Balancing of high-speed compressors presents unique challenges, particularly in high-demand industrial environments where downtime is costly. This paper discusses the successful balancing of a utility air supply compressor operating at 47,600 RPM. The compressor, consisting of four stages, showed high vibration levels at the fourth stage (inlet flow axial, outlet flow radial), which increased from 27 micrometers post-overhaul to 41 micrometers within a year. The dominant vibration occurred at 1X, indicating a potential unbalance issue. After consultation with the manufacturer (IR), it was decided to balance the fourth stage using the 4-run method, as rotor removal and shipment to a balancing workshop were not feasible due to production constraints.

The balancing process reduced vibration from 39 micrometers to 18 micrometers. However, several challenges emerged during the job. Initially, the use of a lock nut post-balancing resulted in abnormal vibration behavior, prompting the decision to permanently replace it with a balancing nut. Additionally, the balancing nut’s lower weight, compared to the original, posed further complications. The need to remove mass from the balance washer was restricted due to its thickness, and the radial correction required between the balancing nut and washer increased the mass removal requirement.

This presentation will delve into the potential causes of the unbalance and their corresponding verification checks, as well as the solutions implemented to overcome the identified challenges. Furthermore, the presentation will provide insights into the limitations of the balancing method used and the rationale behind the final decision to employ the balancing nut as a permanent fixture. Key takeaways will include practical strategies for balancing high-speed compressors under production constraints and the importance of considering component compatibility in achieving long-term stability.

Learning Takeaways

1. Onsite Balancing Under Production Constraints.
2. Vibration Analysis as a Diagnostic Tool
3. Importance of Hardware Compatibility and challenges.
4. Mass Removal Strategy and Geometry Constraints

I stand as a distinguished Senior Reliability and Condition Monitoring Engineer at SABIC, , where I play a pivotal role within the Asset Management Department.

With over 15 years of extensive experience in the Oil & Gas industry, I have developed a deep expertise in rotating machinery diagnostics, predictive maintenance, and AI-driven asset management. 

My expertise spans the entire spectrum of equipment lifecycle, encompassing testing, commissioning, inspection, maintenance, technical services, RCFA investigations and maintenance optimization.

I’m committed to professional excellence is underscored by a suite of certifications including CRE, CMRP, CLS, MLA II, and Vibration Cat III, among others.

I hold a PhD focused on AI in Condition Monitoring and an MBA in AI for Business Organizations. 

This unique combination of technical expertise and business acumen enables me to lead cross-functional teams effectively, optimize maintenance strategies, and align asset reliability with corporate goals.