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"GLITCH" Definition, Sources, and Methods of Correcting

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Optimization and Control

"GLITCH" Application Notes

Bently Nevada ™ Asset

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and Imperfections
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The term "GLITCH" is Bently Nevada Corporation's Related Offerings

nomenclature for describing all forms of vibration
Monitoring Systems
measurement error from an observed shaft surface. This
does not include other possible noise and signal error Sensors and Transducers
sources, such as electrical line noise, monitor problems or Test and Calibration Equipment
problems associated with casing mounted transducers.
Casing mounted transducers, such as velocity coils or Related Links
accelerometers are also SUbject to signal error sources in
the form of cross axis vibrations, improper mountings, line Application Notes
noise as well as several others particular to each type of Bently Nevada User Forum
transducer; however, glitch deals with observed shaft
Customer Application Centers
surface anomalies only. In order to clarify the sources of
these vibration measurement errors, sometimes referred to Customer Success Stories
as runout, the follOWing diSCUssion shall focus on the two ORBIT MagaZine
categories of "GLITCH", mechanical and electrical Rightrax Sensors

Sources of Glitch

Mechanically Induced Runout:

Nonconcentric Surfaces/Bows
A shaft surface which has been Improperly machined (egg shaped or non concentnc) will yield a Sinusoidal
displacement Signal with a frequency COincident with the rotational speed of the .-otating element A second
condition on a rotating element, which will yield the same apparent dynamic motion condition. manifests when
the rotating element has been physically bent or bowed.

Sources of improperly machined surfaces can usually be traced to a worn or defective set of bearings on the
machine used for final machining or grinding or a worn-out set of lathe centers on a lathe. Bows in a rotating

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GE Energy - "GLITCH" Definition, Sources, and Methods of Correcting Page 2 of 5

element are typically Introduced due to Improper handling of the rotor dunng its manufactunng cycle This
may be the result of a sudden or Jarring load applied or due to long-term storage of the element with improper
supports for the rotor In the case of the latter. an Improperly supported rotor may Introduce a permanent sag
or bow due to gravitatIOnal forces

Surface Irregularities or Imperfections

The presence of surface imperfections or irregularities will yield a runout condition as observed by the
proximity transducer The sUliace imperfections discussed herein are Ir1 the form of scratches. dents. burrs,
etc

In general. surface Irregularities are created due to improper handling of the rotor during the manufacturing
cycle. Care should be taken to protect the shaft surface to be used for dynamic rnotion measurements. In
essence, these surface areas should be given the same protective measures used to protect a bearing
journal surface Crane lifts should be made with cables attached to shaft areas away from the probe
measurement surfaces Support fixtures for storage of rotors should not Introduce surface scratches, dents,
etc

Occasionally. surface irregularities are introduced via a machine-cutting tool If the too! is dull or the feed is
too rapid, some tool chatter may occur Which can introduce small ripples in the shaft surface.

Electrically Induced Runout:

Residual Magnetism
In general, proximity transducers will operate satisfactorily In the presence of magnetic field, as long as the
field is uniform or symmetrical and not iocalized to a particular location on the rotor If a particular area or
zone of the shaft surface is highly magnetic and the remaining surface is nonmagnetic or at a much lower
value. an electrical runout condition will manifest. This is due to the resultant change in sensitivity on the shaft
surface to the applied field from the pro)(imity transducers.

Residual magnetism runout problems are seldom encountered. However, various physical inspection
techniques employed during the manufacturing cycle, such as the use of magnetic chucks, can introduce
residual magnetism problems. The most common inspection technique, where residual magnetism may be a
byproduct, is a Magnetic Particle inspection (Magnaflux®) to check for cracks on castings, or weldments, or
after other manufacturing cycles. The magnetic field introduced to the rotor for this inspection should be
neutralized after the inspection program is completed. This is done with the Magnaflux machine and involves
continuously reversing the polarity and passing a current through the rotor at continuously decreasing
amperes. If done properly. this procedure should neutralize the magnetic properties of the rotor. In some
cases a proper polarity reversal is not performed, and residual magnetism is produced.

