VIBRATION

ANALYSIS
(PROFILES
LECTUR &
E 03
SPECTRUM)
 Course Outline
LECTURE 01 Introduction to Plant Maintenance and its Regimes
Basic
LECTURE 02
Maintenance & Damage
Maintenance Planning, Failure Mechanisms, SHM
Concepts
Week 01

LECTURE 03 Vibration Analysis (Profile & Spectrum)

Week 02
LECTURE 04
Vibration Analysis
Corrective Techniques (Balancing, Align., Looseness)

LECTURE 05 Failure Mode Analysis

Week 03
LECTURE 06 Visual Inspection (DPT & BT)

Non-Destructive Testing
LECTURE 07 Radiographic Inspection (RT & NI)
Week 04
LECTURE 08 Magnetic Electric Inspection (MPI)
 Lecture Outline
What is Vibration?

Why Monitor Machine Vibration?

How is Machine Vib. Described?

Vibration Spectrums

Energy in Spectrums

Lines of Revolution (LOR)

Analysis Techniques

Measurement Point Identification

Locating Turning Speed

Data Collection Techniques

What is Vibration

Video-1
 What is Vibration
Most of us are familiar with vibration; a vibrating object moves to
and fro, back and forth. A vibrating object oscillates.

We often experience
examples of vibration in our
daily life
What is Machine Vibration
Rotating Machines Vibrate while Operating

Vibrating Belts Vibrating Motors

Vibrating Fans Vibrating pumps

 What Causes Machine
Vibration
Almost all machine vibration is due to one or more of
these causes:

Repeating Forces
Improper
Imbalanced Misaligned Worn machine
Driven

Looseness

Resonance
 Imbalance
Imbalanced
Imbalanced machine
machine components
components contains
contains heavy
heavy spot
spot which
which
one rotated, exert a repeating force on the machine.
one rotated, exert a repeating force on the machine. ImbalanceImbalance
is
is often
often caused
caused byby machine
machine errors,
errors, non
non uniform
uniform material
material
density
density , variation in bolt sizes, air cavities in cast parts, missing
, variation in bolt sizes, air cavities in cast parts, missing
balance
balance weights,
weights, andand broken
broken deform,
deform, corroded,
corroded, or
or dirty
dirty fan
fan
blades.
blades.

Uneven Rotor
Corroded tip

Bent Shaft

Dirt
 Misaligned
Misaligned machine components create “bending
moments” which when rotated, exert a repeating
force on the machine. Misalignment is often
caused by inaccurate assembly, uneven floors,
thermal expansions, and distortions due to
fastening torque.

Parallel Misalignment Angular Misalignment

 Worn Machine
Worn machine components exert a repeating force
on the machine because of the rubbing of uneven
worn surfaces. Wear in roller bearings, gears, and
belts is often due to improper mounting, poor
lubrication, manufacturing defects, and overloading

Worn Roller Worn Teeth Worn Belt

 Improperly Driven

Improperly driven machine components exert a repeating

force on the machine because of intermittent power supply.
Examples include pumps receiving air in pulses, internal
combustion engines with misfiring cylinders, and
intermittent brush commutator contact in DC motors

Intermittent Brush
contact Misfiring
Uneven
supply Cylinder
 Looseness
Looseness can cause vibration in both rotating
and non-rotating machinery. Looseness is often
due to excessive bearing clearances, loose
mounting bolts, mismatches parts, corrosion,
and cracked structures

Excessive
Excessive
Clearance
Clearance
Loose
Loose
bolts
bolts
 Resonance

Resonance is an excitation of ‘Natural Vibration’.

Everything has a ‘natural frequency’ fnn, everything vibrates!

This fnn does not cause any problems until another vibration source runs at a
same/similar frequency.
 Resonance
 A repeating force causing resonance may be small and may
originate from the motion of a good machine component.
 Resonance, however, should always be avoided as it
causes rapid and severe damage.

