Hydraulic Unbalance in Oil Injected Twin Rotary Screw Compressor Vibration Analysis (A Case History Related To Iran Oil Industries)
Hydraulic Unbalance in Oil Injected Twin Rotary Screw Compressor Vibration Analysis (A Case History Related To Iran Oil Industries)
Hydraulic Unbalance in Oil Injected Twin Rotary Screw Compressor Vibration Analysis (A Case History Related To Iran Oil Industries)
I. INTRODUCTION
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suction end, forming the back edge of the trapped gas pocket.
The two separate gas cylinders in each rotor are joined to form
a "V" shaped wedge of gas with the point of the "V" at the
intersection of the threads on the suction end.
volume of each screw thread as the meshing thread proceeds Fig. 5 How compressors are started Compression back the fluid in
down the length of the rotor. This is analogous to the suction left reciprocating and right twin rotary screw compressor
stroke in a reciprocating compressor as the piston is drawn
down the cylinder. Further rotation begins to reduce the trapped volume in the
"V" and compress the trapped gas. The intersection point of
the male lobe in the female flute is like the piston in the
reciprocating. That is starting up the cylinder and compressing
the gas ahead of it.
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valve and an axial port is used on the discharge end wall. of machine in different loads, speeds and situations [8]-[10].
These two ports provide relief of the internal compressed gas In addition, traditional vibration measuring programs could
and allow it to be pushed into the discharge housing. be performed for all parts and components in screw
Positioning of the discharge ports is very important as this compressors. It is worthy to know that these methods could be
controls the amount of internal compression. In the effective in gear box [11]-[13].
reciprocating compressors, the discharge process is complete Besides, all vibration data such as overall vibrations, TWF,
when the piston reaches the top of the compression stroke and FFT and phase values could be evaluated in vibration analysis
the discharge valve closes. [14]. Besides, these methods could be effective in rotor
The end of the discharge process in the screw occurs as the unbalance identification [15], [16].
trapped pocket is filled by the male lobe at the outlet end wall These kinds of data are available in on line vibration
of the compressor. The reciprocating compressors Always has monitoring systems in most critical screw compressors.
a small amount of gas, (clearance volume), that is left at the Furthermore, a condition based monitoring system using
top of the stroke to expand on the next suction stroke, taking ultrasonic signal recently developed for gear boxes. High
up space that could have been used to draw in more suction frequency ultrasonic sensor is used as a transducer to collect
International Science Index, Mechanical and Mechatronics Engineering Vol:7, No:11, 2013 waset.org/Publication/9997612
charge. At the end of the discharge process in the screw, no data base on run frequency and gear mesh frequencies. Finally
clearance volume remains. All compressed gas is pushed out signals could filter within an ultrasonic range [17].
the discharge ports. This is a significant factor that helps the The phase analysis could be evaluated the condition of
screw compressor to be able to run at much higher coupling or misalignment, soft foot and high low flanges. In
compression ratios than a reciprocating compressor [2]. addition, vibration modal analysis could be identified the
machine overall condition with assist of data collector VDAU-
6000. On the other hand, noise-monitoring systems usually
performed in screw compressors.
Moreover, oil analysis is one of the other critical
checkpoints always recommended in screw compressors.
Nowadays thermography developed to evaluating the
bearing temperature in screw compressors and gearbox.
The lubrication system of different parts of screw
compressors considered as a main technical category in
Fig. 8 How compressors are finished fluid discharge in left monitoring systems. An environmental friendly palm-grease
reciprocating and right twin rotary screw compressor
has already been formulated from modified RBDPO (Refined
Bleach Deodorized Palm Oil) as base oil and lithium soap as
II. EXPERIMENTAL DETAILS
thickener. Such palm-grease is dedicated for general
Screw compressors usually connected to an increasing RPM application and or equipment working in different industries.
heavy gearbox with several main shafts and a high KW The grease was manufactured via 4 steps of processes:
electromotor (usually more than 38 KW). The couplings are saponification in pressurized reactor, soap dilution by heating,
usually rubber type to damping the related vibrations. The cooled recrystallization and homogenization. The lubrication
foundation could be rigid or flexible in different industrial performance tests result using 4-ball wear-test showed that the
plants. The flexible foundation screw compressors vibration amount of wear on ball specimen was smaller in test with the
behavior is usually more complicated and that is because of palm- grease than the test with mineral (HVI 160S) grease.
the annoying noises generated. The monitoring system is This ability of the palm-grease to provide better surface
connected to some on line vibration monitoring system in protection or anti wear property will be helpful in different
board substation. type of machine lubrication like screw compressors [18].