Precipitation Hardening
17-4 pH steel nearly always presents an electrical runout problem. Some form of material replacement (shrink
a collar, overspray a matenal) IS normally required to eliminate glitch.

Other pH steels, such as 15-5 pH, seems less prone to glitch, but any pH steel may cause difficulties

Metallurgical Segregation
The scale factor yielded from a proximity transducer IS dependent upon several variables. One variable
involves the specifiC metal or metallurgy it is to observe. Typically. steel alloys for shaft matenals contain a
variety of alloying agents. In general, the final metallurgical composition of these alloys is a homogenous
mixture. On some rotating elements microscopic segregation of the steel alloys may occur. Since the
proximity transducer responds with different voltage outputs depending upon specific metals. the lack of a
homogenous metallurgical composition around Ule circumference of a shaft may give rise to varying electrical
outputs.

Residual Stress Concentrations

During the normal manufacturing cycle of rotors, a vanety of machining and surface treatment processes can
introduce small amounts of localized stress concentrations Although these stress areas do not adversely
affect the mechanical properties of the rotor, they may give rise to an electrical runout from the proximity
transducers. Since one of the variables affecting voltage OLitput from the transducer is the resistance of the
observed shaft surface. any deviation of the resistance around the circumference of the shaft (due to varying
stress levels) will produce a voltage change.

Measurement of Glitch
The observation of mechanical runout at a rotor speed below which dynamic vibration is eliminated (typically
less than 10 c/o of the rotor operating speed) on an oscilloscope will yield a SinUSOidal dynamic waveform for
non-concentric surfaces or shaft bows. Surface irregularities or imperfections will appear on an oscilloscope
as sharp voltage spikes superimposed on the dynamic waveforrn

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Nonconcentnc surfaces or shaft bows may also be measured by a dial indicator moun1ed in the probe area of
the shaft, which in turn, is mounted at the bearing journals in vee blocks. or roller bearings. The
circumference of the probe area IS marked off In 36 positions (10 degree Intervals) with zero in line axially with
the thrust collar keyway Dial gauge readings are recorded at each Indicated position Two sets of readings
are taken. approximately half an Inch apart axially, one on each side of the probe position centerline. The two
sets of readings are averaged to give a record of mechanical runout Amencan Petroleum Institute (API)
Standard 670 recommends that "the combined total electrical and mechanical runout does not exceed 25
percent of the maximum allowed peak to peak vibration amplitude or 0,25 mil (6 micrometers), whichever is
greater" The shaft surface finish should be from 16 to 32 micro inches (OA to 0.8 micrometers) root mean
square, also per API 670,

The observation of a residual magnetism runout condition on an oscilloscope can yield a sinusoidal motion
indication. However, tile sine wave wJ!i be distorted and to some extent tend towards a square wave. A final
check for residual magnetism embraces the use of a small handheld field strength indicator manufactured by
Magnaflux Corp, Holding this meter at the shaft smface and hand turning the rotor will confirm the presence
or absence of magnetic fields of less than 2 gauss with variations less than 1 gauss

An oscilloscope observation of metallurgical segregation will typically indicate a somewhat sinusoidal

waveform With 11igh voltage, high frequency spikes supemnposed on the waveform.

