Shaft Monitoring: Bearings Seals

Shaft Monitoring
Seals
Bearings
Lubrication
Control system
Operation
Condition monitoring
Mechanical design Maintenance
Trouble shooting
Compressor Training Power Generation 1

14.10.05
Ulrich Taetz , PG I14314
.
Shaft Position Indication
The compressor is equipped with shaft position probes which

continuously indicate the position of the shaft relative to the
thrust bearing on a monitor.
The probes are of the proximity type (non-contacting)and a
function on the basis of eddy current principle.
They are arranged opposite a disk which is mounted on the shaft

end. If thrust bearing wear occurs, the corresponding axial shift of
the rotor is indicated on the monitor.
In case safe limits are exceeded, an alarm and subsequently a

shut-down are initiated.

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1
Shaft Position Indication
The vibration probes are installed on the shaft near the

journal bearings.
The vibration probes are also of the proximity type and
function on the basis of the eddy current principle.
The probes are mounted on the bearing housings.
They continuously indicate the vibration level of the shaft
relative to the bearing housings. On each bearing housing,
two probes are mounted 90° apart (X-Y probe
arrangement) to measure vibration in two planes. This
ensures that vibration is registered regardless of the
shape of the shaft orbit.
If shaft vibration becomes excessive, an alarm and
subsequently a shut-down are initiated.

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Shaft Speed Indication
The compressor is also equipped with keyphasor

transducer.
Transducer which produces a once-per-shaft-revolution

voltage pulse, called keyphasor signal.
This signal is used primarily to measure rotation speed

and as a reference for measuring vibration phase lag end.
It is extremely useful as a quick reference between shaft

rotation speed and vibration frequency, and is an essential
element in measuring rotor run out information.

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2
Bearing Temperature Monitoring
Journal and thrust bearing are equipped with

Resistance TemperatureDetectors.
The RTD’s extend into small drilled holes in the

journal and thrust bearing pads to measure the
temperatures close to the babbit lining.
In case of exceeding the limits alarm and shut-down

is provided here, too.

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RotorAbs Vibration
X Rotor,abs. = X Rotor, rel

rel.. + X Casing, rel
rel.. + X Pedestal
90 0

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3
Rotor Vibrations
Vibrations
Lateral Torsional
Forced Self-Excited
l Unbalance l Internal Damping
l Surge l Aerodynamic Whirl
l Rotating Stall l Oil Whirl
l Pressure Pulsation's l Floating Ring Seals
l Labyrinth Seals
l Acoustic Resonance
l Fluid Trapped in Rotor
l Bearing Journal Differential Heating

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Rotor Vibrations
Relative shaft vibration can emerge through:
· Actual shaft vibration or
· casing vibration or
· shaft and casing vibration .
In case of doubt please measure:
· relative shaft vibration (non contact measuring) and
· casing vibration (seismic measuring)

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4
Shaft Monitoring Devices – Axial/Radial
Movement
RADIAL MOVEMENT
AXIAL MOVEMENT

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Shaft Monitoring Devices

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5

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6
Control Panel

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Radial vibration
The compressor has been provided
with radial vibration probes to
measure the radial vibration of the
shaft.
Two probes are mounted at an angle

of 90º near each main bearing. This
provides accurate measurement of
radial vibrations.

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7
Axial displacement
Each probe observes a groove,

machined in the shaft. The groove
provides a so called once per turn event
which will provide a voltage pulse every
time the groove passes the key phasor
probe. The key phasor pulse provides a
reference mark for phase angle,
frequency measurements and all
vibration data acquisition.

