VIBRATION ANALYSIS (PROFILES

& SPECTRUM)
LECTURE 03
 Course Outline
LECTURE 01 Introduction to Plant Maintenance and its Regimes
Basic Maintenance & Damage Concepts
Week 01
LECTURE 02 Maintenance Planning, Failure Mechanisms, SHM

LECTURE 03 Vibration Analysis (Profile & Spectrum)

Week 02
LECTURE 04
Vibration Analysis
Corrective Techniques (Balancing, Align., Looseness)

LECTURE 05 Failure Mode Analysis

Week 03
LECTURE 06 Visual Inspection (DPT & BT)

Non-Destructive Testing
LECTURE 07 Radiographic Inspection (RT & NI)
Week 04
LECTURE 08 Magnetic Electric Inspection (MPI)
 Lecture Outline
What is Vibration?

Why Monitor Machine Vibration?

How is Machine Vib. Described?

Vibration Spectrums

Energy in Spectrums

Lines of Revolution (LOR)

Analysis Techniques

Measurement Point Identification

Locating Turning Speed

Data Collection Techniques

Video-1
Most of us are familiar with vibration; a vibrating object moves
to and fro, back and forth. A vibrating object oscillates.

We often experience
examples of vibration in our
daily life
Rotating Machines Vibrate while Operating

Vibrating Belts Vibrating Motors

Vibrating Fans Vibrating pumps

 Almost all machine vibration is due to one or more of
these causes:

Repeating Forces
Improper
Imbalanced Misaligned Worn machine
Driven

Looseness

Resonance
 Imbalanced machine components contains heavy spot which
one rotated, exert a repeating force on the machine. Imbalance
is often caused by machine errors, non uniform material density ,
variation in bolt sizes, air cavities in cast parts, missing balance
weights, and broken deform, corroded, or dirty fan blades.

Uneven Rotor
Corroded tip

Bent Shaft

Dirt
 Misaligned machine components create “bending
moments” which when rotated, exert a repeating
force on the machine. Misalignment is often
caused by inaccurate assembly, uneven floors,
thermal expansions, and distortions due to
fastening torque.

Parallel Misalignment Angular Misalignment

Worn machine components exert a repeating force
on the machine because of the rubbing of uneven
worn surfaces. Wear in roller bearings, gears, and
belts is often due to improper mounting, poor
lubrication, manufacturing defects, and overloading

Worn Roller Worn Teeth Worn Belt

 Improperly driven machine components exert a repeating
force on the machine because of intermittent power supply.
Examples include pumps receiving air in pulses, internal
combustion engines with misfiring cylinders, and
intermittent brush commutator contact in DC motors

Intermittent Brush
contact Misfiring
Uneven
supply Cylinder
Looseness can cause vibration in both rotating
and non-rotating machinery. Looseness is often
due to excessive bearing clearances, loose
mounting bolts, mismatches parts, corrosion,
and cracked structures

Excessive
Clearance
Loose
bolts
Resonance is an excitation of ‘Natural Vibration’.

Everything has a ‘natural frequency’ fn, everything vibrates!

This fn does not cause any problems until another vibration source runs at a
same/similar frequency.
 A repeating force causing resonance may be small and may
originate from the motion of a good machine component.
 Resonance, however, should always be avoided as it
causes rapid and severe damage.

. For example, whole bridges have collapsed due to their

natural oscillation rates being excited by the mere rhythm
of soldiers marching in unison across the bridges
 The Tacoma Narrows Bridge in Washington opened to traffic
on 1st July 1940. Unlike most suspension bridges of it’s time
the Tacoma Narrows Bridge was unusually long and narrow.
 The original design had called for trusses to stiffen the span
but funds were not available and inadequate stiffening was
used.
 Wind blowing over and under the deck creates lift causing the
bridge to move up and down.
 As the bridge was moving at its natural frequency the
resonance amplified the movement Video- 2
 Monitoring the vibration characteristics of a
machine gives us an understanding of the 'health'
condition of the machine.
 We can use this information to detect problems that
might be developing.
Below we discuss some common problems that can
be avoided by monitoring machine vibration.
 Severe Machine damage
 High power consumption
 Machine unavailability
 Delay shipments
 Accumulation of unfinished goods
 Unnecessary maintenance
 Quality Problems
 Bad Company image
 Occupation hazards
 Machine vibration that is not detected early enough will
often lead to severe machine damage requiring costly
repairs or even total machine replacement.

