

WHAT IS THE SAFE TRIAL WEIGHT

THE GENERAL RULE IS THE TRIAL WEIGHT ADDED SHOULD PRODUCE A FORCE AT THE BEARINGS EQUAL TO 10% OF THE ROTOR WEIGHT F = 0.01X(RPM/1000)2 X W XR WHERE F = FORCE IN KG FORCE W = TRIAL WEIGHT IN GMS R = RADIUS IN CMS

AN EXAMPLE ROTOR WEIGHT = 1000 Kg F = 10% OF 1000 = 100 RPM = 3000 R = 50 cms APPLYING THE FORMULA F = 0.01X(RPM/1000)2XWXR 100 = 0.01X(3000/1000)2XWX50 100 = 0.01X(3)2XWX50 100 = 0.01X9XWX50 100 = 0.01X450XW 100 = 4.5XW W = 100/4.5 W = 22.22 gms

TRIAL WEIGHT GUIDELINES

AFTER THE ADDITION OF TW THERE MUST BE ATLEAST 30% CHANGE IN AMPLITUDE ALTERNATIVELY THE PHASE ANGLE MUST HAVE CHANGED BY 300 IF THE ABOVE CONDITIONS ARE NOT MET THEN TRY WITH HEAVIER TRIAL WEIGHT THE ABOVE GUIDELINES IF FOLLOWED GENERALLY GIVES GOOD CALIBRATION

EFFECTS OF ADDITION OF TRIAL WEIGHT

1. INITIAL READINGS 20 MICRONS AT 600 2. READINGS AFTER TRIAL WEIGHT ADDITION 27 MICRONS AT 600

WHAT DOES THIS INDICATE ?

B

OA - ORIGINAL VIBRATION READING OB - VIBRATION READING AFTER ADDITION OF TRIAL WEIGHT

A
B

OA - ORIGINAL READING OB - READINGS AFTER ADDITION OF TRIAL WEIGHT

WHAT DOES THIS VECTOR PLOT INDICATE ? OA - ORIGINAL READINGS OB - READINGS AFTER ADDING TW

SINGLE PLANE BALANCING VECTOR METHOD

OPERATE THE ROTOR AT THE BALANCING SPEED AND WITH ANALYSER FILTER TUNED TO 1XRPM PROCEED TO MEASURE AND RECORD THE ORIGINAL UNBALANCE DATA AMPLITUDE AND PHASE. O STOP THE ROTOR AND ADD A TRIAL WEIGHT. RECORD THE AMOUNT OF TRIAL WEIGHT. AGAIN,OPERATE THE ROTOR AT THE BALANCING SPEED AND OBSERVE AND RECORD THE NEW UNBALANCE DATA. THIS IS RECORDED AS O+T

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USING POLAR GRAPH PAPER CONSTRUCT VECTORS O & O +T

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CONSTRUCT VECTOR T BY CONNECTING THE ENDS OF VECTORS O AND O + T . THE VECTOR T

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MEASURE THE LENGTH OF VECTOR T AND USE THE FORMULA TO DETERMINE THE CORRECT BALANCE WEIGHT NEEDED CORRECT WEIGHT = TRIAL WEIGHT X O / T USING THE PROTRACTOR MEASURE THE INTRUDED ANGLE BETWEEN O AND T

THETA 270 90

180

APPLYING BALANCE CORRECTION BY TRANSPOSING T VECTOR

APPLYING CORRECTION....

ROTATE THE TRIAL WEIGHT BY AN ANGLE THETA IN THE DIRECTION OPPOSITE TO THAT OF THE DIRECTION OF MOVEMENT OF O+T VECTOR. REMOVE THE TRIAL WEIGHT AND APPLY THE CORRECTION WEIGHT. IN CASE TRIM BALANCING IS REQUIRED CARRY OUT THE SAME REPEATING THE PROCEDURE.

O
HORI. O+T

T - AXIAL

VERT.

