Vibration Analysis Services

FES Systems Inc.

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What is Vibration?

Vibration is the movement of a body about its reference position. Vibration occurs because of an excitation force that causes motion.
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Vibration Terms

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Time Waveform Analysis

hf hig

q. re

overall vibration

tim

e
low

fre

q.

y nc e qu fre

Individual vibration signals combine to form a complex time waveform showing overall vibration

complex time waveform

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Overall Vibration
The total vibration energy measured within a specific frequency range.
includes a combination of all vibration signals within measured frequency range does not include vibration signals outside measured frequency range produces a numerical value
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Amplitude vs. Frequency

Vibration amplitude indicates the severity of the problem. Vibration frequency indicates the source of the problem.
1X

amplitude

2X

3X

4X

frequency
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Vibration- Measurable Characteristics

Velocity is the first derivative of displacement as a function of time, it is the rate of change in displacement (the speed of the vibration). Acceleration is the second derivative of displacement, it is the rate of change of velocity (the change in speed of the vibration).

90

Acceleration

180

Velocity

270

Displacement

360

Time
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Scale Factors
When comparing overall vibration signals, it is imperative that both signals be measured on the same frequency range and with the same scale factors. NOTE: RMS is .707 of peak.

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Measurements & Units

Displacement (Distance)
mils or micrometer, mm

Velocity (Speed - Rate of change of displcmt)

in/sec or mm/sec

Acceleration (Rate of change of velocity)

Gs or in/sec2 or mm/sec2

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Lines of Resolution
Individual Vertical Lines or Bins Located Adjacent to One Another Along the Frequency Axis. Each Bin is used to Store Individual Amplitude at a Specific Frequency Location.
7200 CPM 7200 CPM

3570 CPM

Amplitude

Amplitude

Frequency in CPM

Frequency in CPM

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Accelerometers
Rugged Devices Operate in Wide Frequency Range (Near 0 to above 40 kHz) Good High Frequency Response Some Models Suitable For High Temperature Require Additional Electronics
(may be built into the sensor housing)

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Velocity Sensors
Often Measure Bearing Housings or Machinery Casing Vibration Effective in Low to Mid Frequency Range (10 Hz to around 1,500 Hz) Self Generating Devices

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Displacement Probe/Eddy Probe

Measure Relative Distance Between Two (2) Surfaces Accurate Low Frequency Response

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Multi-Parameter Monitoring
Same Data in Velocity and Acceleration
0.40 - Model 32L S/N AB10099P #2 West -C3H Compressor Inboard Horizontal Route Spectrum 06-Feb-01 14:02:05 OVRALL= .6123 V-DG PK = .6091 LOAD = 100.0 RPM = 2990. RPS = 49.83 Reference Env/Prf-Std
5 FES Model 32L S/N AB10099P #2 W est -C3H Compressor Inboard H orizontal Route Spectrum 06-Feb-01 14:02:05 OVR ALL= .6123 V-DG PK = 8.19 LOAD = 100.0 RPM = 2990. RPS = 49.83 Reference Env/Prf-Std

0.32 PK Velocity in In/Sec

4 PK Acceleration in G-s

0.24

0.16

0.08

0 0 40 80 120 160 Frequency in kCPM 200 240

0 0 40 80 120 160 Frequency in kCPM 200 240

Velocity Spectrum

On the same bearing, low freq. events (imbalance, misalignment, etc.) show best in the velocity spectrum; while high freq. events (bearing faults, gearmesh) show best in the acceleration spectrum

Acceleration Spectrum

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Sensor Relationships
100 Displacement (mils) 10 Acceleration (g's)

Amplitude 1.0 (mils, in/sec, gs)

Velocity (in/sec)

0.1 1 0.01 10 100 1,000 10,000 Common Machinery Operating Range

Frequency (Hz)

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Resonance

typically 10% or greater

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Detection vs. Analysis

Detection
Alarm limits are established for each measurement. When the measurements value exceeds its programmed alarm limits, the predictive maintenance software or data collector notifies the analyst of a problem.

Analysis
Once detected, analyzing exceptional measurements provides insight to the problem itself, and to its root cause.

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Important Frequency Peaks

Rotational Speed or Even Multiples Always present but excessive amplitude or multiple harmonics can indicate a problem. Electric motors always have frequency peaks at shaft rotational speed and at line frequency i.e. 60 Hz. Two pole motors will always display a 2X line frequency peak.

