Vibrations

Spring 2016 | Volume 33, Number 1

Dedicated to the dissemination of practical information on evaluating machinery behavior and condition.

Turbocharger Rolling-Element
Bearing Observed During Failure
By Maryon J. Williams, Jr., Ph.D., P.E.

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Nov. 28Dec. 2, 2016

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SPRING 2016

Contents

Volume 33, Number 1

ISSN 1066-8268

Vibrations is published quarterly in

spring, summer, fall, and winter by
the Vibration Institute. Statements of
fact and opinion are the responsibility
of the authors alone and do not imply
an opinion on the part of the officers
or members of the Vibration Institute.
Acceptance of advertising does not imply
an endorsement by the Vibration Institute.
2016 by the Vibration Institute. All rights
reserved. Materials may not be reproduced
or translated without the express written
permission of the Vibration Institute.
Technical Editor
Barry T. Cease
ceasevibration@icloud.com
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Feature Article

Turbocharger Rolling-Element
Bearing Observed During Failure
By Maryon J. (Skip) Williams, Jr., Ph.D., P.E.

Case History

Analyzing the Start-Up Vibration

of HOT PUMPS
By Joppu Thomas

16

Case History

Rub Identification in Hydrogen

Centrifugal Compressor
By Juan C. Ustiola

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2016 Newly Certified Individuals

24

A Fond Farewell

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Please send any correspondence
regarding change of address or
advertising to the Vibration Institute.

By David Correlli, VI Board President

By Robin Ginner

Vibration Institute
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VIBRATIONS

SPRING 2016

editorial

LETTER FROM THE PRESIDENT

Acceptance of Certifications
Clarification

n the winter issue of Vibrations magazine, I stated, Effective January 1,

2016, the Vibration Institute will accept certificates from any reputable organization as a prerequisite for taking a VI
certification exam. However, based on
inquires and the apparent confusion surrounding that article, I feel it is necessary
to clarify our position.
Holding a certificate at a certain category does not in-and-of-itself qualify someone to take the next category exam; this is
true even if an individual holds a Vibration
Institute certificate. The existing certification is only a partial prerequisite for taking
the next level exam. In addition to holding
a valid certificate, the candidate must also
meet both the training and experience requirements set forth in ISO 18436-2:2014.
The Vibration Institute will accept current and valid certifications from Certifying Bodies that are accredited to ISO/
IEC 17024:2012 by an official Accrediting Body as partial prerequisite to take
Vibration Institute exams. To the best of
our knowledge, in addition to the Vibration Institute, accredited by the American
National Standards Institute (ANSI), there
are currently only two other organizations that meet this requirement: Mobius
Institute Board of Certification (MIBoC),
accredited by the Joint Accreditation System of Australia and New Zealand (JASANZ); and the British Institute of Non-Destructive Testing (BINDT), accredited by

SPRING 2016

the United Kingdom Accreditation Service

(UKAS).
For other reputable non-accredited Certifying Bodies to qualify, they will need
to submit an application to the Vibration
Institute showing that they meet several
key requirements in the three governing
Standards with respect to Conformity Assessment and Certification of Persons as it
relates to Condition Monitoring and Diagnosis of Machines. These Standards are
ISO/IEC 17024:2012, ISO 18436-1:2012,
and ISO 18436-2:2014. Applications will
be reviewed by the Vibration Institute, and
if the requirements are met, current and
valid certifications from that organization
will be accepted as partial prerequisite.
However, first party or self-declaration of
certification, which is allowed by ISO, will
not be accepted as a prerequisite to take a
Vibration Institute certification exam under any circumstances.
As stated in my original article, although
the Vibration Institute may accept other
qualifying organizations certificates as
partial prerequisite, the Vibration Institute
will neither recognize other certificates nor
issue a Vibration Institute certificate at that
category without a candidate taking and
passing a VI exam.
If any non-accredited certifying organization would like to apply, please contact
the Vibration Institute for an application. If
anyone has any questions, please feel free
to contact Vibration Institute or me. V

Dave Corelli
VI Board President

VIBRATIONS

feature article

Turbocharger
Rolling-Element Bearing
Observed During Failure
S

By Maryon J. (Skip) Williams, Jr., Ph.D., P.E.

Certified Vibration Specialist IV
Condition Analyzing Corporation
Eatontown, NJ

kip Williams is Senior Engineer with Condition Analyzing Corporation (www.cacvibe.com). He has conducted vibration surveys
and has analyzed the data from ships for over 25 years. He contributes to ISO/TC 108/SC 2/ WG2 Vibration of Ships and to ISO/TC
8/SC 8/WG12 Ship Vibration. He was project leader for ANSI/ASA
S2.28-2009 Guide for the Measurement and Evaluation of Broadband
Vibration of Surface Ship Auxiliary Machinery.
ABSTRACT

This article shows the failure of a rolling-element bearing in real time

on the turbocharger of a ships Diesel engine. The failure was anticipated because the bearing had failed previously when the turbocharger
reached a certain speed. Instrumentation was prepared to take continuous samples of the data before, during, and after the failure. While the
time from initial detection of a bearing fault until failure of the bearing
can typically take months, the failure reported here occurred in mere
seconds. The vibration data at failure indicated a bearing cage problem
which was later confirmed with debris in the bearing cage.
BACKGROUND

