Essential Vibration Theory, Setup & Analysis Chapter 6

UNBALANCE

Unbalance is one of the leading causes of vibration in rotating machinery. Unbalance is simply an
unequal distribution of rotor weight along the shaft axis. This section will cover the principles of
unbalance, and how to recognize it. No attempt is made here to teach balancing techniques. This
subject is given the time needed in the Essential Balancing Theory & Solutions seminar.

Rotating bodies are designed to move within a prescribed orbit around the shaft centerline called
the Central Principal Axis, sometimes called the Mass Centerline. The central principal axis is
the axis of rotation or the axis that the rotor revolves around. Ideally, the central principal axis
and shaft centerline are identical. This can only be achieved in a weightless environment with a
perfectly balanced machine devoid of mechanical defects.

The rotor in Fig 6-3 represents the ideal rotor where the shaft centerline and the central principal
axis are identical during rotation. Theoretically this describes an orbit that is a perfect circle, but
cannot be achieved. Consequently, unbalance exists, to some degree, in all rotating bodies.

Perfect Rotor

Central Principal Axis A Perfect Rotor

Rotor CG Axis of Rotation In a Weightless Environment
Shaft Centerline Produces a Perfect Circular Orbit

Orbit CG

FIG 6-3

Since its’ known that all rotating bodies have some level of unbalance, tolerances have been
established to determine levels of heath based on how much a rotating body deviates from a
perfect orbit. There are several Balance Tolerance Guides published by ANSI, ISO and VDI to
name a few. These guidelines are used extensively in the balancing industry to derive acceptable
levels of unbalance based on the rotor type, speed, weight and configuration. Naturally, this is a
separate topic that is covered in a balancing seminar.

For the vibration analyst, the general vibration severity charts are adequate to determine
acceptable levels of unbalance for most general rotating machinery.

NOTES

Essential Vibration Analysis 6-5

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

 CENTRIFUGAL FORCE & UNBALANCE
Unbalance imposes high dynamic loads on support bearings due to the centrifugal forces
generated during rotation. Centrifugal Force, in pounds, can be calculated if these 3 variables
are known:
. Rotor speed (RPM)
. Unbalance force or weight in Ounces or Grams (Oz or Gr)
. Distance of unbalance force from the shaft centerline in inches (In) Oz-In or Gr-In

Ounce-Inches (Oz-In) is the relationship Measure of Unbalance Force

between the unbalance weight in Ounces and
its distance from the shaft centerline in Inches.

Referring to the perfect rotor in Fig 6-3, if 1 18 Oz-in 1 Oz

2 Oz
36 Oz-in
ounce of weight were placed at an 18 inch
radius, it would produce 18 Oz-in of unbalance. 18” Radius 18” Radius
Fig 6-3A shows the relationship between the
amount of unbalance weight and its radius from 10” Radius 16” Radius
the shaft centerline.
420 Gr-In 42 Gr 2 Oz 32 Oz-in
While displacement and velocity measurements
are suitable to determine unbalance amplitude
levels, the true measure of unbalance is
expressed in terms of Oz-in or Gr-In.
Centrifugal force, in pounds, is determined by FIG 6-3A
rotor speed and the Oz-in or Gr-in value of the unbalance force.

CENTRIFUGAL FORCE EQUATION USING OUNCE INCHES (OZ-IN)

Given: FC = Centrifugal force in Pounds

1.77 = Constant to convert Oz-in to pounds
1000 = Constant to determine the square factor

FC = 1.77 x (RPM ÷ 1000)2 x Oz-in Equation 6-1

Example 1 RPM = 180

Oz-in = 36
FC = 1.77 x (180 ÷ 1000)2 x 36
FC = 1.77 x .0324 x 36
FC = 2.06 pounds

Example 2 RPM = 1800

Oz-in = 36
FC = 1.77 x (1800 ÷ 1000)2 x 36
FC = 1.77 x 3.24 x 36
FC = 206 pounds

Example 3 RPM = 3600

Oz-in = 36
FC = 1.77 x (3600 ÷ 1000)2 x 36
FC = 1.77 x 12.96 x 36
FC = 825 pounds

Essential Vibration Analysis 6-6

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

 TYPES OF UNBALANCE

Static Can be balanced in a Single Plane, usually at the rotor center of gravity
Couple Must be balanced in two Planes, usually at the ends of the rotor
Dynamic Must be balanced in two Planes, usually at the ends of the rotor
Overhung Rotors Can often be balanced with a single weight on the inboard plane

Each type of unbalance has different phase characteristics, but share common vibration traits:
. Unbalance only occurs at 1 x RPM. Vibration at any other frequency is not unbalance.

