Technical Paper

CM1004
SKF Reliability Systems
Fundamental Considerations for
Maintaining Your (Machinery)
Balance in an Unbalanced World
This paper is intended to provide useful
information for in-place field balancing of
turbomachinery (pumps, fans, turbines,
compressors, etc.). It is assumed that some
knowledge of the actual method details are
already known or available. The method
most commonly employed (and assumed
here) is known by various names: the
three-run method, the trial weight
method, the Thearle method, the influence
coefficient method, etc.
This information is basic, but nonetheless
important to know and apply during field
balancing. It is the result of countless
troubleshooting and consulting
experiences. This is a list of hints and
reminders, not a how-to instruction.
1. MAKE SURE THAT AN UNBALANCE
PROBLEM EXISTS, prior to expending time
and effort in hopes of resolving the
balance problem. ALL turbomachinery
operates in some state of unbalance it is
only a matter of degree or severity.
Acceptable unbalance levels vary
(sometimes as a result of subjective
opinion) with machine, installation,
operating conditions, etc. However,
unbalance problems are almost always
indicated by a higher-than- usual vibration
amplitude at the running speed (or 1X)
frequency (divide the rotor RPM by 60 to
get the 1X frequency in Hertz,
abbreviated as Hz, which is cycles/second
for example; an 1800 RPM machine has a
running speed frequency of: 1800 RPM
60 = 30 Hz). If there is not an increase in
the 1X vibration amplitude an unbalance
problem is not likely.
Another indicator of unbalance is that the
vibration amplitude should vary with
changes in machine speed for example;
higher vibration amplitude at higher
speeds. Correcting high vibration
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Fundamental Considerations for Maintaining Your
(Machinery) Balance in an Unbalanced World
2
problems by balancing is a reasonable percentage shot
since unbalance is the most frequent cause of vibration
problems. However, many man-hours and plant-hours are
wasted annually by assuming this is always true it only
takes a few minutes to confirm (unusually high 1X
vibration and stable phase readings should be evident).
2. PHASE ANGLE READINGS MUST BE STABLE; if not, then
it is unlikely that unbalance is the main cause of the
excessive vibration. In any case, it will be difficult-to-
impossible to improve balance condition by this method if
phase angle readings are not stable. The phase angle
reading should be stable and repeatable within about 15
(for strobe readings), or better, during any given trial or
operating run. The use of a key-phasor tach signal will
yield superior results over a stroboscopic technique for
measuring a phase reference angle; for example, the key
phasor is much faster, more precise ( 3 or so), repeatable,
and stable.
3. A FIXED ORIENTATION AND SIGN CONVENTION MUST
BE ADHERED TO while employing a given balance solution
method; The direction of rotation (clockwise or
counterclockwise), viewing position/orientation, direction of
increasing/decreasing angles, and key-phasor or strobe
position must all remain constant and be consistent with the
graphical or mathematical (vector) solution being employed.
The key-phasor and strobe solutions cannot be
interchanged for this reason. Although similar, there are
small but crucial differences in resolving the vector
solutions for key-phasor vs. strobe balancing (sign
convention, direction of rotation vs. direction of increasing
phase angles, vector orientation, etc.).
4. VIBRATION SENSOR LOCATION(S) MUST BE THE SAME
for all (trial) runs during a given balance operation. Moving
the sensor mounting location, even slightly, will alter the
test conditions and readings (vibration phase and amplitude)
unnecessarily. It is also a good practice to locate sensors
(vibration, key-phasor/strobe) in the same locations for
future balance operations, once good results are obtained.
Sensor locations on a machine may be marked by ink, paint
or a shallow drill-point indentation.
5. THE MACHINE SPEED SHOULD BE IN THE SAME
CRITICAL SPEED REGION DURING TRIAL RUNS AND
NORMAL OPERATION. That is, if a machine operates above
first critical shaft speed, then the trial balance runs should
be in this same speed region (above first critical, below
second critical, in this case). This is not always possible,
but is very desirable. Also, always run trial balance speeds
as close to normal machine running speed as possible (or
practical) and do not vary shaft speeds appreciably from
one trial run to the next. If your machine operates under
1800 RPM, it is likely that critical speeds are not a
consideration, for example; you are probably running below
first critical speed. If you dont know what critical
speed means, or how it relates to your machinery, then find
out before getting too involved with balancing a variety of
turbomachinery.
6. HAVE (TRIAL AND CORRECTION) WEIGHTS AVAILABLE,
AS WELL AS A PRACTICAL AND SAFE MEANS OF
MOUNTING. This sounds obvious but is often overlooked.
It is embarrassing to disrupt plant operations to balance a
particular machine only to discover that it will take
unexpected hardware is a must. It is preferred that the bolts
thread-in along an axis parallel to the shaft longitudinal axis,
not radial. A weight which dislodges is a lethal weapon
and can seriously injure anyone in its path safety is a
major consideration!!!
7. SOME TRIAL/CORRECTION WEIGHT LOCATION
CONSIDERATIONS ARE:
Mount trial and correction weights at the same radial
distance from the shaft, or else a (simple) correction
factor* must be applied.
Mount trial and correction weights in the same plane
(plane perpendicular to the shaft longitudinal, main,
axis).
If the desired correction weight position is not
convenient or practical, there is a way to divide or
split the required amount of weight into two or more
parts*. This enables mounting of weights at
convenient locations such as blades, vanes, existing
holes, etc.
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Fundamental Considerations for Maintaining Your
(Machinery) Balance in an Unbalanced World
3
Weights should be mounted as close as possible to
the (rotor) imbalance source.
* Contact SKF Condition Monitoring for description.
8. IN CASES OF PERSISTENT BALANCE METHOD
DIFFICULTY, KEY-PHASOR/TACH SIGNAL INTEGRITY
SHOULD BE CONFIRMED. The voltage level (amplitude),
polarity, frequency and repeatability of any key-phasor/
tach signals should be ascertained on an oscilloscope
display. This can be a hidden source of difficulty in cases
where the balance method is not yielding the proper results
(other hidden problems can be: a bothersome structural
resonance, harmonics, intermittent damping, etc.).
9. TWO-PLANE BALANCING. Many balance problems
cannot be eliminated by a single plane balance method since
dynamic and/or couple unbalance forces exist, and a two-
plane balance method must be utilized. In general, a long,
wide rotor is more likely to be a two-plane problem than a
tall, thin rotor. The actual test methods are similar (you
employ two different locations/areas for mounting sensors
and weights, instead of a single location) but the graphical
or mathematical solution is much longer. It is suggested
that a small, hand-held programmable pocket calculator
be used; this is almost a necessity for two-plane problems,
and a great convenience for single-plane problems. They
cost under a few hundred dollars and programs are readily
available from SKF Condition Monitoring. Again, note that
strobe and key-phasor program solutions are not entirely
interchangeable they are slightly different from each other
(see number 3).
10. ONE-RUN BALANCE. After the balance is successfully
performed, future balancing on that machine can usually be
done with only one step to add (or remove) weights. The
data from previous solutions will yield a phase lag and
sensitivity (or influence coefficient) which enables
determination of required correction weight (and location)
directly from the initial (operating) vibration (amplitude and
phase) readings. This assumes that the system (machine,
bearings, mounts, foundation, piping and process
conditions, etc.) have not changed significantly between the
two balance efforts. Machine repairs and modifications,
long-term structural response changes, drastic loading or
erosion of the rotor mass, etc. can invalidate this technique.
However, many machines are sufficiently stable as
systems to permit successful use of this technique.
Contact SKF Condition Monitoring for further information
about this technique.
11. AVOID SEAT-OF-PANTS DIAGNOSTICS AND
COMMITTEE EFFORTS, have confidence and
understanding of the method. High/low or heavy/light
spots can be determined from initial vibration/phase
readings however, the reasoning differs for strobe vs. key-
phasor, certain types of vibration sensors (eddy probe),
some balance instruments (and control settings), whether
strobe phase angle readings are taken off a rotor shaft or
stationary marker, etc. It is strongly suggested that, at least
initially, you avoid attempting to reason out the why and
stick to the how.
Audiences, invited and uninvited, tend to be liberal with
dialogue and opinion, but usually lack relevant knowledge.
Audiences also tend to disrupt the order and flow of the test/
solution effort (a well-known professional recommends
performing balancing at 3:00 AM, in the rain, to discourage
the uninvited!). Plant personnel (mechanics, engineers,
operators, etc.) need to be a part of the overall machine
diagnosis process, as they often have relevant information,
but they dont need to be a regular part of the actual
balancing effort, as a group.
12. BALANCING CAN BE DONE WITHOUT SPECIALIZED
EQUIPMENT, however, it is usually not as convenient or
effective. The necessary vibration amplitude and phase
information can be obtained from an oscilloscope display
(either orbit or time-domain waveform). There are also
other methods ranging from a steady hand and chalk mark
to a four-run method without phase. None of these
methods are as accurate, convenient or reliable as the basic
method assumed in this text. Other methods will work, but
not as often and not as well.
13. RUNOUT is a term (and scapegoat for many
problems) which loosely means a portion of the signal
response from a non-contact eddy probe which does not
originate from shaft motion it is a source of error.
Vibration (phase and amplitude) data taken from eddy probe
sensors may sometimes need to be corrected for runout

