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Fundamentals of Machine Condition Exam

SKF Reliability Maintenance Institute

Name:

Company/Plant:

Date:

1. Velocity, for vibration purposes, is usually measured as ______________________.

a) microns (mils)
b) mm/sec (in./sec (ips)
c) g's
d) kilometers per hour (kph)

2. Displacement, for vibration measurement purposes, can be defined as the total


movement of a vibrating system. In practical terms, vibration displacement is a
measurement of ____________________.

a) speed
b) frequency
c) distance
d) fatigue

3. Acceleration is defined as the change in velocity with respect to time. Which of the
following is most commonly used to describe vibration acceleration measurements?

a) g’s broadband
b) g’s peak
c) g’s peak-to-peak
d) g’s average

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4. Displacement vibration measurements are usually measured in microns (thousandths
of an inch, or mils in imperial units). In the following diagram, the sine wave
represents the displacement time waveform. Identify the parameter used to define the
correct displacement amplitude scaling.

a) sinusoidal interpolation
b) rms
c) peak
d) peak-to-peak

5. Which is the most common amplitude measurement unit for general-purpose


vibration readings on machines that run at speeds between 1000 and 5000 RPM?

a) displacement
b) velocity
c) acceleration
d) cycles per second

6. For which of the following would acceleration measurement units be most suited?

a) slow turning paper machine rolls


b) high frequency gearmesh vibration
c) shaft eccentricity on multi-stage pump
d) oil whirl in a steam turbine

7. The vibration unit of acceleration can be measured across a wide frequency range.
However, for machinery vibration purposes, which one of the following frequency
ranges would be most appropriate for acceleration readings?

a) 60,000 CPM (1,000 Hz) and above


b) 60 to 60,000 CPM (1 to 1,000 Hz)
c) 600 to 60,000 CPM (10 to 1,000 Hz)
d) 60 to 1,000 CPM (1 to 16.67 Hz)

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8. For sinusoidal vibration, such as the vibration due to unbalance, the relationship between
velocity and displacement at running speed is a function of the ___________.

a) mass unbalance force


b) frequency / speed of the vibration
c) damping
d) radius of the unbalance weight
e) size of the unbalance weight

9. Two machines sit side-by-side in a plant. Machine A has a running speed of 600
RPM and machine B operates at 3585 RPM. The latest vibration readings from both
machines show that they both have the same vibration velocity of 8 mm/sec (0.28
inches per second) at their respective running speeds. Machine A has a spectrum
peak of 8 mm/sec (0.28 inches per second) at 600 CPM and machine B has a peak of
8 mm/sec (0.28 inches per second) at 3585 CPM. Given these conditions, the 600-
RPM machine will have considerably higher ____________ than the machine
running at 3585 RPM.

a) displacement
b) acceleration
c) maintenance costs
d) integration multiples

10. The vibration of a fan is 25 mm/sec peak (1.0 inches per second peak) at its running
speed. To compare this value to a vibration acceptance specification listed in RMS
velocity, the peak value must be ____________.

a) multiplied by 0.707
b) divided by 0.707
c) multiplied by 1.414
d) squared.

11. Vibration readings are to be taken on a large slow-speed fan using an accelerometer. To
display the vibration in units of displacement, the data from the accelerometer would be
__________________.

a) differentiated
b) double integrated
c) squared and then summed
d) artificially digitized

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12. If vibration on a 600-RPM fan is measured with an accelerometer, what error is most
often encountered when viewing the vibration spectrum if the signal is converted to
displacement units?

a) a very large amplitude error at low frequencies in the spectrum (a ski slope)
b) very low spectrum amplitudes at the lower frequencies with sidebands at the
accelerometer’s resonant frequency
c) very high amplitudes at higher frequencies with evenly spaced harmonics
d) running speed frequencies are miscalculated due to the bandwidth factor and
aliasing effects

13. A vibration-based condition monitoring program will __________________.

a) increase machine availability


b) eliminate all failures
c) eliminate the need for other routine inspections
d) eliminate all run-to-failure maintenance practices

14. It is generally accepted that collecting only overall vibration readings will detect 80%
of machinery faults or defects. To improve the overall effectiveness of defect/fault
detection, what additional reading or measurement type should be acquired?