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Axial displacement
The compressor shaft has been

provided with two axial displacement
probes. These probes are mounted on
the thrust bearing side of the
compressor.
The compressor and gearbox have

each been provided with an additional
axial probe, which functions as a key
phasor :

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8

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Continuous Vibration Monitoring System
FIELD WIRING EXTENSION CABLE

RACK AND PROXIMITOR AND PROBE

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9
Shaft monitoring Devices - Proximitor
SIGNAL OUTPUT TRANSDUCER POWER

SIGNAL COMMON
ELECTRICAL LENGTH

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Principle

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10
Principle – Eddy Current Flow
R
CONDUCTIVE
NEVADA
BENTLY
MATERIAL
(Shaft)
RF SIGNAL
1.8 mm
0.8 mm
EDDY CURRENTS
0 mm

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FUNCTIONAL PRINCIPLE
A voltage signal is generated in the proximitor through

measurement of the clearance width between the probe and
the shaft
shaft.. This signal is indicated on the monitor as a dis-
dis-
tance or as a vibration level
level..
The proximitor obtains its supply voltage of – 18 V or –24 V

from the monitor
monitor.. It consists of an electronic circuit which
generates a high
high-- frequency signal which is than transmitted
to the probe.
The probe consists of a housing with a measuring head attached

at the front and containing a coil embedded in synthetic resin
and covered over with fibre
fibre-- glass
glass..

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11
This coil causes the high

high-- frequency energy generated in the
proximitor to be emitted into the surrounding area in the form
of a magnetic field
field.. Eddy currents are generated when this field
is penetrated by an electrically conductive material (metal).
The effect becomes greater as the material comes closer to the
tip of the probe.
The level of the high

high-- frequency signal generated in the proximi
proximi--
tor becomes lower as the material gets closer to the probe tip
tip..

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Principle – Small Gap
RF SIGNAL 0

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Principle – Large Gap
RF SIGNAL 0

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Principle – Changing Gap
RF SIGNAL 0

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Principle – Demodulator Operation
DEMODULATOR
INPUT 0
PROXIMITOR 0
OUTPUT

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The alteration in the high

high-- frequency signal is transformed into
a direct
direct-- voltage signal in the proximitor and is transmitted to the
monitor as an output signal
signal..
The alteration of the output voltage at the proximitor is propor –

tional to the alteration in the distance between the probe and the
shaft.. If the distance remains constant
shaft constant,, than the output voltage
also remains constant
constant,, while if the distance alters, than the output
voltage also becomes altered
altered..

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14
Measurement of the shaft vibration is performed according to the

same principle as that for the axial position probes
probes..
When the shaft rotates

rotates,, it does not run one hundred percent round
In the bearing but moves in such a manner that at one point in time
it is closer to the probe and at another it is further away from the
probe.
Since the clearance between the probe and the shaft alters very ra -
pidly during the above rotation, the high
high-- frequency signal no lon -
ger has a constant magnitude but changes in direct proportion to
the movement of the shaft
shaft..

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This signal is than termed “amplitude

amplitude-- modulated
modulated““
The proximitor than supplies an alternating

alternating-- voltage signal as the
output signal,
signal, and this signal vibrates around a constant direct vol
vol--
tage ( proportional to the medium distance )
The magnitude of this alternating voltage corresponds to the alte -

ration in clearance between the probe and the shaft and is indicated
on the monitor as a distance alteration in µm (or
(or mils)
mils )

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15
Principle

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Principle – Proximitor Calibration

Equipment Set UP
PROBE
TARGET
SPINDLE MICROMETER
EXTENSION CABLE
PROXIMITOR
NEVADA
BENTLY
out
com vt
-VT
INPUT
DC VOLTMETER

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16
Calibration - Proximitor Calibration Graph
24
22
CHANGE IN GAP
20
OUTPUT IN VOLTS - DC
18
16
CHANGE IN VOLTAGE
14
12
10
8
6
2
0
mils 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
PROBE GAP

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Calibration - Proximitor Calibration

Equipment Set Up

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17
System 3500

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System3500

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Proximitor (System 3500)
ELECTRICAL LENGTH
SIGNAL OUTPUT
SIGNAL COMMON
TRANSDUCER POWER

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Proximitor Operation (System 3500)
<100mil
RF SIGNAL
EXTENSION
PROXIMITOR
CABLE
AND PROBE
DEMODULATOR
OSCILLATOR

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19
Eddy Current Flow (System 3500)
CONDUCTIVE
MATERIAL
RF SIGNAL
EDDY CURRENTS