SKF Reliability Systems

4141 Ruffin Road
San Diego, California 92123
USA
Telephone (+1) 858-496-3400
FAX (+1) 858-496-3531
Web: www.skfreliability.com
Although care has been taken to
assure the accuracy of the data
compiled in this publication, SKF
does not assume any liability for
errors or omissions. SKF
reserves the right to alter any part
of this publication without prior
notice.
SKF is a registered trademark
of SKF USA Inc.
All other trademarks are the
property of their respective
owners.
CM1004 (Revised 11-99)
Copyright 1999 by
SKF Reliability Systems
ALL RIGHTS RESERVED
"Fundamental
Considerations
for Maintaining
Your (Machinery)
Balance in an
Unbalanced
World"
error. Programs and methods exist to
facilitate this correction process.
14. SHOP BALANCE VS. FIELD BALANCE. It
is common to remove a rotor from a
machine and send it to a shop for balancing
on a test-stand. In some cases this may be
the only practical means of balancing; in
other cases a shop balance may not be
possible. Occasionally, a rotor which has
been shop-balanced will yield poor (or
even worse-than-original) balance-
vibration results when reinstalled and
operated. This does not necessarily mean
that the rotor was incorrectly balanced in
the shop it may result from differences
between test-stand conditions and operating
conditions. A shop test-stand will have
different bearings, bearing spans, structural
response, stiffness, mechanical impedance,
etc. the test-stand cannot duplicate the
actual machine system and its response.
The test-stand rotating speed may also, by
necessity, differ significantly from machine
operating speeds. Sometimes all these
differences are not significant, at other
times they are highly significant. For these
reasons (and for reasons of time, cost and
convenience) the field balance method is
often preferred and may yield superior
results.
15. ANYONE CAPABLE OF LEARNING TO
TIME AN AUTOMATIC IGNITION SYSTEM CAN
LEARN THIS METHOD OF BALANCING. The
equipment, methods and (modest) level of
skill required are similar.