Practical Application of Vibration

Monitoring and Analysis

Organized by Handal Wira Mandiri
Presented by Cistech Alpha Indonesia
Eric Suseno

Gran Mahakam Hotel, Jakarta 22‐25 January 2008

 Practical Application of Vibration
Monitoring and Analysis

Overview

Gran Mahakam Hotel, Jakarta 22‐25 January 2008

 Overview
Evolution of Machinery Maintenance
MACHINERY AVAILABILITY,
RELIABILITY & PERFORMANCE HIGH AVAILABILITY
HIGH RELIABILITY
HIGH PERFORMANCE
LESS MAINTENANCE COST

PREDICTIVE
MAINTENANCE

PREVENTIVE
MAINTENANCE
CORRECTIVE
MAINTENANCE

INDUSTRIAL
TECHNOLOGY PROGRESSION PRESENT
REVOLUSION

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22‐25 January 2008 Monitoring and Analysis
 Overview
Evolution of Machinery Maintenance

• Operate till breakdown

No action if not fatal failure, actually is not maintenance but repair only, so
called corrective maintenance
• Time‐based maintenance
Periodical
P i di l preventive
ti action
ti (i
(i.e. parts
t replacement)
l t) tto preventt ffailure,
il so
called Preventive Maintenance (PM)
• Condition‐based maintenance
Periodical condition monitoring to predict failure by evaluating the trend of
some parameters from time to time, so called Predictive Maintenance
((PdM)) or Condition Monitoringg (CM)
( )

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22‐25 January 2008 Monitoring and Analysis
 Overview
Evolution of Machinery Maintenance – Corrective Maintenance
“Fix
Fix it only if it is broken”
broken
• A passive/reactive philosophy
No measures are taken to anticipate and prevent failure
• Very expensive in case of:
¾ Fatal damage – failed component could harmfully affect other
components t
¾ Safety risk – related to human, environment or the whole plant
¾ Unplanned downtime – inconvenient production stoppage, loss revenue
¾ Unplanned repair work – labor, tools & equipment, spare parts
¾ Product waste – coagulation, freezing, spoiling, …
¾UUncertain
ce ta spa
spares
es inventory
e to y – ag
agingg spa
sparee or
o no
o spa
sparee

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22‐25 January 2008 Monitoring and Analysis
 Overview
Evolution of Machinery Maintenance – Preventive Maintenance
“Fix
Fix it before it is broken
broken”
• A proactive philosophy
Maintenance on regular time basis to prevent failure regardless the condition

• Also costly in case of:

¾ Regular extra downtime – frequent production stoppage for maintenance
¾ Regular extra work – labor, tools & equipment
¾ Longer duration of maintenance – more tasks to do
¾ Unnecessary parts replacement – parts that reached ‘lifetime’ in many
cases still good for longer period usage
¾ Risk of premature failure – sometime parts don’t reach its “lifetime”
¾ Risk
s of
o reassembly
easse b y errors
e o s – more
o e disassembly,
d sasse b y, more
o e eerror
o probability
p obab ty

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22‐25 January 2008 Monitoring and Analysis
 Overview
Evolution of Machinery Maintenance – Predictive Maintenance
“Fix
Fix it only if it will be broken”
broken
• An advanced proactive philosophy
Determines the condition of machinery as it operates, to schedule the most
effective and efficient repair of problem component prior to failure
¾ Higher machine availability, reliability and performance
¾ Greater safetyy & environment
¾ Better product quality
¾ Longer machinery life
¾ The most cost effective
¾ Mandatory for critical machinery

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22‐25 January 2008 Monitoring and Analysis
 Overview
Predictive Maintenance – the Concept

• Detection of a developing fault

• Trending of the fault
• O
Operate
t th
the machine
hi up tto bbutt b
before
f ffailure
il
• Plan maintenance ahead of time and save money
• Focus on problem component and solve the root cause Failure

Machine ccondition
Danger Level

Alert Level
Fault detection

Lead time
before failure
Running Time

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 Overview
Predictive Maintenance – the Tools

• Vibration monitoring and analysis

• Thermography
• Lube/oil analysis
• Current analysis
• Ultrasound/acoustic analysis
• Thickness/corrosion check
• Process parameter monitoring (temperature,
pressure flow,
pressure, flow …))
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22‐25 January 2008 Monitoring and Analysis
 Overview
Predictive Maintenance – some Pictures

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22‐25 January 2008 Monitoring and Analysis
 Overview
Predictive Maintenance – some Pictures

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22‐25 January 2008 Monitoring and Analysis
 Overview
Predictive Maintenance – some Pictures

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22‐25 January 2008 Monitoring and Analysis
 Overview
Predictive Maintenance – some Pictures

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 Overview
Vibration Monitoring and Analysis – Outline

• Vibration Basics – Day 1

• Vibration Data Acquisition – Day 2
• Vibration Condition Evaluation – Day 3
• Vibration Fault Analysis – Day 3
• Vibration Practice – Day 4

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 Practical Application of Vibration
Monitoring and Analysis

Vibration Basics

Gran Mahakam Hotel, Jakarta 22‐25 January 2008

 Vibration Basics
Fact about Rotating Machinery

• All rotating parts generate vibration

• The vibration indicates the healthy condition of the
machine
• In general, worst the machine condition, higher the
vibration
• Individual components
p on a machine train ggenerate
vibration signals unique to each component

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 Vibration Basics
What is Vibration? – Sine Wave Model

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 Vibration Basics
What is Vibration? – Displacement, Velocity, Acceleration

• Displacement is the change in distance or position of

an object
j relative to a reference
• Velocity is the first derivative of displacement as a
function of time, it is the rate of change in
displacement
• Acceleration is the second derivative of displacement,
it is the rate of change of velocity

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22‐25 January 2008 Monitoring and Analysis
 Vibration Basics
What is Vibration? – Displacement, Velocity, Acceleration

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 Vibration Basics
What is Vibration? – the Unit and Conversion

•Displacement (D)
mils or micron (μm)
•Velocity (V) V = D.ω
A = V.ω = D.ω2
inch/sec (ips) or mm/sec ω = 2πf
•Acceleration (A)
Beware of the unit consistency
g or inch/sec2 (ipss) or m/sec2 when do conversion!

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 Vibration Basics
What is Vibration? – Exercise
xercise 1
Exercise
An electric motor runs at speed 1500 rpm. The
vibration measured in unit of velocityy is 4.5 mm/sec.
/
How much is the vibration in unit of displacement?

f = 25 Hz
π = 3.14
4.5 mm/sec
D= = 28.66x10 −3 mm = 28.66 µm
2x3.14x25/sec

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22‐25 January 2008 Monitoring and Analysis
 Vibration Basics
What is Vibration? – Exercise
xercise 2
Exercise
A pump runs at speed 3000 rpm. The vibration
measured in unit of displacement
p is 1 mils. How much
is the vibration in unit of acceleration?

f = 50 Hz
π = 3.14
A = 1 mils x (2x3.14x50/sec) 2 = 98.596x103 mils/sec2 = 98.596 ipss

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 Vibration Basics
What is Vibration? – Exercise
xercise 3
Exercise
A fan runs at speed 1200 rpm. The vibration measured
in unit of acceleration is 0.1 gg. How much is the
vibration in unit of velocity?
f = 20 Hz
π = 3.14
g = 9.8
9 8 m/sec 2
0.1x9.8 m/sec 2
V= = 7.8x10-3 m/sec = 7.8 mm/sec
2x3.14x20/sec

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22‐25 January 2008 Monitoring and Analysis
 Vibration Basics
What is Vibration? – Peak, Peak to Peak, RMS

Peak is distance from neutral to upper position or from neutral to lower

position
Peak to Peak is distance from upper position to lower position
RMS is effective value, by mathematic the formula is Root‐Mean‐Square

Peak to Peak = 2x Peak

RMS = ½ √2 x Peak = 0.7x Peak
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 Vibration Basics
What is Vibration? – Amplitude, Frequency, Phase

Amplitude A
1
a (t) = A sin(θ0+ωt)
Frequency f =
F
T A
Phase θ 0

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22‐25 January 2008 Monitoring and Analysis
 Vibration Basics
What is Vibration? – Amplitude, Frequency, Phase

• Vibration Amplitude indicates the severity of problem

How much is it vibrating?
• Vibration Frequency indicates the source of problem
What is vibrating?
• Vibration Phase indicates the behavior of problem
How is it vibrating?

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 Vibration Basics
Vibration Frequency – What is vibrating?

