560130

Design Modifications of Papermachine Support Structures to Control Vibration
Andrew K. Costain, B.Sc.Eng.

Dale G. Eyre, Eng., B.Sc., M.Sc., D.Sc.
J Michael Robichaud, P.Eng., CMRP

Bretech Engineering Ltd.

ABSTRACT

The generally accepted methods for vibration control of equipment and structures include Force Reduction, Mass
Addition, Tuning, Isolation, and Damping. This paper will describe the use of tuning, or changing, the natural
frequency of a system or component to control vibration response of large structures. Several case studies will be
presented, with emphasis on pragmatic solutions to papermachine vibration problems.

1. INTRODUCTION

Notwithstanding the replacement of worn or defective components, such as damaged bearings, 5 basic methods exist
for vibration control of industrial equipment, as detailed below;

Force Reduction of excitation inputs due to, for example, unbalance or misalignment will decrease the
corresponding vibration response of the system.

Mass Addition will reduce the effect (system response) of a constant excitation force not considered practical
for papermachine support structures.

Tuning (changing) the natural frequency of a system or component will reduce or eliminate amplification due
to resonance.

Isolation rearranges the excitation forces to achieve some reduction or cancellation

Damping is the conversion of mechanical energy (vibrations) into heat not considered practical for
papermachine support structures.

2. BASIC METHODS FOR PAPERMACHINE VIBRATION CONTROL

The typical and preferred methods for vibration control of paper machine structures are force reduction and tuning.
These methods are described in detail on the following pages.

2.1 Force Reduction

Force reduction of inputs related to rotating components, such as unbalance, misalignment, looseness, and rubbing,
will result in a corresponding reduction of vibration response. Typically, force input increases in proportion to the
frequency (speed). For higher speed machines, balancing to specified tolerances and precision shaft alignment may
be required to moderate the input force. As shown in Equation 1, below, force due to unbalance increases with the
square of the speed. Conversely, on slower machines, residual unbalance may not necessarily result in unacceptably
high force input and corresponding vibration response.

TAPPI/PIMA PaperCon08 Conference, May 4-7 2008, Dallas, TX Page 1 of 15

2
2
f
e M F

[Equation 1 unbalance force]

where F = force, lb [N]
M = mass, lb-sec
2
/in [kg]
e = eccentricity, in [m]
f = frequency, Hz

For force inputs at or near the system natural frequency, f
n
, (resonance), amplification of the vibration response is
likely to occur. This may cause otherwise acceptable (residual) force inputs to result in excessive vibrations. For
well damped systems, force reduction may sufficiently control the vibration response. For lightly damped systems,
force reduction is typically used in conjunction with Tuning.

2.2 Tuning

Tuning is a process used to eliminate amplification due to resonance by changing a system or component natural
frequency, f
n
, so that it is no longer coincident with the frequency of a specific force input. Resonance of industrial
equipment will amplify vibration response, in theory up to , depending on system damping characteristics.

The Synchronous Amplification Factor (SAF) is a measure of how much 1X vibration is amplified when the system
passes through a resonance. Systems with a high effective damping tend to have a low SAF, and systems with low
effective damping have a high SAF. The Bode Plot, shown in Figure 1, below, indicates that systems with a high
SAF (lightly damped) have a narrow range of resonance with high amplification; systems with low SAF (well
damped) have relatively broad range of resonance with low amplification. Note that the range of resonance
indicates the amount of tuning (change in the system natural frequency) required to eliminate resonance. Resonant
frequencies that are nonsynchronous exhibit similar behavior.

Figure 1 Bode Plot


Before attempting to tune a resonant system, the natural frequency (and damping characteristics) should be
determined experimentally, typically by a forced response (bump) test. Once the frequency relationship between
force input and system natural frequency, f
n
, are evaluated, a decision must be made on whether to raise or lower the
natural frequency. For a simple (sdof) vibrating system, f
n
is proportional to the stiffness to mass ratio. Equation 2,
below, indicates that adding stiffness will raise the f
n
, and, conversely, adding mass will lower the f
n
.

