BASIC VIBRATION

BY TPC MAINTENANCE OSI TEAM

OVERVIEW
Introduction to Condition monitoring What causes vibration in machinery? Vibration terminology
Basic vibration theory Unit use in vibration analysis

Vibration transducer and signal processing

Different transducers used in vibration monitoring Basic signal processing from transducer output to analyzer

OVERVIEW
Fault diagnosis of:
Unbalance Misalignment Looseness Anti-friction bearing

TPC Case History

Highlight different problems successfully detected in TPC I & II
1P-33 Motor bearing defect 2B-302 High impacting 2R-102B High enveloping vibration 3C-102A Improved vibration after precision alignment 5B-125 High vibration due to bearing looseness

OVERVIEW
Used of Vibration Simulator
Simulate different fault and look at the related spectrum

Introduction to Condition Monitoring

Maintenance Practices

Reactive Based

Run to failure Unpredictable machine condition High cost

Time Based

Condition Based

Machine are disassembled & overhaul on fixed schedule More prominent practices in the 80s High cost

Repair only machine with known fault Technology based monitoring such as
Vibration analysis Oil analysis Thermography Motor current analysis Ultrasonic

Proactive Based

Root cause failure analysis Used technology as in condition based maintenance

Introduction to Condition Monitoring

TPC Vibration Monitoring Program

TPC I

TPC II

SPEL I No. Critical Equipments Monitor: 42

SPP No. Critical Equipments Monitor: 64

SPEL II No. Critical Equipments Monitor: 23

CP No. Critical Equipments Monitor: 54

Introduction to Condition Monitoring

Vibration provides the most information about plant machinery non-intrusively Vibration is a superior foundation for a Condition Based approach to maintenance Of course, many other valid measurement can be made, such as:
current, voltage, temperature, flow, torque, act

A mature Condition Based Maintenance program will include them all as needed

What causes vibration?

Vibration is caused by an excitation force such as:
Driving torque acting on the machine Reaction from the load on the machine Additional stresses caused by a problem
unbalance misalignment loose part fluctuating fluid pressure bearing defect

To analyse a problem, the analyst tries to relate the vibration to the excitation force

BASIC VIBRATION
What is Vibration? How is it described? How is it measured?

What is Vibration?
The movement of a body about a reference position.

A shaft in a journal moving about the center of rotation

Describing Vibration (Terminology)

Amplitude
How big is the vibration?

Waveform
How the vibration change over time?

Frequency
How rapidly does the vibration change?

Phase
What is the delay between event?

The Basic Vibration Parameter

Displacement
Distance of an object from its reference point (micron, mils)

Velocity
The rate of change of displacement with time (mm/sec, in/sec)

Acceleration
The rate of change of velocity with time (mm/sec, gs)

Different ways of describing the amplitude of waveform

Zero to Peak Root Mean Square Average Peak to Peak

RMS = 0.707 times the peak value Avg = 0.637 times the peak value Pk-Pk = 2 times the peak value Caution! This only applies to the "simple" vibration shown here, not for complex waveforms

Period and Frequency

The period of a waveform is the time taken for the waveform to repeat itself

This waveform has a period of 0.04 sec. This waveform repeat itself every 0.04 sec

Period and Frequency

The Calculation for Frequency is: Frequency = 1/T T = Time For this example T =0.04 sec = time to complete one revolution. Frequency = 1/0.04 = 25 Hertz or 1500 cpm

Period and Frequency

Frequency is the rate at which a simple waveform repeats itself
Peak at 25 Hz

Period and Frequency

Oh! Just one more thing:

Sometimes frequency is expressed in orders, which are multiples of shaft speed For example, if the shaft speed is 1500 rpm, a frequency of 25 Hz is 1order Then 50 Hz is the second order and so on

Simple Vibrations and Frequency

The simplest simple vibration( like our example) has just one frequency

These vibration are very easy to handle

Typical machine vibration waveform are not simple, often a mix of many frequencies

Not so easy, but well see how to do it later

Measuring Machine Condition

Any parameter Measurable without stopping machine, given measure of operating status

Transducer (sensor)

Electrical signal

Signal processing

Problem detection

Automated Diagnostics

Manual Diagnostic

Vibration Transducers
Vibration transducers are devices for converting vibration into equivalent electrical signals for analysis The most common transducers include:

Displacement Transducer
measures shaft displacement relative to bearing

Velocity Transducers
measures casing velocity vibration

Accelerometer
measures casing acceleration vibration

Application of Vibration Transducers

Displacement transducers:

Typically used for shaft relative movement at low frequencies

commonly used for low to intermediate frequency, where velocity believed to give best guide to vibration severity

Velocity transducers

Accelerometers:

best for high frequency such as bearing impacting, high speed gear & blading problems transducers of choice for industrial application

Displacement Transducers
Measures relative displacement between probe tip and rotating shaft or target Useful on machine with high case to rotor weight ratio (e.g. Steam turbine) May be already installed as OEM equipment Usually permanently installed Limited frequency range due to run out

typical 0 to 1000 Hz

Requires special power supply, signal conditioner & cables

Displacement Transducers
D et il m s e p n a c P re o b

C L
D rr i v e

S h a f t

P T aa re Nh oi e f b pr t S
-D 9 V C

B D i o a C s r G lg a te pa V o

-V 2C 4 D

P T r ao a re Fw m oi a y S b pA r h F f t

Velocity Transducers
Seismic transducer works well where there is significant casing vibration Older style of transducers; developed in 1940 Gives velocity signal directly Self-generating, no power required Limited frequency range (10Hz to1000Hz) Tend to be relatively large and heavy Calibration may shift due to wear and temperature( due to damping)

Velocity Transducers

Accelerometer Transducers
The transducer of the choice in industry today Very wide frequency range possible

from 0 to 20 kHz( different transducers) typically from 2 to 15kHz

Extremely rugged, no moving parts Relatively small and lightweight Easy mount for permanent or intermittent use Requires constant current power supply for built-in amplifier Signal output in acceleration

Accelerometer Transducers
Amplifier Insulator Conductive Plate Insulator Preload Bolt Inertial Mass Piezoelectric Crystal

Signal Processing
We have already looked at measuring the level of a simple waveform (single frequency) A complex signal can be broken down into simple components, using the process of frequency analysis The level of each component can be measured using the simple approach Moreover, the frequencies of the components in a machine vibration signal can be used to identify many different faults Fault severity is linked to the amplitude of the components associated with that fault

Signal Processing

De i fa sa pt lm a t c s e t m ea nt te w au vr ei o r m f r b o m 4 0 m g w n e . N T oi tf O i o cet tw h s e c o p m pe lf . e l x im ts y t h e a v e o r N i m

Signal Processing
We begin with a vibration waveform, represented by the transducer signal...

Amplitude
T i m e

Signal Processing
... we feed the signal into the analyzer and the process begins...

A n a lr y z e

Amplitude

T i m e

Amplitude
T i m e

Signal Processing
Each waveform component has a separate frequency ...

Spectrum, or signature, shows the amplitudes of all the frequency components in the signal

T i m e

y c n e u q e r F

T i m e

Amplitude

Complex waveform is broken down into simple waveform components

T i m e

Amplitude

y u q ec re Fn

Amplitude

The waveform picked up by the transducer is a complex mixture of waveform

Signal Processing
The spectrum and the waveform are just two ways of looking at the same information

S p c t r u m W a v e f o r me

Amplitude

T i m e

Amplitude
F r e q u e n c y

In general, both the waveform and spectrum should be used together to maximize information

Signal Processing
Or i h l i W l Ibc me a l a n

Mm i lnt s e a n i g Ln oe os ss e

The spectrum of the displacement from 40 MW steam turbine is much easier to understand. It is easy to see the relative severity of oil whirl, unbalance, misalignment and looseness.

DIAGNOSTICS
Identifying the Characteristic Vibration Patterns of Common Faults Unbalance Misalignment Looseness Anti- Friction Bearing

Unbalance
Simple unbalance occurs when the center of mass of a rotating object differs from the center of rotation. (static unbalance)
C e n t e r o f M a s s

C e n t e r o f R o tn a t i o

Unbalance
When rotation axis is not coincident with a principal of inertia of the rotation bodyoften called dynamic unbalance
P ra ip n c i l A x if s o It n e r i a

A x if s o R o tn a t i o

Unbalance
Causes of unbalance include:

Improper assembly of parts Material buildup on blades or impellers Wear on rotating elements Broken or missing rotor parts Improper or no balance specs on rotor

