Você está na página 1de 30

Application &

Installation Guide

Vibration

LEBW4972-04

Caterpillar: Confidential Green 
Caterpillar: Confidential Green 
Contents

Vibration ..................................................................... 1 
Basic Theory .............................................................. 2 
Linear Vibration Definitions ......................................... 2 
Frequency .......................................................... 3 
Displacement ...................................................... 3 
Velocity ............................................................. 3 
Acceleration ....................................................... 4 
Vibration Identification ................................................. 6 
Vibration Measurement .............................................. 6 
Order of Vibration .................................................... 8 
Vibration Level Guidelines .......................................... 9 
Vibration Causes and Corrective Actions ............................ 11 
Causes ................................................................. 11 
Corrective Actions ................................................... 11 
One Component .................................................. 11 
1/2 Order Vibration .............................................. 11 
1st Order Vibration .............................................. 11 
2nd Order Vibration ............................................. 11 
Higher Order Vibration .......................................... 11 
Non-Engine Vibration ............................................ 11 
Excessive Engine Motion ............................................ 12 
Misalignment/Unbalance........................................ 12 
Resonance ......................................................... 13 
Torque Reaction .................................................. 13 

Caterpillar: Confidential Green 
Balance Procedure Overview .......................................... 14 
General Balance Procedure ........................................ 15 
Rotor Alignment Balance Procedure .............................. 15 
Mass Balance Procedure ............................................ 16 
Torsional Vibration...................................................... 17 
Torsional Vibration Analysis ........................................ 18 
Required Data ........................................................ 19 
Driveline Design...................................................... 20 
Reference Material ..................................................... 22 
Media List ............................................................. 22 
Engine/Driven Equipment Vibration Measurement Data Sheet
......................................................................... 23 

Caterpillar: Confidential Green 
Foreword
This section of the Application and Installation Guide generally describes
Vibration, its causes and suggested corrections for Cat® engines listed on the
cover of this section. Additional engine systems, components and dynamics are
addressed in other sections of this Application and Installation Guide.
Engine-specific information and data are available from a variety of sources.
Refer to the Introduction section of this guide for additional references.
Systems and components described in this guide may not be available
or applicable for every engine.

Information contained in this publication may be considered confidential.


Discretion is recommended when distributing. Materials and specifications are
subject to change without notice.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the Power
Edge trade dress, as well as corporate and product identity used herein, are
trademarks of Caterpillar and may not be used without permission.

Caterpillar: Confidential Green 
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

Vibration
All mechanical systems with mass and elasticity are capable of relative
motion. If this motion repeats itself over a given time period, it is known as
linear vibration. Engines produce linear vibration due to combustion forces,
torque reactions and structural mass and stiffness combinations and
manufacturing tolerances on rotating components. All these forces may create
conditions ranging from unwanted noise to high stress levels, and possible
failure of the engine or driven components. Torsional vibration can create
similar conditions but is caused by the twisting and untwisting of a shaft.
This guide:
 Reviews the basic theory and nomenclature of linear vibration.
 Identifies causes of engine-related linear vibration.
 Provides instruction for possible corrective action.
 Reviews the basics of torsional vibrations, including an understanding
of causes and approaches to addressing them.
 Describes torsional vibration analysis (TVA), its importance, and
information required to complete a TVA.

SECTION CONTENTS

Basic Theory ..................... 2  Corrective Actions


 Linear Vibration Definitions  Excessive Engine Motion
Vibration Identification ........ 6  Balance Procedure
 Vibration Measurement Reference Material ............ 21
 Order of Vibration  Media List
 Vibration Level Guidelines  Vibration Measurement
Vibration Causes and Data Sheet
Corrective Actions ............ 10
 Causes

© 2018 Caterpillar
All rights reserved. Page 1
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Basic Theory
Engine vibrations are produced housed in a building or close to
and maintained by regular, periodic sensitive instruments or equipment,
driving forces set up by unbalanced such as computers.
moving masses. These are called Other factors influencing vibration
forced vibrations. are foundation design, soil load
Free vibrations have no driving characteristics, and other machinery
force. When set in motion, such operating in close proximity.
vibrations, if undamped, would
continue indefinitely with constant Linear Vibration Definitions
amplitude and natural frequency. Linear vibration occurs as a mass is
deflected and returned along the
If the frequency of a forced same path. This can be illustrated as
vibration is the same as the natural a single mass spring system as shown
frequency of a free vibration, then in Figure 1. While no external force is
excessive vibration will result. This imposed on the system, the weight
synchronization of forced and free remains at rest and there is no
vibration is called resonance. vibration. When the weight is moved
Resonance stresses can cause or displaced and then released,
serious problems and even reach vibration occurs. The weight travels
destructive levels. up and down through its original
position until frictional forces cause it
The vibration generated by the
to rest.
engine could also result in structural
damage if a rigid installation was

