FAKULTI TEKNOLOGI DAN KEJURUTERAAN MEKANIKAL

SEMESTER II – 2023/2024

BMKU 4853

LAB ASSIGNMENT

ROTOR BALANCING

GROUP 2

NO. NAME STUDENT ID

1 ABDUL SYAKIR BIN GHAZALI B042120022

2 AHMAD DARWIS BIN MUHMAD AHSIN B042010097

3 MARZIATUL AKMA BINTI WAHAB B042120004

4 MUHAMMAD WAFIY BIN MOHAMAD SANI B042120020

Date of the Laboratory:29 May 2024

1.0 INTRODUCTION

For rotating machinery to run smoothly and last a longer, the rotor balance is essential.
When there is an imbalance in the mass distribution around the rotor's axis of rotation, it might
be caused by wear and tear from operation, difference in the materials, or manufacturing faults.
Rotor imbalance has a significant effect, resulting in excessive vibrations that wear out
components, make noise, and perhaps cause system failures. Therefore, precise rotor balance is
essential to reduce these hazards and preserve efficient and seamless operation.

In this report the three rotor balancing methods are studied. The first one is when the trial
weight is removed. Then trial weight left on and finally, the four-run method. This report
discusses their procedures, effectiveness in vibration reduction, limitations, and potential
improvements.

Trial weight remove

The process of trial weight removal begins with an initial measurement of the rotor's
vibration levels to establish a baseline. A known trial weight is then added to a specific location
on the rotor, and the vibration levels are measured again to determine the effect of the added
weight. By analyzing the changes in vibration, the phase and amplitude of the imbalance can be
measured. The trial weight is then removed, and another measurement is taken to confirm the
initial imbalance. Based on the observation, correction weights are calculated and applied to the
appropriate locations on the rotor. After applying these weights, the vibration levels are
measured again to ensure the imbalance has been corrected. This process may be repeated with
additional adjustments until the desired balance is achieved.

Trial weight left on

For the trial weight removal method, the initial measurement of the rotor's vibration
levels is taken to create a baseline. A measured trial weight is then added to the rotor, and then
vibration levels are measured again to determine the effect after the weight has been added. By
analyzing the changes in vibration, the phase and amplitude of the imbalance can be measured.
Unlike the removal method, the trial weight is left on the rotor, and additional correction weights
are calculated and applied to the appropriate locations to balance the rotor. The vibration levels
are measured once more to ensure that the imbalance has been corrected. This process may be
repeated with further adjustments until the desired balance is achieved. Although time-
consuming, this method allows for precise determination and correction of rotor imbalance,
ensuring smooth and efficient operation of the machinery.
Four run method

The four-run method is a dynamic balancing technique used to correct rotor imbalance in
rotating machinery. It involves taking multiple measurements, with measured trial weights, to
determine the precise location and magnitude of the imbalance. For setting a baseline, the
process starts with a preliminary assessment of the rotor's vibration levels. The impact of the
additional weight will be determined by measuring the vibration levels once more after a known
trial weight is affixed to a particular spot on the rotor. The vibration levels are then recorded
again after this trial weight is relocated to a new location, which is 120 degrees from the first
position. The vibration levels are recorded once more after repeating this procedure with the trial
weight in a third position, which is often 90 degrees from the first position. The imbalance vector
of the rotor can be found by comparing the variations in vibration amplitude and phase angle
throughout the course of these four runs. The size and placement of the corrective weights
required to balance the rotor are then determined using the vibration data. After the rotor is fitted
with these correction weights, a last measurement is made to make sure the rotor is balanced.
The four-run method offers a precise and scientific way of identifying and fixing rotor
imbalances to ensure the efficient functioning of the machinery.

