MACHINERY FAULT DIAGNOSIS

Vibration Limits ISO 10816 Misalignment Structural Looseness Rolling Element Bearings Blades & Vanes Electrical Motors
Misalignment is the condition when the geometric centerline of two coupled shafts Structural looseness occurs when the machine is not correctly supported on its base.
Electromagnetic forces vibrations
a rms a [m/s2]

Wear
[m/s2]
Mechanical vibration Evaluation of machine vibration by measurements on non- are not co-linear along the rotation axis of both shafts at operating condition. MP
PM
fBPF Radial
Wear
rotating parts. The revised ISO 10816-3/ -7 is valid since August 2009. A 1X and 2X vibration signal predominant in the axial direction is generally the in- MP
PM PM
Twice line frequency vibration: 2 fL
Poor mounting Wear
dicator of a misalignment between two coupled shafts. Lifetime exceeded
Poor base PM Bar meshing frequency: fbar = fn nbar
Bearing overload
MP
PM
MP
PM Poor base support Incorrect assembly Synchronous frequency: fsyn = 2 fL / p
Angular Misalignment Warped base Manufacturing error Slip Frequency: fslip = fsyn fn
Angular misalignment is seen when the Insufficient lubrica- Pole pass frequency: fp = p fslip
1X
shaft centerlines coincide at one point v [mm/s]
tion Wear
Wear
f [Hz]

along the projected axis of both shafts. Radial

Structural looseness may produce a 1X signal A blade or vane generate a signal frequency fL: line frequency. Stator eccentricity
The spectrum shows high axial vibration The vibration spectrum has a higher noise level and bearing characteristic
f [Hz]
Example:
in the radial direction predominant in the called blade pass frequency fBPF = s fn 3 struts in the intake; x=3 nbar: number of rotor bars Eccentric rotor
at 1X plus some 2X and 3X with 180 frequencies can be identified. Increased level of shock pulses.
horizontal reading. 9 blades; s = 9 p: number of poles Rotor problems
phase difference across the coupling in Identify and trend fBPF, an increase and harmonics x fBPF = fn s x
Measurements should be made on the bolts,
the axial direction. These signals may be
also visible in the radial direction at a feet and bases in order to see a change in the Race Damage may be a symptom of a problem like blade-diffuser
or volute air gap differences.
Loose connections

lower amplitude and in phase. amplitude and phase. A decrease in amplitude Roller bearing geometry and damage
v [mm/s]
1X 2X 3X and 180 phase difference will confirm this
problem.
frequencies:
3
4
Stator Eccentricity
f [Hz]
Axial
2

1 Outer race damage

2 Inner race damage
3 Rolling element damage
Fluid Loose iron
Shorted stator
laminations
1 4 Cage damage

Resonance
PM PM
d Soft foot
Unbalance
There are two basic moving fluid problems
D Outer race damage 1 BPFO 2 .. 3 .. 4 BPFO diagnosed with vibration analysis:
f [Hz]
a [m/s2]
Turbulence
PM PM
Unbalance is the condition when the geometric centerline of a rotation axis Resonance is a condition caused when forcing frequency coincides with (or is close to) Cavitation
doesnt coincide with the mass centerline.
F
unbalance
= m d 2
v [mm/s] 1X
Parallel Misalignment the natural frequency of the machines structure. The result will be a high vibration.
angle of contact
a [m/s2] 1X 2X
Radial
Parallel misalignment is produced when D pitch diameter Outer race damage 1X and 2X signals
d

frequency BPFO as well as

m d rolling element diameter a [m/s2] Turbulence a [m/s2] Cavitation
the centerlines are parallel but offset. harmonics clearly visible 2fL fL without sidebands
The spectrum shows high radial vibra- 1st form of natural flexure 2nd form of natural flexure 3rd form of natural flexure Z number of rolling elements f [Hz] 1X 1X fBPF
Radial predominant
v
tion at 2X and a lower 1X with 180
v v
n shaft RPM Inner race damage
tx tx High resolution should be used
phase difference across the coupling in
a [m/s2]
t tx t t
Ball Pass Frequency, Outer Race fN Sidebands at intervals of 1X when analyzing two poles machines
the radial direction.
These signals may be also visible in the BPFO = n Z ( 1 d cos )

Random
60 2 D 1 BPFI 2 .. 3 .. 4 BPFI
axial direction in a lower amplitude and
f [Hz]
t f [Hz]
A pure unbalance will generate a signal at the rotation speed 1X vibration signal Ball Pass Frequency, Inner Race
Random

predominant at the radial direction. 180 phase difference across the cou- Shaft 1 , 2 and 3 critical
st nd rd

BPFI = n Z ( 1+ d cos )
Inner race damage
pling in the axial direction.
Eccentric rotor
speeds cause a resonance state frequency BPFI as well as