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Important Frequency Peaks

Gas Pulsation Frequencies
Screw compressors - gas pulsation frequency(cpm) occurs at [No. of lobes on male rotor] X [ rotational speed (RPM)] Pumps or fans - fluid pulsation frequency(cpm) occurs at [No. of vanes, lobes or blades] X [ rotational speed (RPM)] Recip. Compressors - gas pulsation frequency (cpm) occurs at [No. of pistons] x [ rotational speed (RPM)] Harmonics or even multiples (2X and 3X) of gas pulsation frequencies always present and are most noticeable on oil separator vessels.
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Setting Up the Measurement

Physical Considerations
Selecting the Machinery Selecting Measurement Planes Selecting Sensor Locations Surface Preparation Sensor Mounting Techniques

Database Considerations
Parameters (multi-parameters) Alarm Limits Setting Fmax Scale Factors
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Selecting the Machinery

Critical - If a failure or shutdown occurs,
production is stopped, or machine performance creates an unsafe environment

Essential Spared - If a failure or

shutdown occurs, production is disrupted

Non Essential Spared - If a failure

or shutdown occurs, production loss is inconvenienced, however, a spare unit can be brought on-line, or a repair can bring the production unit back on-line without significant loss of production

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Thinking Ahead
Walk Through Machinery Data Sheets

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Measurement Planes

radial
vertical horizontal

axial

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Sensor Location
(qualifying and identifying)
Measurement POINT numbering follows flow of power: Motor Non-Driven End (NDE) Motor Driven End (DE) Compressor Driven End (DE) Compressor Non-Driven End (NDE)

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Sensor Location

The accelerometer must be located over the bearing of interest. Avoid air gaps in housings whenever possible. Air gaps will skew vibration readings.
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Sensor Location

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Mounting Methods

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Hand-held/Probe Mounting
Rapid and convenient. Subject to many sources of error. Use only as a last resort.

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Types of Alarms
Overall Vibration Limits Spectral Enveloping Spectral Bands Phase Alarms

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Acceptable Vibration Levels

Tables are published that show overall vibration levels as a function of rotational speed or vibration frequency for the purpose of determining whether vibration levels are acceptable. As a general rule for compressors operating at 3600 RPM an overall vibration level of 0.3 ips RMS would be cause for concern

For piping and valves overall readings exceeding 1.0 ips RMS would be cause for concern though actual stress values induced by the vibration may be quite low and no corrective action needed. Some engineering evaluation should be conducted to determine this.

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ISO Guidelines
ISO 2372 overall velocity vibration guidelines

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acceleration - Gs (peak)

Assessing Overall Vibration Severity

Frequency - CPM FES Systems Inc. 36

velocity - in/sec (peak)

Overall Vibration Trend Plot

0.24 0.20 PK Velocity in In/Sec 0.16 0.12 0.08 0.04 0 0 100 200 300 400 Days: 11-AUG-95 To 11-DEC-96 500 VIB - Alignment Fault ALIGNMENT -M1H MOTOR OUTBOARD BRG. - HORIZONTAL Trend Display of FAULT OVERALL VALUE

-- Baseline -Value: .06350 Date: 11-AUG-95

ALERT WARNING

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Spectral Enveloping
0.40 0.35 PK Velocity in In/Sec 0.30 0.25 0.20 0.15 0.10 0.05 0 0 400 800 1200 Frequency in Hz 1600 2000 VIB - Balance Fault BALANCE -M2A MOTOR INBOARD AXIAL Route Spectrum 14-MAR-96 12:10:26 OVRALL= .3260 V-DG PK = .3257 LOAD = 100.0 RPM = 1777. RPS = 29.62 Reference Envelope

alarm is triggered

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Phase Alarms
A2 - Machine #6 (Various Setups) MACH#6 -PPH PEAK PHASE DATA 0 Correlation Display Phase vs Peak Data Period: 26-Dec-96 To 28-Dec-96 2.500 90 270

180 Peak

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Acceptable Vibration Levels

Motor and compressors with sleeve bearings do not lend Motor and compressors with sleeve bearings do not lend themselves well to to readings with accelerometers andand for for themselves well readings with accelerometers dependable information a device such as a proximity probe dependable information a device such as a proximity probe should be used measure vibration in mils displacement. should be used to to measure vibration in mils displacement. Probes should be oriented in two planes 90 apart and Probes should be oriented in two planes 90 apart and displacement cannot exceed the shaft to bearing clearance. displacement cannot exceed the shaft to bearing clearance.