TRI - AXIAL PLOT

BALANCING WITHOUT PHASE WHY BALANCE WITHOUT PHASE ? NO METHOD OF OBTAINING PHASE AVAILABLE ON THE JOB BRIGHT SUNLIGHT VERY SLOW SPEED ROTOR WITH BLADES - CAN BE DIFFICULT TO OBTAIN CLEAR REFERENCE HAZARDOUS AREA MAY PRECLUDE USE OF STROBE LIGHT METHOD USED THREE POINT CIRCLE METHOD

DOMINANT FREQUENCY
DOMINANT FREQUENCY IS USEFUL IN A MACHINE THAT HAS SEVERAL ROTATING PARTS DOMINANT FREQUENCY REVEALS WHICH PART OF THE MACHINE IS CAUSING MOST VIBRATION STEPS TO FIND DOMINANT FREQ. MEASURE AND RECORD THE DISPLACEMENT D AT THE GIVEN POINT AT THE SAME POINT MEASURE AND RECORD THE VELOCITY V DOMINANT FREQUENCY = VELOCITY X 19120 DISPLACEMENT

THREE POINT CIRCLE METHOD

WITH THE ROTOR OPERATING AT NORMAL SPEED, MEASURE AND RECORD ORIGINAL VIBRATION AMPLITUDE AS O DRAW A CIRCLE WITH RADIUS EQUAL TO O AS SHOWN IN FIG.1 STOP THE ROTOR. MAKE THREE POINTS A,B,C APPROX. 1200 APART. THESE POINTS NEED NOT BE EXACTLY 1200 APART. BUT THE ANGLES OF SEPERATION MUST BE KNOWN. MARK A,B,C ON THE ORIGINAL CIRCLE AS SHOWN IN FIGURE.2

FIGURE .1

FIGURE.2

THREE POINT CIRCLE METHOD

SELECT A SUITABLE TRIAL WEIGHT AND ATTACH AT A ON THE ROTOR START THE ROTOR. RUN IT TO NORMAL SPEED AND RECORD THE NEW VIBRATION AMPLITUDE AS O + T1 WITH POINT A AS CENTRE DRAW A CIRCLE WITH RADIUS O+T1 AS SHOWN IN FIGURE.3 STOP THE ROTOR AND MOVE THE TRIAL WEIGHT TO POSITION B ON THE ROTOR

B
FIGURE.3

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START THE ROTOR AND RUN IT TO NORMAL SPEED. MEASURE AND RECORD THE NEW VIBRATION AMPLITUDE AS O+T2 WITH B AS THE CENTRE POINT DRAW A CIRCLE WITH RADIUS EQUAL TO O+T2 AS SHOWN IN THE FIGURE.4 STOP THE ROTOR AND MOVE THE TRIAL WEIGHT TO POSITION C

O+T2 B

FIGURE.4

MORE ..... START THE ROTOR AND RUN IT TO THE NORMAL SPEED. MEASURE AND RECORD THE NEW VIBRATION AMPLITUDE AS O+T3 WITH POINT C AS THE CNETRE DRAW A CIRCLE WITH A RADIUS EQUAL TO O+T3 THE THREE CIRCLES DRAWN FROM POINTS A,B,C WILL INTER-SECT AT A COMMON POINT D AS SHOWN IN FIGURE.5

D C C

FIGURE.5

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DRAW A LINE FROM THE CENTRE OF THE ORIGINAL CIRCLE TO POINT D AND LABEL THE LINE AS T MEASURE THE LENGTH OF THE LINE T USING THE SAME SCALE BALANCE CORRECTION WEIGHT CW = TW X ( O / T ), WHERE CW = CORRECTION WEIGHT TW = TRIAL WEIGHT O = THE ORIGINAL UNBALANCE VIBRATION READING T = THE MEASURED RESULTANT VECTOR

D T

O
C C

FIGURE 6

USING PROTRACTOR MEASURE THE ANGLE BETWEEN LINE T AND LINE OA AS SHOWN IN FIGURE.7. THE MEASURED ANGLE IS THE ANGULAR LOCATION OF THE CORRECT WEIGHT LOCATED RELATIVE TO POINT A ON THE ROTOR STOP THE ROTOR AND REMOVE THE ORIGINAL TRIAL WEIGHT FROM POINT C

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O
C C

FIGURE 7 ATTACH THE CORRECTION WEIGHT ON THE ROTOR AT THE ANGULAR POSITION DETERRMINED FROM THE FIGURE.7

BALANCE WEIGHT

C FIGURE.8

SINGLE PLANE BALANCING CHART SOLUTION

IT IS A SIMPLE AND QUICK METHOD FOR SOLVING SINGLE PLANE BALANCING PROBLEMS IT USES TABULAR DATA AS OPPOSED TO MAKING A GRAPHIC VECTOR DIAGRAM THEREFORE PAPER ,TOOLS AND TIME REQUIRED FOR SUCH DIAGRAMS ARE NOT NEEDED THE RESULTS ARE FAIRLY ACCURATE AND MORE THAN THREE RUNS MAY BE REQUIRED IF THE NUMBER OF RUNS PERMISSIBLE IS LIMITED THEN GRAPHIC VECTOR SOLUTION IS RECOMMENDED

