Table of Contents

Topic Vibrations solution process / scope Vibration symptoms Actions for vibration related field problems

Page 1 1 2

Table 1 3

Vibration symptoms Actions for field related vibration problems

Page 1 3-7

Appendix A B

Preliminary data requirements Preliminary investigation, vibration description requirements, and likely causes of high vibration Component damage assessment

Page 8-9 10-14

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A Vibrations Solution Process

Scope:
The scope of this solution process is limited to vibration related problems. These problems have root causes that directly lead to excessive vibration in the compressor rotor stages or in the bullgear system. It does not relate to vibration related problems that may affect other systems or components such as the driver, baseplate, etc.

Vibration Symptoms:
The following symptoms are accepted as being sufficient to require that the Vibrations Solution Process be followed. If one or more of the listed symptoms are not present; but, vibration is still suspected as being excessive; consultation with aftermarket service support reps should be made. There is no criteria addressing an unacceptable rate of change of vibration. However, unusual changes in the vibration behavior should be reported to the appropriate aftermarket representative at the factory.

Table 1
1 During shop testing with the fully warmed up compressor operating at steady load, with the probes and controls functioning properly, the stage vibration reading at the end of the mechanical test period exceeds the shop acceptance level. Or, if the vibration level exceeds the shutdown limits any time during the test. Or, if the vibration level repeatability exceeds the alarm limit. During compressor commissioning, the vibration signals exceed the field acceptance limits with the compressor warmed up and operating at steady load. Or, if the vibration level exceeds the shutdown limits any time during the test. Or, if the vibration level repeatability exceeds the alarm limit.

After commissioning and during warranty; during startup, steady load operation, or normal shutdowns; the stage vibration signals repeatability exceed the alarm values.

The compressor has experienced a severe rotor contact within the gearcase/stage area with or without an indication of vibration shutdown in the control panel.

Actions For Vibration Related Problems: If any of the symptoms listed in Table 1 are present, the actions outlined in Table 3 are appropriate. Note that actions are presented for different time periods of the solution process. These include: 1. Prior to opening the unit for inspection or repair 2. Problem Evaluation 3. Disassembly 4. Repair and Re-assembly 5. Re-start 6. Solution Follow Up

Table 3. Actions For Field Related Vibration Problems Prior to opening compressor for inspection or repair
Responsibility Service Technician Action Collect preliminary data (see Appendix A), and provide copy to customer service engineer and reliability engineering Comments/Suggestions Data includes general description of compressor, site, problem, customer comments, machine history, application, data logs, and initial machine inspection. This is where available CMC event and analysis logs are recommended.

Service Technician

Centac Customer Service Engineer Service Technician with Centac Customer Service Engineer

Check compressor system for those specific causes of vibration that can be investigated prior to opening the compressor. And, identify and/or refine the description of the vibration symptoms. See Appendix B. Update preliminary data to include shop related information. See Appendix A. Open/create a service file for the machine problem in question. Collectively decide on the next steps to be taken.

The Customer Service Engineer can obtain advice from reliability engineering and/or advance engineering.

Table 3. During disassembly of the compressor

Responsibility Service Technician Action Assure a controlled disassembly process which collects and preserves data that may be needed to determine the root cause of the problem Document parts damage and other findings pertinent to the problem. Provide inspection data to Centac Customer Service Engineer. Discuss findings to determine next steps to be taken. If no additional help is needed; establish action plan, document plan and apparent problem/solution, and proceed to compressor repair and rebuild step. If help is required to establish the problem cause and solution, or if an earlier action did not solve the problem, proceed to the problem evaluation step. Comments/Suggestions Investigate/report on air/oil seal rubs, diffuser rubs, loose/bent parts, gear mesh errors, FOD, assembly or set up errors, varnishing, fretting, and etc. See Appendix C for specific data to secure and to report on as part of the disassembly process.

Service Technician

Service Technician and Centac Customer Service Engineer

Next steps include possible replacement parts, added help at site, need for problem evaluation phase, etc. All parts must be returned to either Davidson/ Vignate for evaluation.

