Cat Ii
Cat Ii
Cat Ii
ACTIVITY BOOK
CATEGORY II
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Table of Contents
VIBRATION FUNDAMENTALS ........................................................................................... 4
WINDOWING .............................................................................................................. 17
AVERAGING ................................................................................................................ 18
DIAGNOSING MISALIGNMENT....................................................................................... 29
DIAGNOSING LOOSENESS............................................................................................ 30
BELTS ........................................................................................................................ 35
VIBRATION FUNDAMENTALS
[1] Circle the RMS level on this chart.
[2] True or
False: The
peak- peak
level is always
twice the peak
level.
A.
True B.
False
[3] The measurement that relates to the rate of change of the vertical movement
of the shaft in the bearing is...
A.
Displacement
B. Velocity
C. Acceleration
[4] The measurement that is proportional to the stress of the shaft on the bearing is...
A.
Displacement
B. Velocity
C. Acceleration
[5] The measurement that is proportional to the force of the shaft on the bearing is...
A.
Displacement
B. Velocity
C. Acceleration
[6] Which two vibration measures are 180 degrees out of phase?
A. Displacement and
Acceleration B. Velocity and
Acceleration
C. Displacement and
Velocity D. All of the
above
in/sec pk_________________________________________________________________________
Gs rms__________________________________________________________________________
[2] What is the phase relationship between the following two signals?
A. In phase
B. 180 degrees out of
phase C. 90 degrees
out of phase
A.
Lead B.
Lag
_________________________________________________________________________________________
_________________________________________________________________________________________
[2] Please name at least two ways to calculate the RMS Overall level
_________________________________________________________________________________________
_________________________________________________________________________________________
[2] If the 10X peak is at 2500 CPM, the running speed of the machine is
_________________ CPM
A. 250
CPM B.
2500 CPM
C. 4.2 CPM
[3] Sketch: Draw a 2 Hz sine wave with amplitude of 1 mm/sec. Draw the
corresponding spectrum on the chart below in mm/sec rms. Annotate the y-axis
(show the min and max value on the graph scale.)
_________________
_________________
_________________
_________________
_________________
____
[5] The
following
order
normalized spectrum came from a motor driving a pump at 1485 RPM via a
flexible coupling. Calculate the frequency of the peak at 6X: ____________________
CPM
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obiusinst
itute.co
m
Copyrigh
t 2005
- 2013
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biusinsti
tute.com
Docume
nt ID:
ABII
161012
Vibration Training Activity Booklet CAT II Page 9 of 37
[1] If the following compressor ran at 1485 CPM, and there are 12 vanes on the
impeller, calculate the compressor vane-pass rate: _______________ CPM
______________ Hz ______________ X
[ 3]
If
[5] If the motor speed was 1480 RPM, and the input gear of the gearbox had 39
teeth, and the pinion had 15 teeth, and the compressor had 12 vanes, provide
the following details:
UNDERSTANDING SIGNALS
[1] Sketch: Imagine a machine that generates a 2 Hz signal of 2 mm/sec and
a second 2 Hz signal of 1 mm/sec. There is 0 degrees phase angle between the
two signals.
Draw the resultant time waveform and spectrum in mm/sec rms. Annotate the
y-axis (show the min and max value on the graph scale.)
[2] Question:
What is the amplitude of
the peak in the spectrum
you have sketched (state
the units)?
______ ________________
______ ________________
______ ________________
______ ________
_______ ________________
_______ ________________
_______ ________________
_______ ____
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ID: ABII 161012
Vibration Training Activity Booklet CAT II Page 13 of 37
[8] If a signal of 200 Hz was varying in amplitude at a rate of 20 Hz, what pattern
would you see in the spectrum?
A. A peak at 200 Hz, 400 Hz, 600
Hz, etc. B. A peak at 200 Hz and
20 Hz.
C. Peaks at 180 Hz, 200 Hz and 220 Hz.
[9] Two signals very close to each other in frequency will cause
A.
Subtraction
B.
Harmonics C.
Beating
D. Amplitude modulation
[10] Describe what you would hear if an electric motor generated signals at 99 Hz and
100 Hz
A. Your last
sound B.
Nothing
C. A throbbing sound with a period of 1
second D. Amplitude modulation
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Document ID: ABII 161012
Page 14 of 37 Vibration Training Activity Booklet CAT II
SIGNAL PROCESSING
Useful information:
[1] If the first graph is the spectrum of the raw, unfiltered signal coming from the
transducer, and that signal was put through a filter such that the spectrum in the
lower graph was the result, what sort of filter must have been used?
A. High
pass B.