M
K
2
1
f
n
[Equation 2 natural frequency for simple vibrating system]

where f
n
= system natural frequency, Hz
K = stiffness, lb/in [N/m]
M = mass, lb-sec
2
/in [kg]

Since increasing mass and/or decreasing stiffness (to lower the f
n
) may compromise the strength of a machine or its
supporting structure, adding stiffness (to raise the f
n
) is the most common practical application of detuning. When
adding stiffeners to a resonant system, the optimal location for end connections is the system antinodes, and
installations at nodes will be ineffective. A modal or operating deflection shape analysis is useful for determining
the location of antinodes. Care should be taken to ensure that: 1) the added mass of the stiffener does not cancel its
stiffening effect (note that pipe has the best stiffness to mass ratio), 2) stiffeners do not introduce new component
natural frequencies that are coincident with force input frequencies (i.e. resonance), and 3) stiffener end connections
are as fixed (rigid) as practically possible.

0.0 20.0000 Hertz
0.0
1.2000
Cross Channel Spectrum
FRF, Pump #1, -10Y, Pump Frame
LBFi: 0.7265
Hert: 10.5000
26-Feb-03
15:39:31
J OB ID: 198
12 Hz
0.0 20.0000 Hertz
0.0
0.4200
Peak
in/sec
Peak Hold
Coast Down Spectrum
in/s: 0.3485
Hert: 11.8752
26-Feb-03
12:24:20
J OB ID: 202198
11.9 Hz

Figure 2A forced response test of vertical pump Figure 2B peak hold coastdown of vertical pump

Figures 2A and 2B, above, show the evaluation of system f
n
for a vertical pump, using both forced response testing
and peak hold coastdown methods. In this case, 1X pump rotating speed, 700 rpm, is coincident with a system
natural frequency (i.e. resonance). Note that by analyzing phase and coherence data, the 10.5 Hz peak shown in
Figure 2A was found to be an external force input, rather than a system natural frequency.

3. TEST & EVALUATION

Evaluation and assessment of vibration response is necessary to determine the most effective vibration control
strategy. Consideration should also be given to current and future machine requirements (planned operating speeds),
equipment reliability, and project costs & roi.

Four basic vibration acquisition test methods are employed to produce information about the structure and direct a
solution to the undesired machine vibration. These methods are described below;

3.1 Transient and Speed Trial Data

Speed trial and transient testing methods involve the continuous acquisition of data for a period of time and
operating conditions. These methods will capture any events which are not continuous, such as beats resulting from
amplitude and/or frequency modulation. Vibration beating may be of particular interest, since dryer sections produce
closely spaced forcing frequencies due to the draw or speed difference from the wet end to the dry end required to
keep sheet tension. Beats can be very destructive over time to frame condition and directly affect machine
reliability.

Speed trials involve continuous data acquisition over a machine operating range or range of interest. This data is
acquired to investigate the relationship of machine speed versus vibration amplitude and frequency. As speed
changes, so do associated forcing functions - as machine speed increases, vibration levels should show a gradual
corresponding increase. The speed trial data analysis may reveal system natural frequencies and other unusual
vibration amplitude patterns present in the machine operation.

Resonance occurs when forcing frequencies are coincident with system natural frequencies. At resonance, system
response (vibration amplitude) is amplified. A sudden sharp peak followed by decreases in amplitude as machine
speed increases is an indication of the presence of a system natural frequency. The amount of amplification depends
on the system damping characteristics.

Unbalance in rolls may also be indicated in speed trial data. A sharp and continual increase in amplitude with
increased speed may indicate an unbalance condition, since calculated force due to unbalance increases by the
square of the rotational frequency (as shown in Equation 2). A key factor affecting vibration response due to
unbalance is the rotating speed of the roll.

Multiple channels of vibration data acquired simultaneously with increasing machine speed on all papermachine
components, tending and drive sides, will also allow the investigation of component phase relationships.

Figure 3 contains the 0 to 40 Hz waterfall plot of data in acceleration (gs) of a dryer section measurement. This
data was acquired midframe on the tending side in the machine direction. The multi-axis plot contains data on three
axes, the vibration amplitude, time, and frequency.

Amplitude
Frequency
Time
Figure 3 Vibration Waterfall Plot, 0-40 Hz


High vibration response from resonance is identified in several location of this plot as well and a proportional
vibration increase with speed typical of unbalance in a rotating component. Using the trend over a given speed
range comparison of vibration representing unbalance is separated from resonant response.

