GE Measurement & Control

Vibration
Transducers

Transducers fundamentals
1. Introduction
2. Displacement

3. Velocity
4. Acceleration
5. Other transducers

Introduction to vibration

What is vibration?
Vibration is the motion of a machine or
machine part in harmonic motion either side of
its neutral or stationary position
Vibration is the response of a system to some
internal or external excitation or force applied
to the system

What is vibration?
Machines vibrate differently to one another
due to differing stiffness, mass and damping
These three fundamental conditions combine
to determine how the machine reacts to forces
which excite vibration

What causes vibration?

Unbalance of rotating parts

Eccentric rotor
Bent shaft

Misalignment
Mechanical looseness

Rotor rubbing
6

What causes vibration?

Sleeve bearings: wear, oil whirl, oil whip

Rolling element bearings (REBs): defects

Hydraulic & aerodynamic forces

Electrical problems
Gear problems

Drive belt problems

7

What is vibration?

UPPER
LIMIT
NEUTRAL
POSITION

LOWER
LIMIT
8

Vibration features & units

Displacement
peak

phase

LIMIT
NEUTRAL
POSITION
LOWER

Units = microns (peak

to peak)

acceleration

UPPER
DISPLACEMENT

The total distance

travelled by the
vibrating part, from
one extreme limit to
the other or peak to
peak

peak
velocity
TIME

LIMIT
PEAK TO PEAK
PERIOD

DISPLACEMENT

Vibration Signal Characteristics

Signal Amplitude

Amplitude Expressed in displacement, velocity or

acceleration and is an indicator of severity, i.e.
Is the machine running smoothly or roughly?

Frequency
Used to distinguish the force causing the vibration
defined as the repetition rate of a periodic vibration.
Vibration frequency measured in cycles per
minute (CPM) or hertz (Hz).
Sometimes expressed in multiples of rotative
speed of the machine, such as one times rpm
(1X), two times rpm (2X), 43% of rpm (.43X), etc.

Phase

1X Vibration

5X Vibration

The timing relationship, in degrees, between two (or

more) signals. A means of describing the location or
shape of the rotor at a particular instant in time.
10

Vibration amplitude
The vibration amplitude is the primary
indicator of a machines condition
The greater the amplitude, the more severe the
vibration

Overall vibration amplitude (direct amplitude)

is the unfiltered trending parameter

12

AMPLITUDE
pk
pk
rms
0

pk

Peak-to-peak refers to the total amount of vibration.

Zero-to-peak refers to the total amount of vibration from the
maximum height of either the positive or negative peak to the
zero voltage axis.
Root mean square (RMS) is a function of the signal conditioning
performed in the monitor or diagnostic instrument and not the
output of the transducer.
13

Amplitude versus Time Domain

Waveform Plot
Uses the raw vibration signal from the
transducer
Reveals the true dynamic response of
the machine
Time waveforms show short transient
vibrations clearly, where amplitude
meter damping often prevents responses
of analysers to true peak amplitudes
14

Amplitude versus Time Domain

Waveform Plot
34
32
30

Amplitude

28
26
24
22
20
18
16
14
12
10
0

180

360

540

720

900

1080

1260

1440

Time (seconds)

15

Overall amplitude trending

Many machine problems can be detected
using overall vibration trends
Analysis of trends is simple and basic
Preset alarm levels can be simply applied,
usually double the normal vibration levels, or
25% of full scale range (FSR) above.

16

Overall amplitude trending

17

Vibration features and vibration units

Velocity
Minimum

The speed at which

displacement occurs

Units - mm/s (peak) (RMS)

Maximum

DISPLACEMENT

Because the speed is

constantly changing, the
peak or RMS velocity are
usually selected

Velocity

Velocity

TIME

Minimum
Velocity

18

Vibration frequency
Vibration analysis relates the vibration
frequencies captured with the rotational speed
and characteristic fault frequencies of machine
components.