We cover all services and you
have a choice; a $200.000
operational or a $5000 funeral.
Just as it is costly to
detect medical problems
at a late stage, it is also It might be cheaper
the same for machines. to replace it!
 A machine that is vibrating consumes more power.

 We can minimize this problem by regularly

monitoring and maintaining the machine.
 Because an unmonitored machine is more likely to break
down, it is more often out of action.
 A machine should be consistently available to generate
the money to justify its investment.
Its unavailability does not
This is so often justify its initial cost, the
unavailable to make floor space it occupies, the
money it is actually How? business opportunities we
losing money. miss out on!
Because an unmonitored machine is more likely to break
down, it is also more likely to cause delays in the shipping
of goods.

I’ve got a dinghy!

Maybe we can
catch it.
  Because an unmonitored machine is prone to breaking
down it is often unavailable.
 Goods still in the making tend to get stuck at the input point of
the machine. This leads to unnecessary wastage.

This needs Is there a

processing now! market for
By tomorrow it’ll
be no good sour milk?
Hmm!
 To constantly ensure proper machine condition, some
companies stop running machines according to
predetermined schedules to adjust and replace parts
regardless of whether or not the machines are malfunctioning.

It’s good that you’re

getting full checkups It’s even better that
every week. you’re making me rich
unnecessarily!
 Sometimes a machine can be running into trouble even
though it appears to be functioning normally.
 If not caught early, the problem could lead to poor
quality products being made.

And you didn’t

know?
These are all wrong Have you any idea More than a vb
because the machine what this will cost instrument?
bearing is worn the company?!
 Machines that are not regularly monitored can lead to shipment delays
and produce goods of poor quality.
 Just one incident of shipment delinquency or product defect is often
enough to seriously strain or even end relationships with customers.

I’m out of here.

Delayed
Quality
System
LTD.

 A bad company image associated with shipment delays and poor

quality is something to be avoided.
 Due to the noise and shaking they create, vibrating
machines can cause occupational hazards and human
discomfort.

Now What?
Vibration transmits as a sine wave.

We can measure this sine wave in an

Amplitude versus Time domain

This is called a Time Waveform

Video-3
• Amplitude How Much

• Frequency How Often

• Phase. When
 Unfortunately there can be
multiple sine waves emitting
from a machine, So our
wave form becomes
complex
 We call this a complex sine
waveform
 Analysis is very difficult on this
type of waveform.
 Fortunately we have what’s
called an ‘FFT’ which converts
the complex waveform back into
several simple waveforms
Video-4
Transducer Waveform

Amplitude
Overall
Energy Time

FFT
Amplitude Spectrum

Frequency
• Complex waveform The waveform is
changes to a converted to an
simple waveform amplitude/frequency
domain
Amplitude
Amplitude

Amplitude
Tim
e
  Before we learn how to diagnose
potential faults within a spectrum,
we need to understand the units of
measurement.

