APPLICATIONS

The color of runout

17-4 PH stainless steel as seen under polarizing light at
50X magnification. The colors show martensite matrix
formations and delta-ferrite with copper precipitates
all of which contribute to the materials tendency
toward high levels of electrical runout.

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Understanding and
Mitigating Shaft Runout
Introduction
This article explains what runout is, why it is

guarantee that runout can be mitigated or pre-

important, and the root causes of runout in

vented in every application, it can be managed

machinery shafts. It also outlines common meth-

effectively and kept to within allowable levels in

ods for reducing runout to allowable levels and

the vast majority of applications. This is evi-

suggests best practices to observe during fabri-

denced by the millions of successful proximity

cation and machining to help avoid runout

probe applications for turbomachinery around

difficulties in the first place. While there is no

the world over the past forty years.

Nathan Littrell
Senior Engineer, Bently Nevada Asset Condition Monitoring
GE Energy
nate.littrell@ge.com

[ Vo l . 2 5 N o. 3 2 0 0 5 ] O R B I T 5

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0
90

270
180

270

90

Probe Output

(elliptically
exagerated
for clarity)
Max

Min
90

180

180

270

360

Degrees of Shaft Rotation

a) Out-of-round shaft with
perfectly uniform electrical
properties.

b) Perfectly round shaft with

non-uniform electrical
properties.

Figure 1 Apparent probe gap for a) an out-of-round shaft with uniform electrical properties and b) a perfectly
round shaft with non-uniform electrical properties.

What is Runout?
The signal from an eddy current proximity probe is a

Notice also that these signals have nothing to do with

function of the gap between the probe tip and the target

the dynamic motion or vibration of the shaft. They are

material. However, it is also a function of the electrical

inherent properties of the shaft that will be observed

conductivity and magnetic permeability of the target

regardless of whether it is stationary or rotating at high

material. Thus, two different materials (for example,

speed. These signals are known as runout. For conven-

4140 type steel and aluminum) can be positioned with

ience, we divide runout into two primary categories as

the same physical gap from a proximity probe, yet will

follows:

give different outputs due to their dissimilar electrical

properties.

Mechanical Runout is a measure of the shafts

deviation from a perfectly uniform radius as its

For a rotating shaft, physical out-of-roundness results in

circumference is traversed. This type of runout

a change in gap. This is shown in Figure 1a. However, a

can be measured by a dial indicator.

perfectly round shaft with non-uniform electro-magnetic properties will also result in a change in probe
output, even though the physical gap is uniform. This is
shown in Figure 1b. In this example, both shafts give
identical probe outputs even though they have different

Electrical Runout is a measure of a shafts electrical

property variations as its circumference is traversed.
This type of runout cannot be measured by a dial
indicator.

physical shapes. In practice, mechanical runout can

Because a proximity probe senses both types of runout,

indeed be somewhat sinusoidal as shown in the exam-

it is customary to speak of Total Indicated Runout (TIR)

ple. However, electrical runout is rarely if ever

which is simply the sum of mechanical runout and elec-

sinusoidal and is generally characterized by a noisy

trical runout. In most cases, when runout is discussed in

waveform with numerous spikes. It is represented as a

conjunction with proximity probes, it is understood to

sinusoid in this example merely for illustrative purposes.

mean TIR.

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BECAUSE THE RUNOUT

VIBRATION,

SIGNAL IS NOT RELATED TO ACTUAL SHAFT

IT CAN LEAD TO ERRONEOUS VIBRATION READINGS

AND MACHINERY DIAGNOSTIC

CONCLUSIONS.

Why Be Concerned About Runout?