Mass Spring System

Figure 1

© 2018 Caterpillar
Page 2 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

Frequency of dynamic stresses and are most


commonly used.
Refer to Figure 2 for an illustration
of the following definitions. Maximum Displacement
displacement from the mean position The total distance traveled by
is called amplitude. The interval in the weight, from one peak to the
which the motion is repeated is called opposite peak, is peak-to-peak
the cycle. The time required for the displacement, as shown in Figure 2.
weight to complete one cycle is This measurement is expressed in mm
called a period. rms when using metric system of
If the weight needs one second units, or when using imperial units, in
to complete a cycle, the vibration mils peak to peak (p-p), one mil
frequency is one cycle per second equaling one-thousandth of an inch
(cps) or 1 Hz. [0.025 mm (0.001 in.)]. It is
a unit of vibration severity.
If one minute, hour or day were
required, its frequency would be Average and root-mean-square
one cycle per minute, hour or day, (rms) are sometimes used to measure
respectively. A system completing its vibration (rms = 0.707 times the peak
full motion 20 times in one minute of vibration.) These terms are
would have a frequency of 20 cycles referred to in theoretical discussions,
per minute, or 20 cpm. and it is very important to use correct
units when comparing measurements
Establishing frequency is necessary to standards and published limits.
when analyzing vibration. It allows
identification of the engine Velocity
component or condition causing Another method to analyze
the vibration. vibration is measuring mass velocity.
Note that the weight depicted in
Machinery vibration is complex and
Figure 1 and Figure 2 is not only
consists of many frequencies.
moving, but changing direction.
Displacement, velocity and
The speed of the weight is also
acceleration are all used to diagnose
constantly changing. At its limit,
particular problems. Displacement
the speed is zero. Its speed or
measurements are better indicators
velocity is greatest while passing
through the neutral position.

© 2018 Caterpillar
All rights reserved. Page 3
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

One Period

Figure 2

Velocity is an extremely important D= Peak-to-peak displacement,


characteristic of vibration; but in mils. 1 mil (0.001 in.).
because of its changing nature, F= Frequency in cycles-per-
a single point is commonly chosen for minute (cpm).
measurement. This is peak velocity
and normally expressed in inches per
Note that this formula is applicable
second for measurements in imperial
for imperial units only.
units. For measurements in metric
units, it is expressed in mm/second
rms. Acceleration
Velocity is a direct measure of Acceleration is another
vibration and provides the best characteristic of vibration. It is the
overall indicator of machinery rate of velocity change. In Figure 2,
condition. It does not, however, note that peak acceleration is at
reflect the effect of vibration on the extreme limit of travel where
brittle material. velocity is zero. As velocity increases,
acceleration decreases until it
The relationship between peak reaches zero at the neutral point.
velocity and peak-to-peak
Acceleration is dimensioned in units
displacement is compared by:
of “g” (peak) or (mm/s² rms for
Vpeak = 52.3 x D x F x 10-6 metric measurements) where “g”
equals the force of gravity at the
Where: earth’s surface:
Vpeak = Vibration velocity in inches (9.8 m/s2 = 386 in./s2 = 32.3 ft/s2)
per second peak.

© 2018 Caterpillar
Page 4 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

Acceleration measurements, or
“g’s”, are used where relatively large
forces are encountered. At very high
frequencies (60,000 cpm or 1000 Hz),
it is perhaps the best indicator of
vibration.

Vibration acceleration can be


calculated from peak displacement:
When using imperial units:
gpeak = 1.42 x D x F2 x 10-8
Note that overall, or total peak-
to-peak displacement, shown in
Figure 3, is approximately the sum of
individual vibrations. Figure 3

© 2018 Caterpillar
All rights reserved. Page 5
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Vibration Identification
If excessive linear vibration motion horizontal directions at each bearing
is present or suspected, an initial location, and in an axial direction at
inspection should be performed to the rear face of each major piece of
confirm that: equipment. For example, an engine
 Engine, coupling and driven driving a two bearing generator set
equipment mounting bolts are will require measurements at ten
properly torqued, and that all jacking points, two at each bearing and two
bolts and set screws are backed off. in an axial direction, as illustrated in
Figure 4.
 Engine, coupling and driven
equipment are properly aligned. Engine only applications and other
types of packaged units may require
 All external piping is properly isolated fewer measurement points, but the
from the engine and driven following descriptions and graphic in
equipment with appropriate flexible Figure 4 still apply.
couplings.
Marine propulsion applications will
 All vibration isolators are properly also require a measurement in the
adjusted, all springs (if equipped) are vertical direction at the right rear
compressed the same amount, and engine mounting foot. This is required
none are fully compressed (closed). to check for rolling of the engine. The
If the initial inspection results do measurement is taken
not identify the problem, then at the point where the engine is
vibration measurements should be anchored by means of a fitted bolt.
made to determine the source prior Vibration measurements must be
to starting corrective action. The made at the advertised driven
Cat® vibration tool provides reports equipment rating (100% load). If
listing overall vibration levels and additional data is desired, it is
individual order values up to 10th recommended that measurements
order. As an alternative, the be made at 0% load, 50% load, 75%
Vibration Measurement Data Sheet, at load and, depending on the rating,
the end of this guide, is provided for 110% load.
convenient recording of raw data at
various engine speed and load For generator set applications,
conditions. This form can be used for if measurements are taken while a
the basic engine as well as any generator is loaded, the magnetic
packaged unit, including one or two field of the generator leads must be
bearing generator sets, marine avoided. In addition, if the generator
propulsion engine/reduction gear rotor failure is suspected, two sets of
sets, and pump or compressor measurements should be made at the
packages. 0% load condition for generator set
applications; one with the exciter
Vibration Measurement turned “on” and one with the exciter
At a minimum, vibration should be turned “off.”
measured in both vertical and