a) date and time


b) exponential decay
c) environmental emissivity
d) vibration spectra

15. Condition monitoring is a process of evaluating the health or condition of machines


to help make timely maintenance decisions. Condition monitoring is based
____________________.

a) strictly on vibration analysis


b) on any measurement that indicates the health of the machine
c) on unproven technologies
d) solely on the evaluation of the metallic particles in lube oil samples

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16. A velocity spectrum with 400 lines of resolution and a frequency span of 0 (zero) to
120,000 CPM (2000 Hz) is acquired with an accelerometer on a machine running at
2950 RPM. What is a recommended low frequency cutoff setting to minimize
possible integration errors without limiting the ability to properly analyze or diagnose
machinery problems?

a) 0 CPM
b) .3 times 120,000 CPM
c) .5 times shaft speed
d) .3 times shaft speed

17. The spectrum RMS, sum, or normal averaging function (depending on the make and
model of the vibration instrument) in a data collection instrument is used to
___________________________.

a) remove noise or spurious signals from readings


b) minimize data collection time
c) better view beat information
d) normalize the digitization rate

18. Vibration spectra were originally collected from 0 to 60,000 CPM (0 to 1000 Hz)
with 400 lines of resolution. With all other data collection parameters remaining the
same, increasing the frequency range to 0 to 120,000 CPM (0 to 2000 Hz) will
________________________.

a) increase the amount of time to acquire the reading


b) require a different transducer
c) decrease the amount of time to acquire the reading
d) require more data collector memory

19. To improve the frequency resolution of a spectrum used to analyze a machine


problem, the number of lines of resolution (spectrum lines) was increased from 400
lines to 3200 lines. The frequency range is 0 to 6,000 CPM (0 to 100 Hz). What
affect will the increase in the number of lines have on the measurement?

a) the frequency range will increase by a factor of eight


b) the data acquisition time will be reduced by a factor of eight
c) the data acquisition time will increase by a factor of eight
d) the analog to digital sampling rate will increase
e) there will be no noticeable change

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20. Windows are used in a spectrum analyzer to correct and/or minimize digital sampling
errors. For general vibration data collection for condition monitoring, the
__________ window provides the best compromise of frequency and amplitude
accuracy and is therefore the most common window used.

a) Kaiser-Bessel
b) Cosine^4
c) Hanning
d) Flat top
.

21. The dynamic range of a data collector refers to the _________________________.

a) maximum frequency range for acceleration readings


b) ratio of the maximum to minimum amplitudes the instrument can read for a
given input setting
c) full scale amplitude reading
d) maximum input voltage

22. To obtain a vibration reading with the least amount of noise in the least amount of
time, how many spectrum averages should be selected?

a) 0 to 1
b) 4 to 8
c) 128 to 256
d) 1024 to 2048

23. A peak in a velocity spectrum appears to be a multiple of the running speed of the
motor. Which of the following techniques would be used to determine if the
frequency is related to shaft speed?

a) switching to displacement units


b) orbit analysis of sub synchronous harmonics
c) RMS averaging with a high pass filter set above running speed
d) synchronous time averaging
e) cannot be determined

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24. A large ski slop is observed on a velocity vibration spectrum. The peak at running speed
is in the middle of the ski-slope. The amplitude measured at this peak will be ______ .

a. correct, the ski slope correction factor is applied automatically


b. correct, ski slope only affects the very high frequency values
c. incorrect, the data within the ski slope is often artificially amplified due to
the error
d. incorrect, the data within the ski slope is suppressed

25. If an analyzer has the capability of simultaneously analyzing signals of 5.0 volts
down to 0.5 millivolts (0.005 volts), what is the dynamic range of the analyzer in dB?

a) 28
b) 74
c) 80
d) 88

26. A measurement point on a machine route shows abnormally high vibration over the
previous measurement. The machine does not physically feel or look like its
vibration is abnormal. What would NOT be a cause of the increase in vibration?

a) Fast Fourier Transform algorithm error


b) incorrect transducer mounting method
c) broken cable or connection
d) measurement not taken at the same location

27. Trends of the overall vibration on a pump show large amplitude changes in the
monthly velocity readings. Which of the following is the least likely to have
produced the variation in the readings?

a) the person who collected the readings


b) pump flow rates
c) transducer mounting locations
d) analog to digital drift in the data collector
e) product grade