. For example, whole bridges have collapsed due to their

natural oscillation rates being excited by the mere rhythm
of soldiers marching in unison across the bridges
 Case Study Tacoma
Narrows Bridge
 The Tacoma Narrows Bridge in Washington opened to traffic
on 1st July 1940. Unlike most suspension bridges of it’s time
the Tacoma Narrows Bridge was unusually long and narrow.
 The original design had called for trusses to stiffen the span
but funds were not available and inadequate stiffening was
used.
 Wind blowing over and under the deck creates lift causing the
bridge to move up and down.
 As the bridge was moving at its natural frequency the
resonance amplified the movement Video- 2
 Why Monitor
Machines Vibration?
 Machines Vibration
 Monitoring the vibration characteristics of a
machine gives us an understanding of the 'health'
condition of the machine.
 We can use this information to detect problems that
might be developing.
 Why Monitor Machines
Below we discuss some common problems that can
be avoided by monitoring machine vibration.
 Severe Machine damage
 High power consumption
 Machine unavailability
 Delay shipments
 Accumulation of unfinished goods
 Unnecessary maintenance
 Quality Problems
 Bad Company image
 Occupation hazards
 Severe Machine Damage
Machine vibration that is not detected early enough will
often lead to severe machine damage requiring costly
repairs or even total machine replacement.

Just
Just asas itit is
is costly
costly to
to
detect
detect medical problems
medical problems
We
We cover
cover all
all services
services and
and you
you at
at a
a late
late stage,
stage, itit is
is also It
have a choice; a $200.000
have a choice; a $200.000
also It might
might be
be cheaper
cheaper
the
the same
same for for machines.
machines. to
operational
operational or
or a
a $5000
$5000 to replace it!
replace it!
funeral.
funeral.
 High Power Consumption
 A machine that is vibrating consumes more power.

 We can minimize this problem by regularly

monitoring and maintaining the machine.
 Machine Unavailability
 Because an unmonitored machine is more likely to break
down, it is more often out of action.
 A machine should be consistently available to generate
the money to justify its investment.
Its unavailability does not
This
This is
is so
so often
often justify its initial cost, the
unavailable
unavailable to to make
make floor space it occupies, the
money
money it it is
is actually
actually How? business opportunities we
losing money.
losing money. miss out on!
 Delay Shipments

Because an unmonitored machine is more likely to break

down, it is also more likely to cause delays in the shipping
of goods.

I’ve got a dinghy!

Maybe we can catch
it.
 Accumulation of Unfinished Goods
 Because an unmonitored machine is prone to breaking
down it is often unavailable.
 Goods still in the making tend to get stuck at the input point of
the machine. This leads to unnecessary wastage.

This
This needs
needs Is there a
processing
processing now!
now! market for
By
By tomorrow it’ll
tomorrow it’ll
be sour milk?
be no
no good
good
Hmm!
 Unnecessary Maintenance
To constantly ensure proper machine condition, some
companies stop running machines according to
predetermined schedules to adjust and replace parts
regardless of whether or not the machines are malfunctioning.

It’s
It’s good
good that
that you’re
you’re
getting full checkups It’s
It’s even
even better
better that
that
getting full checkups
every you’re
you’re making me rich
making me rich
every week.
week.
unnecessarily!
unnecessarily!
 Quality Problems
 Sometimes a machine can be running into trouble even
though it appears to be functioning normally.
 If not caught early, the problem could lead to poor
quality products being made.

And
And you
you didn’t
didn’t
know?
know?
These
These are
are all
all wrong Have More
More than
than a
a vb
vb
wrong Have you any
you any idea
idea
because the machine what instrument?
instrument?
because the machine what this
this will
will cost
cost
bearing
bearing is
is worn
worn the
the company?!
company?!
 Bad Company Image
 Machines that are not regularly monitored can lead to shipment
delays and produce goods of poor quality.
 Just one incident of shipment delinquency or product defect is often
enough to seriously strain or even end relationships with customers.

I’m out of here.

Delayed
Quality
System
LTD.

 A bad company image associated with shipment delays and poor

quality is something to be avoided.
 Occupational Hazards
Due to the noise and shaking they create, vibrating
machines can cause occupational hazards and human
discomfort.