Low pass
C. Band
pass
D. Notch (band stop)
[4] For the same Fmax, if you increase the number of lines of resolution...
A. The measurement will take longer to
acquire B. The test time will not change
C. The measurement will take less time to acquire
[5] Why shouldn't you always collect the highest resolution measurement possible?
A. The test takes longer
B. The data takes more room in the database
C. The data takes longer to unload from the
data collector D. All of the above
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[6] If a spectrum had 1600 lines of resolution, how many samples were in the time
record?
A. 1024
samples B.
2048 samples
C. 4096
samples
[7] If the record length is 10 seconds, and there were 1024 samples, what is the Fmax?
A. 40 Hz
B. 40
CPM C.
400 Hz
D. 4000 Hz
[8] If the Fmax is 10,000 Hz and you have a 1600 line spectrum, how long does it
take to sample the vibration signal if you have one average only?
A. Not enough
information B. 6.25
seconds
C. 1.6
seconds D.
0.16 seconds
[9] If the Fmax is 120 Hz and you have a 3200 line spectrum, how long does it
take to sample the vibration signal if you have 10 averages (no overlap)?
A. 267
seconds B.
27 seconds
C. 12
seconds D.
6 seconds
[10] What Fmax and Lines of resolution settings are required to separate vibration
signals of 100 Hz and 100.50 Hz? (assume that a Hanning window will be used):
________________________________________________________________________________
[11] If a spectrum had a peak at 250 Hz, and the spectrum had 800 lines and
Fmax = 800 Hz, and the window was turned of, which of the following is true about
the actual source of vibration?
A. 250 0.5
Hz B. 250
1 Hz C.
250 1.5 Hz
D. 250 2
Hz
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Document ID: ABII 161012
Vibration Training Activity Booklet CAT II Page 17 of 37
WINDOWING
[1] We experience leakage because:
A. The signal does not begin and end at zero in the time record
it is finite. B. There are errors in the FFT calculation.
C. Time waveforms can often have a lot of noise.
[2] The window most commonly used when route testing rotating equipment is:
A.
Hanning
B. Flat
top
C. Exponential
D. Uniform/Rectangular/No window
[3] The window most commonly used for bump tests is:
A.
Hanning
B. Flat
top
C. Exponential
D. Uniform/Rectangular/No window
[5] The primary reason for windowing the time waveform is:
A. To increase frequency
accuracy. B. To improve
amplitude accuracy.
C. To correct the leakage phenomenon.
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AVERAGING
[1] How many averages should one normally use when using linear
averaging with an Fmax of 10,000 Hz?
A. 2 averages
B. 5-10
averages C.
50 averages
[2] The most commonly used averaging method used for routine data collection is:
A. Time synchronous
averaging B. Linear
averaging
C. Peak-hold averaging
[3] True or False: Linear averaging works by averaging the time waveform.
A.
True B.
False
[4] True or False: Linear averaging removes noise from the spectrum
A.
True B.
False
[5] When performing a bump test, which averaging method should be used?
A. Time synchronous
averaging B. Linear
averaging
C. Peak-hold
averaging D. Free
run averaging
[6] How many averages should normally be used when using time synchronous
averaging?
A. 4-6
averages B.
10 averages
C. 20
averages
D. 100 averages (or more)
[7] True or False: Time synchronous averaging removes noise from the waveform
A.
True B.
False
[2] True or False: I can use the same sensor for all of my vibration tests.
A.
True B.
False
[5] When a signal is integrated (accel-vel) what happens to low frequency (<160 Hz)
signals?
A. They are increased in
amplitude B. They are
reduced in amplitude C. The
amplitude is not affected
[6] When integrating from acceleration to velocity, why is a high pass filter?
A. To filter out noise in the signal which is caused by
machine 'rumble' B. To filter out electrical noise
C. To filter out the low frequency signals that are amplified during the
integration process
[7] What type of sensor measures the relative movement between the shaft and
bearing?
A. Displacement non-contact eddy
current probe B. Velocity sensor
C. Accelerometer
[9] What is a piezovelocity sensor and why might someone choose to use
one instead of an accelerometer?
________________________________________________________________________________
________________________________________________________________________________
[10] Which transducer is best suited to a machine tool application with very low
vibration?
A. 10
mV/g B.
100 mV/g
C. 1000 mV/g
[11] What would happen if you used a 10 mV/g sensor on the quiet machine tool?
A. The machine tool would appear to vibrate much more than it actually did
B. The voltage output would be small, and the amplitude resolution of
data would be unacceptable
C. The sensor would 'saturate' and the vibration data would be poor
[12] What would happen if you used a 1000 mV/g accelerometer on a noisy rock
crusher?