Observation of reSidual stress concentrations on an OSCilloscope will yield a sinUSOidal waveform with high
voltage, high frequency spikes supenmposed on the waveform

It should be noted that the oscilloscope waveform in all the above cases may also be very irregular,
depending on the number of other shaft surface anomalies

If desired, the electrical runout can be detemllned by subtraction of mechanical ,unout from the total rUnout

Glitch Reduction
Various methods of reducing glitch are available and have been successfully used by firms. It is not possible
to define which method is best because each can achieve lhe desired result However, it is possible to narrow
the chOice of methods when they are con~idered on a cost and time basis,

It IS also notable that proper matenal selection, heat treating, and allOWing control can have a large effect on
the runout condition of a rotor. If rotors are to be replaced or rebUilt, it is far more cost-effective to detect and
correct glitch at the earliest stages of machine assembly.

a Degausslng- ReSidual magnetism In a shaft, caused as a result of magnetic particle crack detection or
by working in a magnetic field, can produce very senous electrical runout It is therefore prudent to
measure residual magnetism in the probe area of every shaft before attempting glitch removal. A
localized residua' magnetism of field strength 5 gauss on a rolling shaft can give an electrical runout in
the order of 0,5 mil. Thus any shaft, which exhibits residual magnetism in excess of 2,0 gauss, or
variations greater than 1 gauss, should be degaussed. This is generally not a complete glitch removal
process on its own, but it does help to ensure that glitch readings do not change as a result of a shaft
losing residual magnetism in service.

b. Diamond Burnishing - This API recommended method has a high success rate of reducing glitch to
within acceptable limits The probe area IS rolled under a diamond-burnishing tool to work a shaft
surface to a uniform finish. In effect, th!s procedure produces an even work-hardened surface, which
requires no additional treatment This method is undoubtedly the easiest with very little skill required.

c. Further Macl1!ning - Should a probe area be oLitside acceptable limits, the target area can be reground,
and should be degaussed following grlndll1g. This can be a hit and miss method that could lead to even
more unacceptable results

d. Polishing or Stoning - Similar process to Ic) but not qUite so drastic However, the problem of making
matters worse stili exists.

e Sleeving - Shrinking a sleeve onto the shaft tlas been used, but It is an expensive way of producing
results as unpredictable as (e) and (d) above. As with both of those methods. further treatment may be
necessary,

f. Plasma Spray Finishing - Altt10ugh not recommended by API, metal coating has been used effectively
as a solution for stubborn runout problems Aluminum ... Nickel flame spray coatings are currently being
used very successfuliy In the Industry to reduce glitch problems, often to lessl!lan 1/2 mil pp.

The Metco@ process consists of machining a 1-1/2 inch Wide. 0.060 deep grove around the shaft, The groove
IS then grit blasted, and coated with a bond coat of Metco 447 to about 0,010 inch thickness. The remainder
of the grove IS then flame sprayed filled with Meteo 52C aluminum Silicon composite and machined flat with

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the surface of tile sllaf!. Since the electrical properties are different from 4140 steel, a specially calibrated
Proximitor® must be used at lhese locations.

Protection of Probe Areas

The removal of glitch by one or a combination of the treatments discussed above is essential for customer
acceptance of levels of recorded vibration Having treated the probe areas it is essential to protect these
areas to prevent corrosion damage, scratching and indiscruninate "cleaning up" During production and
testing, this protection IS afforded by the care taken by skilled craftsmen wr,o appreciate the sensitive nature
of this surface.

Between acceptance testing and startup much less care can be exerCised There have been many field
reports of probe areas being damaged by rust scratches or dents Cleaning up the damage by stoning or
polishing may give the desired appearance but ttle onginal glitch recordings would tlave been completely
altered and undoubtedly taken beyond acceptable limits. Glitch removal then has to be carried out in the field
by selective micropeening, and conSidering the adverse conditions. the results are Invariably inferior to those
which can be achieved In the shop It is therefore recommended that after glitch treatment and recordings are
taken in the shop, the probe areas be given a coating of non-metallic epoxy resin, which can remains, for the
life of the machine. This coating Will not affect probe readings but will protect ttle probe area from corrosion
and all minor mechanical damage

Compensation
Obviously, shaft treatment to remove the source of runout IS the most desirable procedure. If this is done,
there is no reason to have to "account for" runout rn subsequent vibration signals

However, the occasional shaft material or forging may not respond well to the standard shaft treatment
methods. The shaft may have a "permanent" bow or It may be impossible or Impractical to treat the shaft
surface before a time when Vibration data IS required on a given machine If it IS Impractical to treat the shaft
surface or remove the shaft bow, an electronic method may be used. The following IS an explanation and
discussion of this application.