Now What?
 How is Machine
vibration described?
How Does Vibration
Travel

Video-3
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration Characteristics

• Amplitude How Much

• Frequency How Often
• Phase. When
 How Does Vibration Travel

 Unfortunately there can be  We call this a complex sine

multiple sine waves emitting waveform
from a machine, So our  Analysis is very difficult on this
wave form becomes type of waveform.
complex  Fortunately we have what’s
called an ‘FFT’ which converts
the complex waveform back into
several simple waveforms

Video-4
Signal Acquisition & Understanding the
Vibration Spectrum

Transducer Waveform

Amplitude
Overall
Energy Time

FFT
Amplitude Spectrum

Frequency
 How the Vibration Spectrum is Created

• Complex waveform The waveform is

changes to a converted to an
simple waveform amplitude/frequency
domain
Amplitude

Tim
e
Amplitude

Amplitude
y
e nc
e qu
Tim Fr
e
Spectrums
 Spectrums
 Before we learn how to diagnose
potential faults within a spectrum,
we need to understand the units of
measurement.

 The vibration data that is

converted from the waveform by
the FFT process can be seen very
clearly
 However there are a few
considerations we need to take into
account first.
 The amplitude scale and the
amplitude units are important

 As well as the frequency scale

and units
Amplitude Units

C1 - Example 4
E4 -MOH MOTOR OUTBOARD HORIZONTAL
0.5
Route Spectrum
09-Feb-00 12:41:33

OVRALL= .5785 V-DG

0.4 There are three different RMS = .5716
LOAD = 100.0
amplitude measurements we use, RPM = 2937.
RPS = 48.95
these are:
RMS Velocity in mm/Sec

0.3
Acceleration
Velocity
0.2 Displacement

0.1

0
Freq: 2.937
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .01038
 Amplitude Units
 Acceleration
◦ Measures the change in velocity over a period of time
 Velocity
◦ Rate of movement
 Displacement
◦ Measures total movement in relation to a reference point

 A good way of remembering this is to think of a car:

◦ From rest to 60mph is your acceleration (change in velocity over time)
◦ Drive at 60mph for x-time (this is your velocity)
◦ From start to finish is the total distance traveled (Displacement)
 Measuring Amplitude
 You can measure amplitude from a time waveform as shown:
0 to Peak

RMS
Average
Amplitude

Time ‘t’
+
-

Peak to Peak

 The period ‘t’ is the time required for one revolution of the shaft in this illustration, which
equals one cycle of the waveform

◦ During this period, the amplitude of the waveform reaches a positive (+) peak, returns to rest, and
reaches a negative (-) peak before returning to rest
 Measuring Amplitude
 Peak (Pk) – Amplitude measured from the ‘at rest’ position (0) to the
highest value (0 to Peak)
 Peak to Peak (Pk-Pk) – Amplitude measured from the peak positive (+)
value to the peak negative (-) value
 RMS (Root Mean Square) – obtained by averaging the square of the signal
level over a period of time and then taking the square root result
 Average (Avg) – Amplitude value that averages the peak values of the
waveform 0 to Peak

RMS
Average
 You can calculate the different amplitudes

Amplitude
when one of the values are known: Time
◦ RMS = 0.707 times the peak value ‘t’
◦ Avg = 0.637 times the peak value
◦ Pk-Pk = 2 times the peak value

+
-
Peak to
Peak
 Amplitude Units
 Acceleration - G-s
 Value from the base line to the peak amplitude
 Looks a force generated in our machine (High
frequency domain)

 Velocity RMS - MM/Sec

 RMS - root mean square,
 Displacement - microns appears at 0.707 the value of
 Total movement, value is from the amplitude
Peak to Peak  Gives a good overall picture,
 Ignores all high frequencies and of the vibration in our machine
looks at the low frequency
 What Effect Do These Have In Our Spectrum

