balancing newsbalancing newsInformation for the quality and performance of rotating equipment - From the Schenck Balancing & Diagnostic Systems Group

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2016_Vol. 2 & 3

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A little Maintenance Goes a Long Way......................................1

Schenck Hosts High Speed Conference........................................5

A Repeat Performance for Schenck................................................5

CAB 690: Gone But Not Forgotten..................................................6

Monitoring Hydropower Machines................................................7

Schenck Participates in EASA Conference..................................10

Schenck Exhibits at IMTS...................................................................11

Can We Chat?.........................................................................................12

IN THIS ISSUE:

A Little Maintenance Goes a Long Way

Basic balancing machine maintenance will result in accurate readings and extended machine life.

With some basic horizontal balancing machine maintenance you can extend the life of your existing Schenck balancing machines as well as continue to attain accurate readings. Maintaining the superior performance of your balancing machine will greatly reduce the chances of any extended downtime periods, as well as the need for additional balancing runs and unnecessary corrections saving you money.

It is important to follow good balancing machine maintenance practices. Basic machine maintenance aspects can be overlooked, causing: wear items to fail, increased friction and heat, or noise in the system. All of which will interfere with the machine’s ability to transmit unbalance forces from the rotor to the measuring system, resulting in erroneous balancing results.

Recommended preventative maintenance of both critical mechanical and electrical components are as follows:

Roller BearingsThe roller bearings of the twin roller carriages are subject to the most wear as they are the running surface upon which the rotor’s journals run. Roller bearings are without a doubt the highest wear item. They are also critical in transmitting the rotor’s unbalance forces accurately to the measuring system.

Bearing surfaces should be kept smooth. Pitting, gouges, or burrs on the surface of the rollers can compromise the sensitivity of the measuring system. These imperfections can be a source of mechanical noise and could also damage the journal surfaces of your rotor.

Often going unnoticed is the crown of the rollers. The rollers must have a sufficient crown in order to minimize the contact surface area *. This will reduce friction as well as any associated noise. The crown also provides a rotational degree of freedom necessary to provide accurate measurement results. Crowned rollers, which are worn fl at, will result in measurement error.

This will lead to more measuring runs and unbalance corrections, increasing the time needed for an operator to balance a rotor.

*Note: This does not apply to certain specializedmachines intentionally equipped with manufactured fl at rollers. These machines incorporate a diff erentstyle of pedestal, which places the rotationalfreedom point somewhere other than at the rollers.

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A roller has a suffi cient roller crown if the rotor’s journal is in contact with the middle 1/3 of the roller’s width. A tip for identifying rollers with fl at surfaces is to apply a small amount of machine oil to the rollers, then slowly hand-turn a rotor in the machine.

Observe the track made by the rotor journal in the oil fi lm on the roller surface (wear pattern). The track should be no wider than 1/3 the roller width. A wider than 1/3 track indicates an insuffi cient crown.

Additional roller bearing maintenance includes:

For rollers with enclosed bearings and lubrication for life:

After approx. 250 operating hours:

- Check rollers for tightness.

- Check rollers for play andmonitor regularly.

Replace rollers with tight bearings and bearings with too much play as well as rollers with damaged rolling elements, cages, and running surfaces.

For rollers with removable gaskets in the bearings:

After approx. 250 operating hours

- Check rollers for tightness.

- Check rollers for play.

In case of tight rollers: Dismount bearings, rinse thoroughly and fi ll with new bearing grease. Fill about 1/3 of the hollow spaces in the bearing with grease.

In case of too much bearing play: Mount new anti-friction bearings.

In case of damaged running surfaces: Replace damaged rollers.

When pressing replacement rollers onto their axles, never press through the bearing. Use a piece of sleeving or tubing to press against the bearing inner race.

After approx. 2000 running hours:

If rollers or roller carriages are found to be damaged or worn, please contact Schenck’s Service and/or Spare Parts Department for directions on how to have rollers replaced, returned for repair, or to schedule an on-site service visit.

Keeping spare rollers on-hand will minimize downtime, and ensure the best performance from your Schenck Balancing machine.

Bearings that are still in good condition after 2000 operating hours should be rinsed thoroughly and fi lled with new bearing grease. Fill about 1/3 of the hollow spaces in the bearing with grease. Before re-mounting bearings, after rinsing, check bearings for usability. In general, a visual check is suffi cient. Check rolling elements, running surfaces and ball cages for damage (cracks).

Keeping the journals of the rotor, and crown of the roller lubricated is important.

*See Lubrication details further down in this article.

Note: Damaged bearings should be replaced immediately.