In addition to extending the life of equipment, efficient rotor balancing improves both
operating effectiveness and safety. Balanced rotors reduce maintenance expenses and downtime
by lowering the load on bearings and other supporting components.
 2.0 METHODOLOGY

Balancing Method 1 : Trial weight is removed

PROCEDURE:

1. Setup and Initial Measurement: Mounting the rotor on the balancing machine and
connecting the vibration sensor and tachometer to measure baseline vibrations
provide a starting point to identify any existing imbalance.
2. Make a “ reference run” or “calibration run” to measure vibration and phase.
3. Add Trial Weight: Attaching a known trial weight which is 8.7 g to a specific
location on the rotor and recording its position and mass enables targeted
adjustments to counteract imbalance.
4. Make trial run: Running the rotor again with the trial weight 8.7 g attached
allows for the measurement of vibrations, providing crucial data for calculating
the required correction weights.
5. Trial Weight Removal and Correction: Utilizing the vibration data, the necessary
correction weights are calculated to address the imbalance. Once determined, the
trial weight is removed, and the calculated correction weights are added to the
rotor which is 11.23g.
6. Final Measurement: Running the rotor once more and measuring the vibrations
ensures that the corrective measures have effectively addressed the imbalance,
resulting in optimized performance and reduced vibration levels.
RESULT

Speed : 30 Hz
Unit of measurement : mm/s

First Run: Original

Measurement RDE RNDE

Direction
Amplitude Phase Amplitude Phase

Horizontal 2.89 204.5 5.81 197.4

Vertical 2.31 143.3 2.01 116.8

Second Run: Trial Weight

Mass of the trial weight: 8.7 g

Measurement RDE RNDE

Direction
Amplitude Phase Amplitude Phase

Horizontal 3.86 250.2 3.07 251.3

Vertical 1.42 171.4 1.09 159.2

Third Run: Correction Weight

Mass of the Correction Weight :

Weight we use : 11.2 g
Weight in calculation:

Original
Trial X Trial Weight
 5.81
Balancing Weight= x 8.7
4.5
= 11.23 g

Get 35 ° in vector calculation. So, put balancing weight at 20° or 40° cause the value
is in between and choose the small value in channel number 3

Clockwise 20 °

Measurement RDE RNDE

Direction
Amplitude Phase Amplitude Phase

Horizontal 1.91 269.9 1.04 307.2

Vertical 0.867 171.2 0.510 186.8

Clockwise 40 °

Measurement RDE RNDE

Direction
Amplitude Phase Amplitude Phase

Horizontal 0.814 197.2 1.12 103.6

Vertical 0.734 137.5 0.223 51.8

⸫ so, we choose 1.04 in 20° value smaller rather than 1.12 from 40°

Percentage from original value and after run value when the trial weight is removed

5.81−1.04
x 100 = 82 %
5.81
Figure 2.1: Amplitude in trial-weight removed method in channel 3

Figure 2.2: Positioning in trial-weight removed method

Figure 2.3: Vector plot in trial-weight removed method
DISCUSSION

1. Vibration Reduction Level:

a. Refers to the degree to which vibrations are reduced or dampened during the
experiment.
b. This experiment shows that removing the trial weight reduces the percentage
difference between the original and after run values by 80%.
c. Based on the graph, the amplitude drops from the first to the third run.
2. Limitations
a. Equipment limitations, such as the tools themselves, may not be totally calibrated
or correct, causing the balance results to be inaccurate.
b. Environmental factors: vibrations from surrounding machinery and temperature
fluctuations may interfere with the balancing process, reducing its accuracy.
c. The equipment used for balancing may not be very precise or sensitive, making it
difficult to establish a perfect equilibrium.
3. Improvements
a. Involve using higher-quality equipment,
b. Controlling environmental variables
c. Employing advanced vibration reduction techniques like active vibration control
systems.
Balancing Method 2 : Trial weight is left on

PROCEDURE:

1. Setup and Initial Measurement: The rotor is mounted on the balancing machine and the
vibration sensor and tachometer are connected to measure baseline vibrations, providing a
starting point to identify any existing imbalance.

2. A “Reference run” or “calibration run” is conducted to measure the vibration and phase.

3. Add trial weight: A known trial weight which is 8.7 g is attached to a specific location on
the rotor and its position and mass are recorded to enable targeted adjustments to
counteract imbalance.