19T - Example 6
19T - Example 6
E6 -G3H 19T
GBox Shaft 26Inboard Horz
- Example
100 E6 -G3H GBox Shaft 2 Inboard Horz
0.8 E6 -G3H GBox Shaft 2 Inboard Horz Route Spectrum
0.24 Route Spectrum
31-Jan-01 10:57:43

0.7
Route Spectrum
31-Jan-01 10:57:43
31-Jan-01 10:57:43
OVRALL= 1.32 V-DG
Velocity RMS
0.21 OVRALL=
P-P = 58.121.32 V-DG
80 OVRALL=
RMS
LOAD
PK
LOAD
= 1.31
= 100.0
= .6325
= 100.0

1.32 V-DG
Good overall value
0.6 RPM
LOAD = =1052.
100.0
0.18 RPM
RPS == 1052.
17.54
RPM = 1052.
RPS = 17.54
Microns

RPS = 17.54
 Acceleration G-s
Velocity ininmm/Sec

0.5
60
0.15
G-s

Accentuates the high

in


Displacement
Acceleration

0.4
0.12
40
frequencies
Good for anti-friction
RMS

0.3 
0.09
P-P
PK

0.2
0.06
bearings & Gears)
20

0.1
0.03

0
 Displacement -
0
0
0
0
20000
20000
40000
40000
60000
60000
80000
80000
100000
100000
microns
0 20000 40000Frequency in 60000
CPM 80000 100000
Label: Chipped Gear Tooth
Label: Chipped Gear Tooth
Label: Chipped Gear Tooth
Frequency in CPM
Frequency in CPM  Accentuates the low
frequencies
 Monitoring Techniques

Vib Acceleration
accentuates HIGH frequencies,
and attenuates LOW frequencies.

Acceleration

Velocity
“flat” treats all frequencies equally.

Velocity

Displacement
accentuates LOW frequencies,
and attenuates HIGH frequencies.

Displacement

Freq

Video-5
 Frequency Units
 Frequency refers to how often something occurs:
◦ How often a shaft rotates?
◦ How often a rolling element hits a defected race?

 There are three ways to express frequency:

1. CPM – Cycles Per Minute
 1CPM = 1RPM

2. Hz – Cycles Per Second

 CPM / 60

3. Orders – Multiples of Turning Speed

 Consider
 a motor has a rotational
Frequency/Turning Speed speed of 1485RPM, in terms of frequency this
equates to:
◦ 1485 CPM (1rpm = 1cpm)
◦ 24.75 Hz (1485/60) (minutes to seconds)
◦ 1 Orders (1 x revolution of the shaft)
Energy in
Spectrum
Energy in the Spectrum
C1 - Example 4
E4 -MOH MOTOR OUTBOARD HORIZONTAL
0.5
Route Spectrum
09-Feb-00 12:41:33

OVRALL= .5785 V-DG

0.4 RMS = .5716
LOAD = 100.0
RPM = 2937.
RPS = 48.95
RMS Velocity in mm/Sec

0.3

0.2

0.1

0
Freq: 2.937
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .01038
 Synchronous Energy
Los - Example 8
EX 8 -P2V Pump Outboard Vertical
1.0
 Synchronous energy - related to Analyze Spectrum
15-Nov-95 10:00:16

turning speed. RMS = 1.27

LOAD = 100.0
0.8
RPM = 737.
RPS = 12.28

 We can see from the

RMS Velocity in mm/Sec

spectrum that the first peak
0.6

is at 1 Orders (which means

it is 1 x turning speed) 0.4

 All the other peaks are

0.2
harmonics off, which means they
are related to the first peak
0
Freq: 736.86
0 6000 12000 18000 24000 30000 Ordr: 1.000
Frequency in CPM Spec: .245
Label: Looseness

Examples of synchronous energy:

1) Imbalance 2) Misalignment 3)Looseness 4) Gears
 Non-Synchronous Energy
BF - Example 5
E5 -R4A ROLL BRG. #4 - AXIAL
2.0
Route Spectrum
12-Jul-96 17:16:42
 Non-synchronous energy - 1.8
OVRALL= 2.63 V-DG
RMS = 2.69
not related to turning speed
1.6
LOAD = 100.0
MPM = 3225.
1.4 RPM = 380.