Sources of Mechanical Runout

Even if a target material has non-uniform physical or

Machining processes

electrical properties, it does not create a problem for

So-called lobing of the shaft (see Figures 2 and 3).

probes observing the same location on the target at all

This is particularly problematic when centerless

times such as an axial position measurement using the

grinding machines are used because variations in

end of a shaft. However, proximity probes are often used

shaft hardness can result in a non-circular geome-

for radial vibration measurements where the track

try. Grinding on centers provides a reference for the

observed by the probe is constantly changing (repeating

wheel to work against and is less prone to runout.

itself every 360 degrees) as the shaft rotates. This results

in a proximity probe signal composed of both actual
vibration and runout. Because the runout signal is not
related to actual shaft vibration, it can lead to erroneous
vibration readings and machinery diagnostic conclu-

Tool chatter. Selection of the correct tool and holder,

as well as adjustment, is critical for all machining
processes. Make certain tools are not dull.
Improper feed rate and speed of cutting tools.

sions. To avoid this problem, the amount of TIR must be

Surface finish is strongly affected by cutting tool

kept to allowable levels, generally 25% or less of

feeds and speeds.

expected vibration amplitudes.

Dents from handling

Many customers specify the amount of allowable runout

Rust patches

for new or refurbished rotors as part of their purchasing

Rotor bow due to thermal effects, gravity, or other

documentation to their vendors. American Petroleum

Institute (API) Standard 612 is one such frequently cited
specification. It pertains specifically to mechanical drive

influences/loads
Defective or worn bearings in the machine or lathe
supports

steam turbines and requires the TIR to be 0.25 mil pp or

25% of allowable vibration, whichever is greater. API 617

Sources of Electrical Runout

has identical runout requirements and pertains to

process centrifugal and axial compressors as well as

Metallurgy

turbo-expanders. Similar API standards exist for other

The material chemical composition is fundamental to its

machine types.

electrical and magnetic properties. As well, the materials

Failure to meet runout specifications can cause expensive delays and re-work, impacting both the customer
and their machinery supplier. For this reason, discovering
and correcting electrical runout issues early in the manu-

purity can affect runout. In general, non-ferrous materials such as copper and aluminum exhibit the fewest
electrical runout problems, since they are devoid of any
significant magnetic effects.

facturing process can save a great deal of cost. It is

Conversely, the worst materials in terms of electrical

much easier to treat the problem when the shaft is on

runout are precipitation-hardened steels. Precipitation

blocks or mounted on a lathe than when installed in

hardening is a process where clumps of different crystal

the machine.

states are formed in the matrix of the parent metal. The

[ Vo l . 2 5 N o. 3 2 0 0 5 ] O R B I T 7

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probe observes these clumps as they pass by while the

shaft rotates, producing the unwanted runout signal.
17-4 PH can be particularly troublesome in this regard
(see photo on page 4).

Heat Treatment
The purpose of heat treatment is to modify the crystal
structure of a material to tailor the material mechanical
properties (toughness, ductility, etc.) to the application.

Bently Nevada Proximitor sensors are calibrated to AISI

The magnetic properties of ferrous materials are a

4140 type steel. However, this material is available in sev-

function of the crystal structure, so it follows that heat

eral grades, and variations in probe system response will

treatment is a factor in the resulting electrical uniformity

vary among these grades. In general, the vacuum arc

of the shaft.

remelt (VAR) or double vacuum arc remelt (DVAR) materials possess the best homogeneity and exhibit the fewest
number of problems with electrical runout.

Many large shafts are quenched as part of the heat

treatment process by lowering into tanks of salt water
or other liquids. Most commonly, the shaft is horizontal

It is recognized that the choice of shaft materials is rarely

when lowered into the quench tank, which results in an

as simple as merely considering the materials runout

asymmetrical quench profile. It is recommended to lower

properties. Instead, designers are faced with multiple cri-

the shaft vertically into the quench tank if possible to

teria and inevitable tradeoffs. Pumps are a good example

improve the radial homogeneity of the quench.

of machines that must often employ more exotic materi-

Grinding

als due to the corrosive nature of the process fluid that

will be handled, whether seawater, liquefied sulfur, acids,
or others. Motors are another machine type that commonly use materials other than 4140 type steels. As will
be discussed later, when a designer requires certain shaft
metallurgies, yet the material exhibits intractable runout
characteristics, one approach is to attach a collar or
coating of a different material to the shaft.