PROCEDURE
1. MEASURE VIBRATION AMPLITUDE (O) AND ANGULAR POSITION OF THE REFERENCE MARK (PHASE) OF UNBALANCED PART O = --------- AT ----------- DEGREES 2. ADD A KNOWN TRIAL WEIGHT 3. MEASURE THE RESULTING AMPLITUDE O+T AND PHASE O+T = ----------- AT ---------DEGREES 4. CALCULATE THE RATIO OF UNBALANCE = (O+T) / O 5. DETERMINE THE AMOUNT AND DIRECTION OF PHASE SHIFT OF O+T RELATIVE TO O 6. CHOOSE PHASE SHIFT TO NEAREST 10 DEGREE INCREMENT

7. LOCATE ANGLE OF PHASE SHIFT COLUMN IN TABLE WHICH CORRESPONDS TO STEP 6 VALUE 8. IN RATIO OF UNBALANCE COLUMN LOCATE RATIO NEAREST TO VALUE CALCULATED IN STEP 4 9. OPPOSITE THIS RATIO LOCATE ANGLE AND FACTOR VALUES IN PREVIOUSLY DEFINED PHASE SHIFT COLUMN 10. MULTIPLY THE TRIAL WEIGHT AMOUNT BY FACTOR VALUE. THIS IS THE CORRECT BALANCE WEIGHT REQUIRED

MORE .....

11. THE ANGLE VALUE IS THE NUMBER OF DEGREES THE CORRECT BALANCE WEIGHT IS TO BE MOVED FROM THE TRIAL WEIGHT LOCATION.THE WEIGHT IS MOVED OPPOSITE THE DIRECTION OF PHASE SHIFT NOTED IN STEP 5 12. IF FURTHER CORRECTION IS NEEDED CONSIDER THIS AS O+T RUN AND REPEAT THE PROCEDURE FROM STEP.4

MORE .....

BALANCING OVERHUNG ROTORS

PLANE A

PLANE B

BRG 1

BRG 2

BALANCING OVERHUNG ROTORS

1. USING PROCEDURE SIMILAR TO SINGLE PLANE VECTOR SOLUTION FIND THE AMPLITUDE AND PHASE IN BEARING NO.1 2. ADD A TRIAL WEIGHT TO THE ROTOR IN PLANE B AND NOTE THE AMPLITUDE AND PHASE READINGS. 3. USING SINGLE PLANE VECTOR SOLUTION COMPUTE THE LOCATION AND AMOUNT OF CORRECTION WEIGHT AND BALANCE UNTIL THE DESIRED VIBRATION LEVEL IS REACHED IN BEARING 1. 4. OBSERVE THE VIBRATION READING IN BEARING N0.2.IF THE VIBRATION LEVEL IS WITHIN THE PERMISSIBLE LEVEL THEN ONLY SINGLE PLANE BALANCING WILL SUFFICE.

5. IF THE VIBRATION IN BEARING 2 IS NOT ACCEPTABLE,THEN ADD TWO EQUAL AND OPPOSITE TRIAL WEIGHTS IN PLANES A AND B. NOTE THE NEW AMPLITUDE AND PHASE READINGS. 6. USING THE VIBRATION READINGS FROM STEP 4 AND STEP 5, COMPUTE THE COUPLE CORRECTION REQUIRED USING SINGLE PLANE VECTOR SOLUTION. 7. APPLY THE CORRECTION WEIGHTS IN BOTH THE PLANES AS A COUPLE UNTIL ACCEPTABLE LEVEL IS REACHED. 8. CHECK THE VIBRATION IN BEARING 1 AND IF ANY FRESH CORRECTION IS REQUIRED PROCEED WITH STEPS 1 TO 4 AGAIN.