Table 3. Problem Evaluation

Responsibility Aftermarket Customer Service Engineer Action Consult with Reliability/Customer Service manager and the Chief Engineer to establish need and priorities for a root cause analysis. Also, take necessary steps to contain the problem and to quickly address safety issues early. May also request parts to be returned for inspection. Aftermarket If root cause analysis is not Customer needed; determine action plan, Service Engineer document plan, and proceed to repair and rebuild step. If root cause analysis is needed, request Oversight Committee to schedule and assign root cause. Oversight Committee: Engineering managers, Q/A managers, A/M manager and Service managers. Oversight Assign, schedule, and direct root Committee cause team. Root Cause Task Determine root cause of the Team problem. Document results. Advise Oversight Committee and Aftermarket Customer Service Engineer of the root cause and recommended (and possible alternative) solution. Oversight Approve, schedule, and assign Committee those actions that are needed to implement the corrective action. Oversight Assure that the approved Committee corrective actions are implemented, monitored, and documented. Comments/Suggestions

Table 3. Compressor Repair and Re-assembly

Responsibility Aftermarket Customer Service Engineer Service Technician CTC Service Manager Action Determine and communicate to service technician replace, refurbish, or reuse of repair components. Follow Centac service practices and document repair in X-Site report. Audit compressor repairs. Adjust repair requirements as required. Report progress to Aftermarket Customer Service Engineer. Comments/Suggestions

Table 3. Startup
Responsibility Service Technician Action Follow Centac service practices, start and monitor compressor operation making system adjustments as are required. Document start-up results in the X-Site report. Assure that the problem has been resolved. Comments/Suggestions

Aftermarket Customer Service Engineer

Table 3. Solution Follow-up

Responsibility Service Technician Supervisor Aftermarket Customer Service Engineer Oversight Committee Action Release service technician from site when customer agrees that the initial problem has been resolved. Insure that the factory service file is complete. The file must contain the units repair history, startup and operational data. Monitor results. Verify if problem is fully resolved and that corrective action was effective. Enter data into the electronic service problem data file. Assure submission and follow progress of ECRs for design, manufacturing, or other process changes that the solution requires Review problem solving processes and initiates changes in the process if they are required. Comments/Suggestions

Electronic file/program needs to be designed, written, and implemented.

Aftermarket Reliability Engineer

Division needs an ECR like process for manufacturing and other process change requests.

Oversight Committee

Appendix A Preliminary Data

1. General Description of Compressor Customer Location Application Compressor Model Serial Number Hours Pressure Horsepower Driver Type Driver Size Driver Supplier # of Starts

2. Problem Description Date A. Initial Complaint Symptom(s) Yes High Vibration Changing/Fluctuating Vibration Upward Trending Vibration Vibration Higher Than Similar Machines at Same Site Unusual Noise Found During Routine Maintenance Other B. When is Problem Seen Yes No Cold Start Hot Start Unloaded Loaded Start Up Coastdown C. Condition of Compressor Now D. Other No How High Describe below Describe below Explain below

Describe below

Yes

No

Appendix A Preliminary Data

3. Machine History A. What problems has machine had in the past? B. What actions were taken? C. What were the results of these actions? D. Field Vibration, Prior to Problem Pk-Pk (mils) Vibration 1X (mils) Vibration Yes Spectrum Measured Acceleration Signature Measured CDS Taken Other E. Field, Current With Problem Pk-Pk (mils) Vibration 1X (mils) Vibration Yes Spectrum measured Acceleration Signature Measured CDS Taken Other F. Design and Application What operation was compressor designed for? How is the compressor actually being operated? G. Recent Operation Logs H. Initial Machine Inspection Results of check of possible problem causes (see Appendix B) No No

Appendix B
Before the compressor is restarted or opened for further investigation and/or repair, it is important to: 1. Identify and refine the description of the high vibration symptoms. 2. Check the compressor system for those specific causes of vibration that can be investigated prior to opening the compressor. 3. Obtain all significant data that may otherwise be lost or unavailable should the compressor system be operated, re-started, or opened for inspection. A. Preliminary Investigations that should be made: 1. Check for areas of major damage that precludes continuing running or from re-starting the compressor. 2. Slow roll the bullgear 3. Confirm the impeller clearances. 4. Check the instrumentation for proper operation and adjustments. 5. Visually check the oil for dirt, discoloration, water, air, or other contaminates. 6. Visually check the seal area of each stage using the seal vent line ports. 7. Confirm the available oil pressure with the compressor stopped using the pre-lube pump. 8. And, check for any other reasons that the compressor should not be run. Initial Date

B. Provide a complete description of the timing and the duration of the high vibration signals. When Yes No 1. Start up 2. Unloaded 3. Loaded 4. Coast-down 5. Surge 6. Other (Describe) Yes No Duration: 1. Continuous, all the time 2. Transient 3. Periodic, cyclic 4. Trending over a long period

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III. Likely causes of high vibration signals. Symptom of High Vibration High 1X Vibration Likely Mechanism Loss of Balance Any form of high vibration Usually none until impeller touches diffuser, then multiple frequencies Excessive loads on journal bearings Excessive loads on thrust bearings Likely Root Cause(s) Tests/Checks to Make. Will assist to confirm root cause. Take ADRE or other vibration spectrum measurement to confirm 1X. Spectrum should be taken during start-up, at speed/loaded, and during coastdown.

