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Case Study - Unexpected Vibraion On A Centrifugal Compressor Caused by Vibration Probe Support
Case Study - Unexpected Vibraion On A Centrifugal Compressor Caused by Vibration Probe Support
a Centrifugal Compressor
Caused by Vibration
Probe Support
S Y M P O S I A : 2 4 – 2 6 M AY 2 0 2 2 Yves Bidaut
SHORT C O U R S E S : 2 3 M AY 2 0 2 2
MAN Energy Solutions Schweiz AG
Author - Biography
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Synopsis
During the commissioning of a Main Air Compressor in an Air Separation Unit,
the rotor showed increased radial vibrations at the Non-Drive End probe.
The RCA revealed: The vibration resulted from the excitation of a natural
frequency of the vibration probe support, triggered by the pressure fluctuation at
the suction of the 11 blades-impeller.
The probe support was redesigned to increase its stiffness in order to shift the
natural frequency. After replacement of the support, no particular vibration
appeared anymore.
Generally: The vibration probe support requires careful attention, especially if the
machine is standardized for a very large operation speed range.
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Outline
1. Background
2. Description
3. Findings
4. Root Cause Analysis
5. Actions
6. Measurements after modification
7. Lessons learned, Conclusion
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Background – Train Arrangement, Compressor
During commissioning:
increased radial vibrations appeared
at Non-Drive End probe
Vibrations below trip limit
Vibrations increased with opening IGV
Because of unexpected vibrations
Origine of phenomenon investigated. 6 / 23
Findings – Lateral Vibrations (1/3)
110 4’500
Inlet
80
3’000
40
Discharge Pressure
1’500 Increased NDE-Vibration up to
30
Vibration (X,Y) - NDE 1’000
60 mm with speed () then with
20 IGV- Position load ().
500
Vibration below alarm (70 mm)
10
Vibration (X,Y) - DE
12.00 h
12.30 h
13.00 h
13.30 h
14.00 h
14.30 h
15.00 h
15.30 h
16.00 h
16.30 h
17.00 h
17.30 h
18.00 h
18.30 h
19.00 h
Time DE-Vibration still low ()
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Findings – Lateral Vibrations (2/3)
110 5’000
Speed
() during increased
80
3’500 discharge pressure @
70 constant IGV & speed
50
2’500
All other vibration signals
IGV
2’000 (DE-MAC, Steam Turbine,
40
Axial Position) barely
1’500
30 affected by operational
20
Vibration (X,Y) MAC - NDE 1’000 conditions.
10 500
Vibration (X,Y) MAC - DE
0 0
20.00 h
20.10 h
20.20 h
20.30 h
20.40 h
20.50 h
21.00 h
21.10 h
21.20 h
21.30 h
21.40 h
21.50 h
Time
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Findings – Lateral Vibrations (3/3) - Waterfall diagrams
110 5’000
70
40
1’500
30
1x 3x 5x 7x 9x
11x
20 Vibration (X,Y) MAC - NDE 1’000
10 500
Vibration (X,Y) MAC - DE
0 0
20.00 h
20.10 h
20.20 h
20.30 h
20.40 h
20.50 h
21.00 h
21.10 h
21.20 h
21.30 h
21.40 h
21.50 h
DE Time
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Root Cause Analysis – Further Investigations of Vibrations
Additional measurements performed at different operating conditions in order to characterize
phenomenon. Test IGV Speed Discharge Pressure ASU
3’960 rpm ≈ 2.9 bara 100% 90%
Test Procedure :
1 35% 4’036 rpm 2.9 4.7 bara 100% 65%
4’155 rpm ≈ 3.1 bara 100% 80%
3’960 rpm ≈ 3.1 bara 100% 90%
2 45% 4’036 rpm 3.2 3.7 bara 100% 80%
4’155 rpm ≈ 3.3 bara 100% 90%
3’960 rpm ≈ 3.3 bara 100% 90%
60%
4’036 rpm 3.3 3.6 bara 100% 85%
3
50% 3’960 rpm ≈ 3.2 bara 100%
60% 4’155 rpm ≈ 3.7 bara 100%
4 45% 3’960 4’155 rpm 3.2 - 3.4 bara 100%
5 45% 3’960 4’155 rpm 3.2 3.4 bara 75%
20 1’000
Vibrations (X,Y) - NDE
10 500
13.50 h
14.10 h
14.30 h
14.50 h
15.10 h
15.30 h
15.50 h
16.10 h
16.30 h
16.50 h
17.10 h
17.30 h
17.50 h
direct
Time
11x
60 2’500
50 IGV 2’000
40
1’500
30
1’000
20
Vibration (X,Y) - NDE
500
Vibration NDE (mm, pk-pk) 10
0 0
direct
9.20 h
9.30 h
9.40 h
9.50 h
10.00 h
10.10 h
Time
direct
745.25 Hz (11x)
67.75 Hz (1x)
NDE-
Probe
DE-
Probe
Stage 1 Stage 2 Stage 3
Bearing
support
Cross Section
3D-NX-Model
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RCA – Modal Analysis of Probe Support – FEA-Results
RCA
Increased vibration results from the excitation of natural frequency of
probe support, triggered by pressure fluctuation at the suction of the
11 blades-impeller (forced vibration)
Countermeasure
Design of support revised Increased stiffness to shift natural frequencies
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Countermeasure : Modified Probe Support
Modified
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Countermeasure : Modified Probe Support
FEA - Results
464 Hz 1’487 Hz
90 4’000
80 Speed
10 500
Vibration (X,Y) - DE
0 0 All vibrations
6.00 h
4.00 h
5.00 h
7.00 h
8.00 h
9.00 h
10.00 h
low and stable
Time
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Lessons learnt / Summary
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Case Study – Support Probe
Thank you !
Questions ?
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