ONE RUN BALANCING USING FLASH ANGLE TECHNIQUE

THIS IS A VERY USEFUL TECHNIQUE FOR BALANCING ROTORS WHICH REQUIRE BALANCING FREQUENTLY. THE TECHNIQUE IS BASED ON THE FOLLOWING PREMISES; 1. THE UNBALANCE CONSTANT FOR A ROTOR GENERALLY REMAINS SAME 2. REGARDLESS OF WHERE THE UNBALANCE SHIFTED, IT ALWAYS APPEARED UNDER THE STROBE LIGHT AT THE SAME ANGULAR LOCATION FLASH ANGLE OF A ROTOR IT IS THE ANGLE MEASURED IN THE DIRECTION OF SHAFT ROTATION BETWN. THE POSITION OF PICKUP AND THE POSITION OF HEAVY SPOT UNDER STROBE LIGHT

FLASH ANGLE - MEASUREMENT

FLASH ANGLE

STEPS TO FIND FLASH ANGLE

1. PROCEED TO BALANCE THE ROTOR BY VECTOR METHOD.

2. STOP THE ROTOR AND TURN IT UNTIL THE REFERENCE MARK IS IN THE SAME POSITION OBSERVED UNDER STROBE LIGHT ON THE ORIGINAL RUN. 3. NOTE THE LOCATION OF CORRECTION WEIGHT. THE SPOT EXACTLY 1800 OPPOSITE IS THE HEAVY SPOT.
4. FOLLOWING THE DIRECTION OF ROTATION NOTE THE ANGLE BETWEEN PICKUP AND THE HEAVY SPOT. THIS ANGLE IS KNOWN AS FLASH ANGLE AND IS NOTED.

CALCULATION OF UNBALANCE CONSTANT OF THE ROTOR

1. BALANCE THE ROTOR SUCCESSFULLY USING THE USUAL PROCEDURE.

2. DIVIDE THE UNBALANCE CORRECTION WEIGHT APPLIED BY THE ORIGINAL AMPLITUDE.

3. THIS CONSTANT IS KNOWN AS UNBALANCE CONSTANT AND THE UNIT IS GMS/MICRON 4. IN FUTURE IF THE ROTOR REQUIRES BALANCING AGAIN,TO GET THE CORRECTION WEIGHT,MULTIPLY THE VIBRATION AMPLITUDE BY THE UNBALANCE CONSTANT.

HOW TO BALANCE IN ONE RUN ?

1. OPERATE THE MACHINE AND RECORD THE VIBRATION AMPLITUDE AND PHASE.

2. STOP THE MACHINE AND TURN THE ROTOR UNTIL THE REFERENCE MARK IS IN THE SAME POSITION AS OBSERVED UNDER THE STROB LIGHT. 3. MEASURE OFF THE FLASH ANGLE (ALREADY NOTED FROM PREVIOUS BALANCING) FROM THE PICKUP IN THE DIRECTION OF ROTATION.THIS IS THE HEAVY SPOT.
4. MULTIPLY THE AMPLITUDE BY UNBALANCE CONSTANT TO GET THE CORRECTION WEIGHT REQUIRED. 5. APPLY THE CORRECTION WEIGHT AT A SPOT 1800 OPPOSITE TO THE HEAVY SPOT.

TWO PLANE BALANCING

WHEN DYNAMIC UNBALANCE IS PRESENT TWO PLANE BALANCING IS ADOPTED MANY TECHNIQUES ARE IN USE CHOICE OF THE TECHNIQUE IS DEPENDENT ON ROTOR CONFIG. LENGTH TO DIAMETER RATIO, ROTOR FLEXIBILITY AND CROSS EFFECT

TWO PLANE BALANCING TECHNIQUES

1. SEPERATE SINGLE PLANE APPROACH 2. SIMULTANEOUS SINGLE PLANE APPROACH 3. FORCE COUPLE DERIVATION 4. TWO PLANE VECTOR CALCULATION a) GRAPHICAL METHOD b) USING AUTOMATIC BALANCING INSTRUMENT OR PROGRAMMABLE HAND CALCULATOR

CROSS EFFECT

CROSS EFFECT OR CORRECTION PLANE INTERFERENCE IS DEFINED AS THE EFFECT ON THE UNBALANCE INDICATION AT ONE END OF A ROTOR CAUSED BY UNBALANCE AT THE OPPOSITE END

