Cover image for Case histories in vibration analysis and metal fatigue for the practicing engineer
Title:
Case histories in vibration analysis and metal fatigue for the practicing engineer
Personal Author:
Publication Information:
Hoboken, N.J. : Wiley, c2012
Physical Description:
xvii, 288 p. : ill. ; 24 cm.
ISBN:
9781118169469

Available:*

Library
Item Barcode
Call Number
Material Type
Item Category 1
Status
Searching...
30000010306152 TJ177 S64 2012 Open Access Book Book
Searching...

On Order

Summary

Summary

This highly accessible book provides analytical methods and guidelines for solving vibration problems in industrial plants and demonstrates their practical use through case histories from the author's personal experience in the mechanical engineering industry. It takes a simple, analytical approach to the subject, placing emphasis on practical applicability over theory, and covers both fixed and rotating equipment, as well as pressure vessels. It is an ideal guide for readers with diverse experience, ranging from undergraduate students to mechanics and professional engineers.


Author Notes

ANTHONY SOFRONAS, DEng, PE, has spent the past forty-five years troubleshooting field failures and designing machinery for ExxonMobil, General Electric, and the Bendix Corporation. He is currently a consultant to industry, presenting seminars worldwide under the aegis of his company Engineered Products. Dr. Sofronas has published many technical papers and articles, including a bimonthly column for Hydrocarbon Processing dedicated to engineering case histories. He is also the author of Analytical Troubleshooting of Process Machinery and Pressure Vessels (Wiley).


