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Basic Vibration Monitoring System & Analysis

Mechanical Rotating Equipment Inspection

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

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Basics of Vibration Monitoring System and Analysis

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PRINCIPLES OF VIBRATION

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Objectives
• We will cover the following topics:
• Basic vibration motion
• Amplitude: peak, peak-to-peak and rms
• Displacement, velocity and acceleration
• Vibration units & sub-units
• Vibration Sensors
• ISO Standard
• Vibration Plots
• Basic Spectrum Analysis
• Balancing

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Vibration
• All machines vibrate.
• The vibration changes as the condition changes
• What you can hear is only part of the story.
• Vibration analysis can help you detect a wide variety of
fault conditions.

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Vibration Data Acquisition Equipment

• CSI 2130/2140
• ADRE 208/408
• System 1 Classic/Evolution

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Measuring the vibration

• We use a vibration sensor instead of a screw driver.

• We need to convert the vibration into and
electronic signal that we can measure.
• The most common vibration sensor is the
although are also
common.

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Typical vibration measurement procedure

• The accelerometer is connected to the data

collector and carried from machine to machine.
• The accelerometer is mounted on the bearing, typically
via a strong magnet between sensor and bearing.
• The data collector records the signal from the sensor.

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Vibration Unit & Sub-unit

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Describing vibration data

• Important terms: RMS (Root Mean Square), Average,

Peak and Peak-to-Peak.
• These values have been collected and trended for many
years

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Describing vibration data: pk and pk-pk

• For a purely sinusoidal signal: Peak-to-Peak = 2 x Peak

• -to- is abbreviated pk-pk
• abbreviated to pk

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Describing vibration data: RMS

• RMS = 0.707 x Peak = Peak / sqr (2)

• The RMS value is the effective value of a varying voltage
or current.
• It is the equivalent steady DC (constant) value which
gives the same effect.
• For example, a lamp connected to a 6V RMS AC supply
will shine with the same brightness when connected to
a steady 6V DC supply.

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Complex Signal

• For pure sine waves, and individual frequencies, the

peak-peak is twice the peak value and the rms level is
0.707 times the peak value.
• But for complex signals, this is not true.

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Vibration units

• When we discuss vibration amplitudes, we must quote

the units.
• The units are in terms of displacement,
velocity, or acceleration.
• Displacement, velocity and acceleration describe
three different characteristics of the vibration.

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Amplitude units: Displacement

• Displacement (or distance) between the sensor and the

shaft.
• Typical units:
– Metric: micron pk-pk
– Imperial: mils pk-pk

– 1 Micron = 1µm = 1 X 10^-3 mm = 0.04 mils

– 1 Mil = 1 X 10^-3 inch = 25.4 microns

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Amplitude units: Displacement

• At low speeds the displacement can be high

(acceleration will be low).
• At high speeds the displacement will be very
small.
• Therefore displacement is a more sensitive unit at low
frequencies and with low speed machines.

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Amplitude units: Displacement

• Commonly used on low speed machines.

Speeds below 600 RPM
• Commonly used on machines with proximity probes
installed (machines with journal/sleeve/plain
bearings).
• Commonly used when performing balancing.

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Amplitude units: Velocity

• Velocity is a common vibration unit.

• Velocity is the rate of change of displacement.
• Typical units:
– Metric: mm/sec/ rms
– Imperial: in/sec (or IPS)

– 1 mm = 0.04 inch
– 1 inch = 25.4 mm

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Amplitude units: Velocity

• In general velocity is a good measure of vibration

across most machine speeds and frequencies of
interest.
• Machines with speed 1,000 to 10,000 RPM
At very low speeds there is very low velocity.

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Amplitude units: Velocity

• Velocity units are the most commonly used vibration

units:
– Machines with rolling element bearings.
– Journal bearing machine without proximity probes
installed.
• Velocity is a measure of severity.