Grinding the bearing journals to final dimensions and finish is generally the last step in the shaft manufacturing
process. The grinding process generates significant heat
that is localized at the point where the grinding wheel
touches the shaft. It is important to have maximum
coolant flow on the work piece and to start and stop the
grinding process slowly. Avoid sudden increases or
decreases in feed rate when grinding. It is also recom-

Forging

mended to keep the wheel freshly dressed to limit heat

The forging process involves forming an ingot into the

build up. Because grinding results are highly dependent

rough shape of the shaft using enormous hydraulic

on the operator, it is recommended that this step be

hammers and presses. During the forging process, the

closely monitored if runout problems are occurring.

material flows into the shape of the shaft and gains a

Magnetism

grain structure that is present throughout the cross

section of the material. This grain structure defines a set
of large scale boundaries that contain the smaller scale
crystal boundaries. A non-uniform grain structure can
result in electrical runout.

8 O R B I T [ Vo l . 2 5 N o. 3 2 0 0 5 ]

Residual magnetic fields in the shaft can cause significant variation in the output of the proximity probe
system. Degaussing (discussed later in this article) is the
recommended remedy.

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Stress Effects

Measuring Mechanical Runout

Stress affects the crystal structure and magnetic proper-

The first step in dealing with runout is to make an accu-

ties of materials. Occasionally, a shaft with runout

rate measurement of the physical profile of the shaft to

problems can be traced back to an event that caused

determine the mechanical runout. Once the mechanical

the probe area to undergo significant mechanical stress.

profile has been determined, electrical runout can then

It is best practice to support shafts in slings in such a

be inferred generally by simply subtracting the

way that they are not subject to significant bending

mechanical runout from the TIR measurement made

stresses during installation and handling. Bead blasting

with a proximity probe.

or other impact-based cleaning processes create compressive stress in the surface of the shaft and can induce
runout.

When assessing mechanical runout, accuracy is paramount. Special care must be taken due to the extremely
small dimensions being measured. This requires a meas-

Handling

uring instrument capable of resolving increments finer

In addition to the stress effects mentioned above, it is

than 0.1mil (.0025 mm). While there are several choices

possible to bruise metal by hitting or dropping the shaft

for such instruments, some are more practical, accurate,

on the probe tracks during intermediate steps of manu-

and convenient than others.

facture. The external damage is erased by subsequent

steps such as machining, but the damage to the crystal
structure may go quite deep into the material. Thus, it is
important to handle the shaft carefully at all steps in the
process.

LVDTs (Linear Variable Differential Transformers)

LVDTs operate on the principle of a transformer with
a movable core. As the core moves, the gain of the
transformer changes and the displacement is
inferred from that signal. Units are available with a

Plating

resolution in the 0.01 mil (.0003 mm) range and are

Occasionally, a rotor is refurbished by plating the bear-

particularly well-suited for highly accurate mechan-

ing journal area to replace worn material. Sometimes,

ical runout determination.

this surface will be intentionally roughed up to allow

the chrome plating to adhere better. However, the probe
will see through the plating to the rough surface underneath, resulting in runout. Also, chrome plating has very
different electrical properties than typical shaft materials
and strongly affects proximity probe output. In general,
plating in the area of proximity probes is not recommended. However, when this is not an option, plating
thickness should be at least 20 mils to prevent the see
through effect mentioned above, and the Proximitor

Dial indicators
While inexpensive, reliable, and found in most every
machinists tool box, mechanical dial indicators are
generally limited to increments no finer than a tenth
of a mil. Analog versions use a conventional needletype indicator that can be very difficult to read with
the required resolution, and for this reason are
unsuitable for runout measurements. In addition,
they do not allow for automated data acquisition.

sensor should be calibrated to the plating material rather

Dial indicators with a digital display are also avail-

than the substrate shaft metallurgy.

able, and are generally capable of providing the

[ Vo l . 2 5 N o. 3 2 0 0 5 ] O R B I T 9

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necessary resolution. In addition, some of the more

runout once it is already present. These methods will be

advanced versions feature an electrical output in

discussed later in this article. However, before attempting

addition to the display, making them suitable for

to reduce the amount of electrical runout, it is generally

automatic data acquisition.

