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Lebw4972-04 1
Lebw4972-04 1
Lebw4972-04 1
Installation Guide
Vibration
LEBW4972-04
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Caterpillar: Confidential Green
Contents
Vibration ..................................................................... 1
Basic Theory .............................................................. 2
Linear Vibration Definitions ......................................... 2
Frequency .......................................................... 3
Displacement ...................................................... 3
Velocity ............................................................. 3
Acceleration ....................................................... 4
Vibration Identification ................................................. 6
Vibration Measurement .............................................. 6
Order of Vibration .................................................... 8
Vibration Level Guidelines .......................................... 9
Vibration Causes and Corrective Actions ............................ 11
Causes ................................................................. 11
Corrective Actions ................................................... 11
One Component .................................................. 11
1/2 Order Vibration .............................................. 11
1st Order Vibration .............................................. 11
2nd Order Vibration ............................................. 11
Higher Order Vibration .......................................... 11
Non-Engine Vibration ............................................ 11
Excessive Engine Motion ............................................ 12
Misalignment/Unbalance........................................ 12
Resonance ......................................................... 13
Torque Reaction .................................................. 13
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Balance Procedure Overview .......................................... 14
General Balance Procedure ........................................ 15
Rotor Alignment Balance Procedure .............................. 15
Mass Balance Procedure ............................................ 16
Torsional Vibration...................................................... 17
Torsional Vibration Analysis ........................................ 18
Required Data ........................................................ 19
Driveline Design...................................................... 20
Reference Material ..................................................... 22
Media List ............................................................. 22
Engine/Driven Equipment Vibration Measurement Data Sheet
......................................................................... 23
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Foreword
This section of the Application and Installation Guide generally describes
Vibration, its causes and suggested corrections for Cat® engines listed on the
cover of this section. Additional engine systems, components and dynamics are
addressed in other sections of this Application and Installation Guide.
Engine-specific information and data are available from a variety of sources.
Refer to the Introduction section of this guide for additional references.
Systems and components described in this guide may not be available
or applicable for every engine.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the Power
Edge trade dress, as well as corporate and product identity used herein, are
trademarks of Caterpillar and may not be used without permission.
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Vibration Application and Installation Guide
Vibration
All mechanical systems with mass and elasticity are capable of relative
motion. If this motion repeats itself over a given time period, it is known as
linear vibration. Engines produce linear vibration due to combustion forces,
torque reactions and structural mass and stiffness combinations and
manufacturing tolerances on rotating components. All these forces may create
conditions ranging from unwanted noise to high stress levels, and possible
failure of the engine or driven components. Torsional vibration can create
similar conditions but is caused by the twisting and untwisting of a shaft.
This guide:
Reviews the basic theory and nomenclature of linear vibration.
Identifies causes of engine-related linear vibration.
Provides instruction for possible corrective action.
Reviews the basics of torsional vibrations, including an understanding
of causes and approaches to addressing them.
Describes torsional vibration analysis (TVA), its importance, and
information required to complete a TVA.
SECTION CONTENTS
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Application and Installation Guide Vibration
Basic Theory
Engine vibrations are produced housed in a building or close to
and maintained by regular, periodic sensitive instruments or equipment,
driving forces set up by unbalanced such as computers.
moving masses. These are called Other factors influencing vibration
forced vibrations. are foundation design, soil load
Free vibrations have no driving characteristics, and other machinery
force. When set in motion, such operating in close proximity.
vibrations, if undamped, would
continue indefinitely with constant Linear Vibration Definitions
amplitude and natural frequency. Linear vibration occurs as a mass is
deflected and returned along the
If the frequency of a forced same path. This can be illustrated as
vibration is the same as the natural a single mass spring system as shown
frequency of a free vibration, then in Figure 1. While no external force is
excessive vibration will result. This imposed on the system, the weight
synchronization of forced and free remains at rest and there is no
vibration is called resonance. vibration. When the weight is moved
Resonance stresses can cause or displaced and then released,
serious problems and even reach vibration occurs. The weight travels
destructive levels. up and down through its original
position until frictional forces cause it
The vibration generated by the
to rest.
engine could also result in structural
damage if a rigid installation was
Figure 1
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Vibration Application and Installation Guide
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Application and Installation Guide Vibration
One Period
Figure 2
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Vibration Application and Installation Guide
Acceleration measurements, or
“g’s”, are used where relatively large
forces are encountered. At very high
frequencies (60,000 cpm or 1000 Hz),
it is perhaps the best indicator of
vibration.
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Application and Installation Guide Vibration
Vibration Identification
If excessive linear vibration motion horizontal directions at each bearing
is present or suspected, an initial location, and in an axial direction at
inspection should be performed to the rear face of each major piece of
confirm that: equipment. For example, an engine
Engine, coupling and driven driving a two bearing generator set
equipment mounting bolts are will require measurements at ten
properly torqued, and that all jacking points, two at each bearing and two
bolts and set screws are backed off. in an axial direction, as illustrated in
Figure 4.