Characteristics of Unbalance
High amplitude radial peaks at 1x shaft RPM Very low axial vibration level at 1x shaft RPM Harmonics of shaft RPM are very low in amplitude 1x RPM pattern visible in the waveform If harmonic of shaft RPM have significant amplitude, other faults should be suspected

Characteristics of Unbalance
1x shaft speed

Very little harmonics

Misalignment
Misalignment occurs when the center lines of two shafts are offset or meet at an angle Different categories of this defect include:

offset misalignment angular misalignment bearing misalignment

Well look at offset/angular misalignment

Misalignment

Characteristic of misalignment
High axial vibration at 1,2,3 x shaft RPM High radial vibration at 1,2,3 x shaft RPM Higher orders of shaft RPM (>4x) are generally low in amplitude A repeatable pattern is visible in the time domain with little or no visible impacting A phase shift of about 180 deg seen across the coupling or between bearing

Characteristic of misalignment

Shaft centerlines meet at an angle Often strong component at 1X RPM May cause dominant vibration in any plane Therefore important to take 2 radial readings per bearing plus one axial reading per shaft

Characteristic of misalignment

Shaft centerlines parallel but offset Strong radial component at 2 X Run Speed Other shaft orders also appear Almost always combined with angular misalignment

Misalignment
3C-102A Before Alignment
1x shaft speed

2x shaft speed

Misalignment
3C-102A After Alignment

Vibration at 1x & 2x shaft speed reduced

LOOSENESS
There are two main types of looseness:
Structural Looseness

Faulty or Eroded Base Mounts Cracked or Split Casings Improperly Torque Bearing Caps Bearing Supports

Rotating Element Looseness

Impellers Fan Blades Bearings Couplings

Characteristics of Looseness
Spectra show large number of orders Vibration is often directional: horizontal & vertical amplitudes may differ significantly Sub-synchronous peaks sometimes occur "Half-harmonics" and "one-third harmonics", etc., may occur in some cases Waveform often shows erratic impacting and no clear pattern as with misalignment

LOOSENESS
OB-153A Bearing Looseness before repair
Vibration at 1x shaft speed and its harmonics

LOOSENESS
OB-153A Bearing Looseness after repair

Vibration at higher harmonic reduced after repair done on the bearing

ANTI-FRICTION BEARING Causes of premature bearing failures include:

Improper techniques for mounting bearing on shaft and in housing during machine rebuild Excessive or inadequate lubrication

More bearings fail from too much lubrication than from inadequate lubrication. E.g. high axial load on non-thrust type bearing Two-fold stress increase may reduce life ten-fold

Incorrect application of bearings shortens life

Excessive vibration causes increased stress

Incorrect bearing fits may cause damage

Bearing Defect Characteristics Rolling element bearing defects show characteristic vibration frequency patterns

Harmonics of non-synchronous peaks visible

Multiples of bearing frequencies

Sidebands may become apparent

shaft frequency for inner race fault cage frequency for rolling element fault

Spectrum floor level may show broadband rise

Acceleration waveform shows impacting

Calculating Defect Frequencies

Require physical dimensions and shaft speed

pitch and ball/roller diameters, number of balls/rollers

Or need manufacturers bearing data..

ANTI-FRICTION BEARING
Fn re ec T q u y y p e Di et so cn r i p

nn i dt na h aa m l tt i c r e h a w a F FnT Rrt g T F e r rna e F uc a erc o re ey q u te e ao i ts l i r ca i l u S u e yt w l e cf ah a B B Fn o eal S an e R ha F lpq ct i b t n tr ts re ah ce t c lae y e cs l sq P F r t ah b a l B Bsu Roau POc e ct ir ft Faa no hcl OR cawla u e t e r nu e t t ae cr t ls Pec t h s a F ye ib r ah B Bsu Riclu PIlR e ctnla Fa c no nal I naq aw e ne e r n e ft t a r c r t a c

