VibrationAnalysisOfRotatingEquipment CaMau

PETROVIETNAM CAMAU FERTILIZER Co., Ltd.
Vibration analysis of rotating equipment

L nh Tun., Dr. Eng.
Hochiminh City University of Technology

Dynamic balancing solution
CAMAU CITY, November 3-7, 2014
Plan
I . Overview of Vibration Testing
II. Vibration parameters
III. Amplitudes
IV. Frequency analysis
V. Apparatus & Data acquisition
VI. Measurement preliminary
VII. Machinery monitoring & Diagnosis of defects
VIII. Case study
November 3-7, 2014 Vibration analysis of rotating equipment 2

I. Overview of Vibration Analysis
This presentation should give :
- introduction to the collection and analysis of vibration from rotating

machinery;
- understanding why measuring and analyzing machine vibration can give

you an insight into the machines condition.
better plan maintenance activities, reduce downtime, & generally

reduce maintenance costs & add to company profit.


Look for patterns and change

Vibration standards
November 3-7, 2014 Vibration analysis of rotating 6

equipment
Vibration tells an interesting story

equipment
Taking the measurement

equipment
The vibration signal the waveform

equipment
The vibration signal

equipment
Introducing the frequency

equipment
Increase the frequency

equipment
Add another source of vibration

equipment
Simplifying the vibration data

equipment
Introducing the spectrum

equipment
The spectrum in detail

equipment
Control the test conditions

equipment
A more complex spectrum

equipment
Introducing forcing frequencies

equipment
The practical application

equipment
The practical application

equipment
Introducing resolution

equipment
High frequency bearing techniques

equipment
Dynamic effects due to ?
clearance generated of contacts during operation of a machine
types of applied excitations to structures (shocks, strong wind, road
traffic, noise,)
existence of unbalanced forces in the moving elements of
alternative motion / rotation
Consequences
fatigue accelerated from part
wear faster (bearings,)
damaging and rupture
generation of excessive noise
effects generally harmful except in certain applications as

the vibrating transport , compactor of concrete (vibrator),
pneumatic hammers, vibration tables,
equipment
Why vibration tests ?
Engineering development testing
Qualification testing
Reliability qualification testing
Production screening testing
Machinery condition monitoring
Significant question need to be answer in planning vibration tests:

What field data should be taken ?
Where should the transducers be placed / test item to achieve the
maximum useful information over a given frequency bandwidth.
How should the field data be stored for future reference & recall ?
What is the effect of changing BCs between field & test & environment
due to test fixture?
Which testing procedures are best suited to simulating a given field
environment?
Properly plan the field test
November 3-7, 2014
/ laboratory simulation
Vibration analysis of rotating 25
equipment
General structure showing internal, external &
boundary types of excitation forces
Bq
Boundary S1 Xp
Sq Hpq
p Fq
internal
External
Sn1
n1 n2 n3
X p H pq S q H pq Fq H pq Bq
q 1 n1 1 n 2 1
internal external boundary

equipment
Predictive maintenance/Diagnostic applications
= Monitoring vibration characteristics of rotating machinery
Applications: predictive maintenance, acceptance testing, quality
control, loose part detection, noise control, leak detection, machine
design and engineering
Equipment and Processes typically monitored by Vibration Analysis
Centrifugal Reciprocating Continuous Process

Pumps Pumps Continuous casters
Compressors Compressors Hot & cold strip lines
Blowers Diesel engines Annealing lines
Fans Gasoline engines Plating lines
Motor/generators Cylinders Paper machines
Ball mills Other machines Can manufacturing
Chillers
November 3-7, 2014 Vibration analysis of rotating lines 27
equipment
Pickle lines
Cont
d
Centrifugal Machine-Trains Continuous Process
Product rolls Boring machines Printing
Mixers Hobing machines Dyeing and finishing
Gearboxes Machining centers Roofing manufacturing lines
Chemical production lines
Centrifuges Temper mills
Petroleum production lines
Transmissions Metal-working machines Neoprene production lines
Turbines Rolling mills, and most Polyester production lines
Generators Machining equipment Nylon production lines
Rotary dryers Flooring production lines
Electric motors Machinery Continuous
All rotating process lines