© 2018 Caterpillar
Page 6 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

Cat Vibration Measurement Points

Figure 4

*Note: Use ISO8528-9 for ISO measurement locations (REHS3679)

Point 1 – EFV (Engine Front Vert.) Point 5 – ERA (Engine Rear Axial)
Vertical direction at the front of the Axial direction at the rear of the
engine; locate the probe on the block engine; locate the probe on the right
top deck in the plane of the rear outside edge of the block at the
crankshaft centerline. crankshaft centerline.

Point 2 – EFH (Engine Front Hor.) Point 6 – XFV (Driven Front Vert.)
Horizontal direction at the front of Vertical direction at the driven
the engine; locate the probe on the equipment front bearing; locate the
side of the block at the crankshaft probe on the bearing housing at the
centerline. shaft centerline.

Point 3 – ERV (Engine Rear Vert.) Point 7 – XFH (Driven Front Hor.)
Vertical direction at the rear of Horizontal direction at the driven
the engine; locate the probe on the equipment front bearing; locate the
block top deck (or rear housing) in probe on the side of the bearing
the plane of the crankshaft housing at the shaft centerline.
centerline.
Point 8 – XRV (Driven Rear Vert.)
Point 4 – ERH (Engine Rear Hor.) Vertical direction at the driven
Horizontal direction at the rear of equipment rear bearing; locate the
the engine; locate the probe on the probe on the bearing housing at the
side of the block at the crankshaft shaft centerline.
centerline.

© 2018 Caterpillar
All rights reserved. Page 7
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Point 9 – XRH (Driven Rear Hor.) hertz range, with energy presented in
Horizontal direction at the driven ½ order intervals.
equipment rear bearing; locate the
probe on the side of the bearing Order of Vibration
housing at the shaft centerline. In discussions of vibration, the
frequency of the motion is commonly
Point 10 – XRA (Driven Rear Axial) referred to in terms of order of
Axial direction at the driven vibration. In an engine, the order of
equipment rear; locate the probe on vibration is the number of vibratory
the right rear outside edge of the cycles exhibited by a component
driven equipment structure (not sheet during one revolution
metal) at the shaft centerline. of the crankshaft.
Point 11* - ERR (Engine Rear Rot.) One-Half Order is one occurrence
Vertical direction at the right rear every two crankshaft revolutions.
engine mounting foot. First Order is one occurrence per
* - marine applications only, when crankshaft revolution.
engine is anchored with fitted bolt. Second Order is two occurrences
ISO 8528-9 per crankshaft revolution.
The International Standard (ISO Higher Order describes occurrences
8528-9) can also be referenced as at 1½, 2½ or more crankshaft
guidance for vibration measurement. revolutions.
The ISO Standard recommends
measurements to be taken in vertical, Vibration Frequency (cpm)
Order=
horizontal, and axial directions for all Engine Speed (rpm)
measurement locations. The ISO
standard does not specify that data Overall vibration motion is the
for all three directions be taken vector sum of the motion of all the
simultaneously, but if a vibration tool orders.
with this capability is available to do Data should be reported in terms of
this, it is reasonable to conclude that peak-to-peak displacement (mils pk-
approach would be preferred. The pk or mm rms) at half order
same can also be said for taken data frequencies, whole order frequencies,
in all three directions, for all points, as well as overall displacement (mils
simultaneously. In factory or mm rms), overall velocity level
development and troubleshooting of (in/s peak or mm/s rms) and if
significant issues, a vibration tool required overall acceleration (in/s² or
with this degree of capability is the mm/s²) for each of the measuring
typical method for vibration testing. locations. The data sheet at the end
The ISO standard also references data of this guide can be used to record
to be taken across a frequency range and report the measured vibration
of 2-1000 hertz. data.
Note: The Caterpillar standard All measurements must be made on
compiles vibration data in the 2-300 the main rigid structural members of
the engine and driven equipment.