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28. For repeatable trend information in a condition monitoring database, data should be
collected __________________________________.

a) only during day shift


b) at the point of highest vibration
c) at well-defined measurement locations
d) when the machine is not running

29. An advantage of a walk-around data collection system is


_________________________ .

a) the exercise
b) the physical observations that can be made at the machine site
c) a walk-around system is cheaper than an on-line system
d) they provide instantaneous and continuous data for emergency shutdowns

30. When determining how frequently data should be collected on a machine with rolling
element bearings, which of the following is the most important consideration?

a) manufacturer’s recommendation
b) machine history
c) a calendar
d) the direction of shaft rotation

31. Vibration-based condition monitoring involves the routine collection of vibration


readings on machinery. In turn, these readings are compared to pre-defined exception
conditions (also referred to as alarm limits). One method of setting effective alarm
limits is __________________________________.

a) setting the alarm values so low that the machine never fails
b) government regulations
c) creating vibration alarms configured for the specific machine based on
history
d) setting an absolute vibration limit of 8 mm/sec (0.3 inches per second) for
all machines

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32. Two alarm or exception levels are usually established for the overall vibration
readings acquired on a machine. What is the first step that should be taken when one
of the lower level alarms is exceeded?

a) perform a diagnosis to determine the fault and source


b) perform a time-to-failure calculation
c) increase in the alarm setting
d) reduce the alarm setting
e) check the data to ensure it is valid

33. In vibration analysis, frequency is _________________________.

a) how often a machine fails


b) the number of cycles of vibration occurring over a defined period of time
c) a measure of the amplitude of the vibration
d) used interchangeably with "period"

34. Vibration is said to be periodic if it _______________________________.

a) occurs during one cycle


b) occurs randomly
c) does not repeat in a given time span
d) repeats itself at equally spaced time intervals

35. If a spectrum is collected with a frequency range of 0 to 36,000 CPM (0 to 600 Hz.) and
1,600 lines of resolution, what is the frequency resolution?

a) 22.5 CPM
b) 22.5 Hz
c) .001 inches per second
d) 82 db

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36. If a spectrum measurement has a frequency range of 0 to 100,000 CPM (0 to 1667 Hz.),
how many spectrum lines are required for a frequency resolution of 125 CPM?

a) 100
b) 400
c) 800
d) 3,200

37. Frequency, for vibration measurements, is often stated in Hertz (Hz). Electrical
problems sometimes appear at two times line frequency or 100 Hz for 50 Hz supplies
(120 Hz for 60 Hz supplies). What is 100 Hz in cycles per minute?

a) 1.75 (2)
b) 200 (240)
c) 6,000 (7,200)
d) 3,000 (3,600)

38. Correction of the static unbalance in a rotor will allow the _____ unbalance to
remain.

a) component
b) dynamic
c) couple
d) static

39. The vibration team identifies a fan with high vibration at one times (1X) running speed.
The vibration is high in the horizontal direction at the drive end and non-drive end
bearings. You are asked to balance the fan. Before field balancing, what would an
experienced balancing expert do first?

a) Gather trial weights, a welder, and tag out the machine


b) Install a piece of reflective tape on the shaft
c) Perform an amplitude and phase analysis to determine the true vibration
source
d) Order a replacement fan wheel

40. An accelerometer measures vibration __________________________.

a) in a 360-degree orbit
b) in-line with its sensitive axis
c) tangent to its sensitive axis

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d) perpendicular to the polar axis

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41. The ISO standard 10816-1 for overall velocity measurements uses which one of the
following frequency bands?

a) 600 to 60,000 CPM


b) 1,800 to 3,600 CPM
c) 10,000 to 90,000 CPM
d) 60 to 1,000 CPM

42. A transducer used for vibration analysis is a device which


________________________________.

a) changes speeds in a rotating machine


b) converts electrical energy into a scaled digital voltage
c) creates vibration
d) converts mechanical motion to an electrical signal

43. Measuring displacement with an accelerometer requires conversion of the signal in the
data collector/ analyzer. This process is called ___________________.

a) double integration
b) differentiation
c) artificial articulation
d) transduction

