Vibration Analysis Level I Course Guide

WarmestWelcometoVibration
AnalysisLevelICourse
VibrationAnalysisLevelI
y
IMRANAHMAD
DirectorTechnical
SUMICOTechnologies(Pvt)Ltd
+923214276092
imran.ahmad@sumico.com.pk
p
www.sumico.com.pk
Timings
1st Session
Session
TeaBreak
2nd Session
S i
Lunch/PrayerBreak
3rd Session
Tea Break
TeaBreak
4th Session
0900 1045
09001045
10451100
1100 1300
11001300
13001400
14001530
15301545
1530
1545
15451700
TypicalMachineryProblemsthatCanBeFoundUsing
VibrationAnalysis
Unbalance
Mi li
Misalignment
t
Mechanicallooseness
Structural problems
Structuralproblems
Bentshaft
Bearingfaults
g
TypicalMachineryProblemsthatCanBeFoundUsingVibration
Analysis
Gearfaults
Beltproblems
Lubricationproblems
Electricalmotorfaults
Cavitationsandturbulence
others
WhatisCBM&Why?
What is CBM & Why ?
Totryandmaximisetheplantsproductionandincreasethe
meantimebetweenoutagesmanyindustriesaremoved
g
y
towardsaConditionBasedMaintenanceapproach.
ConditionBasedMaintenanceorCBMisanactivitythat
attemptstopredictandtrendcomponentfailurenon
intrusivelygiventheenduservaluableadvancedwarningofthe
problemathand.
Maximisingassetreliabilityisoftheutmostimportancein
todaysglobaleconomy.
Ascompetitionandthepressuretoproduceproductscheaper
increasesthehigherconsequenceofmachine/productionfailure
becomes.
CBMOverview
Mostmachinefaultsgeneratesomekindofsignaturethatis
uniquetotheparticularfaultdeveloping.Byusingthe
correct technology to detect these signatures we can not
correcttechnologytodetectthesesignatureswecannot
onlytellthatafaultisdeveloping,butdistinguishwhatthe
faulttypeis.
Thereareseveraltechnologiesavailabletohelpdetermine
There are several technologies available to help determine
theconditionofthemachinebeingmonitoredandthetype
offaultdevelopingandtheseare:
VibrationAnalysis
y
Tribology
Sonics
Thermography
Diagnosingamachineisjustlikeaperson
Di
i
hi i j lik
Vibration:
The pulse of the
machine
Oil:
The life blood of
the machine
Thermography:
Taking its
temperature
Total
Picture
Motor Current:
The brain waves
of the machine
OverviewofTechnologies
Overview of Technologies
VibrationAnalysis
UsedtoDetect,AnalyseandConfirmplantmachineryproblems.This
y
p
yp
canbedoneinthreeways:
Online(4500T&CSI6500)forautomatedandcontinuousmonitoringand
protectionofcriticalplantitems
Portable(2130Analyser)Routebaseddatacollectionandanalysis
Wirelessusedforremotemonitoringofmovingorinaccessibleequipment
g
Tribology
Istheanalysisofinteractivesurfacesinrelativemotion.
Lubricantsareanalysedonsiteusingthe5200minilabseries.
Theresultsareplottedinasimpletounderstandtrivectorplotshowingthe
ChemistryContaminationandWearofeachlubricant,thisallowingthe
lubricant to be changed on condition rather than on a time based interval
lubricanttobechangedonconditionratherthanonatimebasedinterval.
Wear
Contamination
Chemistry
g
Sonics
ThroughaprocessknownasheterodyningUltrasonicsoundsthat
arenonaudibletohumanearsareconvertedbackdowntoa
d bl
h
db kd
frequencythatisaudibletohumanears,allowingtheoperatorto
hearandrecognisefaultsdevelopingwithinplantoperatingsystems,
such as:
suchas:
Mechanical Bearings,Rubs,GearDefectsetc
ElectricalDefects
ValveOperation
SteamTrapOperation
LeakDetection PressurisedSystemsandVacuumSystems
g
Thermography
ThermalImagingisusedtolocatepotentialproblemsbydetecting
g g
p
p
y
g
abnormaltemperaturefluctuationsataglance.
Thiscanbeusedinawidearrayofcircumstancesbutismostcommonly
usedinelectricalcontrolpanels
g
Correctivetechnologiesallowtheengineertosetupthemachinetotry
andpreventprematuremachinefailurefromsuchcausesasImbalance
andMisalignment
d Mi li
t
Whentheseforcesareinduceduponamachinecomponentssuchas
bearings,sealsandevensupportsfailduetostress
TechnologiessuchasLaserAlignmentandBalancingpreventthesefrombeing
Technologies such as Laser Alignment and Balancing prevent these from being
somuchofaproblem
y
g
MachineryHealthManager
A1 - Recirculation Pump #5
-M2H MOTOR
O O INBOARD
O
BRG.
G - HORIZONTA
O
O
PK In/Sec
RCP#5
C #
0.025
0.020
0.015
0.010
0.005
0
PK In/Sec
ALERT
0.05
0.04
0.03
0.02
0.01
0
0
Acc in G-s
s
Trend Display
36-65xTS
FAULT
1.0
0.5
0
-0.5
-1.0
-1.5
0
The
machines due to be monitored are defined within the
Eachtechnologyisstoredandanalysedfromasinglesoftwareplatform,
software.
software
allowingtheanalystto:
allowing the analyst to:
100
200
300
Days: 11-Aug-95 To 11-Dec-96
400
500
Route Spectrum
11-Dec-96 17:33:57
OVERALL= .0604 V-DG
PK = .0605
LOAD = 100.0
RPM = 3593. (59.89 Hz)
40
As
much information as possible about the machines being monitored
Storealldataandinformationinonedatabase
isEasilycrossreferencedataforconformationofanalysis
preferred when building the database.
80
120
160
Frequency in kCPM
200
240
Route Waveform
11 D 96 17
11-Dec-96
17:33:57
33 57
RMS = .4233
PK(+/-) = 1.13/1.22
CRESTF= 2.89
Collaborate all data into one single report

Collaboratealldataintoonesinglereport.
2
3
4
Revolution Number
Overview
O
i
of
ConditionMonitoring
Maintenance Philosophies
MaintenancePhilosophies
DefinitionofMaintenance
Definition of Maintenance
The
Theactofcausingtocontinue
act of causing to continue
(Webster)
Keepingequipmentinrepair
(Oxford)
Maintenance
ReactiveMaintenance
OftencalledBreakdownMaintenance
andhastheconceptfixitwhenit
breaks.
breaks
Thisisprobablythemostcommon
typeofmaintenanceinindustrytoday
butcanbethemostcostly,especially
oncriticalmachines.
Maintenancecostsareusuallyhigher
duetothecatastrophicfailurethat
occurs.
Predictive Maintenance
Also known as Condition Based
Maintenance.
This approach uses non-intru
technologies to determine the actua
condition of a machine and its rate of
failure.
This can be very effective in
extending machine life with big
financial savings if implemented
properly.
Planned Maintenance
Also known as Shutdown
Maintenance. This is based upon
p
Timed Intervals between
maintenance.
Can be very effective if maintenance
and resources are aimed at the
machines that need it the most.
However it can be very difficult to
distinguish which machines actually
need maintenance.
Proactive Maintenance
Often referred to as Root Cause
Analysis.
This philosophy works hand in hand
with Predictive Maintenance,
eliminating the source of the fault to
try to prevent it from re-occurring.
y
TodaysIndustrialDemand
Itshouldbeunacceptabletodeliver
lessperformanceformoremoney
l
f
f
sameperformanceformoremoney
Itcouldbeacceptabletodeliver
sameperformanceforlessmoney
same performance for less money
moreperformanceforthesamemoney
moreperformanceformoremoney
Thedesireis MorePerformanceforLessMoney!!!!
j
PredictiveMaintenanceObjectives
To
Toconfirmgood
confirm goodcondition
conditionmachines
machines
Todetectdevelopingproblems
Todeterminethenatureandseverityofthe
d
i
h
d
i
f h
problem
Toschedulerepairsthatcanbestfitwith
productionandmaintenanceneeds
q
PredictiveMaintenanceTechniques
Vibrationmeasurement
Vibration
measurement
Electricaltesting
Motorcurrentanalysis
l i
Reciprocatingmachinetesting
Thicknesstesting
Visual inspection
Visualinspection
Andmanymore
PredictiveMaintenanceBasicFacts
Every
Everymechanicalorelectricalfaultsona
mechanical or electrical faults on a
machinehasadistinctvibrationbehavior.
Anychangeinthevibrationsignature
Any change in the vibration signature
indicateschangesinthedynamicoperating
condition of the machine
conditionofthemachine
( )
PredictiveMaintenanceMechanism(VA)
Establish
Establishadatabaseofallthemachinesthat
a database of all the machines that
needtobemonitored
Establishadatacollectionroutethatbest
Establish a data collection route that best
optimizethedatacollectiontime
Downloadrouteintothedatacollector
D
l d
i
h d
ll
Collectdata
Uploadcollecteddataintothedatabase
PredictiveMaintenanceMechanism
Run
Runexceptionreportstodetectthe
exception reports to detect the
problematicmachines
Analyzeonlythemachinesintheexception
Analyze only the machines in the exception
reports
Generaterepairworktobeperformed
G
i
k b
f
d
Againcollectdataonthemachineonwhich
workisbeingdone.
PredictiveMaintenance
Predictive Maintenance
Rules
+
Experi
Start
NO
YES
Create
Ref.
Regular
Meas.
Compare
limits
Fault
Diagnostics
Input
m/c
specs
Create
New Ref. & Limits
Fault
correction
VibrationFundamentals
Vibration Fundamentals
How Much Vibration is Too Much ?
1. Use Absolute Vibration Levels
- Given
Gi
by
b machine
hi makers
k
- Published Vibration Severity Standards
eg. ISO 2372, VDI 2056, BS 4675
2. Use Relative Vibration Levels
ISO10816
3
ISO 108163
11
0 44
0.44
7.1
0.28
4,5
0.18
3,5
,
0.11
2,8
0.07
2,3
0.04
1.4
0.03
0,71
0.02
mm/s rms
rigid
flexible
rigid
flexible
pumps > 15 kW
rigid
flexible
medium sized machines
radial, axial, mixed flow
integrated driver
external driver
Group 4
Group 3
15 kW < P 300 kW
motors
160 mm H < 315 mm
Group 2
rigid
flexible
inch/s rms
Foundation
large machines
300 kW < P < 50 MW
Machine Type
motors
315 mm H
Group 1
Group
A
B
C
D
newly commissioned
unrestricted long-term operation
restricted long-term operation
vibration causes damage
ISO10816
3
ISO 108163
140
5.51
113
4.45
90
3 54
3.54
71
2.80
56
2.20
45
1.77
36
1.42
28
1.10
22
0.87
18
0.71
11
0.43
m rms
rigid
flexible
rigid
flexible
pumps > 15 kW
rigid
flexible
medium sized machines
radial, axial, mixed flow
integrated driver
external driver
Group 4
Group 3
15 kW < P 300 kW
motors
60 mm H < 3
315
5 mm
160
Group 2
rigid
mil rms
flexible
Foundation
large machines
300 kW < P < 50 MW
Machine Type
motors
315
3
5 mm
H
Group 1
Group
A
newly commissioned
unrestricted long-term operation
restricted long-term operation
Vibrationstandardsareguidelines
Vibration standards are guidelines
Just Tolerable
Just
Tolerable
Allowable
Just Tolerable
All
Allowable
bl
Allowable
Good
Good
Large Machines
with rigid and heavy
foundations whose
G d
Good
natural Frequency
Small
<300 kW on special
exceeds
Machines< 15 kW
foundations
machine speed
15 kW<
Medium Machines
<75kW
Group K
Group M
Group G
45
28
18
11.2
71
7.1
4.5
2.8
18
1.8
1.12
1.71
0 45
0.45
0.28
0.18
Velociity mm//s RMS
Nott
N
Permissible
10 times = 2
20dB
Not
Permissible
Not
Permissible
2.5 time
es = 8dB
ISO2372 ( BS 4675 , VDI 2056 )
PredictiveMaintenanceDatabaseSetup
Predictive Maintenance Database Setup
Identify
Identifywhichmachinestomonitor
which machines to monitor
Identifyeachmachinecharacteristics
Defineanalysisrequirementsforeach
fi
l i
i
f
h
machine
Defineacceptablelevelsandalarmlimits
Definedatacollectionpointlocationsand
p
monitoringmethods
WhichMachinetoMonitor?
Which Machine to Monitor?
Machinethatarevitaltotheoperation
Machine
that are vital to the operation
Machinesthatareexpensivetorepair
Machinesthataretroublemakers
hi
h
bl
k
Machinesthatareinremoteorinaccessible
locations
WhyMachineCharacteristics?
Why Machine Characteristics?
Initially
Initially,theknowledgeofthemachinedesign
the knowledge of the machine design
anditsoperatingcharacteristicsismandatory
to successfully establish a good database
tosuccessfullyestablishagooddatabase
Later,thisknowledgewillprovidethebasis
for analyzing the data accurately
foranalyzingthedataaccurately
WhatMachineInformationIsneeded?
What Machine Information Is needed?
Machinespeed
p
Machineload
Bearingtype
g yp
Couplingtype
yp
Geartypeandteethcount
Bladesandvanes
g
yp
p
g
Machinedrawingsandtypicaloperating
conditions
MachineAnalysisRequirements
Machine Analysis Requirements
List
Listallpossibleproblemsofthemachine
all possible problems of the machine
Determinetheparticulareffectsthateach
problem impose on the machine
problemimposeonthemachine
Determinethebestmethodtomonitorthe
severityoftheproblem
i
f h
bl
ManpowerRequiredDependson
Manpower Required Depends on
Numberofdatacollectionpoints:
Number of data collection points:
Complexityofthemachine
Numberofmachinestobemonitored
Number of machines to be monitored
ManpowerRequiredDependson
Manpower Required Depends on
Analysistimerequired
Analysis time required
Complexityofthemachine
Complexityoftheproblem
Complexity of the problem
Frequencyofanalysis
Machineclassification
Machinehistory
MachineComplexity
Machine Complexity
Simplexmachines
Simplex machines
Constantspeedandload
Directdrive(coupling)
Direct drive (coupling)
510measurementpoints
MachineComplexity
Machine Complexity
CompoundMachines:
Compound Machines:
Constantspeedandload
Intermediatedrive(gearboxandbelts)
Intermediate drive (gearbox and belts)
1020measurementpoints
MachineComplexity
Machine Complexity
ComplexMachines
Complex Machines
Variablespeedandload
Multiplecomponents
Multiple components
Morethan20measurementpoint
MachineClassifications:
Machine Classifications:
VitalMachines:
Vital Machines:
Irreplaceable
Halt production
Haltproduction
Hardtofindparts
E
Expensivetorepair
i t
i
MachineClassification
Machine Classification
CriticalMachines:
Critical Machines:
Haltpartofproduction
Expensive to repair
Expensivetorepair
Costlyreplacement
H d t fi d
Hardtofindparts
t
Frequentrepairs
SupportMachines:
Support Machines:
Nottooexpensivetorepair
Parts are readily available
Partsarereadilyavailable
Affectbutdonthaltoperation
M d t l
Moderatelycostlyrepairorreplacement
tl
i
l
t
OtherMachines:
Other Machines:
Partsarereadilyavailable
Replacement is easy and inexpensive
Replacementiseasyandinexpensive
Donotaffectoperationdirectly
N hi t
Nohistoryofrepair
f
i
MonitoringFrequency
Monitoring Frequency
VitalMachines
OnlineMonitoringorevery12weeks
CriticalMachines
Every24weeks
SupportMachines
Every48weeks
OtherMachines
Every812weeks
E
8 12
k
MethodsofDataCollection
Methods of Data Collection
Online
On lineContinuousMonitoring
Continuous Monitoring
ManualDatacollectionthroughportabledata
collection
ContinuousMonitoring
Continuous Monitoring
Realtime
Real timedataacquisitionthroughdedicated
data acquisition through dedicated
sensorsandinstrumentationthatmonitorthe
machine during every second of its operation
machineduringeverysecondofitsoperation.
Sometimestheinstrumentationsuppliedwith
relays for automatic shutdown when alarm
relaysforautomaticshutdownwhenalarm
levelsareexceeded.
ManualDataAcquisition
Manual Data Acquisition
Using
Usingaportableinstrumentationwith
a portable instrumentation with
sensors,datacanbecapturedonascheduled
intervals
DatathenisdumpedbacktoaPCfor
trending analysis and reporting
trending,analysis,andreporting.
ManpowerRequiredforDataCollection
Manpower Required for Data Collection
Levelofexpertise:Tech
Level
of expertise: Tech
Amountoftraining:Minimum
Frequencyoftraining:onceayear
f i i
Highlevelofcommitment
ManpowerRequiredforDataAnalysis
Manpower Required for Data Analysis
Level
Levelofexpertise:Engineerorhighly
of expertise: Engineer or highly
knowledgemechanic
Duties:analyzedataandrunandmanagethe
Duties: analyze data and run and manage the
program
Amountoftraining:Varies
A
f i i
V i
Highlevelofcommitment
PredictiveMaintenance
Results:
Increasemachine
availability
Saveonmaintenancecost
Reducespare
parts
Reduce spareparts
inventory
Increasemachinelife
Avoid unnecessary repairs
Avoidunnecessaryrepairs
Organizemaintenance
activities
I
Improveplantsafety
l t f t
IntroductiontoVibration
Analysis
l
Introduction to Vibration Analysis
IntroductiontoVibrationAnalysis
GeneralDescription
Vibration
General DescriptionVibration
Therearemanydifferentparameterswecanmeasuretohelpusdetermine
machineryhealth:
Voltage
Power
Pressure
Viscosity
Current
Flow
Flow
Temp
Torque
Speed
Density Emission
ParticlesLoad
Nonecontainsasmuchinformationasthevibrationsignature!!!
None contains as much information as the vibration signature!!!
Notonlydoesitprovidetheseverityoftheproblembutcanalsopointtothe
sourceoftheproblem
VibrationcanbesimplystatedasAresponsetosomeformofexcitation
TheexcitationisgenerallyreferredtoastheForcingFunction
Vibrationisthemotionofabodyaboutareferencepositioncausedbyaforce
GeneralDescription ForcingFunction
Whenaforcingfunctionisappliedtoa
shaft within a plain bearing the free
shaftwithinaplainbearingthefree
movementwillcausetheshaftto
vibratewithinthebearing
Herewearemeasuringactualshaft
movement
movement
When a forcing function is applied