equipment
Overview of equipment employed
Output from structure

motion transducer
X
Test
item Amplifier
Frequency Computer for data
analyzer storage & analysis
Exciter Amplifier
Force transducer
input to structure

equipment
Vibration = oscillation in a mechanical system, defined by
- frequency (or frequencies) & amplitude
Prescribed loading
Frequency Amplitude
= =
1/T Displacement
/ Velocity
/ Acceleration

equipment
Equation of motion
mx kx
k
x (k / m) x 0,
m
Displacement x x0 cos(t )
dx
Velocity v x x0 sin(t )
dt
dv
Acceleration a v x0 2 cos(t )
dt
Frequency of vibration f = 1 / = / 2
equipment
Relations between parameters
Acceleration, a
2X Velocity, v
amplitude
X Displacement, x
X
Dephase = /2
time
Unit (ISO 1000)
Quantities SI Vibration Equivalent unit

unit unit
Displacement, x m m 1 m = 10-6 m
Velocity, v m/s mm/s 1 mm/s = 10-3 m/s
Acceleration, a m/s2 g 1 g = 9.81 m/s2
equipment
III. Amplitudes
Notion of amplitude
upper limit
equilibrium position
lower limit
Amplitude of a wave vibratory

=
variation compared to the equilibrium point
Quantities associated to vibration amplitude displacement,

velocity &
acceleration
Maximum amplitude
Double amplitude or peak to peak
Effective amplitude
November 3-7, 2014 Vibration A
analysis
eff of rotating 33
equipment
III. Amplitudes
Notion of amplitude
Ac 2
Peak
Aeff 0.707 Ap
amplitude
Effective amplitude 2
time
Peak to peak
amplitude
T
Peak 1 2
amplitude Aeff
T0
a (t )dt
Effective amplitude
time
Peak to peak
November 3-7, 2014 amplitudeanalysis of rotating
Vibration 34
equipment
III. Amplitudes
Choice of amplitude scale
On a logarithmic amplitude axis depict better the vibration
spectra over a very wide dynamic range !
Linear scale: hide many components

which could be important

equipment
III. Amplitudes
Decibel (dB)
Definition: unit which denotes the magnitude of a quantity WRT an
arbitrarily established reference value of the quantity, in terms of the
logarithm (to the base 10) of the ratio of the quantities
W
dB 10 log
W0
In vibration: ex: acceleration
are =10-5 ms-2
a
La 20 log vre =10-8 ms-1
are xre =10-11 m
(ISO 1683)
Total levels
Vibration of a rotating equipment = composition of many internal forces
At first,
November we measure theVibration
3-7, 2014 total levels
analysis of rotating 36
equipment
Response to an periodic excitation:
Fourier transform:

equipment
Contd
Presentation in the frequency domain
DFT
(Discrete
Fourier
Transform)

equipment
Non-periodic function:
Response to an transient excitation (non-periodic)
Decomposition in Decomposition in
elementary impulses elementary steps (echelons)

equipment
Contd Response to an any excitation
by superposition of impulsive responses
Excitation Response

equipment
Contd
Response to an any excitation
by superposition of stepping responses (indicial)
Excitation Response

equipment
Contd
Ex: Impulsive response, ( f0 = 1)
Indicial response, ( f0 = 1)

equipment
Principle elements of a Measurement chain

Studied structure
Means of measurement
Transducer: mechanical quantity electric signal
Charge amplifier: independent / built-in
Analyzer: analog digital, signal treatment / FFT
Means of excitation
Exciter: shock hammers, pots de vibration
Power amplifier
Signal generator: excitation signal

equipment
General diagram of a measurement circuit of mobility
Command
Signal
Power
Generator Shaker
amplifier
Monitor
Control Force
Transducer
Signal-
Test
Generator Conditioning
Structure
Amplifiers
Response
November 3-7, 2014 Vibration analysis of rotating Transducers 44
equipment
Type of measurement
SIGNAL MEASUREMENT
x X sin t displacement: X
x X cos t velocity : X
x 2 X sin t acceleration : 2X
Ex: Vibrations
Frequency displacement acceleration
0.5 Hz 1 m ~ 10-5 m/s2
15 800 Hz 1 m ~ 104 m/s2
10-5 m/s2 is indetectable !