A. Sparks would fly from the transducer leads
B. The data collector would overload and may be damaged
C. The sensor would 'saturate' and the vibration data would be poor
[13] True or False: The frequency response is the same regardless of the sensitivity.
A.
True B.
False
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Vibration Training Activity Booklet CAT II Page 21 of 37
[3] If you cannot access a suitable test location for the sensor you should...
A. find another machine to monitor - that one is too hard.
B. buy a longer 'stinger' so that you can reach in to the best location.
C. mount the sensor anywhere that it vibrates - it is better
than nothing. D. permanently mount a sensor, and connect
it to a junction box.
[4] Circle the best transducer mounting point from the available options: A B C D
[6] Which is the best method of mounting a sensor (the best frequency response)?
A. Stinger, or probe
tip B. Flat magnetic
mount
C. Two-pole magnetic
mount D. Stud mount
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
[2] When considering the vibration sensor, what is the settling time?
A. A setting on my data collector I have never understood
B. The time it takes the sensor to convert the entire
vibration pattern. C. The time it takes for the transducer
to generate a stable output.
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Document ID: ABII 161012
Vibration Training Activity Booklet CAT II Page 23 of 37
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
[5] What type of phase measurement is often more convenient when measuring
phase to diagnose typical machine faults?
A. Absolute
phase B.
Relative phase
[6] True or False: A strobe should be used as a phase reference when balancing.
A.
True B.
False
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[4] What is wrong with this machine? Please briefly explain why you have come to this
conclusion.
________________________________________________________________________________
________________________________________________________________________________
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Document ID: ABII 161012
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[5] What is wrong with this machine? Please briefly explain why you have come to this
conclusion.
________________________________________________________________________________
________________________________________________________________________________
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Document ID: ABII
161012
Vibration Training Activity Booklet CAT II Page 27 of 37
DIAGNOSING IMBALANCE
[1] If a machine (not overhung) is out of balance, the spectrum will have...
A. peaks at 1X, 2X, and 3X.
B. a high peak at 1X in the axial direction.
C. a high peak at 1X in the vertical and
horizontal direction. D. a high peak at 2X.
[9] If I have a large 24 Hz (1440 RPM) motor-pump with a peak at running speed of
3.0 mm/sec rms (and the fault was suspected to be imbalance), according to the
chart below, what is the severity of this condition?
DIAGNOSING ECCENTRICITY
[1] If a sheave/pulley or rotor is eccentric, the spectrum will have...
A. peaks at 1X, 2X, and 3X.
B. a high peak at 1X in the axial
direction. C. a high peak at 1X in
the radial directions. D. a high peak
at 2X.
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DIAGNOSING MISALIGNMENT
[1] If a machine has angular misalignment, in the axial direction the spectrum will
have...
A. peaks at 1X, 2X, 3X,
4X, etc. B. a high
amplitude peak at 1X.
C. high amplitude peaks at 1X
and 2X. D. a high peak at 2X
only.
[2] Describe the phase relationship across the coupling when angular misalignment
exists.
A. In-phase in the radial direction, and out-of-phase in the
axial direction. B. Out-of-phase in the radial and axial
directions.
C. In-phase in the axial direction and out-of-phase in the
radial directions. D. In-phase in the radial and axial
directions.
[3] If a machine has parallel misalignment, in the radial directions the spectrum will
have...
A. peaks at 1X, 2X, 3X, 4X, etc.
B. a moderate-high amplitude peak at 1X and a
high 2X peak. C. moderate amplitude peaks at 1X
and 2X.
D. a high peak at 2X only.
[4] Describe the phase relationship across the coupling when parallel misalignment
exists.
A. In-phase in the radial direction, and out-of-phase in the
axial direction. B. Out-of-phase in the radial and axial
directions.
C. In-phase in the axial direction and out-of-phase in the
radial directions. D. In-phase in the radial and axial
directions.
[2] If a shaft is bent, what will be the phase relationship when measured at either end
of the machine?
A. In-phase in the vertical direction, but out-of-phase in the
horizontal direction. B. In-phase when measured axially.
C. Out-of-phase when measured axially.
D. Phase is not a useful tool for diagnosing a bent shaft.
DIAGNOSING LOOSENESS
[1] Name one of the causes of rotating looseness.
A. Motor not bolted down securely.
B. Loose cowling or other metallic
structure. C. Wear within a rolling
element bearing.
D. Pedestal bearing not bolted down sufciently.
[3] If you witnessed a 1X peak in the vertical direction, and a much stronger 1X
peak in the horizontal direction, which would you suspect?