CORRECTION PLANES LEFT RIGHT

LEFT BEARING

RIGHT BEARING

CORRECTION PLANES

UNBALANCE

2 MICRONS AT 300

12 MICRONS AT 900

CROSS EFFECT

CORRECTION PLANES

UNBALANCE

11 MICRONS AT 2100

13.2 MICRONS AT 900

CROSS EFFECT

CROSS EFFECT

1. DUE TO CROSS EFFECT THE UNBALANCE INDICATION OBSERVED WILL NOT BE TRUE UNBALANCE

2. THE INDICATION IS THE RESULTANT OF UNBALANCE AND THE CROSS EFFECT FROM THE OPPOSITE END

SINGLE PLANE VECTOR METHOD FOR TWO PLANE BALANCING

1. TREAT EACH CORRECTION PLANE AS A SINGLE PLANE PROBLEM

2. USING THE NEAREST BEARING FOR THE VIBRATION READINGS, EACH PLANE IS BALANCED INDIVIDUALLY

RECOMMENDED PROCEDURE
1. OBSERVE AMP. AND PHASE AT BOTH BEARINGS AND SELECT BEARING WITH MOST VIBRATION TO BALANCE FIRST 2. USING SINGLE PLANE VECTOR METHOD BALANCE THE END WITH HIGHEST VIB. 3. AFTER BALANCING FIRST PLANE NOTE AND RECORD NEW AMP. AND PHASE DATA FOR SECOND PLANE. THESE READINGS ARE THE ORIGINAL READINGS FOR SECOND END 4. USING NEW DATA BALANCE THE SECOND PLANE USING STANDARD VECTOR TECHNIQUE 5. CHANGES IN THE FIRST PLANE WILL BE NOTICED. IF THE CHANGE IS AN INCREASE TO AN UNACCEPTABLE LEVEL, REBALANCE THE FIRST PLANE WHILE REBALANCING DO NOT DISTURB THE PREVIOUS CORRECTIONS

CASE OF SEVERE CROSS EFFECT

X
Y

VECTOR METHOD FOR TWO PLANE BALANCING

1. USING SINGLE PLANE VECTOR TECHNIQUE MANY RUNS MAY BE REQUIRED TO ACHIEVE GOOD BALANCNG. 2. THERE ARE MACHINES WHICH TAKE ONE HOUR TO ONE FULL DAY FOR EACH START - STOP OPERATION. 3. THEREFORE THERE IS A NEED TO MINIMISE THE NUMBER OF BALANCING RUNS. 4. TWO PLANE VECTOR METHOD SIMPLIFIES THE BALANCING PROBLEM WHEN A LOT OF TIME IS REQUIRED FOR A START - STOP OPERATION OR WHERE SEVERE CROSS EFFECT IS ENCOUNTERED

TWO PLANE VECTOR METHOD

1. THIS METHOD MAKES THE BALANCING POSSIBLE IN THREE START - STOP OPERATIONS. 2. ORIGINAL UNBALANCE READINGS ARE NOTED AT THE TWO BEARINGS 3. TRIAL WEIGHT IS ADDED TO THE FIRST PLANE AND READINGS ARE NOTED AFTER SPINNING THE ROTOR 4. THE TRIAL WEIGHT IS REMOVED FROM FIRST PLANE AND ADDED IN THE SECOND PLANE 5. VIBRATION READINGS ARE NOTED AFTER SPINNING THE ROTOR AGAIN. 6. A SERIES OF VECTOR DIAGRAMS ARE DRAWN AND THE CORRECTION REQUIRED AT BOTH THE PLANES IS WORKED OUT 7. THE UNBALANCE CORRECTION IS APPLIED TO BOTH THE PLANES SIMULTANEOUSLY

TWO PLANE BALANCING - VECTOR METHOD - STEPS

1. OPERATE THE MACHINE IN THE BAL. SPEED RANGE.. RECORD THE ORIGINAL PHASE #1, ORIGINAL AMP. #2 AT NEAR END ; ORIGINAL PHASE #3 AND ORIGINAL AMP. #4 AT FAR END 2. STOP THE MACHINE AND ADD A TRIAL WEIGHT IN THE NEAR END CORRECTION PLANE. RECORD THE ANGULAR POS. OF TRIAL WEIGHT IN DEGREES CLOCKWISE FROM THE REFERENCE POINT AS #5.. RECORD THE TRIAL WEIGHT AS #6 3. WITH THE TRIAL WEIGHT SPIN THE ROTOR AND NOTE THE FOLLOWING # 7 NEW PHASE NEAR END # 8 NEW AMP. NEAR END # 9 NEW PHASE FAR END # 10 NEW AMP. FAR END

