balancing newsbalancing newsInformation on the quality and performance of rotating equipment - From the Schenck Balancing & Diagnostic Systems Group

2015_Vol. 1

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IN THIS ISSUE:Schenck Balancing Services.................................1

Project Management in Balance...........................2

High Vibration on an ID-Fan Case Study...........3-5

Schenck Academy: A Hands-On Focus.............6-7

Schenck Trade Shows and Seminars...................8

Improving the Quality of Rotating Components & Assemblies Through Dynamic Balancing ServicesJoseph Palazzolo - Senior Application Engineer, Schenck Trebel

Our in-house balancing service uses the latest Schenck technology to provide improved rotor quality. With the finest workmanship and technical experience, Schenck balancing services is a cost-effective solution for many. Balancing is a value-added process that improves the quality and performance of the rotating component as well as the overall system and next higher level assembly that component is installed into.

Able to accommodate any size rotor using a wide variety of machines installed at our facilities in the Chicago and New York areas, Schenck Trebel Corporation can accommodate short runs for prototype development and overhaul applications as well as large scale production runs for contract balancing.

As an industry leader, Schenck’s expertise and experience is unmatched. Schenck was founded in Darmstadt, Germany in 1881. In 2014 Schenck celebrated 50 years in North America. Our reputation is well regarded by our customers, and their testimonials speak volumes.

Schenck Trebel Balancing Services: What our customers are saying about us . . .

Gas Analyzer Rotors – “Very Good Job! These rotors are the heart of our Stack Gas Analyzer, and they have been working great” . . . “you were willing to expedite and ship partials to meet our requirements.:

Fan/impellers – “We will continue to use Schenck for balancing in the future. We were very happy with the entire process from quote to delivery.”

Magnetic Rotors – “…Great communication, fast turnaround, fantastic pricing . . .”

Schenck Balancing Machines are sold and used throughout the world for balancing industrial and commercial rotating equipment. The industry knowledge and high quality equipment is available at our balancing services shops to provide quality improvement for the production and maintenance of rotating components such as:

Centrifugal Pumps, Compressors, Armatures, Generators, Fans, Gyros, Industrial Impellers, Electric Motors, Gears, Blowers, Aerospace Components, Turbochargers, HVAC Equipment, Flywheels, Crankshafts, Pulleys, Gas and Steam Turbines, Drums, Chucks, Drivetrain Components, etc., to name a few.

Schenck Trebel is a world leader in balancing and vibration analysis equipment for the production, maintenance and repair of rotating components. For more information, contact: Schenck Balancing Services at 1-800-873-2357.

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Project Management in BalanceRon Girling, Manager, Order Processing & Planning, Schenck RoTec

Project management at Schenck RoTec Corporation is the discipline of ensuring our products and services are deliv-ered and represented as defined/specified during the sales process. We exemplify the perfect balance of exceeding customer expectations, controlling internal costs, meeting timely delivery, and the achievement of specific goals that are consistent with an international industry leader.

At Schenck RoTec of Auburn Hills, Michigan, the team handles supporting the automotive, truck, and off-road manufacturers in North America. This often includes pur-chases within North America for uses worldwide. Our product offerings include equipment capabilities that bal-ance chassis and powertrain components, facilitating con-trolled fluid fill, providing validation and end of line testing, and managing tire and wheel assembly. The Schenck Ro-Tec sales team offers these world class products in one of the world’s largest manufacturing markets.

It is the responsibility of the Project Manager to support the resource decisions of engineering and operations as they are defined for a particular project. Project planning is a collective process of managers selecting Schenck Rotec resources and vendors best skilled for a particular project. As a Project Manager, It is my responsibility to ensure the specific goals of the project assigned to the resources are met. This collaborative process involves managing through participation and communication.

The project manager must be engaged in every project knowing that no project is any more important than the next. Each project requires comprehensive contract re-view, timing and resource planning, vendor selection, leadership, and financial accountability. All projects are a corporate commitment to meet predefined customer goals and objectives, while adhering to the budget.

The greatest challenge of any project manager is to ac-complish the project goals and objectives as originally de-fined within the sales process. Projects evolve; at times there are customer driven product changes, resources are often moved between projects, or there may even be un-foreseen timing delays. It is unlikely for every project to follow a natural course from start and finish, without some sort of change or exception.