! Choice of the quantity to measure
equipment
Choice of the quantity
Level
of
vibrations acceleration
velocity
displacement
frequency
Displacement ( X ) : measure clearances, expansion, at low freq.
unbalance indication
Velocity ( X ) : cover the largest range of frequency used in
the standards for the evaluation of vibration intensity
Acceleration ( 2X ) : measure vibration at high freq. (shock).
equipment
Vibration sensors
Definition
MECHANICAL QUANTITY
- displacement (X )
- velocity (X )
- acceleration (2X )
- (presure, stress)
- absolute or relative
SENSOR
ELECTRICAL QUANTITY
- voltage (V ) X
- current ( I ) = X (: sensibility)
- charge (Q ) 2X
X
equipment
Specifications of sensors
Range of measurements ex: 0 to 10 g
-1 mm to +1
mm
Frequency range (or pass band ) ex: 1 Hz to 1.5 kHz
Sensibility ex: 10 pC/g, 300 mV/(cm/s)
Transverse sensibility
Precision
Sensibility to external parasites
- magnetic field ex: 0.1 g/Tesla
- noise ex: 0.01 pC/dB
- temperature
etc

equipment
Classification of sensors
3 types of classification
Type of the Measured quantity Physical properties

measurement
- absolute - displacement - electrodynamic
movement or - velocity - piezoelectric
- relative - acceleration - capacity
- force - etc

equipment
Mass-spring transducers (seismic transducers)`
0 u0 2
u

equipment
Contd
seismometer
accelerometer

equipment
Acceleration-measuring transducers
0 at small values of the frequency ratio
n : high, the transducer is an accelerometer
/n < 0.2 + undamped : response curve is flat
undamped accelerometer
Range of measurable freq. increases as is increased, up to

an optimum value of damping
0.65 gives accurate results at freqs up to 60% of n
1/n2 : for a given 0

increase n needs large aplification !
Another solution: piezoelectric sensor.
equipment
Piezoelectric accelerometers
Principle: electro-mechanical interaction

equipment
Typical response curve
useful range : over the flat portion of the response curve

equipment
Typical piezo accelerometer constructions
Compression-type
must be attached to the structure with care in order to

! minimize distortion of the housing and base which can cause
an electrical output

equipment
Contd
Shear-type (Delta-shear & Isoshear type)
Typical specifications:
- sensitivity, 10 500 pC/g; - useful freq. range, 3 5000 Hz;
- acceleration range, 1 500g; - temperature range, 254760C;
- resonance freq., 25,000 Hz; - transverse response, 3%

equipment
Contd
Shear-mode annular
extremely small !
Beam-type
Bimorph structure
[Harris'
November 3-7,Shock
2014 & Vibration Handbook]
Vibration analysis of rotating 57
equipment
Laser doppler vibrometers (LDV)
Principle: Doppler shift of laser light which has been backscattered from
a vibrating test object
to produce a real-time analog signal output instantaneous velocity
Velocity measurement range: min peak 0.5 m/s max peak 10 m/s
(typical)
Main features:
- No transducer mounting or mass loading effects.
- No built-in transverse sensitivity or other environmental effects.
- Measure remotely from nearly any standoff distance.
- Ultra-high spatial resolution with small measurement spot (5-100 m).
- Easily fitted with fringe-counter electronics for producing absolute
calibration of dynamic displacement.
- Laser beam can be automatically scanned to produce full-field vibration
pattern images.
equipment
Types of Laser Doppler Vibrometers

equipment
Electrodynamic transducers
Principle: (electrodynamic pickup)
Voltage e generated in the coil

Velocity of the coil relative to the
magnet
Advantages:
reliable
sensible (commonly of the order of 300 mV/cm s-1)
weak impedance
without external supply
Disadvantages:
heavy
limited pass band
Differential-transformer pickups , proximity probe,
[Harris'
November 3-7, 2014Shock & Vibration Handbook]
Vibration analysis
equipment
of rotating 60
Domains of utilization of sensors
Relative
amplitude
10 000 Accelerometer
1000
Velocity
100 transducer
10 Displacement
transducer
(seismic)
Frequency (Hz)
0.1 1 10 100 1000 10 000
equipment
Vibration measurement system
combined into a single unit vibration meter