recommended that mechanical runout be addressed

Form measuring equipment

first, to try and bring the TIR within tolerances. This

These are specialized devices that evaluate components in terms of geometric dimensioning and
tolerancing definitions. The machine typically holds
the component vertically on a turntable and measures the form of the surface using a stylus. Output is
the radial deviation from absolute roundness along
with values describing the concentricity, eccentricity, and roundness as defined by Geometrical
Dimensioning and Tolerancing (GDT) standards.
Unfortunately, such equipment is of only academic
interest for most rotating machinery because it cannot handle components larger than 60 kg.
Based on the foregoing discussion, only two practical
choices exist for measuring mechanical runout in most
instances: LVDTs and electronic dial indicators.

Measuring Electrical Runout

Since electrical and mechanical runout are remedied in
different ways, it is important to obtain separate profiles
of the mechanical and electrical runout. Often, it is
easiest to measure TIR and mechanical runout simultaneously. The electrical runout is then found by simply
subtracting the mechanical runout from the TIR, as previously mentioned. Measurements should be made at
suitably small intervals (typically every 10-20 degrees)
to provide sufficient detail in the profiles.
While we have already discussed several practices that
can help prevent electrical runout at the manufacturing
stage, there are also methods (such as diamond burnishing and degaussing) that can be used to reduce electrical

1 0 O R B I T [ Vo l . 2 5 N o. 3 2 0 0 5 ]

Excerpt from a typical runout report for both coupling

and non-coupling ends of a pump rotor. The top trace of
each plot shows the runout waveform while the bottom
trace shows the Keyphasor pulse, indicating one
complete shaft revolution between pulses.

APPLICATIONS

serves two purposes. First, the processes of grinding and

Lobing Effects

machining to further reduce mechanical runout can

As mentioned earlier, lobing is a common artifact of

themselves introduce additional electrical runout. Thus,

centerless grinding operations. When measuring the

there is little point in proceeding to address excessive

shaft profile in a lathe or other device where the shaft

electrical runout until mechanical runout has been

is rotated about its axial centerline, the user is mea-

addressed. Second, because it is typically more difficult

suring radial (rather than diametral) variations. As a

to address electrical runout, mitigation is generally only

result, there is no ambiguity in the profile measure-

appropriate when mechanical runout reduction alone

ment. In contrast, v-blocks cause the user to measure

cannot bring the TIR to within the specified limits.

diametral variation, and can result in ambiguity

regarding the shaft profile. This is easiest to visualize

Sources of Error and Non-Repeatability

by way of examples, as shown in Figures 2 and 3.

API 687 (Repair of Special Purpose Rotors) provides a

Notice that the dial indicator in Figure 2 gives

very detailed description of how to measure runout. API

exactly the same output shape (dark blue line) for

specifications, in general, require that:

both shafts and that it reflects the change in diame-

1. The shaft be supported in v-blocks;

ter (not radius) as the shafts are rotated. The user

2. The probe be perpendicular to one face of the v-block;

3. Runout be measured in terms of peak-to-peak probe
output.

may incorrectly conclude that the one-lobed shaft

had a two-lobed profile, and efforts to correct this
through grinding would only exacerbate the problem. In Figure 3, notice that the three-lobed shaft

One of the primary reasons that v-blocks are recom-

provides a dial indicator output suggesting perfect

mended is that the runout measurement should be made

roundness, when, in fact, it has three lobes. Only by

in apparatus separate from that in which the machining

examining the motion of the center of the inscribed

was actually performed. For example, if a lathe has bear-

circle for all three shafts does the user obtain the

ing wear that produces an elliptical shaft cross-section,

true profile. This ambiguity can be removed by mak-

the shaft will appear perfectly round as long as it is in that

ing the mechanical runout measurement with a

particular lathe. By moving the shaft to a separate meas-

fixture that rotates the shaft about its centerline

uring environment (i.e., v-blocks or a balancing machine),

(such as a balancing machine). As previously

the error introduced by the lathe will not be masked.

mentioned, it is not recommended that the measurement be made on the same lathe in which the

However, while the use of v-blocks represents recognized

shaft is being machined, as the runout measured

good practice, it is not immune from its own sources of

becomes the combined effect of the shaft and the

errors as detailed below.

lathe bearings, and the two can offset one another.