© 2018 Caterpillar
Page 8 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

The instrument pickups must be The overall peak value can be


positioned on the previously defined divided by square root of 2 to obtain
locations. the overall rms.
For reasons of consistency, and Some machines driven by engines
comparison with factory development are connected through gear boxes and
vibration data, it is recommended that will operate at a different rpm than
vibration measurements be taken using the engine. Although the tool setup
a Caterpillar Vibration Analyzer, part information described above is for
number 469-1620. concentration of data to be based on
If Caterpillar measuring equipment is single and half order integers, in
not available, an equivalent device order to capture vibration at even
capable of measuring vibration at increments for the engine and the
selected frequencies, and capable of load, the tool may need to be
compiling overall velocity and overall adjusted for analysis at smaller orders
displacement should be used. such as 1/8 or 1/12 orders.
If an alternate tool is used, due to Vibration Level Guidelines
the difference in algorithm that tools
The following vibration level
use to compile data (such as summing
guidelines are used for assessing the
and averaging of different order
vibration severity of the core engine
intervals), it is important to
or package installation.
understand that the data results may
or may not be comparable to factory Attachments to the engine or
data, and vibration limit guidelines package installation typically raise
provided later in this document may vibration values and are not
not be applicable. included in these guidelines.
The following information regarding The vibration levels for any load
how the Caterpillar Vibration Analyzer condition, at any of the measuring
compiles data is provided as a guide to locations, must not exceed the
set up an alternate tool so that it can guidelines shown in Table 1 on the
more closely produce data comparable next page.
to what would be produced by the These guidelines apply to both gas
Caterpillar Vibration Analyzer. and diesel engine packages installed
Conversion of the time sampled data with or without isolation mounts. If
to the frequency domain is completed linear vibration is higher than these
by performing a Fast Fourier Transform guidelines, refer to the Vibration
(FFT). Causes and Corrective Actions
section in this guide.
The overall acceleration, velocity,
and displacement results are Consult the manufacturer of the
determined by calculating the square driven equipment for any such
root of the sum of the squares of each vibration guidelines.
spectral line, at only ½ and whole A vibration worksheet is provided at
integer orders up to 300Hz the end of this guide.
(or 1000Hz for the ISO method).

© 2018 Caterpillar
All rights reserved. Page 9
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Overall Overall Overall Individual


Displacement Velocity Acceleration Orders
Measurement
Location mils p-p mm rms in/s pk mm/s rms g's pk m/s2 rms mils p-p mm rms
Cat Limits
Genset 8.5 0.08 1.35 24.2 N/A N/A 5 0.05
ISO8528-9 Limits
Engine Limits 80.3 0.72 2.5 45 4.04 28 N/A N/A
Gen Value 1 Limits 35.4 0.32 1.11 20 1.87 13 N/A N/A
Gen Value 2 Limits 50.4 0.45 1.56 28 2.6 18 N/A N/A
Table 1

1. Some retail generator set packages are developed to meet the ISO8528-9 level 2 vibration standard.
For more information, refer to REHS3679.
2. ISO8528-9 limits in the table above are applicable to gensets operating at 1300-2000rpm, rated above 200kW.
3. For other rpm and rating refer to the ISO8528-9.

© 2018 Caterpillar
Page 10 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

Vibration Causes and Corrective Actions


Causes Corrective Actions
Experience has shown that linear
vibration motion problems can be Individual Component
attributed to: If one component is the only item
with excessive motion, the
 Misalignment of engine and driven
component mounting will have to be
equipment.
altered until the motion is reduced to
 Unbalance of rotating parts.
an acceptable level at operating rpm.
 Resonance from structural mass
(weight) and stiffness (rigidity) 1/2 Order Vibration
combinations. When the vibration motion
 Torque reaction. measurements show that 1/2 order is
 Cylinder misfiring. causing the problem, the engine fuel
 Combustion forces. and governing system should
 Unbalance of reciprocating parts.
be serviced to eliminate engine
misfiring. No other work should be
 Isolator mis-application and mis-
adjustment
attempted until engine misfiring is
eliminated.
 Structure cracks or loose bolted
joints 1st Order Vibration
 Auxiliary components rigidly Refer to the Balance Procedure
attached to the machine in this guide.
 Shorted windings in poles of
2nd Order Vibration
electrical rotating machines
When excessive second order
vibration occurs on 4-cylinder and vee
The following table correlates 8 engines, the timing of the second
vibration characteristics to these order force balancers should be
possible causes: checked.
Vibration
Correctable Causes Higher Order Vibration
Characteristic
Other high order vibration levels
Individual component Mounting of component cannot be corrected with flywheel
1/2 x engine rpm Isolator adjustment or
(one-half order) misfiring of one or more balance weights or balancer timing.
cylinders Usually these orders involve the
1 x engine rpm Unbalance, structural characteristics of the
(first order) misalignment, out-of-
time balance weights,
generator and base which will need to
crankcase overfill be investigated.
2 x engine rpm Unbalance, out-of-time
(second order) balance weights Non-Engine Vibration
1 1/2, 2 1/2, third Normal cylinder and If the vibration motion involves non-
higher orders combustion (not
correctable)
engine mounted structures
Large vibration motion Resonance and the engine vibration motion is
Motion increases as load Torque reaction – acceptable, either the off-engine
is applied insecure mounting or
inadequate base
components must have their mounting

© 2018 Caterpillar
All rights reserved. Page 11
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

altered or proper vibration isolators


must be installed between the engine
or generator set and the structure.