Figure 1: Layout of engine, step-up gear to generator/motor

A unique situation was provided when it was known that a bearing

on the main Diesel engine turbocharger of an oil tanker had failed on
previous occasions. The propulsion system consisted of a medium speed
8-cylinder engine with a reduction gear to the propeller of ratio 5:053:1
(Figure 1). The propeller was controllable pitch, meaning the thrust forward or aft was controlled by the pitch of the propeller, not by the speed
and direction of the propeller. Also attached to the gear was a PTO generator with a step-up ratio of 2.022:1. The normal engine speed was a
constant 595 rpm. The expected forcing frequencies from this machine
are shown in Table 1.
The turbocharger bearings were proprietary anti-friction roller type
lubricated with oil pumps operating on the same shaft as the turbine and
compressor and mounted on the outside of the compressor and turbine
wheels. The compressor bearing was the thrust bearing and consisted of
11 balls in two rows. The turbine bearing had 11 rollers in one row. The
bearings were mounted on damped spring assemblies on the radial and
axial sides meant to absorb a degree of imbalance in the rotor. After a
Figure 2: - Waterfall plot during failure

VIBRATIONS

SPRING 2016

feature article
Table 1: Speeds & Forcing Frequencies
Component

Rotation rate (rpm)

Harmonics

Comment

Engine

595

2X, 4X, 6X-engine

8 cylinders

Turbocharger

8,000-18,000

11X

11 full compressor vanes

Step Up Gears

595/1203

91X-engine

Teeth 91/184 (2.022:1)

Reduction Gears

595/118

19X, 76X -engine

Teeth 19/96 (5.042:1)

Propeller

118

4X

4 blades

fig.

fig.

fig.

fig.

fig.

fig.

failure of the turbine side lube oil pump, a replacement rotor was balanced and installed. On two subsequent occasions the turbocharger
bearings had also failed when the rotation rate reached 13,400 rpm.
fig.

TURBOCHARGER BEARING FAILURE

The vessel was run at lower load than normal with a propeller
pitch of 55% until the end of the voyage. The greatest vibration
was found in the axial direction with radial vibration low. Measurements were set up on the turbocharger with an axially-mounted general-purpose accelerometer. Initial readings were taken at Fmax of
5,000 Hz with minimal high-frequency activity. Sampling was then
taken with Fmax of 500 Hz and 800 lines with aterfall slices every
9.6 seconds. With these settings up to 16 minutes could be saved in
a single waterfall. Toward the end of the voyage the propeller pitch
was gradually increased to 73% over a time period of half an hour.
During the increased loading, the turbocharger rpm increased from
10,000 rpm to 13,400 rpm when the turbocharger failed (Figure 2).

SPRING 2016

Figure 3:
Figure 4:
Figure 5:
Figure 6:
Figure 7:
Figure 8:
Figure 9:

T-9 minutes
T-9.6 seconds
Failure
T+9.6 seconds
T+19.2 seconds
T+2 minutes (Maximum vibration at rotation rate)
T+3 minutes

VIBRATIONS

feature article

Figure 10: Time sample of axial acceleration from one waterfall

slice to the next before and after the failure. Pulses correspond to
0.47X-rotation rate or FTF.

The failure was preceded with no indication of abnormal parameters on the turbocharger, turbocharger lube oil pump, engine
or gear. What was observed during the load increase was a decrease in the vibration at rotation rate from 0.09 to 0.03 inch per
second peak, then a slight increase to 0.05 ips peak. From one
waterfall slice to the next, an increase in 1X-rotation rate to 0.17
ips suddenly appeared, but more importantly a new frequency of
0.47X-rotation rate also appeared (Figure 6). In other words, the
time from detection of an abnormal spectrum until the failure was
observed was less than 10 seconds or approximately 2000 rotations. The vibration at 0.47X-rotation rate continued for only one
more waterfall slice (Figure 7) and was not seen again. Vibration
also appeared at the upper rotation-rate sideband at 1.47X-rotation rate. Over the next 2 minutes, vibration at 1X-rotation rate
increased to 0.73 ips peak (Figure 8). A time sample just after the
failure showed spikes at intervals of 9.4 milliseconds corresponding to the vibration at 0.47X-rotation rate (Figure 10).
After the failure the vibration at rotation rate decreased as the
pitch of the propeller was reduced to limit the vibration while the
vessel proceeded into port. The turbocharger never locked up
and continued to function until the vessel got to the dock.
When the vessel reached port, the turbocharger was disassembled. . The bearing spring assemblies in the bearing were found
broken as shown in Figure 11, Figure 12 and Figure 13 with a
spring clip lodged in a roller of the turbine bearing.
ANALYSIS

Figure 11: Turbine bearing (left) and compressor bearing (right)

The vibration at 0.47X-rotation rate in the regular spectra is the

frequency expected for a Fundamental Train Frequency bearing
defect (FTF). The clip lodged in the bearing roller is further evidence of the failure of the bearing cage.
Vibration on a turbocharger normally consists of three compo-

Figure 12: Turbine bearing with loose spring clip

Figure 13: View of installed turbine bearing with spring clips in

rollers. Oil pump also shown.