Failure to mount the probe perpendicular to one

Oil wedge It is known that a film of oil builds up

face of the v-block

between two surfaces moving relative to each other.

This is a common error made in the field and results

This oil film becomes part of the runout measure-

in incorrect mechanical runout readings. It affects

ment and is unpredictable. A moving measurement

only the mechanical runout measurement (not the

may exhibit a dependency on shaft speed, even at

electrical). The maximum mechanical runout error

slow roll. Thus, when documenting runout under

introduced is the sine of the probes angular devia-

slow roll conditions, it is important to record the

tion from block face perpendicularity.

actual shaft rotative speed.

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Figure 2 When mounted in v-blocks and measured with a dial indicator, these one- and two-lobe shafts give identical
dial indicator profiles. The only way to ascertain the true mechanical profile is to make the dial indicator measurements
using apparatus that keeps the shaft fixed about its centerline such as a lathe. This allows radial, rather than diametral,
variation to be observed.

Figure 3 This 3-lobed shaft appears to be perfectly round when mounted in v-blocks and measured with a dial indicator.

1 2 O R B I T [ Vo l . 2 5 N o. 3 2 0 0 5 ]

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WHEN ASSESSING MECHANICAL RUNOUT,

ACCURACY IS PARAMOUNT.

Stick slip V-block measurements will sometimes

use an apparatus (such as a drive belt) that slowly
rotates the shaft. However, manual barring of the
shaft is most common. While API specifications
recommend rotation intervals of no more than 20
degrees, this is a relatively large gap between data
points. As the rotor is moved, it may not settle into
position repeatably, leading to significant error. To
help counteract this stick slip effect, smaller
measurement intervals (10 degrees or less) are
recommended.
Bow/sag If a shaft has a bow or sag from gravity
(and all shafts exhibit some level of this), it is possible
that this will show up as runout as the shaft flexes
during rotation. Anisotropic stiffness (unequal with
respect to direction) will definitely cause irregularity
in the runout reading due to rotor sag. To minimize
this effect, make the runout measurements as close
as possible to the shaft supports (e.g., v-blocks).

Methods of Mitigating Electrical Runout

The old adage an ounce or prevention is worth a pound
of cure is particularly true for electrical runout. In the
section Sources of Electrical Runout, we noted a variety
of things that can lead to electrical runout and offered
advice on how to carefully choose and handle materials
to minimize the potential for electrical runout. However, if
excessive levels of electrical runout exist, there are steps
that can be taken to reduce them.

Degaussing (Demagnetizing)
One method of checking residual magnetic field strength
is by using a small, hand-held field indicator, available in
digital and analog versions from manufacturers such as
Magnaflux. Even a relatively small amount of localized
residual magnetism can contribute to runout. For example, a localized concentration of 5 gauss on a rotating
shaft can give electrical runout on the order of 0.5 mil.
Therefore, it is always good practice to check the shaft

Inconsistent Transducer Models When measur-

with a field indicator and, if required, degauss in the area

ing TIR, it is not necessary to use the same probe in

of the probe tracks.

the shop as the installed probes in the field, as this

is rarely practical. However, it is strongly recommended that the same probe series be used to
eliminate possible sources of inconsistencies. For
example, if the machine will be permanently monitored with Bently Nevada 3300 XL 8mm proximity
probes, it is advisable to use this type of transducer
system for the bench runout measurements as well.
While the differences between transducer series are
generally small, runout measurements are typically
trying to resolve dimensions of 0.25 mils or less. As

A degausser emits an AC pulse of decreasing strength.

The magnetic field generated scrambles the domains
in the material to reduce the residual magnetism. While
special degaussing apparatus is available, a very common field practice is to use an arc welder set to AC with
the cables shorted together. The cables are waved over
the area to be degaussed, or sometimes wrapped
around the shaft. The current in the cables sets up a
large enough magnetic field to effectively degauss the
shaft.

such, even the smallest sources of variation can

affect the results.

