RESOLVING VIBRATION ISSUES OF DIESEL ENGINE
DRIVEN FIRE WATER PUMPS
Case Study
By
Sherief Mekawey
Principal MDS Engineer
GE-Bently Nevada
Contents
Background
Technical Data and Acceptance Criteria
Contractual Vibration Points
Vibration Measurement Locations at Field
Analysis
Conclusions from Investigation
Proposed Actions
Final Vibration Results
Lessons Learnt
2
Background
Four numbers of Fire Water Pumps supplied newly failed to
pass SAT in 2006 due to high vibration on the Pump Head.
2 vibration consultants were involved to solve the problems
without success.
3rd vibration consultant (GE) was involved in Oct 2009,
implementation of recommendations started in 2010, hand
over in 2012.
Technical Data and Acceptance Criteria
Pump:
Vertically suspended centrifugal
pump, 3 stages
1750 rpm, water lubricated, 880
cu.m/hr
Acceptance Criteria:
As per NFPA 20 article 7.6.1.5
which refers to Hydraulic Institute
Standard (5.84 mm/s rms) at
Pump Head
Drive Shaft :
Double Universal Joint Cardan Shaft
Gearbox:
750 HP, 1750 RPM,
1:1 Ratio, Right Angle
Threaded Coupling Type
Diesel Engine:
12 Cylinders, DITA, 800HP, 1750
RPM
Contractual Vibration Points
Vibration Measurement Locations at Field
Analysis
Pump A
Comparison of vibration
signatures of Pumps A,
B & D on the GB output
Vertical location
Pump B
Observation#1:Vibration
signature
on
Gearbox
indicated that a significant
energy components getting
transmitted from the Diesel
Engine at 1X, 3X, 3.5X and
6X
Similar vib signature as recorded on
diesel engine
Pump D
Reason could be: vibration isolators are not installed either under
the engine feet nor under the frame on which the engine is
mounted.
Foundation/supporting arrangement for Diesel Engine, Gearbox and Pump.
Observation#2: Startup/coast down waterfall indicated resonance
in the speed range 1200 to 1400 rpm
Critical speed in the range of 12001400rpm
Pump-A
Pump-B
Observation#3: Bump test
data on the Gearbox
structure
indicated
a
resonance at 22.5Hz and
33 Hz, which is less than
20% separation margin
(Pump Running speed
28.75cps)
Pump-D
10
Pump-A
Pump-B
Observation#4:
High
frequency spectrum on
GB indicated 1X GMF
with sidebands, possibly
due to wear of gear
teeth/excessive
backlash.
Pump-D
11
Conclusions from Investigation
Unbalance of Gearbox cordon shaft or coupling hub
mounted at gearbox input shaft
Transfer of vibrations from diesel engine to the gearbox
and pump assembly
Structural resonances from gearbox support assembly.
Premature wear of gear teeth / excessive backlash.
12
Proposed Actions
In situ balancing of gearbox cordon shaft and GB O/P
shaft.
Installation of vibration isolators below the engine feet or
the base frame
Modify the Gearbox structure to shift the natural
frequency with 30% separation margin.
Inspection of Gearbox for excessive gear wear/backlash.
13
Actions in Sequence
Action#1: In-situ Balancing done on
GB I/P and GB O/P shafts to reduce
unbalance on cordon shaft and to
reduce excitation on the GB
structure respectively. (coupling
between Engine and GB used to
balance the GB I/P shaft. GB fan at
the top used to balance the GB O/P
shaft).
14
Waterfall signature
1X component
before balancing
before balancing
Action#1 (contd): In-situ
balancing resulted in reduction of
1X. However the 22Hz
resonance component was
excited
1X component after
balancing
Waterfall signature
after balancing
Vib component at 22Hz
shown after balancing
15
Action#2: The engine stand was replaced with a new stand with vibration isolators
16
Comparison of vibration spectrum before and after the modification of
engine base frame with vibration isolators
17
Action#3: Pump Head structure modified
Old Pump head
New Pump head
18
GB TOP
Bump test on the GB and pump head (with
modified head) showed natural frequency at
41.25 Hz (achieved 41% separation margin)
GB Bottom
Pump head
19
Action#4: Gearbox inspected and found only 70% teeth contact. GB OEM
brought to site, gear backlash was checked and adjusted to conform to OEM
specifications
20
Comparison of vibration spectrum before and after the backlash adjustment
on the Gearbox
Before
High frequency GMF
components & side bands
Now
Drastic reduction of High frequency GMF
components & side bands
21
Final Vibration Results
Pump-D selected as pilot, implemented all the mentioned action items and resulted in
great improvement. Red highlighted in table below is the contract specified location
(Limit 5.84 mm/s rms)
22
Lessons Learned
All contractual limits must be carefully acknowledged
during design and verified during FAT.
Solving the problems in factory is much easier than
doing it on site.
Get the right consultant involved at the first chance.
Understand the size of problem since beginning could
save time, cost and efforts.
Major modifications might be a solution whenever the
problem is complex.
23
END OF THE CASE
QUESTIONS?
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