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Acceptable Vibration Levels

For Individual spectrum peaks limits are set by their perceived For Individual spectrum peaks are limits are set by their perceived cause but some general limits shown below:
cause but some general limits are shown below:

Compressors: Compressors: Rotational speed 1X, 2X, 2X, 3X 3X 0.25 ips RMS Rotational speed 1X, 0.25 ips RMS Gas Pulsation at compressor 0.27 ips RMS Gas Pulsation at compr. 0.27 ips RMS Bearing fault frequencies 0.15 ips RMS Bearing fault frequencies 0.15 ips RMS Roller bearings (2000-3000 Hz) 2.5 gs Roller bearings (2000-3000 Hz) 2.5 gs

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Acceptable Vibration Levels Motors: Rotational Speed 1X, 2X, 3X 0.25 ips RMS Line Frequency 1X, 2X 0.13 ips RMS Motors: Bearing fault frequencies 0.15 ips RMS Rotational Speed 1X, 2X, 3X 0.25 ips RMS
Line Frequency 1X, 2X Bearing fault frequencies 0.13 ips RMS 0.15 ips RMS

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Readings-How Often?
At start up - Baseline
At start up - Baseline

Six after start startup upunless unlessaaproblem problem suspected. After Six months months after is is suspected. After that every year after afterthat thatunless unless deteriorating that every66month month to to one one year aa deteriorating trend isisobserved. trend observed.
At 25000 25000 hours be taken every three months At hours readings readingsshould should be taken every three months extend thetime time before before an isis required. toto extend the an internal internalinspection inspection required.

Anytime an unusual unusualnoise noise or vibration is Anytime an or vibration is noticed. noticed.

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Spectrum Analysis Techniques

Collect Useful Information Analyze

500 HP/3570 RPM Motor

Model 23LE C3 C4 C2

M1

M2

C1

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Spectrum Analysis Techniques

Some compressors have a combination of sleeve bearings and ball thrust bearings that require different analysis techniques.

FES Model GL Series Compressors

Thrust and Sleeve Bearing Location

Sleeve Bearing Location

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Sleeve Bearing Wear Pattern

Latter stages of journal bearing wear are normally evidenced by presence of whole series of running speed harmonics (up to 10 or 20). Wiped journal bearings often will allow high vertical amplitudes compared to horizontal, but may show only one pronounced peak at 1X RPM. Journal bearings with excessive clearance may allow a minor unbalance and/or misalignment to cause high vibration which would be much lower if bearing Source: Technical Associates Inc. clearances were set to specifications. Illustrated Vibration Chart
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Why Do Bearings Fail?

Inadequate Lubrication
- too much - too little - contaminated

Excessive Load Caused by:

- misalignment - imbalance - bent shaft - etc.....

Spall On Outer Race

Improper Handling or Installation Age

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Typical Bearing Failure Rate

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Bearing Defect Frequencies

BPFO
Ball Pass Frequency Outer Race

BPFI
Ball Pass Frequency Inner Race

BSF
Ball Spin Frequency

FTF
Cage Frequency or Fundamental Train Frequency

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Bearing Failure Stages

Stage 1
No apparent change on typical velocity spectrum

Stage 2
Defects harmonic frequencies appear

defects fund. frequency range

defects harmonic frequency range

Stage 3
Defects fundamental frequencies also appear and may exhibit sidebands

Stage 4
Defects harmonic frequencies develop multiple sidebands (haystack), fundamental freqs. grow and also develop sidebands

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Sidebands
0.14 RMS Acceleration in G-s 0.12 0.10 0.08 0.06 0.04 0.02 0 0 1000 2000 Frequency in Hz 3000 4000 Freq: 2634.6 Ordr: 43.84 Spec: .02417 Dfrq: 120.19 VIB - Alignment Fault ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL Route Spectrum 01-AUG-96 15:15:26 OVRALL= .0665 V-DG RMS = .2506 LOAD = 100.0 RPM = 3606. RPS = 60.10

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0.06 0.05 PK Velocity in In/Sec 0.04 0.03 0.02 0.01 0 0

VIB - Alignment Fault ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL Route Spectrum 01-AUG-96 15:15:26 OVRALL= .0665 V-DG PK = .0660 LOAD = 100.0 RPM = 3606. RPS = 60.10

Harmonics

1000

2000 Frequency in Hz

3000

4000

Freq: 57.69 Ordr: .960 Spec: .02572

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Waterfall Plot
VIB - Alignment Fault ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL 0.05 Max Amp .0456 PK Velocity in In/Sec 0 11-DEC-96 21-NOV-96 28-OCT-96 30-SEP-96 05-SEP-96 01-AUG-96 0 1000 2000 Frequency in Hz 3000 4000 Freq: 57.69 Ordr: .975 Sp 1: .02589 01-AUG-96 15:15:26 RPM= 3550.