• Individual components on a machine train generate

vibration at each respective
p frequency
q y

Vibration
amplitude

Frequency
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 Vibration Basics
Vibration Frequency – What is vibrating?
xample
Example
• Motor speed 1500 rpm (25 Hz)
• Gear ratio 1:2 (speed reducer)
• Fan speed 750 rpm (12.5 Hz)

Vibration from component

related to motor speed 0s 0.08 s

Vibration from component

related to fan speed 0s 0.08 s

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 Vibration Basics
Vibration Frequency – the Unit

• RPM (Revolutions Per Minute) – Speed

• CPM (Cycles Per Minute) – Frequency
• CPS (Cycles Per Second) or Hz (Hertz)
• Orders of Running Speed – how many times event
occurs per shaft revolution (1x rpm, 2x rpm, …)

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 Vibration Basics
Sum of Vibration in Time Domain

f1

+
f2

=
f1 + f2

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22‐25 January 2008 Monitoring and Analysis
 Vibration Basics
Sum of Vibration in Time Domain

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 Vibration Basics
Sum of Vibration in Frequency Domain

f1

+ f1 f

f2

= 2f1 f

f1 + f2

f1 2f1 f
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 Vibration Basics
Vibration Amplitude and Frequency

Questions?

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 Vibration Basics
Vibration Phase – How is it vibrating?
xample
Example
180 deg different between two vibration sources

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 Vibration Basics
Vibration Phase – Relative to a Reference

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 Vibration Basics
Vibration as Result of Force x Mobility

Vibration
Internal
Forces

Structurall
Vibration = Forces x Mobility Mobility

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 Vibration Basics
Vibration as Result of Force x Mobility

Forces x Mobility = Vibration

DD

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 Vibration Basics
Vibration as Result of Force x Mobility

h(t)
Force Input Impulse
response
function t
Output Point 1
Point 2

H(f))
Mobilityy
Point 1
t f
H(f))
Mobility
Point 2
f
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 Vibration Basics
Vibration as Result of Force x Mobility
Measured vibration from the same source may be different from point to point

Point 1

Forces x Mobility = Vibration

Point 2

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22‐25 January 2008 Monitoring and Analysis
 Vibration Basics
Vibration Basics

Questions?

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 Practical Application of Vibration
Monitoring and Analysis

Vibration Data Acquisition

Gran Mahakam Hotel, Jakarta 22‐25 January 2008

 Vibration Data Acquisition
In the past

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 Vibration Data Acquisition
In the past

• The first portable vibration measuring instrument

manufactured byy Schenck,, introduced at an exhibition
in Leipzig in 1925

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 Vibration Data Acquisition
Types of Machine’s Vibration Measurement

Absolute
Bearing Vibration

Relative Absolute
Shaft Vibration Shaft Vibration

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 Vibration Data Acquisition
Types of Machine’s Vibration Measurement
– Bearing
earing Vibration or Shaft Vibration?

• Rule 1: The vibration measurement that delivers the

highest information content should be chosen
• Rule 2: If no experience is available, the maximum
information will be obtained by measuring
¾Relative shaft vibrations on machines with sleeve
b i
bearings
¾Absolute bearing vibrations on machines with
rolling‐element bearings
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 Vibration Data Acquisition
Measuring Bearing Vibration

• Horizontal direction
• Vertical direction
• Axial direction

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 Vibration Data Acquisition
Measuring Shaft Vibration

• Using two sensors, perpendicular to the shaft with

distance 90o each other
A B

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 Vibration Data Acquisition
Vibration Sensors

• Displacement sensor
• Velocity sensor Acceleration

• Acceleration sensor
• Phase sensor (tacho)
Velocity

Displacement

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 Vibration Data Acquisition
Displacement Sensor

• With external oscillator

• With integrated oscillator

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 Vibration Data Acquisition
Displacement Sensor

• Is a non contacting sensor

• Electromagnetic field from a coil at the sensor tip
induces eddy‐currents in conducting material through
air gap, which is proportional to the gap
• So called eddy‐current probe or sometime also called
proximity probe
• The probe, oscillator and cable are a set of measuring
chain that cannot freely substituted

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 Vibration Data Acquisition
Displacement Sensor

• Measure relative distance between two surfaces

• Monitor shaft vibration
• Used on machine with fluid film bearing (journal)
• Accurate low frequency response
• Limited high frequency sensitivity
• Require external power source
• Influenced by material density variations and
mechanical run‐out
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 Vibration Data Acquisition
Displacement Sensor

• More difficult to install compared to other sensor type

• Easier to damage especially at sensor tip

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 Vibration Data Acquisition
Displacement Sensor – Properties

• Frequency range 0 ... 1 kHz

• Linear measuring range 1 1.5
5 / 2 / 4 / 8 mm and larger
• Transmission factor 8 / 4 / 2 mV/µm

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 Vibration Data Acquisition
Displacement Sensor – Typical Transmission Curve
0

GAP voltagge [V]

-5

-10

-15

-20
0 0,5 1,0 1,5 2,0 2,5 3,0
s [mm]
[ ]

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 Vibration Data Acquisition
Displacement Sensor – Determining the Sensitivity
0

GAP voltagge [V]

-5

∆U ∆U
Sensitivity = G -10

∆s
-15 ∆s

-20
0 0,5 1,0 1,5 2,0 2,5 3,0
s [mm]
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 Vibration Data Acquisition
Displacement Sensor – Other Application

• Thrust
• Shaft expansion

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 Vibration Data Acquisition
Velocity Sensor

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 Vibration Data Acquisition
Velocity Sensor

• Consists of a magnetic core suspended on springs and

surrounded byy a coil of wire. Relative motion between
the coil and core produces an output voltage
proportional to velocity
1 Helical spring
2 Spool

3 Spool carrier

4 Permanent magnet

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 Vibration Data Acquisition
Velocity Sensor

• Attached to bearing housing to monitor absolute

bearingg vibration
• Used on machine with rolling element bearing
• Effective in low to mid frequency range (10 Hz to
around 1.5 kHz)
• Active sensor,, requires
q no p
power
• Influenced by strong magnetic field
• Mechanical moving inside can stick or fail
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 Vibration Data Acquisition
Acceleration Sensor

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 Vibration Data Acquisition
Acceleration Sensor

• Consists of piezoelectric crystal elements and a mass.

When the p piezoelectric crystal
y is stressed byy the mass
due to vibration from machine, it produces an
electrical output proportional to acceleration.
1 2
3
4
5
7
5 1 Housing
2 Charge amplifier
3 Pre-tensioning element
6 4 Seismic mass
5 Piezo-electric element
6 Base
7 C
Cable connection

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 Vibration Data Acquisition
Acceleration Sensor

• Wide frequency range (near 0 to above 40 kHz)

• Good for high frequency response but low sensitive at
low frequency
• Rugged construction and not Influenced by magnetic
field
• Some models available for high temperature
• Small size and light weight, suitable for portable survey
• Requires power

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 Vibration Data Acquisition
Photo‐electric Phase/Reference/Trigger/Speed Sensor

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 Vibration Data Acquisition
Sensor Attachment

• Using extension probe

• Using magnet mounting
• Using threaded stud

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 Vibration Data Acquisition
Sensor Attachment – Extension Probe

Sensor

Probe

Center punch
Center-punch Dimpled plate

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 Vibration Data Acquisition
Sensor Attachment – Extension Probe

• Usable frequency range of accelerometer using

extension probe:
p
¾ Aluminum 1 to 700 Hz
¾ Steel 1 Hz to 1 kHz
• Easy
E to attach
h
• Care required when holding the probe
• Offline measurement, suitable for measurement point
that is not possible to attach magnet

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 Vibration Data Acquisition
Sensor Attachment – Magnet Mounting

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 Vibration Data Acquisition
Sensor Attachment – Magnet Mounting

• Usable frequency range of accelerometer using

magnet
g mounting:
g 1 Hz to 2,2
, kHz
• Easy to attach, operator hands‐free
• Magnet should sit flat and surface should clean
• Ferrous material required
• Offline measurement

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 Vibration Data Acquisition
Sensor Attachment – Threaded Stud

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 Vibration Data Acquisition
Sensor Attachment – Threaded Stud

• Usable frequency range of accelerometer using

threaded stud: 1 Hz to 20 kHz
• Best possible measurement reproducibility
• Requires more preparation work to install the sensor
• Online measurement, permanent installation

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 Vibration Data Acquisition
Measurement Parameter Setup

• Measurement unit and signal detection (e.g. mm/sec rms)

• Frequency Setting (e.g.
(e g 10 Hz to 1 kHz)

• Line resolution (e.g. 1600 lines)

• Average (e.g.
(e g frequency domain
domain, 16x)

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 Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting

• Lower and upper frequency limit are set according

what frequency
q y range
g we are interested
• Frequency setting will affect the resolution

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 Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting

Component Upper Frequency Limit (Fmax)

Shaft vibration 10x rpm
p
Gearbox 3x Gear Mesh Frequency
Rolling element bearing 10x Ball Pass Frequency
P
Pump 3 V
3x Vane P
Pass FFrequency
Motor/generator 6x Line Frequency
Fan 3x Blade Pass Frequency
Sleeve bearing 10x rpm
Engine 12x rpm

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 Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting

Application Lower Frequency Limit (Fmin)

Machineryy monitoringg 1% Fmax
General measurement 3 to 10 Hz
Gear Box 0.25x GMF (or 20x rpm)
S i l application
Special li ti 10 to
t 20x
20 rpm

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 Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting
xample
Example
Driving gear 52T, driven gear 17T, 600 rpm driving shaft
How do we set the frequency setting?