to a shaft within a bearing housing
where there is very little free
movement, then the vibration will
transmit
i to the
h casing
i
Measuring the casing movement of
a specific component as result of
the forcing function
VibrationfromMechanicalFaults
b at o o
ec a ca au ts
VibrationCharacteristics
Amplitude
HowMuch
Frequency
HowOften
Phase.
When
GeneralDescription MeasuringResponse
YoucanalsolookatvibrationastheamountofTime ittakestocomplete
aparticularcycle
If
Ifweexaminethemotionofaforcingfunctiononafanblade
we examine the motion of a forcing function on a fan blade Heavy
HeavySpot
Spot over
over
aperiodoftimeadistinctsignaturewilloccur.
This motion is called a

sine wave.
The horizontal axis is
measuring Time
The vertical axis is
measuring Amplitude
This is known as a
Ti
Time
Waveform
W
f
Amplitude versus Time
TimeWaveforms
Time Waveforms
Unfortunatelytherearemultiplesourcesofforcingfunctionsthatcanemitfroma
machineorcomponent.
Thusresultinginthetimewaveformbecomingcomplexinnature
Ex15
0.4
Theplotshownontherightis
acomplextimewaveform.
l ti
f
0.2
EX 8
1.0
Acceleration in G-s
RMS Velocity in mm/Sec
R
Thisisjustoneformat
(domain)foranalysing
vibration data
vibrationdata.
Datacanalsobeanalysedina
Spectrum (AmplitudeVs
Frequency) throughaprocess
known as the FFT
knownastheFFT
Route Waveform
22-Aug-02 11:33:16
0.3
AmplitudeversusTime
A8 - Example 15
-F2V Fan Outboard Vertical
PK = .1495
1495
LOAD = 100.0
RPM = 832. (13.86 Hz)
Los - Example 8
-P2V Pump Outboard Vertical
PK(+) = .3263
Analyze
PK(-) =Spectrum
.3572
15-Nov-95
10:00:16
CRESTF= 3.38
0.1
RMS = 1.27
LOAD = 100.0
RPM = 737.
RPS = 12.28
0.0
0.8
-0.1
0.6
-0.2
-0.3
0.4
-0.4
0
50
100
0.2
150
200
Time in mSecs
250
300
350
Time: 120.44
Ampl: -.07595
0
0
6000
Label: Looseness
12000
18000
Frequency in CPM
24000
30000
Freq:
q 736.86
Ordr: 1.000
Spec: .245
FastFourierTransform
Fast Fourier Transform FFTProcess
FFT Process
Whenaproblemstartstodevelopwithinarotatingcomponentitwill
generateavibrationsignature.Thissignatureshouldbecapturedinthe
timewaveform
Distinguishingthatsignaturecanbeverydifficultwhenlookingatatimeplot
Di ti
i hi th t i t
b
diffi lt h l ki
t ti
l t
Tounderstandtheproblemweneedtounderstandthefrequency
Howoftenisitoccurring?
TheFFTisaprocessthatdeterminesthefrequencyofasignalfromatime
waveform.
f
TheFFTisnamedafteran18th centurymathematiciannamedJean
BaptiseJosephFourier. Heestablished:
Anyperiodicsignalcanberepresentedasaseriesofsinesandcosines.
Meaningifyoutakeatimewaveformandmathematicallycalculatethe
f
k
f
d
h
ll
l l
h
vibrationfrequency,itcanbeconvertedtoamorefamiliarformat
Tim
e
Amplitude
e
Ampliitude
Amplitude
e
How the Vibration Spectrum is Created

HowtheVibrationSpectrumisCreated
q
y
FrequencyDomain
Thefrequencydomain(Spectrum)plotsthedataasAmplitudeinthe(Y)
axisandFrequencyinthe(X)axis.Thisdataisderivedfromthetime
domain mathematicalmanipulationofthetimewaveform.
p
Recallthewaveformandspectrumfromthepreviousslide.Ifyoutriedto
determineallthefrequenciesfromthewaveformplot,youwouldneedall
dayjusttoanalyseonepointofdata.
AstheFFTplotsthefrequenciesfromthewaveformforyoutheanalysisof
thisdatabecomeseasierandreducestheamountoftimeneededfor
analysisofeachpoint.
Ex15
0.4
A8 - Example 15
-F2V Fan Outboard Vertical
0.3
PK = .1495
LOAD = 100.0
RPM = 832. (13.86 Hz)
PK(+) = .3263
PK(-) = .3572
CRESTF= 3.38
0.1
0.0
-0.1
Los - Example 8
Analyze Spectrum
15-Nov-95 10:00:16
RMS = 1.27
LOAD = 100.0
RPM = 737.
RPS = 12.28
0.8
RMS Velocity in mm
m/Sec
Acceleration in G
G-s
0.2
EX 8
1.0
Route Waveform
22-Aug-02 11:33:16
0.6
0.4
-0.2
0.2
-0.3
-0.4
0
50
100
150
200
Time in mSecs
250
300
350
Time: 120.44
Ampl: -.07595
0
0
6000
Label: Looseness
12000
18000
Frequency in CPM
24000
30000
Freq: 736.86
Ordr: 1.000
Spec: .245
Analysis
l
Units of Measurements
UnitsofMeasurements
MeasuringAmplitudeandFrequency
Measuring Amplitude and Frequency
Youcanmeasureamplitudefromatimewaveformasshown:
0 to Peak
RMS
Amplitud
de
Average
Time t
Peak to Peak
Theperiodtisthetimerequiredforonerevolutionoftheshaftinthis
illustration which equals one cycle of the waveform
illustration,whichequalsonecycleofthewaveform
Duringthisperiod,theamplitudeofthewaveformreachesapositive(+)peak,
returnstorest,andreachesanegative()peakbeforereturningtorest
Youcancalculatethedifferent
amplitudeswhenoneofthevaluesare
known:
RMS=0.707timesthepeakvalue
RMS 0 707 times the peak value
Avg=0.637timesthepeakvalue
PkPk=2timesthepeakvalue
0 to Peak
RMS
Average
Amplitude
Peak(Pk) Amplitudemeasuredfromtheatrestposition(0)tothe
highestvalue(0toPeak)
Peak to Peak (Pk
PeaktoPeak
(PkPk)
Pk) Amplitudemeasuredfromthepeakpositive(+)
Amplitude measured from the peak positive (+)
valuetothepeaknegative()value
RMS (RootMeanSquare) obtainedbyaveragingthesquareofthesignal
leveloveraperiodoftimeandthentakingthesquarerootresult
A
Average(Avg)
(A ) Amplitudevaluethataveragesthepeakvaluesofthe
A lit d
l th t
th
k l
f th
waveform
Time tt
Peak to
P k
Peak
Severityofavibrationproblemcanbedeterminedbytheamplitudeof
thevibration.
Wecanmeasureamplitudeinoneofthreeways
1. Displacement measuresthedistancetheshaftmovesinrelationtoa
referencepoint.
2. Velocity measuresthedisplacementoftheshaftinrelationtotime
3. Acceleration measuresthechangeinvelocityinrelationtotime
The most common industrial applications are:

Themostcommonindustrialapplicationsare:
1. Displacement
2. Velocity
3. Acceleration
Microns PeaktoPeakvalue
mm/sec RMS
Gs
Peakvalue
Gs=1xforceofgravity(Gforce)
g
y(
)
AmplitudeRelationships
Amplitude Relationships
Thethreetypesofamplitudemeasurementsusedtodisplaydataaredirectlyrelated
toeachother
Changingfromoneamplitudeunittothenextaltersthewayinwhichthedataisdisplayed
Ex15
0.35
5
140
A8 - Example 15
-F1H Fan Inboard Horizontal
Low frequencies require very

Forlittle
normal
speed
forceoperating
to move an
object
ranges, velocity data
provides the best indication of
Increasing
frequency
that
machine
hi the
condition
diti
0.30
120
4
PK
Acceleration
nin
inMicrons
G-s
P-P
Displacement
0.25
100
3
0.20
0
20
80
the objects move with the

same velocity, the force
needed to move it increases,
thereby reducing the distance it
can travel
0.15
60
2
0.10
40
1
0.05
20
00
0
20000
Label: Large Fan Unit - Easy
40000
Frequency in CPM
Highandlowfrequency
h dl f
eventscanbeseen
R t S
Route
Spectrum
t
22-Aug-02 11:30:50
OVERALL= 3.45 V-DG
RMS==.3909
PK
3.44
P-P
104.98
LOAD = 100.0
RPM = 831. (13.85 Hz)
60000
Velocityisthedefaultunit
forstandarddatacollection
techniques
Displacement measures
low frequency events
ignoring high frequencies
Relative shaft motion
Acceleration accentuates
the high frequencies
ignoring the low frequencies
Good for early bearing
detection (Whenever there
is Metal to Metal Impacting
involve)
FrequencyUnits
Frequency Units
Frequencyreferstohowoftensomethingoccurs:
Howoftenashaftrotates?
Howoftenarollingelementhitsadefectedrace?
Therearethreewaystoexpressfrequency:
1. CPM CyclesPerMinute
1CPM=1RPM
y
2. Hz CyclesPerSecond
CPM/60
3. Orders MultiplesofTurningSpeed
Frequency/TurningSpeed
Consideramotorhasarotationalspeedof1485RPM,intermsof
frequencythisequatesto:
1485 CPM (1rpm=1cpm)
(1rpm = 1cpm)
1485CPM
24.75Hz
(1485/60)(minutestoseconds)
1Orders
(1xrevolutionoftheshaft)
q
y
FrequencyUnits
Shownbelowisatableshowingthe
relationship between all three frequency
relationshipbetweenallthreefrequency
unitswithreferencetotheturningspeed
Motor Turning Speed = 1500RPM

CPM
1500
2250
3000
6000
12000
Hz
25
37.5
50
100
200
Orders
1.5
FrequencyDomain
Frequency Domain
Thevibrationanalystcandividethefrequencydomaindata
intothreemajorareasofinterest
h
f
1.
2.
3
3.
Synchronous
EqualtoTsorHarmonicsofTs
Subsynchronous <1xTs
N
Nonsynchronous
h
>1xTsbutnotaninteger
1 T b t t i t
NoteTsistheturningspeedorrotationalfrequency(RPM)
oftheshaftatthepositionwhereyoumakethe
measurement
measurement
Eachdefectthatcanmaterialiseinthefrequencydomain
canbecategorisedintooneofthreetypesofenergylisted
above
Knowingthetypeofenergywithinthedatacanhelptheanalyst
quicklyeliminate2/3rd ofthefaulttypes
HarmonicOrders
Harmonic Orders
Harmonics arecursorsthatareexactmultiplesoftheprimaryfrequency
Theyareusedtolocateotherfrequenciesrelatedtotheprimarycursor
1.0
RMS V
Velocity in mm/Sec
0.8
0.6
EX3
Los - Example 3
Analyze Spectrum
15-Nov-95 10:00:16
Here the primary cursor is at 1

Order ((1xTs).
) All the other cursors
are harmonics (exact multiples of
the primary cursor)
RMS = 1.27
LOAD = 100.0
RPM = 737.
RPS = 12.28
04
0.4
Therefore:
0.2
Whentheprimarycursorsislocatedon1Orderalltheharmonicswillbe
synchronous
h 0
Freq: 736.86
0
6000
12000
18000
24000
30000
Ordr: 1.000
Harmoniccursorscanbeusedtoshownonsynchronousandsub
Frequency in CPM
Spec: .245
synchronousharmonicsdependingupontheenergyoftheprimary
frequency
Energy in the Spectrum