Excessive Engine Motion


If the engine unit has excessive
motion, it will generally be due to
misalignment/unbalance, resonance
or torque reaction. However, if the
vibration motion for the first and Figure 5
second order still remain excessive
after examination and correction, the Misalignment/unbalanced vibration
engine should be removed from the motion is relatively constant over the
set and placed on suitable isolators. speed range, as shown in Figure 5,
Another condition that causes but exceeds accepted limits. For
excessive engine motion is rigid body generator set applications, this
mode. Due to sizing and selection of may be determined by operating
engine or package mounts, the engine between 45 Hz and 65 Hz.
and package will move as a rigid Misalignment/unbalanced vibration
body. This can only be corrected by motion is not changed by load.
changing the package mounts. If misalignment or unbalance is
If vibration is present, but the identified:
engine is within limits, a vibration  Check the alignment of the
specialist should be consulted. If the unit. Refer to Caterpillar
bare engine exceeds the limits, Special Instructions listed
engine components rotating at engine under Reference Material at
speed (first order) or twice engine the end of this section.
speed (second order) should be  If vibration is still excessive,
inspected. refer to the Balance Procedure
at the end of this section.
Misalignment/Unbalance
Most linear vibrations of generator  If vibration is still present after
sets or other packaged units are the balance procedure, mount
caused by misalignment or unbalance the unit on isolators and repeat
of the rotating members. This the balance procedure until a
typically results in first order satisfactory level of vibration is
vibration which can be corrected in obtained.
the field.

© 2018 Caterpillar
Page 12 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

Resonance  If vibration is still excessive,


Resonance occurs when a large refer to the Balance Procedure
vibration motion (amplitude) takes at the end of this section.
place within a narrow speed range, as  If vibration is still present after
shown in Figure 6. the balance procedure, mount
The vibration can occur on the the unit on isolators and
generator set and/or the attached recheck. If the unit is
equipment, such as piping and air satisfactory, the problem is
cleaners. When vibrations peak out in an improper mounting system
a narrow speed range, the vibrating which requires changing.
component is in resonance. Consult the proper specialist.
 Should the balance procedure
fail and the set has excessive
linear vibration motion when
installed on the proper
isolators, check for structural
damage or loose bolted joints,
and repeat the balance
procedure until the linear
vibration motion level is
satisfactory.
Figure 6
Torque Reaction
When the vibration motion increases
There are two methods of reducing
as load is applied, as shown in Figure
resonance vibration levels. These are:
7, torque reaction is the likely
 Changing the natural frequency problem. With a two-bearing
of the part that is resonant. generator, it can be caused by
 Reduction of the exciting insecure mounting of the engine or
force. generator to its base and/or by
a base not sufficiently rigid to
If the following checks show that
withstand the associated forces.
the cause of the problem is the
structure that the engine, generator
set, or other packaged unit is
mounted on, a vibration specialist or
mounting system specialist should be
consulted.
 Check the alignment of the
unit. Refer to Caterpillar
Special Instructions listed
under Reference Material at
the end of this section.
Figure 7

© 2018 Caterpillar
All rights reserved. Page 13
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Balance Procedure
Torque reaction problems are not
found with close-coupled generators. Overview
The rigid joint between the flywheel With a single bearing generator, the
housing and the generator body is front of the rotor is supported and
generally adequate to withstand located by the flywheel causing the
torque. orientation of any radial runout of the
Assuming that a free standing two- flywheel pilot at the time of
bearing generator is mounted on a generator installation to affect runout
weak base, in cases such as non- and misalignment of the generator
factory supplied base, first order rotor. There is sufficient clearance
motion and orders related to the within the flywheel pilot to allow the
number of cylinders firing with one rotor to change alignment by
crankshaft revolution are due to tightening up the coupling plate bolts
torque reaction which, in turn, causes with the flywheel oriented in
misalignment. In this case, the first different angular positions.
order motion would be most For a single bearing generator set, a
prevalent. balance procedure must address a
This condition is generally rotor runout or misalignment issue
encountered when the engine is and potentially address any mass
driving a conventional two-bearing unbalance as well. For a two-bearing
generator which is not close-coupled. generator set, the rotor is fully
Check the alignment of supported and located by the
the unit. generator with a flexible coupling
If the two-bearing generator set absorbing any misalignment with the
utilizes a structural steel base which flywheel. A balance procedure for a
is point-mounted, for example, pads two-bearing will focus on only the
and isolators, torque reaction can mass unbalances in the rotating
deflect the weak base. This deflection system.
can cause severe misalignment and For these reasons, there are 3
resulting vibration. balance procedures that follow. The
If the unit continues to exhibit first procedure works for most
vibration after alignment, the base is misalignment issues, but on single
likely not strong enough to hold the bearing generators this process
torque reaction and needs affects both the mass balance and
strengthening. rotor alignment simultaneously. The
ability to independently affect or
One method of strengthening is further affect just one of these root
to weld plates on top and bottom of causes is sometimes required. The
the base across the width of the base second procedure affects only the
from 6 in. forward of the rear engine rotor misalignment and is therefore
supports to 6 in. behind the generator only beneficial for single bearing
feet closest to the engine. generators. The last procedure
affects only the mass balance.