Frequencies must be considered in association

with the amplitude of the frequency peak to
assess the severity of the problem

22

PHASE
PHASE
(BETWEEN VIBRATION SIGNALS)

A A
M
P
L
I
T
U B
D
E

TIME
(DEGREES)

PHASE

TIME
(DEGREES)
27

PHASE ANGLE
The phase angle is defined as the number of
degrees from the Keyphasor pulse to the first
positive peak of vibration.

VIBRATION
SIGNAL
PHASE
LAG

TIME

KEYPHASOR
SIGNAL
DEGREES
OF
ROTATION

360

28

Vibration characteristics

Sensitive
Axis

time
Vibration transducers produce
an electrical signal that
represents the vibration in the
sensitive axis of the transducer.

37

Vibration transducers

Machine vibration

Rolling Element Bearing

Fluid Film Bearing

39
Introduction to vibration
2/14/2013

Machine vibration

Rolling element
bearing machine

Fluid film
bearing machine
40
Introduction to vibration
2/14/2013

Vibration transducers
The vibration transducer is responsible for
accurately sensing the vibration of interest
There are numerous types of transducers; each
having limitations according to their
requirements

41
Introduction to vibration
2/14/2013

Vibration transducers

Motion
Vibration
Transducer

Electrical
Signals

Any transducer converts one kind

of energy into a different kind
(into an electrical signal).

42

Vibration transducers
Four types that are commonly used in
condition monitoring are
Velocity Transducers
Accelerometers & Velomitors
Proximity Probes

43
Introduction to vibration
2/14/2013

Vibration Measurements
Mechanical vibration is the dynamic motion of machine components.
The vibration measurement is the measurement of this mechanical
vibration relative to a known reference.
Rotors, Bearing, Seals, Bearing Housings and Machine Cases
Accurately measuring and monitoring the vibration of these components
will describe the mechanical condition of the machine.
Four transducers to measure vibration:
Proximity Transducers

Velocity Siesmoprobes

Accelerometers

Velomitors

44

Displacement
Definition
Typical application
Displacement is the change Measuring rotor position
in distance or position of an
within the clearance of fluid
object relative to a
film bearings.
reference.
Used for permanent
monitoring of turbines, large
pumps, compressors
transducer
shaft

Capable of low frequency

Eddy-current
response (down to
0 Hz).
proximity
probe

bearing

Units: microns (m) or

of an inch (mil)

The non-contact transducer senses relative motion

thousandths
between the shaft and bearing of the machine

45

Velocity
Definition
Typical application
Velocity is the time rate of Measuring vibration of machine
change of the displacement
casing and other structural
of an object.
response characteristics.
Useful for medium frequencies
(~10 Hz to 10,000 Hz).

Units: millimeters per second

(mm/s) or inches per second (ips).
Moving-coil
sensor

Piezoelectric
(crystal)
sensor
46

Acceleration
Typical application
Definition
Acceleration is the time rate
Universally used with
of change of an objects
portable vibration analyzers
velocity.
Measuring high frequency
vibration of gear mesh,
rolling element bearing
defects, etc.
Capable of high frequency
response (up to ~20 kHz).
Piezoelectric
sensor

Units: meters per second2

(m/s2), inches per second2
(in/s2), or Standard Gravity
(g).

47

Relationships between vibration signals

Displacement
Velocity
Acceleration
Time
Machine Casing

Displacement, velocity and

acceleration measurements are
out of step with each other.

Displacement = maximum ( - direction )

Velocity = zero
Acceleration = maximum ( + direction )
48

Displacement transducers

Position
Radial

shaft position is a measurement of

the shaft centerline radial position within the
radial bearing.
Derived from the dc information provided
by the proximity system.
Used to determine bearing wear,
misalignment, external preloads and other
malfunctions.
50