44. The most frequently used transducer for periodic vibration data collection is the
____________________.

a) proximity probe
b) strobe light
c) accelerometer
d) strain gauge

45. Which of the following transducers provides a direct measurement of shaft vibration
relative to the bearing surface?

a) Double integrated accelerometer


b) Single integrated velocity transducer
c) Proximity probe
d) Shaft rider

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46. Which of the following transducer mounting methods provides the LEAST repeatable
readings?

a) Stud-mounted accelerometer
b) Hand-held vibration probe
c) Accelerometer on a magnetic base mounted on a flat surface
d) Accelerometer mounted on a pad glued to the machine with epoxy

47. Which of the following is a typical flat frequency range of a moving coil seismic velocity
transducer?

a) 120 to 600 CPM (2 to 10 Hz)


b) 600 to 60,000 CPM (10 to 1,000 Hz)
c) 120 to 180,000 CPM (2 to 3,000 Hz)
d) 0 to 3,000,000 CPM (0 to 50,000 Hz)
e) 300 to 600 CPM (5 to 10 Hz)

48. Proximity probes (also called non-contact eddy current pickups) are effective in
detecting ________________________________.

a) onset of rotor unbalance/eccentricity problems


b) worn gear teeth
c) incipient wear of rolling element bearings
d) induction motor electrical defects

49. The measurement of low frequency vibration often requires the use of special
transducers with lower frequency limits and increased sensitivities. Which of the
following accelerometers would provide the BEST readings on a machine running 50
RPM?

a) 10 mv/g, 2.5-10,000 Hz +/- 3 db


b) 100 mv/g, 150-600,000 CPM +/- 3 db
c) 500 mv/g, 60-60,000 CPM +/- 3 db
d) 1,000 mv/g, .5-1,000 Hertz +/- 5%

50. Double integration of an acceleration signal ______________________________.

a) may generate low-frequency data that are unreliable


b) may generate high-frequency data that are unreliable
c) will provide a signal that is proportional to velocity
d) will provide a periodic signal proportional to phase inversion

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51. To achieve the HIGHEST/BEST frequency response, an accelerometer should be
_________________________________.

a) mounted with a two-pole, high-force magnet


b) mounted to a machined surface with a threaded stud with a thin coat of
silicon grease (or equivalent) placed between the accelerometer and
mounting surface
c) glued directly to the surface with an epoxy adhesive
d) used with a minimum length, hand-held probe tip

52. Axial phase readings are acquired on the non-drive-end of a motor with the probe
mounted flat on the bearing housing. When the readings are taken on the drive-end of
the motor, the pickup must be turned to mount on the bearing at that location. The
inboard axial readings must be changed by __________________________ in order to
obtain an accurate comparison with the non-drive-end readings.

a) 360 degrees
b) 0 degrees
c) the inverse of shaft rotation
d) 180 degrees

53. When selecting a vibration measurement unit for the detection of high frequency
vibration (greater than 120,000 CPM or 2,000 Hz), which of the following is the best
indicator of severity?

a) Velocity
b) Acceleration
c) Displacement
d) Phase

54. For effective monitoring, particularly on machines outfitted with rolling element
bearings, the best location for mounting a vibration transducer is on the
_____________________.

a) base
b) foundation in a radial direction
c) bearing housing at or as close as possible to the load zone
d) the shaft

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55. For periodic checks when collecting readings for a walk-around condition monitoring
program, the most practical and effective way of mounting an accelerometer is
_________________________.

a) A stud mount with epoxy


b) A magnetic mount
c) A hand-held transducer
d) An extension probe

56. To best determine the axial movement of a machine, axial phase readings should be
acquired _______________________ .

a) As close to the centerline of the shaft as possible


b) At the feet, tangential to shaft rotation
c) When the machine is not running
d) At the 3:00 and 9:00 positions

57. Electrical hum is suspected as the source of higher than usual vibration at 4 times
running speed RPM on a 4-pole induction motor. If this diagnosis is correct, the
vibration amplitude at 4 times running speed will ______________________ when the
power is cut.

a) produce harmonic distortion


b) decrease gradually and change frequency as the machine slows down
c) increase momentarily and then decrease slowly
d) decrease instantaneously

58. When axial vibration amplitudes at running speed are greater than 50 percent of both the
horizontal and radial vibration amplitudes, and other influences (e.g., bent shaft,
resonance, etc.) have been eliminated, it is usually and indication of
________________.