GMF = T1 x rpm1 = T2 x rpm2 = 52 x 10 Hz = 520 Hz

Fmax > 3x GMF = 1560 Hz Æ 1600 Hz
0 25x GMF = 130 Hz Æ 100 Hz
Fmin < 0.25x

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 Vibration Data Acquisition
Measurement Parameter Setup – Line Resolution

• Line resolution is frequency range divided by number

of line on the frequency
q y axis
• Higher the resolution, more accurate the spectrum for
analysis
• But consequently, higher the resolution, longer time
required for data acquisition

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 Vibration Data Acquisition
Measurement Parameter Setup – Average

• Average is statistical average to smooth out varying

amplitude
p in order to improve
p measurement accuracyy
• Average can be done in time domain (original signal)
or in frequency domain (FFT spectrum)
• Higher the number of average, more accurate the
data, but consequently takes longer time

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 Practical Application of Vibration
Monitoring and Analysis

Vibration Condition Evaluation

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 Vibration Condition Evaluation
Evaluation Method

• Comparison of measurements with limits from

standards and guidelines
• Comparison of measurements with limits from the
machine manufacturer
• Evaluation
E l ti on the th b
basis
i off experience
i and
dddata
t from
f
measurements by the operator at identical or similar
machines
• Evaluation of the measurements over time (Trend)

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 Vibration Condition Evaluation
Measurement over Time

• To do trending, the measurement condition should be

the same:
¾Same measurement point
¾Same attachment method
¾S
¾Same parameter
t setup
t
¾Same speed
¾Same load
• Trend is the best way to evaluate machine condition
and perform Predictive Maintenance
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 Vibration Condition Evaluation
Evaluation According to ISO 10816

• Mechanical vibrations – Evaluation of vibrations from

machines by measurement on non rotating parts
Part 1 General instructions
Part 2 Large, stationary steam turbine/generator sets with power above 50
MW
Part 3 Industrial machines with nominal power above 15 kW and nominal
speeds between 120 rpm and 15000 rpm; measured on‐site
Part 4 Machine sets with gas turbine drive
drive, excluding aircraft jet engines
Part 5 Machine sets in hydro‐electric power and pumping plants
Part 6 Reciprocating machines with power above 100 kW

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 Vibration Condition Evaluation
Evaluation According to ISO 10816

• Application
¾Operational monitoring and acceptance tests of
machines
¾No torsional vibrations
¾N enviromental
¾No i t l vibrations
ib ti

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 Vibration Condition Evaluation
Evaluation According to ISO 10816

• Evaluation zones
¾Zone A
Vibrations in newly installed machines
¾Zone B
Machines may be operated continuously without restriction
¾Zone C
Machines may be operated only for a limited time
¾Zone D
Vibrations are excessive and may cause permanent damage to the
machines

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 Vibration Condition Evaluation
Evaluation According to ISO 10816

• Guideline for measurement and evaluation

Criterion I
The maximum measured radial vibration value* may
not exceed a specific maximum value

*effective value RMS in the frequency range 10 Hz to 1 kHz vibration

velocity resp. vibration displacement
att speeds
d < 600 rpm, frequency
f range 2 H
Hz tto 1 kH
kHz

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 Vibration Condition Evaluation
Evaluation According to ISO 10816

• Limit values for vibration monitoring

When measuring at a number of points, the maximum measured vibration
value is the vibration severity of the machine

PRE‐ALARM limit = Ref. value + 25% x (upper limit of zone B)

When no baseline value is available:

PRE‐ALARM limit < 1.25 x (upper limit of zone B)
MAIN ALARM limit < 1.25 x (upper limit of zone C)

or other values when machines are well known

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 Vibration Condition Evaluation
Evaluation According to ISO 10816

• Criterion II
The maximum measured radial vibration value*
should not exhibit an appreciable increase or decrease
relative to a reference value
*effective value RMS in the frequency range 10 Hz to 1 kHz vibration
velocity resp. vibration displacement
at speeds < 600 rpm, frequency range 2 Hz to 1 kHz

Appreciable deviations from reference value typically > 25% x (upper limit of
zone B). Diagnostic investigation is appropriate, even though the limit value
may not have been reached
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 Vibration Condition Evaluation
Evaluation According to ISO 10816

• Elasticity of the sub‐structure

Rigid sub‐structure:
Lowest resonant frequency of the combination of machine and sub‐
sub
structure at least 25% above the lowest fundamental excitation frequency
(typically = machine service speed)
Flexible sub‐structure:
sub structure:
when the conditions above are not met

Remark:
Consideration for each measurement direction, e.g. a machine may be
vertically rigid and horizontally flexible; then a different limit value for each
measurement direction

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 Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3

• Steam turbines with power up to and including 50 MW

• Steam turbines with power above 50 MW when service speed is lower than
1500 rpm or higher than 3600 rpm
• Gas turbines with power up to and including 3 MW
• Turbo‐compressors
• Pumps
P
• Generators
• Electric motors
• Blowers
• Fans with power up to and including 300 kW

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 Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 1

• Large machines with nominal power above 300 kW; electrical machines with
shaft height H ≤ 315 mm

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A
29 2.3
B
rigid 57 4.5
C
90 7.1
D
A
45 3.5
B
90 7.1
C
140 11
D

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 Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 2

• Medium size machines with nominal power from 15 kW to 300 kW;

electrical machines with shaft height 150 ≤ H ≤ 315 mm

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A 1.4
22
rigid
B
45 2.8
C
71 4.5
D

A 2.3
37
B
71 4.5
C
113 7.1
D

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 Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 3

• Pumps with multi‐vane impellers and separate drive (with radial, semi‐radial
or axial flow) with nominal power above 15 kW

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A
18 2.3
B
rigid 36 4.5
C
56 7.1
D
A
28 3.5
B
flexible 56 7.1
C
90 11
D

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 Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 4

• Pumps with multi‐vane impellers and integrated drive (with radial, semi‐
radial or axial flow) with nominal power above 15 kW

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A
11 1.4
B
rigid 22 2.8
C
36 4.5
D
A
18 2.3
B
flexible 36 4.5
C
56 7.1
D

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 Vibration Condition Evaluation
Evaluation According to ISO 7919

• Mechanical vibrations excluding repiprocating

machines. Measurement and ecaluation of shaft
vibrations
Part 1 General instructions
Part 2 Large, stationary steam turbine/generator sets
Part 3 Coupled industrial machines
Part 4 Gas turbines
Part 5 Machine sets in hydro‐electric power and pumping plants

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 Vibration Condition Evaluation
Evaluation According to ISO 7919

• Evaluation zones
¾Zone A
Vibrations in newly installed machines
¾Zone B
Machines may be operated continuously without restriction
¾Zone C
Machines may be operated only for a limited time
¾Zone D
Vibrations are excessive and may cause permanent damage to the
machines

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 Vibration Condition Evaluation
Evaluation According to ISO 7919

• Guideline for measurement and evaluation

Criterion I
The relative shaft vibrations may not excees the
prescribed maximum values

Criterion II
The changes in the shaft vibrations
vibrations, relative to an
initial level, may not exceed the prescribed maximum
values
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 Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 2

• Large, stationary steam turbine/generator sets

Evaluation zone Shaft speed in rpm

1,500 1,800 3,000 3,600

i Maximaler
maximum relative Schwingweg
l ti shaft ib ti der
h ft vibration di Welle
displacement
l t

A
100 90 80 75
B
200 185 165 150
C
320 290 260 240
D

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 Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 3
450
400

aft vibration displacement

• Coupled industrial machines 300

200
150
D
100
C

o the bearing, in µm
70

Peak-peak value of sha

B
50
40
A
30

relative to
20

10
1 2 4 6 10 20 30
Shaft speed x 1,000 in rpm

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 Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 4
450
400

k-peak value of shaft vibration displacement

• Gas turbines 300

200 D
150

relattive to the bearing, in µm

100 C
70

50
B
40

30 A

Peak
20

10
3 4 6 8 10 20
Shaft speed x 1,000 in rpm

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 Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 5
• Machine sets in hydro‐electric and pump plants

on displacement
Evaluation zones, smax Evaluation zones, sp-p
displacement

500 1000
relative to the bearing, smaax in µm

900

relative tto the bearing, sp-pp in µm

400 800
D 700 D
Maximum shaft vibration d

ak value of vibratio
300 600

500
200
400
C
C
300

Peak-pea
100
90
B 200
80 B
70
150
60
50
100
40
90
A 80 A
30 70
60
20 50
60 100 200 500 1000 1
2000 60 100 200 500 1000 2000
Max. shaft speed in rpm. Max. shaft speed in rpm.