EnergyintheSpectrum
E4
05
0.5
C1 - Example 4
-MOH MOTOR OUTBOARD HORIZONTAL
Route Spectrum
09-Feb-00 12:41:33
OVRALL= .5785 V-DG
RMS = .5716
LOAD = 100.0
RPM = 2937.
RPS = 48.95
0.4
0.3
0.2
01
0.1
0
0
20
40
60
80
100
Frequency in kCPM
120
140
160
Freq: 2.937
Ordr: 1.000
Spec: .01038
y
gy
SynchronousEnergy
EX 8
1.0
Los - Example 8
Analyze Spectrum
15-Nov-95 10:00:16
Synchronousenergy relatedto
0.8
turningspeed.
i
d
0.6
Wecanseefromthe
spectrum that the first peak
spectrumthatthefirstpeak
isat1Orders(whichmeansit0.4
is1xturningspeed)
Alltheotherpeaksare
All
th th
k
harmonicsoff,whichmeans
theyarerelatedtothefirst
peak
RMS = 1.27
LOAD = 100.0
RPM = 737.
RPS = 12.28
RMS Veloc
city in mm/Sec
0.2
0
0
6000
12000
18000
Frequency in CPM
24000
Label: Looseness
Examples of synchronous energy:

1) Imbalance
2) Misalignment
3) Gearmesh
30000
Freq: 736.86
Ordr: 1.000
Spec: .245
245
y
gy
NonSynchronousEnergy
E5
2.0
BF - Example 5
-R4A ROLL BRG. #4 - AXIAL
Route Spectrum
12-Jul-96 17:16:42
Nonsynchronousenergy
not related to turning speed
notrelatedtoturningspeed
1.8
OVRALL= 2.63 V-DG

RMS = 2.69
LOAD = 100
100.0
0
MPM = 3225.
RPM = 380.
Wecanseefromthe
spectrum that the first
spectrumthatthefirst
peakisat10.24Orders.
Thisisnotrelatedto
turning speed.
turningspeed.
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
0
6000
12000
18000
Frequency in CPM
24000
30000
Freq: 3888.9
Ordr: 10.24
Spec: .748
Label: Outer Race Defect

Priority: 1
Examples of non-synchronous energy:
Bearings
Multiples of belt frequency
Other Machine Speeds
y
gy
SubSynchronousEnergy
Subsynchronousenergy Less
than turning speed
thanturningspeed
Thespectrumshowsthefirst
impactingpeakbelow1Order.
Thisissubsynchronousenergy
Examplesofsubsynchronous
energyare:
BeltFrequencies
Other Machine Speeds
OtherMachineSpeeds
CageFrequencies
EnergyinaSpectrum
Energy in a Spectrum
Synchronous
N x RPM where N is an integer
g
Sub-synchronous
<1 x RPM
Non-synchronous
F x RPM where F is >1x RPM but not integer
g
y
gy
CausesofSubSynchronousEnergy
Frequenciesthatshow
belowtherotational
frequency(Lessthan1
Order)aresubsynchronous.
Anothercomponent
Another
component
Cagefrequencies
Primarybeltfrequency
Oilwhirl(plainbearings)
y
gy
CausesofSynchronousEnergy
Frequenciesthatareequal
toooradirectmultipleof
runningspeedare
Synchronous
Possiblecausesof
Possible causes of
Synchronousenergyare:
Imbalance
Misalignment
Looseness
Vane pass frequency
Vanepassfrequency
Gearsetc
Los - Example 8
Analyze Spectrum
15-Nov-95 10:00:16
RMS = 1.27
LOAD = 100.0
RPM = 737.
RPS = 12.28
0.8
EX 8
1.0
0.6
0.4
0.2
0
0
6000
Label: Looseness
12000
18000
Frequency in CPM
24000
30000
Freq: 736.86
Ordr: 1.000
Spec: .245
y
gy
CausesofNonSynchronousEnergy
Frequenciesabove(butnot
integermultiplesof)turning
speedarenonsynchronous.
Possiblecausesofnon
synchronous energy are:
synchronousenergyare:
Anothercomponent
Antifrictionbearings
Electrical
Systemresonances
Multiples of belt frequency
Multiplesofbeltfrequency
E5
2.0
BF - Example 5
-R4A ROLL BRG. #4 - AXIA
Route Spectrum
12-Jul-96 17:16:42
1.8
OVRALL= 2.63 V-DG

RMS = 2.69
LOAD = 100.0
MPM = 3225.
RPM = 380.
1.6
RMS Velocitty in mm/Sec
1.4
1.2
10
1.0
0.8
0.6
0.4
0.2
0
0
6000

Priority: 1
12000
18000
Frequency in CPM
24000
30000
Freq: 3888.9
Ordr: 10.24
Spec: .748
LinesofResolution
Lines
of Resolution
LOR
LinesofResolution
Lines of Resolution
LinesofResolution(LOR)determinehowclearthepeaks(data)are
definedwithinourspectrum.
ThemorelineswehaveoverthesameFmax(Maximumfrequency
scale).Themoreaccurateourdatawillbe
Example.
Thediagrambelowshowsdatathathasbeencollectedusing400LOR.
Noticehowthetopofthepeaksarecapped.WhentheLORare
increasedthedatabecomesmoreaccurate.
LinesofResolution
TA16
0.20
0.5
L2 - TA 16
-M1H Motor Outboard Horizontal
Analyze Spectrum
13-Mar-01 09:14:16
09:13:53
PK Acceleration
Acceleration in
in G-s
G-s
PK
Thespectrumshowndisplays
The
spectrum shown displays
dataat800L.O.Rwithan
Fmaxof1600Hz
The second spectrum

displays the same data but
with 3200 L.O.R over the
same Fmax
PK = .3852
3852
.7078
7078
LOAD = 100.0
RPM = 1497.
1496.
RPS = 24.95
24.94
0.16
0.4
0.12
0.3
0.08
0.2
0.04
0.1
0
0
400
800
Frequency in Hz
1200
1600
LinesofResolution
Lines of Resolution
TherangeofLORsettingsthatwecanchoosefromontheanalyzer
startsat100Linesandgoupto12800Lines.
100 Li
d
12800 Li
TheaveragenumberofLORisaround1600Linesforatypical
The
average number of LOR is around 1600 Lines for a typical
motor/pumpsetup
To change the LOR settings we need to alter our parameter set

set.
This is done in the Database Setup program
Remember. If you double your lines of resolution you double your
data collection time.
p
y
SpectralSummary
E5
RMS
S Velocity in mm/S
Sec
Accceleration,
Velocity Dissplacement
V
Am
mplitudes
s
2.0
BF - Example 5
-R4A ROLL BRG. #4 - AXIAL
Energy Types
18
1.8
1.6
Synchronous
1.4
Non Synchronous
1.2
Sub Synchronous
H
Harmonics
i
Multiples of Primary
Frequency
Route Spectrum
12-Jul-96 17:16:42
OVRALL= 2.63 V-DG
RMS = 2.69
LOAD = 100.0
MPM = 3225.
RPM = 380.
Resolution
1.0
Clarity of the spectral

d t
data
0.8
0.6
0.4
0.2
0
0
6000

Priority: 1
12000
18000
Frequency in CPM
Frequency
Hz (CPS), CPM, Orders
24000
30000
Freq: 3888.9
Ordr: 10.24
Spec:
p
.748
Analysis
Data Collection
DataCollection
g
q
TransducersandMountingTechniques
Althoughtherearemanydifferenttypesoftransducers
available,themostcommontypeusedfordaytodaydata
collectionareAccelerometers.
Thesetransducersprovideanelectricalchargeproportionalto
acceleration by stressing piezoelectric crystals typically
accelerationbystressingpiezoelectriccrystalstypically
100mV/gsensorsareused.
DataQualityy
Whetheritisyourjobtocollectthedataand/oranalysethe
dataitisimportanttounderstandthatthetechnologieswill
notgiveyoutheanswertoamachinesproblemunlessyou
havecollectedmeaningful,qualitydata
Therearecertainconsiderationsthatmustbetakenpriortoany
databeingcollected,theseare:
Agoodunderstandingoftheinternalmakeupofthemachine,inorder
A
good understanding of the internal make up of the machine in order
tounderstandthebesttransmissionpathfordatacollection bearing
locations,loadzonesetc.
Ensuredataiscollectedinarepeatablemannersowecancompare
p
p
twoormorereadingstoeachother trendingpurposes
Variablespeedmachines itisveryimportanttocollectdatawiththe
correctrunningspeedenterintotheanalyser
TransmissionPath
Damagedcausedtoamachinecomponentwillcauseacertain
amountofvibration/soundorheattopropagateawayfromthe
initial impact
initialimpact.
Inmanycasesthefurtheryouareawayfromtheinitialeventthe
weakerthesignalwillbecome,resultinginthedataappearingto
belowerinvalue.
Itistheeffectoftheimpact/forcethatwearetryingtodetect
Inmoreextremecasestheimpactcanbelostamongstothermachine
noisebythetimeithasreachedyourtransducer,resultinginno
detectionofamachineproblem.
Usuallythebestplacetoacquiredatafromamachine,isatthebearings.
Thisisbecausethebearingsaretheonlypartofthemachinethatconnectthe
internalrotatingcomponentstothestationarycomponents(Casing)
p
RepeatableData
Collectdatainthesamemannereachtime.
Inordertoaidwithrepeatabledatatheanalyserrequestsfor
d
datatobecollectedincertainlocationsonthemachine.
b
ll
d i
i l
i
h
hi
Thisconsistencywillallowyoutotrendthemachineryconditionand
y
y
y
properlyjudgetheprogressionoffaults
ThesearecalledMeasurementPoints
A measurement point is determined by three characters

and a description.
Each character refers to a particular place on the
machine being monitored
E.g.
E g M1H is a typical measurement point
MeasurementPoints
Measurement Points
Ameasurementpointisdefinedasthreealphanumericdigits
alongwiththeirrespectivedefinition
Orientationandlocationoneachcomponent
Orientation and location on each component
Theimageontherightis
takenfromthescreenof
the 2130 analyser during
the2130analyserduring
acollectionroute
Themeasurementpoint
identifiercanbeseenin
identifier
can be seen in
thetoprightwhilethe
pointdescriptionis
shownjustbelow
j
MeasurementPoints
Measurement Points
ThefirstletterofthePointIdentifierreferstothetypeof
machinebeingmonitored
M
M =Motor
Motor
P =Pump
P
Pump
F =Fan
F
Fan
Thesecondcharacterrepresentedbyanumberindicatesthe
locationonthemachine
Inboard(DriveEnd) orOutboard(NonDriveEnd)
Thethirdletterreferstotheorientationofthesensoror the
typeofprocessingbeingdonebytheanalyser
H=Horizontal
V=Vertical
P=PeakvueChangeinDSPofAnalyser
MeasurementPoints
Measurement Points
Thefollowingexampleshowshowthenumberingsystem
changesasyoucrossfromonecomponenttothenext
M1H Motor Outboard Horizontal

M1P Motor Outboard Horizontal Peakvue
P1H Pump Inboard Horizontal

P1P Pump Inboard Horizontal Peakvue
Noticehowthe1isnotalwaystheOutboard
Thischangeswhenthenextcomponentisrequiredfordatacollection
Thenumberingsystemstartsfrom1again
The numbering system starts from 1 again
Analysis
Fault Diagnostics
FaultDiagnostics
Imbalance,Misalignment,Looseness
FaultDiagnostics
Fault Diagnostics
Eachtypeofmachinefault
yp
f
ordefect
f revealsaspecific
p
vibrationcharacteristic inthespectrumandtimewaveform
domainthatdistinguishthatfaultfromanother.
Si l b
Simplybygainingabasicknowledgeofthesepatternsand
i i
b i k
l d
f th
tt
d
applyingafewrulesofthumb wecanstarttoanalyse
machinevibrationandpreventmachinefailure.
Thissectionconcentratesthecharacteristics/patternsand
rulesthatapplytodiagnosemachinefaultssuchas:
IImbalance
b l
Bearings
Resonance
Misalignment
Mi
li
t
(Peakvue)
LLooseness
Belts
Gears
G
Electrical
Imbalance
Imbalance
Imbalance(Unbalance)occurswhenthecentreofmassdiffers
fromthecentreofrotation.
Ifthecentreofmasschangesontherotorduetoaheavyspot
orsomeotherinfluencethenacentrifugalforceisproduced.
This results in the centre of rotation being offset from the
Thisresultsinthecentreofrotationbeingoffsetfromthe
centreofmasscausingthevibrationtoincreaseatthe
rotationalfrequency.
Imbalance(Types)
( yp )
Imbalance
CausesofImbalance
ImproperAssembly
Material build up / dirt
Materialbuildup/dirt
Weartocomponents
Brokenormissingparts
Alloftheaboveconditionswillresultinanunbalancedstate
DiagnosticRulesforImbalance
Periodicnon
Periodic
nonimpacting
impactingsinusoidalwaveform
sinusoidal waveform
Spectralpeakat1xTs(1Order)
Verylittleaxialvibration
Similaramplitudesbetweenhorizontalandverticalplains
p
p
Synchronousfaulttype
Amplitudeswillincreasewithspeed
Verylowharmonicsof1xTs
ImbalanceSpectralData
Imbalance Spectral Data
Thespectrumshownrepresentsasimpleunbalancestate
Singlepeakat1xTs(1Order)
Littleindicationofharmonics
Little indication of harmonics
RMS Velocity in mm//Sec
Ex2
IF - Example 2
Route Spectrum
16-Sep-99 08:36:29
Whatshouldthe
waveformshow?
OVRALL= 4.58 V-DG

RMS = 4.56
LOAD = 100.0
RPM = 3000.
RPS = 50.00
0
0
20000
40000
Frequency in CPM
60000
80000
Freq: 3000.0
Ordr: 1.000
Spec: 4.539
ImbalanceWaveformData
Imbalance Waveform Data
DespitethewaveformbeingdisplayedinAcceleration
Defaultunitforroutebasedwaveformdata
Thereisstillapredominantsinusoidalwaveformpattern
There is still a predominant sinusoidal waveform pattern
1xRevolutionsinewave
10
1.0
0.8
0.6
Ex2
IF - Example 2
Waveform Display
02-Feb-00 15:13:51
PK = .5289
LOAD = 100.0
RPM = 2985.
RPS = 49.76
Acceleration in G-s
A
0.4
0.2
PK(+)) = .8332
PK(
8332
PK(-) = .8893
CRESTF= 2.38
-0.0
-0.2
-0.4
-0.6
-0.8
Ch
Changingtheunitstovelocitywouldreducetheamountofhigh
i th-1.0 it t
l it
ld d
th
t f hi h
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
frequencynoiseresidingonthewaveform
Revolution Number
ImbalanceTrendData
Imbalance Trend Data
Thetrenddataisagoodwayofdeterminingiftherehasbeen
achangeincondition,asthisplotsamplitudeagainsttime
( e e t e s days)
(wheretimeisindays)
Herethe1xTsparameterisbeingtrended
Vibrationhasbeensteadyat3mm/secforaperiodoftime
Asuddenchangeinstateshouldalerttheanalysttoafaultdeveloping
E02N - JB1420C CONDY RECOVERY PUMP
JB1420C -M1H Motor Outboard Horizontal
14
Trend Display
of
1xTS
RMS Velo
ocity in mm/Sec
12
-- Baseline -Value: 3.063