Measuring Machine Vibration

Proximity probes measure distance
Between probe and shaft

Non contacting
Magnetic energy absorbed proportional to
distance
51

RADIAL AND AXIAL MOVEMENT

RADIAL MOVEMENT

AXIAL MOVEMENT

52

Eddy Current Theory

Proximitor
CONDUCTIVE
MATERIAL

Probe
RF SIGNAL

EDDY CURRENTS

53

Probe Close to Rotor

RF SIGNAL

54

Probe Away from Rotor

RF SIGNAL

55

Changing Distance Between Probe

and Rotor Produces a Change in
Signal Strength

RF SIGNAL

56

Proximity Transducer System Gap Signal

RF SIGNAL

RF SIGNAL

RF SIGNAL

0
57

Demodulator Operation
0
RF SIGNAL

DEMODULATOR
0
INPUT

PROXIMITOR
OUTPUT

58

Proximity Systems
- Proximitor and Probe Operation
<100mil
To
Monitor
RF SIGNAL

EXTENSION
CABLE
AND PROBE

PROXIMITOR

DEMODULATOR
OSCILLATOR

59

PROXIMITOR CALIBRATION GRAPH

24
22
CHANGE IN GAP

18
16
CHANGE IN VOLTAGE

OUTPUT IN VOLTS - DC

20

14

12
10
8
6
4
2
0
mils 0

10

20 30

40

50

60

70

80 90 100 110 120 130 140

PROBE GAP

60

Proximity Transducer System

Three Components:

Proximitor

Probe - Installed on the machine

and is referred to as the sensor.

Extension
Cable

Extension Cable - Connects to the

probe's cable and allows you to reach
a convenient junction box.
Proximitor - Module that contains
Transducer Systems electronics
(oscillator/demodulator) and is
usually mounted in a junction box.
Probes

Mounting Bases

62

Proximity Transducer System - Proximitor

Electrical Length
Probe Cable +
Extension Cable =

Signal Output

Total System Electrical

Length

Signal Common

The Total Electrical

Length must match
the calibration of the
Proximitor.

<100mil

Transducer Power

Linear Range

RF SIGNAL

63

Probe Mounting

Commonly mounted
directly inside the bearing

Probe views the shaft

directly

64

Transducer Orientation Options

65

Probe Orientation

Y Orientation
Channel 1

X Orientation
Channel 2

66

Radial (XY) transducers

Y

Orbit Plot
Orbit plot shows magnified view
of the movement of the shaft
centerline within the clearance
of the fluid film bearing.

Animation

67

Radial vibration

Examples of internal installations

2
1
Bracket-Mounted Single Probes

Bracket-Mounted
Redundant Probes

3
Bearing-Mounted Single Probes
68

XY Probes Installed in
Housings

69

Axial (Thrust) Rotor Position

70

Axial rotor loads

Axial Load

Process Gas Flow

Compressor Suction
(low-pressure end)

Compressor Discharge
(high-pressure end)
Nuovo Pignone, S.p.A.

Pressure differences can produce large axial forces on the machine rotor.
71

Probe location

Thrust position measurement

Thrust Collar

Rotor Shaft

Channel A Probe

Channel B Probe
Install probes within about 30 cm
(~12 in) of thrust collar.

Thermal expansion of rotor

introduces large errors when
measurements are made too
far away from the thrust collar.

Animation

72

AXIAL (Thrust) POSITION

THRUST
BEARING
ASSEMBLY

THRUST
PADS

THRUST
COLLAR

73

THRUST POSITION
20

15

10

20

40

60

80

100

0.5

1.0

1.5

2.0

2.5

mm

HOT FLOAT ZONE

COUNTER
DIRECTION

MILS

COLD FLOAT ZONE

NORMAL
DIRECTION

74

Example installations
Radial

Radial

Keyphasor

Radial vibration
Keyphasor
Thrust position
Thrust

This gearbox photo shows an XY radial vibration probe pair

and a Keyphasor* probe mounted in 21000 housings, and
dual axial thrust position probes mounted in a 21022 housing.
75

Machine train diagram

General installation guidelines
VD
HD

VD

HD

VD

HD

VD
HD

Probe designation
Example: 1VD

Bearing
number
1AD

DRIVER

Probe
Measurement
orientation
type

4AD
GEAR
BOX
8AD

LOAD

5AD

K
K
6VA
HD VD

VD

As viewed,
driver-to-driven

VD

HD

HD

HD

VD

6
Orientation

Measurement

A = Axial

D = Displacement

H = Horizontal

V = Velocity

V = Vertical

A = Acceleration

77

Proximity probe installation pitfalls

Inappropriate target size

Target size is adequate for probe being used.