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 Practical Application of Vibration
Monitoring and Analysis

Vibration Fault Analysis

Gran Mahakam Hotel, Jakarta 22‐25 January 2008

 Vibration Fault Analysis
Common Machinery Vibration Problems

• Unbalance
• Misalignment
• Eccentricity
• Bent Shaft
• Mechanical Looseness
• Shaft Crack
• Journal Bearing Faults
• Rolling Element Bearing Faults
• Rotor Rub
• Cavitations
• Electrical Motor Problems
• Gear Faults

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 Vibration Fault Analysis
Unbalance

• When unbalance is dominant, radial vibration (horizontal and vertical) will

normally be quite much higher than axial
• Horizontal vibration is normally higher than vertical
• Always indicated by high vibration at 1x rpm (but 1x rpm is not always
unbalance!)
• Amplitude at 1x rpm will normally ≥ 80% of the overall amplitude when the
problem is limited to unbalance
• The effect on unbalance may sometimes be amplified by resonance
• Unbalance
U b l can b
be a greatt contributor
t ib t tto hi
high
h llooseness vibration
ib ti

RPM
Radial
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 Vibration Fault Analysis
Unbalance

• When unbalance dominates over other problems, there will normally be

about 90o (±30o) phase difference between horizontal and vertical
directions on the same bearingg
• When significant unbalance exist, the horizontal phase difference between
outboard and inboard should be close to the vertical phase difference
• Unbalance rotors normally exhibit steady and repeatable phase in radial
directions
DIR. 1 2 3 4
A 60O 70O 60O 80O
H 30O 25O 30O 40O
V 120O 110O 120O 135O

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 Vibration Fault Analysis
Force/Static Unbalance

• Approximately the same unbalance forces at 1x rpm are normally present

both on outboard and inboard bearing. However, horizontal and vertical
responses
p mayy differ depending
p g on the support
pp stiffness
• With pure force unbalance, outboard horizontal phase will equal to inboard
horizontal phase on the same shaft
• Likewise, outboard vertical phase should approximately equal to inboard
vertical phase on the same shaft
• The horizontal phase difference between outboard and inboard should
approximately equal the vertical phase difference between them

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 Vibration Fault Analysis
Couple Unbalance

• In pure couple unbalance, the rotor is statically balance

• High vibration at 1x rpm on both outboard and inboard bearings, but it may
be higher on one bearing than on the other
• Substantial couple unbalance can sometimes generate high axial vibration
• The horizontal phase difference between outboard and inboard will
approximate 180o
• Similarly, vertical phase difference between outboard and inboard will
approximate 180o
DIR
DIR. 1 2 3 4
A 60O 70O 60O 80O
H 30O 210O 200O 180O
V 120O 295O 280O 300O
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 Vibration Fault Analysis
Dynamic Unbalance

• Combination of static unbalance and couple unbalance

• High vibration at 1x rpm on both outboard and inboard bearings, but it may
be higher on one bearing than on the other
• Like static and couple unbalance, phase is still steady and repeatable when
dynamic unbalance dominates
• The horizontal phase difference between outboard and inboard could be
anything from 0o to 180o. The difference should approximately equal the
vertical phase difference
DIR
DIR. 1 2 3 4
A 60O 70O 60O 80O
H 30O 90O 80O 70O
V 120O 180O 170O 165O
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 Vibration Fault Analysis
Overhung Unbalance

• Can generate large axial forces at 1x rpm which can cause axial vibration to
be equal or greater than radial
• Often generate high degree of couple unbalance in addition to static
unbalance; both of which must be corrected
• For pure unbalance of an overhung rotor, axial phase at bearing 1 will
approximately equal that at bearing 2 (±30o). The phase difference depends
on how dominant the unbalance problem is as compared to other such as
misalignment, resonance, etc
• Normally, overhung rotor unbalance can be corrected by first taking care of
the static unbalance component which would leave the remainder as couple
unbalance with phase difference approaching 180o. The couple component
would then require placement of correction weights in two planes 180o
opposite one another
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 Vibration Fault Analysis
Eccentric Rotor

• Like unbalance, high radial (horizontal and vertical) vibration at 1x rpm. In

case of eccentric pulley, the largest vibration most often occurs in the
direction of belt tension at 1x rpm
p of the eccentric ppulleyy
• May cause significantly higher vibration in one radial direction than in the
other (as does resonance and sometimes looseness as well)
• Attempts to balance eccentric rotor will often result in reducing vibration in
one direction, but increasing in the other radial direction
• Approximately 0o or 180o phase difference between horizontal and vertical
directions on the same bearing

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 Vibration Fault Analysis
Misalignment

• Normally causes both high axial and radial vibration. However, it is not
always having high axial, especially when parallel offset dominates over
angular
g misalignment
g
• Generates higher than normal 2x rpm vibration which can act not only in
axial direction but also in radial
• If the misalignment becomes severe, can also cause large numbers of
harmonics which will make the spectrum appear like looseness problem
• For significant misalignment, radial (both horizontal and vertical) phase
differences will be either 0o or 180o (±30o) between inboard and outboard
bearing
• Most of the time, horizontal phase difference approaching 180o out of
phase compare with vertical phase difference

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 Vibration Fault Analysis
Angular Misalignment

• High axial vibration, particularly at 1x, 2x (and 3x) rpm. One of this peaks
sometime dominates over the others
• Typically, amplitude of either 2x or 3x rpm reach approximately 30 30‐50%
50% of
1x rpm in axial direction
• Best indication is 180o phase difference across the coupling in axial direction

10

3.1
1

0.31

mm/s 1X 2X 3X

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 Vibration Fault Analysis
Parallel Misalignment

• High radial vibration, particularly at 1x, 2x (and 3x) rpm. One of this peaks
sometime dominates over the others
• Typically, amplitude at 2x rpm reach approximately 50% of 1x rpm in radial
direction. Can exceed the 1x rpm if parallel misalignment becomes severe
• Best indication is 180o phase difference across the coupling in radial
(horizontal and vertical) direction

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 Vibration Fault Analysis
Bearing Misalignment

• Considerable axial vibration at 1x (and 2x) rpm

• Axial phase at four points 90o apart each other will also shift 90o from one
point to the next
• Attempts to align the coupling or balance the rotor will not solve the
problem. The effected bearing must be removed and correctly installed
Point
P i t11, 2
2, 3 and
d 4 are axial t 90o apartt each
i l measurement, h other
th
Cocked (misaligned) bearing will have axial phase e.g. as follow:
Axial 1 = 10o BEARING
A i l 2 = 100o
Axial SHAFT 1
Axial 3 = 190o 4
2
Axial 4 = 280o
3

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 Vibration Fault Analysis
Bent Shaft

• Dominant vibration normally is at 1x rpm if bent near the shaft center

(indication like unbalance), and particularly at 2x rpm if bent near the
coupling
p g ((indication like misalignment)
g )
• Axial phase difference between inboard and outboard bearing will approach
180o
• If the shaft is bowed through or very near the bearing, axial phase at four
points 90o apart each other will also shift 90o from one point to the next,
like cocked bearing
BEARING
SHAFT 1

4
2
3

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 Vibration Fault Analysis
Mechanical Looseness

• Mechanical looseness always indicated by rising harmonics and sub‐

harmonics
Shaft loose mm/s

10

3.1
1

0.31

.5X 1X 1.5X 2X 3X
mm/s
Bearing loose
10

3.1
1

0.31

.5X 1X 1.5X 2X 3X

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 ILLUSTRATEDVIBRATION DIAGNOSTIC CHART
PROBLEM
SOURCE
MASS UNBALANCE
A. FORCE
UNBALANCE

B.COUPLE
UNBALANCE

C. DYNAMIC
,
lL
lL.~
TYPICAL

1XRADIAL
PHASE

-
SPECTRUM RELATIONSHIP
1XRADIAL

.~~""

:'
II
7;::;;:~;i;;,;ri,i~~~~'
.'