VIBRATIONS

SPRING 2016

feature article
nents: (1) vibration from the engine
at low-frequencies, (2) vibration at
turbocharger rotation rate, and (3)
vibration at compressor vane-pass
frequencies. Vibration from the
engine is constant with load and is
sometimes associated with cracking
of the turbocharger foundation. Vibration at turbocharger rotation rate
is associated with imbalance in the
rotor or wear in the bearings. The
manufactures recommended alarm
level for filtered rotation rate vibration was 0.17 ips peak. The alarm
levels for turbocharger rotation rate
used during the this study were 0.27
ips peak for the 1st alarm (alert)
and 0.40 ips peak for the 2nd alarm
(fault). Sometimes vibration at 2X,
3X, or 4X-rotation rate indicates
additional wear, but was not seen in
this case. Vibration from the engine
was normal, and no lube oil failure
occurred this time. Vibration at
compressor vane-pass frequencies
of 11X and 22X-rotation rate also
were not seen in this case.
Possible mechanisms for a bearing failure in a turbocharger:
1. Thrust bearing overload
2. Excessive
vibration
transmitted from the engine
3. Lube oil failure
4. Imbalance in the rotor
5. Wrong
thrust
bearing,
incorrect
installation,
excessive axial clearance
The loading on the thrust bearing decreased in the axial direction
with increasing speed (Figure 14
and Figure 15). The decrease in
the axial vibration with increasing
load was due to compression of the
axial load spring with increasing
axial thrust. The turbocharger is an
axial turbine and a radial compressor meaning the exhaust gas passes through the turbine in the axial
direction and the intake air passes
through the compressor in the radial direction (Figure 16). A major
component of the axial thrust is the
SPRING 2016

pull of the compressor wheel away

from the turbine.
The manufacturer reported that
an incorrect balance procedure had
been used to balance the rotor. The
balance condition is specific for
each turbocharger by the manufacturer, but ISO quality grade 2.5 is
a close approximation. When the
correct procedure was used and the
rotor re-installed, no further problems occurred.
Still, the absence of significant
vibration at 1X-rotation rate before
the failure indicated that balance
was not the primary cause. It is
possible that one of the other factors (wrong bearing, installation
or clearance) might have been inadvertently corrected during the
re-commissioning repair.

Figure 14: Time course of failure: 30-minute period (10 sec intervals)

CONCLUSIONS

As vibration analysts we have

several tools available to us to diagnose bearing failures, including
high-frequency algorithms. Often
these techniques show a degree of
bearing failure, and the question is,
When is the bearing going to fail?
The same question arises when one
decides how often to conduct vibration tests: should the frequency be
monthly, weekly, or continuously
with automatic shutdown of the
machine?
Bearing failure rates can happen
in months, weeks, days, hours, minutes or even seconds depending on
the cause, machine loading, and machine speed. The example here was
one where the high machine speed
(over 10,000 rpm) clearly played a
role. This is one example when a
failure could not be predicted using
traditional vibration analysis techniques even 10 seconds beforehand.
While the conditions of this failure
are unique due to the circumstances
of the installation, there is no one
way to predict the moment of bearing failure with certainty. V

Figure 15: Zoom on failure event (3-minute period).

Note only two readings at 0.47X-rotation rate

Figure 16: Turbocharge with axial flow turbine and

radial flow compressor

VIBRATIONS

case history

Analyzing the Start-Up

Vibration of HOT PUMPS
ABSTRACT

One line monitoring and diagnostic systems

are widely employed by petrochemical plants
and refineries worldwide for monitoring critical
machinery. These systems provide comprehensive diagnostic capabilities which can be used to
reduce machine downtime and provide considerable savings in maintenance costs. This case
history shows how the diagnostic capabilities
of an online monitoring system were utilized by
a leading refinery in the Middle East to solve a
vibration problem experienced with a 740 KW
Hot Pump. Hot pumps are centrifugal pumps employed in services with temperatures above 150
C (300 F); warm-up of these pumps are required
prior to start-up. These pumps must be handled
carefully during start-up to ensure normal levels
of vibration and to prevent unwanted trips.

VIBRATIONS

By Joppu Thomas
INTRODUCTION

he subject of this case history was a hot service pump of center-hung

configuration with a multiple volute casing. The pump was directly
driven by a 740 KW induction motor with a rated capacity of 2,800
m3/hr with fluid specific gravity of 0.6. The pumping temperature was 280
C (540 F).
1ST START-UP ATTEMPT

The commissioning team attempted a start-up of the pump many times.

However, the pump tripped on high vibration each time. High vibration was
experienced at both the pump drive-end and non-drive-end bearings. The
values exceeded 150 microns (6 mills) at both ends. The recorded run time
was barely a few seconds. The pump had a fluid film bearing (plain sleeve)
installed at the drive-end (DE) and a fluid film bearing/antifriction bearing
combination installed on the thrust end (ODE). Since the run time of the
pump was only a few seconds, it was decided to analyze the coast-down
transient data to help determine the cause of high vibration. Due to the
rapid acceleration of the pump during startup, start up transient amplitude
and phase data were not considered meaningful. Therefore coast-down data
SPRING 2016

case history

was recorded and analyzed. Figure 2 below

shows the vibration trend plots for the pump
DE and NDE bearings.
PUMP COAST-DOWN &
SLOW ROLL DATA

Following the first start up attempt, coastdown and slow roll data from the pump was
examined. A slow roll vibration level of 125
microns (5 mils) and 163 microns (6.4 mills)
was observed at the drive end (DE) and nondrive-end (NDE) of the pump respectively
at a speed 10% of operating speed (~ 300
rpm). In addition, this radial vibration at the
drive and non-drive-end was observed to be
in-phase. Both orthogonal set of probes (X
& Y) installed on the pump bearings indicated high amplitudes. Slow roll data on
rotating equipment is typically collected at
speeds < 10% of the operating speed of the
machine. At these slow speeds, the dynamic forces due to problems such as unbalance
are very low and can be reasonably discounted; the vibration seen at these very
slow speeds can be due to mechanical or
electrical run-out, a physical bow or bend in
the rotor, or other problems that are not always easy to determine without this unique
data. Prior tests at these hot pumps had routinely measured slow-roll vibration at or
near 10 microns (1/2 mill).
BEARING INSPECTION