3.2 Forced Response

Forced Response Testing (impact testing) is used to identify the natural frequencies of systems and components. The
raw data acquired during impact testing is evaluated for amplitude, coherence and phase shift to verify the accuracy
of the sample. This data is then crosschecked with system forcing functions to identify possible areas where
resonance will occur.

Sample data plots for the impact testing are shown in 4 and 5. The data was acquired on a point located at press felt
roll 202F, in the upper frame of the press section. The indicated peak is 25.9 Hz. Note that other valid peaks are
also present.

0.0 250.0000 Hertz
0.0
0.0240
Peak
in/sec
Spectrum
096 - -50Z:1X(Ch B)
in/s: 0.0196
Hert: 25.9375
30-May-07
14:05:00
JOBID:UTOPIAFRF

0.0 250.0000 Hertz
0.0
0.0150
sec/LBF
Transfer Function B/A
096 - -50Z:1X
in/s: 0.0137
Hert: 25.9375
30-May-07
14:05:00
JOBID: UTOPIAFRF

Figure 4A forced response test Figure 4B transfer function

The validity of an impact test is considered with reference to the dominance of the peak shown in the natural
frequency transfer function compared with the coherence and the phase shift data. The coherence plot verifies that
the vibration data acquired by the accelerometer is in fact a result of the impact by the modal hammer. In this test, a
valid data point will have a coherence value of 0.95 or higher on a scale of 1.0, the indicated value in Figure 5 is
0.996. Additionally, a phase shift of approximately 180 degrees in the cross channel phase plot is consistent with
resonance conditions (see Figure 5B).
0.0 250.0000 Hertz
0.3000
1.1000
Cross Channel Coherence
096 - -50Z:1X
: 0.9960
Hert: 25.9375
30-May-07
14:05:00
JOBID: UTOPIAFRF

0.0 250.0000 Hertz
-180.0000
180.0000
Degrees
Cross Phase
096 - -50Z:1X
Degr: -144.4332
Hert: 25.9375
30-May-07
14:05:00
JOBID: UTOPIAFRF

Figure 5A forced response test coherence Figure 5B forced response test cross phase

All Forced Response data requires evaluation using the criteria presented in prior to acceptance as a valid natural
frequency of the tested component(s)

Forced response testing indicates system natural frequencies, typically the 1
st
and 2
nd
bending modes. When forcing
functions (such as 1X dryer turning speed) are coincident with the natural frequency, a significant increase in
vibration amplitude will occur (i.e. resonance).

Additional components of interest to natural frequency modes, other than peak frequency and amplitude, are
damping and amplification. The amount of damping in a structure affects the resonant response, such that, with no
damping, one would expect to get infinite motion with very small excitation. As the damping increases, the resonant
response from a given force reduces.

In a lightly damped system, the frequency peak is narrow at its base in the spectral plot. This narrow peak implies
large amplification over a narrow frequency range. Conversely, a highly damped system shows a peak at a natural
frequency with a wide base with lower amplification factor over a typically wider frequency range. Associated with
system damping is how much the system vibration amplitude will be amplified by a coincident forcing function. The
degree of amplification may be quantified by Equation 3, where Q is the amplification factor, f
c
is the center or peak
frequency, and f
a
and f
b
are the frequencies at which the amplitude peak is 0.707 of its maximum.

fa fb
fc
Q
= [Equation 3 Amplification Factor using power points]

where f
c
= peak power point, Hz
f
a
, f
b
= rms power points, Hz
Q = amplification factor

In Figure 6 below, the amplification factor for the natural frequency peak of the #212 Felt Roll in the upper frame of
dryer section 2, peaks at 0.707 of the center frequency amplitude, and Hz, are used to calculate Q, the amplification
factor. Therefore, the vibration amplitudes at a frequency of 25.9 Hz will be amplified by a factor of 26.0.

0.0 50.0000 Hertz
0.0
0.0240
Peak
in/sec
Spectrum
096 - -50Z:1X(Ch B)
in/s: 0.0196
Hert: 25.9375
30-May-07
14:05:00
JOB ID: UTOPIAFRF

Figure 6 calculation of amplification factor

Factors affecting natural frequencies include geometry and support stiffness (i.e. bearings, supporting structure, and
felt wrap).