Static Unbalance 60 2 D
when operation is near these no harmonic relationship numerous sidebands at
f [Hz]
f [Hz] f [Hz]
f f f f intervals of 1X.
critical speeds.
0 0
v [mm/s]
1X 2X 3X 1 nat 2 nat 3 nat
st nd rd Ball Spin Frequency
flexure flexure flexure nD d Rolling element damage
270 90 270 90
Radial 2 BSF = ( 1 [ cos ]2 )
180 180 60 d D a [m/s2] Sidebands in intervals of FTF
Rotor offset
Resonance can be confused with other Fundamental Train Frequency Misalignment
Gear
2BSF 4BSF 6 .. 8 ..
FTF = n ( 1 d cos )
common problems in machinery. Resonance Step-up

mm/s
60 2 D Poor base
S Resonance requires some additional
tests to be diagnosed.
m Rolling elements rollover

Example of rollover frequencies

frequency BSF with
harmonics as well as
Spur Gear Worm Gear PM PM
rev/min sidebands in intervals
Ball bearing SKF 6211; n = 2998 RPM f [Hz]
Driving gear Gear wheel
f [Hz]
of FTF. Gear
U The static unbalance is seen when the ma- Driven gear 0-P

Grad
Phase jump at 180 [m/s2]

chine is not in operation, the rotor will turn so Dimensions Rollover frequencies Cage damage fp 1X 2X Tslippage
Alignment Tolerance Table
a [m/s2]
the unbalance mass is at the lowest position. a [m/s2] Gear wheel pair
D = 77.50 mm BPFO = n / 60 4.0781 = 204 Hz FTF and 2nd, 3rd, 4th harmonics Radial
Static unbalance is caused by The static unbalance produces a vibration
PM PM d = 14.29 mm BPFI = n / 60 5.922 = 294 Hz
an unbalance mass out of the signal at 1X, radial predominant and on phase rev/min 2fL
gravity centerline. signals in both shaft extremes. v [mm/s] v [mm/s]
v1 = 30 mm/s Z = 10 2 BSF = n / 60 5.239 = 264 Hz Gear (wheel) Pinion Gear train
1 = 60...80 Worm gear
1.O.

Moment Unbalance = 0 FTF = n / 60 0.4079 = 20 Hz Cage rotation frequency

FTF and harmonics visible

f [Hz] Planet Gear Ring (cone) Bevel Gear

0
0
Sun gear
Lubrication Problems
270 90 v1 = 3 mm/s
U = -U 270 90
180
1.O. 1 = 240
Planet gear
f [Hz] t [ms]

180 fp, 1X, 2X and 2fL signals Modulation of the vibration time
-m f [Hz] f [Hz]
Carrier Bevel gear
signal with the slip frequency fslip
1X and 2fL with sidebands at fP
Amplitude at rotation frequency fn by residual Strong increase in amplitude of the rotation Major fluctuation in
unbalance on rigid rotor. frequency fn at the point of resonance, step- level of shock pulses and
Large temperature in-
crease after lubrication Radial predominant Tslip 2-5 s
S damage frequencies

Gear Faults
up dependent on the excitation (unbalanced High resolution needed
condition) and damping.
Subsequent
Incremento de

Rotor problems
small tempera-
la temperatura
ture increase
Gear Meshing Gear meshing is the contact pattern of the pin-
m
Run Up or Coast Down Test End point
of tooth
meshing
ion and wheel teeth when transmitting power.
The red dotted line 1. Rotor thermal bow 2. Broken or cracked rotor bars
U b Left flank
Working flank is the contact path 1X 1X 2X 3X 4X
Performed when the machine Insufficient lubricant. Right 89
85
Flank line Top land where the meshing a [m/s2]
Race damage Maintenance error a [m/s2]
Moment unbalance may be statically bal-
86 85
is turned on or turned off. Defective sealing Underrating Defective grease regulator
flank 89
5
88 4 87 3
86 2 teeth will be in contact Radial Radial
Tip edge
Moment unbalance is caused by anced. When rotating dynamic unbalance Contaminated lubricant used Grease nipple blocked
6
5
88
Pitch
4 87
Non
3
2
1
during the rotation.
6 Pitch surface
produces a vibration signal at 1X, radial
1
two identical unbalance masses Series of spectra at different Starting point
point working flank
Root flank
Pitch line
located at 180 in the transverse predominant and in opposite phase signals vibration signals tracking may
Incorrect mounting
of tooth meshing Root mantel flank

area of the shaft. in both shaft extremes. reveal a resonance. Bearing forces on floating bearing Flank profile
Bearing rings out of round, deformed Incorrect installation
Gear mesh frequency fZ = z fn
Dynamic Unbalance 0
RPM The use of tachometer is
optional and the data collec-


Incorrect installation
Wrong bearing storage
Wrong housing calculation
Manufacturing error in
Severe vibration
Where z is the number of teeth of the gear rotating at fn.