"
will increase
increase =
REMARKS
Force Unbalance will be in-phase and steady. Amplitude due
by the square of speed below first rotor critical
to unbalance
(a 3X speed
9X higher vibration). 1X RPM always present and normally
dominates spectrum. Can be corrected by placement of only one balance
correction weight in one plane at Rotor center of gravity (CG). Approx. 0°
phase difference should exist between OB & IB horizontals, as well as
between OB & IB verticals. Also, approx. 90. phase difference between
horizontal & vertical readings usually occurs on each bearing of
unbalanced rotor (:I:30'.
Couple Unbalance results in 180. out-of-phase motion on same shaft. 1X
RPM alwayscpresent and normally dominates spectrum. Amplitude varies
with square of increasing speed below first rotor critical speed. May cause
high axial vibration as well as radial. Correction requires placement of
balance weights in at least 2 planes. Note that approx. 180. phase
difference should exist between OB & IB horizontals, as well as between
OB & IBverticals. Also, approx. a 90° difference between the horizontal &
vertical phase readings on each bearing usually occurs (:I:30'

Dynamic Unbalance is the dominant type of unbalance found and is a

lL ~
UNBALANCE 1XRADIAL - - I combination of both force and couple unbalance. 1XRPMdominates the
spectrum, and truly requires 2 plane correction. Here, the radial phase
difference between outboard and inboard bearings can range anywhere
.""~:;/"':<;;;,:,;;:,;::::~ . from 0° to 180°.However, the horizontal phase difference should closely
match the vertical phase difference, when comparing outboard and inboard
- ~ . bearing measurements (:I:30"). Secondarily, if unbalance predominates,
roughly a 90. phase difference usually results between the horizontal and
vertical readings on each bearing (:I:40").

~
D. OVERHUNG ROTOR Overhung Rotor Unbalance causes high 1X RPM in both Axial and Radial
UNBALANCE directions. Axial readings tend to be in-phase whereas radial phase
readings might be unsteady. However, the horizontal phase differences will

I ~X~'AL
O'
usually match the vertical phase differences on the unbalanced rotor
I (:I:30"). Overhung rotors have both force and couple unbalance, each of
which will likely require correction. Thus, correction weights will most
LLL4L always have to be placed in 2 planes to counteract both force and couple
unbalance. ' .
ECCENTRIC ROTOR z H Eccentricity occurs when center of rotation is offset from geo",!etric
~ a: centerline of a pulley,gear,bearing, motor armature, etc. Largestvibration
x ~ occurs at 1X RPM of eccentriccomponent in a direction1hrucenterlinesof
the two rotors. Comparative horizontal and vertical phase readings usually
~
lil
~ differ either by 0° or by 180° (each of which indicate straight-line motion).
x ,
Attempts to balance eccentric rotors often result in reducing vibrationin
RADIAL one radial direction, but increasing it in the other radial direction
(depending on amount of eccentricity).' - .

BENT SHAFT Bent shaft problems cause high axialvibrationwithaxial phase differences

~
tending towards 180° on the same machine component. Dominant

lIe
vibrationnormally occum at 1X if bent near shaft center, but at 2X If bent
near the coupling. (Be careful to account for transducer orientationfor
each axialmeasurement if you reversa probe direction.) Use dial indicators
to confirm bent shaft.

MISALIGNMENT Angular Misalignment is 'characterized by high axial vibration, 180°

out-of.phase across the coupling. Typically will have high axial vibration
A. ANGULAR withboth1X and 2X RPM. However,not unusual for either 1X, 2X or 3X to
dominate. These symptoms mayalso indicatecoupling problems as well.
MISAUGNMENT
.[[.~ Severe angular misalignment may excite many 1X RPM harmonics. Unlike
Mechanical Looseness Type 3, these multiple harmonics do not typically
have a raised noise floor on the spectra.

B.PARALLEL Offset Misalignment has similar vibration symptoms to Angular, but shows
MISAUGNMENT high radial vibration which approaches 180° out-of-phase across coupling.
2X often larger than 1)(, but Its height relativeto 1Xis often dictated by

~~
1X RADIAL coupling type and construction. When either Angular or Radial
Misalignment becomes severe, they can generate either high amplitude
peaks at much higher harmonics (4~8X), or even a whole series of high
,3X ." ",'.:":, ! ~ i,,',".""~"" , frequency harmonics similar in appearance to mechanical looseness.
Coupling type and material will often greatly influence the entire spectrum
when misalignmentis severe. Does not typically have raised noise floor.

C. MISAUGNED (fP Cocked Bearing willgenerate considerable axial vibration. WIllcause

BEARING COCKED PHASE(1j TwistingMotionwithapproximately180. phase shift top to bottom and/or
11r2i A>OAL 1 2:00 side to side as measured In axial direction on same bearing. housing.
ON S"'AFT
lliL 2 5:00
3 8:00
4 11:00
~
Attemptsto align coupling or balance the rotor willnot alleviate problem.
Bearingusuallymust be removed and correctly installed.

RESONANCE Resonance occurs when a Forcing Frequency coincides with a System

~
1st Critical
Natural Frequency, and can cause dramatic amplitude amplification, which
might result in premature, or even catastrophic failure. This may be a
natural frequency of the rotor, but can often originate from support frame,
foundation, gearbox or even drive belts. If a rotor Is at or near resonance, It
can be almost impossible to balance due to the great phase shift it
d experiences (SO' at resonance; nearly 180° when passes thru). Otten
r::::7I~ '"- - "' 1':71 requires changing naturalfrequency to a higher or lowerfrequency. Natural
~"'---"'~ Frequencies do not generally change with a change in speed,which helps
facilitate their identification (unless on a large plain bearing machine or on a
2nd Critical 0 rotor whichhas significantoverhang).

PaQe 1 of 5
 PROBLEM TYPICAL PHASE
SOURCE SPECTRUM RELATIONSHIP REMARKS
Mechanical Looseness is indicated by either Type A, B or Cvibratlon
MECHANICAL RADIAL spectra.
'J)Ipe A is caused by Structural looseness/weakness of machine feet,
LOOSENESS
TYPE A ~ baseplate 'or foundation: also by deteriorated grouting, loose hold-down
1I .-bolts at the base; and distortion of the frame or base (i.e., soft foot). Phase
analysis may reveal approx. 900 to 1800 phase difference between vertical
measurements on bolt, machine foot, baseplate or base itself.
'J)Ipe 8 is generally caused by loose pillowblock bo"s, cracks in frame
x RADIAL structure 0 r in bearing pedestal.
x'" JYpe C is nonnally generated by improper fit between component parts
which will cause many hannonics due to nonlinear response of loose parts

iT:11i TYPE B
to dynamic forces from rotor. Causes a truncation of time wave!orm and a
raised noise floor in the spectrum. Type C is often caused by a bearing liner
loose in its cap, a bearing loose and tuming on its shaft, excessive
clearance in either a sleeve or rolling element bearing, a loose impeller on a
TYPE C

~
shaft, etc. Type C Ph.!Se is often unstable and may vary widely from one

".
measurement to next, particularly if rotor shifts position on shaft from one
::
startup to next. Mechanical Looseness Is often highly directional and may
NOTE RAISED NOISE R.OOR c,""*"'~'",.", cause very different readings when comparing levels at 300 increments In
INDICAllNG LOOSENESS radial direction all the way around one bearing housing. Also, note that
, ,
looseness will often cause subhannonic mu"iples at'exactly 1/2 or 1/3X
RPM (.5)(, 1.5X, 2.5)(, etc.).
Rotor Rub produces similar spectra to Mechanical Looseness when
ROTOR RUB rotating parts contact stationary components. Rub may be either partial or
throughout the entire shaft revolution. Usually generates a series of
X frequencies, often exciting one or more resonances. Often excites integer
TRUNCATED -.t
fraction subhannonlcs of running speed (1/2, 113, 1/4, 1/5,...1/n),
FLATTENED depending on location of rotor natural frequencies. Rotor rub can excite
many high frequencies (simiiar to wide-band noise when chalk is drug
WAVEFORM along a blackboard). It can be very serious and of short duration if caused
by shaft contacting bearing babbitt. A full annular rub throughoutan entire
n n' n shaft revolution can induce "reverse precession" with the rotor whirling at
VVV critical speed in a direction opposite shaft rotation (Inherently unstable
which can lead to catastrophic failure).

JOURNAL BEARINGS Latterstages of joumal bearing wear are nonnallyevidenced by presence

of whole series of running speed hannonics (up to 10 or 20). Wiped
A. WEAR/CLEARANCE joumal bearings often will allow high vertical amplitudes compared to
horizontal, but, may show only one pronounced peak at lX RPM. Joumal
PROBLEMS bearings with excessive clearance may allowa minor unbalance and/or
misalignment to cause high vibration which would be much tower if
bearing clearances were set to spec.