 The vibration data that is

converted from the waveform by
the FFT process can be seen very
clearly

 However there are a few

considerations we need to take into
account first.
 The amplitude scale and the
amplitude units are important

 As well as the frequency scale

and units
There are three different
amplitude measurements we use,
these are:
Acceleration
Velocity
Displacement
 Acceleration
◦ Measures the change in velocity over a period of time

 Velocity
◦ Rate of movement
 Displacement
◦ Measures total movement in relation to a reference point

 A good way of remembering this is to think of a car:

◦ From rest to 60mph is your acceleration (change in velocity over time)
◦ Drive at 60mph for x-time (this is your velocity)
◦ From start to finish is the total distance traveled (Displacement)
 You can measure amplitude from a time waveform as shown:

+ 0 to Peak

RMS
Average
Amplitude

Time ‘t’
-

Peak to Peak

 The period ‘t’ is the time required for one revolution of the shaft in this
illustration, which equals one cycle of the waveform
◦ During this period, the amplitude of the waveform reaches a positive (+) peak,
returns to rest, and reaches a negative (-) peak before returning to rest
 Peak (Pk) – Amplitude measured from the ‘at rest’ position (0) to the
highest value (0 to Peak)
 Peak to Peak (Pk-Pk) – Amplitude measured from the peak positive (+)
value to the peak negative (-) value
 RMS (Root Mean Square) – obtained by averaging the square of the signal
level over a period of time and then taking the square root result
 Average (Avg) – Amplitude value that averages the peak values of the
waveform 0 to Peak

RMS

+
Average
 You can calculate the different amplitudes
when one of the values are known:

Amplitude
Time
◦ RMS = 0.707 times the peak value ‘t’
◦ Avg = 0.637 times the peak value
◦ Pk-Pk = 2 times the peak value

- Peak to
Peak

 Displacement - microns
 Total movement, value is from
Peak to Peak
 Ignores all high frequencies and
looks at the low frequency
 Acceleration - G-s
 Value from the base line to the peak
amplitude
 Looks a force generated in our machine
(High frequency domain)
 Velocity RMS - MM/Sec
 RMS - root mean square,
appears at 0.707 the value of
the amplitude
 Gives a good overall picture,
of the vibration in our machine
 19T - Example 6
19T - Example 6
E6 -G3H 19T
GBox Shaft 2 Inboard
- Example 6 Horz
100 E6 -G3H GBox Shaft 2 Inboard Horz
0.8 E6 -G3H GBox Shaft 2 Inboard Horz Route Spectrum
0.24 Route Spectrum
31-Jan-01
Route 10:57:43
Spectrum

0.7
31-Jan-01 10:57:43
31-Jan-01 10:57:43
OVRALL= 1.32 V-DG
 Velocity RMS
0.21 OVRALL= 1.32 V-DG
80 P-P = 58.12
OVRALL=
RMS = 1.31
LOAD
PK
1.32 V-DG
= =.6325
100.0
LOAD = 100.0
 Good overall value
0.6 RPM ==1052.
LOAD 100.0
in Microns

0.18 RPM = 1052.

RPS =
RPM = 1052.
17.54
RPS = 17.54
Velocity in mm/Sec

RPS = 17.54
 Acceleration G-s
PK Accelerat ion in G-s

0.5
60
0.15
 Accentuates the high
P Displacement

0.4
0.12 frequencies
40
 Good for anti-friction
RMS

0.3
0.09
P-

bearings & Gears)

0.2
0.06
20

0.1
0.03

0
 Displacement -
0
0
0
0
20000
20000
40000
40000
60000
60000
80000
80000
100000
100000
microns
0 20000 40000Frequency in CPM
60000 80000 100000
Label: Chipped Gear Tooth
Label: Chipped Gear Tooth
Label: Chipped Gear Tooth
Frequency in CPM
Frequency in CPM  Accentuates the low
frequencies
Vib Acceleration
accentuates HIGH frequencies,
and attenuates LOW frequencies.

Acceleration

Velocity
“flat” treats all frequencies equally.

Velocity

Displacement
accentuates LOW frequencies,
and attenuates HIGH frequencies.

Displacement

Freq

Video-5
 Frequency refers to how often something occurs:
◦ How often a shaft rotates?
◦ How often a rolling element hits a defected race?