Vector Nulling - Digital Vector Filter

Also called slow roll compensation; this system IS an integral part of the Digital Vector Filter. It provides a
means for nulling a slow roll vector. It should be noted that the nulling operation IS a true vector subtraction
(phase and amplitude) and not merely a voltage suppression circuit. The nulling Circuit operates on the filtered
vibration wavefoml (the vector information in the DVF) Since the filter employed in the DVF-3 is tuned to the
rotational (1 X rpm) frequency of the rotor the nulling circuit eliminates that portion of shaft runout, which is
coincident with the rotational frequency. Typically, it is used to eliminate a 1X component of runout such as a
bow in the shaft or a nonconcentric (egg-shaped) shaft condition at the probe measurement plane, All higher
orders of runout (non 1X components. such as scratches. metallurgical Irregularities. etc.) are eliminated
through the filter action of the DVF-3

Once the initial slow-roll vector has been nulled, It is automatically subtracted from all future dynamic signals.
This system provides the means for properly examining the mechanical response and impedance of a
system, definition of the balance resonances (critical speeds), and amplification factors. over the operating
speed range. Vector nulling also allows for the compensation of the reSidual unbalance vector after a balance
resonance, and for observation of a higher balance resonance response.

It is possible, and even probable on larger machinery, tllat nominal axial position changes and differential
expansion up to running speed will cause a vibration probe to observe a "new" lateral location on the shaft,
When considenng the overall runout pattern this "new" shaft location may be significantly different than the
overall pattern observed with the machine at slow-roll.

Vector nulling does not, 11Owever, deal with the overall runout pattern because of the filter in the system. only
the 1X runout vector is considered The once-peHurn runout vector is not likely to change from slow-roll to
operating speed and tel11peratul'e. In this regard, vector nulling offers a distinct advantage over any other type
of digital runout compensation. Vector nu!llng also offers the capability of nullll1g the residual vector of shaft
motion after passing through a resonant speed region to observe the action of the next higher resonance
when Bode plots (amplitude vs rprll and phase vs rpm) are made

Recommendations
The above considerations lead to the follOWing conclUSions and recommendations by Bently Nevada:

Glitch can often be controlled at its source (the shaft) to a Jevei acceptable for monitonng purposes, and
in most cases to levels usable for machine acceptance testing and diagnostic purposes. Every
reasonable attempt should be \nade to correct the runout problem at its source

2 The use of electronic run out compensation for continuous machine monitOring should be avoided
except in rare cases (e g. a damaged srlaft that cannot be corrected until the next turnaround). Bently

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Nevada does not recommend the use of electronic runout COlllpensatlon In a vibration monitor system
Wired for automatic machine shutdown.

3 Nul!lIlg - compensation for an initial 1X vector - can be accomplis fled with the Digital Vector Filter 3

4 When reproducillg vibration data from magnetic tape special care should be taken to ensure proper
synchrollization of the signal Most tape recorders provide a function whereby one channel can be
dedicated as a synchronizing Signal for tape flutter compensation

5. When runout compensation IS used, it should be used as a "last resort" In all cases, both the anginal
transducer signal and the compensated signal must be available for observation on external
IIlstruments

References
"New Techniques 'n overcomlllg Electrical Runoul' by Dale W Beebe, Turbodyne Corporation, Hydrocarbon
Processing August 1976.

Electrical Runout and Eddy Current Displacement Proximity Transducers, by Biggs, David H , ASME Paper,
September 1975. (Bently Nevada Literature No, L0360)

Elliot-Wledeke paper

API 670, Second edition, Section 4 12 Machine Shaft Requirements for Electrical and Mechanical Runout

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