Date: 07-Apr-00
10
8
FAULT
6
0
0
100
200
300
400
Days: 07-Apr-00 To 21-May-01
500
Date: 21-May-01
Time:14:24:29
Ampl: 11.21
Imbalance Problem Practical

ImbalanceProblem
Thefollowingfanunithasanimbalancepresentontherotor.
1xTsPeakintheSpectrum
1xTsPeakintheWaveform
1xTs Peak in the Waveform
Imbalance
Ex2
IF - Example 2
Route Spectrum
16-Sep-99 08:36:29
OVRALL= 4.58 V-DG
RMS = 4.56
LOAD = 100.0
RPM = 3000.
RPS = 50.00
0
0
20000
Ex2
1.0
40000
Frequency
eque cy in C
CPM
IF - Example 2
60000
80000
Freq:
Ordr:
Spec:
3000.0
1.000
4 539
4.539
Waveform Display
02-Feb-00 15:13:51
0.8
PK = .5289
LOAD = 100.0
RPM = 2985.
RPS = 49.76
0.6
Acceleration in G-s
0.4
PK(+) = .8332
PK(-) = .8893
CRESTF= 2.38
0.2
-0.0
-0.2
-0.4
-0.6
-0.8
-1.0
0
0.5
1.0
1.5
2.0
2.5
Revolution Number
3.0
3.5
4.0
4.5
5.0
Whatwouldhappentothedataifthefollowingoccurredto
th f ?
thefan?
ImbalanceCaseStudy1
Imbalance Case Study 1
Background
ThefollowingdataistakenfromaRecirculationFandesignedtocirculate
thehotairthroughanOventoaidwithdryingtheprocess.Theovenis
verticallymountedandtheproductcomesintotheovenfromthetopand
exitsatthebottom.ThereisoneRecirculationFanandoneExtractFan.
L
Lossoffunctionfromeitherfanresultsintheovenbeingtakenoffline.
f f ti f
ith f
lt i th
b i t k
ffli
Bm/c - TOP RECIRC FAN
TRF B m/c -F2H Fan Outboard Horizontal
Thespectralplotsshows
The
spectral plots shows
adominant1xTspeak(1
Order)withverylittle
othervibrationpresent
OVERALL= 4.70
4 70 V
V-DG
DG
RMS = 4.70
LOAD = 100.0
RPM = 1246.
RPS = 20.77
RMS Velo
ocity in mm/Sec
ROUTE SPECTRUM
08-Nov-04 14:16:45
0
0
20000
40000
60000
Frequency in CPM
80000
100000
Freq: 1246.3
Ordr: 1.000
Spec: 4.673
ImbalanceCaseStudy1
Thewaveformfromthisdatashownonthefollowingpage
representsasinusoidalwaveformclearlyshownonceper
revolutionoftheshaft
e o ut o o t e s a t herethewaveformisdisplayedin
e et e a eo
s d sp ayed
velocity.
Route Waveform
08-Nov-04 14:16:45
All
Allindicationspoint
indications point
towardsanimbalance
problem.The
amplitudesshouldbe
checkedinbothradial
directionstoconfirm
thisproblem
RMS = 4.66
LOAD = 100.0
RPM = 1246.
RPS = 20.77
Velocity in mm
m/Sec
PK(+) = 7.03
PK(-) = 7.40
CRESTF= 1.59
-4
-8
8
-12
0
3
Revolution Number
ImbalanceCaseStudy1
Theplotshownindicatesamultispectralplotshowingallthe
radialdirections.
TRF B m/c - Multiple Points (08-Nov-04)
Max Amp
4.27
Plot
Scale
TRF B m/c -F2V
RMS Veloc
city in mm/Sec
It
Itisclearthatthe
is clear that the
amplitudesare
commontoboth
b i
bearing
I b d
Inboard
andOutboardinall
radialplains
TRF B m/c -F2H
TRF B m/c -F1V
TRF B m/c -F1H

8000
16000
Frequency in CPM
24000
ImbalanceCaseStudy1
Thetrenddataforthe1xTsparameterhasbeensteadyfora
considerableamountoftime.Thelasttworeadingshasshown
a s g ca t c ease a p tude
asignificantincreaseinamplitude
Trend Display
of
1xTS
RMS Velocity
y in mm/Sec
5
-- Baseline -Value: .428
Date: 24-Nov-00
The
Thefanwas
fan was
recommendedtobe
cleanedatthenext
availableopportunity
il bl
t it
andforittobere
testedafterwards
3
FAULT
ALERT
300
600
900
Days: 24-Nov-00 To 08-Nov-04
1200
1500
Date: 08-Nov-04
Time: 14:16:38
Ampl: 4.688
ImbalanceSummary
Imbalance Summary
DiagnosticRulesforImbalance
Diagnostic Rules for Imbalance
Periodicnonimpactingsinusoidalwaveform
Spectralpeakat1xTs(1Order)
Spectral peak at 1xTs (1 Order)
Verylittleaxialvibration
Similaramplitudesbetweenhorizontaland
Si il
lit d b t
h i t l d
verticalplains
Synchronous fault type
Amplitudeswillincreasewithspeed
Verylowharmonicsof1xTs
V l h
i
f1 T
Misalignment
Misalignment
Whentwomatingshaftsdonotsharethesamecollinearaxis
thenmisalignmentisinduced.
Misalignmentisoneoftheprimaryreasonsforpremature
machinefailure.Theforcesthatareexertedonthemachine
anditscomponentswheninamisalignedstatearegreatly
p
g
increasedfromnormaloperatingconditions
Misalignment
OperationalDeflectionShape(ODS)isatechniquethat
machinemovementbaseduponthephaseandmagnitudeof
data co ected o t e a a yse S o be o s a
datacollectedfromtheanalyser.Shownbelowisanimage
age
fromtheODSillustratingtheforcesthatareexertedontothe
machineandcomponentswhenrunninginamisaligned
condition
Misalignment
Misalignmentcanbebrokenintothreebasiccategories,these
are:
Angular Wheretheshaftcentrelinescrossproducinga1xTspeakaxially
Offset Where the shaft centrelines are parallel but they do not meet
producing
p
g a radial 2xTs p
peak
More commonly seen A combination of the above
Misalignment
g
Misalignment
g
Anothercommonproblem
associatedwithalignmentis
b i
bearingmisalignment.
i li
t
Bearingmisalignmentoccurs
whenthebearingsarenot
mountedinthesameplain
t d i th
l i
possiblydueto:
oneormoreofthebearings
being cocked in the housing
beingcockedinthehousing
Themachineitselfdistortsdueto
thermalgrowthorsoftfoot
conditions
Misalignmentatthedrivecauses
shaftbending.
Misalignment
DiagnosticRulesforMisalignment
Highaxiallevelsofvibrationat1xTs
g
Highradiallevelsofvibrationat2xTs
Repeatableperiodsinewaveformshowing1or2clearpeaksper
revolution (Most likely M
revolution(Mostlikely
M or
or W
W shape)
shape)
Datacanusuallybeseenacrossthecoupling
DiagnosticRulesforBearingMisalignment
Diagnostic Rules for Bearing Misalignment
Highlevelsofvibrationat1xTsand2xTs
Repeatableperiodicsinewaveformshowing1or2clearpeaksper
revolution
l ti
Datausuallyshowneitherthedriverordrivencomponent
g
p
OffsetMisalignmentSpectralData
Thespectraldatashownrepresentsasimplemisalignment
plot.
Theprimarycursordenotesthe1xTspeakwhiletheharmoniccursors
indicatealarger2xTspeak.Thistypeofdataiscommontothatof
OffsetMisalignment
ST.1 - Raw Water Pump
P029
-M2H
Route Spectrum
15-FEB-93 11:04:18
RM
MS Velocity in mm/Sec
c
OVRALL= 6.50 V-DG

RMS = 6.47
LOAD = 100.0
RPM = 2976.
RPS = 49.61
0
0
10000
20000
30000
Frequency in CPM
40000
50000
Freq: 2925.0
Ordr: .983
Spec: 2.046
g
g
p
AngularMisalignmentSpectralData
Thespectraldatabelowrepresentsasimplemisalignment
plot.
Theprimarycursordenotesthe1xTspeakwhilethedatawastaken
intheaxialdirection.ThistypeofdataiscommontothatofAngular
Misalignment
B29 - PUMP NO 3
3601PUM003-M2A Motor Inboard Axial
Route Spectrum
04-Aug-04 08:49:05
OVERALL= 6.33 V-DG

RMS = 6.31
LOAD = 100.0
RPM = 1071
1071. (17
(17.84
84 H
Hz))
RMS
S Velocity in mm/Sec
0
0
30
60
Frequency in kCPM
90
120
Freq: 1.071
Ordr: 1.000
Spec: 5.966
g
OffsetMisalignmentWaveformData
Thewaveformaboveisshowingtwoclearpeaksper
revolutionoftheshaft.Thistypeofwaveformresemblingan
MorWshapeiscommontooffsetmisalignment.
o
s ape s co
o to o set sa g e t
Datashowninvelocity
ST.1 - Raw Water Pump

P029
-M2H
40
Waveform Display
26-MAR-93 13:32:52
Velocity in mm/Sec
30
RMS = 17.00
LOAD = 100.0
RPM = 2996.
RPS = 49
49.93
93
20
PK(+) = 30.66
PK(-) = 26.81
CRESTF= 1.82
10
-10
-20
-30
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
Revolution Number
4.0
4.5
5.0
MisalignmentWaveform
Misalignment Waveform
Thewaveformdatashownaboveispredominantlyshowing
onesinusoidalwaveformperrevolutionoftheshaft.
HerethedataisshownAcceleration
Here the data is shown Acceleration
B29 - PUMP NO 3
3601PUM003-M2A
3601PUM003
M2A Motor Inboard Axia
0.8
Route Waveform
04-Aug-04 08:49:05
0.6
PK = .2596
LOAD = 100.0
RPM = 1071. (17.84 Hz)
Acceleration in G-s
0.4
PK(+) = .6277
PK(-) = .5683
CRESTF= 3.42
0.2
0.0
-0.2
-0.4
-0.6
-0 8
-0.8
0
0.4
0.8
1.2
1.6
2.0
2.4
Revolution Number
2.8
3.2
3.6
Rev : .680
Ampl: -.306
y
CaseStudy3
KilnMainMotorGearbox
Introduction
TheKilndrivegearboxmotorhadbeenreplacedduringa
The Kiln drive gearbox motor had been replaced during a
plannedplantshutdown.
Duringthestartupoftheplantaftertheshutdownitwas
notedthatthemotorandgearboxwereexcessivelynoisy.
Vibrationdatawastakenduringtherunupoftheplantto
determinethecauseoftheproblem.
p
Main Motor
Kiln Gearbox
y
CaseStudy3
Thespectralplotshownaboveisthedatatakenfromthedrive
endofthemotor.Herethereisadominant2xTspeak.
0804
2.4
Route Spectrum
29-Mar-01 11:33:43
In addition to the misalignment the excessive forces

being applied to the machine were causing excessive
loading on the gears.
2.1
OVRALL= 2.47 V-DG

RMS = 2.46
LOAD = 100.0
RPM = 1418.
RPS = 23.64
Max Amp
5.98
RM S V
Velocity in mm /Sec
1.8
Amplitude - Mixed Units
04 - Kiln Drive
-M2H Motor Inboard Horizontal
1.5
0804
04 - Kiln Drive
-G2A Shaft 01 Outboard Axial
1.2
0.9
After
Shutdown
0.6
0.3
26-Mar-01
12:11: 12
23-Jan-01
15:02: 00
0
0
20000
Before
Shutdown 40000
25-Oct-00
09:04: 17
60000
08-Aug-00
14:06: 56
Frequency in CPM
0
5
4
3
2
1
0
29-Mar-01
09:40: 20
29-Mar-01
09:40: 09
60
120
180
Frequency in kCPM
240
300
Freq: 1418.3
Ordr: 1.000
Spec: 1.346
y
CaseStudy3
Duringdatacollectionitwasalsoobservedthatthegrouting
aroundthefrontfeetofthemotorhadbeguntocrackasa
resultoftheexcessiveforcebeingappliedtothemotorbase
andfeetduetothemisalignment.
Conclusion
Itwasconfirmedtheengineersthatreplacedthemotorduringthe
shutdownandassumedasthemotorwasalikeforlikeswap,aslongas
th k t th hi i th
theykepttheshimsinthecorrectplacethenalignmentwasnot
t l
th
li
t
t
necessary.
Correctiveactionwasrequiredandproductionwasstoppedsothe
motorcouldberealignedandthemountingsresecured.
t
ld b
li d d th
ti
d
MisalignmentSummary
Misalignment Summary
DiagnosticRulesforMisalignment
Diagnostic Rules for Misalignment
Periodicnonimpactingsinusoidalwaveformwith
1 or 2 clear peaks per revolution (Most Likely M
1or2clearpeaksperrevolution(MostLikely
M
orWshape)
Spectralpeakat1xTsand2xTs
Spectral peak at 1xTs and 2xTs
Axialvibrationat1xTs
Synchronous fault type
Datacanbeseenacrossthecouplingoracrossthe
component itself
componentitself
Looseness
Howwouldlooseness?
Looseness
Loosenesscanbebrokendownintotwomaincategories,
Structural andComponent
Structural looseness occurs when there is free
movement within the machines support structure causing
excessive vibration. This can be a result of:
Loose support bolts to the components feet and supports
Cracked welds
Deterioration of the base itself.
Component looseness generally occurs when there is

excessive clearance to the components
p
within the
machine, such as:
Excessive clearance between the shaft and bearings
Excessive clearance between the shaft and an impeller etc
etc.
Looseness
DiagnosticRulesforLooseness
Multipleharmonicsofthe1xTspeak
p
p
Structural
MultipleHarmonicsofthecomponentthatisloose Component
Numberofharmonicswillincreaseastheloosenessprogresses
Random non periodic waveform Structural
Random,nonperiodicwaveform
Waveformshowspredominantimpacts Component
Raisednoiselevelaroundthe1xTs+harmonics
Halfharmonicsmayalsobepresent
CanbepresentinallDirections
p
((Structural))
LoosenessSpectralData
ThespectralplotshownisdemonstratingLooseness.
The1xTspeakhasbeenhighlightedbytheprimarycursorandthe
p
g g
y
p
y
relevantharmonicshavebeendisplayed.
Multipleharmonicsof1xTsareshownuptoaround10ordersof1xTs.
M4441
4.0
40 - Kiln Main Drive

