FIELD ANALYSIS AND BALANCING TOOLS

Dennis H. Shreve
IRD® Balancing
651-A Lakeview Plaza Blvd.
Worthington, Ohio 43085

Abstract

Considering the economic pressures today for minimizing production downtime and
improving operating efficiency, there is increased emphasis for on-site problem detection,
analysis, and resolution being accomplished as fast as possible. This set of requirements
places a great deal of pressure on maintenance personnel for having all the right tools in one
place, at one time, and having them readily available in a single, compact, and easy-to-use
package.

Over the last several decades, we have experienced an evolution of having portable
instrumentation that could read the data (detection), to sophisticated host-based software that
could determine root-cause (analysis), to yet more equipment that could offer the problem
solution (correction). The level of sophistication in hand-held electronic devices today,
coupled with our experiences and successes in predictive maintenance, allow for all three
functions (detection, analysis, and correction) to be integrated into a single, compact, easy-to-
use package.

This paper first examines the needs for the basic set of tools for machine condition
monitoring applications, including a look at the key elements of detection, analysis, and
correction. It then examines the requirements for tools in each area, and proposes a solution
on how they can be combined in one palm-sized instrument and portable toolkit for
maintenance personnel.

Introduction

Over the past few years, we have experienced an evolutionary (if not revolutionary) set of
changes in vibration measurement practices for performing predictive maintenance functions
and maintaining assets. Technology has been good to us and offered significant advances for
the tool set necessary to accomplish the goals and objectives of our jobs.

A key point to remember is that the best analyzing equipment and the most powerful
diagnostics software will not solve a single vibration problem. It is a skilled person in the art
of applying data that is required. Someone with a toolbox and the right set of tools must be
present to fix the problem. Since machinery unbalance is the most common cause of
excessive vibration, it is absolutely essential that balancing tools occupy a reasonable portion
of the toolbox.

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Balancing technology logically falls into the category of field service and repair. However,
the associated tasks are highly technical and require a good set of tools and analytical skills.
For example, balancing involves a good set of mathematical skills in understanding vectors,
algebra, and trigonometry. However, with the technology available today, balancing
instruments automatically perform these calculations. The user only needs to know how to
take good quality measurements and to go through the proper sequence of operator interface
functions on the instrument.

Addressing a difficult vibration problem has two major paths – one for diagnosis, and one for
correction. On the diagnosis path, there are three main elements: (1) data collection, (2) data
analysis, and (3) determining a possible root cause for the problem. Moving to the correction
path, there are again three elements: (1) examining alternatives, (2) selecting the best
alternative, and (3) problem resolution.

DETECTION is a key element to any successful program. The quality of the output of a
process will never be any better than the quality of the input. Thus, it is essential to have the
right measuring device to detect a potential problem. For detecting vibration, this means that
we need an accurate sensor (probably more than a screwdriver and a tuned ear) and an
instrument capable of interpreting the electronic signal and converting it to some meaningful,
calibrated units. As an example, let’s say that we need an accelerometer with an output of
100 millivolts per g of vibration, an accurate mounting method, a reliable cable and
connection, and an accurate measuring instrument. Once this is established, and we secure
the right components, we have a means for quantifying and qualifying the amount of
vibration that is occurring at any physical location that we select for measuring.

ANALYSIS is the next step in the process. Once we have data, we must decide what it
means. It is not enough to say, “Yep, this thing sure is shaking!” We need to say what is
vibrating, how much, and under what conditions. In fact, we might want to look at how one
part of a machine is behaving relative to another part. This is where it is important to have a
reading of a parameter called phase in addition to the vibration level. This shows us relative
movement of one machine component as compared to another. It is said to either be in phase
or out of phase by some measured angle. (“180 degrees out of phase” means that
components are moving opposite of each other.)

In order to quantify motion, it is necessary to have another sensor to detect position of the
rotating part relative to the vibration magnitude. This is generally accomplished with a photo
tachometer (i.e., laser) device and a measurement of speed and relative position of a
reference mark on the part.