Owing to the high vibration noticed, the

contractor decided to open the pump bearings for a quick inspection. The drive-end
and non-drive-end bearing clearances
were checked and found to be within recommended tolerances. The wear marks on

SPRING 2016

the bearings also appeared normal. It was advised to the contractor to do a

manual slow roll check on the pump rotor
after assembly of the bearings and check for
run-out. Typically the slow roll vectors are
around 5 microns (0.2 mills). This is mostly
due to mechanical/electrical run-out of the
probe target surface and some small residual
bow of the rotor. However the values measured during manual rotation were much
larger around 26 microns (1 mill).
EXPLORING THE REASON
FOR VIBRATION

Many hot pumps employed in refineries all

around the world experience high levels of
vibration during start-up. However, many of
these cases go unnoticed due to absence of
shaft proximity probe monitoring systems.

A set point multiplier is a useful feature provided for machinery with proximity probe
based monitoring systems which exhibit

Certification Surveillance
In order to protect the Institute members who have justly earned certification as
a Vibration Analyst, the Vibration Institute wants to pursue individuals who falsify
Institute certification in any manner.
If you are aware of any instance in which you believe an individual is falsifying his/
her certification status, please call or contact the Vibration Institute immediately.
If you are aware of any individual who you believe is violating basic ethics, please
contact the Institute as soon as possible. Failure to do so degrades the reputation
of your certification and the Vibration Institute.
(630) 654-2254
information@vi-institute.org

VIBRATIONS

case history

Figure 2: Trend of pump vibration during start-up and coastdown?

high levels of vibration during transient

condition. TRIP/SET POINT MULTIPLIERS enable the ALARM & TRIP values to
be temporarily elevated until steady state
conditions are achieved in these machines.
Since most machines are designed to start
and operate below set levels of vibration,
caution must be exercised before application of a multiplier. Arriving at a proper
value and duration for a set-point multiplier involves making a database of vibration
levels and their duration during multiple
start-stops of machine. Pumps employed
in hot service commonly experience startup vibration due to uneven expansion of the
casing during warm-up. In extreme cases,
poor warm-up can lead to shaft bows. Various warm-up piping arrangements are put
forward by pump manufacturers.
API 686 gives guidelines for warm-up
piping arrangements. Typical warm-up arrangements for a top-suction, top discharge
pump (center-hung configuration) normally
consists of two routes of entry for the warmup fluid - through the discharge check valve
bypass and through the warm-up line at the
bottom of the pump casing. The entry route
through the discharge check valve bypass
introduces fluid into the discharge volute of
the pump. The introduction of fluid through
the bottom of the pump casing ensures a
uniform bottom-up heating of the casing
and rotor.
Due to the high start-up vibration experienced at the pump in question, an investigation of the warm-up piping system/arrangement was carried out by the refinery
engineering team. It was noted that at a few
pumps, the discharge check valve by-pass
route was absent thus heating was carried
out solely through the bottom casing drains.
These bottom warm-up only pumps consistently experienced lower levels of vibration during start-up.
The investigation also discovered a particular hot pump which experienced high
vibration during start-up until a discharge
drain line was introduced. Introduction of
the discharge drain line was intended as a
temporary measure until repairs to the check
valve by-pass arrangement could be made.
The drain line from the discharge was uti-

10

VIBRATIONS

SPRING 2016

case history
lized to introduce warm-up fluid into the casing bottom. Following the introduction of the discharge
drain line, this pump experienced lower levels of vibration during start-up.
The investigation concluded that the hot pump
warm-up piping arrangements played a significant
role in the start-up vibration levels experienced at
the pumps. Subsequently, it was agreed to perform
only bottom-up warm-ups of the pumps. Also it was
agreed that a controlled warm-up was required with
a maximum casing top to bottom temperature differential not to exceed 50 C (122 F). On the basis of all
the above incidents, the engineering team concluded
that heating from the pump top to bottom is an inferior practice as it results in an excessive temperature
differential within the pump casing (top to bottom).
This temperature differential creates a very large
humping or bowing tendency since the pump expands more at the top than the bottom. As a result,
the bearing brackets & housings might shift down at
both ends of the pump (center-hung arrangement)
and the rotor will bow along with them. However, it
is worth mentioning that a few hot pumps of similar
arrangement from a different manufacturer did not
show a significant effect on start-up vibration, irrespective of their warm-up routing the exact cause
for this was not known.
TRIP/SET POINT MULTIPLER

With the reason for excessive start-up vibration identified, it was necessary to estimate and apply a suitable TRIP or SETPOINT MULTIPLER to the machines. The criterion for arriving at the trip multiplier
duration and set points are based on machine history. A carefully compiled data base of the vibration
data for a machine during multiple start-ups is very
valuable information. The SET POINT multiplier
duration should be sufficient to overcome start-up
temperature transients and stabilization. A bowed
rotor or unevenly heated casing on these machines
can endure anywhere between 45 to 180 seconds before the vibration levels stabilize below alarm levels.
Depending on the machine, sometimes it is advisable
to apply a multiplier to a specific vibration channel,
based on prior history where the other channels exhibit lower levels of vibration.
CONCLUSION

The pump was finally put in service with the modified warm-up arrangement and exhibited acceptable
vibration levels. The operation team modified the
warm-up procedures and piping per the findings of
the investigation to ensure a bottom-up heating of
SPRING 2016