-G2H Shaft 01 Outboard Horizontal
Route Spectrum
06-Nov-02 11:02:11
3.5
OVERALL= 5.22 V-DG
RMS = 5.22
LOAD = 100.0
RPM = 635. (10.58 Hz)
30
3.0
2.5
2.0
1.5
1.0
0.5
0
0
200
400
600
Frequency in Hz
800
1000
Freq: 10.58
Ordr: 1.000
Spec: 3.088
p
((Component)
p
)
LoosenessSpectralData
Thespectralplotshownisdemonstratingrotational
Looseness.
Theprimarycursorison5xTspeak
The5Orderpeakisvanepassfrequency(5vanesontheimpeller)
Multipleharmonicsof5xTsareshownindicatingtheimpellerhas
p
g
p
comeloose.
Ex 9
1.5
L1 - Example 9
-P2A Pump Outboard Axial
Route Spectrum*
17-Aug-01 08:52:02
RMS V
Velocity in mm/Sec
1.2
0.9
The raised noise level around

the vane pass frequency is
common to a pumping
problem known as Cavitation
OVERALL= 6.62 V-DG
RMS = 6.13
LOAD = 100
100.0
0
RPM = 2974. (49.57 Hz)
This would be the likely cause

of the impeller problem
06
0.6
0.3
0
0
40
80
120
160
Frequency in kCPM
Label: Centrifugal Pump - Medium
200
240
Freq: 14.88
Ordr: 5.002
Spec: .742
LoosenessWaveformData
Herethewaveformisdemonstratingalotofenergyand
appearstobemorerandomandnonperiodic.
Displayingthewaveforminvelocitymayhelptoshowtherandom
nonperiodicpattern.
M4441
1.2

Route Waveform
06-Nov-02 11:02:11
RMS = .3174
LOAD = 100.0
RPM = 635. (10.58 Hz)
0.8
PK(+) = .9797
PK(-) = .9874
CRESTF= 3.11
Acceleration in G-s
0.4
0.0
-0.4
-0.8
-1.2
0
50
100
150
200
250
Time in mSecs
300
350
400
LoosenessTrendData
Looseness Trend Data
Herethetrendplotisshowingtheparameterlabelledasthe3
15xTs.Thisismeasuringtheamountofenergyfrom3ordersto
15orders,whichiswheretheharmonicsofloosenesswill
5 o de s,
c s e e t e a o cs o oose ess
appear.
M4441

Trend Display
of
3-15xTS
-- Baseline -Value: .837

837
Date: 28-Feb-02
5
FAULT
4
ALERT
3
0
0
10
20
30
Days: 28-Feb-02 To 16-Apr-02
40
50
CaseStudy4
Case Study 4 ReciprocatorFan
Reciprocator Fan
Introduction
Datahadbeencollectedonthefollowingfanforseveral
Data had been collected on the following fan for several
monthsaspartofaroutineperiodicvibrationroutine.Duringa
routinevisittothemachineitwasobservedthattherewasa
lot of low frequency activity showing around the bearing on
lotoflowfrequencyactivityshowingaroundthebearingon
theinboardofthefan(F1H)
CaseStudy4
Reciprocator Fan
Themultipleplotsshownaboveindicatethechangeovertime
fromthedatatakenonF1H.
Itisquiteapparentthatthedatashownhereisindicatingmultiple
harmonicsofthe1xTsfrequency(theriseenergyasyoumovefurther
awayfromthe1xTs).
Thistypeofdataiscommontothatofaloosenessproblem.
M2237
40 - Precip Fan
2.4
Max Amp
2.74
2.0
1.6
1.2
RMS Velocitty in mm/Sec
0.8
0.4
0
29-Oct-02
11:00:02
18-Sep-02
09:13:26
29-Aug-02
15:30:18
22-Aug-02
11:14:48
0
300
600
Frequency in Hz
900
1200
29-Oct-02
11:00:02
RPM= 998.9
Freq:
Ordr:
Sp 4:
16.65
1.000
2.811
y
p
CaseStudy4
ReciprocatorFan
Thewaveformdatatakenforthisparticularpointisnot
showingarandomtypeofwaveformpatternwhichyou
wouldexpectfromStructurallooseness,
ou d e pect o St uctu a oose ess, but
butthereisamore
t e e sa o e
arepeatable(timedinterval)pattern.
M2237
40 - Precip Fan
-F1H Fan Inboard Horizonta
Analyze Waveform
18-Sep-02 09:24:16
RMS = .3747
LOAD = 100.0
RPM = 998. (16.63 Hz)
Acceleration in G-s
A
PK(+) = 2.36
PK(-) = 2.83
CRESTF= 7.55
-1
-2
-3
-4
0
100
200
300
400
500
Time in mSecs
600
700
800
CaseStudy4
Reciprocator Fan
ThistypeofwaveformwouldmorebeindicatingComponent
loosenessandmayindicateaproblemwithaloosebearing.
Conclusion
Itwasrecommendedthatthebearingshouldbeinspectedat
thenextavailableopportunity.
Upon
Uponinspectionitwasfoundthatthebearingwasa
inspection it was found that the bearing was a TaperLock
Taper Lock
bearingandthetaperlockwasloose,thusresultinginexcessive
clearancebetweenthebearingandtherotor.
LoosenessSummaryy
DiagnosticRulesforLooseness
Diagnostic Rules for Looseness
Multipleharmonicsofthe1xTspeak
Numberofharmonicswillincreaseasthelooseness
progresses
Random,nonperiodicwaveform Structural
Waveformshowspredominantimpacts
f
h
d i
i
Component
Raisednoiselevelaroundthe1xTs+harmonics
Halfharmonicsmayalsobepresent
Half harmonics may also be present
CanbepresentinallDirections
Analysis
Fault Diagnostics
FaultDiagnostics
Gears,Bearings,Peakvue,Electrical,Belts,
Resonance
GearDefects
Gear Defects
Therearemanydifferenttypesofgearsandgearcombinations
availableforvariousspeedandpowerrequirements.
Regardlessofgeartypetheyallproducethesamebasic
Regardless of gear type they all produce the same basic
vibrationpatternsandcharacteristicswhenadefectispresent
Thefollowingtopicwilldiscussthe
basiccharacteristicsforthefollowing
typesofgears:
SpurGears
HelicalGears
BevelGears
SpurGears
Spur Gears
SpurGears aremostcommonlythoughtofwhendiagnosing
gears.Theteetharecutparalleltotheshaft.Thesegearsare
good at po e t a s ss o a d speed c a ges but a e o s e
goodatpowertransmissionandspeedchangesbutarenoisier
thanothergeartypes.
SpurGearAdvantages
Highefficiency
Lowheatgeneration
L h
i
SpurGearDisadvantages
Canbeverynoisy
y
y
HelicalGears
Helical Gears
HelicalGears haveteethcutatanangletotheshaft.These
gearsaremuchquieterthanspurgearsbutduetotheangular
natureofthegearmeshing,axialthrustandthereforeaxial
vibrationishigherthanthoseofspurgears
Sometimes
Sometimestocounteracttheaxialthrustthesegearscanbedoubleup
to counter act the axial thrust these gears can be double up
andareknownasDoubleHelicalorWishboneGears
HelicalGearAdvantages
QuietOperation
Quiet Operation
HelicalGearDisadvantages
Lesspowertransmissionefficiency
and greater heat generation than
andgreaterheatgenerationthan
spurgears
Axialloadingonbearings
BevelGears
Bevel Gears
BevelGears areusedtotransmitpowerandspeedtoan
outputshaftperpendiculartothedriveshaft.Thesegearsuse
abeveldesigntotransmitthepowerbetter.
Thesegearsaremostcommonlyseenonrightanglegearboxes(where
the input shaft is at 90 degrees to the output shaft)
theinputshaftisat90degreestotheoutputshaft)
BevelGearAdvantages
Bevel Gear Advantages
Convertsthedirectionofpowertransmission
BevelGearDisadvantages
Lessefficient
Higherheatgeneration
GearAnalysis
Gear Analysis
Vibrationanalysisofgearscanprovideawealthofinformationaboutthe
mechanicalhealthofthegears.Thissectiondiscussesthebasicfrequencies
thatmaybepresentwithinagearbox.
GearMeshFrequencySpectralData
G
M hF
S t lD t
Thegearmeshfrequency(GMF)referstothefrequencyatwhichtomating
gearsinteractwitheachotherandisthemostcommonlydiscussedgear
frequency.
However,GMFbyitselfisnotadefectfrequency.TheGMFshouldalways
bepresentinthespectraldataregardlessofgearcondition.Whatis
importantistheamplitudeasthismayvarydependingupongearcondition
orloadingofthegear.
Gears
Twomatinggearswillgenerateafrequencyknownasthe
GMFandwillshowinthespectraldataregardlessofgear
condition.
co d t o
M4441
1.2

-G1V Shaft 01 Inboard Vertical
Route Spectrum*
p
08-Jun-02 23:11:51
OVERALL= 2.22 V-DG
RMS = 2.14
LOAD = 100.0
RPM= 1548. (25.80 Hz)
0.9
0.6
0.3
0
0
200
400
600
Frequency in Hz
800
1000
Freq: 386.98
Ordr: 15.00
Spec: .864
CalculatingGMF
Calculating GMF SingleReduction
Single Reduction
SingleReductionGearTrain
TheGMFissimplydefinedasthenumberofteethonagearmultiplied
py
g
p
byitsturningspeed
GMF=(#teeth)x(Turningspeed)
Example:
E
l
Considerthefollowinggeartrain,
INPUT
OUTPUT
Input
= 1490RPM
Gear 1
= 44 Teeth
Gear 2
= 71 Teeth
GMF = #teeth x turning speed

GMF = 44teeth x 1490 RPM
GMF = 65560 CPM
or 65560/60 = 1092.6 Hz
CalculatingGMF
Calculating GMF MultiReduction
Multi Reduction
CalculatingtheGMFforgearboxesthathavemultipletrainsuse
thefollowing.
GMF=(#teeth)x(Turningspeed)
GearRatio=(#teethin)/(#teethout)
Speed out = (Speed in) x (Gear Ratio)
Speedout=(Speedin)x(GearRatio)
Example:
Considerthefollowinggeartrain:
INPUT
OUTPUT
Input
= 1490RPM
Gear 1
Gear 2
= 15 teeth
= 21 teeth
Gear 3
Gear 4
= 19 teeth
= 54 teeth
CalculatingGMF
Calculating GMF MultiReduction
Multi Reduction
INPUT
Input
= 1490RPM
Gear 1
Gear 2
= 15 teeth
= 21 teeth
Gear 3
Gear 4
= 19 teeth
= 54 teeth
OUTPUT
Gear Ratio 1
p
Out
Speed
= 15 teeth / 21 teeth
= 1490 RPM x 0.714
= 0.714
= 1064.28 RPM
Gear Ratio 2
Speed Out
= 19 teeth / 54 teeth
= 1064.28 RPM x 0.351
= 0.351
= 374.47 RPM
GMF 1 = 1490 RPM x 15 teeth

= 22350 CPM
GMF 2 = 1064.28 RPM x 19 teeth = 20221.32 CPM
GMFCalculationExercise
GMF Calculation Exercise
UsingtheformulasonP153fromthemanualcalculate:
Speedsofallshafts
AllGMFfromthefollowinggearboxarrangement
All GMF from the following gearbox arrangement
INPUT
OUTPUT
Input
= 1000 RPM
Gear 1
Gear 2
= 10 teeth
= 40 teeth
Gear 3
Gear 4
= 10 teeth
= 20 teeth
GearRatio1 =10/40
Shaft2speed =1000x0.25
Gear Ratio 2
GearRatio2
=10/20
10/20
Shaft3Speed =250x0.5
GMF1
=1000x10
GMF2
=250x10
=0.25
=250RPM
=0.5
05
=125RPM
=10000CPM
=2500CPM
Gears
Gears SidebandFrequencies
Sideband Frequencies
Sidebandsarethemostcommonindicationthatagearis
defected.
Sidebandsareequallyspacedfrequenciesinthespectraldatathat
materialiseeithersideofthemainGMFpeak.
Thesidebandfrequencyspacingisequaltoeithertheturningspeedof
The sideband frequency spacing is equal to either the turning speed of
theinputgearortheturningspeedoftheoutputgear.
Sidebandsshowinthedatawheneitherthe
gearisworn,looseoreccentric.
Thespeedoftheshaftwiththebadgearonitwill
p
producethemostdominantsidebandsinthe
spectraldata.
Gears
ThespectraldatashowsGMFwithsidebanddata.
Thesidebandsareequallyspacedatintervalsof310CPM.Thisis
indicatingthegearthatrotatesat310RPMistheonethatiswornor
g
g
damaged.
X401A
1.0
FPP - SAND MILLS (OLD)A

-G3A Shaft 02 Inboard Axial
Route Spectrum
07-Nov-02 09:11:53
(SST-Corrected)
RMS Velocity in m
mm/Sec
0.8
GMF
OVERALL= 2.18 V-DG

RMS = 2.17
LOAD = 100.0
RPM = 310. (5.17 Hz)
0.6
0.4
Sidebands
0.2
0
0
8000
16000
Frequencyin CPM
24000
Freq: 18363.
Ordr: 59.23
Spec: .564
Dfrq: 310.82
Gears
Gears WaveformData
Waveform Data
Gearscanproducedifferenttypesofwaveforms,theone
shownbelowisindicatinggearwear.
As
Asthedefectiveteethcomeintomeshthenoisegeneratedincreases
the defective teeth come into mesh the noise generated increases
showinganincreaseinamplitudeinthevibrationdata
X401A
1.5
FPP - SAND MILLS (OLD)A

-G3A Shaft 02 Inboard Axial
Route Waveform
07 Nov 02 09:11:53
07-Nov-02
1.2
PK = .4580
LOAD = 100.0
RPM = 311. (5.19 Hz)
0.9
Acceleration in G-s
0.6
PK(+) = 1.27
PK(-) = 1.13
CRESTF= 3.91
0.3
0
-0.3
-0.6
-0.9
-1.2
-1.5
0
3
4
Revolution Number
CaseStudy5
Gearbox
Case Study 5 Gearbox
Thefollowingcasestudyisfromamotorgearboxunitthat
drivesaroller.
Product
Product(Fibre)isfedalongthetopoftherollwhilebeingwashed
(Fibre) is fed along the top of the roll while being washed
throughaseriesofbaths.
ThereareseveraloftheseWashNipRollersinacontinuousstream,
failureofanyoneofthemresultsinlostproduction
Dataiscollectedona
Data
is collected on a
fortnightlybasisaspartof
aroutinedatacollection
route
CaseStudy5
Gearbox
Thespectraldatashownbelowistakenfromthemotorinthe
axialdirection
(As
(Asthemotorismounteddirectlyintothegearboxthefirsthelicalgear
the motor is mounted directly into the gearbox the first helical gear
ismountedontheendofthemotorshaft).
L1NG - WASH LINE NIP UNIT 3
3-32J03 -MIA MOTOR INBOARD AXIAL
0.6
TheGMFishighlightedby
Th
GMF i hi hli ht d b
theprimarycursorat49
Orders
Th f lt f
Thefaultfrequencydata
d t
(dottedlines)indicatethe
sidebanddatashowing
gear wear on the first gear
gearwearonthefirstgear
inthegeartrain
Route Spectrum
01-Aug-04
01
Aug 04 10:21:41
EEEEE EEEEE
0.5
OVERALL= 1.08 V-DG