Dirt build up on impeller Nose bolt has backed out Foreign object damage to impeller Broken or cracked vane on impeller Attachment has loosened Loose nose cone, washer, or bolt Loose thrust collar Impeller not locked during assembly Excessive use of Loctite on rotor bolt Impeller interfering with pinion csink Surface damage to polygon Faces of impeller/pinion not square. Hand work used on attachment . Rotor not balanced to specification Pinion gear runout Loss of bearing dampening can induce an increase of 1X, easily found with run down. Misapplication (surge, air too cold, oil too cold, etc). Excessive piping strain on heads, gearcase. Misalignment of thrust bearing during installation. Thrust collar not square to pinion axis/thrust bearing. Thrust face design inadequate for application.

Accelerometer measurement of axial vibration. Confirm if surge pressure has deteriorated.

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1X or subsychroun ous or vibration increases when load or unload compressor 1X or fraction of running speed

Faulty Journal Bearings

Damaged bearing Bearings not manufactured to required tolerances Bearing design not correct for the application

Vibration signal level when loaded/unloaded Spectrum loaded, unloaded, coastdown.

Oil/seal rubs

Contaminate in seal area Loose or sticking seal Journal surface pitted, dirty, etc. Undersize seal Bearings oil whirl/whip or seal out of tolerance.

0.4X

Oil whirl/whip

Erratic, or 1X Oil or interruption subsychroun ous or vibration increases when load or unload compressor Varies Faulty Oil

Air/oil seal leaks may indicate damaged seal. Spectrum loaded, unloaded, coastdown. View shaft through seal vent and check for discoloration in seal area. Check CMC log Inspect thrust bearing surfaces for damage.

Oil is dirty Oil contaminated with water Faulty component Faulty probe setting Electrical interference

Erratic signal or includes line frequency

Faulty Vibration Instrumentati on

Visual check of oil Oil sample analysis Check gap setting Swap leads Check power supply to transmitters Look for source of external interference such as contacts, cell phones, etc.

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1X, 3X

Rotor run-out, HERO

Vibration increases when load compressor, or signal may show side-bands about gear mesh frequency, or vibration may change as ambient/oil temperatures change Varies, but often vibration changes as compressor is loaded or unloaded High subsynchronous vibration

Faulty Gearcase Bores, Rotors, Gears, etc.

mechanical run-out of the pinion journal Electrical run-out of the pinion journal Polygon distorts journal in 3lobe shape Assembly Errors, Alignment, etc. Faulty Gearcase Bores, Rotors, Gears, etc.

Slow roll vibration measurement Vibration measurements during coastdown

Wrong Bearing

Wrong Bearing Installed

Spectra test, unloaded, loaded, at surge, and during coastdown.

Bearing Instability

Oil too hot, wrong viscosity Stage is too lightly loaded Bearing bore is oversized 1. Loose, bent, distorted rotor

High supersynchronous vibration, 3X etc.

Loose, bent, distorted rotor

Spectra test, unloaded, loaded, at surge, and during coastdown Spectra test, unloaded, loaded, at surge, and during coastdown

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Random frequencies, or 1X

Gear Mesh Errors

Damaged or worn pinion tooth Damaged or worn bullgear tooth

Casing accelerometer measurements Spectra test, unloaded, loaded, at surge, and during coastdown

1X, 3X, or 4X

Bearing Varnish

Incorrect or contaminated oil Operating temperature is too hot Bearing undersized

Varies

1X, 2X of motor speed

Premature Starter Transition Gear/motor misalignment

Coupling locked, not lubricated, damaged Motor incorrectly aligned

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Appendix C Component Damage Assessment

Plain Bearing - Stage______ Part # ____________ Serial # ____________

Damaged Area (Describe)

Yes Pads Damaged Frosted Excess varnish Wear/Rub Babbitt Flow/Melted Scratched Severity of Damage Number of pads Affected

No Profile to Spec. Minimum Bore to Spec. Shell OD to Spec. Oil Porting to Spec. Oil Drain to Spec. Bearing Orientation OK.