Each part (motor-gearbox-compressor) has a separated The electro motors of screw compressors usually equipped
vibration monitoring system. with slider bearings. Several modeling techniques developed
The electro motor usually equipped with journal bearings. in recent years for simulate such bearing conditions. The
These kind of bearings also equipped with some none contact homotopy analysis method (HAM) [19] for strongly nonlinear
probes and Bently Nevada vibration monitoring systems. problems is used to give explicit analytic solution for
Therefore, all vibration analysis techniques and methods like lubrications problems in slider bearings [20].
shaft centerline analysis [3] could be applied in critical These kind of bearings usually equipped with a vertical
conditions. direction none contact probe or two classical none contact
A new wireless condition monitoring system also developed probe for most critical equipment. The foundation of screw
in recent years. The main advantages of such system are in compressor may be flexible or rigid. Types of foundation
reducing the installation errors and increasing the monitoring could effects directly on vibration limits.
accuracy and speed [4]. Damping is a complex phenomenon, which acts in the form
The gear boxes usually equipped with shock pulse of absorption and dissipation of the energy in the vibrational
measurement (SPM) on line monitoring [5]-[7]. The bearing systems. Different factors effect on the damping such as type
condition unite (BCU) trends could be evaluated the condition of joints in the connections. There are several methods for
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foundation modeling and design like vibration modal analysis vibration rates may loosen the rubbers, both in compressor and
that is based on the phase values [21]. electromotor sides. These phenomena could produce coupling
Different maintenance strategies such as corrective, time unbalance that is hard to diagnose in complex screw
based, preventive, condition-based and predictive exist for compressors FFT and TWF. In addition, coupling abnormal
different equipment like screw compressors. noises could be disappeared in noise pollution of screw
A new fuzzy multi criteria model is introduced and it is compressor.
used for the optimization decision making of the complex It is strongly recommended to performed phase analysis
system maintenance strategy with five Criteria. Maintenance between two sides of both couplings especially between
strategies have been modeled with consideration of four fuzzy gearbox and compressor. The traditional strobe light method
parameters in the multi criteria decision making. could be helpful in some urgent conditions but the
One of the Criteria elaborates minimization of total disadvantages of this method is the danger of working with
Completion time. The second Criteria has been considered in naked critical coupling (without cover coupling) [24].
this model due to describe minimize cost. The other Criteria Shaft crack is also is one of the usual faults in both male
are in regards to minimization of risk and working man and and female or in main rotor of single screw compressors.
International Science Index, Mechanical and Mechatronics Engineering Vol:7, No:11, 2013 waset.org/Publication/9997612
maximize retrieval parts. This kind of modeling systems could Small size crack usually produce because of bad operation
be selected the types of maintenance strategy [22]. condition. The cracks may be longitudinal or radial.
Reliability Centered Maintenance (RCM) is a process to Shaft crack could be detected by amplitude, 1X, 2X phase
ensure that assets continue to do what their users require in and second harmonics of RPM monitoring. Shaft crack is hard
their present operating context. It is generally used to achieve to diagnose in complex FFT shape of screw compressors.
improvements in fields such as the establishment of safe Some modeling techniques and strategies developed in
minimum levels of maintenance, changes to operating recent years and could be detected the shaft cracks in different
procedures and strategies and the establishment of capital complex rotor shape or process condition base on
maintenance regimes and plans. Successful implementation of mathematical methods with assist of technical software’s [25].
RCM will lead to increase in cost effectiveness, machine Moreover, the axial clearances of male and female
uptime, and a greater understanding of the level of risk that the installation are considered as most challenging machinery
organization is managing. concepts and maintenance issues in screw compressors.
RCM considered as a new revolution in maintenance Maladjustment of rotors will ruin tolerances and caused
strategies. Ball bearings and roller bearings are used both in abnormal axial vibrations. Effect of an axial force and shaft
screw compressors and gearboxes. Gears, male and female are characteristics on the lateral natural frequencies of a flexible
also produced high frequencies. That is why the screw rotating shaft with a cubic nonlinearity is also recently
compressors FFT are usually complicated in high frequencies. investigated.