Important to the process is to continue to apply good busi-ness practices, including continuous assessment of risk and the impact of risk on a project. As a team, Schenck Project Management is encouraged to define risk and identify opportunities for improvement before a challenge becomes problematic. This type of planning facilitates for-ward thinking and encourages contingency measures that not only protect the project but provides opportunity for process improvements for future projects to come. Team participation is critical to any success; it is imperative that we communicate with both internal and external custom-ers at a frequency that guarantees transparency.

Contingency planning and communication are just a few of the proactive measures that are critical to a successful project. We take a hybrid approach to project management and apply two basic project principles born from the phi-losophies of lean manufacturing and task management. Lean project management is a focus on the elimination of waste and the encouragement of continuous process improvement, while project task management is the pro-cess of reducing a project into smaller manageable tasks with clearly defined objectives, resources, and timing con-straints. Combined, the two processes facilitate manage-able and effective project results.

At Schenck RoTec, we manage several projects of differ-ing sizes, processes, and product types. We rely on the cooperative effort of our team and make sure they use the sufficient and effective tools. We manage our business op-erations and customer relations with application software SAP. SAP has proven to be a very powerful tool with forced processes and procedures in managing and tracking the commercial details of a project. In addition to the benefits of SAP, we utilize project scheduling software, and adhere to a mapped process of the project management objec-tives with specific procedures designed to communicate and track task progression. The process includes; internal / external kick-off meetings, design review, timing updates, project review meetings, budget review meetings, and les-sons learned to facilitate continuous improvement.

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Case study: High Vibration on an ID-Fan A Systematic Approach to Find The CauseRoland Kewitsch, Product Manager, Vibro, Schenck Trebel

Object: Large axial (ID) fan, about 10 MW in a power station

Problem: High vibration on fan bearing resulting in the machine tripping

Fig 1: Machine sketch

1. Start the investigation with a visual Inspection

At the time of arrival, we started our investigation with a visual inspection of the machine. Cracks were noticed in the foundation under the motor and the fan. There were “rusty” stains in the cracks around the anchor bolt area under the motor. This indicates that water was getting through the cracks to the anchor bolts and had caused corrosion.

2. Check Vibration Severity on the Motor

The machine was running at 900 rpm. The vibration overall value was measured in the range from 10 Hz to 1 kHz in mm/s (velocity) according to ISO 10816.

Accelerometers were used for the vibration measurements and a laser sensor was used to measure the speed.

Measurements were taken on both motor bearings in the horizontal, vertical, and axial directions. The highest reading measured was on the DE (drive end) in the horizontal direction with approximately 3.5 mm/s rms.

Next the overall vibration value was measured in vertical direction on the motor bearing, the machine foot, and the anchor bolt. The reading on the bearing was 1.8 mm/s rms and 1.0 mm/s rms on both the foot and anchor bolt. Typically vibration readings taken on the machine foundations are much smaller than those on the machine bearing.

3. Measure Vibration Spectrum on the Motor

Spectrum measurements were taken in the horizontal, vertical, and axial direction. The spectra showed the vibration at running speed of the motor (900 rpm or 15 Hz) along with multiple Harmonics of the running speed, up to the 20th Harmonic. The Harmonics are a clear indication of looseness.

Fig 2: Spectrum on Motor, DE,

horizontal With the presence of:

• Multiple Harmonics of the running speed combined with

• Relatively high readings measured on the anchor bolts and

• Cracks in the foundation... looseness of the drive on the foundation was

diagnosed.

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Case study: High Vibration on an ID-Fan - A Systematic Approach to Find The Cause (continued...)

4. Check for critical speeds on the Motor(Order Tracking Analysis)

In addition to the vibration sensors (accelerometers) a reference sensor (laser sensor) was used to provide one pulse per revolution. The vibration analyzer used a tracking filter to follow any changes in speed of the machine and provided the amplitude and phase angle for selected Harmonics.

The 1st and 2nd Harmonics were measured during coast down of the motor on both motor bearings.

Fig 3: Coast down on Motor (Bode diagram), DE, horizontal, blue = 1st, red = 2nd Harmonic. It shows a typical coast down without any dramatic behavior.

7. Check for critical speeds on the Fan (OrderTracking Analysis)

The 1st and 2nd Harmonics were measured during coast down of the fan on both bearings.

Fig 5: Coast down on Fan (Bode diagram), out board bearing, 2nd Harmonic

The spectra reading from both bearings showed vibration at running speed and many Harmonics (similar to the motor). Surprisingly the 2nd Harmonic was clearly dominant, almost 10 x higher than the 1st Harmonic (on the out board bearing).

