Vibration & Condition

Monitoring Training

Section-1

Key Learning Point

Vibration Basics
Mechanical vibration is the dynamic motion of machine components
Vibration is a symptom, not the root cause of a possible problem
Moving parts of Machines create vibration at different frequencies
3 Types of Units: Displacement, Velocity & Acceleration
3 Types of Vibrations: Casing Absolute, Shaft Relative, Absolute Shaft
Integration of accelerometer or velocity sensor is NOT same as measurement of
shaft vibration which is usually measured in displacement units
5 Basic Characteristics of Vibration:
Amplitude
Frequency
Phase
Form/Shape
Position

Input
(Periodic,
random,. . .external)

Rotor

Output
(Excited vibrations)

Key Learning Point

Transducer Operation Principle
3 Types of Transducers: Proximity, Accelerometer & Velocity
Piezo Velocity sensors are Accelerometer with inbuilt integrators
Proximity Transducer Systems:
Measures distance between probe tip & target
Work on eddy current principle (Faradays Law)
3 major components, probe, extension cable & signal conditioner
Used to identify Rotor Related problems
Provides an AC o/p ~ to vibration & DC o/p ~ to gap
Commonly used appl. are shaft vibration, axial position, Diff. expansion,
keyphasor, speed etc.
Performance of the sensor can be effected by Material, Temperature,
Mounting constraints & Run outs (mechanical & electrical)
Accelerometer Transducer Systems:
Produces an o/p charge when held against a vibrating surface (piezoelectric)
Charge o/p is ~ to vibration acceleration (force) f = m x a
Crystal used, compressions & shear mode
Rugged, industrial, high temperature options available..
Commonly used appl. are absolute vibration
Very high frequency rangegood for high speed machines & gear box
Performance of the sensor can be effected by improper mounting, cable
installation, triboelectric noise, sensor mishandling

Key Learning Point

Transducer Operation Principle (Contd..)
Velocity Seismoprobe Transducer Systems:
Made up of a coil supported by springs and a permanently fixed magnet Coil
Movement relative to the magnet generates an o/p ~ velocity vibration
Generally requires no excitation voltage/current or output signal amplifiers
Ideally for low frequency & low rpm machines/applications
Moving parts, calibration & performance should be checked frequently
Sensitive to mounting orientation
Piezo-Velocity Transducer Systems:
Similar to an accelerometer with an inbuilt integrator
Provides an o/p ~ velocity vibration
No Moving parts, higher life expectancy compared to velocity-seismoprobe

Key Learning Point

Transducer Selection
3 Types of Transducers: Proximity, Accelerometer & Velocity
Correct Machine Monitoring, Protection & Data Acquisition will happen only when
Correct Transducer is Chosen for the given Application
Properly installed
At proper location
& when done by People with the necessary Skills
Machines with fluid film/journal/sleeve bearing = Proximity Transducer
Machines with roller bearing = Accelerometer/Velocity Transducer
Other influencing factors for Transducer Selection
Problem to be identified: Rotor/Casing Related
Frequency of interest v/s transducer frequency range
Mounting considerations, space availability, access etc.

Key Learning Point

Measurement Parameters & Concepts
3 Types of Vibrations: Casing Absolute, Shaft Relative, Absolute Shaft
Relative Shaft Vibration:
Movement of shaft w.r.t. to bearing
Measured using Proximity Probes
Use 2 (XY) probes for each bearing (API670 standards)
Casing Absolute Vibration:
Movement of bearing/housing w.r.t. inertial (fixed) reference frame
Measured using Accelerometer/Velocity Probes
Measure using Proximity Probes
Use 2 (XY) probes for each bearing (API670 standards)
Absolute Shaft Vibration:
Used when the shaft & the bearing vibrate equally/similarly,
Combine Relative & Absolute measurements to absolute shaft vibration:
absolute shaft
abs

= relative shaft/bearing + absolute bearing

=
rel
+
abs

As vibration is a vector this is not a simple arithmetical addition

Key Learning Point

Measurement Parameters & Concepts (Contd..)
Axial/Thrust Position:
Measurement of relative position between collar & thrust bearing
Primary purpose is to ensure against an axial rub between rotor & stator
Proximity Sensors are typically used for this measurement
API670 recommends Dual Probe with 2-o-2 voting
Differential Expansion:
Steam turbine has a thick-heavy case & lighter-hollow rotor
Case grows slower than the rotor due to bigger mass
Make sure the case has expanded enoughprevent rotor contact
DE.. is the difference between thermal growth of the rotor & casing
Most critical during a turbine "cold" start-up
Proximity Sensors are typically used for this measurement
There are four type of Differential Expansion measurements in use
Standard/Single Sensor Differential Expansion
Complimentary Input Differential Expansion
Single Ramp Differential Expansion
Dual Ramp Differential Expansion