3.3 High resolution vibration measurements

Radial vibration measurements are acquired using a data acquisition route configured for all dryer cylinder bearings
on the tending side and drive side. The data acquired is used as an assessment tool for the frequency and amplitude
of each contributor to the vibration problem. Occasionally, there are multiple frequencies that can be contributing to
the overall problems, thus requiring more than a single correction or single course of action.

Machine speed during data acquisition is held constant at the highest normal production rate for the machine.
Vibration amplitudes at 1X the dryer turning speed represent movement induced by the turning speed of the roll and
may indicate unbalance.

Vibration amplitudes of 0.04 in/sec peak (ips pk) have been identified as the maximum acceptable vibration
amplitude at 1X dryer turning speed for dryer cylinders based on historical data and experience. Sample spectral
and waveform data is shown in Figure 7.

Figure 7 sample vibration spectrum and waveform

This sample plot indicates the spectra and associated acceleration waveform for a horizontal measurement on the
tending side bearing housing of dryer 33. The amplitude of the 1X dryer vibration in this plot, 0.205 ips pk, exceeds
the acceptable amplitude of 0.04 ips pk, indicating the presence of dryer unbalance or frame movement.

Dryer unbalance is typically a combination of static and couple unbalance, and the severity of it is represented by
the vibration magnitude at 1X the roll turning speed. The phase of the 1X component is measured relative to a phase
marker (reflective paint) painted on a dryer head bolt. Generally, if the unbalance force is a result of pure unbalance
and not affected by resonance or structural deflection, the unbalance force will increase as per Equation 1.

3.4 Operating Deflection Shape

Operating deflection shape (ODS) analysis is a powerful post-test analysis technique, in which users can observe,
analyze, and document the relative dynamic behavior of machines and structures.


Vibration amplitude and phase data is associated with specific points on a model to visually display the relative
movements of papermachine components. The model can then be animated at any frequency present in the vibration
data. This is valuable in identifying the frequencies causing the deflection of rolls and frames as well as in
determining the phase relationship between these components.

Animations are created in .avi movie format using cross-channel data, images from the animations are shown below.

Figure 8A ODS press model Figure 8B ODS former model

Animations are run at specific forcing frequencies identified during previous data analysis using field data.

The results of ODS animation results is a key indication of problem locations and the limit of the affected areas or
components. As data is acquired during a periodic vibration measurements variables including transient or beat
vibration must be identified and addressed to ensure accurate results. Incorrect data acquisition and analysis is one
of the leading potential sources for incorrect diagnosis.

4. Sample Structural Vibration Case Studies

Three case studies selected from previous analysis and corrections follow. Each correction deals with a problem
that was identified and corrected through structural tuning or force reduction. Strong similarities exist in the data
and careful analysis is necessary to determine the cost effective source to solution.

4.1 Case Study #1

A large newsprint machine was to increase nominal operating speed from 3400 fpm to 4000 fpm. Since existing
runability problems at the dryer section (excessive sheet breaks) was already a concern, and since existing vibration
forces were expected to increase with speed, a detailed dynamic analysis was conducted of the dryer section.

The baseline vibration assessment revealed; 1) several dryer cylinder bearing defects, and 2) felt roll unbalance
problems, as shown in Figs 9A and 9B, below.


0.0 4.2000 Seconds
-1.2000
1.2000
G's
Waveformof Dryer Can #20 - Y Direction
G's: -0.2682
Seconds: 0.1699
09/12/02
11:57:29
J OB ID: 202137-3
0.0 200.0000 Hertz
0.0
0.4800
Peak
in/sec
Spectrumof Felt Roll F28 - X Direction
in/sec: 0.3924
Hertz: 13.0000
09/12/02
16:04:45
J OB ID: 202137-4A
0.0 200.0000 Hertz
0.0
0.0300
Peak
in/sec
Spectrumof Dryer Can #20 - Y Direction
in/sec: 0.0217
Hertz: 3.7500
09/12/02
11:57:29
J OB ID: 202137-3
0.0 4.2000 Seconds
-0.6000
0.6000
G's
Waveformof Felt Roll F28 - X Direction
G's: 0.0696
Seconds: 0.0
09/12/02
16:04:45
J OB ID: 202137-4A

Figure 9A dryer bearing defect Figure 9B felt roll unbalance

As shown in Figs 10A and 10B, below, excessive dryer cylinder unbalance was detected at dryer section #1. Similar
results were found at section #2 and #3, with 1X dryer (4 Hz) amplitude up to 0.3 in /sec pk in the machine direction
(target value is 0.04 in/sec pk).