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Probe Numbering (System 3500)
CABLE
TIP
FIXED ASSEMBLY
LOCK NUT
P/N 330106-05-30-10-02-00
S/N APRS 416567

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Extension Cable Numbering (Sytem
(Sytem 3500)
P/N 330130-085-00-00
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P/N 330101-00-08-05-02-00
.
Calibration - Mis-Matched Cables
24
22
20
SHORT
18
16 CORRECT
14
12
10
6
LONG
4
0
mils 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
PROBE GAP
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Calibration - Target Material Effects
24
22
20
18
16
14
12
10
6 4140 STEEL
TUNGSTEN
ALUMINUM
4
COPPER
2
0
mils 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
PROBE GAP

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Calibration - Proximitor Calibration

Equipment Setup
PROBE
TARGET
SPINDLE MICROMETER
EXTENSION CABLE
PROXIMITOR
DC VOLTMETER
-VT
INPUT

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Transducer Orientation

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Probe Orientation
Y Orientation
Channel 1
X Orientation
Channel 2
Driver End

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Thurst System
THRUST
COLLAR
CHANNEL A
PROBE
PROXIMITOR
CHANNEL B SHAFT
PROBE
PROXIMITOR
CHANNEL A CHANNEL B
RECORDER RECORDER
OUTPUT OUTPUT
ALERT DANGER
RELAY RELAY
CONTACTS CONTACTS CHANNEL B
RECORDER
SIGNAL INPUT RELAY

MODULE
(REAR OF RACK)

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Axial Displacement Probe Adjustment
• Check voltage for Zero Position indication on the monitor (Standard : 10 VDC), zero position is
defined as shaft position in the middle of the axial bearing clearance.
§Push shaft to a defined axial position to bring thrust collar in contact with axial bearing and check
voltage
§Push shaft to the opposed axial position to bring thrust collar in contact with axial bearing and
check voltage
§Both voltage readings must be symmetric to Zero position gap voltage
Example :
shaft on active side : Ug = 8,80 VDC
shaft on inactive side : Ug = 11,2 VDC
Active side = 10 V – 1,20 V

Inactive side = 10 V + 1,20 V
-> Centre (Zero) Position = 10,0 V

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Axial Displacement Probe Adjustment

If both voltage readings are not symmetric to Zero position gap voltage, the probe needs to be
readjusted :
§ Check voltage difference ∆Ug between active and inactive side shaft positions
§ Necessary probe setting is Zero position (+/ -) ½ of ∆Ug .
§ Adjust probe to necessary gap voltage by adjusting sleeve and locking nut
§ Verify probe setting by pushing the shaft towards both ends of axial bearing and check voltage
Example :
shaft on active side : Ug = 8,40 VDC
shaft on inactive side : Ug = 10,8 VDC
-> Centre position = 9,6 V
∆ Ug = 10,8 – 8,4 = 2,4 V

½ ∆ Ug = 1,2 V
Necessary probe settings :
Active side = 10 V – 1,20 V = 8,8 V

Inactive side = 10 V + 1,20 V = 11,2V
-> Centre (Zero) Position = 10,0 V

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Axial Clearance

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Vibration Signal Characteristics
There are five basic signal characteristics that need to be

observed:
l Amplitude
l Frequency
l Phase
l Form
l Position
All of them together are used to reach an accurate
assessment of the mechanical condition of a
machine
26
Amplitude
pk
pk
rms
0
pk
Peak -to-peak refers to the total amount of vibration.