RMS = 1.07
LOAD = 100.0
RPM = 1175. (19.58 Hz)
0.4
>REN Wash Nip

E=Gm(1>2)-S1
0.3
0.2
0.1
0
0
10
20
30
40
50
Frequency in Orders
60
70
80
Ordr: 49.00
Freq: 57551.
57551
Spec: .275
Dord: .00649
CaseStudy5
Gearbox
Thewaveformdataisshowingadistinctpatterncommonly
associatedwithgears.
TheamplitudeincreasesInnoiseasthedamagedteethcome
The amplitude increases In noise as the damaged teeth come
intomesh
Producingover2Gsofforceinboththepositiveandnegativedirection
CaseStudy5
Gearbox
Thegearswereinspectedduetothecriticalnatureofthe
asset.Itwasfoundthegeartobeseverelydamaged.
Anewgearboxwasfittedandnewdatawastakenshowingthe
A new gearbox was fitted and new data was taken showing the
differencebetweenthegoodandbadgear
BearingDefects
g
RollingElement
g
PlainBearings
Peakvue
RollingElementBearings
Rolling Element Bearings
Rollingelementbearingshavespecificbearingfailuremodes
thatcanbeobservedinthespectralandwaveformdata.
Bearingfrequenciesdifferfrommostotherfrequencies
present within the spectral data because unless the bearing
presentwithinthespectraldatabecauseunlessthebearing
hasadefecttherewillbenofrequencypeaksinthedata
relatingtothebearing.Onlyifthebearinghasadefectwill
frequenciesshowinthespectraldata.
There are four main fundamental bearing defect
frequencies
q
these are:
g
g
Outer Race
Inner Race
HowBearingFaultsGenerateVibration
g
HowBearingFaultsGenerateVibration
g
Bearingdefectfrequenciesarecalculatedbaseduponthegeometryofthe
bearingthesecalculationsmayinclude:
Numberofrollingelements
PitchCircleDiameter
Rollingelementdiameter
Contactangle
DefinedwithinMachineryHealthManagerthereareover100000predefinedbearing
storedintheCSIbearingwarehouse
BEARINGSinCSIWarehouse:
c:\RBMsuite\SysData\CSI_CMP.WH
****************************************************
BRGID BearingType #B/R FTF BSF BPFO BPFI
12143RHP6218110.4182.9674.5986.402
24421SKF6313E80.3761.8943.0094.991
25372 SKF I 26313
25372SKFI26313190.4333.5688.21910.781
19 0 433 3 568 8 219 10 781
CharacteristicsofBearingDefects
High
Highfrequencyraisednoiselevel(Humpofenergy)
frequency raised noise level (Hump of energy)
NonSynchronousharmonicpeaks(Bothlowandhigh
frequency)
Timewaveformwillshowalotofnoise/impacting
Earlystagesofbearingwearmayshowbetterifviewedin
accelerationinthefrequencydomain
l ti i th f
d
i
Fundamentalbearingdefectfrequency(Firstcalculable
q
y) y
p
p
frequency)maynotbepresentinthespectraldata
Failure Mode 1
FailureMode1
Theearlystagesofbearingdefectsproducelow
amplitudesofvibrationathigherfrequencies
(Appearsontherighthandsideofthespectrum).
( pp
g
p
)
Thesearenormallyhumpsofenergyorpeaks
thatareharmonicstothefundamental
frequency.
(Thefundamentalfrequencyshouldnotbe
visibleatthisstage).
i ibl
hi
)
FailureMode2
DistinctharmonicsofNonSynchronouspeaks
appear.
(Theseshouldappearlowerdownthescaleofthe
spectrum towardstheleft/middleoftheplot)
Sidebandsmayappeararoundthesefrequencies
usuallyequatingtoturningspeed.
(Thefaultfrequenciesmaynotmatchexactlywith
thepeaksinthespectrumduetothefactthatthe
bearing geometry will have changed)
bearinggeometrywillhavechanged).
FailureMode3
Thefundamentalfrequencynormallyappearsatthisstage
(Firstcalculablefrequencyofthebearing towardstheleft
handsideofthespectralplot).Thisisclassedasadvanced
stagesofbearingwear.
Sidebandsmaybevisiblethatequatetootherbearing
frequencies BSF,FTFetc).
)
FailureMode4
Failure Mode 4
Thebearingdegradessomuchthatthespectrum
The
bearing degrades so much that the spectrum
becomesamassofnoise.Atthispointthebearing
willfailatanypoint(Ifitlastthislong mostfail
aroundMode3).
g
g BPFI
Typicaldatashowingadefectedinnerrace
Fundamentalfrequencyshowing
Harmonicslowandhighfrequency+sidebands
g
g BPFO
DatashowingadefectrelatedtotheBPFO
Thefundamentalfrequencyisshowing
Harmonicsfromlowtohighfrequency
Harmonics from low to high frequency
g
g BSF
BearingdefectshowingtheBSF Rollingelements
SidebandsaroundtheBSF=FTF
Rolling Element Bearings FTF
TheFTFistheonlybearingfrequencythatissubsynchronous
Maynotdetectthenwithconventionalvibrationdata
FTFdefectat0.4ordersshowninPeakvue
Bearing
FTF&BSF
FTF & BSF
BPFI&BPFO
BPFI & BPFO
Rolling Element Bearings Waveform
Asabearingbecomesdefectedthentheamountof
noise/forcegeneratedastherollingelementsimpactthe
de ect e a ea c eases
defectiveareaincreases.
ThiscanshowsignificantGlevelsinthetimewaveform.Thisvalueis
trendedinthesoftwareasthePeakPeakvalue
Thisdataistakenfroma
pumpwithadamaged
bearing
Theforcelevelsare
reaching40Gs
y
g
CaseStudy6
BearingDefect
Thespectralplotbelowisshowingthedatafromthe
inboardverticaldirectionofthemotor.
Theprimarycursorisindicatingthefundamentaldefect
BPFO f
BPFOfrequency+harmonics.
+h
i
Thefrequencyrangeoftheharmonicscoversbothlow
andhighfrequencyrangessuggestingthebearingismore
advancedstagesoffailure.
CaseStudy6
Case Study 6 BearingDefect
Bearing Defect
Thetimewaveformisshowingsignificantimpactinglevels
reachinginexcessof+/ 8Gsofforce.
This
Thislevelofimpactingishigherthanwouldbesuspectedforamotorof
level of impacting is higher than would be suspected for a motor of
thistype.
Therepetitiveimpacting
The
repetitive impacting
patternshownaboveis
commontoantifriction
bearingdefects.
g
Inthisinstancetheimpacting
isrepresentingtherolling
elementsstrikingadefecton
therace.
CaseStudy6
Case Study 6 BearingDefect
Bearing Defect
Thetrendplotaboveisshowingtheincreaseinamplitudeof
thePeakPeakparameter.
The
Thepeak
peakpeak
peakparameterismeasuringtheamountofenergyinthe
parameter is measuring the amount of energy in the
timewaveformfromthePeak+tothePeak
Conclusion
C
l i
Themotorwasreportedashavingabearing
defecttotheengineeringgroup.Asthe
f d
fundamentaldefectfrequencywaspresent
t ld f tf
t
andthetrendhadshownsuddenincreasesit
wasrecommendedtochangethebearingat
the next available opportunity
thenextavailableopportunity.
BearingDefects
g
RollingElement
PlainBearings
Peakvue
PlainBearings
Plain Bearings
Rotatingelementsarenotusedinsleeve(plain)bearings;
rathertheshaftridesonalayeroflubricatingoilinsidethe
bea g jou a
bearingjournal.
Thereforethefundamentalfrequenciesseenfromantifrictionbearings
donotapplytosleevebearings.
Sincethereisnocontactbetweenthe
bearingandtheshaftmonitoringof
sleevebearingsforvibrationanalysis
usuallyrequirestheuseof
displacementprobesmounted45
p
p
degreeseithersideoftopdeadcentre.
PlainBearings
Plain Bearings
Astherearenorotatingcomponentsinthebearingthat
producehighfrequencynoise(force)thereisnoneedto
monitorahighfrequencyrange.Usually10to15ordersof
turningspeedwillbesufficient.
Sleevebearingshavespecificdefectsthatcontribute
towardsbearingfailure,theseare:
Excessiveclearance
Excessive clearance
Hydraulicinstability(oilwhirl)
PlainBearings SpectralDiagnostics
ExcessiveClearance
Whenthereisexcessiveclearancebetweentherotorandthebearing
thenthiswillhaveaneffectonthesystemvibration.Whenthe
bearings have excessive clearance then a looseness
bearingshaveexcessiveclearancethena
looseness occurs.
occurs
Thespectraldatashownbelowisindicatingasleevebearingwith
excessive clearance
excessiveclearance.
As the clearance increases then the

harmonics of 1xTs will increase and can
go up to 1015xTs.
TBT
16
Fu - Turbine Brg Thrust End

-R1Y Radial 'Y' Direction
Route Spectrum*
27-Jul-04 14:08:21
OVERALL= 2.93 V-DG

P-P = 22.71
LOAD = 100
100.0
0
RPM= 941. (15.69 Hz)
Like looseness the more harmonics

there are the more severe the problem
will be.
A good sleeve bearing will still show
a few harmonics as there is a small
clearance
l
between
b t
the
th shaft
h ft and
d
bearing
P-P Dis pla c

cement in Microns
12
0
0
6
Frequency in Orders
12
Ordr:
Freq:
Spec:
1.000
15.68
7.494
PlainBearings
Plain Bearings SpectralDiagnostics
Spectral Diagnostics
OilWhirl
Oneofthemajorproblemsencounteredwiththesetypesofbearingsis
j p
yp
g
thepossibilityofhydraulicinstabilityoftheshaftwithinthebearing;
knownasoilwhirloroilwhip.
OilWhirlisaresultofturbulentflowwithintheoilresultingintheoil
pushingtheshaftaroundofcentre.
TBT
16
Fu - Turbine Brg Thrust End

-R1Y Radial 'Y' Direction
Route Spectrum*
27-Jul-04 14:08:21
Oil Whi
Whirll att 0
0.4
4 orders
d
OVERALL= 2.93 V-DG

P-P = 22.71
LOAD = 100.0
RPM= 941. (15.69 Hz)
P-P Dis pla c e m e nt in M ic rons
12
Thisdefectissubsynchronousdata.
Whentheamplitudeoftheoilwhirlis
equaltoorgreaterthanthe1xTspeaka
problemexists
IInthisinstanceoilwhirlcanbe
thi i t
il hi l
b
correctedby:
Properlyloadingthebearing
Changetheoilviscosity
Changetheoilpressure
Ch
th il
0
0
Thedominantpeakwithinthespectral
datawillbetypicallyat0.4orders.(.40
.48)
6
Frequency in Orders
12
Ordr:
Freq:
Spec:
1.000
15.68
7.494
Oil Whirl
OilWhirl
BearingDefects
RollingElement
PlainBearings
Peakvue
PeakvueProcessing
Peakvue Processing
Thedetectionofbearingandgeardefectsisoneoftheprimary
expectationsofapredictivemaintenanceprogram.
Asanalystswecanspendalotoftimetyingtodeterminethesefaults.
Peakvueisaprocessthatconcentratesonthesedefectstohelptheanalysts
determinepotentialfaultsdeveloping
PeakvuestandsforthePeakValue andisatechniquethatdetectshigh
frequency stress waves generatedfrommetaltometalcontact,suchas:
frequencystresswaves
generated from metal to metal contact such as:
Bearingdefects Rotatingelementsstrikingadefectontherace
Geardefects Damagedteethinmesh
Itisthedetectionofthesehighfrequencystresswavesthatwillaidwith
analysis
analysis
PeakvueProcessing
Peakvue Processing Filters
Inordertocapturethestresswavesignaltheprocessrequires
theuseofafiltertoremoveallunwantednoisethatcan
do
dominatethedata
ate t e data
1. Conventional Vibration
Signals that are filtered
from the Peakvue Signal
Imbalance
Misalignment
Misalignment
Gears
Bearings
Resonance
2. Peakvue filter removing

low frequency noise from
the stress wave data
This is to prevent low
frequency noise
consuming the stress
wave activity
3. High frequency stress wave

activity occurring in the 1000Hz 20000Hz frequency range at a
rate governed by a low
frequency event
Bearings
Gears
PeakvueProcessing
Peakvue Processing Filters
Therearetwotypesoffiltersavailable
BandPassFilters
Band Pass Filters
f
Thebandpassfilterremovesallthedataaboveandbelowthefilter
cornervalues
HighPassFilter
Thehighpassfilterremovesalldatalowerinfrequencytothatofthe
g p
q
y
filterselectionallowingonlythehighfrequencystresswavestopass
through
After
Afterthefilteringprocesswhatshouldremainisthehigh
the filtering process what should remain is the high
frequencystresswaveactivitythatisoccurringattherateof
theexcitation suchasfromabearing.
PeakvueProcessing
Peakvue Processing SpectralData
Spectral Data
ShownbelowisatypicalPeakvuespectrumwithadefect
present
Stress waves are showing

clearly in the data at 4.6 Orders
Thefilterusedisshowninthetop
The
filter used is shown in the top
righthandcorner
Good
G
d Spectrum
S
t
will
ill
show only a noise
level
Noise removed by
y
filter
PeakvueProcessing
Peakvue Processing WaveformData
Waveform Data
Asstresswavesaresmallinamplitudeseverityoftheproblem
canbejudgedusingthetimewaveform
PeakValueofforcefromtheimpact
Peak Value of force from the impact
RMS Acc
celeration in G-s
Thewaveformcanresembleaspectrumasthereisno
negativehalftothedata
B42 - ZONE 5 DF FAN 1
16/16EXT01-M2P Motor Inboard Horz Peakvue
0.8
0.7
0.6
0.5
0.4
03
0.3
0.2
Route Spectrum
09-Jul-03 09:50:49
(PkVue-HP 1000 Hz)
OVERALL= 1.37 A-DG
RMS = 1.37
LOAD = 100.0
RPM = 1342
1342. (22
(22.37
37 Hz)
>NTN 6217
N=BPFO -OB
For Peakvue analysis
Use the Spectrum
0.1
Diagnose the defect
Acceleration in G-s
200
400
600
Frequency in Hz
800
1000
Route
R
t W
Waveform
f
09-Jul-03 09:50:49
(PkVue-HP 1000 Hz)
RMS = 2.97
PK(+) = 8.35
CRESTF= 2.81
8
7
6
5
4
3
2
1
0
0
12
16
20
24
Revolution Number
Label: Bearing Fault - BPFO NTN6217
28
32
36
Freq: 1.250
Ordr: .05587
Spec: .01367
Use the Waveform