Target size is too small for the probe.

Problem: Some of the electromagnetic field from the

face of the probe tip does not contact the target surface.
78

Proximity probe installation pitfalls

Crosstalk

Problem: Electromagnetic fields from closely-spaced probe

tips interfere with each other, producing false vibration signals.
79

Proximity probe installation pitfalls

Sideview

Problem: Electromagnetic field is attenuated by conductive

materials that are too close to the sides of the probe tip.

80

Proximity probe installation pitfalls

Run-out

Problem: Another common problem is called run out you

can find more information going to the link below
http://www.ge-energy.com/prod_serv/products/oc/en/bently_nevada/proxprobes.htm
81

Phase Reference Signal

0

-V
ONE
REVOLUTION

ONE
REVOLUTION

-V
82

Timebase Waveform with Phase

Reference
More useful information provided with Phase
Reference
Balancing
Phase reference signal creates blank-bright
on waveform
Called a Keyphasor by Bently Nevada

83

Keyphasor transducer
Phase angle measurement

Keyway Notch or Projection

Typical Probe Installation

* Trademark of General Electric Company

Animation

84

Keyphasor Applications
Proximity transducer used as a ONCE PER REVOLUTION marker on a
machine shaft KEYPHASOR.

Transducer mounted to observe a "notch" or a "projection" on the shaft

and produces a voltage pulse once each revolution.

Voltage pulse is much more significant than normal vibration or distance

measurements. Significant difference in voltage discriminates between a
ONCE PER REVOLUTION signal, and background noise or vibration.
The Keyphasor is a very useful tool when diagnosing machinery problems. At a
minimum, the generated pulse can be used to measure machine speed.
85

Phase measurement
The phase angle is defined as the number of
degrees from the Keyphasor pulse to the first
positive peak of vibration.

VIBRATION
SIGNAL
PHASE
LAG

TIME

KEYPHASOR
SIGNAL
DEGREES
OF
ROTATION

360

87

Vibration amplitude relative phase

pk

pk

X Probe

rms

pk
pk

Y Probe

pk
rms

pk
88

Radial Position
Proximity Probes are used in
the X-Y configuration to measure
radial vibration, the dc signal from
the transducer can be used to
indicate the radial position
of the rotor within the bearing

89

Orbit plot

90

Transducer system components

Proximitor*
Sensor

Extension
Cable
Probe

Example: 3300 XL 5 Metre Proximity Transducer System

92

Proximity transducers

http://www.ge-energy.com/prod_serv/products/oc/en/bently_nevada/proxprobes.htm
93

Accessories & related products

http://www.ge-energy.com/prod_serv/products/oc/en/bently_nevada/prox_probe_acc.htm

94

Velocity transducers

Velocity transducer basics

Velocity sensors

Design: Either a moving coil

sensor or an accelerometer with
onboard integrating circuit.
Operation: Moving-coil design is
self-powered, but piezoelectric
design requires a power source.

Various examples of Bently Nevada* seismic transducers

96

Typical frequency ranges

Seismic transducer basics

Accelerometer: Highest frequency

response. Used for gear mesh,
impulse and other high frequency
applications.
Piezovelocity Sensor: Lower high
frequency response, but less noise
than using an external integrating
amplifier with an accelerometer.
Moving Coil Sensor: More limited
frequency response, but has no
requirement for an external power
supply.

Accelerometer

Piezovelocity Sensor

Moving Coil Sensor

97

Velocity sensor specifics

charge amp. &
integration circuit

magnet

case

preload band
moving coil

Sensitive
Axis

mass
crystal

mounting stud
Traditional Moving-Coil Sensor

Velomitor* Piezo-Velocity Sensor

(click to play animation)

98

330500 typical frequency response

Velocity sensor specifics

Transducer sensitivity
is specified at 100 Hz.

