Introduction

Welcome to Level 3, Lesson 6 – Measuring Fan And Motor

Vibrations, part of CTC’s free online vibration analysis training
series.
We hope you enjoyed and benefitted from the previous course
and will continue to build your vibration analysis knowledge as
you progress through Level 3.

Measuring Fan And Motor Vibrations is created and presented by CTC for
complimentary educational use only. This training presentation may not be edited
or used for any other purpose without express written consent from CTC.
Training
Objectives

Upon completion of this lesson, you will understand:

The fundamentals of using vibration monitoring to analyze faults and prevent

1
machine failure of fans and motors in industrial environments.
Understanding
Fans And Motors

Quite often we view the fans and motors we

rely on as very common machines.

We forget they provide critical air flows for

industrial processes, and cooling, heating,
dehumidification, and humidification for
office buildings, convention centers,
theatres, recreational facilities, and hotels.
Understanding Fans And Motors –
Common Mode Of Failure

Although they come in many shapes and sizes, fans and

motors share a common mode of failure.

Bearings are often overlooked and overworked, suffering

from lack of lubrication, too much heat, or poor
applications. When this happens, the bearings wear and
deteriorate, generating vibrations.

Measuring the vibrations and analyzing the faults will

prevent catastrophic failures, as shown in these photos.
Understanding Fans And Motors –
Preventing Failure

A good routine vibration program using a portable data

collector, or permanent online vibration monitoring, will
become the foundation of any predictive maintenance
initiative.

Measuring, trending, alarming, and analyzing fan and

motor vibration will provide earlier warning of developing
problems and will allow replacement parts to be ordered.

Bearings can be replaced during scheduled downtimes

prior to non-repairable damage occurring.
Sensor Placement
For Fans And Motors

Accelerometers are typically placed at key locations on

the motor and fan bearings.

Since the bearings are the load-carrying part of the

mechanical drive train, accelerometers should be placed
on the input and output bearing housing to measure the
vibration levels.

In this photo, you can see permanent accelerometers

mounted on motor and fan bearings.
Sensor Placement
For Fans And Motors

Vibration sensors should

be placed in radial Bearing vibration Unbalance
(horizontal and vertical) and
axial locations on the Misalignment Electrical faults
motor and fan bearings.
Blade pass Belt frequencies
This will provide the best
(aerodynamic
detection of all vibration
disturbances)
components, including:
Portable
Mounting Methods
There are three common mounting methods used with portable vibration measurements:

Curved Surface Quick Flat Surface Magnet

Magnet Disconnect And Target
Portable Mounting –
Curved Surface Magnets

Mounting sensors with a curved surface magnet is

convenient for rounded surfaces.

Maximum frequency response: 2,000 Hz (120,000 CPM)

Offers repeatability based on user mounting – user

must take care to place the magnet in the same spot
every time to ensure repeatable results.
Portable Mounting –
Quick Disconnects
Mounting sensors with quick disconnects is
convenient for mounting on a permanent target.

Maximum frequency response: 6,500 Hz (390,000 CPM)

Offers excellent repeatability – the permanently

mounted stud creates a consistent mounting
location for portable routes. The receptacle
features a triaxial locating notch and ¼-turn
engagement onto the stud, ensuring the sensor is
oriented in the same position when connected to
the stud for every reading.
Portable Mounting –
Flat Surface Magnet And Target

Mounting sensors with a flat surface magnet and

target is convenient for mounting on a permanent
target.

Maximum frequency response: 10,000 Hz (600,000 CPM)

Offers excellent repeatability – target makes for a

permanently affixed, magnetically attractive
mounting base for repeatable measurements.
Permanent
Mounting Methods
There are two common mounting methods used with permanent vibration measurements:

Adhesive Stud
Surface Mounting Mounting

Both methods require surface preparation prior to mounting the sensor.

Permanent Mounting –
Adhesive Surface Mounting

Adhesive surface mounting

requires a clean, dry, and flat
surface before adhering the
mounting pad to the machine.
Permanent Mounting –
Stud Mounting

Stud mounting requires a spot

face with a drilled and tapped
hole.
Permanent Mounting –
Spot Facing

Since both methods require a

flat, prepared surface for
mounting, spot facing is the
easiest way to accomplish this.

A spot facing tool can provide

the flat surface and drill the
hole in one operation.
Permanent Mounting –
Frequency Response
If the correct care is taken during permanent mounting:

a frequency response of the maximum frequency

15,000 Hz (900,000 CPM) response of the accelerometer
should be achievable using an should be achievable using a
adhesive mount stud mount
Portable
Cables And Connectors

Portable data collection requires a flexible cable and

connector with a good strain relief.

It needs to be easy to use, but also very rugged for

repetitive bending and stretching.

The twisted wiring pairs minimize noise.

Portable
Cables And Connector

The sensor connector on the

cable should be soldered, have
a good strain relief, and fit
comfortably in your hand.
Permanent
Cables And Connectors
Permanent data collection utilizes a very rugged cable and
connector that is intended to stay in place for the life of the
machine.

Cables should have heavy-duty jackets to protect them from

abrasion and the surrounding environment.

Many applications utilize FEP jackets, and for severe environments,

stainless steel armor jackets can be used.
Permanent
Cables And Connectors

Connectors for permanent data collection should also be

chosen based on the application and environment.

Temperature and Ingress Protection (IP) against liquids and

dust should always be considered.

Chemical contact should also be reviewed and planned for

when choosing a connector or cable.

Choose the cable connector that fits your application to

avoid a weak link in the vibration measurement and data
collection.
Cable
Termination

The opposite end of the sensor

cable needs to be organized
and connected to portable or
permanent vibration data
collection.

Wiring should be well laid out

and labeled with identification
tags.
Cable Termination –
Portable Data Collection
Simple portable data collection with an individual sensor
and portable mount usually takes care of itself by directly
mounting to the data collector.

Using a portable data collector to measure permanently

mounted sensors requires organization and termination of
the sensor cables – a switch box is a convenient method.

Permanent monitoring also requires organization and

termination of the sensor cables. These can be organized
as individual cables or combined in a cable reduction box
with a large multi-conductor cable.
Plain
Bearings
Some fans and motors have plain bearings, often referred
to as sleeve bearings or journal bearings.

There are no rolling elements in plain bearings, and

typically the shaft is supported by a film or wedge of foil.

In most cases, the primary measurement is the movement

of the shaft inside the journal or sleeve.

This type of measurement should be made with a

displacement sensor (eddy current probe) – these non-
contact sensors provide valuable information on shaft
vibration and the gap between the shaft and journal or
sleeve.
Conclusion
Vibration monitoring on fans and motors can be very beneficial. It
doesn’t matter if it is route-based portable measurements or
permanent monitoring – both methods can achieve success in
providing better reliability and improved performance for any
predictive maintenance program.

Mechanical and electrical defects can be identified through

vibration analysis. Choosing the right sensor, mounting method,
cable, and connector will provide quality data. Organizing the
sensor wiring in a switch box or cable reduction box reduces
measurement errors.

Operator safety should never be compromised – permanent

sensors and cables keep your fingers and hands out of harm’s
way.
Why Choose
CTC?
Superior durability Accuracy and performance

Industry’s best lead times Knowledgeable staff

Industry leading warranties

Connect With CTC
We look forward to hearing from you
FAILURE
18-20 mA

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