4. STOP THE MACHINE. REMOVE TRIAL WT. FROM THE NEAR END AND ADD A TRIAL WEIGHT IN THE FAR END CORRECTION PLANE.. NOTE THE FOLLOWING # 11 POSITION OF TRIAL WEIGHT # 12 AMOUNT OF TRIAL WEIGHT 5. SPIN THE ROTOR AND NOTE THE FOLLOWING # 13 NEW PHASE NEAR END # 14 NEW AMP. NEAR END # 15 NEW PHASE FAR END # 16 NEW AMP. FAR END 6. USING POLAR GRAPH PAPER DRAW VECTORS N,F,N2,F2,N3,F3 AT THE OBSERVED PHASE ANGLE ON A SUITABLE SCALE AS SHOWN IN THE FIG.1

FIGURE 1

N3

F2 F

N2

F3

7. CONSTRUCT VECTOR A BY DRAWING A LINE CONNECTING THE ENDS OF VECTOR N AND N2 . THIS VECTOR A IS TO POINT FROM THE END OF N TO N2 . THIS DIRECTION IS USEFUL IN FINDING THE ANGLE OF VECTOR A THE ANGLE OF VECTOR A IS FOUND BY TRANSPOSING THE VECTOR TO THE ORIGIN AND NOTED AS # 17. THE AMP. OF VECTOR A IS FOUND BY MEASURING THE LENGTH AND IS NOTED AS # 18 USING THE SAME PRPCEDURE FIND THE ANGLE AND AMP. OF VECTORS B ( F - F3 ) , aA ( F - F2 ), AND bB ( N - N3 ) . ENTER THESE ITEMS AS # 19 TO # 24

N3

A
F2 F F3 N2

8. DO THE CALCULATIONS AS INDICATED

AND FIND THE VALUES # 25 TO # 32. DURING THE CALCULATION IF THE ANGLE IS OBTAINED AS NEGATIVE THEN THE VALUE IS CONVERTED TO A POSITIVE ANGLE BY SUBTRACTING THE ANGLE FROM 360. SIMILARLY IF THE ANGLE IS MORE THAN 360 THEN THE BY SUBTRACTING 360 FROM THE ANGLE ANGLE IS OBTAINED 9. CONSTRUCT VECTORS aN AND bF USING THE SAME SCALE AS VECTORS N, F. THE ANGLE AND AMP.IS OBTAINED FROM # 29 TO # 32

aN
D F

N bF
C C

10. USING THE SAME PROCEDURE AS IN

STEP 7 CONSTRUCT VECTORS C AND D. FIND AND ENTER THE VALUES AS # 33 TO # 36 11.CALCULATE ITEMS #37 AND #38 AS OUTLINED BY THE PROCEDURE IN STEP 8 12.USING NEW SHEET OF GRAPH PAPER CONSTRUCT THE UNITY VECTOR 1 UNIT AT AN ANGLE OF 00. THESE VALUES ARE NOTED AS # 39 AND # 40 THIS UNITY VECTOR OF ONE UNIT CAN BE DRAWN ON A SUITABLE SCALE 13.ON THE SAME POLAR GRAPH DRAW VECTOR ab USING THE SAME SCALE SELECTED FOR UNITY VECTOR. THE VALUE FOR VECTOR ab ARE OBTAINED FROM # 37 AND # 38

ab

14.CONSTRUCT VECTOR E AND NOTE THE VALUES AS # 41 AND # 42 15.CALCULATE THE VALUES FOR ITEMS # 43 THROUGH # 54 FOLLOWING THE STEP OUTLINED IN STEP 8. # 51 AND # 52 REPRESENT THE POSITION AND AMOUNT OF BALANCE WEIGHT REQD. FOR THE NEAR END. THE ANGLES FOR LOCATION OF BALANCING WEIGHTS ARE CLOCKWISE FROM THE REF. MARK

GRAPHICAL CHECK FOR THE SOLUTION

A) ON A NEW POLAR GRAPH PAPER DRAW THE VECTOR q A USING VALUES # 43 AND # 44 AND DRAW VECTOR FB
USING VALUES # 45 AND # 46. USE THE SAME SCALE AS THE ONE USED FOR VECTORS N, F ETC. B) CALCULATE THE AMPLITUDE AND ANGLE VALUES FOR VECTOR fbB . AMPLITUDE = # 50 x # 24 ANGLE = # 49 + # 23