This clearly shows the dramatic increase of the 2nd Harmonic near running speed.

Please note:The running speed of the fan was about 850 rpm when the highest vibration readings occurred. However, at the same time the 2nd Harmonic is at about 1700 rpm (2 x 850rpm).

This means that the resonance frequency of the machine bearing is about 1700 rpm and gets excited by presence of the 2nd Harmonic of the running speed.

5. Check Vibration Severity on the Fan

Overall vibration readings were taken in the horizontal and vertical directions on both fan bearings. The highest reading was measured on the out board bearing with approximately 5.0 mm/s rms in both directions. This vibration reading is too high for this type of machine.

6. Measure Vibration Spectrum on the Fan

Fig 4: Spectrum on Fan, out board bearing

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Case study: High Vibration on an ID-Fan - A Systematic Approach to Find The Cause (continued...)

Fig 6: Coast down on Fan (Nyquist diagram), out board bearing, 2nd Harmonic

Figure 6 shows the same data as figure 5 with regard to the 2nd Harmonic but in “Nyquist” form. It shows clearly the machine is going through a resonance at approximately 850 rpm.

8. Conclusions

It appears that the motor vibration over time caused cracks in the foundation which resulted in looseness.

Looseness created vibration of the components at higher Harmonics which traveled throughout the complete machine.

The fan has a resonance around 1700 rpm which is excited by the presence of the 2nd Harmonic at running speed of the machine. Therefore, the vibration amplitude is amplified when running at that speed which caused the machine to trip.

For more information on our Vibration Measuring and Monitoring Equipment, visit us at www.schenck-usa.com.

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What our attendees are saying….

“The course clearly provided me with a foundation in balancing and the hands-on learning in the afternoon solidified the coursework.”

“Lab sessions were helpful and tied together with the class discussions.”

“The hands-on really helped to bring it all together.”

“I had minimal exposure to balancing so both the lectures and hands-on work was beneficial.”

“Great use of classroom coupled with hands-on work. Also good discussions on real parts!”

“Actually learned how to properly run balancer.”

Schenck Academy: A Hands-On Training ApproachDavid Fanning, Senior Application Engineer, Schenck Trebel

The benefits of training are well known across all industries. Employing trained personnel not only improves processes but also strengthens the entire corporation as a whole. As an engineering based company, this is a deeply rooted philosophy within Schenck Trebel Corporation.

To learn balancing, you must touch, feel, and “do” balancing. Every application and situation is unique and will bring with it its own obstacles and challenges. At Schenck this fundamental principle is clear. As such, the Schenck Academy training seminars have been developed as comprehensive training seminars that incorporate both theoretical classroom sessions as well as hands-on machine based practical sessions.

Attendees will find that each of these sessions calls upon various learning methods that work together to provide an interactive training program with a personal touch that leaves a lasting impression. According to what our attendees are saying, this approach is effective.

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Attending a Schenck Academy training program is more than simply being presented with information. Our training classes involve a proper, comprehensive approach to training that is critical to reaching attendees and passing along balancing knowledge. This approach maintains that in-person face-to-face training is paramount for attendees who want to be involved in their training experience.

The goal of our instructors at the Schenck Academy is to guide and instruct attendees rather than to simply show attendees. In this way our attendees are encouraged and urged to participate, particularly during the afternoon hands-on training sessions. Touch, see, feel, listen, troubleshoot, diagnose, and balance! The opportunity that is afforded to attendees to learn through a guided hands-on approach is extremely valuable. This also provides for an open environment where attendees can share common problems and solutions with other attendees across various industries. Attendees can also interact with our instructors and tap into their extensive knowledge base.

Benjamin Franklin was quoted as saying, “Tell me and I forget. Teach me and I remember. Involve me and I learn.” Never is this philosophy truer than when dealing with balancing applications and balancing training.

For additional information on our training seminars and a full listing of our scheduled offerings please refer page 8 of this issue of Balancing News.

“Tell me and I forget.Teach me and I remember.Involve me and I learn.”

- Benjamin Franklin

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Schenck Trebel upcoming trade shows and seminar information

TRADE SHOW DATES/LOCATION BOOTH

PUMP/TURBO SYMPOSIA

POWERGEN December 8-10Las Vegas Conv. CenterLas Vegas, NV

3542

1928 September 12-17George R. Brown Conv. CenterHouston, TX