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Amplitude units: Acceleration

• Acceleration is becoming more and more popular as a

unit of vibration.
• Acceleration is the rate of change of velocity.
• Typical units:
– Metric: or mm/sec2 or m/s2
– Imperial:

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Amplitude units: Acceleration

• Acceleration is most sensitive to high frequency

vibration.
• At low speed there is very little acceleration.
• Acceleration units are typically used on:
– High speed machines > 10,000 RPM
– High frequency analysis: bearing and gearbox
analysis.
• Acceleration is proportional to the forces within the
machine.

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When to use disp, vel & acc?

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VIBRATION SENSORS

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Sensors
• Accelerometer
• Velocity Sensor
• Proximity Probe

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Accelerometer
• Accelerometers are a piezo-electronic (crystal) device.
• A pre- loaded crystal is charged with current and as the
crystal is compressed or de-compressed by vibration an
output proportional to g's (gravity) is provided.
• A "g" is equal to 9.80 meters/second2 or one (1) standard
earth gravity.

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Accelerometer Advantages
• Measures casing vibration
• Measures absolute vibration
• Integrate to Velocity
• Double integrate to Displacement
• Easy to mount
• Large range of frequency response
• Available in many configurations

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Accelerometer Disadvantages
• Does not measure shaft vibration
• Sensitive to mounting techniques and surface
conditions
• Difficult to perform calibration check
• One accelerometer does not fit all applications

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Mounting Location

Horizontal (X)

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Velocity Sensor
• Two (2) types of Velocity Sensors exist, mechanical and
electronic.
• Mechanical types are the most common and are made
up of a spring mounted coil mounted inside a magnet.
Vibration causes the coil to move in relation to the
magnet which produces a voltage output directly
proportional to Velocity.
• Electronic Velocity Sensors are Accelerometers with an
electronic integrator built in to the unit.

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Proximity Probe
• Eddy or Proximity Probes are a displacement device that
measure the relative motion between the probe
mounting location and the target (shaft).

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Proximity Probes

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Part Numbering
• Proximitor

• Probe

AA = Unthreaded length
BB = Case length
CC = Total length

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Part Numbering
• Extension Cable

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Component Mismatch Effects

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Proximity Probe Advantages

• Non‐contact
• Measure relative shaft vibration
• Measure shaft centerline position (DC gap)
• Measure axial position (Thrust)
• Provide Speed or Trigger
• Simple calibration
• Suitable for harsh environments

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Proximity Probe Disadvantages

• Probe can move (vibrate)
• work on all metals
• Plated shafts may give false
measurement
• Measurement is affected by
scratches & tool marks in shaft
• Available system lengths (probe, cable & driver) 5, 7, or 9
meter are standard

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VIBRATION STANDARD

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ISO 10816 Standard

• Vibration is filtered first: 3 Hz to 1000 Hz

• It is intended to represent the energy level of machine
vibration an indicator of whether the machine is OK
How high is too high?
• All machines vibrate at different amplitudes
– Size of machine
– How they are mounted
• Should we have one set of alarm limits?

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ISO 10816 Standard

Part 1: General guidelines

Part 2: Large land-based steam turbine generator

sets in excess of 50 MW

Part 3: Industrial machines with nominal power above

75 kW and nominal speeds between 120 r/min
and 15000 r/min when measured in situ

Part 4: Gas turbine driven sets excluding aircraft

derivatives

Part 5: Machine sets in hydraulic power generating

and pumping plants
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10816.3: Industrial machines

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ISO 108616.3 Zone

Zone A: The Vibration of newly commissioned machines
would normally fall within this Zone.
Zone B: Machines with Vibration within this zone are
normally considered acceptable for unrestricted longterm
operation.
Zone C: Machines with Vibration within this zone are
normally considered unsatisfactory for long-term
continuous operation. Generally, the machine may be
operated for a limited period in this condition until a
suitable opportunity arises for remedial action.
Zone D: Vibration values within this zone are normally
considered to be of sufficient severity to cause damage to
the machine.
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PTS 12.01.03

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VIBRATION PLOTS

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The goal of vibration analysis

• Vibration Analysis is used to detect early precursors to

machine failure, allowing machinery to be repaired or
replaced before an expensive failure occurs.
• Early detection of mechanical fatigue and breakdown.

