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Vibration Analysis
Theory and
Practice
An overview of…
Various Maintenance Methods
¾ Breakdown
¾ Preventive
¾ Predictive
¾ Reliability centered (Proactive)
Vibration analysis
¾ What is machine vibration
¾ Measuring and analyzing vibration
¾ The BIG 4
Why do machines stop running?
Component failures:
¾ Failed bearings
¾ Broken fan blades
¾ Seized couplings
¾ And the list goes on…
Why Question Existing
Maintenance Practices?
Minimize failures:
¾ Balance and align machines
¾ Improved maintenance practices
¾ Clean lubricants
Disadvantages:
¾ Secondary costs of failure (10X$)
¾ High downtime
¾ Large spare parts inventory
¾ Worker safety issues
Preventive Maintenance
Advantages:
¾ No surprise downtime
¾ No unexpected failures
¾ No secondary damage
¾ All maintenance is planned
¾ Sounds great!
Proactive Maintenance
“Fix it once, fix it right!”
¾ Also known as “reliability centered maintenance” and
“precision maintenance”
¾ Change machine design, purchasing and maintenance procedures to
reduce failures and increase machine reliability
¾ Precision balancing, laser alignment, etc.
What technology is available
Condition monitoring:
¾ Vibration analysis
¾ Oil analysis
¾ Wear particle analysis
¾ Thermography
¾ Ultrasound
¾ Steam Trap
Which Technology to use?
Infrared Thermography
15%
Ultrasonic 10%
5% 45%
Motor Current
Vibration Analysis
10%
15% %
Steam Trap
Oil
Period = 1/Frequency
Fan speed = 5 Hz or 300 RPM
Increase the Frequency
¾ The fan is now going twice as
fast.
¾ Fan speed = 10 Hz or
600 RPM
The ‘Amplitude’
Rub Imbalance
New vibration = 10 x 8 = 80 Hz
8 blades x 10 revolutions/second
The ‘Spectrum’
Spectrum - Examples
5 Hz = 300 RPM
5 Hz
FFT
10 Hz = 600 RPM
10 Hz
FFT
A More Complex Spectrum
Rub Imbalance
10 Hz
FFT
80 Hz
Bearing faults
Looseness
The Big 4
¾ Imbalance
¾ Misalignment
¾ Looseness
¾ Faulty Bearings
Imbalance
What causes “Imbalance”?
¾ A heavy spot along the shaft
¾ Causes high vibration and premature bearing failure
¾ Your vbSeries data collector can correct imbalance
Misalignment
What is “Misalignment”?
¾ Definition: “The shaft center-lines are not collinear”
¾ Can be detected in vibration signature
¾ Corrected with dial indicators and lasers
¾ Also cause of high vibration, and thus bearing damage
Looseness
¾ Rotating looseness
- excessive clearance
between rotation &
stationary parts
6204 BPFO
Aux Comp C7 - Mntg Base #1 - Vertical - Acc Time 800 ms
17/08/1999 14:02:15
O/All 2.235 m/s/s rms
1.6
1.2
resonates. 1
m/s/s rms
0.8
6204 BPFO
0.6
6204 BPFO
6204 BPFO
6204 BPFO
0.4
0.2
April 26
Where do I mount the Sensor?
¾ The sensor is
commonly attached
using a magnet.
Mounting the sensor
¾ Proper mounting
is very important.
¾ “Repeatability” is
essential.
¾ Good “mechanical
transmission path”
from the bearing.
Repeatability
¾ Vibration changes
when the speed and
load change.
1.2
0.8
m/s/s rms
0.6
0.4
0.2
15
10
-5
-10
m/s/s rms
-15
0 10 20 30 40 50 60 70 80 90 100
ms
6/03/2000 12:27:05 O/All 5.982 m/s/s rms <set RPM> <add note>
0.01
0.005
peak-peak
-0.005
mm peak-
-0.01
-0.015
3.5
2.5
mm/s rms
1.5
0.5
0
12/06/1998 1:28:20 10/07/1998 1:32:32 14/08/1998 1:23:53 11/09/1998 1:25:20
Velocity
What does it mean…..?
®
¾ ASCENT® removes the
guesswork.
Reality Check!
Predictive maintenance:
¾ Monitoring machines regularly with
repeatable results requires discipline
¾ Not all machines can be monitored
¾ Some machines cannot be monitored
frequently enough
¾ Technologies are not perfect
¾ Recommendations are not always followed
¾ Some machines will still fail until analysis
experience grows
Normal Fatigue
Infant
Service Life & Failure
Probability of Failure Mortality
Time