Conversely, the dryer sections #4 and #5 were found to be well within tolerance. Note that sections #1, #2, and #3
are driven by dryer felts, and sections #4 and #5 are driven by enclosed gear trains.

Figure 10A 1X dryer vibration amplitude Figure 10B 1X dryer phase / magnitude vectors
Tending Side 1X Vibr at ion - 3650 FPM
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
0.200
1 2 3 4 5 6 7
Dr yer Cylinder #' s
V
i
b
r
a
t
i
o
n

A
m
p
l
i
t
u
d
e

(
i
n
/
s
e
c

p
k
)
TendingSideHorizontal
TendingSideVertical
TendingSideAxial
VibrationLimit
0.238 0.210 0.202

An operating deflection analysis indicated excessive machine direction motion in the supporting structure. The ods
model is shown in Fig 11, below. Machine direction is +x.


Figure 11 operating deflection shape model

Visual examination of the support structure revealed previously installed machine direction braces, as shown in Fig
12A, below. These were found to be undersized, and in generally poor condition, with many of the structural welds
broken.

Figure 12A failed structural brace Figure 12B example structural brace

Recommendations were submitted to design and install suitable machine direction bracing, similar to that shown in
Fig 12B, above. At the time of writing, this work is in progress.

4.2 Case Study #2

A large papermachine was experiencing sheet breaks and runnability issues associated with dryer section vibration.
Vibration in the 3
rd
and 4
th
sections in particular was excessive in the machine direction with visible sheet draw
tension variations. Sheet breaks were accounting for up to 4 hrs lost production per day.


Baseline vibration assessment identified: 1) dryer unbalance, and 2) machine direction frame resonance at current
operating speed. See waterfall plot in Figure 13 below. Frame resonance was affecting felt roll vibration.

Figure 13 waterfall plot machine direction sill beam

Data acquired using both constant speed and transient techniques identified speed range where residual vibration
amplitude was amplified in resonance. The dryer section was composed of 6 sections with individual sill beam
separations by section. Data indicated both in phase and out of phase machine direction vibration as measured over
time. Steady state amplitudes reached 1X dryer vibration amplitudes in excess of 0.6 ips-pk (target 0.04 ips-pk).
Typical data plots are shown below in Figure 14 A and B.

ROUTEWAVEFORM
08-Feb-06 10:10: 42
RMS= .0499
PK(+) = .1550
PK(-) = .2205
CRESTF= 4.42
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7
-0.3
-0.2
-0.1
0.0
0.1
0.2
Timein Seconds
A
c
c
e
le
r
a
t
io
n
in
G
-
s
PM 2- Dryer #52
D52 -TSH Tending SideHorizont al
ROUTESPECTRUM
08-Feb-06 10:10: 42
OVERALL= .4891V-DG
PK = .5311
LOAD= 100.0
RPM = 94.
RPS= 1.57
0 30 60 90 120 150
0
0.1
0.2
0.3
0.4
0.5
0.6
Frequencyin Hz
P
K
V
e
lo
c
it
y
in
In
/S
e
c
Freq:
Ordr:
Spec:
3.938
2.501
.411

Figure 14A typical spectrum dryer bearing Figure 14B 1X dryer magnitude

An operating deflection analysis indicated excessive machine direction motion in the supporting structure and in
particular vibration for the sill beam and below. This is the root cause of the upper frame vibration and the location
for correction.


Bracing was installed during an annual outage in 4 of the 6 dryer sections (as time permitted) in conjunction with
trim balancing of residual dryer vibration.

Figure 16A installed structural brace Figure 16B example dryer balance weights

Vibration amplitudes were reduced to the target amplitude and breaks in the dryer section stopped. Machine speed
is increasing and reliability improving.

4.3 Case Study #3

A large papermachine was experiencing very high machine direction vibration at 1X dryer turning speed. Machine
design is 3500 FPM with current speeds of operation up to 4000 FPM with production plans for speed up to the
drive limit of 4600 FPM. As all 4 dryer sections are on a continuous sill beam the two areas of concern exist with
sheet draw between press/dryer and dryer/calender and the mechanical failure potential from vibration amplitudes as
high as 1.5 ips overall.