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Time Waveform
• Time waveforms display a short time sample of the raw
vibration.
• Though typically not as useful as other analysis
formats, time waveform analysis can provide clues to
machine condition that are not always evident in the
frequency spectrum and, when available, should be
used as part of analysis program.

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Spectrum

There is a way to convert the waveform to spectrum. It

is called the or Fourier The result
is the

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Areas of a spectrum

• Spectrum analysis separates the total vibration into

discrete frequencies so that the source(s) of a given
problem may be easily identified.

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Areas of a spectrum

Harmonics

Sideband

Broadband

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Waterfall Plot
• Changes in vibration levels as a function of changing
machine speeds or loads are normally analyzed
using waterfall plots.
• Waterfalls, also referred to as cascade plots or spectral
maps, consist of a series of spectrums placed one
behind the other to generate a 3-dimensional graph.

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Orbit Plot

• If we now plot the two time waveforms against

each other, we would get a circle called a Lissojous
figure, or an orbit.
• Orbits are used to analyze the movement of shaft in
journal bearings.

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Orbit Plot

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Orbit Plot

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Bode Plot
• A Bode plot displays order magnitudes and phases as a
function of rotational speed or frequency.
• It can help to identify the resonance speed of a rotor or
examine the rotor dynamics on an order basis.

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Polar Plot
• A polar plot displays data in polar coordinates, which
enables you to see phase changes in the range of zero
to 360 degrees.
• The polar plot zero degree point always is located at
the angular position of a transducer.

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Shaft Centerline
• The centerline plot shows where the shaft is located in
the bearing.
• It can be used to see if there is misalignment or
excessive preload.

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SPECTRUM ANALYSIS

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Imbalance
• Force Imbalance

• Couple Imbalance

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Imbalance
• Dynamic Imbalance

• Overhung Rotor Imbalance

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Misalignment
• Angular Misalignment

• Parallel Misalignment

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Looseness

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Antifriction Bearing Defect

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Other Problems Detected by VA

• Pump/Compressor • Gear
• Eccentric rotor • Tooth wear
• Bent shaft • Gear eccentricity/backlash
• Resonance • Crack/broken tooth
• Rotor rub • Electric Motor
• Oil whirl/whip • Shorted lamination
• Turbulence • Eccentric rotor
• Cavitation • Rotor problems
• Shaft crack • Broken/crack rotor bars
• Soft foot • Belt
• Worn/loose

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ROTOR BALANCING

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Force Imbalance

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Couple Imbalance

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Causes of Imbalance
• Material build up (dirt, dust, product)
• Material loss (Cavitation, erosion)
• Poor manufacture
• Incorrect assembly (key, couplings, blades)
• Poor original balancing

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Type of Balancing
• Shop Balancing
• Often use balancing small rigid rotor/components
of at low speed
• Do not mimic real machine support and constraints
• High speed turbomachinery balancing is done in
vacuum tight pits

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Type of Balancing
• Field Balancing
• Trim balancing (single/multiplane)
• Four run method balancing (w/o phase)

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Trim Balancing Workflow

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Trim Balancing

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Four Run Method Balancing

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Balancing Standard
• Shop Balancing Standards
1. ISO Rotating
Rigid Bodies
recommended balance tolerances.
2. American National Standards Institute (ANSI) adopted
this standard in 1989 with ANSI S2.19-1989.
3. API has different set of standards

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Shop Balancing Standards

• Balance quality grades
for various groups of
representative rigid
rotors
• Source: ISO 1940-/1

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Shop Balancing Standards

• Maximum permissible
residual specific
unbalance value
corresponding to various balance
quality grades
• Source: ISO 1940-/1
(SI Units)

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THANK YOU

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