A. Rotating looseness.
B. Non-rotating looseness.
C. Structural looseness (foundation
flexibility). D. Pedestal bearing
looseness.
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Document ID: ABII 161012
Vibration Training Activity Booklet CAT II Page 31 of 37
[4] If you witnessed a 1X, 2X, and 3X peak, which would you suspect?
A. Rotating looseness.
B. Non-rotating looseness.
C. Structural looseness (foundation
flexibility). D. Pedestal bearing
looseness.
DIAGNOSING RESONANCE
[1] What is the diference between a natural frequency and resonance?
________________________________________________________________________________
________________________________________________________________________________
[2] If the running speed of the machine was changed so that it now coincided with a
natural frequency, how would the vibration amplitude change?
A. It will remain unchanged
B. It will increase if the machine was out-of-balance and the machine speed
was decreased. C. It will decrease in amplitude due to resonance
D. It will increase in amplitude due to resonance
[3] True or false: Bearing forcing frequency calculations are 100% accurate.
A.
True B.
False
[4] A defect on a ball or roller will often cause which pattern in a spectrum?
A. High 1x
B. Cage rate vibration
C. Non synchronous peak with cage rate
sidebands D. Non synchronous peak with
1x sidebands
[5] If we knew that BPO was 3.2X and BPI was 4.8X, how many balls are there?
A. There must be 8 balls (3.2 +
4.8 = 8) B. There must be 10
balls (2 + 8 = 10) C. There
must be 7 balls (3 + 4 = 7)
[7] If the inner race is spinning, which fault is described by these peaks in a
spectrum: 3.2x, 4.2x, 5.2x, 8.4x, 12.6x
A. Outer
race B. Ball
fault C.
Inner race
D. Cage
fault
[2] An eccentric rotor (with a rotating differential air gap) will produce...
A. a high 1X peak at the motor running speed
B. a peak at the rotor bar frequency with twice line-frequency sidebands
C. increased amplitude at 1X vibration and twice line frequency, with
pole-pass sidebands D. harmonics of 1X with pole-pass sidebands
[3] A motor (not on a VFD) turns at 1740 RPM. The pole-pass frequency is
A. 60
RPM B.
24 Hz C.
29 Hz
D. 240 RPM
GEARBOX ANALYSIS
[1] The input gear of a single reduction gearbox has 32 teeth. Which of these
patterns would you expect to see in the spectrum?
A. A peak at 32x only
B. Peaks at 8x, 16x, 24x
and 32x C. Peaks at 31x,
32x, 33x
D. None of the above
[2] Why is time waveform analysis useful in analyzing vibration from gearboxes?
A. You can easily identify the shaft speed from the
time waveform B. You can see the pattern of wear on
the teeth
C. You can detect damage to individual teeth
D. Time waveform analysis is good for all rotating components so it
must be good for gearboxes
[3] What efect is present in the time waveform from this gearbox?
A.
Looseness
B. Beating
C. Random vibration
D. Amplitude modulation
[4] What is the best tool for detecting cracked or broken gear teeth?
A. Motor current analysis
B. Perform thermographic analysis on the
lubricant C. A wrench and a large hammer
D. Time waveform analysis
BELTS
[1] The 'belt rate' forcing frequency is...
A. lower than the machine
RPM B. higher than the
machine RPM C. the same
as the output RPM
[4] If two sheaves/pulleys are not aligned correctly, the vibration pattern will produce...
A. a strong 1X component in the radial
directions B. a series of harmonics of
the belt rate
C. a strong 1X component in the axial
direction D. strong 1X, 2X, and 3X
peaks
[5] If a belt resonance coincides with the sheave/pulley RPM, the vibration pattern will
produce...
A. a strong 1X component in the radial
directions B. a series of harmonics of
the belt rate
C. a strong 1X component in the axial
direction D. strong 1X, 2X, and 3X
peaks
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Document ID: ABII 161012
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MAINTENANCE PRACTICES
[1] In a general sense, a plant that wishes to remain competitive will try to
move from a ________ mode to a ________ mode of operation.
A. predictive /
preventive B.
reactive / proactive
C. run to failure /
preventive D. proactive
/ predictive
[7] Which maintenance philosophy can actually reduce plant reliability compared with
doing nothing?
A. Root cause failure
analysis B. Predictive
maintenance
C. Preventive
maintenance D.
Proactive maintenance
[9] Which maintenance philosophy would result in lower spare parts cost?
A. Breakdown
maintenance B.
Predictive maintenance
C. Preventive
maintenance