99

Interconnect cable
Velocity sensor specifics

Part Number 9571-AXX

100

High temp & low frequency sensors

Velocity & acceleration transducers

330750 (4-bolt sensor) & 330752

190501 CT low frequency
(threaded stud sensor) high
transducer is designed for
temperature velocity transducers.
monitoring cooling tower fans.
For surface temperature up to
1.5 Hz to 1000 Hz response
400C (752F).
accommodates machine speeds
as low as 90 rpm.

Sensor

Signal
Conditioning
Electronics

(330750 version is shown here)

101

Moving coil velocity sensors

330505 low frequency velocity
transducer
Hydroelectric turbine generators
0.5 Hz to 1000 Hz response
20 mV/mm/s (500 mV/ips)
Specific mounting orientation

9200 & 74712 Seismoprobe

velocity transducer
General purpose monitoring
4.5 Hz to 1000 Hz response
20 mV/mm/s (500 mV/ips)
Specific mounting orientation

102

Velomitor piezo-velocity sensors

350900 High-Temp Velocity and
Acceleration Sensor (HTVAS).
Gas turbine monitoring
25 Hz to 2000 Hz (velocity)
4 mV/mm/s (100 mV/ips)
10 Hz to 10 kHz (acceleration)
1.02 mV/m/s2 (10 mV/g)

330500 velocity transducer

General purpose monitoring
4.5 Hz to 5000 Hz response
4 mV/mm/s (100 mV/ips)

Sensor

Signal
Conditioning
Electronics
103

Housings

Installation guidelines

Velocity transducer housing:

Part number 21128

104

Transducer positioning examples

Installation guidelines

Vertical

Vertical machines
Axial

Horizontal

East

Horizontal machines

South
105

Acceleration transducers

Accelerometer specifics
charge amplifier

case

case

charge amplifier
preload band

preload screw

mass

Sensitive
axis

mass

element

element

mounting stud

mounting stud

compression type sensor

shear type sensor

Piezoelectric accelerometer
107

Typical frequency ranges

Seismic transducer basics

Accelerometer: Highest frequency

response. Used for gear mesh,
impulse and other high frequency
applications.
Piezovelocity Sensor: Lower high
frequency response, but less noise
than using an external integrating
amplifier with an accelerometer.
Moving Coil Sensor: More limited
frequency response, but has no
requirement for an external power
supply.

Accelerometer

Piezovelocity Sensor

Moving Coil Sensor

108

330400 typical frequency response

Accelerometer Specifics

Transducer sensitivity
is specified at 100 Hz.

109

Accelerometers
Acceleration transducers

330400 general purpose

accelerometer.
10 Hz to 15 kHz response
API 670 compliant
50 g peak amplitude range
100 mV/g sensitivity

330450 High Temperature

Acceleration Sensor (HTAS)
Mounting up to 400C (752F)

111

Velocity & acceleration transducers

http://www.ge-energy.com/prod_serv/products/oc/en/bently_nevada/acc_vel.htm

113

Adaptors

Installation guidelines

Example: Various mounting adaptors for

Bently Nevada* seismic transducers.

114

Transducer mounting
Installation guidelines

1. Ensure ambient conditions are acceptable.

2. Verify mounting surface is adequately
prepared.
3. Drill and tap mounting hole.
4. Apply acoustic couplant.
5. Tighten transducer to specified torque.
Detailed information is included in the appropriate product manuals.
115

Machinery application
Seismic transducer basics

Accelerometer installed to measure gear mesh

vibration on a speed increasing gearbox.
Close-up view of accelerometer
and junction box.

116

Transducer positioning example

Installation guidelines

Vertical

Vertical Machines
Axial

Horizontal

East

Horizontal Machines

South
117

118

Typical Transducer Configuration

Rotating Machinery
X

Y X Y

Accels

Accel
T13-16

T25-28

Axial
Axial
LM2500
X

T9-10 T11-12
T1-T8

T17-18 Gearbox T23-24

T33-36

KO

T41-44

KO

Accel
Axial
LP
Compressor
T19-20

Axial
LP
Compressor

T21-22
T29-30
X

T31-32

T37-38

T39-40

119

Transducer selection

Machine vibration

Rolling Element Bearings

Fluid Film Bearings

121
Introduction to vibration
2/14/2013

What transducer should you use?