4. Make trial run: A trial run is performed with the 8.7 g trial weight attached, allowing for
the measurements of vibrations and providing crucial data for calculating the required
correction weight.

5. Correction: Utilizing the vibration data, the necessary correction weights are calculated to
address the imbalance. Once determined, the calculated correction weight of 4.4 g is
added to the rotor.

6. Final measurement: The rotor is run once more, and the vibrations are measured to ensure
that the corrective measures have effectively addressed the imbalance, resulting in
optimized performance and reduced vibration levels.
RESULT

Speed : 28 Hz

Unit of measurement : mm/s

First Run: Original

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 3.76 214.8 3.50 196.9

Vertical 1.65 138.6 1.32 124.0

Second Run: Trial Weight

Mass of the trial weight: 8.7 g

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 2.29 258.4 1.17 269.4

Vertical 1.11 164.1 0.779 172.2

Third Run: Correction Weight

Mass of the Correction Weight:

Weight we use: 4.4 g

Weight in calculation:

Original+Trial
×Trial weig h t
Trial

1.17
Balancing weig h t= × 8.7=3.2 g
3.2

Get 87 o in vector calculation. So, put the balancing weight at 80 o

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 1.31 249.6 0.103 2.1

Vertical 0.796 154.8 0.269 179.3

Percentage from original value and after run value when the trial weight is left on

3.50−0.103
×100=97 %
3.5
Figure 2.4: Amplitude in trial-weight left on method in channel 3

Figure 2.5 Positioning in trial-weight left on method

Figure 2.6: Vector plot in trial-weight left on method
DISCUSSION

1. Vibration reduction level

a. Initially the rotor exhibited significant vibrations amplitude, with the highest
value being 3.5 mm/s at the RNDE in channel 3.
b. The addition of trial weight and correction weight, the vibrations were reduced.
c. In the third run, the amplitude at the RNDE in channel 3 was reduced to 0.103
mm/s, demonstrating the reduction of 97% from the original value.
2. Limitations
a. Phase angle Estimation: The precision to determine the specific phase angle for
positioning the correction weight. Miscalculating the phase angle can result in
incomplete balancing.
b. Correction weight attachment precision: The precise positioning of the trial and
correction weights on the rotor.
c. Measurement Accuracy: The accuracy of the initial and subsequent measurements
depends on the precision and calibration of the sensors.

3. Improvement

a. Enhanced Measurement Tools: Use higher precision vibration sensors and

tachometer can improve the accuracy of the vibration measurements.
b. Optimal Trial Weight Selection: Choosing the best trial weight beforehand could
enhance the effectiveness and precision of the balancing process.
c. Environmental Control: Conducting the balancing process in a controlled
environment could minimize the impact of external factors.
Balancing Method 3 : Four Run Method

PROCEDURE:

1. Setup and Initial Measurement: The rotor is mounted on the balancing machine and the
vibration sensor and tachometer are connected to measure baseline vibrations, providing a
starting point to identify any existing imbalance.

2. A “Reference run” or “calibration run” is conducted to measure the vibration and phase.

3. Add trial weight: A known trial weight which is 8.7 g is attached to a specific location on
the rotor and its position and mass are recorded to enable targeted adjustments to
counteract imbalance.

4. Make first trial run: A trial run is performed at 0° with the 8.7 g trial weight attached,
allowing for the measurements of vibrations and providing crucial data for calculating the
required correction weight.

5. Make a second trial run: The second trial run is performed with the trial weight is move to
a new location on the rotor, typically 120° from the first position. Then measure the
vibration levels with the trial weight in the new position. The amplitude and phase angle is
recorded.

6. Make a third trial run: The second trial run is performed with the trial weight is move to
another new location on the rotor, typically 120° from the second position. Then measure
the vibration levels with the trial weight in the new position. Again, record the amplitude
and phase angle

7. Data analysis and correction: Analyze the vibration data from all four runs. Using the
vibration data, calculate the magnitude and location of the correction weights needed to
balance the rotor. The calculated correction weight of 16.2 g is added to the rotor.