Baseline vibration assessment identified: 1) dryer unbalance, and 2) machine direction frame resonance at current
operating speed. The trend plots shown in Figure 18 identify the amplitude pattern typical of resonance along with
the phase shift.

PM1 Speed Tri al - Machi ne Di recti on Vi brati on
1X Dryer 37, Ampl i tude and Phase
March 2003
-120
-100
-80
-60
-40
-20
0
20
40
60
80
100
120
2000 2500 3000 3500 4000 4500 5000 5500 6000
Machine Speed (FPM)
C
o
r
r
e
c
t
e
d

P
h
a
s
e

A
n
g
l
e

(
D
e
g
r
e
e
s
)
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
V
i
b
r
a
t
i
o
n

A
m
p
l
i
t
u
d
e
(
i
n
.
/
s
e
c

p
e
a
k
)
Measured Phase
Projected Phase
Measured Amplitude

Figure 17 waterfall plot machine direction sill beam

Speed trials identified that although the machine was operating in resonance at speed ranges between 3900 and 4100
FPM, the frame stiffness was lower than expected and dryer unbalance continued to deflect the frame with resulting
high vibration amplitudes.

Structural corrections identified include both stiffness for a natural frequency change and strength for increased
operating speed loads.

As with previous analysis, 1X dryer peak magnitude and phase is evaluated for peak amplitudes vs. target and their
associated vector (phase & magnitude).

Figure 18A 1X dryer magnitude Figure 18B 1X dryer magnitude/phase
Tending Side, 1XDryer Vibration - March 2003
Dryer Section 4
0.00
0.04
0.08
0.12
0.16
0.20
0.24
0.28
0.32
0.36
0.40
0.44
0.48
0.52
0.56
0.60
D28 D29 D30 D31 D32 D33 D34 D35 D36 D37 D38 D39
Dr yer Can #
V
i
b
r
a
t
i
o
n

A
m
p
l
i
t
u
d
e

(
i
n
.
/
s
e
c
.

p
e
a
k
)
Vibr ation Limit
(0.04 in./sec.)
0.70
(in/sec peak)

The operating deflection shape analysis identified a uniform motion in the machine direction with an out of phase
movement between the tending side and the drive side. This out of phase motion places higher loads on frames and
gear drive systems.



Using a computer FEA of the frame system along with load calculations and structural design two large braces were
added to each side of the machine section. The braces were installed and a subsequent follow-up testing identified
vibration amplitudes at the sill beam were reduced from 0.6 IPS pk at 1X dryer vibration to 0.02 ips pk.

Figure 20A installed structural brace Figure 20B installed brace bench

Vibration amplitudes were reduced to the target amplitude and machine speed increased to 4500 FPM.

5. CONCLUSION

There are 5 basic and distinct methods available for vibration control of industrial equipment; two are effective for
controlling vibration of papermachine structures as described in this paper. Prior to proceeding with a vibration
control method, the vibrating system, including force inputs and system natural frequencies, must be evaluated.


BIBLIOGRAPHY

[1] Costain, A. and Robichaud, J. M., Practical Methods for Vibration Control of Industrial Equipment,
CMVA, (2003)

[2] Costain, A., Case Studies on Paper Machine Vibration Problems, CMVA, (2003)

[3] Eshleman, R. Machinery Vibration Analysis: Diagnostics, Condition Evaluation, and Correction,
Vibration Institute, (2002)

[4] Jackson, C. The Practical Vibration Primer
Gulf Publishing Company - Houston, TX, (1979)

[5] Bently, Donald E. Fundamentals of Rotating Machinery Diagnostics
Bently Pressurized Bearings Press, (2002)


Design Modifications
of Papermachine Support Structures
to Control Vibration
presented by
Andrew Costain
introduction
test methods
design strategies
examples
established in 1984
based in Saint John, NB
45 Engineers & Technicians
computed
improving fixed assets productivity
is the most powerful mechanism
to improve shareholders return
introduction
test methods
vibration assessment & condition evaluation
forced response testing
speed trial testing
operating deflection shape analysis
peak magnitude & phase measurements
ROUTE WAVEFORM
16-OCT-03 21: 20: 34
RMS = .0373
PK(+) = .1844
PK(-) = .1670
CRESTF= 4.95
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7
-0.20
-0.15
-0.10
-0.05
-0.00
0.05
0.10
0.15
0.20
Ti me i n Seconds
A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
PM 5 - Dr yer #52
D52 -TSH Tendi ng Si de Hor i zontal
ROUTE SPECTRUM
16-OCT-03 21: 20: 34
OVRALL= .0924 V-DG
PK = .0986
LOAD = 100.0
RPM = 232.
RPS = 3.87
0 5 10 15 20 25 30 35 40
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
Fr equency i n Hz
P
K