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are strongly encouraged to enlist the assistance of a

qualified GE services professional when burnishing is
required. In addition to performing the burnishing work,
these individuals can provide the necessary hands-on
training for those customers that prefer in-house
competencies in the use of burnishing tools.

Alternate probe track material

In some instances, electrical runout can prove quite
intractable. In such instances, the most expedient soluA diamond-tipped burnishing tool. The tool is
mounted in a lathe and can provide surface finishes
of 10 microinches or less. When used by a skilled
practitioner, diamond-tip burnishing can be effective
in reducing electrical runout because it alters the
shafts crystal structure.

tion is generally to use an alternate target material for

the probe to observe. The two most common methods
for this are collars and coatings.
Collars
Collars can be very effective, provided they are

Probe Gap

attached to the shaft in such a way that they cannot come loose or induce additional loads or

A simple first attempt at reducing electrical runout is to

stresses on the machine. Additionally, the collar

gap the probes closer to the shaft. Sometimes this can

must be ground after it is shrunk onto the shaft to

change the runout measurement. However, be certain

ensure that it is suitably concentric. However, some

that the probes are not gapped so close that they take

shaft geometries cannot accommodate a collar. In

the probes outside their linear region or allow the probes

other situations, the shaft geometry may allow for

to contact the shaft during periods of high vibration.

a collar, but significant thermal gradients due to

differential expansion problems may make use of

Burnishing
Burnishing is a technique of smoothing the surface of the
shaft using a rounded diamond tip mounted on a lathe.
The burnisher tip is pushed against the shaft surface by
a spring loaded tool holder. This process mechanically
alters the crystal structure on the surface of the shaft by
plastic deformation, allowing surface finishes of less than
10 microinches to be realized. While burnishing can be
an effective method of reducing electrical runout, it is
more of an art than a science. Unless applied by a skilled
practitioner, burnishing can actually worsen electrical
runout. Further, if some burnishing is good, more is not
necessarily better. Once burnishing has minimized the
electrical runout, additional burnishing may increase

a collar unwise.
Coatings
Depositing a layer of less runout-prone material
onto a shaft can be employed successfully, and
there are several technologies for this. The idea is
similar to that of plating (already discussed) and
many of the same considerations apply. Primary
concerns are to choose a material that is nonferrous and applies with sufficient density that
inclusions do not generate a runout signal of their
own. The material must also be applied in a thick
enough layer to prevent the probe from seeing
through to the substrate.

rather than decrease the runout. For these reasons, we

Obviously, both approaches require a proximity

have deliberately chosen not to include step-by-step

probe system calibrated to the target material, not

burnishing instructions in this article. Instead, customers

the shaft material.

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Occasionally, users will request that we provide compen-

A Word About Compensation

When performing machinery diagnostics, a common
practice is to subtract a known runout signal from the
overall vibration waveform to obtain a runout-free
waveform. This is known as compensation and is a way
of dealing with both mechanical and electrical runout.

sation features in our permanent monitoring hardware.

Both vector and waveform compensation are valuable
features when performing machinery diagnostics, and
the runout signal can generally be validated and
updated as needed as part of the diagnostic process.

Many diagnostic products (such as the ADRE System

This is not the case for permanent monitoring and we

and System 1 software) allow such compensation. In

strongly advise against the use of compensation for

addition to waveform compensation for unfiltered plots

machinery protection applications. Runout signals can

such as timebases and orbits, the signal can also be fil-

change over time due to factors such as surface

tered to a specific frequency, such as shaft rotative

scratches incurred during operation or maintenance,

speed (1X). This allows it to be characterized as a vector

and/or changes in the amount and distribution of shaft

and used to compensate filtered plots (such as Bod

magnetism. When compensation is embedded in a per-

and Polar see Figures 4 and 5).

manent monitor, the runout profile stored in the monitor

Figure 4 ADRE

Sxp software is one example of a diagnostic system that provides runout compensation features as
shown by the compensated (green) and uncompensated (red) data in this polar plot.The red arrow denotes the 1X runout
vector. For a polar plot, compensation has the effect of shifting the data to the origin at slow-roll speeds.