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With a grasp on two key components of vibration, the magnitude and relative phase, we can
begin analyzing. However, nothing more can be done until we know what frequencies are
contributing to the vibration. It could be anywhere from 1X RPM to exact multiples or any
factor thereof, depending on the physical characteristics of the machine. Knowing the
rotational speed and physical makeup of the machine(s), telltale frequencies pinpoint
problems with rolling element bearings, gearboxes, etc. A closer look at frequencies also
helps us to decide root-cause, as to whether the problem stems from unbalance, looseness,
alignment, etc.

CORRECTION is next. With a potential problem being detected, and enough analysis work
to pinpoint a possible cause, we need to offer a solution and go to the next phase of the
process. Corrective methods typically include:

• Alignment
• Tightening of loose parts
• Cleaning
• Replacing failed components, such as bearings
• Methods for treating vibration, such as stiffening, damping, and isolation
• Active cancellation.

Prior to initiating any type of field correction, common sense maintenance should be
performed. Some examples are:

• Cleaning
• Thorough inspection
• Checking hardware components for looseness.

Approximately 40% of vibration problems associated with machinery maintenance stem

from components being unbalanced. Unbalance is characterized by measuring a high amount
of vibration at a 1X running speed component.

Balancing as a Correction Tool

Now, let’s concentrate on balancing as our primary means for correction. Basically, we can
look at balancing as a procedure of measuring vibration and adding or removing weight to
adjust mass distribution. The major goal is to reduce vibration. Why do we go to all this
expense and trouble? There are a number of benefits:

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 • Minimize noise
• Increase bearing life
• Decrease operating stresses
• Consume less energy
• Improve product quality
• Decrease operator fatigue
• Eliminate fatigue of support structures
• Satisfy customers.

The source of an unbalance problem usually stems from less than perfect manufacturing,
typically categorized by:

• Design errors
• Material variation
• Form, fit, and assembly variation.

These problems are generally addressed in the latter stages of the manufacturing process, and
are addressed by “production balancing”.

Regardless of the efforts to produce an ideal machine, vibration and unbalance problems do
arise in the field. These maladies are usually caused by deposits or erosion on moving parts,
losing previously installed balancing weights, damage, maintenance actions, shifting of parts,
or the gradual relief of residual stresses in the shaft or body of the machine. This is called
‘field balancing”, or balancing in place. Today, it is possible to address most balancing
problems in the field without having to totally disassemble the machine and sending the rotor
out for “shop balancing”. Field balancing is significantly more challenging than production
or shop balancing because it requires that the tool kit and tools be hauled out to the site and
set up anew. Furthermore, each machine has a different set of characteristics and bears little
resemblance to any previous machines that have been balanced. Field balancing is a bit
challenging, but the efforts almost always pay off and produce a better running condition.

When being called to perform a balancing operation in the field (which seems to be the root
cause of a vibration problem about 40% of the time), it is important to eliminate any other
possible causes, such as resonances, eccentric pulleys, looseness, alignment, and causes
stemming from other drive components. In order to avoid going down the wrong path for
correction, it is first necessary to verify unbalance with some analysis. The success of field
balancing is never a 100% certainty. The probability of success is more like 80%, even when
unbalance is known to be the culprit. Sometimes, there are other sources of 1X RPM
vibration that cannot be corrected by weight distribution.

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The Ideal Set of Tools

It hasn’t been too long ago that each of the 3 fundamentals for problem resolution,
DETECTION, ANALYSIS, and CORRECTION, required unique sets of physical tools. A
small portable hand-held instrument or meter was typically selected for DETECTION. A
linked processor capable of interpreting the measurements then performed ANALYSIS. Yet
another device was used for CORRECTION. Thus, the successful maintenance technician
usually had a big toolbox, containing a comprehensive set of tools, and the knowledge and
skill set required to use them correctly.