Roller bearing failure is a major factor in failure of rotating The shaft is assumed to be uniform, and the Euler-Bernoulli
machinery. As a fatal defect is detected, it is common to shut theory is used to model the rotating shaft. Method of multiple
down the machinery as soon as possible to avoid catastrophic scales is used to solve the dimensionless partial differential
damages. Performing such an action, which usually occurs at equation of the motion.
inconvenient times, typically results in substantial time and Linear and nonlinear lateral natural frequencies are plotted
economical losses. It is, therefore, important to monitor the for various shaft parameters and effects of these parameters
condition of roller bearings and to know the details of severity and cubic nonlinearity is discussed. In addition, the natural
of defects before they cause serious catastrophic frequencies are plotted as damping coefficients functions. In
consequences. addition, lateral natural frequencies increases by applying
Traditional FFT and TWF are most effective methods in tension axial loading and decreases by applying compression
roller bearings and ball bearings fault diagnosis. The small hill axial loading at the ends of the rotating shaft [26].
shape type frequencies are appeared around bearing high
frequencies in first stages. After that by developing bad
bearing condition the frequencies shifted themselves to ball or
roller pass frequency and its small sidebands. In this stage
bearing is completely damaged and noises are appeared during
operation [23].
Besides, monitoring overall acceleration and bearing
condition units (BCU) could be effective in fault diagnosis.
The thermography and sound analysis could be helpful in
roller bearings and ball bearings fault diagnosis. These
methods are developed too much in recent years. The
couplings in both sides of gear box are considered as most
Fig. 9 Typical on line monitoring systems for screw compressors
challenging parts of screw compressors. The couplings usually
equipped with contact piezoelectric sensors
are rubber types and produced run frequencies.
The couplings are usually under high tension. High
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International Journal of Mechanical and Mechatronics Engineering
Vol:7, No:11, 2013
Vibration limits
the power of driver in KW (size of equipment).
Good Danger condition
Location Alert condition (fair)
Case history Air compressor Pj-K-2801 C Tuesday, condition (rough)
less than
March 19, 2013 Driver between2.8-7.1mm/s above7.1mm/s
2.8mm/s
The overall vibrations were increased in all parts, locations less than
Gear box between4.5-11mm/s above11mm/s
4.5mm/s
and directions considerably compared to previous trending less than
driven between4.5-11mm/s above11mm/s
data. The vibration data are shown in Table II. 4.5mm/s
TABLE II
HIGHEST AMPLITUDES MEASURED AIR COMPRESSOR / PJ-K-2801 C
Highest Amplitudes Measured
Position Type displacement in micrometer p-p Velocity in mm/sec (r.m.s) Acceleration (mm/s2) Location health condition
Driver motor 19 2.3 5.1 motor Allowable
Gearbox Gear box 16 3 4.9 Gearbox Allowable
Driven compressor 19 2.8 4 compressor Tolerable
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TABLE III
HIGHEST AMPLITUDES MEASURED AIR COMPRESSOR / PJ-K-2801 C AFTER REPAIR
Highest Amplitudes Measured
Position Type displacement in micrometer p-p Velocity in mm/sec (r.m.s) Acceleration (mm/s2) Location health condition
Driver motor 8.8 2 0.6 motor good
Gearbox Gear box 9 1.6 3.7 Gearbox good
Driven compressor 9 1.6 1.9 compressor good
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bent shaft because of male and female sensitive geometry. [23] Mohamadi Monavar H., Ahmadi H. and Mohtasebi S.S. 2008. Prediction
of Defects in Roller Bearings Using Vibration Signal Analysis. World
The further machining operation for improving tolerances Applied Sciences Journal, 4: 152-154.
caused hydraulic unbalance in screw compressor. The [24] Hariharan V. and Srinivasan P.S.S. 2010. Vibrational Analysis of
hydraulic unbalance shows itself in run frequency, its Flexible Coupling by Considering Unbalance. World Applied Sciences
Journal, 8: 1022-1023.
harmonics and sidebands. In such cases, it is strongly [25] Eftekhari M., Javadi M. and Farsani R.E. 2011. Free vibration analysis
recommended to use the spare compressor if possible. of cracked functionally graded material beam. World Applied Sciences
Besides, it is recommended to check all air and oil Journal, 12:1223-1224.
controlling paths like unloading valves, its seat, its plug, its [26] Hosseini H., Ganji D.D., Abaspour M. and Kaliji H.D. 2011. Effect of
Axial Force on Natural Frequency of Lateral Vibration of Flexible
cylinder and their piping systems in the urgent operation time Rotating Shafts. World Applied Sciences Journal, 15: 853-854.
for possible leakage accurately.
REFERENCES
[1] Huang F. 2000. Oil-Free Screw Compressor or Oil-Injected Screw
Compressor. International Compressor Engineering Conference Purdue
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