ANTI-FRICTION BEARING
B e a r i n Na g o lo F .B os f lr T F T y p e R o ls l e r
T3 O8 R 2 3 1 T3 O2 R 2 3 2 T3 O4 R 2 3 2 T3 O6 R 2 3 2 T3 O8 R 2 3 2 T3 O0 R 2 3 3 T3 O2 R 2 3 3 T3 O4 R 2 3 3 T3 O6 R 2 3 3 T3 O8 R 2 3 3 T3 O0 R 2 3 4 T3 O4 R 2 3 4 T3 O8 R 2 3 4 T3 O2 R 2 3 5 T3 O6 R 2 3 5 T36 O1 R0 2 0 8 T3 O6 R 2 9 2 T3 O8 R 2 9 2

B S F

B P F O

B P F I

1 5 1 4 1 5 1 4 1 4 1 5 1 5 1 6 1 6 1 5 1 6 1 6 1 6 1 6 1 6 5 4 3 1 3 2

.2 4 1 .7 4 0 .1 4 1 .7 4 0 .9 4 0 .0 4 1 .2 4 1 .6 4 1 .6 4 1 .5 4 1 .6 4 1 .5 4 1 .5 4 1 .5 4 1 .5 4 1 .6 4 7 .9 4 5 .1 4 6

2 .5 6 6 2 .7 5 2 2 .9 6 1 2 .6 5 1 2 .4 5 7 2 .1 6 0 2 .2 6 5 2 .5 7 9 2 .1 7 9 2 .6 7 8 2 .5 8 1 2 .7 7 7 2 .3 7 7 2 .0 7 7 2 .5 7 6 1 0 .4 4 9 5 .8 9 7 6 .9 3 7

6 .7 1 7 5 .3 7 0 6 .0 1 6 5 .0 7 0 5 .6 7 2 6 .9 1 4 6 .4 1 7 6 .2 6 5 6 .1 6 5 6 .2 2 3 6 .1 6 6 6 .4 6 4 6 .1 6 4 6 .8 6 3 6 .7 6 3 2 5 .0 7 2 1 4 .0 2 2 1 4 .0 7 6

8 .3 8 2 8 .7 2 9 8 .9 8 3 8 .9 2 9 8 .4 2 7 8 .0 8 5 8 .6 8 2 9 .8 3 4 9 .9 3 4 8 .8 7 6 9 .8 2 2 9 .6 3 5 9 .9 2 5 9 .2 3 6 9 .3 3 6 2 8 .0 2 8 1 6 .0 7 8 1 7 .0 2 4

Multiply Shaft Speed By Factor to Get Bearing Frequency

CASE HISTORIES
1P-33 Motor bearing defect Process member inform that the motor was noisy and vibration measurement was carried on the motor on 08-01-01. Since the equipment was not in OSI monitoring schedule at that time, 2P-33 vibration measurement was also taken for comparison. Vibration spectrum taken on Motor DE bearing show peak at outer race frequency and its harmonic with sidebands of cage frequency. Peaks from bearing frequencies had disappear after bearing was replaced.

CASE HISTORIES
1P-33 Motor Bearing Defect (before repair)
Velocity measurement taken on 1P-33 Motor bearing DE

Peak at 3rd & 4th harmonic of BPFO Motor DE bearing

CASE HISTORIES
1P-33 Motor Bearing Defect (after repair)
Velocity measurement taken on 1P-33 Motor bearing DE

Peak at 3rd & 4th harmonic of BPFO Motor DE bearing disappear after replacing bearing

CASE HISTORIES
1P-33 Motor bearing defect
Enveloping vibration measurement taken on 1P-33 Motor bearing DE
Enveloping vibration show peak at BPOR (outer race) frequency and its harmonic

Sideband of cage frequency

CASE HISTORIES
1P-33 Motor bearing defect
Enveloping vibration measurement taken on 2P-33 Motor bearing DE

Enveloping vibration show peak at running speed and its harmonic. No peak at bearing frequencies

CASE HISTORIES
1P-33 Motor bearing defect

Discoloration of inner race most probably Outer race defect only on one side due lubrication breakdown and load

Defect on two balls and discoloration of ball most probably due lubrication breakdown

Close up view of the defect area

CASE HISTORIES
2B-302 High Impacting High rotor pass frequency(4x) and enveloping vibration at driven rotor pulley side. Five sense check had found broken drain nozzle of the air chamber at pulley side. The high vibration was due to rotor rub as a result of unbalance air pressure at pulley side. Vibration level went back to normal after replacement of broken drain nozzle & before deteriorating into unplanned break-down maintenance.