With recent advances in technology, coupled with the needs to consolidate assets and to
minimize outlays for capital equipment, there has been a concerted effort by instruments
suppliers to incorporate detection, analysis, and correction methods into a single package.
There has also been a driving force to combine this functionally into a small, hand-held
(preferably palm-sized) instrument.

This paper is intended to examine the basic features and key attributes of one such product
that is currently available in the marketplace.

Fundamental Requirements

Now that it is stated that we need a single package to detect, analyze, and correct problems in
complex machinery that stem for an early onset of increased vibration levels, we need to
define our requirements. Although this list is by no means comprehensive, this represents a
typical ‘wish list’:

• Small, lightweight, and hand-held package.

• Proven platform for performance.
• Accurate and reliable.
• Functionally independent, with no dependence on host software.
• Easy to use – intuitive operator interface.
• Complete package – all accessories and peripherals included.
• On-board data storage and recall.
• Local screen saves as bitmap files.
• Local printing capability.
• Built-in analysis capabilities for vibration amplitude, frequencies, and phase.
• Incorporate two-plane balancing capability.

These qualities span all three fundamental elements of asset management: detection, analysis,
and correction.

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Single Package Application

If a problem is suspected with plant machinery, it is first necessary to do an overall vibration

measurement with a known good instrument, thereby qualifying and quantifying the
observation. At the same time, it is wise to measure and verify the running speed. It would
be desirable to perform these measurements without requirements for in-depth training and
lots of set up time. Thus, we could quickly confirm that the machine is running at its target
speed and the vibration reading is at a specific level.

Next, we should perform a frequency spectrum measurement to show what frequencies are
contributing to the overall vibration level. With a built-in FFT capability, we can quickly
progress beyond the overall vibration level and show the contributions by frequency.

Now, knowing the rotating speed and looking at the frequency spectrum, we can very quickly
ascertain whether or not we have a 1X RPM problem – and most likely a problem associated
with unbalance.

If unbalance is deemed as the problem, it is desirable to quickly move to a correction of the

problem by having a field-balancing tool.

Ideally, we could perform all these functions out of one tool case with some independence,
and no need to use “lifelines” like computer assistance, phoning a friend, or asking members
of the audience that might be present! (Stealing lines from the popular “Who Wants To Be a
Millionaire?” show.)

One package for addressing field problems won’t necessarily make us instant millionaires,
but it certainly should improve our efficiency and credibility for vibration analysis and
problem solving for condition-based maintenance.

Implementation

Now that we have established that size and weight are two important parameters for our field
tool, and we can only assume that price carries an equal weighting, we need to look at
requirements. First of all, we need to follow the K.I.S.S. principal, and keep it simple. At
initial power-on, the instrument menu needs to self-evident and prompting the user. One
implementation would be to have three general settings: (1) Analysis, (2) Balancing, and (3)
Instrument Setup. Analysis should be listed first, as it is a prompt to take an initial reading.
The sub-menu should also be simple, with a preset group of parameters, so as to a
meaningful ‘standard’ reading is obtainable with a single press of a button. There should
also be a provision for the more sophisticated user to have access to easily adjust other
measurement parameters. In addition to seeing the overall vibration level, a frequency plot
(FFT) calculation should automatically follow. There should also be a measurement of
running speed available at a single press of a button. This, with initial data collected and
displayed, it is easy to verify the presence of a 1X running speed component as a major
contributor to the overall vibration level.

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Once adequate data is available and studied, it is time to address the possible root cause of
the vibration. As mentioned before, with 40% of the vibration problems stemming from an
unbalance condition, where a major contributor is at 1X running speed, it makes sense to
incorporate balancing as a dedicated correction tool – again, with a simple-to-use, user-
prompting implementation.

The balancing function should be so simple to guide the user right through the proper
sequence of steps: the initial run, the introduction of a trial weight, the second run, and
finally, the recommendation on the size and location of the weight to be used for correction.
The balancing implementation should also have the provision for a bit of added functionality,
like one or two planes, continuous or fixed rotor positions, adding or removing weight, and
additional trim runs.