 There are three ways to express frequency:

1. CPM – Cycles Per Minute
– 1CPM = 1RPM

2. Hz – Cycles Per Second

– CPM / 60

3. Orders – Multiples of Turning Speed

– Frequency/Turning Speed

 Consider a motor has a rotational speed of 1485RPM, in terms of frequency this

equates to:
◦ 1485 CPM (1rpm = 1cpm)
◦ 24.75 Hz (1485/60) (minutes to seconds)
◦ 1 Orders (1 x revolution of the shaft)
 Synchronous energy - related to
turning speed.

 We can see from the

spectrum that the first peak
is at 1 Orders (which means
it is 1 x turning speed)
 All the other peaks are
harmonics off, which means
they are related to the first
peak

Examples of synchronous energy:

1) Imbalance 2) Misalignment 3)Looseness 4) Gears
 Non-synchronous energy -
not related to turning speed

 We can see from the

spectrum that the first
peak is at 10.24 Orders.
This is not related to
turning speed.

• Examples of non-synchronous energy:

• Bearings Multiples of belt frequency Other Machine Speeds
 Sub-synchronous energy -
Less than turning speed

 The spectrum shows the first

impacting peak below 1 Order.
This is sub-synchronous
energy
 Examples of sub-synchronous
energy are:
 Belt Frequencies
 Other Machine Speeds
 Cage Frequencies
 Lines of Resolution (LOR) determine how clear the peaks(data) are
defined within our spectrum.
 The more lines we have over the same F-max (Maximum
frequency scale). The more accurate our data will be
 Example.
◦ The diagram below shows data that has been collected using 400 LOR.
Notice how the top of the peaks are capped. When the LOR are
increased the data becomes more accurate.
 L2 - TA 16
TA16 -M1H Motor Outboard Horizontal
0.20
0.5
Analyze Spectrum
13-Mar-01 09:14:16
09:13:53

.3852
PK = .7078
LOAD = 100.0
 The spectrum shown
0.16
0.4
RPM = 1497.
1496.
RPS = 24.95
24.94
displays data at 800 L.O.R
with an Fmax of 1600 Hz
PK Accelerat ion in G-s
PK Accelerat ion in G-s

0.12
0.3

0.08
0.2
 The second spectrum
displays the same data but
0.04
0.1 with 3200 L.O.R over the
same Fmax
0

0 400 800 1200 1600

Frequency in Hz
 There are 8 LOR settings we can choose from on the analyzer.
These start at 100 Lines and go up to 12800 Lines.

 The average number of LOR is around 800 Lines for a typical

motor/pump set up

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

This is done in the Database Setup program

Remember. If you double your lines of resolution you double your

data collection time.
Measurement Point Identification
Locating Turning Speed
What is a Measurement Point?

A reference to a particular place/plane on

the machine to be monitored

What do we need them?

To know which machine is inspected?

Where the data was collected?

To ensure same data collection points

To ensure measurement repeatability

 A measurement point is determined by three characters

M1H
Type of side of the machine Measurement
Machine Plane

MOTOR INBOARD HORIZONTAL H=

M = Motor
Horizontal

P = Pump 2 1 1 2 V = Vertical

G=
Gearbox A = Axial
1 = Inboard’(Drive End)
2 = Outboard (Non-Drive End)
 Point identification of Pump

PUMP (P)
MOTOR (M) Coupling
Bearing
(CB)
 Point Identification Horizontal Mount Fan
Fan Bearing 1 (FB1)

MOTOR (M) Fan Bearing 2 (FB2)

Coupling
Bearing
(CB)
 When performing analysis on spectrums and waveforms, it is of utmost
importance to set the turning speed (running speed) correctly

 When the turning speed has been located, the software will re-
calculate all the frequencies to this exact speed.