B. OIL WHIRL 011 Whirl instability occurs at .40 - .48X RPM and is often quite severe.

~
INSTABILITY Considered excessive when amplitude exceeds 40% of bearing
(.40 -.48 X RPM) clearances. Oil Whirl is an oil film excited vibration where deviations in
nonnal operating cond"lons (attitude angle and eccentricity ratio) cause oil
1X - wedge to "push" shaft around within bearing. Destabilizing force in

W RADIAL directionof rotationresults in a whirl (or forwards precession). Oil Whirl is

unstable, since It increases centrifugal forces which increase whirl forces.
Can cause oil to no longer support shaft and can become unstable wh~n
whirlfrequencycoincides witha rotor natural frequenCy. Changes in oil
viscosity, lube pressure and extemal preloads can affect 011whirl.

C. OIL WHIP ",apectraltrlltp Oil Whip may occur if machine operated at or above 2X rotor critical
~ OilWri". frequency. When rotor brought up to twice critical speed, whirl will be very
INSTABiliTY ~"":;::: close to rotor critical and may cause excessive vibration that oil film may
- .- opeedpIIfIB/IS no longer be capable of supporting. Whirl speed will actually '~ock onto"
ROTORSPEED= thlU2Xoli~CIJ/. rotor critical and this peak will not pass through It even if machine is
brought t6' higher and higher speeds. Produces a lateral forward
precessional subhannonic vibration at rotor critical frequency. Inherently
FREQUENC'!. unst~le which can lead to catastrophic failure.
4 ROWNG ELEMENT BEARING FAILURE STAGES
ROLLING ELEMENT STAGE 1,,:.Earliest indications of bearing problems appear in ultrasonic
BEARINGS DOMINANT FAIWAE SCENARIO frequencies.ranging from about 250,000 - 350,000HZ;later,as
-
wear
increases, usually drops to approximately 20,000 60,000 Hz (1,200,000-
ZONE
B ZONE
C ZONED
(4FailureStages) lONEA BEARING
DEFFECT
BEARING
COMPON.
SPIKE
3,600,000 CPM). These are frequencies evaluated by Spike Energy (gSE),
HFD(g) and Shock Pulse (dB). For example, spike energy may first
. FRED.
REGIONINATURAL
FREQ~ENERGY
REGIONI (HFD) EWpear at about .25 gSE in Stage 1 (actual value depending on
fn= Natural Frequencies of cIL measurement location and- machine speed). Acquiring high frequency
Installed Bearing :r enveloped spectra continns whether or not bearing is in Failure Stage 1.
STAGE 1
Components and iiJ
Support Structure en
CI STAGE 2: Slight bearing defects begin to "ring" bearing component
-
natIJraIfrequencies (fJ which predominantly occur in 30K 120K CPM
range. Such natural frequencies may also be resonances of bearing
support structures. Sideband frequencies appear above and below
BEARING DEFECT FREQUENCIES: natural frequency peak at end of Stage 2. Overallspike energy grows (for
example, from .25 to .50 gSE).
BPFI= Nb(1+~COSQ)XRPM ; == SIDEBAND
2 PI! ;\ FREQ. STAGE 3: Bearing defect trequencies and harmonicsappear. Whenwear
progresses, more defect frequency harmonics appear and number of
BPFO= ~(1~Cose) xRPM
2 PI! sri sidebands grow, both around these and bearing component natural
frequencies. Overallspike energy continues to increase (for example,
)CRPM
BSF= 2Bd L
PI! f,_~)2(cose)2
PI! ] from .5 to over 1 gSE). "Wear is now usually visible and may extend
throughout periphery of bearing, particularly when many well fonned

J
sidebands accompany bearing defect frequency hannonlcs. High
frequency demodulated and enveloped spectra belp confinn Stage JII.
FTF=.!.(1-BI!COSe)xRPM
2 PI! Replace bearings nowl (Independent of beiuing defect tnH,uency
Where: amplitudes In vibration spectra).
BPR = Inner Race Frequency
= Outer

t
BPFO Race Frequency (lSEIHFD STAGE 4: Towards the end, amplitude of 1X RPM is even effected. It
BSF = Ball Spin Frequency DECREASES grows, and nonnally causes growth of many running speed hannonics.
FTF = Fund. Train (Cage) Freq. ATRRST; Discrate bearing defect and component naturalfrequencies actually begin
JHENGROWS
N, = Number of Balls or Rollers
SlGNlRCAIITl.Y to "disappear" and are replaced by random, broadband high frequency
B. = BallJRolier Diameter (In or mm) "noise floor". In addition, amplitudes of both high frequency noise floor
ATEND
P. = Bearing PRch Diameter (In or mm)
S and spike energy may in fact decrease; but just prior to failure, spike
=
e Contact Angle (degrees) energy and HFD will usu~11ygrow to excessive amplitudes.
Pace 2 of5
 PROBLEM TYPICAL
SOURCE SPECTRUM REMARKS
Blade Pass Frequency (BPF) = No. of Blades (or Vanes) X RPM. This
HYDRAULIC AND frequency Is inherent in pumps, fans and compressors, and normally does
AERODYNAMIC FORCES not present a problem. However, large amplitude BPF (and harmonics)
can be generated in pump if gap between rotating vanes and stationary
diffusers is not equal all the way around. Also, BPF (or harmonic)
A. BLADE PASS & BPF sometimes can coincide with a system natural frequency causing high
VANE PASS vibration. High BPF can be generated if impeller wear ring seizes on shaft,
or if welds fastening diffuser vanes fail. Also, high BPF can be caused by
abrupt bends in pipe (or duct), obstructions which disturb flow, damper
settings or if pump or fan rotor is positioned eccentrically within housing.
RANDOM Row Turbulence often occurs in blowers due to variations in pressure
or velocity of the air passing thru the fan or connected ductwork. This flow

l(t~
B.FLOW ViBRATION
BPF= BLADEOR disruption. causes turbulence which will generate random, low frequency
TURBULENCE 1X -~;;\ I VANE PASS
vibration, typically in the range of 50 .to 2000 CPM. If surging occurs
within a compressor, random broadband high frequency vibration can
occur. Excessive turbulence can also excite broadband high frequency.
FREQUENC'{ Cavitation normally generates random, higher frequency broadband
RANDOM HIGH energy which is sometimes superimposed with blade pass frequency
harmonics. Normally indicates insufficient suction pressure (starvation).
Cavitation can be quite destructive to pump intemals if left uncorrected. It
C. CAVITATION
1X .
can particularly erode impeller vanes. When present, it often sounds as If
"gravel" is passing thru pump. Cavitation is usually caused by insufficient
L ~ BP~~FREO.~BRAnON A CPM
120K inlet flow. Can occur during one survey, and be absent the next survey ( If
changes in suction valve settings are made).
GEARS GMF= #TG XRf'Ma = #TpXAPMp
Normal Spectrum shows Gear & Pinion Speeds, along with Gear Mesh
Frequency (GMF) and very small GMF harmonics. GMF harmonics
A. NORMAL commonly will have running speed sidebands around them. Allpeaks are
of low amplitude, and no natural frequencies of gears are excited. FMA)(
.SPECTRUM 3GMF recomended at 3.25X GMF (minimum) when It teeth are known. If tooth
3.25X GMF count is not known, set FMAX
at 200X RPM on each shaft.
B. TOOTH WEAR Key indicator of Tooth Wear is excitation of Gear Natural Frequency (f,,),
along with sidebands around it spaced at the running speed of the bad
gear. Gear Mesh Frequency (GMF) mayor may not change in amplitude,
although high amplitude sidebands and number of sidebands surrounding
GMF usually occur when wear is noticeable. Sidebands may be better
wear indicator than GMF frequencies themselves. Also, high amplitudes
commonly occur at either 2XGMF or at 3XGMF (esp. 3XGMF), even when
51~ 3.25X GMF
GMF amplitude is acceptable.
C. TOOTH LOAD Gear Mesh Frequencies are often very sensitiveto load. High GMF
amplitudes do not necessarily indicate a problem, particularly if
sideband frequencies remain low level,and no gear naturalfrequencies
are excited. Each Analysis should be performed with system at
3.25X GMF maximumoperating load for meaningfulspectral comparisons.
D. GEAR ECCENTRICITY Fairly high amplitude sidebands around GMF harmonics often suggest
gear eccentricity, backlash, or non-parallel shafts which allow the rotation
AND BACKLASH I~ of one gear to "modulate" either the GMF amplitude or the running speed
of the other gear. The gear with the problem is indicated by the spacing of
I~~ _c
ii:
~
:
CI
GMF the sideband frequencies.Also, 1X RPM level of eccentric gear will
normally be high if eccentricity is the dominant problem. Improper
backlash normally excites GMF harmonics and Gear Natural Frequency,
both of which will be sidebanded at 1X RPM. GMF amplitudes will often
3.25X GMF decrease with increasing load if backlash is the problem.