Electrical and Mechanical Connections

Ensure all electrical interconnecting cables are properly connected at regular intervals. Cable insulation (sheathing) should not be cracked or broken. Never interchange cable connections on the back of the instrumentation for vibration pickups 1 and 2. The cable from vibration pickup 1 must be connected to instrumentation pickup input 1, and cable from vibration pickup 2 must be connected to instrumentation pickup input 2.

Vibration Pick Up and Pick up rod

The vibration pickup is totally enclosed and designed for years of trouble-free operation. However, should it become necessary to replace a pickup, please refer to your machine’s manual and/or call the Schenck Service Department for assistance. Malfunctions of the pickups are very rare. However, a complete pickup and pickup rod should be available as a spare part.

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Periodically ensure that vibration pickup connecting rods are properly assembled and secured to the oscillating bridge. Improperly assembled or secured vibration pickup connection rods will result in unsteady balance indication and erroneous measurements. Inspect for loose pickups and loose pickup cable connections, as this will also infl uence the sensitivity of the measuring system.

Photoelectric Scanning Head (belt drive only)

The lens should be cleaned with a soft, lint-free cloth. For repair of the photoelectric photo head, it is recommended that you contact Schenck Trebel for service assistance.

BeltsIt is recommended to visually inspect the belt every time the operator loads a new rotor into the machine. Inspect for excessive wear along the edges of the belt. This can be evidence of a misalignment, causing side tracking of the belt. Also inspect for drying and cracking along the belt body. Excessive wear to the belt body from a rough surface on the rotor or debris on the pulleys may result in exposure of the belt’s reinforcing fi bers. The consequences of excessive belt wear can be poor contact with the rotor, increased friction, compromised belt tension and drive capability, and most importantly, possible injury to the operator. Excessive belt wear can also cause damage to the rotor, balancing machine, and shop surroundings. Belt wear and improper belt tracking is a source of mechanical noise,

which can impair the sensitivity of the measuring system. It is recommended that stock replacement belts are kept on hand as spares so that down time is minimized and there is little aff ect on productivity.

Lubrication

Supports:

It is recommended to grease the fi ttings for the support moving pinion every 500 hours of operation.

Bed Assembly:

Keep support moving gear, rack, or chain clean and lightly greased. Clean and lightly oil bed ways prior to moving the supports.

Roller Carriage Assemblies:

Lubricate rotor journals with a few drops of oil before each balancing run. We recommend using a light machining oil per ISO VG 22, such as a Mobil Velocite #10. If rotor is kept running for more than two or three minutes, add extra oil during run. Threaded portion of carriage height adjusting screw should be kept clean and lightly oiled.

Drive Motor:

Drive motors are lubricated prior to delivery with a high quality lithium base bearing grease. Some drive motors are supplied with sealed bearings, and do not require periodic lubrication.

If the drive motor is equipped with bearing service point(s), the drive motor should be lubricated to ensure that the bearings are properly lubricated for the fi rst twelve-months of service. When lubricating drive motor bearings, be sure not to over lubricate, over lubricating could damage bearing seals. Lubrication of the drive motor bearings shall be performed every twelve months there after.

For end-drive machines, with a transmission, the transmission must be serviced at regular intervals. This will extend the serviceable life of the transmission and your balancing machine. The oil should be checked periodically and changed at regular scheduled intervals.

Initial Oil Change - After the fi rst 250 hours of operation, the transmission oil shall be changed. The best time to change the oil is immediately after the balancing machine has been operated while the oil is warm.

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The transmission has been serviced with MOBIL DTE Heavy Medium Circulating Oil that meets the specifi cation requirements of ISO 68. When servicing or changing transmission oil, it is recommended that MOBIL DTE Heavy Medium Circulating Oil be used, and if an equivalent is not available, compatible oil can be used. Please refer to your machines service manual for details.

In general, good housekeeping is recommended to help maintain good measuring results and extend the life of your balancing machine. Keeping the bed ways free of dust and chips will help maintain the alignment of the supports. Any debris in the bed ways could prevent the operator from moving the supports easily and setting them in position, with proper alignment. The supports should move freely along the bed length and not bind. They should be locked in place so that they are not skewed in relation to the bed ways. Inspection of the bed ways and support alignment is critical to ensuring the rotors unbalance forces are transmitted accurately through to the measuring system. Make certain that nothing is wedged into the bearing supports that could restrict movement of the pedestal support or vibration pickup rod. During rotor unbalance correction, (for example, during grinding of the rotor while on the machine supports) the rollers, bed ways, chain for the moving gear, and idler pulleys can be covered to prevent grinding dust from entering these critical machine components.