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Stator problems generate high vibration at 2X line frequency (2FL). Stator eccentricity produces uneven stationary air gap between rotor and stator which produces very directional vibration. Differential Air Gap should not exceed 5% for induction motors and 10% for synchronous motors. Soft foot and warped bases can produce an eccentric stator. Loose iron is due to stator support weakness or looseness. Shorted stator laminations can cause uneven, localized heating which can distort the stator itself. This produces thermally-induced vibration which can significantly grow with operating time causing stator distortion and static air gap problems.
Source: Technical Associates Inc. Illustrated Vibration Chart

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Eccentric Rotors produce a rotating variable air gap between the rotor and stator which induces pulsating vibration (normally between 2FL and closest running speed harmonic). Often requires "zoom" spectrum to separate 2FL and running speed harmonic. Eccentric rotors generate 2FL surrounded by Pole Pass frequency sidebands (FP), as well as FP sidebands around running speed. FP appears itself at low frequency (Pole Pass Frequency = Slip Frequency X #Poles). Common values of FP range from about 20 to 120 CPM (0.3 - 2.0 Hz). Soft foot or misalignment often induces a variable air gap due to distortion (actually a mechanical problem; not electrical).
Source: Technical Associates Inc. Illustrated Vibration Chart

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Broken or Cracked rotor bars or shorting rings; bad joints between rotor bars and shorting rings; or shorted rotor laminations will produce high 1X running speed vibration with pole pass frequency sidebands (FP). In addition, these problems generate FP sidebands around the second, third, fourth and fifth running speed harmonics.
Source: Technical Associates Inc. Illustrated Vibration Chart

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Loose or open rotor bars are indicated by 2X line frequency (2FL) sidebands surrounding Rotor Bar Pass Frequency (RBPF) and/or its harmonics (RBPF = Number of Bars X RPM). Often will cause high levels at 2X RBPF, with only a small amplitude at 1X RBPF. Electrically induced arcing between loose rotor bars and end rings will often show high levels at 2X RBPF (with 2FL sidebands); but little or no increase in amplitudes at 1X RBPF.
Source: Technical Associates Inc. Illustrated Vibration Chart

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Phasing problems due to loose or broken connectors can cause excessive vibration at 2X Line Frequency (2FL) which will have sidebands around it spaced at 1/3 Line Frequency (1/3 FL). Levels at 2FL can exceed 1.0 in/sec if left uncorrected. This is particularly a problem if the defective connector is only sporadically making contact. Loose or broken connectors must be repaired to prevent catastrophic failure.
Source: Technical Associates Inc. Illustrated Vibration Chart

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0.40

Dosk - RAM 700 HP Motor Test1 RAM TEST 1-M2L Mot. Inboard Horiz./2X Line Freq Route Spectrum 10-Apr-01 08:20:35 OVRALL= .3045 V-DG PK = .3028 LOAD = 100.0 RPM = 3579. RPS = 59.64 Reference Env/Prf-Std

0.32

PK Velocity in In/Sec

0.24

0.16

0.08

0 0 8000 16000 Frequency in CPM 24000 Freq: Ordr: Spec: 7200.0 2.012 .283

The 2x Line frequency on this motor is .283 in/sec. this indicates a stator eccentricity problem. The spectrum was taken at 6400 lines of resolution.
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0.40

Dosk - RAM 700 HP Motor Test1 RAM TEST 1-M2L Mot. Inboard Horiz./2X Line Freq Route Spectrum 10-Apr-01 08:20:35 OVRALL= .3045 V-DG PK = .2922 LOAD = 100.0 RPM = 3579. RPS = 59.64 Reference Env/Prf-Std

0.32

2 x Line Freq.
PK Velocity in In/Sec 0.24

0.16

0.08

7140 RPM 2x turning speed

0 6800 7000 7200 Frequency in CPM 7400 7600 Freq: Ordr: Spec: 7200.0 2.012 .283

The 2 x Line Frequency must be separated from 2 x turning speed to determine rotor or stator problems. The data collector must be set The x Line F number of lines of resolution to separate these two frequencies to a 2 sufficient

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Vibration analysis can be used to determine rotor problems in motors. The rotor bar pass frequency has penetrated the narrow band alarm.
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Vibration Analysis Services

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