E.GEAR Gear. Misalignment almost always excites second order or higher GMF
harmonics which are side banded at running speed. Often will show only
MISALIGNMENT small amplitude 1X GMF, but much higher levels at 2X or 3X GMF.
Important to set FMAJ(high enough t~ capture at least 3 GMF harmonics.
Also, sidebands around 2XGMF Willoften be spaced at 2X RPM. Note that
sideband amplitudes often are not equal on left and right side of GMF and
3.25X GMF GMF harmonics due to the tooth misalignment. Causes uneven wear pattern.
F. CRACKED/BROKEN A Cracked or Broken Tooth will generate a high amplitude at 1X RPM of
TOOTH
J-J--.J-J--l--llME this gear onlY in the time waveform. plus it will excite gear natural

!~ ,rr-r,WAVEFORM
l
frequency (f,,)sidebanded at its running speed. It is best detected in TIme
~
C!J
I- -I- -I- -I- -I Waveform which will show a pronounced spike every time the problem
.tJ. .tJ. .tJ. .tJ. tooth tries to mesh with teeth on the mating gear. lime between impacts
..tJ. 1 OF GEARWITHBROKEN (,6,) will correspond to 1/RPMof gear withthe problem. Amplitudesof
~~ '" 1iPM ORCRACKED1'001;1 Impact Spikes in lime Waveform often will be 10X to 20X higher than that
at 1X RPM in the FFT I

G. GEARASSEMBLY GAPF= GMF Gear Assembly Phase Freq. (GAPF) can result in Fractional Gear Mesh
N;" Frequencies (if N,,> 1). It literally means (TdN,.) gear teeth will contact
PH_~$_r;
6OORPM
PROBLEMS ~Z (Tp'N,.) pinion teeth and will generate N" wear pattems, where N" in a given
' 25T;To 25T", (5p<s C!JQ tooth combination equals the product of prime factors common to the

m:
:
:
: 15T;Tp15T/~3
'1000
: RPM
~."",--GMF--15,000
...,..-r= ""N;:= S-
NA",
5 I
~~
I~ .
number of teeth on the gear and pinion (N,,= Assembly Phase Factor).
GAPF (or harmonics) can show up rightfrom the beginningif there were
manufacturing problems. Also,Its sudden appearance ina periodicsurvey
spectrum can indicate damage Ifcontaminate particlespass through the
mesh, resulting in damage to the teeth in mesh at the time of ingestion just
GAPF= 3000 CPM '" O.20X GMF (FRACTIONAL GMF) as they enter and leave meshing orthat.gears have been reoriented.
c;;--
"<t
H. HUNTING TOOTH Hunting Tooth Frequency (flfT)occurs when faults are present on both the
PROBLEMS t gear and pinion which might have occurred during the manufacturing
D~VER DRNEN .j::g
. C\/
process, due to mishandling, or in the field. It can cause quite high
857 RPM
+ vibration, but since It occurs at low frequencies predominately lass than

~
1000~~ 600 CPM,It is often missed. A gear set withthis tooth repeat problem
l3~"1 .~4.
J
,C\/ normally emits a "growling"sound from the drive. The maximum effect
1 t +
occurs whenthe faultypinion and gear teeth both enter mesh at the same
~ 17
6=1X2X3 6. NA = 1 is the idealassembly time (on some drives, this may occur only 1~of every 10to 20 revolutions,
dependingon the flfT formula).Note that T referto number of
and T"""""
7= 1X7 }NA-- 1 phase factorIngear design
teeth on the gear and pinion,respectively. N"istheAssemblyPhaseFactor
I - (6X 1000)(1) =.1!!QQ.= 143 CPM (One Pulse Per 7 Pinion Revolutions) defined above. Will often modulate both GMF and Gear RPMpeaks.
Hr (6)(7) 7
Paae3 of 5
 PROBLEM TYPICAL
SOURCE SPECTRUM REMARKS
GEARS (CONTINUED) ~ Excessive Clearance of bearings supporting the gears can not only excite
many running speed harmonics, but will often cause high amplitude

-~
~o response at GMF, 2GMF and/or 3GM~ These high GMF amplitudes are
I.LOOSEBEARING
FIT I
II:
~J:
3GMF actually a response to, and not the cause of, loosaness within the bearings
supporting the gearing. Such excessive clearance can be causad either
by extensive bearing wear or by improper bearing fit onto the journal
during installation. Left uncorrected, it can cause excessive gear wear and
damage to otherCcomponents.

AC INDUCTION /fAOTORS 3200 UN!: FFr

Stator problems generate high vibration at 2X line frequency (2FJ. Stator
eccentricityproduces uneven stationary air gap between rotor and stator
A. STATOR ECCENTRICITY, RADIAL
which produces very directional vibration. Differential Air Gap should not
SHORTED LAMINATIONS exceed 5% for induction motors and 10% for synchronous motors. Soft
2FL FL= UN!: FREQ. foot and warped bases can produce an eccentric stator. Loose iron is due.
OR LOOSE IRON 1X I
2X , to stator support weakness or looseness. Shorted stator laminations can
cause uneven, localized heating which can distort the stator itself. This
produces thermally-inducedvibrationwhich can significantlygrow with
12KCPM operating time causing stator distortion and static airgap problems.
EccentricRotors produce a rotating variable air gap between the rotorand
B. ECCENTRICROTOR 3200 UN!: FFT stator whichinduces pulsatingvibration(normallybetween 2FLand closest
(Variable AirGap) RADIAL
running speed harmonic). Often requires "zoom" spectrum to separate 2FL
FL= Electrical Une Freq. and running speed harmonic. Eccentric rotors generate 2FLsurrounded by
2FL Pole Pass frequency sidebands (f.), as well as F. sidebands around
Ns = Synch. Speed = ~L Fp SIDEBANDS
P AROUND 2FL runningspeed. Fpappeers Itself at low frequency (Pole Pass Frequency =
Fs= Slip Freq. = Ns- RPM Slip Frequency X # Poles). Common values of F. range from about 20 to
Fp= Pole Pass Freq. = FsXP 120 CPM (0.3 - 2.0 Hz). Soft foot or misalignment often induces a variable
P = # Poles 12KCPM air gap due to dis.tortion (actually a mechanical problem; not electrical).
3200"""'i:iNEFFf
C. ROTOR PROBLEMS Broken or Cracked rotor bars or shorting rings; bad joints between rotor
Fp SIDEBANDS AROUND OPER. SPEED HARO.IONICS bars and shorting rings;or shorted rotorlaminationswillproduce high 1X
Stator running speed vibration with pole pass frequency sidebands (F.). In
Rotor Bars. addition, these problems will often generate F. sidebands around the
second, third, fourth and fifthrunning speed harmonics. Loose or open
Rotor. rotor bars are indicated by 2X line freq. (2FJ sidebands surrounding Rotor
2 Pole Motor-. Bar Pass Frequency (RBPF) and/or its harmonics (RBPF = Numberof
. Alr-Gap- Bars X RPM). Often will cause high levels at 2X RBPF, with only a small
Conductors amplitude at 1X RBPF. Electrically induced arcing between loose rotor
bars and end rings will often show high levels at 2X RBPF (with 2FL
Magnetic Field. sidebands); but little or no increase in amplitudes at 1X RBPF.

D. PHASING PROBLEM RADIAL

Phasing problems due to loose or broken connectors can cause excessive
vibration at 2X Une Freq. (2FJ which will have sidebands around it spaced
(Loose Connector) at 1/3 Une Freq. (1/3 FJ. Levels at 2FL can exceed 1.0 In/sec if left
uncorrected. This is particularlya problem if the defective connector is only
sporadically making contact. Loose or broken connectors must b_erepaired
to prevent catastrophic failure.

