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    Lecture 12

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    five2ninex
    This document provides an overview of vibration monitoring and machine failure analysis. It discusses how vibration profiles can be used to predict machine failures by identifying abnormal vibration patterns. Rotating machinery and reciprocating/linear machinery generate different vibration sources that produce unique profiles. Vibration data is captured using transducers and analyzed in the time and frequency domains to diagnose issues. Common machine problems like misalignment or bearing wear produce distinct vibration frequencies that can indicate impending failure.

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    Lecture 12

    Uploaded by

    five2ninex
    111 views24 pages
    This document provides an overview of vibration monitoring and machine failure analysis. It discusses how vibration profiles can be used to predict machine failures by identifying abnormal vibration patterns. Rotating machinery and reciprocating/linear machinery generate different vibration sources that produce unique profiles. Vibration data is captured using transducers and analyzed in the time and frequency domains to diagnose issues. Common machine problems like misalignment or bearing wear produce distinct vibration frequencies that can indicate impending failure.

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    Lecture12

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    This document provides an overview of vibration monitoring and machine failure analysis. It discusses how vibration profiles can be used to predict machine failures by identifying abnormal vibration patterns. Rotating machinery and reciprocating/linear machinery generate different vibration sources that produce unique profiles. Vibration data is captured using transducers and analyzed in the time and frequency domains to diagnose issues. Common machine problems like misalignment or bearing wear produce distinct vibration frequencies that can indicate impending failure.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    111 views24 pages

    Lecture 12

    Uploaded by

    five2ninex
    This document provides an overview of vibration monitoring and machine failure analysis. It discusses how vibration profiles can be used to predict machine failures by identifying abnormal vibration patterns. Rotating machinery and reciprocating/linear machinery generate different vibration sources that produce unique profiles. Vibration data is captured using transducers and analyzed in the time and frequency domains to diagnose issues. Common machine problems like misalignment or bearing wear produce distinct vibration frequencies that can indicate impending failure.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 24

    Lecture 12 – Vibration

    Monitoring and Machine Failure

    Lecture 12 – Vibration Monitoring and Machine Failure 1


    New Plan
    Predictive
    Maintenance
    Organisation
    Financial Organisational
    Implications Change

    Structure or Loads
    Machine Design Monitoring
    Maintenance
    FMEA
    Techniques
    Design
    Concepts
    Damage
    Consequences Identification
    Hierarchy

    Lecture 12 – Vibration Monitoring and Machine Failure 2


    Lecture Overview
    SHM/CM/SPC
    Comparison

    Data-Driven Model-Driven
    Approach Approach

    Vibration Data to
    Monitoring for Decision
    Machine
    Damage Sensor Feature
    Issues Extraction

    Signal Pattern
    Processing Processing

    Lecture 12 – Vibration Monitoring and Machine Failure 3


    Lecture Overview
    „ Vibration Monitoring
    „ Vibration Profiles
    „ Measuring Vibration
    „ Vibration Sources
    „ Rotating Machinery
    „ Reciprocating/Linear Machinery

    Lecture 12 – Vibration Monitoring and Machine Failure 4


    Machines

    Drivers

    Intermediate
    Drives

    Driven
    Components

    Lecture 12 – Vibration Monitoring and Machine Failure 5


    Vibration Monitoring
    „ All mechanical equipment in motion generates a
    vibration profile, or signature, that reflects its
    operating condition.
    „ The above statement is true regardless of speed
    or whether mode of operation is rotation,
    reciprocation or linear motion.
    „ Use of vibration analysis not restricted to
    predictive maintenance – can be used to
    evaluate fluid flow through pipes and vessels,
    detect leaks and improve plant reliability and
    performance.

    Lecture 12 – Vibration Monitoring and Machine Failure 6


    Introduction to Vibration Monitoring

    Lecture 12 – Vibration Monitoring and Machine Failure 7


    Vibration Profiles
    „ Vibration data recorded from machines is
    usually extremely complex as there are many
    sources of vibration. Each source generates its
    own profile which will essentially be added
    together to give the composite profile.
    „ Time-domain plots must be used for linear and
    reciprocating machinery – useful in overall
    analysis of machine trains to study operating
    condition changes but time-domain data are
    difficult to use.

    Lecture 12 – Vibration Monitoring and Machine Failure 8


    Vibration Profiles
    „ Time-domain data may be broken down into
    their frequency components using a Fast Fourier
    Transform (FFT).
    „ Frequency-domain data required for equipment
    operating at more than one running speed and
    all rotating applications.
    „ Key to using vibration signature analysis for
    predictive maintenance is ability to differentiate
    between normal and abnormal vibration profiles.