V
e
l
o
c
i
t
y

i
n

I
n
/
S
e
c
Fr eq:
Ordr :
Spec:
10.22
2.642
.01355
1X dryer
2X dryer
1X felt roll
Time Domain
Frequency Domain
MACHINERY VIBRATION ANALYSIS
ROUTE WAVEFORM
28-FEB-00 11:45:59
RMS = .5096
PK(+) = 2.09
PK(-) = 1.86
CRESTF= 4.11
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
-2.5
-2.0
-1.5
-1.0
-0.5
0
0.5
1.0
1.5
2.0
Time in Seconds
A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
PM#1 - Dryer #24
D24 -TSH Tending Side Horiz.
ROUTE SPECTRUM
28-FEB-00 11:45:59
OVRALL= .3989 V-DG
PK = .3987
LOAD = 100.0
RPM = 220.
RPS = 3.67
0 4000 8000 12000
0
0.04
0.08
0.12
0.16
0.20
Frequency in CPM
P
K

V
e
l
o
c
i
t
y

i
n

I
n
/
S
e
c
Freq:
Ordr:
Spec:
Dfrq:
9161.3
41.64
.07664
213.28
0.0 150.0000 Hertz
0.0
0.0200
Peak
in/sec
Spectrum
350 - 283Y/001X(Ch B)
in/s: 0.0179
Hert: 51.0000
15-Aug-06
13:29:05
J OB ID: MODDAO2PM
0.0 150.0000 Hertz
0.0
1.2000
350 - 283Y/001X
J
0.0 150.000 Hertz
-180.0000
180.0000
Degrees
Cross Phase
350 - 283Y/001X
0.0 150.0000 Hertz
0.0
0.00350
Peak
in/sec
Spectrum
01C - 010X/001X(Ch B)
in/s: 0.00313
Hert: 2.4375
28-Dec-03
15:42:29
J OB ID: D3P9
0.0 150.0000 Hertz
0.0
1.2000
01C - 010X/001X
: 1.0000
Hert: 2.4375
28-Dec-03
15:42:29
J OB ID: D3P9
0.0 150.0000 Hertz
-180.0000
180.0000
Degrees
Cross Phase
01C - 010X/001X
Degr: -89.5108
Hert: 2.4375
28-Dec-03
15:42:29
J OB ID: D3P9
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
Speed (FPM)
F
r
e
q
u
e
n
c
y

(
H
z
)
1X 48" RollS
2X 42.5" Roll
1X 42.5" Roll
Primary Bel-Bond, X Dir., TS
Secondary Bel-Bond, Y Dir., DS
PM1 Fourdrinier January, 2004
PM1 Fourdrinier January, 2004
3000 FPM
2500 FPM
2200 FPM
D12
(0.05 ips)
D14
(0.13 ips)
D16
(0.08 ips)
D18
(0.07 ips)
D20
(0.02 ips)
D22
(0.10 ips)
D13
(0.10 ips)
D15
(0.13 ips)
D17
(0.08 ips)
D19
(0.13 ips)
D21
(0.08 ips)
D23
(0.12 ips)
No. 5 Paper Machine Baseline Assessment
Drive and Tending Sides, 1XDryer Vibration
Dryer Section 2, October 2003
0.289
0.00
0.04
0.08
0.12
0.16
0.20
D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23
Dryer #
V
i
b
r
a
t
i
o
n

A
m
p
l
i
t
u
d
e

(
i
n
.
/
s
e
c
.

p
e
a
k
)
Tending Side Drive Side
Vibration Limit (0.04 in./sec.)
No. 5 Paper Machine Baseline Assessment
Drive and Tending Sides, 1XDryer Vibration
Dryer Section 3, October 2003
0.287 0.239 0.204 0.222 0.206 0.199
0.2
0.00
0.04
0.08
0.12
0.16
0.20
D24 D25 D26 D27 D28 D29 D30 D31 D32 D33 D34 D35 D36 D37 D38 D39
Dryer #
V
i
b
r
a
t
i
o
n