Vibration measuring instrumentation
[Mechanical
November 3-7, 2014 Vibration &Vibration
Shockanalysis
Measurements,
of rotating Brel Kjr] 62
equipment
Measurement point: A sensor is placed on the machine
- on bearing housing, & vibration is converted into an electrical signal
- most common sensor: accelerometer
- displacement "proximity
probes" used on large
turbines & compressors
- vibration monitoring
equipment is typically
carried from machine to
machine, & the sensor
is temporarily mounted
on the bearing

equipment
Preparation of measurement point
Mounting the sensorpoint

equipment
Contd

equipment
Validation
2 measures at the same point can only compared with:
identical pass bands of 2 measuring instruments.

same mounting of sensor
same unit & parameter
same operating of the machine
Operation conditions
strongly affect on the vibration parameters
each vibration measurement should be done at a fixed operation
condition

equipment
Data sheets for logging test information
Basic data concerning the test measurements:
Date, times, and duration of test.

Identification of test by test number.
Identification of equipment, machine, or device under test.
Conditions of operation during the measurement.
Any anomalies in operation and their times of occurrence.
Location of test, using diagram where appropriate.
Environmental conditions during test; note anomalies where appropriate.
Persons participating in the test.

equipment
Contd
Equipment, including transducers, cables, signal conditions, data recorders,
telemeter:
Type.
Manufacturer, model number, and serial number.
Transducer sensitivity, exact location, orientation, and type of mounting.
Signal conditioner and amplifier gain and attenuator settings; note any
changes in these settings during the test.
Filter settings, if any.
Recorder speed, number of tracks, tape speed, gain settings; note any
changes in these settings during the test.
Calibration information:
Transducer calibration.
Overall system (end-to-end) calibration of system.
Phase of output signal relative to input signal.
Any changes in calibration between pretest and posttest conditions.
equipment
Thank you !
Hochiminh City University of Technology

VibrationAnalysisOfRotatingEquipment CaMau

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PETROVIETNAM CAMAU FERTILIZER Co., Ltd.

Vibration analysis of rotating equipment

Hochiminh City University of Technology

November 3-7, 2014 Vibration analysis of rotating equipment 2

This presentation should give :

- introduction to the collection and analysis of vibration from rotating

- understanding why measuring and analyzing machine vibration can give

better plan maintenance activities, reduce downtime, & generally

November 3-7, 2014 Vibration analysis of rotating equipment 3

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effects generally harmful except in certain applications as

Significant question need to be answer in planning vibration tests:

November 3-7, 2014 Vibration analysis of rotating 26

Centrifugal Reciprocating Continuous Process

November 3-7, 2014 Vibration analysis of rotating 28

Output from structure

November 3-7, 2014 Vibration analysis of rotating 29

November 3-7, 2014 Vibration analysis of rotating 30

Unit (ISO 1000)

Quantities SI Vibration Equivalent unit

Amplitude of a wave vibratory

Quantities associated to vibration amplitude displacement,

Linear scale: hide many components

November 3-7, 2014 Vibration analysis of rotating 35

Response to an periodic excitation:

November 3-7, 2014 Vibration analysis of rotating 37

November 3-7, 2014 Vibration analysis of rotating 38

Response to an transient excitation (non-periodic)

November 3-7, 2014 Vibration analysis of rotating 39

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November 3-7, 2014 Vibration analysis of rotating 42

Principle elements of a Measurement chain

Signal generator: excitation signal

November 3-7, 2014 Vibration analysis of rotating 43

10-5 m/s2 is indetectable !

November 3-7, 2014 Vibration analysis of rotating 48

Type of the Measured quantity Physical properties

November 3-7, 2014 Vibration analysis of rotating 49

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November 3-7, 2014 Vibration analysis of rotating 51

Range of measurable freq. increases as is increased, up to

1/n2 : for a given 0

November 3-7, 2014 Vibration analysis of rotating 53