Engine, coupling and driven
equipment are properly aligned. Engine only applications and other
types of packaged units may require
All external piping is properly isolated fewer measurement points, but the
from the engine and driven following descriptions and graphic in
equipment with appropriate flexible Figure 4 still apply.
couplings.
Marine propulsion applications will
All vibration isolators are properly also require a measurement in the
adjusted, all springs (if equipped) are vertical direction at the right rear
compressed the same amount, and engine mounting foot. This is required
none are fully compressed (closed). to check for rolling of the engine. The
If the initial inspection results do measurement is taken
not identify the problem, then at the point where the engine is
vibration measurements should be anchored by means of a fitted bolt.
made to determine the source prior Vibration measurements must be
to starting corrective action. The made at the advertised driven
Cat® vibration tool provides reports equipment rating (100% load). If
listing overall vibration levels and additional data is desired, it is
individual order values up to 10th recommended that measurements
order. As an alternative, the be made at 0% load, 50% load, 75%
Vibration Measurement Data Sheet, at load and, depending on the rating,
the end of this guide, is provided for 110% load.
convenient recording of raw data at
various engine speed and load For generator set applications,
conditions. This form can be used for if measurements are taken while a
the basic engine as well as any generator is loaded, the magnetic
packaged unit, including one or two field of the generator leads must be
bearing generator sets, marine avoided. In addition, if the generator
propulsion engine/reduction gear rotor failure is suspected, two sets of
sets, and pump or compressor measurements should be made at the
packages. 0% load condition for generator set
applications; one with the exciter
Vibration Measurement turned “on” and one with the exciter
At a minimum, vibration should be turned “off.”
measured in both vertical and
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Vibration Application and Installation Guide
Figure 4
Point 1 – EFV (Engine Front Vert.) Point 5 – ERA (Engine Rear Axial)
Vertical direction at the front of the Axial direction at the rear of the
engine; locate the probe on the block engine; locate the probe on the right
top deck in the plane of the rear outside edge of the block at the
crankshaft centerline. crankshaft centerline.
Point 2 – EFH (Engine Front Hor.) Point 6 – XFV (Driven Front Vert.)
Horizontal direction at the front of Vertical direction at the driven
the engine; locate the probe on the equipment front bearing; locate the
side of the block at the crankshaft probe on the bearing housing at the
centerline. shaft centerline.
Point 3 – ERV (Engine Rear Vert.) Point 7 – XFH (Driven Front Hor.)
Vertical direction at the rear of Horizontal direction at the driven
the engine; locate the probe on the equipment front bearing; locate the
block top deck (or rear housing) in probe on the side of the bearing
the plane of the crankshaft housing at the shaft centerline.
centerline.
Point 8 – XRV (Driven Rear Vert.)
Point 4 – ERH (Engine Rear Hor.) Vertical direction at the driven
Horizontal direction at the rear of equipment rear bearing; locate the
the engine; locate the probe on the probe on the bearing housing at the
side of the block at the crankshaft shaft centerline.
centerline.
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Application and Installation Guide Vibration
Point 9 – XRH (Driven Rear Hor.) hertz range, with energy presented in
Horizontal direction at the driven ½ order intervals.
equipment rear bearing; locate the
probe on the side of the bearing Order of Vibration
housing at the shaft centerline. In discussions of vibration, the
frequency of the motion is commonly
Point 10 – XRA (Driven Rear Axial) referred to in terms of order of
Axial direction at the driven vibration. In an engine, the order of
equipment rear; locate the probe on vibration is the number of vibratory
the right rear outside edge of the cycles exhibited by a component
driven equipment structure (not sheet during one revolution
metal) at the shaft centerline. of the crankshaft.
Point 11* - ERR (Engine Rear Rot.) One-Half Order is one occurrence
Vertical direction at the right rear every two crankshaft revolutions.
engine mounting foot. First Order is one occurrence per
* - marine applications only, when crankshaft revolution.
engine is anchored with fitted bolt. Second Order is two occurrences
ISO 8528-9 per crankshaft revolution.
The International Standard (ISO Higher Order describes occurrences
8528-9) can also be referenced as at 1½, 2½ or more crankshaft
guidance for vibration measurement. revolutions.
The ISO Standard recommends
measurements to be taken in vertical, Vibration Frequency (cpm)
Order=
horizontal, and axial directions for all Engine Speed (rpm)
measurement locations. The ISO
standard does not specify that data Overall vibration motion is the
for all three directions be taken vector sum of the motion of all the
simultaneously, but if a vibration tool orders.
with this capability is available to do Data should be reported in terms of
this, it is reasonable to conclude that peak-to-peak displacement (mils pk-
approach would be preferred. The pk or mm rms) at half order
same can also be said for taken data frequencies, whole order frequencies,
in all three directions, for all points, as well as overall displacement (mils
simultaneously. In factory or mm rms), overall velocity level
development and troubleshooting of (in/s peak or mm/s rms) and if
significant issues, a vibration tool required overall acceleration (in/s² or
with this degree of capability is the mm/s²) for each of the measuring
typical method for vibration testing. locations. The data sheet at the end
The ISO standard also references data of this guide can be used to record
to be taken across a frequency range and report the measured vibration
of 2-1000 hertz. data.