[ Vo l . 2 5 N o. 3 2 0 0 5 ] O R B I T 1 5

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remains fixed even though the actual runout may be

or they may mask legitimate high vibration problems,

changing over time.

phase changes, or other conditions indicative of an

The nature of combining waveforms and vectors is that

emerging machinery malfunction.

they reinforce in some places and counteract in others

Back when Bently Nevada monitoring hardware utilized

unlike simple scalar addition. Figure 5 illustrates this con-

analog meter movements, users would sometimes want

cept, showing how the runout signal increases the

to compensate for runout by using the offset adjust-

observed vibration signal in some places (i.e., below 6200

ment potentiometer in the meter. For example, if the

rpm) and decreases it in others (i.e., above 6200 rpm).

peak-to-peak amplitude of the runout signal was 0.5

In this case, the vibration is changing while the runout

mils, they reasoned that they could simply offset their

remains fixed. However, the same effect can occur when

meter by 0.5 mils. Thus, a meter that would normally

the runout is changing, regardless of whether the vibra-

indicate 3.2 mils of vibration would indicate only 2.7 mils.

tion levels are stable or changing. Changes in runout

This approach was particularly faulty because it not only

may make the vibration look worse than it actually is,

failed to recognize that runout can change over time, but

Figure 5 Bod plot of same data as in Figure 4. Notice how the compensated data (green) has lower amplitude than
uncompensated data (red) below 6200 rpm, but this is reversed for speeds above 6200 rpm. The complex nature in which
vectors and waveforms combine can cause runout to either increase or decrease the actual vibration amplitude.

1 6 O R B I T [ Vo l . 2 5 N o. 3 2 0 0 5 ]

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that runout is a complex waveform and does not follow

Slow Roll Runout

as a Diagnostic Tool
As pointed out in this article, runout can change,
and for this reason, embedded compensation in
a permanent monitoring system is not recommended. However, runout can vary for more
reasons than just shaft scratches or changes in
shaft magnetism. One of the most serious malfunctions that can result in a runout change is a
shaft crack. While this is not the only symptom of
a crack, any time the slow roll (typically less than
400 rpm) runout amplitude/phase vectors change,
it is imperative to understand why.
Our first rule of shaft cracks states that, If a shaft
is cracked, it is almost certainly bowed. This bow
can change the 1X slow roll runout vectors once
crack propagation takes place. Thus, if the shaft is
bowed, it may simply be gravity sag, or it may be
more serious. The 2X slow roll runout vector should
also be checked. Cracks can cause stiffness asymmetry if they propagate in an uneven pattern,
creating a characteristic twice-per-revolution
flexing. Certain rotor designs are inherently asymmetric such as 2-pole generator rotors, where
normal shaft asymmetry will yield a noticeable
2X component, but its amplitude and phase
should not change over time.
The moral of this story? Always remember to treat
runout data as a valuable source of diagnostic
information not merely noise that interferes
with the true vibration.
You can read more about the topic of shaft crack in
the January 1986 issue of ORBIT.

the rules of scalar subtraction.

The inherent problems in using embedded compensation
in machinery protection systems was addressed a number of years ago in American Petroleum Institute
Standard 670. It specifically prohibits the use of compensation in permanent monitoring systems. Consistent
with API 670, it has long been our practice to provide
compensation in systems used for diagnostic purposes,
but not machinery protection purposes.

Summary
As we have shown, many factors can influence the
amount of runout present in a shaft. The best approach
is to prevent runout rather than mitigate it after the
fact through appropriate diligence at all stages of the
manufacturing process. However, mitigation will still
sometimes be necessary and this article has discussed
several methods that can be employed with good success, ranging from degaussing and burnishing to the
use of alternate materials for the probe tracks. In all
situations, runout can be effectively managed and
should not preclude users from using proximity probes
on machinery with fluid-film bearings, as these transducers afford the most sensitive and reliable machinery
condition measurements available.
For those experiencing runout-related problems or
desiring to prevent such problems from occurring in the
first place, an excellent approach is to enlist the service
of GE Energys field professionals. They can develop a
runout mitigation plan specific to your operations as well
as provide the necessary training for your personnel.

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