© 2018 Caterpillar
Page 14 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

General Balance Procedure Rotor Alignment Balance


The following balance procedure Procedure
can be applied to help improve first The following correction procedure
order vibration for single or two- can be applied to single bearing
bearing generator sets: generator sets to affect only the rotor
 For consistency, make a chalk alignment.
mark or scribe across the  If the preceding general
flywheel and coupling at the balance procedure was done
top, or 0º, to provide an easy first, arrange the coupling and
reference during the balancing flywheel in the orientation
procedure. resulting in the least vibration.
 Remove the bolts holding the  For consistency, make a chalk
generator coupling to flywheel. mark or scribe across the
Bar engine 90° clockwise while flywheel and coupling at the
generator rotor and coupling top, or 0º, to provide an easy
remain with reference mark reference during the balancing
located at the top, or 0º. procedure.
Engines with only 6 coupling
 Loosen bolts holding the
bolts will have to be rotated
generator coupling to flywheel
only 60º. Replace coupling
so that the washers spin free.
bolts and retest for vibration.
For this procedure, the
 If vibration remains, again generator will never be
position coupling reference completely decoupled from the
mark at the top and hold it engine.
while indexing engine another
 Bar the engine and generator
60º or 90° clockwise and
90º clockwise and retighten
retest.
coupling bolts. Retest for
 If necessary, repeat the vibration.
previous step as necessary by
 If vibration remains, bar the
rotating the engine another 60º
engine to orient the flywheel
or 90° clockwise while keeping
reference mark at the 90º
the coupling mark at the top
position. Loosen coupling
until the flywheel has been
bolts, bar engine another 90°
tested across all 360º.
clockwise (total 180°),
 For single bearing generator retighten bolts, and retest.
sets, the entire procedure can
 Repeat the previous step as
be repeated if necessary with
necessary in 90º increments
the coupling (flex plates)
retightening the bolts with the
reference mark oriented at the
flywheel reference mark at
bottom instead of the top to
270º and if necessary 360º.
adjust for any runout in the
flex plates or rotor.

© 2018 Caterpillar
All rights reserved. Page 15
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Mass Balance Procedure  Observe vibration level and


The following corrective procedure relocate weight in 90° or 120°
can be applied to single or two- increments to identify where
bearing generator sets to affect only minimum vibration occurs.
the mass balance of the system. It is  If necessary further testing can
normally completed after the occur at the intermediate bolts
previous procedures were between the two bolt locations
unsuccessful. that resulted in the least
 Orient the coupling assembly vibration.
relative to flywheel where the  Add additional weight at the
least amount of vibration point of minimum vibration
occurred. identified in the previous steps
 Add weight of 56.70 g (2 oz) until vibration level is no
under any single coupling to longer diminished. In no case
flywheel bolt. Flat washers can should more than 141.75 g (5
be used for this purpose. Bolt oz) be added under any one
must be sufficiently long to bolt.
maintain at least 1 1/4 times
the bolt diameter of thread If vibration levels are still
engagement. unacceptable, a vibration control
specialist should be consulted.

© 2018 Caterpillar
Page 16 All rights reserved.
Caterpillar: Confidential Green 
Vibration Application and Installation Guide

contributed by the torsional


Torsional Vibration vibration sources match the natural
Torsional vibration refers to frequency any of the components in
irregularities in the speed of the system, a resonance will occur.
rotation in a shafting system. Any shaft rotating with a mass
In the context of engine-driven attached at each end may
systems, the shafting system is experience torsional vibration. The
referred to as the “driveline” and simplified drive train in Figure 32
formally includes all of the sub- illustrates the torsional system
systems directly connected to the formed by the piston, connecting
crankshaft, both internal to the rod, and crankshaft within a
engine and external. Torsional reciprocating engine. Even without
vibrations appear in the driveline combustion impulses, the forces
as a result of engine combustion generated by inertia as the piston
impulses, reciprocating motion of and connecting rod change direction
the pistons and connecting rods, at each end of the stroke are
and from the operating enough to cause variations in the
characteristics of the driven torque measured in the crankshaft.
equipment, such as a generator,
propeller, pump, or compressor.
Even gear-driven equipment such as
coolant pumps or other auxiliary
components can contribute to the
overall dynamic behavior of the
driveline.
Torsional vibrations may be
understood as the rotational
equivalent of linear vibrations, and
in a similar manner many of the
dynamic concerns that we must
address for linear vibration apply
for torsional vibrations. A driveline
is designed for transmitting the
torque that the engine delivers to
the driven equipment, but it must A systematic study of the entire
also be capable of withstanding the system is required to determine if
oscillating energies of torsional resonances are present in a given
vibrations without damage. The driveline design, and whether those
dimensional design of each of the resonances pose a risk of causing
components in the driveline failure of a particular driveline
contributes torsional characteristics component. This study is called a
to the driveline, which functions as torsional vibration analysis or TVA.
a dynamic system with its own
fundamental characteristics and
natural frequencies. If the
frequency of the excitations