. Unbalance forces are equally applied in the radial plane. It will be greatest in the radial
direction where the machine stiffness, or resistance to displaced motion, is minimum. For most
horizontally mounted machines, this is usually the horizontal direction. Displaced motion can be
20 or 30% higher in the horizontal direction than in the vertical direction.

. Unbalance forces are usually much higher in the radial direction than in the axial direction.
This applies to horizontally mounted machines supported between bearings.

. Unbalance in Overhung Rotors can generate amplitude levels that are higher in the axial
direction than in the radial direction.

. Unbalance aggravates other vibration problems like mechanical looseness, bearing wear,
bent shafts, misalignment, blade or vane distortion, etc. This often produces harmonics of the
problem components.

. Unbalance can be easily corrected, and will usually reduce amplitude levels of other vibration
sources when unbalance is removed.

Fig 6-4 shows a tri-axial reading from the outboard bearing of large blower. This is typical of an
unbalanced condition. The radial readings at 1 x RPM are considerably higher than the axial data.
In this case, the frequency at 1 x RPM in the horizontal direction is only slightly higher than in the
vertical direction, and indicates that the machine has similar rigidity in the radial direction.

FIG 6-4

Essential Vibration Analysis 6-8

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

 DYNAMIC UNBALANCE
Dynamic unbalance is the most common type of unbalance and is simply a combination of
Static and Couple unbalance forces acting in unison on the rotor.

Its’ unrealistic to think that the unequal distributation of forces along the shaft axis will produce a
pure static or a perfect couple unbalance condition. The combination of static and couple
unbalance forces usually induce a central principal axis that is offset from the shaft
centerline and the rotor CG. This is Dynamic unbalance, and produces a hyperbolic orbit that is
tilted and pivots through the central principle axis and not the shaft axis.

The rotor in Fig 6-8 shows a static unbalance heavy spot at the bottom center of the rotor in line
with a dominant couple component of unbalance on the bottom right of the rotor.

The example in Fig 6-8 shows that the orbit is greater on the right side of the rotor than on the left
side. Likewise, the vibration amplitude level will be greater on the side with the largest orbit.
Dynamic Unbalance

90º Dynamic Unbalance Produces a

140 Hyperbolic Orbit

0º 50º

FIG 6-8

Placing this rotor on unrestrained bearing supports will force the static component of unbalance to
roll to the bottom. By placing a mass at the top of the rotor, at the rotor CG can remove the static
unbalance, but the rotor is not balanced.

. If all the static unbalance is removed from the rotor, a couple unbalance will remain.

. If all the couple unbalance is removed, a pure static condition of unbalance will exist.

DYNAMIC UNBALANCE PHASE CHARACTERISTICS:

. 90º phase difference between the horizontal and vertical direction

. Anything but 0º or 180º phase difference across the rotor in the horizontal direction

. Anything but 0º or 180º phase difference across the rotor in the vertical direction

. The phase difference across the rotor in the horizontal direction is the same as the phase shift
across the rotor in the vertical direction. This is the most important phase consideration.

Essential Vibration Analysis 6 - 12

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

Fig 6-9 compares the spectrum at Pos 3H to the spectrum at Pos 4H. The spectrum at Pos 4H is
the same as the top spectrum used in Fig 6-4, where the HVA measurements are compared at
Pos 4.

The amplitude level at 1 x RPM, at Pos 4H, is much higher than at Pos 3 H. This suggests that
the pivot point is much closer to the bearing at Pos 3, which could produce an orbit similar to the
one in Fig 6-8.

This type of spectral comparison can help determine the type of unbalance, and provide insight
into the nature of the problem, without phase data.