Zero-to-peak refers to the total amount of vibration from the
maximum height of either the positive or negative peak to the
zero voltage axis.
Root mean square (RMS) is a function of the signal conditioning
performed in the monitor or diagnostic instrument and not the
output of the transducer.
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Frequency
l Frequency is defined as the repetition rate of a

periodic vibration within a unit of time.
l The frequency of vibration (cycles per minute)
is most often expressed in multiples of rotative
speed of the machine.
l Basic frequency measurements can be
performed with an oscilloscope and Keyphasor
signal.
27
Frequency
TIME/CYCLE

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Phase
l Phase is defined as the timing relationship, in

degrees between two or more signals.
28
Frequency
PHASE
(BETWEEN VIBRATION SIGNALS)
A A
M TIME
P (DEGREES)
L
I PHASE
T
U B
D
E
TIME
(DEGREES)

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Phase Angle
The phase angle is defined as the number of

degrees from the Keyphasor pulse to the first
positive peak of vibration.
VIBRATION
SIGNAL
PHASE
LAG
TIME
KEYPHASOR
SIGNAL
DEGREES
OF 0° 360°
ROTATION

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Form
l Vibration form is the raw waveform displayed

on an oscilloscope and can be separated into two
categories:
w Timebase presentation
w Orbital presentation
Vibration Form
TIMEBASE- an oscilloscope displays the vibration in units of the

transducer (amplitude) versus time horizontally across the display.
TIME
AMPLITUDE
TIME

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30
Vibration Form
ORBIT- is the output of two transducers at 90° angles to one another (XY
plane) in the X-Y mode of the oscilloscope. The orbit is the
representation of the shaft centerline movement.
ORBIT
Shape

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Position
l Radial shaft position is a measurement of the

shaft centerline radial position within the radial
bearing.
w Derived from the dc information provided by
the proximity system.
w Used to determine bearing wear,
misalignment, external preloads and other
malfunctions.
31
Measurement References
l The four basic frames of reference for vibration

measurements on rotating machines are:
w Rotor motion relative to the bearing (Shaft
relative Vibration).
Shaft Relative

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w Bearing motion relative to the bearing
housing.
Casing Absolute

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w Bearing motion relative to the bearing
housing.
w Casing motion relative to a fixed reference
(Casing Absolute Vibration).
w Rotor motion relative to a fixed reference
(Shaft Absolute Vibration).
Shaft Absolute

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Settings
Trip value 2.8 (3.0) API

Amplitude
Alarm value 2.0 (2.5) API

Op. Range API
so zero-to-peak
A=2 x so
0
peak-to-peak

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Settings

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Settings

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Trends
alarm setting 51 µ

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Some relations :
x = distance of vibration µm
v = velocity of vibration mm/s
a = accelleration of velocity m/s2
w = 2 pi f f = n/60 = 1/s = Hz
x = v/w = a/w2
v = x * w = a/w
a = x * w2 = v * w
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Possible causes
A misaligned rotor is forced to operate in a position for

which it was not designed and it may come into contact
with seals,
seals , causing wear or damage and loss of efficiency
efficiency..
Misalignment can also cause wearwear,, damage or fatigue fai-
fai-
lure of flexible couplings
couplings,, greatly shortening their life.
Misaligned disk and diaphragm couplings can produce an

axial vibration
vibration..
Properly functioning gear couplings are much more axi-axi-

ally compliant and less likely produce axial vibration
from misalignment.
misalignment.
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37
Possible causes
The high bearing loads associated with misalignment can

cause overheating
overheating,, wear or fatigue of bearing babbitt in
fluid--films bearings.
fluid bearings .
High fluid film bearing temperature is often the first
warning of a possible misalignment condition.
Extreme misalignment can lead to polishing or wiping

of bearing babbitt material. When a machine is disassem-
disassem-
bled,, bearings should be carefully examined for evidence
bled
of any damage.
damage.

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Possible causes
In a misaligned machine,
machine, the rotor may transmit more
vibration to the casing,
casing, and the machine may experience
higher than normal casing vibration.
vibration.
An increase in casing vibration coupled with a decrease

of shaft relative vibration (and vice versa)
versa) suggests
misalignment..
misalignment
Casing vibration can also increase if the machine support

structure weakens or loosens,
loosens , or if the machine develops
a soft foot
foot..