C) CALCULATE THE AMPLITUDE AND ANGLE FOR VECTOR qaA . AMPLITUDE = # 40 x # 22 ANGLE = # 47 + # 21 D) USING THE CALCULATED VALUES DRAW VECTORS QaA AND fbB

E) CONSTRUCT VECTOR X AND VECTOR Y BY COMPLETING THE PARALLELOGRAM. F) X SHOULD BE EQUAL IN LENGTH AND OPPOSITE IN DIRECTION TO VECTOR N. Y SHOULD BE EQUAL IN LENGTH AND OPPOSITE IN DIRECTION TO VECTOR F

fB qA X

Y qaA
fbB

ROTOR BALANCING USING STATIC COUPLE DERIVATION TECHNIQUE

1. THIS METHOD IS USED FOR 3 PLANE BALANCING OF LARGE TURBO - ROTORS 2. THE METHOD IS BASED ON THE PREMISE THAT ANY KIND OF UNBALANCE CAN BE IDENTIFIED AS a) STATIC UNBALANCE b) COUPLE UNBALANCE c) A COMBINATION OF a) AND b) 3. CORRECTION AT A PLANE NEAR TO THE PLANE OF CENTRE OF GRAVITY USING STATIC VALUE OBTAINED WILL REDUCE THE UNBALANCE RESPONSIBLE FOR FIRST RIGID RESONANCE AS WELL AS FIRST ROTOR CRITICAL

4. CORRECTING THE COUPLE UNBALANCE IN REFERENCE PLANES NEAR THE ENDS THE SECOND RIGID MODE AS WELL AS SECOND ROTOR CRITICAL WILL BE MINIMIZED 5. THIS METHOD IS A COMPROMISE AND MAY NOT WORK FOR ALL FLEXIBLE ROTOR BALANCING. 6. THE TECHNIQUE PROVIDES RESULTS WHEN APPLIED TO SLOW SPEED BALANCING OF LARGE TURBO GEN. ROTORS 7. CAN BE USED FOR RIGID ROTORS ALSO SUCH AS LARGE ARMATURES AND FANS

STATIC COUPLE DERIVATION 1. NOTE THE ORIGINAL RIGHT AND LEFT READINGS AS OR AND OL.USING THE POLAR GAPH PAPER CONSTRUCT VECTORS OR AND OL 2. CONNECT THE END OF VECTOR OR TO THE END OF VECTOR OL AND FIND THE MID POINT OF THIS INTER CONNECTING LINE. 3. DRAW A LINE FROM THE ORIGIN TO THE MIDPOINT OF THE INTER CONNECTING LINE. THIS IS A VECTOR WHICH REPRESENTS ORIGINAL STATIC UNBALANCE SO. 4. THE DIVIDED INTER CONNECTING LINE REPRESENTS THE COUPLE UNBALANCE CR ACTING ON THE RIGHT SIDE AND CL ACTING ON THE LEFT SIDE.

CR

OR SO
CL OL CR CL

5. PROCEED TO APPLY A STATIC TRIAL WEIGHT IN A REFERENCE PLANE NEAR THE PLANE HAVING C.G. IF IT IS NOT POSSIBLE TO ADD TRIAL WEIGHT AT THE CENTER PLANE THE STATIC WEIGHT MAY BE DIVIDED AND APPLIED AT THE END PLANES. 6. THIS TECHNIQUE CAN BE APPLIED TO NON SYMMETRICAL ROTORS ALSO AS LONG AS THE WEIGHTS ARE APPLIED COMPENSATING FOR THE LOCATION OF THE CENTRE OF GRAVITY. 7. AFTER ADDING TRIAL WEIGHTS NOTE THE VIBRATION READINGS AT BOTH THE ENDS AS (O+T)R AND (O+T)L

8. USING THE SAME SCALE AS IN STEP1 CONSTRUCT VECTORS (O+T)R AND (O+T)L

O+TR

CR
O+TL

S O+T

CL

9. WITH VECTORS SO AND SO+T STD. SINGLE PLANE VECTOR SOLUTION IS OBTAINED FOR STATIC UNBALANCE 10.THE STATIC UNBALANCED THUS CORRECTED UNTIL AMPLITUDE READINGS ARE EQUAL AND PHASE READINGS ARE 180 DEG. OPPOSITE 11.THE COUPLE IS THEN CORRECTED USING THE CL AND CR VALUES