1. To protect a 600 rpm fin fan with rolling element

bearings.
2. To protect a steam turbine generator operating at
3000 rpm
3. To Monitor a 7500 rpm precision gearbox with 57
teeth (gear mesh ~ 7.5 kHz)

122
Introduction to vibration
2/14/2013

Vibration plots critical machines

Whats in the vibration signal?

Seismic transducer

Proximity transducer

Amplitude

Amplitude

Frequency

Phase

Frequency
Form
Position

124

Amplitude
pk

pk

rms
0

pk

Bar Graph

Current Value Live Data

125

Amplitude monitoring

Multi Variable Trend Plots

Trend Plots

Bode Plots

126

Amplitude monitoring

X v/s Y Plots

127

Amplitude monitoring

Software Alarms

128

Phase

VIBRATION
SIGNAL
PHASE
LAG

TIME

KEYPHASOR
SIGNAL
DEGREES
OF
ROTATION

360
129

Frequency

Synchronous Spectrum
Half Spectrum

Asynchronous Spectrum
Full Spectrum
130

Synchronous & Asynchronous data

Bently Nevada monitors record the waveform data

through two separate sampling paths:
Synchronous data is linked to the rotating speed of the
machine (fixed number of samples per revolution).
High sample rate = good resolution on Orbit and
waveform plots, but poor frequency resolution
Asynchronous data has a fixed sampling rate
Slower sample rate = Good frequency resolution . Ideal
for fault analysis with accelerometers and velomitors.
Other manufactures need to trade off data quality,
usually with poorer resolution of waveforms and orbits
131

Frequency

Full Spectrum

132

Frequency
Waterfall Plots

Cascade Plots

133

Frequency

Spectral Band

134

Form

135

Form

Orbit Overlays

136

Position

Radial Position

Axial Position

137

Position

Average Shaft Centerline Plots

SW alarms

Gap Reference Voltage

138

Transient vibration data

Bode and Polar plots
Amplitude and Phase displayed together

Slow roll runout vector

Heavy/high spot location

Rotor and structural resonances

Rotor mode shape 1st critical
139

Bode plot

140

Polar plot
Typical synchronous
rotor response
Phase lag angle increases
with machine speed
Amplitude increases to a
maximum value at critical
speed and then reduces

141

Phase Lag (deg)

Transient Data Formats

0

180
240
300
360
60

180

mils pp

*
* 2280

180

2205 * 2250
*
2145

240

2385

1845
*
300 *
3615 *
2985 * 2775

2685*

2400

* 2415
* 2430
* 2445

270

90

* 2460
* 2475

2610

*
2505

1
0
0

500

1000 1500 2000 2500 3000 3500 4000

4.0 mils pp Full Scale

rpm

Bode Plot

180

CCW Rotation

Polar Plot
1X
2X

4000

Machine Speed (rpm)

2370

2310

120

3000

3X

Average Shaft Centerline Postion (not orbit or polar plot)

3.0

2.0

* 9500

2000

* 9400
*9200
* 8700

1000

1.0
1200

*
*500

0
0

1000 2000 3000

Frequency (kcpm)

4000 5000 6000 7000 8000

Hanning Window

Cascade Plot

* 8000
7600
*
* 4500
*5500

*300

0.0
-1.0

0.0

Amplitude 0.20 mils/div

1.0

142

CCW Rotation

Average Shaft Centerline Plot

Steady State Data Formats

2.0

Vertical Position (mils)

0.2
0

Scheduled
Shutdown

-5

-10

Bearing
Backing

-15

-20
0

10

15

20

25

Time (days)

Vertical Position Trend Plot

Orbit Display
Casing Acceleration - g pk

Timebase Display
20.0

7X
15.0

10.0

Gear Mesh Frequency

5.0

120

240

360

kcpm

Half Spectrum Display

480

600
143