© 2018 Caterpillar
All rights reserved. Page 17
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Torsional Vibration Analysis The goal of a TVA is to determine


The starting point for a torsional whether a driveline design is at risk
vibration analysis (TVA) is a of a resonance when at the
thorough accounting of the driveline intended operating speed and load
system and its torsional inputs points. If the operating speed
during normal operation. The matches the resonant speed,
analysis requires consideration of portions of the driveline can
both the physical dimensions of the become excited, with torque
driveline components and the amplitudes reaching many times
characteristics of the torsional their levels in the non-excited
inputs at the expected operating state. Because the resonant torques
conditions in terms of rotational are cyclic, they result in rotational
speed and torque. flexing of the system that, if left
unchecked, can result in a fatigue-
To understand this, consider inside related failure.
the engine how combustion
interacts with the piston and A torsional-related failure of a
crankshaft. Just as the pressure major component, such as the
exerted on the piston by the burning engine’s crankshaft, can be very
fuel and air becomes torque in the costly, both in terms of cost to
crankshaft, the impulse of the repair and revenue lost while the
burning air/fuel charge on the unit is out of service. By
piston is translated into a rotational comparison, the cost of completing
irregularity at the crankshaft. Both a TVA in the design phase is much
the steady torque and the rotational less. As a best practice, Caterpillar
irregularity contributed by the requires the completion of a TVA for
burning fuel/air charge are affected new driveline designs and for
by changes in the rotational speed applications using an existing
and the resistance to motion the driveline layout under new
driven equipment (torque load). load/speed conditions. As stated
That change in burning above, the goal of the TVA is to
characteristics is experienced by ensure the resonant points do not
the crankshaft as a change in the occur at the expected operating
torsional input from the cylinders. conditions.
Changes in the operation of the Since compatibility of the
driven equipment also alter the installation is the system designer’s
torsional input experienced by the responsibility, it is also their
crankshaft, making each driveline responsibility to obtain the TVA.
unique. One driveline design may Caterpillar offers TVA services in
produce very different TVA results many engine price lists, and our TVA
when evaluated at different loads experience is tied to the
and/or speeds. computational methods used by our
TVA provider. TVA services are also
available through many third party

© 2018 Caterpillar
Page 18 All rights reserved.
Vibration Application and Installation Guide

firms. However, our unfamiliarity such as the rotational inertia


with the methods used by those and torsional rigidity of the
other firms makes it difficult for component. Major
Caterpillar to clearly assess the components (such as engines
acceptability of a given driveline- and compressors) are
and-application design from their comprised of many internal
results. parts that must be
For challenging driveline represented individually and
configurations, Caterpillar reserves in the proper physical
the right to require a TVA location relative to one
completed by our provider to ensure another to fully describe
a consistent interpretation of the their mass-elastic systems.
results. If you have any questions  A description of the harmonic
about the acceptability of a inputs contributed by the
proposed driveline design, please component. In the case of an
contact Caterpillar to determine engine or reciprocating
how best to evaluate the risks compressor the relative
involved. timing (“phase angles”) of
the torsional inputs from
Required Data each individual cylinder must
Because the TVA seeks to model also be provided.
the dynamic behavior of the entire  For driven equipment that
driveline, the data required to can vary in load demand on
complete the analysis is extensive, the engine, a load demand
touching on virtually all the curve is required.
driveline-connected components.
The specific data required will vary
with the driveline design and Each TVA provider should be able
application, but in general certain to provide a detailed listing of the
details are common to all TVAs: information they will need to
complete their analysis. Providing
 A general arrangement all of the required information up
drawing or sketch. This front is the first step toward
provides an understanding of receiving the completed analysis in
the relative location of each a timely manner.
piece of equipment and type
of connection between them. Consult the manufacturer for their
torsional information on each major
 A detailed listing of the component. Caterpillar offers
rotational characteristics of documentation summarizing the
each of the driveline mass-elastic and combustion
components. This describes in impulse harmonic information for
detail the mass-elastic each of their engine models. Data
characteristics of the on the driven equipment should be
rotational portion of the evaluated for the speed-load points
component. Mass-elastic at which the driveline is expected
characteristics are details