Table of Contents

Prefacep. xv
1 Introductionp. 1
Referencep. 4
2 Basics of Vibrationp. 5
2.1 Spring-Mass Systems and Resonancep. 5
2.2 Case History: Combining Springs and Masses in a Steam Turbine Problemp. 9
2.3 Useful Questions to Ask Before Beginning a Vibration Analysisp. 12
2.4 Linear Spring Constants and Area Moments of Inertiap. 13
2.5 Vibrating Flat Platesp. 14
2.6 Two-Degree Tuned Vibration Absorberp. 16
2.7 Natural Frequencies of Pipes and Beamsp. 19
2.8 Effect of Clearance on the Natural Frequencyp. 19
2.9 Static Deflection and Pendulum Natural Frequencyp. 21
2.10 Coupled Single-Mass Systemsp. 23
Referencesp. 25
3 Vibration-Measuring Methods and Limitsp. 27
3.1 Important Frequenciesp. 27
3.2 Campbell Diagramsp. 31
3.3 Case History: Systematic Procedure to Identify a Vibration Sourcep. 33
3.4 Vibration-Measuring Termsp. 34
3.5 Cascade Diagramp. 36
3.6 Shock Pulse Methodp. 37
3.7 Measuring Transducersp. 38
3.8 Measurements: Time-Based, Bode, and Orbit Plotsp. 40
4 Simple Analytical Examplesp. 45
4.1 Determining Vibration Amplitudep. 45
4.2 Resonant and Off-Resonant Amplitudesp. 47
4.3 Case History: Transmitted Force and Isolation of a Roof Fanp. 49
4.4 Case History: Seal Failure Due to Misalignment of an Agitator Shaftp. 51
4.5 Case History: Structural Vibrationp. 53
4.6 Case History: Production-Line Grinding Problemp. 54
4.7 Case History: Vehicle on Springsp. 57
4.8 Case History: Vibrating Cantilevered Componentsp. 58
4.9 Bump Testp. 60
4.10 Case History: Vibrating Pump Mounted on a Plate Deckp. 60
4.11 Case History: Misalignment Forcep. 62
4.12 Case History: Vertical Pump Vibrations and Bearing Survivalp. 64
4.13 Case History: Cause of Mysterious Movement on a Centrifuge Deckp. 67
4.14 Case History: Engine Vibration Monitoring Devicep. 70
4.15 Case History: Natural Frequency of A Midsupport Vertical Mixerp. 72
4.16 Case History: Valve Float Analysisp. 73
Referencesp. 75
5 Vibration-Based Problems and Their Sourcesp. 77
5.1 Fatigue Crackingp. 77
5.2 Fretting and Wearp. 79
5.3 Ball and Roller Bearing Failuresp. 83
5.4 Bolt Looseningp. 84
5.5 Flow-Induced Vibrationp. 86
5.5.1 Case History: Stack Vibration Induced by Windp. 87
5.6 Excessive Noisep. 88
5.7 Pressure Pulsationsp. 89
5.8 Mechanical Seal Chipping and Damagep. 90
5.9 Surging of Fans and Other Causes of Vibrationp. 90
5.10 Vibration Due to Beatsp. 92
5.11 The Slip-Stick Problemp. 92
5.12 Drive Belt Vibrationp. 97
Referencesp. 98
6 Causes of Vibrations and Solutions in Machineryp. 99
6.1 Rotating Imbalancep. 99
6.1.1 Case History: Motor Imbalancep. 100
6.2 Causes of Shaft Misalignmentp. 102
6.2.1 Types of Misalignmentp. 102
6.2.2 Thermal Offsetp. 102
6.2.3 Acceptable Coupling Offset and Angular Misalignmentp. 103
6.3 A Problem in Measuring Vibration on Large Machinesp. 104
6.4 Causes of Pump Vibrationp. 105
6.4.1 NPSH Problems and Cavitationp. 105
6.4.2 Suction Vortexp. 107
6.4.3 Off Best Efficiency Pointp. 107
6.4.4 Vertical Pump Vibrationp. 109
6.4.5 Pump Vibration Level Guidelinesp. 111
6.5 Other Causes of Motor Vibrationp. 111
6.5.1 Electrical Causesp. 111
6.5.2 Mechanical Causep. 112
6.5.3 Motor Vibration-Level Guidelinesp. 112
6.6 Causes of Gearbox Vibrationp. 113
6.6.1 Cyclic External Reaction Loadsp. 113
6.6.2 Tooth Breakagep. 113
6.6.3 Gearbox Vibration-Level Guidelinesp. 114
6.6.4 Causes of Cooling Tower Fan System Vibrationp. 114
6.6.5 Complex Gearbox Vibration Spectrap. 115
6.7 Types of Couplings for Alignmentp. 116
Referencesp. 120
7 Piping Vibrationp. 121
7.1 Types of Piping Vibration Problemsp. 121
7.2 Vibration Screening Charts and Allowable Limitsp. 122
7.3 Case History: Water Hammer and Piping Impactsp. 123
7.4 Case History: Heat-Exchanger Tube Vibrationp. 126
7.5 Case History: Useful Equations In Solving a Cracked Nozzlep. 128
7.6 Support and Constraint Considerations in Vibrating Servicesp. 130
7.7 Case History: Control Valve Trim Causing Piping Vibrationp. 130
7.8 Vibration Observed and Possible Causesp. 131
7.9 Acoustical Vibration Problemsp. 131
7.9.1 Case History: Compressor Acoustical Vibration Analysisp. 133
7.9.2 Case History: Tuning Using a Helmholz Resonatorp. 134
7.9.3 Case History: Tuning Using Surge Volumep. 135
7.10 Two-Phase Flow and Slug Flowp. 136
7.11 Case History: U-Tube Heat-Exchanger Vibrationp. 138
7.12 Crack Growth in a Flat Platep. 139
Referencesp. 140
8 Torsional Vibrationp. 141
8.1 Torsional Vibration Definedp. 141
8.2 Case History: Torsional Vibration of a Motor-Generator-Blowerp. 143
8.3 Case History: Engine-Gearbox-Pumpp. 144
8.4 Case History: Internal Combustion Engine-Gearbox-Propellerp. 146