VIBRATIONS

11

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case history

Figure 4: Warm-up piping arrangement

Figure 3: Pump BODE for coast-down (Pump DE)

the pump. The TRIP MULTIPLER setting

was also judiciously applied. A multiplier of 2 times trip value (2X) for a duration
of 120 Seconds was applied which ensured
temperature stabilization of the pump. Subsequent bearing inspection was also done to
physically verify that the applied multiplier
did not exceed the bearing clearance values.
Insufficient warm-up or fast warm-ups can
lead to high vibration in the pump during

REFERENCES

start-up due to a thermally induced bow of

the rotor. A thermally induced bow can also
occur due to a temperature differential in the
mechanical seal area. Some other factors
which can induce a thermal bow are:

1. Length of time pump remained

stationary (not rotating)

in a hot condition.
2. Casing differential temperatures. V

1. Fundamentals of Rotating

Machinery Diagnostics by Donald

E. Bently and Charles T Hatch.
2. Rotordynamics by Agnieszka
Muszynska.
3. Design and Opeartion of pumps for
Hot standby services by Charles.C
.Heald and David.G.Penry.
4. Review of Vibration problem in
power station Boiler feed Pumps by
David France, Weir pumps,Glasgow.

Recertification Requirements
Certification as a Vibration Analyst is valid for five years from the
date of current certification level. After five years, and in compliance with ISO 18436: Part I, certified Vibration Analysts are
required to recertify. Recertification at the current level of certification can be achieved in one of two ways:
Renewal. You may provide evidence of continuing education experience, training and/or technical activity. Points for renewal can
be earned for vibration-related activities including work experience, professional development, attending industry, association or
chapter meetings, and vibration-related presentations and published articles.
Re-examination. You may take the certification exam at the level
you are currently certified. This requires scheduling an examination
and securing a proctor per established Vibration Institute protocol.

14

VIBRATIONS

Vibration Analysts are certified on the basis of ability to function

at a specified level. The motivation for re-certification is to ensure
that the Vibration Analyst maintains the capability to function at the
level certified.
Points toward recertification can be earned in various ways. The
Vibration Institute Certification Committee has approved renewal
requirements as follows:
Category I:
Category II:
Category III:
Category IV:

24 points (beginning January 2011)

28 points (beginning January 2011)
32 points (beginning January 2013)
36 points (beginning January 2014)

Visit www.vi-institute.org and click on Certification to learn more

about earning points for re-certification!

SPRING 2016

RBTS 2 3 r d ANNUAL SEMINAR

May 2-5, 2016, PENN STATE Great Valley, Malvern, Pennsylvania, USA

23rd Annual Seminar & Short Course On

ROTOR DYNAMICS & BEARINGS TECHNOLOGIES
Lateral & Torsional Vibration Analysis / Fluid-Film & Rolling-Element Bearings
A 4-day seminar and workshop for engineers and technical managers involved in
ROTATING MACHINERY design, operation, maintenance, diagnosis, and
troubleshooting, with emphasis on machinery rotor dynamics, drive train
torsional vibrations, and bearing systems (fluid-film & rolling-element) that
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case history

Rub Identification in Hydrogen

Centrifugal Compressor
Juan C. Ustiola,
Vibration Specialist Category III.
MACHINE DESCRIPTION

ABSTRACT

The following case history explains how a rubbing condition

was identified in a centrifugal
compressor by the utilization
of phase, bode and orbit plots.
This information was required
during the troubleshooting process to analyze sudden changes
observed in the vibration levels
during compressor operation.
An abnormal increase was noticed in the control room by the
night shift crew. The rotating
equipment group was quickly
dispatched to investigate the
problem.

he machine to be analyzed is a 5-stage

Hydrogen Centrifugal Compressor
manufactured in 1995 by Nouvo Pignone. It is driven by a steam turbine whose
normal operating speed is between 8,000
and 9,500 rpm. The machine is monitored
using X-Y proximity probe pairs on each
fluid film bearing as shown in the instrumentation diagram (Figure 1) along with
two axial probes and a Keyphasor.

SYMPTOMS

A sudden increase in the vibration levels

was observed in the DCS and PI software
(Figure 2). After observing the abnormal
increase in the vibration levels, an immediate request was made to the vibration specialist to analyze and identify the cause of
the sudden change.
VIBRATION ANALYSIS

Rubs are generally defined as contact be-

Figure 1: System 1 Machinery Diagram

KEYWORDS:

Rub, rubbing, bow, orbit, phase,

bode, shaft centerline, vibration
analysis.

(Right) Figure 2: PI software showing the sudden

increase in vibration levels at the DE X & Y probes.

16

VIBRATIONS

SPRING 2016

case history

Figure 3: Types of rubs [1]

tween stationary and rotating

components of a machine. A
rub in a rotating machine usually doesnt happen by itself; it
is usually a secondary effect of
several malfunctions occurring
at the same time. There are two
types of rubs, as shown in figure
3. The first is an impact rebound
type rub; in this case an impact
occurs, and then the rotor bounces back, and the process is repeated and repeated, etc. The second
is a friction rub that causes fairly
constant contact between a rotating and stationary part.
Our case had all the symptoms
of a friction type, where the rub
looks like unbalance. The vibration characteristics were high
1X vibration, with no major
amplitude in harmonics and no
sub-harmonic frequencies.
There are certain myths about
rubs and the way it is presented.
In our situation (friction type) one
of the most common effects observed in the vibration response
are changes to the 1X vector due
to thermal bowing of the rotor. A
rub under different circumstances
is manifested in different ways.
For example, if operating speed
is sufficiently above the first critical speed (resonance frequency),
then a sub-synchronous frequency may be present such as 1/2 X,
1/3 X, or 1/4 X.
In practice it has been observed
that vibration due to a rub occurring at 1/2 X might take place