CASE HISTORIES
2B-302 High Impacting
Velocity vibration taken on Point 5AV (Driven rotor pulley side)
Data taken on 6/10/00 with amplitude of 9.61 mm/sec

Data taken on 17/10/00 with amplitude of 6.35mm/sec after replaced broken air chamber nozzle.

CASE HISTORIES
2B-302 High Impacting
Enveloping vibration taken on Point 5HE (Driven rotor pulley side)
Data taken on 6/10/00 with amplitude of 4.94 gs

Data taken on 17/10/00 with amplitude of 0.92 gs after replaced broken air chamber nozzle.

CASE HISTORIES
2B-302 High Impacting
Vibration spectrum taken at Point 5AV before repair
Peak at 4x rotor pass frequency at 187.5 Hz

Vibration spectrum taken at Point 5AV after repair

Peak at 4x rotor pass frequency at 187.5 Hz

CASE HISTORIES
2B-302 High Impacting
Waveform data taken on 05/10/00 show high impacting up to 50 gs.

Waveform data taken on 17/10/00 doesnt show clear sign of impacting and amplitude reduced to 20 gs.

CASE HISTORIES
2R-102B High Enveloping Monthly monitoring show an increased in the enveloping vibration on the Mechanical Seal since September 00. The equipment was under closely monitoring for about one month to see the rate of increased. Mechanical group and Process member was informed about the increased and site check found that the needle valve was throttled to inadequate flow rate. The valve was adjusted and the oil was topped up. The vibration on the Mechanical Seal was back to normal after the adjustment.

CASE HISTORIES
2R-102B High Enveloping
Data taken on 11/10/00 with amplitude of 0.0488gs

Data taken on 14/09/00 show increased in value from 0.007gs to 0.0308gs (340%)

Data taken on 02/08/00 with amplitude of 0.007

Data taken on 20/10/00 with amplitude of 0.009 after topping oil and adjusting needle valve.

CASE HISTORIES
2R-102B High Enveloping
Enveloping vibration taken on Reactor mechanical seal bearing before adjusting needle valve
Spectrum shows high noise level without any particular peak indicated that the bearing was running in very rough condition.

Enveloping vibration taken on Reactor mechanical seal bearing after adjusting needle valve

Spectrum shows very low noise floor level after adjusting needle valve and topping of oil

CASE HISTORIES
3C-102A Improved vibration level after precision alignment Vibration on motor had increased after servicing in August 1999. The increased was due to peak at 1x running speed and its lower harmonics. Misalignment was suspected and detail analysis was carried out to confirm the misalignment problem. Precision alignment was carried by Electrical group. Vibration on the motor reduced after the alignment.

CASE HISTORIES
3C-102A Improved vibration level after precision alignment
Vibration started to increased in 27-08-1999 and maintain at that level

Vibration level reduced after precision alignment carried out in August 2000

CASE HISTORIES
3C-102A Improved vibration level after precision alignment
Vibration level increased in August 1999 due peak 1X running speed and its lower harmonic

Vibration level reduced after precision alignment carried out in August 2000

CASE HISTORIES
5B-125 High vibration due to looseness Monthly monitoring done on May 2000 showed an increased in vibration level on the blower at drive rotor pulley side. Quarterly oil sample in June also showed an increased in wear particles from 142 to 2780. Spectral showed peak at rotor pass frequency and its harmonics The blower was overhauled in mid June and found the drive rotor shaft was loosed & worn out at inboard bearing position. The shaft was rebuilt and installed back. Vibration level went back to normal after the repair work.

CASE HISTORIES
5B-125 High vibration due to looseness
Vibration measurement taken on drive rotor pulley(Point 5HV)
Vibration level increased due to peak at rotor pass frequency on 7-06-2000

CASE HISTORIES
5B-125 High vibration due to looseness
Vibration measurement taken on drive rotor pulley side before repair
Vibration show higher peak at rotor pass frequency and its harmonic. The noise floor was also higher.

Vibration measurement taken on drive rotor pulley side after repair

Vibration show lower peak at rotor pass frequency and its harmonic. The noise floor was also lower.

CASE HISTORIES
5B-125 High vibration due to looseness

Inner race of bearing and shaft was found to be loose fit not thigh fit

Pitting found on the shaft where the bearing sit