Determine the severity
y
CaseStudy7
PeakvueonFanBearingg
Thefollowingmachineisa
preheater
pre
heaterfandesignedto
fan designed to
heattheproductpriortoit
enteringaKiln
Thereisnostandbyforthis
machine
Failureresultsinstopped
production
Thefollowingdatawastakenfromtheabovefanunit.
Theproblembearingresidedonthefaninboardbearing.
Datawascollectedonamonthlybasis.Bothconventionalvibration
dataandPeakvuedataweretakenduringtheroutecollection.
y
CaseStudy7
Thedatashownbelowistakenusingconventionalvibration
methodsontheinboardbearingofthefan
1xpeakishighlightedshowingamplitudesof4mm/sec
1x peak is highlighted showing amplitudes of 4mm/sec
Waveformisshowinglessthan1Gofforceboth+/
40 - Preheater Fan
M4425 -F1H Fan Inboard Horizontal
R M S Ve lo c it y in m m /S e c
Route Spectrum
29-Oct-02 11:19:26
OVERALL= 4.18 V-DG
RMS = 4.18
LOAD = 100.0
RPM= 825. (13.75 Hz)
4
3
2
1
0
0
10
20
30
40
50
Frequencyin Orders
60
70
80
A c c e le ra t io n in G - s
1.5
There
Thereareindicationsof
are indications of
bearingfrequencies
showinghighfrequency
Route Waveform
29-Oct-02 11:19:26
RMS = .3837
PK(+/-) = 1.19/1.05
CRESTF= 3.11
10
1.0
0.5
0
-0.5
-1.0
10
-1.5
0
2
3
Revolution Number
Ordr: 1.000
Freq: 13.75
Spec: 3.721
Thesemaybemisseddueto
y
theamplitudeofthe1xpeak
y
CaseStudy7
ThePeakvuedataaboveistakenfromthesamepointasthe
previousdata.
R M S A c c e le ra t io n in G - s
Thisparticularreadingisusinga1000HzHighPassfilter.
This particular reading is using a 1000 Hz High Pass filter.
40 - Preheater Fan
M4425 -F1P Fan Inboard Horz Peakvue
0.7
0.6
Route Spectrum
29-Oct-02
29
Oct 02 11:15:59
(PkVue-HP 1000 Hz)
OVERALL= 1.10 A-DG
RMS = 1.10
LOAD = 100.0
RPM= 830. (13.84 Hz)
>SKF 22240CC
F=BPFO -IO
0.5
0.4
0.3
0.2
01
0.1
Thisisnotnonsynchronous
d
dataandthefrequency
d h f
matchesthatoftheBPFOfor
thebearing.
0
0
10
15
20
25
Frequency in Orders
30
35
40
A c c e le ra t io n in G - s
8
7
Route Waveform
29-Oct-02 11:15:59
(PkVue-HP 1000 Hz)
RMS = 3.31
PK(+) = 7.47
CRESTF= 2.25
DCoff = -3.08
6
5
4
3
2
1
0
0
10
20
30
Revolution Number
40
50
Ordr: 8.176
Freq: 113.14
Spec: .194
Herethedataisshowingthere
H
th d t i h i th
isstresswaveactivityat8.176
orders.
Thewaveformdatais
measuringover7Gsofforce
i
7G ff
asopposetothe1Gfromthe
previousdata.
CaseStudy7 PeakvueonFanBearing
Conclusion
Thereissignificantbearingdamagerelatingtheouterraceof
There is significant bearing damage relating the outer race of
thebearing.
Asthemachinewascriticaltotheprocess,thebearingwas
changedonthenextavailableopportunitythattiedinwith
processrequirements.
Electrical Defects
ElectricalDefects
ElectricalDefects
Electrical Defects
Amotorcanbesimplybrokendownintotwokeycomponents
Rotor
Stator
The stator is stationary

Thestatorisstationary
Consistsofwirewoundincoils
andplacedinslotsofaniron
core.
Thestatorproducesarotating
magneticfield.
The rotor is not stationary

Consists laminations with solid conductors called rotor bars
A circular flow of current through these rotor bars causes
the rotor to become an electromagnet which will rotate in a
magnetic filed.
ElectricalDefects
Electrical Defects SpectralData
Spectral Data
Themostcommonelectricalfrequencythatmaterialisesinthe
spectraldataisthe2xLineFrequency.
For
Formostindustrialapplicationsthelinefrequencyusedtosupply
most industrial applications the line frequency used to supply
motorsis50Hz(Europe).
Thereforethefrequencyofconcernformostelectricalfaultswouldbe
100Hz(2xLf[Lf=linefrequency])
Ex7
0.6
Ex7 - Example 7
Route Spectrum
08-Nov-00 14:27:35
OVERALL= .5613 V-DG
RMS = .5607
LOAD = 100.0
RPM== 2967
RPM
2967. (49
(49.44
44 Hz)
RMS V
Ve loc it y in mm /Se c
0.5
0.4
Thespectralplotis
showing a peak at 100Hz
showingapeakat100Hz
(6000cpm)
2xLf
Thiscanbemistakenfor
misalignment
0.3
0.2
0.1
0
0
500
1000
Frequency in Hz
1500
2000
Freq: 100.00
Ordr: 2.023
Spec: .386
ElectricalDefects
Electrical Defects WaveformData
Waveform Data
Thewaveformdatafroma100Hzpeakwillshowasinusoidal
patternlikethewaveformshownbelow
Ex7
1.5
Ex7 - Example 7
10
1.0
RMS = .5291
LOAD = 100.0
RPM= 2967. (49.44 Hz)
0.5
Ve loc it y in m m /Se c
Againthistypeofpattern
can be associated with
canbeassociatedwith
misalignment.
Route Waveform
08-Nov-00 14:27:35
PK(+) = 1.50
PK(-) = 1.77
CRESTF= 3.31
-0.5
-1.0
-1.5
-2.0
0
3
Revolution Number
Usuallymisalignmentwould
producehigherforce(Higher
waveformlevels)thanthose
fromelectricaldefectsdueto
the stress being applied to
thestressbeingappliedto
themachine
ElectricalDefects
Electrical Defects Causes
Commonfaulttypesthatcanproducethe2xLfpeakareas
follows:
DynamicEccentricity UsuallyRotorRelated
StaticEccentricity UsuallyStatorRelated
LooseIronorSlotDefect RotororStator
OpenorShortedWindings
InsulationBreakdownorImbalancedPhase
I l i B kd
I b l
d Ph
LooseConnectors
ElectricalDefects Peakvue
Peakvuedataalsoshowselectricaldefectsatthe2xLfpeak.
Thismaybeduetotherotororstatorbowing;duetoheatbuildup.
y
g
p
Thespectralplotbelowisindicatinga100Hzpeakusing
Peakvuewitha1000Hzfilter.
CaseStudy
Case Study ElectricalDefect
Electrical Defect
Thefollowingcasestudywastakenfromaglassmanufacturer.
ThedatawasfromtheElectricFrontWallCoolingFan.
This
Thisfanunitisacriticalfantotheprocessandhasnostandbyunit.
fan unit is a critical fan to the process and has no standby unit.
Inthisparticularinstancethemotorfailedshortlyafterthedatawas
collected.
ThePeakvuedatatakenon
themotornondriveendis
showing a dominant 100Hz
showingadominant100Hz
peak.
Thisfrequencyisat2xLfand
isassociatedwithelectrical
problems
CaseStudy
Case Study ElectricalDefect
Electrical Defect
Themultiplotaboveshowsthesamemeasurementpoint
goingbackoverthelast5routereadings.
Thisparticularplotisusefulfordeterminingrateofchange.
This particular plot is useful for determining rate of change.
Itisquiteclearhowthisparticularfrequencysuddenlyappeared
Conclusion
As
Asthemotorfailedshortlyafter
the motor failed shortly after
datacollectionnoactionwas
takentopreventfailure.
Theinvestigationinthemotor
showedoneoftheconnectorshad
comeloosecausingthemotorto
burnout.
Belt Defects
BeltDefects
VBelts
V
Belts
TimingBelts
BeltDefects
Belt Defects
Beltsarethemostcommonlowcostwaytotransmitpower
fromoneshafttoanother.
Beltdrivesrelyonfrictionbetweenthebeltandpulleytotransmit
powerbetweendriveanddrivenshafts
The ability of belt to transmit power depends upon

Theabilityofbelttotransmitpowerdependsupon
1.
2.
3.
4.
BeltTension(tensiononthebeltholdsittightlyagainstthesheave)
Frictionbetweenthebeltandsheave
Thearcofcontactbetweenthebeltandsheave(Wrap)
Thespeedofthebelt
However,beltscanbeeasilydamagedbyheat,oiland
greaseandsincebeltsslipwithinthesheavestheycannot
b
beusedwhereexactspeedchangesarerequired(exceptfor
d h
t
d h
i d(
tf
timingbelts)
BeltDefects
Belt Defects
Beltdefectscanbeconsiderednoncriticalfaultsbymany
maintenancegroupsduetotherelativeeaseofreplacement
requiringminimumdowntime.
equ g
u do t e
Butbeltdefectsareamajorcontributortotheoverallvibrationofthe
machineresultinginprematurefailureofothermachinecomponents.
Sourcesofbeltdrivedefects
Poor Maintenance
Enviromental Factors
Poor Installation
Poor Design
g
Other Defects
BeltDefects
Belt Defects BeltTypes
Belt Types
Therearemanydifferenttypesofbeltdrivesystems.This
sectioncoversthemostcommonlyusedtypesofbeltin
industrytoday.
dust y today
VBelts
Vbeltsarethemostcommontypeofbeltsused.TheyareVshapedin
crosssection
cross
section,thisallowingthebelttowedgeagainstthesideofthe
this allowing the belt to wedge against the side of the
sheave.
Thisdesignallowsthebelttoberunfasterthanmostothertypeofbelt
applicationswithpowertransmissionefficienciesashighas95%
BeltDefects
TimingBelts
Theseareflatbeltswithequallyspacedteeththatmesh
These are flat belts with equally spaced teeth that mesh
withnotchesonthepulley.Timingbeltsaredifferentfrom
otherbeltdrivesastheydonotinduceanyslip.
M
Mostcommonlyusedwhereconstantvelocityandstricttiming
l
d h
l i
d i i i
applicationisrequired.
BeltDefects
Belt Defects FaultCharacteristics
Fault Characteristics
Beltdefects,suchascracks,brokenormissingpieces,hardand
softspotscangeneratevibrationattheturningspeedofthe
belt(1xbelt)andharmonics
Duetothelengthofthebeltinrelationtothepulleys(sheaves)the
1xbelt frequency is subsynchronous
1xbeltfrequencyissub
synchronous andveryoftenthe2xbelt
and very often the 2xbelt
frequencymaybesubsynchronousaswell
Thepredominantharmonicistypicallythe2xBeltfrequency
andcanbeseenintheradialplaininlinewiththebelts.
Severityisjudgedbythenumberandamplitudeoftheharmonics
seeninthespectraldata
BeltDefects
Belt Defects FaultCharacteristics
Fault Characteristics
Justliketwomatingshafts,beltdrivesystemscanalsobe
misalignedinbothangularandoffsetdirections.
When
Whenmisalignmentisinducedintoabeltdrivesystemthenthelifeof
misalignment is induced into a belt drive system then the life of
thebeltissignificantlyreducedaswellastheoverallvibrationofthe
systemincreases.
Offset Misalignment
Angular Misalignment
Pulleymisalignmentresultsinhighaxialvibration atthe
shaftturningspeed.
If
Ifthebeltisalsodefectedthen1xbeltfrequencyandharmonicsmay
the belt is also defected then 1xbelt frequency and harmonics may
alsoshowintheaxialdirection
BeltDefects
Belt Defects Calculations
Calculations
Thefundamentalbeltfrequencycanbecalculatedusingthe
followingequation:
BeltFreq.=(3.142*PulleyTs*PulleyPCD)
Belt(Length)
Where:
Ts=TurningSpeed
PCD=PitchCircleDiameter
Note: ThePCDandbeltlengthmustbeinthesameunits
Atimingwillbeltwillalsohaveaspecificfrequencyrelatedto
thenumberofteethonthepulley
TimingBeltFreq.=(PulleyTs)*(#PulleyTeeth)
BeltDefects
Belt Defects CalculationExample
Calculation Example
BeltFrequencyCalculation
Belt Frequency =(3.142
BeltFrequency
(3.142 *1480
1480 *300)/(2000)
300) / (2000)
BeltFrequency=(1395048)/(2000)
BeltFrequency=697.524CPM
Thisissubsynchronoustothe1xTsofthepulley
Motor RPM
Pulley Diameter
Belt Length
= 1480 RPM
= 300 mm
= 2000mm
BeltDefects
Belt Defects SpectralData
Spectral Data
ThespectraldataaboveisdatatakenofamotorfromanAir
HandlingUnit.
The
Thefrequencyhighlightedbytheprimarycursorisshowingthe1xTsof
frequency highlighted by the primary cursor is showing the 1xTs of
themotor(1Order)
1 x Belt Frequency
showing with harmonics
Dominant 2 x Belt
Frequency
Therearealotofsub
synchronouspeaksshowingin
this data
thisdata.
Thefirstpeakisthe
fundamentalfrequencyofthe
beltrotation.
Thesecondpeakisthe2xbelt
The second peak is the 2xbelt
frequencysuggestingthereis
damagetothebelt
Astheharmonicsofthebelt
increaseinnumberthey
surpass the 1xTs of the motor
surpassthe1xTsofthemotor
andinthiscasethethird
harmonicbecomesnon
synchronousdata.
CaseStudy9
Case Study 9 BeltDefect
Belt Defect
ThefollowingdatawastakenonanAirHandlingUnit.TheAir
HandlingUnitisasupplyfanfromsharedservices.Thisisa
sta d a o e u t t o sta d by capab ty
standaloneunitwithnostandbycapability
BL31 - 559 AHU Supply
559S
0.5
J
Route Spectrum*
22-Feb-05 13:53:33
OVERALL= 1.22 V-DG