For belt-drive machines, keeping dust and debris out of the drive pulley and the idler pulleys will help extend the life of the belt and maintain measuring accuracy. Debris on the pulleys can aff ect the way the belt tracks over the pulleys and over the rotor or tooling. This can cause noise in the system. Any dust or chips can also wear at the belt or cut into it; resulting in more frequent belt replacements.

Schenck machines are designed and built to withstand heavy industrial use. Your balancing machines instrumentation will automatically perform a self-diagnostic test every time the instrument is powered up. Should a problem occur, such as in the case of electronic faults or a software problem in the measuring, or

for questions concerning the testing of circuit boards, our specialists for measuring electronics are available to help troubleshoot and give advice.

An overall inspection of wear items should be performed at regular intervals to help maintain your horizontal and vertical balancing machine’s measuring accuracy, prevent unexpected downtime and provide a safe operating environment for the machine operator. Regular preventative maintenance, along with proper troubleshooting, and spare parts availability, will prove to be cost eff ectiv e to your operations and you will continue to enjoy fi rst-class balancing results from your Schenck balancing machine.

Schenck Trebel provides periodic calibration services based on your application requirements and usage. Schenck also provides automatic scheduling of calibration services to avoid missed calibration deadlines and avoid unplanned downtime of your equipment.

To schedule a service or calibration visit, contact our Service Department by e-mail at service@schenck-usa.com, or by phone 1-800-TREBEL-7 (1-800-873-2357).

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Schenck Hosts High Speed Conference

In June, users and operators of High Speed balancing facilities in the U.S. and members from Schenck’s global High Speed product team came together in St. Louis to share ideas and discuss new technologies and trends. Presentations included the new ISO 21940-12:2016 (11342) document addressing procedures and tolerances for rotors with flexible behaviour, balancing techniques using Residual Mod-al Unbalance, and Schenck’s new CABflex3 Flexible Rotor Balancing software suite.

A special thank you to MD&A for their generous hosting of their facility tour. Their new High Speed balancing facility and balancing team are truly world-class, and we appreciate their support.

A Repeat Performance For Schenck

On September 22, Schenck Trebel competed in the 12th Annual Pratt & Whitney United Way Golf Tour-nament. It was their second year participating in the golf tournament that took place at Bull Creek Golf Course in Columbus, Georgia.

Last year’s tournament raised over $95k, with all of the net proceeds donated to the Chattahoochee Valley United Way chapter. This year’s event exceeded last year, raising over $100k !

Schenck Trebel played with a team of four of its employees, including Ulrik Frodermann, President and CEO, Peter Ehlers, National Sales Manager, Mark Salak, District Sales Manager and Joseph Alberto, Product Line Manager of Universal Balancing Machines.

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CAB 690: Gone But Not Forgotten

From it’s introduction in the 1980’s, the CAB 690 became one of the most popular measuring units from Schenck. The most recent deliveries date back to 2001, other than some special application units delivered in 2006.

Today, we are no longer able to fully service the CAB 690, due to its core electronic parts being discontinued on the market. Please take note of the following, prior to considering an investment in repairs to your existing CAB 690.

Schenck will still support the CAB 690 after 2016 for as long as possible but cannot promise full spare parts availability after that time.

The latest CAB 920 Smart Touch and CAB 925 Aero provide all of the essential functions to fully replace and exceed the CAB 690 functionality with cutting-edge technology.

If you are the owner of a CAB 690 Instrument and would like to consider a replacement instrument, please contact us at sales@schenck-usa.com

The CAB 920 and 925 Aero, offer a Touch Screen operator interface coupled with the latest developments in measuring technology.

CAB 690

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Monitoring Hydropower Machines

Today’s global installed hydro-power capacity represents about 20% of the world’s current electricity generated.

Hydropower provides the largest part of the renewable energy sector. About 50% of the renew-able energy in the USA is generated by hydropower.

The design of a hydropower plant is to convert kinetic energy of water into electric power. There are three typical turbine designs: Pelton turbine (Lestor Allan Pelton, OH), Francis turbine (James B. Francis, MA) and Kaplan turbine (Victor Kaplan, Austria) which are chosen based on head and fl ow of the water.

A = Pelton turbine B = Francis turbine C= Kaplan turbine

The majority of larger turbines are designed in the vertical orientation with the generator on top of the turbine. Some smaller turbines are designed in the horizontal orientation with either one turbine runner or two turbine runners, one on either side of the generator.