Yes

No

None

Minor, Reusable

Substantial

Severe, Destroyed

% Area Affected on Worst Pad

Thrust Bearing - Stage______ Part # ____________ Serial # ____________

Damaged Area (Describe)

Yes Pads Damaged Frosted Excess varnish Wear/Rub Babbitt Flow/Melted Scratched Severity of Damage Number of pads Affected

No Profile to Spec. Minimum Bore to Spec. Shell O.D. to Spec. Oil Porting to Spec. Oil Drain to Spec. Bearing Orientation OK.

Yes

No

None

Minor, Reusable

Substantial

Severe, Destroyed

% Area Affected on Worst Pad

Rotor Assembly - Stage______ Part # ____________ Serial # ____________

Yes Rotor Bolt Tight To Washer? Rotor Bolt Fractured/Bent? Nose Washer fretting/Galling? Nose Washer Square in Counterbore? No Nose Washer Tight in Counterbore? Nose-Piece Tight in Counterbore? Galling/Fretting on Pinion/Impeller Interface? Other Damage to Nose or Washer? Yes No

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Active Thrust Bearing - Stage_____ Part # __________ Serial # __________

Damaged Area (Describe)

Yes Pads Damaged Frosted Excess varnish Wear/Rub Severity of Damage Number of pads affected

No Babbitt Flow/Melted Scratched Babbitt Separated Pocket Dam Damaged

Yes

No

None

Minor, Reusable

Substantial

Severe, Destroyed

% Area Affected on Worst Pad

Inactive Thrust Bearing - Stage_____ Part # __________ Serial # _________

Damaged Area (Describe)

Yes Pads Damaged Frosted Excess varnish Wear/Rub Severity of Damage Number of pads affected

No Babbitt Flow/Melted Scratched Babbitt Separated Pocket Dam Damaged

Yes

No

None

Minor, Reusable

Substantial

Severe, Destroyed

% Area Affected on Worst Pad

Pinion - Stage______ Part # ____________ Serial # ____________

Area of Damage Gear Teeth Plain Bearing Area Thrust Journal Area Probe Area Seal Area Shaft Bent ?, Describe Quantify % Tooth Contact Normal Tooth Contact, Wear Type of Damage Severity of Damage

Abnormal, End loaded

Abnormal, Tip or Root Loaded

Uniform, Excessive

Bullgear - Part # ______________ Serial # ______________

Area of Damage Gear Teeth Plain Bearing Area Thrust Journal Area Seal Area Shaft Bent ?, Describe Quantify % Tooth Contact Normal Tooth Contact, Wear Type of Damage Severity of Damage

Abnormal, End loaded

Abnormal, Tip or Root Loaded

Uniform, Excessive

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Thrust Bolt - Stage______ Part # _____________ Serial # ______________

Yes Tight in Washer? Fractured or Bent? Fretting or Galling at Thrust Washer? No Tight in Counterbore ? Fretting or Galling at Thrust Washer? Other Damage To or By Thrust Bolt ? Yes No

Impeller/Pinion Attachment Stage ________

Yes Impeller Plug fretting/galling ? Impeller/Pinion face galling of fretting ? Pinion Bore Fretting or galling ? Pinion Face fretting or galling ? Pinion thrust end face, fretting or galling ? Pinion thrust end plug fretting or galling ? Thrust collar bore fretting or galling ? Thrust collar face fretting or galling ? No Severity of Damage ? Lobes/Area Affected ?

Impeller - Stage______ Part # ______________ Serial # ______________

Yes Blade contact in Exducer area? Blades bent or missing ? Blade contact in Inducer area? Attachment area damage? Foreign object damage? Dirt build up? Thrust collar bore fretting or galling? Thrust collar face fretting or galling? No Severity of Damage etc. Location of Damage, etc.

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Diffuser - Stage______ Part # ______________ Serial # ______________

Yes Blade contact in Exducer area? Blade contact in Inducer area? Diffuser vanes loose or bent? Diffuser vanes missing? Dirt or other substance build up? ? Water carry over evidence? Foreign object damage? No Severity of Damage ? Location of Damage, etc.

Seals - Stage______ Part # ______________ Serial # ______________ Yes No Yes Air Oil
Rubs? Carbons Float? Dirt Build Up? Other Damage? Rubs? Carbons Float? Dirt Build Up? Other Damage?

No

Air Coolers - Stage______ Part # ______________ Serial # ______________

Yes Water Leaks? Excessive Fouling? No Erosion on Water Side? Erosion, etc. on Air Side? Yes No

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