a) unbalance
b) soft foot
c) misalignment
d) a motor running off magnetic center

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59. Vibration amplitudes that appear at frequencies below, or less than, 1 times running
speed on a machine with failing rolling element bearings may indicate
______________________.

a) an oil whirl condition


b) slip speed induced unbalance
c) sub-surface fatigue cracks
d) excessive bearing clearances

60. Envelope detection of bearing faults looks at ______________________________ .

a) low frequency phenomenon below running speed


b) sidebands around the first and second harmonics of the bearing fault
frequencies
c) frequency patterns that carry/repeat into the higher frequencies
d) the resonant frequency of the accelerometer

61. The appearance of rolling element bearing fault frequencies within a spectrum
_____________________________.

a) always means that immediate replacement is required


b) means that natural frequencies of the machine are being excited
c) can mean that wear/damage is present, that the bearing is improperly loaded,
and/or that the bearing has insufficient lubrication and is allowing metal-to-
metal contact
d) does not necessarily indicate any problem since rolling element bearings
always generate bearing fault frequencies that can readily be seen

62. Due to accessibility problems, a reading must be taken 6 inches from a bearing. Since
the amplitudes of the bearing fault frequencies may not accurately indicate the amount of
damage at this distance, which of the following could provide an indication of further
deterioration over time?

a) Elevated electrical hum vibration


b) An increase in the number of bearing fault harmonics in the spectrum
c) A significant decrease in the overall vibration amplitude
d) Increased displacement amplitudes in the sub-harmonic region

16 201_test
63. For a pure static unbalance condition, the phase angle readings at the non-drive-end and
the drive-end of a machine in the same plane (for example, the vertical plane) will be
______________.

a) in phase within 30 degrees on each other


b) 180 degrees out of phase
c) higher in the horizontal plane
d) within 60 degrees of each other

64. When obtaining phase readings at multiple locations and directions, care should be
taken to ______________________.

a) use eddy current probes


b) use the same phase reference for all readings
c) obtain vibration amplitudes first
d) ensure that the machine has come to a complete stop

65. A phase angle, for vibration measurement purposes can be defined as the timing
between two events at the same frequency, usually measured in degrees. Which of
the following techniques is not used to determine the vibration phase angle at a point
on a machine?

a) A strobe light triggered by a vibration transducer


b) A non-contact (eddy current) probe triggered by a key or keyway in a
shaft as a tachometer pulse reference
c) A photo reflective tachometer triggered by reflective tape on the machine's
shaft
d) A current probe attached to motor phase lead A

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66. The phase analysis of a machine will determine _____________________ ?

a) The operational frequency of a machine


b) How a machine is moving
c) When a machine deviates from normal vibration levels
d) How much vibration amplitude is present at higher than normal
frequencies

67. The autoranging function in a data collector __________________________ .

a) Selects the best frequency range for a measurement


b) Scales the spectrum display to show all peaks
c) Sets the input amplitude range based on the vibration signal
d) Adjusts the viewing angle of the screen for different lighting conditions

68. Which of the following is a measure of the timing between two events at the same
frequency?

a) Coherence
b) Amplification factor
c) Synchronicity
d) Phase
e) Orders

69. When analyzing a machine where a beat frequency is present because of another
machine running nearby at almost the same RPM, improved amplitude and phase
results can be obtained using _________________.

a) a higher frequency resolution


b) an FFT (Fast Fourier Transform) zoom
c) synchronous time averaging
d) an accelerometer with higher sensitivity

70. A peak at exactly one half of running speed could represent


_______________________.

a) an electrical contact
b) oil whirl/whip
c) looseness/rub
d) missing gear teeth

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71. A large paper machine roll is trued on a large lathe and measures less than 0,025 mm
(0.001) inches total radial runout when checked with an accurate dial indicator. Its
turning speed when installed in the machine is approximately 150 RPM. What
possible effect will be seen in the paper if the roll is not balanced before being
installed back in the machine?

a) none, the runout is better than tolerance


b) none, the unbalance is absorbed at the bearings
c) none, the roll is not running fast enough to be of concern
d) some, eccentricity due to unbalance may be translated into the product,
causing regularly spaced deviations in surface finish

72. When evaluating the most likely vibration source to determine the cause of a bearing
fault in an induction motor, high radial and low axial running speed vibration levels
are found. This is usually a characteristic of ________.

