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Maintenance Minders

Field Balancing
Greg Lee, Ludeca, Inc.

O
ne common definition of balance is when the mass Figure 3 depicts the trial weight run. Trial weights pro-
centerline and the rotational centerline of a rotat- vide a method to calibrate the rotor system. A known trial
ing part are equal. Another definition is when zero weight, placed in a known position, will influence the vibra-
vibratory force or vibratory motion is imparted from the tion a specific amount that will permit correcting the mea-
rotating part to the bearings. Field balancing is a technique sured imbalance.
used to balance a rotating part in place without removing
the part from the machine. The advantages of field balancing
are apparent, in that time can be saved by not removing the
rotating part from the machine and sending it to a shop for
balancing. An additional benefit is realized in ensuring that
the rotating part is balanced as installed.
When field balancing, one must have access to the rotat-
ing shaft and have an area to place trial weights and correc-
tion weights. As seen in Figure 1, the access requirements for Figure 3
field balancing eliminate many machines as field balancing
candidates. In this example, we have placed one gram of weight at
270-deg. The resulting vibration was reduced from 10-mil to
5-mil and the angle did not change. This means we placed
the trial weight exactly opposite the heavy spot on the rotor.
Now we can apply the ratio:

UnbalanceWeight TrialWeight
=
InitalRunAmplitude TrialRunAmplitude

Figure 1 UnbalanceWeight 1Gram


Or in our example: =
Balancing Basics 10Mils 5Mils
Balancing in its most basic form is a problem of ratios. To
simplify, we will use a one plane example and eliminate the 1Gram
angle calculations by assuming we know exactly where the UnbalanceWeight = 10mils = 2Grams
heavy spot is located on a rotor. Figure 2 depicts an end view 5Mils
of a rotor. The amount of vibration is measured and indicates
10-mil of vibration 90-deg from the 0 angle reference. No Figure 4 shows the correction and result. As can be seen
weight has been added at this point and the measurement from the ratio, if one gram reduced the vibration from 10-
represents the “as found” condition. mil to 5-mil, then two grams placed at the same location
should reduce the vibration to 0-mil.

Figure 2 Figure 4

106 october 2006 www.pump-zone.com Pumps & Systems


Balancing Today
By adding the angular component, as would be the case in the real world, the solu-
tion becomes more complex and involves the angular vector. Years ago, the standard
practice involved manually plotting these vectors on polar paper to get a solution.
The plotting process is relatively easy for a single plane problem, but becomes dra-
matically more complex when involving a two-plane problem.
Fortunately, modern digital field balancing
equipment with extremely accurate filtering will
quickly calculate complex balancing solutions, with
dramatically improved results. Their superior filtering
and reduction of error (compared to the analog bal-
ancers and manual plotting methods of the past) often
lead to acceptable results on the first balance correc-
tion. Documentation is an added benefit of newer
instruments. In today’s ISO and compliance world, You’re looking at
a paper trail is often required and most of the digital a $24,000 part.
equipment can either connect directly to a printer or
computer port to archive the balancing results.

Conclusions Figure 5
We recently watched a person using an analog bal-
ancer for a two-plane fan that was running near its resonant frequency. This is an
extremely difficult application to balance due to the resonance problem.
The person running the balancer had 20+ years of experience. The machine
owner reported that the last time this fan was balanced, 28 balancing runs were nec-
essary to bring it into tolerance. As the balancing job progressed, it became apparent
with the digital equipment that recalibration was necessary. After the third balanc-
ing shot, the analog method called out for too much weight and grossly overstated It’s a slightly undersized sleeve nut.
the trim weight needed. We spotted it as the reason why
I was using a state-of-the-art digital balancer the shadow the balance job and a customer kept experiencing
as the balance progressed through the first correction and trim, it became apparent premature mechanical seal failure
with the digital equipment that a recalibration run was necessary. The placement in two key pumps. Total annual
of the second trim weight resulted in a significant increase in vibration and in one savings: $24,000. Just an example
plane it was near the original vibration. It looked like we were headed to another of how PRO Services can significantly
28 balancing runs. Changing over to the digital equipment, then recalibrating after
improve reliability and lower
one or two trim runs, we quickly brought the fan into tolerance.
operating costs for any type of
Why did we have to recalibrate after one or two trim weights? Vibration
amplitude and phase angle are influenced by resonance which results in a non- rotating equipment. So you’ll enjoy
linear response when a trial weight is placed on the shaft. Simply put the structure fewer repair bills, less downtime, and
response becomes less compliant as the forcing vibration (unbalance) is reduced. a reduction in parts inventory. Get a
circle 148 on card or go to psfreeinfo.com
Thus the trial weight used when the vibration was high cannot be used for calibra- complimentary PRO Services hard
tion of trim weights after the vibration has been significantly reduced. hat with a free plant assessment.
It is most important to remember the basic fact that, at its core, field balancing Call 1-800-734-7867 or
is a ratio problem. Anything that influences the linear response and angle of the trial
visit ittproservices.com.
weight will affect the accuracy of the correction. If your rotor runs near a resonance
it will probably take several recalibration runs as you reduce the unbalance. Digital PRO Services
balancing methods help take the mystery out of balancing while increasing both the
accuracy and simplicity of the process. maintenance
P&S

s at
Greg Lee is an applications and sales engineer for Ludeca, Inc., 1425 NW 88th See u EC
T
Avenue, Doral, FL 33172, 305-591-8935, Fax: 305-591-1537, Greg.Lee@ WEF #4945
ludeca.com, www.ludeca.com. Bo o t h

Pumps & Systems www.pump-zone.com october 2006 107

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