SPRING 2016

when the running speed is above

two times the first critical speed
and 1/3 X when the running speed
is above three times the first critical speed. In our case this conFigure 4: Waterfall spectrum showing
dition did not apply since our opincrease at 1X Vibration Amplitude.
erating speed was not far enough
above the first critical speed. Full
spectrum waterfall indicates the
change in the 1X vibration amplitude (Figure 4).
It is possible to sort rubbing out
from a balance issue by looking at
the 1x amplitude and phase over
time. If a shaft is unbalanced, the
phase angle should not change
over time at a constant speed.
However if the rotor is bowed
due to a rub, the amplitude and
phase angle may shift over time
as shown in figure 5.
In turbomachinery is always
important to trend the 1x value (Amplitude and Phase) since
Figure 5: 1x Amplitude & Phase shift over the time at constant speed.
the symptoms of many problems occur at that frequency. When rubbing
occurs, sudden changes
in the phase are expected
at a constant speed; this
was observed in this case
study, where two sudden
steps in phase & amplitude were observed within
a period of 13 days. These
changes primarily occur
due to the contact of stationary & rotating parts;
heating from friction is
generated at certain areas
of the rotor (where the rubs Figure 6: Rotor in Healthy Condition (June 2013).

VIBRATIONS

17

case history

Figure 7: Rotor with Rubbing problem (May 2015).

are) which in turn results in a bowed shaft.

Bode plots revealed the change in the critical speed where the
rotor stiffened due to the rub. In some cases it can be higher than
the normal critical speed, since we are modifying the natural frequency.

Figure 8: Orbit plots before and after the rub.

Several diagnostic plots are useful when diagnosing a

rub. Chief among these is the shaft orbit plot (Figure 8).
In some occasions shaft orbit presentations can give quite
dramatic indications of a rub as evidenced by flat spots
on portions of the orbit where contact is occurring and
restriction of orbital motion. [2]
FINDINGS

The drawing shown in figure 9 highlights the areas where

the rubbing occurred in the hydrogen compressor. This
sectional drawing will allow us to visualize the concerned areas in a better way.
The following pictures provide evidence of the problems analyzed through the vibration plots, where our theory of rubbing was proven. The drive end probes (DE)
were the key for the investigation, since the problem was
reflected best in that area. During disassembly much damage was observed in stationary and rotary parts, however,
most of the severe problems were noticed near the suction (non-drive end), where rubbing at the inter-stage labyrinth seals (first stages) and fractures at the diaphragm
were found. By analyzing the evidence, we suspect that
the shaft was internally misaligned & bowed during operation causing a pivoting effect in the DE side where the

18

VIBRATIONS

SPRING 2016

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case history
increase of vibration levels was observed.
Piece of suction strainer found attached at impeller
eye.
Solid deposits found inside and outside the
cylindrical inner bundle (cartridge casing) where rotor
and stationary internals are assembled.
ROOT CAUSE DETERMINATION

So we knew that a significant rub had occurred but

why? What caused or initiated this problem? From
figure 10 below notice that the shaft centerline position
had moved over time. This was observed as evidence Figure 9: Compressor sectional drawing showing key areas of trouble.
of internal misalignment between the rotor and stationary diaphragms, which caused an upward trajectory
heat from friction causing thermal growth changes. These changes
from July 2013 to February 2015.
in thermal growth altered the internal alignment, reducing clearance
Damage was observed in both stationary and rotating parts during enough to generate the contact.
the site inspection. Damage was observed at the inter-stage labyFrom our inspections of the dismantled machine, a possible root
rinth seals, diaphragms and balance drum; contact between these cause of this problem could have been the continuous formation of
components created a rub, resulting in high vibration levels. The deposits in the compressor seals or ingress of foreign debris like
contact between these stationary and rotating parts also generated pieces of the strainer found attached to the first stage impeller. Once

20

Piece of suction strainer found attached at impeller eye.

Solid deposits found inside and outside the cylindrical inner bundle
(cartridge casing) where rotor and stationary internals are assembled.

Severe rub at discharge of lab. seal at 1st stage impeller

Cracks were found on diaphragm (top and bottom half).

VIBRATIONS

SPRING 2016

case history
accumulation of these deposits exceeded the available
clearance, a friction rub could be developed at one point of
the shaft surface, causing an increase of the shaft surface
temperature and subsequent shaft bowing. V
REFERENCES:

1. Bently Nevada Corporation Machinery Diagnostic

Course. Figure 3.

2. Arthit Phuttipongsit (Principal Engineer) The

Morton Effect and Light Rubs in Rotating

Machinery. ORBIT Vol.27 No.1 2007.

BIBLIOGRAPHY:

Figure 10: Shaft centerline position from July 2013 to February 2015.

Ronald L. Eshleman Machinery Vibration Analysis Volume II: Analysis and Correction. Vibration Institute 2002.

All inter-stage labyrinths have heavy contact mark

Solid deposits on labyrinths seals.

Rub observed at balance drum area

Piece of suction strainer lost in 2013 found

trapped between case and bundle.

SPRING 2016

VIBRATIONS

21

newly certified

2016
Newly Certified Individuals
WELCOME
TO OUR NEW
COLLEAGUES
CERTIFIED INDIVIDUALS
November 26, 2015 March 7, 2016

Please note: Every attempt is

made to alphabetize the names
of individuals by surname. We
apologize if any names are out of
order. If you notice a misspelling,
please contact the Institute
headquarters at information@
vi-institute.org.