RMS Velocity in mm/Sec

1.2
 We can see from the 1.0

spectrum that the first 0.8

peak is at 10.24 Orders. 0.6

This is not related to 0.4

turning speed. 0.2

0
Freq: 3888.9
0 6000 12000 18000 24000 30000 Ordr: 10.24
Frequency in CPM Spec: .748
Label: Outer Race Defect
Priority: 1

• Examples of non-synchronous energy:

• Bearings Multiples of belt frequency Other Machine Speeds
Sub-Synchronous
Energy
 Sub-synchronous energy -
Less than turning speed

 The spectrum shows the first

impacting peak below 1 Order.
This is sub-synchronous
energy
 Examples of sub-synchronous
energy are:
 Belt Frequencies
 Other Machine Speeds
 Cage Frequencies
Lines of Resolution
 Lines of Resolution
 Lines of Resolution (LOR) determine how clear the peaks(data) are
defined within our spectrum.
 The more lines we have over the same F-max (Maximum
frequency scale). The more accurate our data will be
 Example.
◦ The diagram below shows data that has been collected using 400 LOR.
Notice how the top of the peaks are capped. When the LOR are
increased the data becomes more accurate.
 Lines of Resolution
L2 - TA 16
TA16 -M1H Motor Outboard Horizontal
0.20
0.5
Analyze Spectrum
13-Mar-01 09:14:16
09:13:53

PK = .3852
.7078
LOAD = 100.0
 The spectrum shown
0.16
0.4
RPM = 1497.
1496.
RPS = 24.95
24.94
displays data at 800 L.O.R
with an Fmax of 1600 Hz
G-s

0.12
0.3
inG-s
Accelerationin
PKAcceleration

0.08
0.2
 The second spectrum
PK

displays the same data but

0.04
0.1 with 3200 L.O.R over the
same Fmax
0
0 400 800 1200 1600
Frequency in Hz
 Lines of Resolution

 There are 8 LOR settings we can choose from on the analyzer.

These start at 100 Lines and go up to 12800 Lines.

 The average number of LOR is around 800 Lines for a typical

motor/pump set up

To change the LOR settings we need to alter our parameter set.

This is done in the Database Setup program

Remember. If you double your lines of resolution you double your

data collection time.
Analysis Techniques
Measurement Point Identification
Locating Turning Speed
Measurement Points
 Identifying Measurement Points

What is a Measurement Point?

A reference to a particular place/plane on

the machine to be monitored

What do we need them?

To know which machine is inspected?

Where the data was collected?

To ensure same data collection points

To ensure measurement repeatability

 Identifying Measurement Points
A measurement point is determined by three characters

M1H
side of the machine

MOTOR INBOARD HORIZONTAL

2 1 1 2

1 = Inboard’(Drive End)
2 = Outboard (Non-Drive End)
 Point identification of Pump

PUMP (P)
MOTOR (M) Coupling
Bearing
(CB)
Point Identification Horizontal Mount
FanFan Bearing 1 (FB1)
MOTOR (M) Fan Bearing 2 (FB2)
Coupling
Bearing
(CB)
Locating Turning
Speed
 Turning Speed
 When performing analysis on spectrums and waveforms, it is of utmost
importance to set the turning speed (running speed) correctly

 When the turning speed has been located, the software will re-
calculate all the frequencies to this exact speed.