8.5 Case History: Effect of Changing Firing Order On Crankshaft Stressp. 152
8.6 Case History: Transient Power Surge Motor-Gearbox-Compressorp. 152
8.7 Case History: Vibratory Torque on the Gear of a Ship Systemp. 155
8.8 Torsional Spring Constants and Mass Moments of Inertiap. 157
8.9 Three-Mass Natural Frequency Simplificationp. 158
8.10 Case History: Torsional Vibration of a Drill Stringp. 160
8.11 Case History: Effect of a Suddenly Applied Torsional Loadp. 160
8.12 Sensitivity Analysis of a Two-Mass Torsional Systemp. 162
8.13 Case History: Engine Natural Frequency as a Continuous Shaftp. 163
8.14 Types of Torsionally Soft Couplingsp. 164
8.15 Torsional Vibration Testingp. 168
8.16 Case History: Out-of-Synchronization Grid Closurep. 170
8.17 Operating Through a Large Torsional Amplitudep. 171
8.18 Case History: Engine Mode Shape as a Continuous Shaftp. 173
8.19 Holzer Method for Calculating Torsional and Linear Multimass Systemsp. 174
8.20 Experimental Determination of Mass Moment of Inertia Jp. 177
Referencesp. 178
9 Turbomachinery Vibrationp. 179
9.1 Unique Vibration Problems of Turbomachineryp. 179
9.1.1 The Rotor Systemp. 180
9.2 Lateral Vibrations of a Simplified Systemp. 181
9.2.1 A Simplified Rotor Systemp. 181
9.2.2 Compressor with High Stiffness Bearingsp. 182
9.2.3 Critical Speed of a Rotor on Spring Supportsp. 183
9.3 Allowable Shaft Displacement Guidelinesp. 185
9.4 Compressor Surge and Rotor Vibrationp. 185
9.5 Rigid and Flexible Rotor Balancingp. 187
9.6 Case History: Checking the Critical Speed of a Motor Rotorp. 190
9.7 Case History: Response of a Missing Blade on a Steam Turbinep. 192
9.8 Case History: Stepped Shaft Into Equivalent Diameterp. 195
9.9 Case History: Two-Diameter Rotor Systemp. 196
9.10 Hydrodynamic Bearing Stiffnessp. 197
9.11 Rotor Dynamics of Pumpsp. 201
Referencesp. 202
10 Very Low Cycle Vibrations and Other Phenomenap. 203
10.1 Very Low Cycle Vibration Definedp. 203
10.2 Vessels In High-Cycle Servicep. 204
10.3 Case History: Cracking of a Rotary Dryerp. 205
10.4 Phantom Failures: Some Failures are Very Elusivep. 207
10.5 Case History: Troubleshooting Gear Face Damagep. 208
10.6 Case History: Thermally Bowed Shaft and Vibrationp. 210
10.7 Case History: Effect of Nonlinear Stiffnessp. 212
10.8 Case History: Effect of Clearance on a Vibrating Systemp. 214
10.9 Case History: Fatigue Failure of a Crankshaftp. 215
10.10 Case History: Understanding Slip-Jerk During Slow Rollp. 218
10.11 Case History: Predicting the Crack Growth on a Machinep. 219
10.12 Case History: Bolt Loosening on Counterweight Boltsp. 222
10.13 Case History: Centrifuge Vibrationp. 223
10.14 Case History: Crack Growth In a Gear Toothp. 225
10.15 Case History: Vibration of a Rotor In Its Casep. 227
10.16 Case History: Gearbox Input Shaft Lockupp. 229
10.17 Case History: Troubleshooting a Roller Bearing Failurep. 231
10.18 Case History: Using Imprints to Determine Loadsp. 232
10.19 Case History: Extruder BlowBackp. 235
10.20 Case History: Vibratory and Rotational Wearp. 239
10.21 Two-Mass System With Known and Unknown Displacementp. 241
10.22 Case History: Fiberglass Mixing Tank Flexing Vibrationp. 241
11 Vibration Failuresp. 245
11.1 Why Things Fail In Vibrationp. 245
11.2 Case History: Spring Failurep. 246
11.3 Case History: Spline Frettingp. 247
11.4 Case History: Sheet Metal Vibration Crackingp. 248
11.5 Case History: Bearing Brinelling and False Brinellingp. 249
11.6 Case History: Crankshaft Failurep. 250
11.7 Case History: Brush Holder Wearp. 251
11.8 Case History: Cracking of a Vibrating Conveyor Structurep. 251
11.9 Case History: Failure of a Cooling Tower Blade Armp. 252
11.10 Case History: Fatigue Failures at High Cyclic Stress Areasp. 254
11.11 Case History: Fatigue Failure of Shaftsp. 254
11.12 Case History: Failure of a Steam Turbine Bladep. 257
11.13 Case History: Failure of a Reciprocating Compressor Slipperp. 258
11.14 Case History: Multiple-Cause Gear Failurep. 259
11.15 Case History: Loose Bolt Failuresp. 259
11.16 Case History: Piston Failure in a Racing Carp. 262
11.17 Case History: Stop Holes For Cracks Don't Always Workp. 262
11.18 Case History: Small Bearing Failure Due To Vibrationp. 264
11.19 Appearance of Fatigue Fracture Surfacesp. 266
Referencesp. 268
12 Metal Fatiguep. 269
12.1 Metal Fatigue Definedp. 269
12.2 Reduction of a Component's Life When Subjected to Excessive Vibrationp. 270
12.3 Case History: Special Case of Fatigue Potentialp. 273
12.4 Metallurgical Examinationp. 274
12.5 Taking Risks and Making High-Level Presentationsp. 275
Referencesp. 277
13 Short History of Vibrationp. 279
Referencesp. 282
Indexp. 285