22

VIBRATIONS

CATEGORY I
Ian Kendrick; David R. Craft; Kevin R.
Grider; Tariq Salim Al-Sultan; Jeremy Boyer;
Mubarak Mohammed Al-Khaldi; Mubarak
Abdullah Aldossari; Joe Overbaugh; Shawn
Paul Morgan; Donald Robb; Ali Abdullah
Al Ousif; Mubarak Aali Alghamdi; Lloyd
Adam Moritz; Vishnu Itwaru; Kaitlin Saranda
Spak; Selwyn Fridey; Nathaniel Parr; Alberto
Izquierdo Leal; Alberto Conde Romero; Felipe
Martin Arroyo; Jesus Gomez Calderon; Luis
Amores Garcia; Angel Luis Garcia Gragera;
David Carrell Marcos; Jesus De La Fuente
Miguel; Enrique Velasco Montoro; Matthew
Sean Adamchick; John Wayne Borelly;
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Troy E. Scott; Luvern Curt Andrist; Russell
Alan Davis; Taylor North Fry; Justin Miller;
Chase Lee Kiser; Shane Lockwood; Stephen
Wayne McGinn; James Wesley Palmer; Trent
Wesley Pol; Jason Christopher Stapley; Jason
R. Ungar; Dongyang Hu; Sivasubramanaian
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Oh; Parthiban Palaniappan; Diego Gerardo
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Fabian De Jesus Loria; Donald Nelson Moreno;
Juan Diego Ugalde; Jeffrey Luna Galera;
Olger Robles Solano; Khisbullah Hudha;
Muhammad Anas Bin Abu Bakar; Mat Rashid
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Carias; Elmer Ulises Gonzalez Hernandez;
Mauricio Ernesto Quionenz Monroy; Oscar
Huber Ramirez Gomez; Imad ur Rahman

Khan; Stephen Owen; Rogelio Diaz Ledo;

Fabricio Doldan Novo; Jose Alberto Garcia
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Docner Andrey Schorbooth Contreras; Loreto
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Ramirez; Rafael Dekar Chavez Molano; Marco
Antonio Izquierdo Licona; Alvaro Angelo
Lara; Victor Hugo Boyzo Torres; Rey David
Coronado Castillo; Pedro Alberto Coronado
Marquez; Juan Carlos Duran Gastelum; Julio
Cesar Lopez Miranda; Cesar Enrique Aguirre
Diaz; Uriel Rodriguez Chairez; Carlos Miguel
Tobon Plascencia; Teboho Timmy Kutoane;
Sandile Ralph Mkhize; Alejandro Pastor
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Jose Manuel Iglesias Garcia; Jose Maria
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Cerezal; Angel Ramirez Martinez; Josep Sans
Calanda; Oriol Save Sanchez; Wilson Alberto
Martinez Vargas; Ashleigh Brianne Gutteridge;
Michael Bruno Mitrovic; Peter John Richards;
Stuart William Hodge; Russell Stuart
Lemmens; Michael Adam Klomp; Christopher
James Woodward; Juan Jesus Gomez Texon;
Anthony Wayne Bradford; Shawn Tye Waltz;
Kris R. Witteveen;

CATEGORY II
William R. Ballenger; Bruce W. Blankenship;
Jerry L. Martin; Luis F. Ovalle; Alfred William
DeVaux; Deon Foonk; Johannes William
Ferreira; Ahmad Adnan Al-Ammar; Hassan
SPRING 2016