A
m
p
l
i
t
u
d
e

(
i
n
.
/
s
e
c
.

p
e
a
k
)
Tending Side Drive Side
Vibration Limit (0.04 in./sec.)
D27
(0.20 ips)
D25
(0.20 ips)
D29
(0.21 ips)
D31
(0.19 ips)
D33
(0.22 ips)
D35
(0.20 ips)
D37
(0.24 ips)
D39
(0.29 ips)
D24
(0.08 ips)
D26
(0.12 ips)
D28
(0.08 ips)
D30
(0.05 ips)
D32
(0.11 ips)
D34
(0.04 ips)
D36
(0.06 ips)
D38
(0.09 ips)
introduction
test methods
design strategies
FORCE REDUCTION
MASS ADDITION
TUNING
ISOLATION
DAMPING
Force Reduction of excitation inputs due to,
for example, unbalance or misalignment, will
decrease the corresponding vibration response of
the system.
Mass Addition will reduce the effect (system
response) of a constant excitation force.
a M F =
Tuning (changing) the natural frequency of a
system or component will reduce or eliminate
amplification due to resonance.
M
K
f
n

Isolation rearranges the excitation forces to
achieve some reduction or cancellation.
Damping is the conversion of mechanical
energy (vibrations) into heat.
1X Vi brati on Magni tude - Dryer Secti on 2, Tendi ng Si de
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Dr yer Cylinder #
1
X

V
i
b
r
a
t
i
o
n

M
a
g
n
i
t
u
d
e
,

i
n
/
s
e
c
Sept 8, 2000
J uly 19, 2001
IN-SITU Roll Balancing
introduction
test methods
design strategies
examples
case study 1
case study 2
case study 3
Baseline Dynamic Assessment
& Structural Modifications
case study 1
Tending Side 1X Vibr at ion - 3650 FPM
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
0.200
1 2 3 4 5 6 7
Dr yer Cylinder #' s
V
i
b
r
a
t
i
o
n

A
m
p
l
i
t
u
d
e

(
i
n
/
s
e
c

p
k
)
Tending Side Horizontal
Tending Side Vertical
Tending Side Axial
Vibration Limit
0.238 0.210 0.202
Typical correction recommendations
High Vibration Amplitudes (exceeds recommended
limits)
1X turning speed of dryers is exciting support
structure natural frequencies.
Machine direction dominant 1X vibration
Observations
1. Dryer Section frame stiffening (tuning) to change
natural frequencies beyond present and projected
operating speed range.
Recommendations
2. IN-SITU ROLL BALANCING to reduce the forcing or
exciting function.
Recommendations
case study 2
ROUTE WAVEFORM
08-Feb-06 10:10: 42
RMS = .0499
PK(+) = .1550
PK(-) = .2205
CRESTF= 4.42
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7
-0.3
-0.2
-0.1
0.0
0.1
0.2
Time in Seconds
A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
PM 2 - Dryer #52
D52 -TSH Tending Side Horizont al
ROUTE SPECTRUM
08-Feb-06 10:10: 42
OVERALL= .4891 V-DG
PK = .5311
LOAD = 100.0
RPM = 94.
RPS = 1.57
0 30 60 90 120 150
0
0.1
0.2
0.3
0.4
0.5
0.6
Frequencyin Hz
P
K

V
e
l
o
c
i
t
y

i
n

I
n
/
S
e
c
Freq:
Ordr:
Spec:
3.938
2.501
.411
Very High Vibration Amplitudes
Vibration increasing sheet breaks
Observations
Recommendations
exciting function.
Recommendations
case study 3
Very High Vibration Amplitudes
1X felt roll turning speed exciting upper frame
resonance
Vibration increasing sheet breaks and reducing
machine speed
Observations
Recommendations
exciting function.
Recommendations

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Design Modifications of Papermachine Support Structures to Control Vibration

Andrew K. Costain, B.Sc.Eng.

[Equation 1 unbalance force]

[Equation 2 natural frequency for simple vibrating system]

= [Equation 3 Amplification Factor using power points]

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