AC SYNCHRONOUS 1600 LINE FFT Loose stator coils In synchronous' motors will generate fairly high vibration
at Coil Pass Freq. (CPF) which equals the number of stator coils X RPM
MOTORS COIL PASS FREO. (# Stator Coils = # Poles X # Coils/Pole). The Coil Pass Frequency will be
surrounded by 1X RPM sidebands. Synchronous motor problems may
1XRPM
(Loose Stator Coils) SIDEBANDS
also be indicated by high amplitude peaks at approx. 60,000to 90,000
CPM, accompanied by 2FL sidebands. Take at least one spectrum up to
90,000 CPM on each motor bearing housing.
Many DC Motor and Control Problems can be detected" by vibration
DC MOTORS AND analysis. Full.waverectified, motors (6 SCA's) generate a signal at 6X
CONTROLS Une Frequency (6FL= 360 Hz= 31,600 CPM); while half.wave rectified DC
SCRFREO. motors (3 SCA's) generate 3X Une Freq. (3FL=180 Hz: 10,800 CPM). The
A.NORMALSPECTRUM SCR firing Frequency is normally present in a DC Motor Spectrum, but at
lowamplitude.Note the absence of other peaks at multiplesof FL,
B. BROKEN ARMATURE When DCMotorspectra are dominatedby l;Iighlevels at SCR or ?X SCA,
SCR this normally Indicateseither BrokenMotorWindingsor FaultyTuningof
WINDINGS, GROUNDING FREQ. the Bectrical ControlSystem. Proper tuning alone can lowervibrationat
PROBLEMS OR FAULTY SCR and 2X SCR significantly If control problems predominate. High
SYSTEM TUNING amplitudes at these frequencies would normallybe above approximately
.10 In/sec, peak at 1 XSCRand about.04 in/sec at 2 X SCR Firing Freq.
C. FAULTYFIRING CARD WhenoneJiring card falls to fire, then 1/3 of power is lost, and can cause
repeated momentaryspeed changes in the motor. This can lead to high
OR BLOWN FUSE amplitudes at 1/3X and 2I3X SCR Frequency (1/3X SCR Freq. = 1X FL for
half.waverectified, but 2X FLfor a full-wave rectified SCA).
Caution: Card/SCR configuration should be known before troubleshooting
motor (# SCA's, # Firing Cards, etc.).

D. FAULTYSCR, SHORTED ~ Faulty SCA's, Shorted Control Cards and/or Loose Connections can
generate noticeable amplitude peaks at many combinations of line
CONTROL CARD, LOOSE ~ ~u:' SCR
FREQ. frequenCy (FL)and SCR firingfrequency. Normally,1 bad SCRcan cause
CONNECll0NS
BLOWN FUSE
AND/OR I I~ high levelsat FLand/or 6FLin 6 SCRmotors. The point to be made is
that neither FL'2FL'4FLnor 6FLshould be present in DCMotorspectra.

E. FAULTYCOMPARITOR SIDEBANDS UKELV EQUAL Faulty Comparitor Cards cause problems with RPM fluptuation or
CARD TO SPEED VARIATIONS 'tIunting". This causes a constant collapsing and regenerating of the
SCR FREQ.
magnetic field. These sidebands often approximate the RPM fluctuation
and require a high resolution FFT to even detect them. Such sidebands
could also be due to generation and regeneration of the magnet.lcfield.
DIFFERENCE FREQUENCIES
F. ELECTRICAL CURRENT NORMALl.Y EQUAL BPFO Bectrically:induced Fluting Is normally detected by a series of difference
IF FW11NG IS PRESENT frequencies with the spacing most often at the outer race defect frequency
PASSAGE THRU DC (BPFO), even If such fluting is present on both the outer and inner races.
MOTOR BEARINGS They most often show up in a range centered at about 100,000 to 150,000
CPM. A 180K CPM spectrum with 1600 lines is recommended for
180K CPM detectiDnwith measurements on both the OB and IBDC motor bearings.

Pace 4 of 5
 PROBLEM TYPICAL
SOURCE SPECTRUM REMARKS
BELT FREQ, = 3.142 X PULlEY RPM X prrCH DIAM.
BELT DRIVE PROBLEMS BELT LENG11-I

llMING BELTFREQ. c BELTFREQ. X# BELT TEETH

A. WORN, LOOSE OR = PULlEY RPM X # PULLEY TEETH

MISMATCHEDBELTS a:
x~ Belt frequencies are below the RPM of either the motor or the driven
""oc machine. When they are wom, loose or mismatched,they normallycause
c
3 to 4 multipleS of belt frequency. Often 2X belt freq. is the dominantpeak.
RADIAL IN LINE
HORIZ.' Amplitudes are normally unsteady, sometimes pulsing with either driver or
WITH BELTS
driven RPM. On timing belt drives, wear or pulley misalignment is
indicated by high amplitudes at the TIming Belt Frequency. Chain drives
will indicate problems at Chain Pass Frequency which equals # Sprocket
PITCH DIAM, X RPM, = PITCH DlAM2 X RPM2 TeethX RPM.

B. BELT/PULLEY Misalignm~ntof pulley produces high vibration at 1X RPM predominantly

In the axial direction. The ratio of amplitudes of driver to driven RPM
MISAUGNMENT AXIAL 1X DRIVER OR DRIVEN depends on wherethe data is taken, as wellas on relativemass and frame
stiffness. Often with pulley misalignment, the highest axial vibration on the
motor will be at fan RPM, or vice versa. Can be confirmed by phase
1oFF ct(fpIGEON 1r'ANGLE measurements by setting Phase Filter at RPM of pulley with highest axiai
amplitude; then compare phase at this particular frequency on each rotor
.SET NOE ~ in the axial direction.

C. ECCENTRICPULLEYS Eccentric pulleys cause high vibration at 1X RPM of the eacentric pulley.
The amplitude is normally highest in line with the belts, and should show
up on both driver and driven bearings. It is sometimes possible to balance
eccentric pulleys by attaching washers to taper..Jock bolts. However, even
if balanced, the eccentricitywillstiliinduce vibrationand reversiblefatigue
stresses in the belt. Pulley eccentricity can be confirmed by phase
e~ ~~
l'X APM ECCENTRIC PULLEY anaiysis showing horizontai & verticai phase differences of neariy D. or
180'. .

D. BELT RESONANCE RADIAL Belt Resonance can cause high amplitudes if the belt natural frequency
should happen to approach, or coincide with, either the motor or driven
~- ~ RPM. Belt natural frequency can be altered by changing either the belt
tension, be" length or cross section. Can be detected by tensioning and
then releasing belt while measuring the response on pulleys or bearings.
(+) 05) However, when operating, belt natural frequencies will tend to be slightly
higher on the tight side and lower on the slack sid!=!.

A Beat Frequencyis the result of two closely spaced frequencies going

BEAT VIBRATION Into and out of synchronization with one another. The wideband spectrum
iWO FREQUENCIES
normally will show one peak pulsating up and down. When you zoom into
TWO FREQUENCIES
this peak (lower spectrum below), it actually shows two closely spaced
180' OUT OF PHASE IN PHASE
peaks. The difference in these two peaks (F2-F,) is the beat frequency -
lWO SIMPLE which appears itself in the wideband spectrum. The beat frequency is not
HARMONIC
MOTlONSOF
commonly seen in normal frequency range measurements since it is
DIFFERENT inherentlylowfrequency,usuallyrangingfrom onlyapproximately5 to 100
FREQUENCY CPM.

F, ANDF2 Maximum vibration will resu" when the time waveform of one frequency
(F,) comes into phase with the waveform of the other frequency (F2).
FB= F2 -F1 = BEAT FREQUENCY Minimum vibration occurs when waveforms of these two frequencies line
up 180' out of phase.
BEAT FREQUENCY
GENERATED BY
iWO FREQUENCIES
u:- L PULSATING
ABOVE

tb
r AMPLITUDES

WlDEBAND SPECTRUM

/ \

F1 .1=2
A = BEAT FREQUENCY
MINIMUM VIBRATION ZOOM SPECTRUM
MAXIMUM VIBRATION OCCURS
OCCURS WHEN 2
FREQUENCIES ARE WHEN 2 FREQUENCIES ARE
180' OUT OF PHASE IN PHASE

'Soft Foot"occurs when a machine's foot or frame deflects greatly when a

SOFT FOOT; SPRUNG hold-down bolt is loosened to hand tightness, causing the foot to rise
more than approximately .002 - .003 inch. This does not aiways cause a
FOOT AND FOOT-RELATED great vibration increase. However, it can do so if the soft foot affects
RESONANCE alignment or motor air gap concentricity.
"Sprung Foot. can cause great frame distortion, resu"ing in increased
vibration, force and stress in the frame, bearing housing, etc. This can
occur when a hold-downbolt is forceably torqued down on the sprung
) ~
~
foot in an attemptto level the foot.
- RAmAL 'Foot-Related Resonance.can cause dramatic amplitude increases from
5X to 15X or more, as compared with that whenthe bolt (orcombinationof
bolts) is loosened to hand tightness. When tight, this bo" can notably
Lr~~.) change the natural frequency of the foot or machine frame itself.

Soft Foot, Sprung Foot or Foot-Related Resonance most often affects

vibration at 1X RPM, but can aiso do so at 2X RPM, 3X RPM, 2X line
frequency, blade pass frequency, etc. (particularly Foot-Aelated
Resonance).

Paae 50f5 @ COPYRIGHT 1994 - TECHNICAL ASSOCIATES OF CHARLOTTE, INC. R-0894-4