Bearing temper- a [m/s2]

tor must support this kind of
0 f [Hz]
Shaft manufacturing error bearing housing ature increases
f [Hz]

U
270 90
Incorrect tooth meshing Unbalanced rotor bar current 1X and harmonics with sidebands
test.
270 90
180 Bearing housing overtorqued fZ 2fZ 3fZ 4fZ
180
Shock
pulse Unbalance rotor conditions at fP
Air gap
The suggested alignment tolerances shown above are general values based upon experience and should PM
High resolution spectrum needed
Observable after some operation
-m not be exceeded. They are to be used only if existing in-house standards or the manufacturer of the Damage Fixed bearing Floating bearing fn1
fz PM

machine or coupling prescribe no other values. frequencies fn1

fz
z2 time Possible beating signal
S envelope Cocked bearing z2

Incorrect installation
Resonance Diagnosing Tests
z1

m Dirt Axial 1X, 2X & 3X

PM
z1

fn2 3. Loose rotor bar Loose connections

PM
Bump Test fn2 f [Hz] 1X 2X fbar 2fbar 1X 2X 2fL
U 3 a [m/s2] a [m/s2]

Shaft Bending
a [m/s2]

In practice, dynamic unbalance is the most Wear 2fZ 3fZ Radial

common form of unbalance found. When

Dynamic unbalance is static
and moment unbalance at
the same time.
Detail of X: Radial
rotating the dynamic unbalance produces PM PM
s 2 Response component vibration
Belt Drive
a vibration signal at 1X, radial predominant Excitation force pulse 1 PM X PM
A shaft bending is produced either by an axial X
and the phase will depend on the mass v [mm/s] 3
asymmetry of the shaft or by external forces on s [mm]
distribution along the axis. fz
the shaft producing the deformation. fz
A bent shaft causes axial opposed forces on the t t

Documentation of Balancing
Double beat Belt transmission a
bearings identified in the vibration spectrum as 1 2
f [Hz] f [Hz]
PM PM
common drive system in
f [Hz]
fbar and 2fbar with 2fL sidebands 2fL excessive signal with sidebands
1X in the axial vibration. 2X and radial readings 2
Decaying function
1 1 2 a [m/s2]
2fbar can be higher at 1/3 fL
can also be visible. industry consisting of: Incorrect tooth shape fZ
1X 2X Shock component, Frequency response, Frequency response, Driver Pulley 1X and 2X can appear Electrical phase problem
Detail of X:
v [mm/s]
natural vibration, vertical vertical horizontal PM PM
Driven Pulley The dynamic relation is: 1 1 =222 2 PM Correction must be done
1 1=
Axial
p fz PM immediately
Belt 3.1416 1 1
Belt frequency fB= 1
f1
l =
Before After 2nd mod. fz
X
1st mod. l
Natural frequency, Natural frequency,
l = Belt length X

vertical horizontal

Belt Drive Faults

PM
PM f [Hz]
Tooth break-out

Contact
a [m/s2]
Belt Worn Eccentric Pulleys fz and Harmonics
a [m/s2]

f [Hz] fN PM PM Detail of X:
PM X PM Sidebands
z1 X z2
1X, 2X, 3XfB
Frequency spectra before/after balancing, and balancing diagram.
Journal Bearings
z1 z2
fz
fz

Unbalance Location
Rotating Looseness Journal bearings provide a very low friction surface to support and guide a rotor
through a cylinder that surrounds the shaft and is filled with a lubricant preventing
The geometric center doesnt coincide with
the rotating center of the pulley.
High 1X of the eccentric pulley visible in the
fn1
fn1

Eccentricity, bent shafts

fn2
fn2
f [Hz]

metal to metal contact. 0.3 0.5X 1X f [Hz]

spectrum, predominant in the radial direction.
a [m/s2]

Rotating looseness occur by an excessive clearance between rotor and bearing. s [m]
The belt frequency fB and first two (or even Detail of X: fz and
three) harmonics are visible in the spectrum. Easy to confuse with unbalance, but: Harmonics
PM PM
Measurement phase in vertical an horizon-
2 fB generally dominates the spectrum. PM X PM Sidebands
tal directions may be 0 or 180 .
PT. PUTRANATA ADI MANDIRI
X
Rolling element bearing: Journal bearing: The vibration may be higher in the direction
Pulley Misalignment of the belts.
fz
fz
Jl. Kartini VIII no. 9
aENV [m/s2] Jakarta 10750Indonesia
s [m]
Belt Resonance
Rotation
Radial
Rotation
Radial
If the belt natural frequency coincides with
Ghost frequencies or machine frequencies
a [m/s2]
f [Hz]
www.vibrasi-alignment.com
www.analisapelumas.com
f [Hz]
frequency 1X frequency 1X High vibration damping due to the oil film: either the driver or driven 1X, this frequency fz fM = Ghost frequency
may be visible in the spectrum.
The relative levels of 1X vibration are and harmonics harmonics and High frequencies signals may not be Gearwheel being manufactured

dependant upon the location of the subharmonics

transmitted
Oil whirl: Cutting tool Tel.: +62-21-6010744
Oil-film stability problems
unbalance mass. Displacement sensor and continuous Email: pt@putranata.com
monitoring recommended
May cause 0,3-0,5X component Worm drive part of the
gear cutting machine Visit us at
in the spectrum Offset Angular

www.pruftechnik.com.sg
Twisted zM
Clearance problems (rotating mechanical looseness) 1X of driver or driven pulley visible and
predominant in the axial reading.
ff H
[Hz]
Hz ff [Hz]
Hz f [Hz]

MachineryFaultsDiagnosis_EN.indd 1 08.02.2012 13:47:43