newly certified

Yahya Alamri; Khaled Saad Al-Ghamdi; Mark Anthony Silvallana

Banal; Willman R. Pinto Flores; Francisco Gerardo Sosa De Los Santos;
Francisco Javier Sanchez Olivares; Jesus Tellez Reyes; Raul Leana
Ortiz; Angel Maria Fernandez Rojas; Wilson Garcia Beltran; Donald
H. Matchett; Ben James Drew; Brett Anthony Esler; Ali Mohammad
Al-Jaafar; Julio Cesar Roque Cormilluni; Leonid Ramirez Sierra; Gino
Blommaert; Sindre Karlsson; Abdullah Al-Abood; Ammar Abdullah
Abussonoon; Mohammed Essa Al Ahmed; Mohammed Sanad Al-Awwad;
Ibrahim Saad BuBshait; Prabu Velayutham; Gareth Ewan Coffee; Robert
George Maybin; Juan Carlos Sotelo; Christian Alexander Smith; Vladimir
Derkach; Nicolas Martinez; Dustin K. Dixon; Ademola Olarinde;
Mohammed Ali Al-Qahtani; Mohammed Abdulraouf Ahmed; Ahmad
Mohammad Alamri; Bernard Chan Poh Khin; Vipin Chandrasekhar;
John Paul Anderson; Edwin Evaristo Tapia Chuquimamani; Yahia A
Abdelhamid Ismail; Hongxing Wang; Gian Carlos Reyes; Elia Doretto;
Eduardo Aguilar Armendariz; David Martinez Cantera; Jorge Angel
Saenz Serdio; Juan Carlos Serrano Orozco; Carlos Galan; Cesar Orlando
Perdomo Venegas; Ed Freddy Arzapalo Barrera; Juan Manuel Rodriguez
Biminchumo; Marco Antonio Luna Duenas; Jaime Bwrayan Mori Torrejon;
Carlos Omar Peralta Lamaure; Mario Alejandro Sime Odar; Victor Jesus
Ticse Carhuallanqui; Diego Alonso Valenzuela Medina; Omar Tawfiq
Albassam; Chellaiah Ganesh; Philippe Athanasiadis; Matias Canedo;
Luc Y. L. Fromaigeat; Michael Albert Hafner; Victor Lara; Yves Kwame
Mayor; Frederic Micco; Hans Claudius Reiss; Stefano Trono; Kyle
Wayne Davis; Jayde Kalei Jarnagin; Dean Michael Kelley; Alexander
Michael LeBlanc; Daniel Lucas Stein; Kyle Patrick Thayer; Britta
Haalboom; Mohd Farhan Abd Jabar; Azlee Bin Anis; Ruslan Bin Miah;
Ahmad Faris Bin Mohd Shukri; Sivananthan Thanabalan; Ove Sagen
Adsen; Petter Hausler; Jaroslaw Nowak; Agnieszka Tkaczyk; Zhenyou
Zhang; Sung-Won Han; Jung-Bin Im; Jeong-Yoon Kim; KyuEun Kim;
Min Seo; Sung-Jin Song; Anandvinoth Swamykannu; Piyanath Jaisuk;
Pongkul Akaravoramas; Poramit Chantasa; Pinyo Sinpoonkird; Somjin
Thanananthasiri; Krisada Vimonmangkang; Siwat Yuthong; Ian Struan
Peter Andrews; Nakikus Goliath; Daniel Humberto Bohorquez Velandia;
Charles Eduardo Correa Rodriguez; Alvaro Hernan Rojas Carvajal;
Sulaiman Abdulaziz Al-Turaifi; Mohammed Abdulmoghni Al-Sulami;
Ahmed Abdullah Al-Ammar; Fahad Mohammed Aldawsari; Abdullah
Nuri Alkhudhayr; Mohammed Salem Badughaish; Wesley Carter; Brian
Joseph Quirk; Brian J. Tafolla; Jason W. Jones; Mark Mosher; Huey
Pierce Cheek; Thomas M. Werking; Jesus Alejandro Cante Garcia;
Joshua David Stewart; David John Starcevich; Dustin Matthew Rothe;
John Robert Myers; Douglas Jillson Simmons; Gene Carl Standley; Ilya
Igorevich Burdukov; Brian Patrick Lawburgh; Mahmoud Nasr Salem;
Nathan Charles Decker; Starsun Levi Hendrix; Jonathan Patrick

Payne; Rick Croix; Matthew Tyler Gilbert; Charles Stevens; Louie

Jefferson Langford; Mike L. Fitch; Ramiro Flores; Ronald Fennell;
Sean D. DeVinney; Steve Duncan; Terry Scroggins; Keith Conley;
Michael A. Szurkowski; Kiran K. Toram; Guruprasad Pandurangan; Ali
M. Al-Shurafa; Majed Hassan Saimaldahr; Faisal Kalim Qazi; Sankar R
Ganesh; Tareq Essam Ibrahim Saqr; Jiaqian Wang; Carl Robert Binns;
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Gu; Jiang Wang; Thomas Jerimy McDowell; Shivakumar Swaminathan;
Michael Supplee; Michael Merten; Sudhar Rajagopalan; Ahmed Rifaat
Abdelhamid; Faisal Ahmed Youssef;

CATEGORY IV
Thomas J. Walter; Nicholas A. Jagan;

CATEGORY III
Juan Carlos Albornoz; Gary F. Carroll; Robert L. Martin, Jr.; James H.

SPRING 2016

VIBRATIONS

23

VI headquarter update

The Vibration Institute staff stands

at the ready to assist you with
anything you may need. Please
contact the appropriate individual
below and they will be happy to help!

ELLIE MURPHY
Finance Associate and Office Manager
emurphy@vi-institute.org

NICOLE CASAS
Marketing and
Communications Associate
ncasas@vi-institute.org

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Director-Certification
dcorelli@vi-institute.org

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Membership Associate
VIMembership@vi-institute.org

DR. RONALD ESHLEMAN

Technical Director-Training

reshleman@vi-institute.org

SUE FONCK
Certification and Training Associate
VICertification@vi-institute.org

JENNIFER HOWSER
Office Assistant
VIOffice@vi-institute.org

A fond farewell

wo and a half years ago I sat down to an interview with members of the
Vibration Institutes Executive Committee to discuss my qualifications
as a Director and the challenges that lie ahead as the leader of an organization that serves the vibration community worldwide. In the time since, Ive
been honored to work closely with the Board of Directors to make some good
and lasting changes that will continue to benefit our members and certified
analysts who call the Vibration Institute their professional association.
It is with mixed emotions that Ive submitted my resignation from the Vibration Institute. Although just over two short years, I have thoroughly enjoyed
the time I have spent at the Vibration Institute. I am appreciative of the trust
the Board has given me, and have had a wonderful experience in my time with
the Institute. My only regret is that I will not have the opportunity to be part
of the continued progress being enjoyed by this time-honored organization.
I have been tapped to lead a school and nature center in my home town of
Eagle River, Wisconsin an organization that is near and dear to my heart and
played a significant part in forging my love of the outdoors in my youth. My
last official day with the Vibration Institute was Friday, February 19, 2016.
In the interim, until a replacement Director can be found, I trust in the skills
and commitment of the Institutes headquarters staff to be able to assist you in
anything you may need. I have enjoyed my time with the Institute, and getting
to know so many of you. I hope to see you on LinkedIn, and wish you all the
best in your careers. V

Kindest regards,
Robin Ginner

Dont know who you should talk

to? Call the Vibration Institute
headquarters at 630-654-2254,
or email the general inbox at
information@vi-institute.org.

24

VIBRATIONS

SPRING 2016

I N D U S T R I A L

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