 Once the turning speed has been set, it is now possible to

determine what is Synchronous/Non-synchronous and Sub-
synchronous energy.
 Turning Speed

 The spectrum is showing  By locating the turning speed, it

numerous impacts appearing at is very clear that the impacts are
different frequencies. Non-synchronous
BFI - Example 6
Ex6 -P2V PUMP OUTBOARD VERTICAL
12
Route Spectrum
30-Jan-96 15:14:51

10 OVRALL= 13.52 V-DG

RMS = 13.46
LOAD = 100.0
RPM = 2987.
RPS = 49.78
RMS Velocity in mm/Sec

0
Freq: 2.987
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .115
 Analysis Techniques Test
 Have a look at the spectrum  When the turning speed has
below. been located
◦ Where was the data taken? ◦ What type of energy is
present?
Los - Example 3
EX3 -P2V Pump Outboard Vertical
1.0
Analyze Spectrum
15-Nov-95 10:00:16

RMS = 1.27
0.8 LOAD = 100.0
RPM = 737.
RPS = 12.28
RMS Velocity in mm/Sec

0.6

P2V
Synchronous
0.4

0.2
Energy

0
Freq: 736.86
0 6000 12000 18000 24000 30000 Ordr: 1.000
Frequency in CPM Spec: .245
 Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

1X

2X
3X- 6X
BEARINGBAND 1 BEARINGBAND 2

9-30X RPM
30-50X RPM
 Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

1X Imbalance

2X
3X- 6X
BEARINGBAND 1 BEARINGBAND 2

9-30X RPM
30-50X RPM
 Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X- 6X
BEARINGBAND 1 BEARINGBAND 2

9-30X RPM
30-50X RPM
 Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X- 6X Looseness
BEARINGBANDBearing
1 Band 1 BAND 2
BEARING Bearing Band 2

9-30X RPM
30-50X RPM
 Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X- 6X Looseness
BEARINGBANDBearing
1 Band 1 BAND 2
BEARING

9-30X RPM
30-50X RPM
 Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X- 6X Looseness
BEARINGBANDBearing
1 Band 1 BAND 2
BEARING Bearing Band 2

9-30X RPM
30-50X RPM
Data Collection
Techniques
 Transducers and Mounting Techniques

 Although there are many different types of transducers

available, the most common type used for day to day
data collection are Accelerometers.

 These transducers provide an electrical charge

proportional to acceleration by stressing piezoelectric
crystals typically 100mV/g sensors are used.
 Mount as Close as Possible to the Bearing
Imagine a doctor who listened to your heart through thick clothing and placed the
stethoscope closer to your kidney than to your heart. You would likely doubt his
diagnosis as he would be basing it on sounds distorted by undue obstruction
and noise from other organs.
We
We measure
measure signals
signals from
from the
the We
We measure
measure signals
signals from
from
heart
heart the
the bearings.
bearings.

Vibration
Vibration
Heart
Heart

Doc, II have
have bad
bad news.
news.
Doc, I’ve
I’ve been
been having
having
heart pain! What!! You
You have
have no
no heartbeat!
heartbeat!
heart pain!
 Mount as Close as Possible to the Bearing

When measuring vibration we must always attach the accelerometer

as close as possible to the bearing. More specifically, we must
attach it as close as possible to the centerline of the bearing to
avoid picking up distorted signals.

Protective
Protective
cover
cover

Bearing
Bearing
Location
Location
 Sensor Mounting - Frequency Range

Stud
Mounting Mount
Pad
Flat
Magnet
Dual Rail
Sensitivity

Magnet

Hand
Probe

Freq
1.5KHz 10KHz 32KHz
 Data Quality
 Whether it is your job to collect the data and/or analyse
the data it is important to understand that the technologies
will not give you the answer to a machines problem unless
you have collected meaningful, quality data
 There are certain considerations that must be taken prior to any data
being collected, these are:

A good understanding of the internal make up of the machine, in order to

understand the best transmission path for data collection - bearing locations, load
zones etc.
Ensure data is collected in a repeatable manner so we can compare two or more
readings to each other - trending purposes
Variable speed machines - it is very important to collect data with the correct
running speed enter into the analyser
 Route-Based Data Collection
Route-based data collection is commonly used for walk
around vibration analysis

 A maximum of 50 routes can be stored to each area

 And one route can only contain 1044 measurement points
 A route includes information from one area only
 A route does not have to include all the equipment defined in that
area
 The order of the equipment in the route can differ from that of the
database
 Equipment can appear in more than one route BUT can not appear
in the same route twice
 Route measurement points may not include all the points configured
on the equipment