RMS = .7701
LOAD = 100.0
RPM = 1272. (21.21 Hz)
0.4
>Belt Freqs
J=Belt 1 Freq
0.2
0.1
x - Fa n spee d
0.3
X - M ot or s p e e d
RM S Ve loc ity in mm /Sec
0
0
4000
8000
Frequency in CPM
Label: Belt defect/worn belts & sheaves
12000
16000
Freq:
q 835.69
Ordr:
.657
Spec: .04393
Thedatashowsthe
motorturningspeed
t t i
d
alongwithasub
synchronouspeakof
thebeltfrequency.
The primary cursor is
Theprimarycursoris
highlightingthe1xbelt
withseveral
harmonics.
The 2xbelt is very
The2xbeltisvery
dominantsuggesting
thereisdamagetothe
belts.
CaseStudy9
Case Study 9 BeltDefect
Belt Defect
Asthisisacriticalmachineitwasrecommendedonthenext
availableopportunitythatthebeltsneededtobecheckedfor
da age a d e a g ed
damageandrealigned.
Themachinewasstoppedandthebeltswereinspectedbaseduponthe
recommendation.
Significantdamagewasfoundtoseveralofthebeltsduringthis
inspectionaswellaswornpulleys.Boththebeltsandpulleyswere
replacedandcorrectlyalignedbeforerestartingthemachine.
Resonance
Resonance
Resonanceisdefinedas:
An excitationofanaturalfrequencybyaperiodicforcing
excitation of a natural frequency by a periodic forcing
function.
All assetscontainnaturalfrequenciesthatvarydepending
uponthestiffnessandmass.
Resonance
Resonancecanbeconsideredtobeavibrationamplifier,thattakesthe
can be considered to be a vibration amplifier that takes the
forceleveloftheperiodicforcingfunctionandamplifiesit;which
significantlyincreasesthemovementoftheasset.
If Vibration is a Fire The Resonance is a Fuel

IfVibrationisaFire,TheResonanceisaFuel
ExampleofResonance
Example of Resonance
Theexampleshownrepresentstheeffectonamplitudeoftheforcing
functionwheninresonance.
Inplot1the1xtsisrunningbelowthenaturalfrequency(Fn).
Fncanbeseeninplot2.
Plot3showstheincreaseinamplitudeoftheforcingfunctionwhenrunatthe
naturalfrequency
t lf
thi i
thisisresonance
Before Excitation
1
Frequency
Resonance Curve
Frequency
Amplified Signal
3
Frequency
Resonance
Therearetwofactorsthatdeterminethenaturalfrequencyof
anassettheseare;
1. Mass Theheavieranobjectthelowerthenaturalfrequency
2. Stiffness Themorerigidastructurethehigherthenaturalfrequency
Resonanceisbecomingmoreofaprobleminindustryin
ece t yea s due to
recentyearsdueto:
Olderequipmenthavingtorunfastertomeetcurrentproduction
demands(oftenabovewhatitwasdesignedfor)
Equipmentisbeingbuiltcheaperandlighter
Thisisresultinginamplificationoftheforcingfunction
creatingexcessivemachinemovementresultingpremature
machinefailure.
EffectsofResonance
TheODSdataisshowingasteelframestructuredeflectingat
onecornerintheverticaldirectionduetoaresonant
co d t o
condition.
CharacteristicsofResonance
Characteristics of Resonance
CharacteristicsofResonance
Resonanceisverydirectionalinnature(Movementmaybegreaterin
y
(
y g
oneplainthantheother)
Vastlydifferentamplitudesoftheforcingfunctionfromonedirection
totheother(betweenHorizontalandVertical Ruleofthumbratiois
3:1difference)
Resonanceisveryspeedsensitive(smallchangesinspeedcanshow
largedifferencesinamplitudeoftheforcingfunction)
Resonancecanoccuratanyfrequencybutmostcommonlyassociated
withthe1xTs
ResolvingaResonance
Resolving a Resonance
Thereareanumberofalterationstothesystemthatcanbe
madetoresolvearesonancecondition.
Howeverifstructuralchangesaretobemadeyouneedtobecareful
youdontexciteanothernaturalfrequencyoncethechangehasbeen
made?
Onceyouaresureyouhavearesonantconditionitcanbe
correctedbyoneofthefollowingmethods:
ChangetheMass
Ch
th M
ChangetheStiffness
Removetheforcingfunction
Dampenthestructure
Dampeningisamethodusedtoconvertmechanicalenergyinto
thermalenergy.Itdoesnotremovetheresonantconditiononly
gy
y
controlstheamountofmovement.
Resonance
Resonance SpectralData
Spectral Data
Thespectrumisshowingthe1xTspeakofthemotorwithamplitudes
reaching19mm/sec.
Thisishighforthe1xTs.
VeryoftenthistypeofdatacanbemistakenforImbalanceasthisdefect
canalsoproduceahigh1xTspeak.
HoweverImbalanceisacentrifugalforceandshouldshowsimilaramplitudesin
bothradialplainswhereasresonanceisverydirectional.
40 - No 1 GCTCompressor
M4551 -M2H Motor Inboard Horizontal
27
Route Spectrum
13-Feb-03 10:14:46
24
OVERALL= 19.95 V-DG
RMS = 19.85
LOAD = 100.0
RPM= 1484. (24.73 Hz)
R M S Ve loc it y in m m /Se c
21
18
15
Inordertohelpresolvethisissue
weneedtochecktheamplitude
ofthe1xTs90degreestothis
point(horizontaltovertical)
Thiscaneasilybedonebyusing
themultipointplot inthe
software
12
0
0
500
1000
Frequency in Hz
1500
2000
Freq: 24.72
Ordr: 1.000
Spec: 19.50
Resonance
Resonance MultiPlot
Multi Plot
Themultipointplotallowstheanalysttodisplayseveralmeasurement
pointsonthesameplot.Hereweareshowingalltheradialpointsfromthe
motor.
motor
Itisveryclearthattheamplitudesofthe1xTspeakareexcessiveinthe
horizontaldirectionwhencomparedtothevertical.Thisisacharacteristicofa
resonantcondition.
40 - No 1 GCTCompressor
GCTCompressor
M4551
- Multiple Points (13-Feb-03)
24
20
Max Amp
22.0
16
12
8
R M S Vee lo c it y in m m /S e c
4
0
M2V 10:15
M2H 10:14
M1V 10:14
Point= M2H
13-Feb-03
10:14:46
RPM= 1484.
M1H 10:14
0
500
1000
Frequency in Hz
1500
2000
Freq:
Ordr:
Sp 3:
25.00
1.011
19.35
CaseStudy10
Case Study 10 Resonance
Thefollowingcasestudyistakenfromamotoranda
reciprocatingcompressor.Theunitismountedonasteelframe
which,inturnsitsonspringmountsdesignedfordampening
c , tu s ts o sp g ou ts des g ed o da pe g
Recentlythemotorhadbeenreplacedduetobearing
defect; however the new motor was smaller and lighter but
defect;howeverthenewmotorwassmallerandlighterbut
deliveredthesamepowerasthepreviousmotor.
Whenthecompressorwasputbackintoserviceitwas
notedtherewasexcessivevibrationcomingfromtheunit.
Theunitwaslefttorunlikethisforseveralmonthsuntilthe
vibration became to excessive
vibrationbecametoexcessive.
CaseStudy10
Datawastakenacrosstheunitusingroutebaseddata
collection.
CP1
60
SL - Compressor
Route Spectrum
02-Feb-04 15:09:54
OVERALL= 45.58 V-DG
PK = 45.32
LOAD = 100.0
RPM= 1490. (24.83 Hz)
PK Velocity in mm/Sec
P
50
40
30
20
10
0
0
300
600
900
Frequency in Hz
1200
1500
1800
Freq:
Ordr:
Spec:
24.83
1.000
45.19
Theplotaboveistakenfromthemotorshowinga1xTspeak
in excess of 40mm/sec
inexcessof40mm/sec.
CaseStudy10
Thisdataisveryhighinamplitude.
Thedatawasthendisplayedinamultiplotformattoshow
The data was then displayed in a multi plot format to show
howtheamplitudewasacrosstheradialplains.
Duetothevastlydifferentamplitudesatthe1xTsfrequency
thedefectonthismotorwasResonance.
CP1
SL - Compressor
- Multiple Points (02-Feb-04)
50
Max Amp
44.1
40
30
PK V elo ccity in m m /Sec
Amplitude differences between radial plains
20
10
0
M2H 15:26
M2V 15:26
0
4000
8000
Frequency in CPM
12000
16000
CaseStudy10
Recommendation
Itwasdeterminedthatthechangeinmotorsizemaybethe
It was determined that the change in motor size may be the
causeoftheresonanceasthemasshadbeenaltered.Avisual
inspectionoftheframeworkalsorevealedthatoneofthe
support beams had cracked along the weld thisalteringthe
supportbeamshadcrackedalongtheweld
this altering the
stiffnessofthestructure.Thesupportwasweldedand
strengthenedandmoredatawasacquiredtodetermineifany
effectontheresonancehadoccurred.
CaseStudy10
Thespectra,showstheBeforeandAfterplotofthemotor
inboardhorizontal.Itshowsasignificantdropinamplitudeof
the1xTspeak.
Bystiffeningthestructurethenaturalfrequencyhadincreasedmoving
it away from the 1xTs peak thus resulting in a significant drop in
itawayfromthe1xTspeakthusresultinginasignificantdropin
amplitude.
CP1
SL - Compressor
50
Max Amp
44.1
40
PK Ve lo c it y in m m /Se c
30
20
10
0
07-May-04
10:08:05
02-Feb-04
15:26:38
0
1000
2000
Frequency in Hz
3000
4000
SummaryofFaults
Summary of Faults
Belt
Frequency
Misalignmeent
Electrical
Imbalance
Resonance
Looseness
Electrical
Advanced Bearing
Wear
Lower Gearmesh
G
Severe
Frequencies
Misalignment
Severe Looseness
c c
Early Bearing Wear

Gearmesh Frequency
Electrical Slot Pass Frequency
c c c
F re q u e n c y
In T e rm s
Of RPM
M o s t L ik e ly C a u s e s
1 x RPM
U n b a la n c e
2 x RPM
M e c h a n ic a l
Loosenes s
3 x RPM
M is a lig n m e n t
Le s s th a n
1 x RPM
O il W h irl (le s s
t h a n 1/ 2 R P M
S y n c h ro n o u s
(A . C . L in e
F re q u e n c y )
2 x S ynch.
F re q u e n c y
M a n y T im
i es RP M
(H a rm o n ic a lly
R e la t e d F re q . )
E le c t ric a l
P ro b le m s
T o rq u e P u ls e s
B a d G e a rs
A e ro d y n a m ic F o rc e s
H y d ra u lic F o rc e s
M e c h a n ic a l L o o s e n e s s
R e c ip ro c a t in g F o rc e s
H ig h F re q u e n c y
B a d A n t ii-F
F ric t io n
(N o t H a rm o n ic a lly B e a rin g s
R e la t e d )
O t h e r P o s s ib le C a u s e s & R e m a rk s
1 ) E c c e n t ric jo u rn a ls , g e a rs o r p u lle y s
2 ) M is a lig n m e n t o r b e n t s h a ft - If h ig h a x ia l vib ra t io n
3 ) B a d B e lt s - If R P M o f b e lt
4) Res onanc e
p ro c a t in g fo rc e s
5 ) R e c ip
6 ) E le c t ric a l p ro b le m s
7) Loosenes s
8 ) D is t o rt io n - s o ft fe e t o r p ip in g s t ra in
1 ) M is a lig n m e n t - if h ig h a x ia l vib ra t io n
2 ) R e c ip ro c a t in g fo rc e s
3) Res onanc e
4 ) B a d b e lt s - if 2 x R P M o f b e lt
U s u a lly a c o m b in a t io n o f m is a lig n m e n t a n d e x c e s s ive a x ia l
c le a ra n c e s (lo o s e n e s s ).
1 ) B a d d rive b e lt s
2 ) B a c k g ro u n d vib ra t io n
3 ) S u b -h a rm o n ic re s o n a n c e
4 ) " B e a t " V ib ra t io n
C o m m o n e le c t ric a l p ro b le m s in c lu d e b ro k e n ro t o r b a rs , e c c e n t ric
ro t o r u n b a la n c e d p h a s e s in p o ly -p h a s e s y s t e m s , u n e q u a l
a ir g a p .
R a re a s a p ro b le m u n le s s re s o n a n c e is e x c it e d
G e a r t e e t h t im
i es RP M of bad gear
N u m b e r o f fa n b la d e s t im e s R P M
N u m b e r o f im p e lle r va n e s t im e s R P M
M a y o c c u r a t 2 , 3 , 4 a n d s o m e t im e s h ig h e r h a rm o n ic s if
s e ve re lo o s e n e s s
1 ) B e a rin g vib ra t io n m a y b e u n s t e a d y - a m p lit u d e a n d fre q u e n c y
2 ) C a vit a t io n , re c irc u la t io n a n d flo w t u rb u le n c e c a u s e ra n d o m ,
h ig h fre q u e n c y vib ra t io n
3 ) Im p ro p e r lu b ric a t io n o f jo u rn a l b e a rin g s
(F ric t io n e x c it e d vib ra t io n )
4 ) R u b b in g
UsefulReferences
SimplifiedHandbookofVibrationAnalysisVolume1 Arthur
R.Crawford
SimplifiedHandbookofVibrationAnalysisVolume2 Arthur
R.Crawford
BSISO1337312002 ConditionMonitoringandDiagnostics
ofMachines GeneralProcedures
BS ISO 133732
BSISO13373
2 ConditionMonitoringandDiagnosticsof
Condition Monitoring and Diagnostics of
Machines Processing,PresentationandAnalysisofVibration
Data

Vibration Analysis Level I Course Guide

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WarmestWelcometoVibration

Collaborate all data into one single report

2. Use Relative Vibration Levels

medium sized machines

radial, axial, mixed flow

medium sized machines

radial, axial, mixed flow

unrestricted long-term operation

restricted long-term operation

Velociity mm//s RMS

ISO2372 ( BS 4675 , VDI 2056 )

When a forcing function is applied

This motion is called a

Amplitude versus Time

How the Vibration Spectrum is Created

The most common industrial applications are:

Low frequencies require very

the objects move with the

Label: Large Fan Unit - Easy

Motor Turning Speed = 1500RPM

Here the primary cursor is at 1

Energy in the Spectrum

RMS Velocity in mm/Sec

Examples of synchronous energy:

OVRALL= 2.63 V-DG

RMS Velocity in mm/Sec

Label: Outer Race Defect

Examples of non-synchronous energy:

Multiples of belt frequency

Other Machine Speeds

OVRALL= 2.63 V-DG

Label: Outer Race Defect

The second spectrum

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

Clarity of the spectral

Label: Outer Race Defect

Hz (CPS), CPM, Orders

A measurement point is determined by three characters

M1H Motor Outboard Horizontal

P1H Pump Inboard Horizontal

RMS Velocity in mm//Sec

OVRALL= 4.58 V-DG

-- Baseline -Value: 3.063

Imbalance Problem Practical

RMS Velocity in mm/Sec

TRF B m/c -F2V

TRF B m/c -F2H

TRF B m/c -F1V

TRF B m/c -F1H

More commonly seen A combination of the above

OVRALL= 6.50 V-DG

OVERALL= 6.33 V-DG

ST.1 - Raw Water Pump

In addition to the misalignment the excessive forces

OVRALL= 2.47 V-DG

Amplitude - Mixed Units

Component looseness generally occurs when there is

40 - Kiln Main Drive

RMS Velocity in mm/Sec

The raised noise level around

This would be the likely cause

40 - Kiln Main Drive