© 2018 Caterpillar
All rights reserved. Page 19
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

to operate. Manufacturers of represent a critical tool in


complex driven equipment (such as manipulating the torsional response
reciprocating compressors) may of a driveline system. One critical
offer software tools to assist in finding of a TVA is whether the
compiling this application-specific torsional damper can dissipate all of
data. the energy it absorbs from the
driveline during operation. If the
Driveline Design input energy level exceeds the
Changes in the design of the dissipation capability of the
components in the driveline can damper, it may fail leaving the
have a significant impact on the driveline susceptible to further
torsional performance of the damage if it is not addressed
system. Even if resonance concerns quickly.
are revealed in a TVA, it is often Coupling – While often considered
possible to tune frequency response a simple “connector” between the
of the driveline by changing a key engine and driven equipment, the
component. Here are a few of the coupling forms a critical part of the
key components that are often driveline torsional solution.
manipulated to improve the Coupling designs vary depending on
torsional response of a driveline the requirements of the application.
system. Generator sets often use compliant
Flywheel – The flywheel is a couplings that place elastomeric
rotating mass that contributes material between the engine and
inertia to the system. Simply put, driven equipment. This provides an
rotational inertia is a resistance to internal damping that is well
changes in rotating speed. The matched to the low torsional
engine incorporates a flywheel to operating characteristics of a
help smooth out the rotational generator. A reciprocating
variations that occur from one compressor contributes much higher
cylinder firing to the next. The torsional energies into the driveline,
engine’s flywheel is typically typically in excess of the limits of
located at the rear, which usually an elastomeric coupling. Engine
places it between the engine and driven reciprocating compressors
the driven equipment. This location typically use torsionally rigid
is strategic, as the flywheel’s inertia couplings, using metal flex plates to
help to isolate the engine’s internal limit the torsional compliance of
torsional variations from those the coupling. The higher rotating
originating outside the engine. mass of this arrangement does,
however, interact with the system
Torsional Damper – Torsional
as a small flywheel, helping to
dampers may be viewed as
manage torsional energy by resisting
rotational shock absorbers. Inside
the variations in rotational speed.
the typical torsional damper is a
system designed to dissipate As stated above, the engine is
torsional vibration energy as heat. designed with components intended
By accomplishing this, they to help keep the natural frequency

© 2018 Caterpillar
Page 20 All rights reserved.
Vibration Application and Installation Guide

of the system away from the energies from that load. A large
designed operating speed. The front-driven load is an important
engine’s rear-mounted flywheel and case where seeking expert advice is
front-mounted torsional dampers critical to achieving an acceptable
are located for best performance outcome. As stated earlier, if you
with a rear-driven load. If it have any questions about the
becomes necessary to drive the load acceptability of a proposed
from the front of the engine, the driveline design, please contact
damper and flywheel become poorly Caterpillar to determine how best
located to help manage torsional to evaluate the risks involved.

© 2018 Caterpillar
All rights reserved. Page 21
Caterpillar: Confidential Green 
Application and Installation Guide Vibration

Reference Material
Media List
The following information is
provided as an additional reference to
subjects discussed in this manual.
SEHS7654: Special Instruction –
Alignment – General Instructions
REHS0423: Special Instruction –
Alignment of Two-Bearing
Generators
REHS0177: Special Instruction –
Alignment of Close Coupled Two-
Bearing Generators
NENG2500: Tool and Shop Product
Guide
LEKQ4023: Linear Vibration
REHS3679: Procedure for Vibration
Measurements on Electric Power
Generator Sets
SEHS7259: Alignment of Single-
Bearing Generators
SEHS7073: Special Instructions
Alignment of Two-Bearing
Generators

© 2018 Caterpillar
Page 22 All rights reserved.
Engine/Driven Equipment Vibration Measurement Data Sheet
Engine/Driven Equipment Description: _____________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
Rating: _______________________________________________________________
Rated Speed: __________________________________________________________
Load Condition: ________________________________________________________

1/2 Order 1st Order Overall Overall Velocity


Location Displacement Displacement Displacement (in/sec or
(mils or mm rms) (mils or mm rms) (mils or mm rms) mm/sec)
Point 1 - EFV
Point 2 - EFH
Point 3 - ERV
Point 4 - ERH
Point 5 - ERA
Point 6 - XFV
Point 7 - XFH
Point 8 - XRV
Point 9 - XRH
Point 10 - XRA
Point 11 – ERR*
* Marine Applications Only, when engine is anchored with fitted bolt.
** Additional orders are useful for more thorough vibration evaluation.

© 2018 Caterpillar
All rights reserved. Page 23
Caterpillar: Confidential Green 
www.cat.com/power-systems

LEBW4972‐04 (07‐18) 
®
©2018 Caterpillar. All rights reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow”, and the “Power Edge” 
trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.     
   

Você também pode gostar