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Today, machine uptime is more important than ever before. Therefore, monitoring the machine status has become absolutely necessary. There are two different levels of machine monitoring either a) safety monitoring or b) condition monitoring.

a) Safety monitoring for hydropower machines, based on vibration monitoring

Safety monitoring systems for hydropower machines are using permanently installed equipment, that measure the vibration overall values of all measurement points simultaneously and gives an alarm / and / or shuts the machine down before a catastrophic failure occurs.

Since the majority of hydropower machines have journal bearings the most effective way to monitor the machine is by measuring the shaft relative vibration by means of two displacement probes per bearing plane. ISO 7919-5 provides recommendations for the type of equipment, what to measure, where to measure and acceptable vibration levels for evaluation.

In addition ISO 10816-5 provides guidelines for measuring and monitoring the bearing housing vibra-tion using seismic transducers, i.e. accelerometers or velocity transducers.

Both standards mentioned above are currently under revision and being combined into one standard (ISO 20816-5) which will cover both applications in the future.

Figure1 - is an example of two displacement probes measuring shaft relative vibration. Figure2 -is an example of one velocity transducer measuring bearing housing vibration.

b) Condition monitoring for hydropower machines, based on vibration analysis and the infl uenceof operating parameters.

Machine condition monitoring is a step above safety monitoring and provides the user with early fault detection and information on developing machine failures prior to a catastrophic failure occurs.

ISO 13373-7 sets guidelines and specific procedures to be considered when performing vibration diagnostics of various types of hydropower machines.

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Hydropower machines are primarily infl uenced by

- Mechanical unbalance- Hydraulically excited forces in the turbine runner- Magnetic forces between stator and rotor in the generator- Mechanical forces in the bearings

Machine vibration is further infl uenced by diff erent operational parameters such as:

- Load- Head- Opening of wicket gate- Bearing oil temperature

When performing condition monitoring it is essential to be able to separate the diff erences in vi-bration caused by a failure mode from the diff erences based on operating modes it is necessary to simultaneously record all vibration and operating parameters.

We are able to provide you with scalable solutions based on your particular needs for small and medi-um sized hydropower plants. Typical solutions include all or some of the following: displacement sen-sors for measuring shaft relative vibration, seismic sensors for measuring the housing and /or bearing vibration, safety monitoring equipment and condition monitoring systems. Depending on the size of the system and the number of turbines / sensors we can off er either the small Compact Monitor or the larger 19 in rack based VC-6000 with up to 36 channels per rack.

Typical Turbine Sensor Positions

Compact Monitor

VC-6000

More information on condition monitoring , or contact us at sales@schenck-usa.com

Figure1 Figure2

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Schenck Participates in the EASA Fall Conference

On September 16th, 2016, Schenck Trebel participated in the 77th Annual EASA Southeastern Chapter Fall Conference. It was held from September 16-17, in North Charleston, South Carolina in the Chapter Members’ Excel Apparatus Services, Inc. facility.

The conference included a strong focus on technical training. Scheck Trebel had the opportunity to host the event and teach their Fundamentals of Balancing Seminar along with hands on training. The demonstration portion of the seminar was performed using a 6,500 pound capacity Schenck Horizontal Balancing Machine.

This year’s Fall Conference along with Schenck’s Fundamentals of Balancing Seminar was a great success. Many thanks to the Southeast EASA Chapter and Excel Apparatus Services, Inc. for giving Schenck Trebel the opportunity to participate. We wish all of the attendees and companies participating in this year's event continued success.

For more information on Schenck’s seminars and workshops, visit our seminar page.

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Schenck Exhibits at IMTS 2016

On September 12-17, Schenck Corporation participated in the International Manufacturing Technology Show (IMTS), one of the largest manufacturing and industrial trade shows in the world, that takes place every two years in Chicago’s McCormick Place.

Schenck exhibited their products in a custom designed booth in the East Pavilion at McCormick Place featuring their Pasio 15, HM30 and the Distec machines.

Rounding out Schenck’s product line were their portable balancing analyzers, the Smart Balancer and their new Vibrotest 80 and Vibroport 80.

Schenck takes this opportunity to thank their Customers for visiting their booth!

Schenck looks forward to participating in the next IMTS Show that is scheduled for September 10-15, 2018.

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Schenck Happenings

Can We Chat? Schenck now off es their customers the convenience of Live Chat! June of 2016 marked the launch of Schenck’s chat feature on their website’s homepage.

Since it’s launch in June, we had over 300 chats with our customers.

Schenck’s live agents have answered visitors’ questions about a wide range of topics dealing with parts, service, sales, events and training, just to name a few.

Schenck’s website chat feature is available during our normal business hours. You may leave us an email any time our agents are not available.

Visit Schenck’s website now and look for the chat icon to engage with a live agent!

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