Key Learning Point

Measurement Parameters & Concepts
Casing Absolute Expansion:
Used to monitor the proper thermal growth of the turbine's shell/casing
Measured during startup, operation, and shutdown
Used in conjunction with a Differential Expansion (DE) measurement
Thermal growth of case & rotor can be monitored to prevent costly rubs
LVDTs are usually used for this application
Other Measurements:
Phase Reference (Keyphasor)
Speed
Over speed
Reverse Rotation
Rotor Acceleration
Temperature
Air Gap Measurement (Hydro Generators)
Valve Position (Steam Turbines)
Rod Drop/Rod Position (Reciprocating Compressors)

Section-2

Key Learning Point

Monitoring & Protection System Basics
Provides usable information about the overall health of the machine/asset
Provides safety shutdown of a plant/machine operation without human intervention
Step-1...Machine Classification (Based on Criticality)
Category A: Critical Machines such as Turbine Generator, Compressors, BFPs
Category B: Semi-Critical Machines such as Fans, Blowers, Medium Size Pumps, Motors etc.
Category C: Non-Critical Machines such as Mills, CT Fans, Coal Handling Plant etc

Step-2... Follow the Best Practice

Know your machines very welltype, OEM, failure modes, bearing types etc.
Know the Application & Technologysensors, systems, measurement parameters, industry
standards etc.
Write good specifications, qualify system providers on technology, quality & support
Not Cost Only, OWN the Specs

Step-3... Implement Step-1 & 2 Based on Category

Category A: Critical Machines such as Turbine Generator, Compressors, BFPs
API670 compliant Online Protection, Condition Monitoring & Diagnostics
Plan for redundancies & backups, Ensure to adopt the Best & Latest Technologies
Proper Design, Installation & Commissioning very critical...
Category B: Semi-Critical Machines such as Fans, Blowers, Medium Size Pumps, Motors etc.
Online Protection & Condition Monitoring, Follow International Standards like API670
Ensure to adopt proven technologies
Proper Design, Installation & Commissioning very critical...
Category C: Non-Critical Machines such as Mills, CT Fans, Coal Handling Plant etc
Localized/Distributed Online Monitoring & Protection
Online Condition Monitoring (some times...used)
Apply Simple & easy to Use Technologies

API 670

4th

Edition

Key Learning Point

The standard details the following measuring techniques:Casing Vibration

Radial Shaft Vibration
Shaft Axial Position
Shaft Rotational Speed
Piston Rod Drop
Phase Reference
Overspeed
Critical Machinery Temperatures

Sensor specification details include:

VM600 Machine Protection &

Monitoring System

Sensitivity
Dynamic range
Operating Temperature Range
Accuracy
Mounting Options
Connector & Cabling Standards
Immunity to Shock, etc.

The key concepts for Protection & Monitoring systems are:

Integral power supplies, processing, display etc. in One Contiguous Rack
A single circuit failure shall not affect more than two channels
Minimum resolution of 2% full scale
Individual Channel Indication LEDs for Status (Alarm, Danger, OK)
4-20mA output per channel
Dual Raw Buffered transducer outputs for each channel

Condition Monitoring Techniques

Key Learning Point

Maintenance Strategies Whats best for us?

Run to breakdown
For inexpensive, not critical machines where duplication exists

Scheduled or Preventive Maintenance

Or time-based maintenance. Time intervals are sometime conservative

Condition Based Maintenance

For expensive assets. Sometimes called predictive maintenance

CMS Systems:
Level-1, Basic Protection & Monitoring only with offline analysis (Reactive Operations)
Level-2, Online Analysis only (Proactive Operations)
Level-3, Online Analysis & Diagnostics (IdealOur Goal)..helps manage your operations
below Alarms
Process Data Integration with DCS/Plant control is critical to success for an effective
Condition Monitoring system program.

Key Learning Point

Analysis System Plots
Static Plots
Machine Train Diagram
Bar graph
Trend
Multivariable Trend
Fast/Average/Historic
Correlation (X v/s Y)
Acceptance Region

Dynamic Plots
Time Waveform
Spectrum
Cascade Plot
Waterfall Plot
Orbit
Shaft Centreline
Polar Plot
Bode Plot

Static Plots are used to represent a scalar values

Dynamic Plots are used to represent the dynamic waveforms/behaviour
Need the whole Tool Kit Often multiple types of plots are used together to
ascertain machine problems
Type of plot & its usage often depends on machine operating state like
stopped, slow roll, steady state, transient (Startup/Shutdown) etc