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38
Possible causes
The reduced stiffness of the machine support allows

vibration to increase
increase.. Sometimes
Sometimes,, tightening loose
foundation bolts will redeuce casing vibration back to
normal levels
levels..
Foundation problems can include a loose soleplate and

loose anchor bolts.
bolts . Oil soaked concrete can lead to dete
dete--
rioration of the concrete foundation and a loss of support
strength..
strength
Grouting serves to provide a high stiffness interface bebe--
tween the soleplate and the surface of the underlying
Foundation..
Foundation
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Possible causes
Pour piping fit can put tremendous loads on the machine

Casing.. Pipe straincan result from loose piping hangers
Casing
or bent,
bent, broken or missing piping supports.
supports. Always check
the piping system of a machine with misalignment symp-
symp -
toms for signs of pipe hanger or support problems.
problems .
During installation,
installation, piping should never be forced to mate
with the machine through use of force.

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39
Possible causes
Soft foot is a condition where one or more machine feet

Are not coplanar after tightening hold down bolts
bolts..
When one foot (the soft foot
foot)) is not properly supported,
supported ,
tightening down will warp the machine casing.
casing.
Locked gear couplings will cause sudden change in

Vibrations..
Vibrations

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40
Possible causes
f = 0.4 – 0.45 x rpm Oil whirl May exist in sleeve bearings

change speed or oiltemperature
f = 1 x rpm Unbalance, Level is greatest in radial

exxentric direction..Portional to unba
direction unba--
journals lance and rotational speed
f = 1,2,3,4 x rpm Mech. loose--

Mech.loose Look for loose bolts,etc
bolts,etc
ness
f = 2 x rpm Misalignment Level is greatest in axial

of couplings
couplings,, direction
bearings

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Possible causes
f = 1,2 or 3 x f of Electrical Amplitude drops instantly

electr.power
electr.power ground loops when power turned off
(50 or 60 Hz) etc
f = number of blades Blade frequ.

frequ. A high level could mean
x rpm
rpm,, multiples a stall or a resonant cond.
cond .
of number of
blades x rpm
f = number of gear Poor gear mesh Wear of mashing surfaces

teeth x rpm

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41

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Shaft Monitoring

Mechanical design Maintenance

Compressor Training Power Generation 1

Shaft Position Indication

The compressor is equipped with shaft position probes which

They are arranged opposite a disk which is mounted on the shaft

In case safe limits are exceeded, an alarm and subsequently a

Compressor Training Power Generation 2

The vibration probes are installed on the shaft near the

Compressor Training Power Generation 3

Shaft Speed Indication

The compressor is also equipped with keyphasor

Transducer which produces a once-per-shaft-revolution

This signal is used primarily to measure rotation speed

It is extremely useful as a quick reference between shaft

Compressor Training Power Generation 4

Journal and thrust bearing are equipped with

The RTD’s extend into small drilled holes in the

In case of exceeding the limits alarm and shut-down

Compressor Training Power Generation 5

X Rotor,abs. = X Rotor, rel

Compressor Training Power Generation 6

l Surge l Aerodynamic Whirl

l Rotating Stall l Oil Whirl

l Pressure Pulsation's l Floating Ring Seals

l Bearing Journal Differential Heating

Compressor Training Power Generation 7

Relative shaft vibration can emerge through:

· Actual shaft vibration or

· shaft and casing vibration .

In case of doubt please measure:

· relative shaft vibration (non contact measuring) and

· casing vibration (seismic measuring)

Compressor Training Power Generation 8

Compressor Training Power Generation 9

Shaft Monitoring Devices

Compressor Training Power Generation 10

Compressor Training Power Generation 11

Shaft Monitoring Devices

Compressor Training Power Generation 12

Compressor Training Power Generation 13

Shaft Monitoring Devices

Two probes are mounted at an angle

Compressor Training Power Generation 14

Each probe observes a groove,

Compressor Training Power Generation 15

Shaft Monitoring Devices

The compressor shaft has been

The compressor and gearbox have

Compressor Training Power Generation 16

Compressor Training Power Generation 17

Continuous Vibration Monitoring System

FIELD WIRING EXTENSION CABLE

Compressor Training Power Generation 18

SIGNAL OUTPUT TRANSDUCER POWER

Compressor Training Power Generation 19

Compressor Training Power Generation 20