FIG 6-9

Regardless of the type of unbalance, these rules apply:

. 1 X RPM dominates the spectrum

. 90º phase difference between the horizontal and vertical direction

. The phase difference across the rotor in the horizontal direction is the same as the phase shift
across the rotor in the vertical direction. This is the most important phase consideration.

NOTES

Essential Vibration Analysis 6 - 13

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

 3RD STAGE BEARING DETERIORATION ON 600 RPM GENERATOR
MECHANICAL LOOSENESS DUE TO EXTENSIVE WEAR ON ROLLING ELEMENT BEARINGS

4950 kW Vertical Water Turbine Generator

4950 kW Generator

Vertical
Water Turbine

600 RPM

5 3

115 RPM

6 4

Position 2 The top spectrum in Fig 6-61 shows low levels of vibration at 1 x RPM and
harmonics. The amplitude at 2 x RPM is twice the level at 1 x RPM. Both are signs of mechanical
looseness.

The axial velocity spectrum shows a dominant peak at 5301 CPM or 8.84 x RPM. The first
harmonic at 17.67 x RPM (10,604 CPM) is also visible. These are non-integer multiples of the
rotating speed, and are bearing defect frequencies. This is clear evidence of bearing problems.

FIG 6-61

6 - 60 Essential Vibration Analysis

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

There are many reasons why bearing defect frequencies appear in a vibration spectrum, and
none of them are good. In this case the looseness condition results from a loss of internal bearing
clearances due to extensive wear on the inner race. Fixed bearing at Position 2.

Position 3 The velocity spectra in Fig 6-62 show multiple harmonics of the rotating speed
frequency. Also, the amplitude at 2 x RPM is higher than the level at 1 x RPM. The amplitude
levels and number of harmonics indicate a severe mechanical looseness condition at this
bearing location.

The axial velocity data shows a dominant peak at 3324 CPM or 5.54 x RPM. This is a non-integer
multiple of the rotating speed, and is a bearing defect frequency.

CONCLUSIONS AND RECOMMENDATIONS

FIG 6-62

The looseness condition results from a loss of internal bearing clearances due to extensive wear
on the inner race of the output gearbox bearing.

Essential Vibration Analysis 6 - 61

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

 3RD STAGE BEARING DETERIORATION ON 514 RPM RAW MILL SYMETRO

The Raw Mill is a critical machine in a cement plant that feeds the kiln.
Acceleration data was the most helpful in diagnosing the condition of Raw Mill Drive
this bearing (SKF 23248) at position 4 on the machine.

The bottom spectra in the ESP waterfall display (Envelope Signal

Processing) in Fig 6-63 was taken on May 21, 2004. The next

333 T 63 RPM
spectrum was taken on June 22, 2004. It shows a large increase in
the amplitude and number of harmonics of the BPIR at 5306 CPM

45 T

45 T
(10.3 x RPM). Data was taken every second day after this and shows 1 2
a moderate but steady increase over the nine-day period.

514 RPM

196 T
196 T
41 T
3 4 14 RPM

333 T 63 RPM

45 T

45 T
5 6

FIG 6-63

The following data was taken on July 2, 2004. The high resolution gSE spectrum in Fig 6-64
clearly shows 1 x BPIR and harmonics surrounded by families of sidebands spaced at the
rotating speed frequency (514 CPM). These are clear indications of an inner race defect.

FIG 6-64

6 - 62 Essential Vibration Analysis

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis

The gSE time waveform data in Fig 6-65 is further evidence of a defect on the inner race of the
SKF 23248 Bearing. The time period (Delta X) between events is .0113151 seconds or 5303
CPM, and is equal to the inner race bearing defect.

FIG 6-65

The acceleration time waveform data in Fig 6-66 has a time period between significant events of
.0113151 seconds or 5303 CPM, and is equal to the BPIR. Amplitude levels are as high as 40 g’s
Pk-Pk. Bearing impact events at this amplitude level are signs of advanced deterioration.

FIG 6-66

The SKF 23248 bearing shows spalling on the inner race and damage to the slides.

Essential Vibration Analysis 6 - 63

Essential Vibration Theory, Setup & Analysis © Copyright 2003 – MacAnalysis