The Imperative of Centrifuge Balancing in Industrial Operations

Published by Nikolai Shelkovenko on

Centrifuge Balancing

Centrifuges are the real workhorses in the chemical, food, oil and gas, and pharmaceutical industries. They perform a huge number of tasks, and their uninterrupted operation at high speeds is only possible with perfect balancing. Imbalance can lead to a host of problems:

  • Reduced product quality and increased waste: Unstable centrifuge operation leads to poor component separation. This, in turn, degrades the final product and increases waste. For instance, in the food industry, this can result in the spoilage of large batches of products.
  • Accelerated wear: Excessive vibration quickly wears out bearings, shafts, and couplings. I once saw an entire production line come to a halt because of this.
  • Increased noise levels: Strong vibration creates noise that can drive even the calmest employee crazy. Besides the discomfort, it’s also hazardous to health.
  • Other vibration-related issues: Imbalance causes uneven loads, increasing the risk of cracks in the centrifuge casing, loosening of fastenings, and other malfunctions. I remember seeing minor imbalances lead to significant equipment damage.

Why Dynamic Centrifuge Balancing Is So Important

The higher the rotation speed, the more severe the consequences of operating with imbalance. I recall a plant where they neglected proper balancing, which led to a complete breakdown of an expensive centrifuge. Regular condition checks and preventive balancing not only extend the equipment’s lifespan but also prevent serious breakdowns and costly downtime.

Dynamic Balancing at the Operation Site: The Optimal Approach

Dynamic balancing is performed directly at the installation site of the centrifuge, without the need for dismantling, using the machine’s own support bearings. This approach has several clear advantages:

  • Speed: There’s no need for transportation and disassembly, allowing balancing to be carried out promptly. Once, we saved an entire day of production this way.
  • Accuracy: Balancing the rotor in its operating bearings eliminates distortions that can arise if balancing is done on a removed component on a balancing machine. This helps avoid numerous minor but annoying issues.
  • Minimal intervention: Dynamic balancing avoids complex assembly and disassembly work, saving time and resources.
  • Optimal results: On-site balancing achieves the lowest possible residual imbalance, ensuring flawless operation of the centrifuge. I remember how, after such a procedure, the equipment worked like new.

Tools and Techniques for Balancing

Balanset-1A Vibration Analyzer

For assessing the initial vibration level and conducting the balancing itself, we use the portable Balanset-1A device. This specialized vibration analyzer and balancing machine is noted for its precision, versatility, and ease of use. Learn more about the capabilities of this instrument – FAQ.

Instructions for Balancing Centrifuge Rotor

Preparation of Equipment and Program Setup

  1. Install vibration sensors perpendicular to the rotation axis of the centrifuge rotor: one on the front side of the rotor, the other on the rear side.
  2. Secure the tachometer on a magnetic stand and ensure it is firmly fixed.
  3. Attach reflective tape to the rotor pulley. Aim the tachometer sensor at the tape so it can read the revolutions.
  4. Connect the vibration sensors and tachometer to the Balanset-1A device. Then connect the device to the laptop.
  5. Launch the Balanset-1A program on the laptop. Ensure the program recognizes all connected sensors.
  6. Select the two-plane balancing mode in the program.
  7. Enter the rotor name and its location for easy identification in reports.

Preparation and Initial Measurement

  1. Weigh the test weight and record its weight and installation radius.
  2. Start the centrifuge rotor and let it reach operating speed. Conduct the initial vibration level measurement.

Balancing in the First Plane

  1. Install the test weight in the first plane (the side where the first vibration sensor is installed).
  2. Start the centrifuge rotor and conduct the second vibration measurement. Ensure that the vibration or phase has changed by at least 20%.

Balancing in the Second Plane

  1. Remove the test weight from the first plane and install it in the second plane (the side where the second vibration sensor is installed).
  2. Start the centrifuge rotor and conduct the third vibration measurement.

Correction and Verification of Balancing

  1. The Balanset-1A program will indicate how much weight and at what angle to install in the first and second planes.
  2. Remove the test weight from the rotor.
  3. Weigh the corrective weights and install them. The angle of installation is measured in the direction of rotor rotation from the test weight installation point.
  4. Start the centrifuge rotor and conduct the final vibration measurement to ensure the balancing was successful.
  5. If the program suggests adding more weight, do so and recheck the balancing.

Completion of Work

  1. Remove all sensors and equipment used for balancing.
  2. Record all data and results in the balancing report.

The Importance of Adhering to Balancing Standards

In the process of balancing centrifuges, it is necessary to follow current standards, such as ISO 1940-1-2007. These standards define acceptable vibration levels for each class of equipment. The stricter the norms, the higher the requirements for balance. Adhering to standards ensures that the centrifuge operates efficiently, reliably, and with minimal wear even under the most intense conditions.

Conclusion

Balancing centrifuges is not just desirable but critically important for maintenance. Neglecting this leads to accelerated wear, reduced productivity, and even catastrophic failures. Regular balancing with modern devices such as the Balanset-1A ensures safe and impeccable equipment operation, which pays off many times over by saving on repairs and production downtime.

Categories: Examplerotors
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