a) uneven air gap


b) unbalance
c) bad bearings
d) shaft eccentricity

73. Higher than usual vibration amplitudes at running speed and 2 times running speed
can be caused by several things, but the most common cause is _________________.

a) unbalance
b) resonance
c) misalignment
d) axial kurtosis

74. A spectrum reveals many harmonics of the machine running speed in the lower
frequencies up to approximately 10 times running speed. Which of the following
would produce this effect?

a) static unbalance
b) an improperly tightened pillow block bearing
c) eccentric armature
d) electrical hum due to an air-gap problem

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75. When measuring amplitude and phase at running speed, you are measuring the
vibration generated by _______________ defects and/or vibration sources.

a) only one
b) two maximum
c) possibly many
d) harmonics of

76. Non-synchronous vibration refers to ____________________________________.

a) vibration occurring in induction motors rather than synchronous motors


b) vibration at 1 times running speed
c) vibration at 1 times running speed and its harmonics
d) vibration greater than 1 times running speed that is not a whole number
multiple of running speed

77. The time waveform is a graphic plot of __________________________________.

a) vibration amplitude versus time


b) frequency versus time
c) amplitude versus frequency
d) phase versus time

78. Multiple harmonics of running speed extending across the spectrum may indicate
looseness. Which of the symptoms listed below could possibly be confused with
looseness?

a) Unbalance
b) Bent shaft
c) Misalignment
d) Eccentric rotor

79. The zoom function in a data collector is used to ___________________ .

a) Speed data collection


b) Improve amplitude resolution to obtain high amplitude accuracy
c) Improve frequency resolution to separate closely spaced frequencies
d) Reduce aliasing effects during analog to digital conversion

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80. A higher than usual vibration amplitude at 1 times running speed is characteristic of
both unbalance and misalignment. There is also a peak at two times running speed
that is slightly less than 1/3 (30%) of the one times running speed amplitude. For
example, 6 mm/sec (0.24 inches per second) at running speed and 1.5 mm/sec (.07
inches per second) at two times running speed. The more likely source of vibration
between misalignment and unbalance is ________________.

a) unbalance
b) misalignment
c) resonance
d) dynamic instability

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FORMULA SHEET

rms value = 0.707 x peak value 1 in = 2.54 cm


o
d=2xr rms value = 1.11 x average value F = 9/5xoC + 32
o
π = 3.1417 peak value = 1.414 x rms value C = 5/9(oF - 32)
area = π r2 peak to peak = 2 times peak
o
circumference = 2π r F - degrees Fahrenheit
o
Bearing Fault Frequencies C - degrees Celsius

Spring Force Inner Race, millivolts = volts x 1,000


BPFI=Nb/2(1+Bd/Pd cosA)xRPM e.g., 2 volts = 2000 millivolts
F = K times x
K = spring constant, Outer Race, volts = millivolts/1000
lb./in BPFO=Nb/2(1-Bd/Pd cosA)xRPM e.g., 500 millivolts = .5 volts
x = displacement, inches

Ball/roller, deci = 1/10


BSF=Pd/2Bd[1-(Bd/PdcosA)2]xRPM
Damping Force centi = 1/100
F= C times V Cage,
C = damping constant FTF=1/2(1-Bd/PdcosA)xRPM milli = 1/1000
V = velocity, in/sec

A = contact angle kilo = 1000


Nb = number of balls Calibration
Pd = pitch diameter Sensitivity x Amplitude = volts

Bd = ball diameter Volts = Amplitude


Sensitivity
Volts = Sensitivity
Amplitude
Note: convert all mv to volts
first

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CONVERSION CHART

Start with… Convert to… Conversion…

g’s peak Inches/sec peak 61.44 x g


f
g’s peak mils pk-to-pk 19,560 x g
2
f
inches/sec peak mils pk-to-pk 318.31 x v
f
inches/sec peak g’s peak .0162 x v x f
2
mils pk-to-pk g’s peak .00005114 x d x f
mils pk-to-pk Inches/sec peak .00314 x d x f

Use the START WITH column to determine what units you are starting with.

Then select the CONVERT TO column for the appropriate conversion

Where:

d = displacement in mils peak to peak


g = acceleration in g’s peak
v = velocity in inches per second peak
f = frequency in Hertz

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