    Lecture 12 – Vibration Monitoring and Machine Failure 9


    Vibration Profiles
    „ Many vibrations are normal for rotating or
    moving machinery, e.g. normal rotation of shafts
    and other rotors, contact with bearings, gear-
    mesh etc.
    „ Specific problems with machinery generate
    abnormal, yet identifiable, vibrations, e.g. loose
    bolts, misaligned shafts, worn bearings, leaks
    and incipient metal fatigue.

    Lecture 12 – Vibration Monitoring and Machine Failure 10


    Vibration Profiles
    „ Predictive maintenance using vibration signature
    analysis is based on the following:
    „ All common machinery problems and failure modes
    have distinct vibration frequency components that can
    be isolated and identified.
    „ Frequency-domain signature is generally used
    because it contains discrete peaks, each representing
    specific vibration source.
    „ There is a cause for each frequency component.
    „ When the machine signature is compared over time, it
    will repeat until some event changes the vibration
    pattern.

    Lecture 12 – Vibration Monitoring and Machine Failure 11


    Vibration Monitoring

    Lecture 12 – Vibration Monitoring and Machine Failure 12


    Vibration-measuring equipment
    „ Vibration data obtained by:
    „ Mounting transducers on the machinery at various
    locations, typically machine housing and bearing
    caps.
    „ Using a portable data-gathering device (vibration
    monitor or analyser) which can acquire data, FFT and
    store.

    Lecture 12 – Vibration Monitoring and Machine Failure 13


    Measuring Vibration

    Lecture 12 – Vibration Monitoring and Machine Failure 14


    Displacement Transducers

    Lecture 12 – Vibration Monitoring and Machine Failure 15


    Velocity Transducers

    Lecture 12 – Vibration Monitoring and Machine Failure 16


    Accelerometers

    Lecture 12 – Vibration Monitoring and Machine Failure 17


    Monitoring Methods

    Lecture 12 – Vibration Monitoring and Machine Failure 18


    Vibration Sources
    „ All machinery with moving parts generates
    mechanical forces during normal operation.
    „ As mechanical condition of machine changes
    because of wear, changes in operating
    environment, load variations etc., so do these
    forces.
    „ Vibration profile that results from motion is the
    result of a force imbalance – there is always
    some imbalance in real-world applications.

    Lecture 12 – Vibration Monitoring and Machine Failure 19


    Rotating Machinery Vibration
    „ A rotating machine has one or more machine
    elements that turn with a shaft – e.g. rolling-
    element bearings, impellers and other rotors.
    „ In a perfectly balanced machine, all rotors run
    on their true centreline and forces are equal.
    „ In industrial machinery, rotors imbalance will
    generally be present due to uneven weight
    distribution or due to the imbalance between
    generated lift and gravity.

    Lecture 12 – Vibration Monitoring and Machine Failure 20


    Rotating Machinery Vibration
    „ Pumps, fans, compressors will be subject to
    imbalance caused by turbulent or unbalanced
    media flow.
    „ Combination of these forces with stiffness of
    rotor-support system will determine the vibration
    level.

    Lecture 12 – Vibration Monitoring and Machine Failure 21


    Reciprocating/Linear Vibration
    „ Reciprocating linear-motion machines
    incorporate components that move linearly in a
    reciprocating fashion to perform work. They are
    bidirectional in that the linear movement
    reverses.
    „ Non-reciprocating linear machines also generate
    work in straight line but do not reverse direction.
    „ Few machines involve linear reciprocating
    motion alone e.g. reciprocating compressor
    contains a rotating crankshaft that transmits
    power to reciprocating pistons for compression.
    Lecture 12 – Vibration Monitoring and Machine Failure 22
    Reciprocating/Linear Vibration
    „ Vibration profiles of reciprocating machines reflect
    combination of rotating and linear-motion forces.
    „ Frequencies are not always associated with one
    complete revolution of shaft e.g. four-cycle engine
    requires two crankshaft revolutions to complete a
    cycle of all pistons.
    „ Level of unbalanced forces substantially higher
    than those generated by rotating machines –
    spikes in vibration profile due to direction
    reversals. (Linear-motion-only machines do not
    generate these spikes).
    Lecture 12 – Vibration Monitoring and Machine Failure 23
    Next Lecture
    „ Vibration Analysis Video
    „ Machine Failure Mode Analysis
    „ General Failure Modes
    „ Failure Modes by Machine-Train Component

    Lecture 12 – Vibration Monitoring and Machine Failure 24

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