8. Final measurement: The rotor is run once more, and the vibrations are measured to ensure
that the corrective measures have effectively addressed the imbalance, resulting in
optimized performance and reduced vibration levels.
RESULT

Speed : 28 Hz

Unit of measurement : mm/s

First Run: Original

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 3.89 - 3.73 -

Vertical 1.68 - 1.32 -

Mass of the trial weight: 8.7g

Second Run: Trial Weight at 0°

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 4.56 - 4.45 -

Vertical 2.05 - 2.08 -

Third Run: Trial Weight at 120°

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 5.36 - 4.87 -

Vertical 2.22 - 2.21 -

Third Run: Trial Weight at 240°

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 2.23 - 1.09 -

Vertical 1.11 - 0.906 -

Fourth Run: Correction Weight

Mass of the Correction Weight: 16.2g

Weight in calculation:

Original+Trial
×Trial weig h t
Trial

3.73
Balancing weig h t= ×8.7=16.2 g
2

Measurement RDE RNDE

Direction

Amplitude Phase Amplitude Phase

Horizontal 1.14 - 1.51 -

Vertical 0.505 - 0.674 -

Percentage from original value and after fourth run value: -

3.73−1.51
× 100=59.5 %
3.73
Figure 2.7: Amplitude in four run method in channel 3

Figure 2.8 Positioning in four run method

Figure 2.9: Vector plot in trial-weight left on method
DISCUSSION

Vibration Reduction Level:

By the fourth and final runs, the vibration levels had significantly decreased due to the
balancing process. At first, the RDE and RDE values of the horizontal vibration
amplitudes were 3.89 and 3.73 mm/s, respectively. These values decreased to 1.14 mm/s
(RDE) and 1.51 mm/s (RNDE) when the correction weight was applied, which is a
reduction of almost 59.5% from the initial values. Significant reductions were also
observed in the vertical vibrations, which went from 1.68 mm/s (RDE) and 1.32 mm/s
(RNDE) at first to 0.505 mm/s (RDE) and 0.674 mm/s (RNDE) following adjustment.

Limitations:

1. Initial Imbalance Estimation: A lack of accuracy in balancing estimation could result in

higher initial vibration levels.
2. Trial and Error Method: The method's reliance on numerous trial runs makes it time-
consuming and less effective.
3. Phase measurements are missing: Phase data is necessary for accurate diagnosis and
precise balancing correction.

Improvements:

1. Simulation and Modeling: To reduce the need for trial runs, use software to model the
system and forecast the best weight placements.
2. Environmental Control: To reduce outside influences, carry out the balancing process in a
controlled setting.
3. Phase Measurement Integration: To improve the precision and accuracy of the diagnosis,
use phase measurements.
4. Advanced Diagnostic Tools: For accurate first readings, use advanced vibration analyzers
and laser alignment devices.
3.0 DISCUSSION

How to determine whether to put correction weight in CW or CCW of the TW.

The direction (clockwise or anticlockwise) in which you move the correction weight depends on
the method used. If the method uses Trial Weight Remove, the correction weight will be CCW.
While the Trial Weight Left On the CW correction weight will be placed on the rotor. The reason
is that when the Trial Weight is removed, the original vibration needs to be canceled, while for
the Trial Weight Left On, the original and trial weight vibrations need to be countered or
canceled.

4.0 CONCLUSION

In conclusion, this report has examined three widely used rotor balancing methods, Trial
Weight Removal, Trial Weight Left On, and the Four-Run Method. Every method includes
advantages and disadvantages, and by being aware of these, people can choose the approach that
best suits their own requirements. All approaches aim to decrease vibrations and improve the
stability of the machinery. Nevertheless, the trial Weight Left On method proved to be the most
precise and successful technique at the conclusion of the experiment, ahead of the Trial Weight
Removal method and the Four Run method.