 Once the turning speed has been set, it is now possible to

determine what is Synchronous/Non-synchronous and Sub-
synchronous energy.
 The spectrum is showing  By locating the turning speed, it
numerous impacts appearing at is very clear that the impacts are
different frequencies. Non-synchronous
BFI - Example 6
Ex6 -P2V PUMP OUTBOARD VERTICAL
12
Route Spectrum
30-Jan-96 15:14:51

10 OVRALL= 13.52 V-DG

RMS = 13.46
LOAD = 100.0
RPM = 2987.
RPS = 49.78
RMS Velocity in mm/Sec

0 20 40 60 80 100 120 140 160

Frequency in kCPM
 Have a look at the spectrum  When the turning speed has
below. been located
◦ Where was the data taken? ◦ What type of energy is
present?
Los - Example 3
EX3 -P2V Pump Outboard Vertical
1.0
Analyze Spectrum
15-Nov -95 10:00:16

RMS = 1.27
0.8 LOAD = 100.0
RPM = 737.
RPS = 12.28
RMS Velocity in mm/Sec

0.6

P2V
0.4
Synchronous
0.2
Energy

0 6000 12000 18000 24000 30000

Frequency in CPM
• Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1X

2X
3X- 6X
BEARING BAND 1 BEARING BAND 2

9-30X RPM
30-50X RPM
• Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1X Imbalance

2X
3X- 6X
BEARING BAND 1 BEARING BAND 2

9-30X RPM
30-50X RPM
• Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X- 6X
BEARING BAND 1 BEARING BAND 2

9-30X RPM
30-50X RPM
• Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X-Looseness
6X
BEARING BAND
Bearing Band 1 1 BEARING BAND
Bearing Band 2 2

9-30X RPM
30-50X RPM
• Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X-Looseness
6X
BEARING BAND
Bearing Band 1 1 BEARING BAND 2

9-30X RPM
30-50X RPM
• Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1X Imbalance

2X Misalignment
3X-Looseness
6X
BEARING BAND
Bearing Band 1 1 BEARING BAND
Bearing Band 2 2

9-30X RPM
30-50X RPM
Data Collection Techniques
 Although there are many different types of transducers
available, the most common type used for day to day
data collection are Accelerometers.

 These transducers provide an electrical charge

proportional to acceleration by stressing piezoelectric
crystals typically 100mV/g sensors are used.
Imagine a doctor who listened to your heart through thick clothing and placed the
stethoscope closer to your kidney than to your heart. You would likely doubt his
diagnosis as he would be basing it on sounds distorted by undue obstruction
and noise from other organs.
We measure signals from the We measure signals from
heart the bearings.

Vibration
Heart

Doc, I’ve been having I have bad news.

heart pain! What!! You have no heartbeat!
When measuring vibration we must always attach the accelerometer
as close as possible to the bearing. More specifically, we must
attach it as close as possible to the centerline of the bearing to
avoid picking up distorted signals.

Protective
cover

Bearing
Location
 Stud
Mounting Mount
Pad
Flat
Magnet
Dual Rail
Sensitivity

Magnet

Hand
Probe

Freq
1.5KHz 10KHz 32KHz
 Whether it is your job to collect the data and/or analyse the
data it is important to understand that the technologies will not
give you the answer to a machines problem unless you have
collected meaningful, quality data

 There are certain considerations that must be taken prior to any

data being collected, these are:

A good understanding of the internal make up of the machine, in order

to understand the best transmission path for data collection - bearing
locations, load zones etc.
Ensure data is collected in a repeatable manner so we can compare
two or more readings to each other - trending purposes
Variable speed machines - it is very important to collect data with the
correct running speed enter into the analyser
 Route-based data collection is commonly used for walk
around vibration analysis

 A maximum of 50 routes can be stored to each area

 And one route can only contain 1044 measurement points

 A route includes information from one area only

 A route does not have to include all the equipment defined in that
area

 The order of the equipment in the route can differ from that of the
database

 Equipment can appear in more than one route BUT can not appear in
the same route twice

 Route measurement points may not include all the points configured
on the equipment