In addition to the basic instrument and its peripherals, there is a group of key accessories for
balancing that needs to be nicely packaged in a kit. This group includes transducers, cables,
chargers, a small scale (for trial weights), and a portable printer.

All information should be presented in clear and concise graphical screens, with prompts for
action and navigation. Summary readouts should also be available at intermediate steps and
at the conclusion of the process.

Local screen storage and printing is a must for fieldwork. There needs to be a provision for
saving images as bitmaps on card or printing them directly. Stored bitmaps allow the user to
cut and paste images into customized formats for reports.

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Field Example

Let us now take a look at a practical example for vibration

analysis and balancing in the field. We will walk through the
typical steps and techniques, and touch on all three fundamental
elements (detection, analysis, and correction) for machine
condition monitoring and asset management.

As we approach the subject machine we are told that it is running

at about 1200 RPM, and that it was discovered to be running
roughly just a few days before.

We power on our data collector/analyzer instrument, and see the Figure 1. Main Menu
initial menu screen as shown in Figure 1.

We choose the analysis mode, and another menu screen appears, as shown in Figure 2.

We select “measure speed” and aim the

photo tachometer (or laser) at the reflective
tape on the machine shaft to verify the
running speed, and we arrive at a “live-
time” display, as shown in Figure 3.

Indeed, this does confirm the machine

speed at 1200 RPM.

Figure 2. Analysis Menu Figure 3. Speed Readout

Now is the time to get a quick vibration measurement, with FFT

(frequencies). We choose the standard measurement with
accelerometer, Item 1 in the Analysis Menu, shown in Figure 4.

Once we select the standard measurement, we begin collecting and

storing overall and spectral data, as shown by Figures 5 and 6.

Figure 4. Standard Measurement

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 Once data are stored, it can be recalled and
displayed through the Review Data menu
selection, as shown by selection of Item 4
in the Analysis Menu, Figure 7.

Figure 5. Overall Figure 6. Spectrum

Figure 7. Review Data

A selection is made from the stored data, Analysis 009, as shown in Figure 8, and the overall
and spectral values are retrieved and displayed as shown in Figures 9 and 10.

Note that we have

an overall vibration
level at 0.435 IPS
(inches per second)
peak, with the
majority of the
contribution (0.377
IPS) at 1X RPM
(1200 RPM).

Figure 8. Selection Figure 9. Overall Figure 10. Spectrum

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From the published charts, we are certainly in the “Rough” category, with definitions as
shown in Table 1 below.
Vibration Velocity Vibration Velocity Severity Level for
(IPS – Peak) (mm/s – Peak) Machine
.001 0.025 Extremely Smooth
.002 0.051 Very Smooth
.004 0.102 Smooth
.008 0.203 Very Good
.016 0.406 Good
.032 0.813 Fair
.064 1.626 Slightly Rough
.128 3.251 Rough

Table 1. Machinery Severity

Based on the significant 1X contribution, we go from the detection and analysis stages to
correction (Balancing), and we make this choice from the following menu (Figure 11).

After this choice, we

either verify or
modify the default
settings for two
planes, as shown in
Figures 12 and 13.

Figure 11. Main Menu Figure 12. Options 1 Figure 13. Options 2

Now, we begin the two-channel balancing process.

Note From Figure 14 that we are provided with a graphical

representation of amplitude and phase readings for both planes.

Figure 14. Balancing

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Now we are prompted to attach a trial
weight in plane 1 and to make another
measurement. As shown in Figure 15,
we add 1.5 grams at 0 degrees to plane 1
of the rotor, and bring the rotor back to
balance speed. The new readings are
shown in Figure 16.

Figure 15. Trial Wt. 1 Figure 16. New Reading 1

Next, we are prompted to remove this

weight and to perform the same operation
for plane 2. As shown in Figure 17, we
add 1.5 grams at 0 degrees in plane 2 of
the rotor, and bring the rotor back to
balance speed. The new readings are
shown in Figure 18.