Note: The Caterpillar standard All measurements must be made on
compiles vibration data in the 2-300 the main rigid structural members of
the engine and driven equipment.
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Vibration Application and Installation Guide
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Application and Installation Guide Vibration
1. Some retail generator set packages are developed to meet the ISO8528-9 level 2 vibration standard.
For more information, refer to REHS3679.
2. ISO8528-9 limits in the table above are applicable to gensets operating at 1300-2000rpm, rated above 200kW.
3. For other rpm and rating refer to the ISO8528-9.
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Vibration Application and Installation Guide
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Application and Installation Guide Vibration
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Vibration Application and Installation Guide
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Application and Installation Guide Vibration
Balance Procedure
Torque reaction problems are not
found with close-coupled generators. Overview
The rigid joint between the flywheel With a single bearing generator, the
housing and the generator body is front of the rotor is supported and
generally adequate to withstand located by the flywheel causing the
torque. orientation of any radial runout of the
Assuming that a free standing two- flywheel pilot at the time of
bearing generator is mounted on a generator installation to affect runout
weak base, in cases such as non- and misalignment of the generator
factory supplied base, first order rotor. There is sufficient clearance
motion and orders related to the within the flywheel pilot to allow the
number of cylinders firing with one rotor to change alignment by
crankshaft revolution are due to tightening up the coupling plate bolts
torque reaction which, in turn, causes with the flywheel oriented in
misalignment. In this case, the first different angular positions.
order motion would be most For a single bearing generator set, a
prevalent. balance procedure must address a
This condition is generally rotor runout or misalignment issue
encountered when the engine is and potentially address any mass
driving a conventional two-bearing unbalance as well. For a two-bearing
generator which is not close-coupled. generator set, the rotor is fully
Check the alignment of supported and located by the
the unit. generator with a flexible coupling
If the two-bearing generator set absorbing any misalignment with the
utilizes a structural steel base which flywheel. A balance procedure for a
is point-mounted, for example, pads two-bearing will focus on only the
and isolators, torque reaction can mass unbalances in the rotating
deflect the weak base. This deflection system.
can cause severe misalignment and For these reasons, there are 3
resulting vibration. balance procedures that follow. The
If the unit continues to exhibit first procedure works for most
vibration after alignment, the base is misalignment issues, but on single
likely not strong enough to hold the bearing generators this process
torque reaction and needs affects both the mass balance and
strengthening. rotor alignment simultaneously. The
ability to independently affect or
One method of strengthening is further affect just one of these root
to weld plates on top and bottom of causes is sometimes required. The
the base across the width of the base second procedure affects only the
from 6 in. forward of the rear engine rotor misalignment and is therefore
supports to 6 in. behind the generator only beneficial for single bearing
feet closest to the engine. generators. The last procedure
affects only the mass balance.
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Application and Installation Guide Vibration
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Application and Installation Guide Vibration
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Vibration Application and Installation Guide
of the system away from the energies from that load. A large
designed operating speed. The front-driven load is an important
engine’s rear-mounted flywheel and case where seeking expert advice is
front-mounted torsional dampers critical to achieving an acceptable
are located for best performance outcome. As stated earlier, if you
with a rear-driven load. If it have any questions about the
becomes necessary to drive the load acceptability of a proposed
from the front of the engine, the driveline design, please contact
damper and flywheel become poorly Caterpillar to determine how best
located to help manage torsional to evaluate the risks involved.
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Application and Installation Guide Vibration
Reference Material
Media List
The following information is
provided as an additional reference to
subjects discussed in this manual.
SEHS7654: Special Instruction –
Alignment – General Instructions
REHS0423: Special Instruction –
Alignment of Two-Bearing
Generators
REHS0177: Special Instruction –
Alignment of Close Coupled Two-
Bearing Generators
NENG2500: Tool and Shop Product
Guide
LEKQ4023: Linear Vibration
REHS3679: Procedure for Vibration
Measurements on Electric Power
Generator Sets
SEHS7259: Alignment of Single-
Bearing Generators
SEHS7073: Special Instructions
Alignment of Two-Bearing
Generators
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Engine/Driven Equipment Vibration Measurement Data Sheet
Engine/Driven Equipment Description: _____________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
Rating: _______________________________________________________________
Rated Speed: __________________________________________________________
Load Condition: ________________________________________________________
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LEBW4972‐04 (07‐18)
®
©2018 Caterpillar. All rights reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow”, and the “Power Edge”
trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.