Figure 17. Trial Wt. 2 Figure 18. New Reading 2

Once that these operations are completed,

the instrument will compute the size and
angle position of correction weights for the
two planes, as shown by the displays in
Figures.19 and 20.

Figure 19. Plane 1 Figure 20. Plane 2

Correction Correction

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Correction weights are measured and placed at the appropriate angles
in each plane, and a set of vibration measurements is made again, as
shown in Figure 21.

At this point in the process, we have the choice of trimming the

balance condition even further or saying that we are done. If we
declare that we are finished, we can look at the vibration summary
tables for the two planes, as shown in Figures 22 and 23.

Figure 21. Correction Run

Alternatively, we can also view the weights

summary, as shown in Figures 24 and 25.

Figure 22. Vibration Figure 23. Vibration

Summary 1 Summary 2

In just a few steps, we were able to take a

machine running at a very rough level of 6
mils to approximately 40 times less, or 0.15
mils.

In fact, it is very useful to take overall and

spectral information once again to verify our
success. See Figures 26 and 27.

Figure 24. Weights Figure 25. Weights

Summary 1 Summary 2

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 In this brief example, we stopped after one
correction. Note that the 1X component
contribution has gone from 0.377 IPS all
the way down to 0.007 IPS – a reduction of
50 times. At 0.034 IPS overall, the
machine is now running in the Fair category
and warrants a look at other factors (other
than balancing) that may be contributing to
vibration.

Figure 26. Overall Figure 27. Spectrum

After Balancing After Balancing

Note that we have taken spectrum data on two different scales, and the one in Figure 27 is at
a full-scale value of only 0.020 IPS. (The spectrum in Figure 10 is displayed with a full-
scale value of 0.500 IPS.)

For a better comparison, the “Before” and “After” data are normalized (without cursor) to the
same scale (0.500 IPS) and shown in Figures 28 and 29.

0.377 IPS @1200 CPM

0.007 IPS @1200 CPM

Figure 28. BEFORE Figure 29. AFTER

Although we finished this particular balancing run with just one correction, the complete
process is shown by the flow chart in Figure 30.

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 Determine 1X RPM
with Tach
Detection
&
Take Spectral Analysis
Information

Is 1X RPM NO
Significant?
Quit

YES Balance Is Not

The Problem
Balance &
Advanced Setup

Initial Run

Add trial weights

Do for all Trial Run

planes
YES Initial Setup &
Trial weights New
Balance
left in place? Computation
(Correction)
NO

Correction Weight
Solution

Correction
Run
Balance Is
Acceptable
YES Spectrum
Are Vibration Levels Quit
Acceptable? Final Check
NO

Trim #n Weight
Solution Trim
Balance
(Correction)
Trim #n Run

Figure 30. Flow Chart for Detection, Analysis, and Correction - using Balancing

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Conclusions

As time is money in any field repair work, balancing is no exception. It behooves the user to
always be prepared (like the Boy Scouts of America motto goes). It makes a lot of sense to
have anything and everything that could possibly be of benefit ready and on site in a
compact, lightweight, and easy-to-use package. This is the trend for the industry as we have
experienced the evolution.

There were several intents in composing this paper, and they are summarized below:

• Reflect on the fundamentals of vibration analysis

• List fundamental requirements in applying the technology
• Identify the required tools for problem resolution
• Examine the elements of field analysis and balancing
• Witness success of a specific implementation.

In covering these elements, it s hoped that the reader will gain some insight in being able to
quickly detect, analyze, and correct vibration and unbalance problems in the field.

References
(1) Dennis H. Shreve, Vibration Analysis: Fundamentals, P/PM Technology, 1995

(2) John S. Mitchell, Machinery Analysis and Monitoring, Penwell Publishing Co., 1981, 1993

(3) IRD Mechanalysis, Dynamic Balancing Handbook, October 1990

(4) R. Keith Mobley, Vibration Fundamentals, Newnes, 1999

(5) Victor Wowk, Machinery Vibration: Balancing, McGraw-Hill, 1995

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