VIBRATION ANALYSIS

BASICS

Presented by : H.S.A

Topics:

Introduction to Vibration Theory

Topics:
Introduction to Vibration Theory

Basic Terminology & Practices

Topics:
Introduction to Vibration Theory

Basic Terminology & Practices

Basic Fault Identification

Topics:
Introduction to Vibration Theory

Basic Terminology & Practices

Basic Fault Identification

Case History Examples (show from MT)

Topics:
Introduction to Vibration Theory

Basic Terminology & Practices

Basic Fault Identification

Case History Examples (Show from MT)

Advanced Topics

Topics:
Introduction to Vibration Theory

Basic Terminology & Practices

Basic Fault Identification

Case History Examples

Advanced Topics

Requested Topics ???

WHAT IS VIBRATION?

MOTION OF A BODY ABOUT A

REFERENCE POINT

For example,
SHAFT VIBRATION

CAUSED BY AN UNDESIRABLE
MECHANICAL FORCE

It's helpful to understand a little

about the signal processing
step in order to get the most
benefit from the Analyzer

VIBRATION
SOURCE
TRANSDUCER
ELECTRICAL
SIGNAL
TIME
WAVEFORM

INFORMATION
NEEDED FOR
ANALYSIS

SIGNAL
PROCESSING
SPECTRUM
PROBLEM
DETECTION
AUTOMATED
DIAGNOSTICS

MANUAL
DIAGNOSTICS

COLLECTION OF VIBRATION
MEASUREMENTS

Compare Across Points

5.3 mils

1.2 mils

2.3 mils

3.1 mils

Directional vibration on outboard bearing

Signal Processing Flow

Transducer
Amplitude

Waveform

Time

FFT

Amplitude

Spectrum

Data Collector/Analyzer

Frequency

Heavy Spot

Rotation

Time Waveform
Heavy Spot

Amplitude
+

Rotation

Time

1 revolution

Time Waveform
Amplitude
+

Heavy Spot

Time
360 degrees

Rotation

1 revolution
3600 rpm

3600 cycles per minute

60 Hz

60 cycles per second

1 order

one times turning speed

Time Waveform
Amplitude
+

Time

1000 rpm

1 revolution

Time Waveform
Amplitude
+

Time

1000 rpm

1 revolution

4 blades

vibration occurs 4 times per revolution

4 x 1000 rpm

vibration occurs at 4000 cycles per minute

=

4000 cpm

Time Waveform
Amplitude
+

12 tooth
gear

Time

1000 rpm

1 revolution

Time Waveform
Amplitude
+

12 tooth
gear

Time

1000 rpm

1 revolution

12 teeth are meshing every revolution of the gear

12 x 1000 rpm

=
=

vibration occurs at 12,000 cycles per minute

12,000 cpm = 200 Hz

+
0

Time

+
0

Time

+
0

Time

Time Waveform contains all the different

frequencies mixed together
+

Time

TIME WAVEFORM

AMPLITUDE VS TIME

We are now entering the

Frequency Domain

FFT - Fast Fourier Transform

We are now entering the

Frequency Domain
FFT - Fast Fourier Transform

Separates individual frequencies

We are now entering the

Frequency Domain
FFT - Fast Fourier Transform

Separates individual frequencies

Detects how much vibration at each

frequency

Amplitude

Frequency

Amplitude

Amplitude

Time

Amplitude

Time

Time

y
en c
u
q
Fre

Time

1x

Frequency

+
0

Time

+
0

4x

Frequency

Time
12x

Frequency

FREQUENCY SPECTRUM (or

FFT)

AMPLITUDE VS FREQUENCY

Amplitude
1.8
1.5
1.2
0.9
0.6
0.3
1000

2000
Frequency

3000

4000

VIBRATION TERMINOLOGY

AMPLITUDE
DISPLACEMENT
VELOCITY
ACCELERATION
FREQUENCY
HERTZ
CPM
ORDERS
PHASE (LAG)
DEGREES

HOW BAD IS IT?

(MOVEMENT)
(SPEED)
(FORCE)

Spectrum
Amplitude

WHERE IS IT
Frequency
(CYCLES / SECOND)
(CYCLES / MINUTE)
(MULTIPLES OF RUN SPEED)
TIME BETWEEN EVENTS
(ROTATIONAL MEASUREMENT)

What's an Fmax,
and why does it matter?

What's an Fmax,
and why does it matter?

Maximum Frequency of the Spectrum

What's an Fmax,
and why does it matter?
Maximum Frequency of the Spectrum

If you don't collect it, you can't analyze it

Fmax = low frequency

Fmax = high frequency

What's an Fmax,
and why does it matter?
Maximum Frequency of the Spectrum

If you don't collect it, you can't analyze it

Why not always collect the highest Fmax

possible?
Limitations of the analyzer
Takes extra data storage space
Reduces the Resolution of the Spectrum

What's the difference between

Acceleration, Velocity, & Displacemen
?

What's the difference between

Acceleration, Velocity, & Displacemen
?

The frequency range of interest

Acceleration
(high freq.)
Velocity
(general purpose)
Displacement
(low freq)

And let's not forget

Phase Analysis

Phase Comparison

In Phase:

180 Out of Phase:

o

Phase Comparison

In Phase:

180 Out of Phase:

o

Amplitude - A
+
0

Amplitude - A
+
Time

Amplitude - B
+

Amplitude - B
+

Time

Time

Time

180 Out of Phase:

In Phase:
A

A
B

Tach Pulse

Phase Measured
between the two

Time
360 degrees

Vibration Signal

Time for a demonstration:

Rotor kit / Strobe

data collection tips

Spectrum Analysis
1.8
1.5
1.2
0.9
0.6
0.3

1xRPM - BALANCE
2xRPM - ALIGNMENT
3-6xRPM - LOOSENESS
GEARS & ANTI FRICTION BEARINGS
6-30xRPM
30-50xRPM
1000

2000
Frequency

3000

4000

Vibration Spectrum and

Parameter Bands
2X

Bearing Bearing

Gears

Bearing

Amplitude

SubHarmonic 1X

1x

50x
Trend of
Bearings

2x

Trend of
Balance
5
mm/sec
Time
(Days)

1
mm/sec

Alarm
Time
(Days)

SELECTED FREQUENCY
BAND ALARMING
2X

Bearing Bearing

Gears

Bearing

Amplitude

SubHarmonic 1X

1x

50x
Trend of
Bearings

2x

Trend of
Balance
5
mm/sec
Time
(Days)

1
mm/sec

Alarm
Time
(Days)

OVERALL ALARM

AREA (ENERGY) UNDER THE SPECTRUM

'SHOTGUN'

METHOD, NO DIAGNOSTIC INFORMATION

ALARM LEVEL = 0.1 IN/SEC

PEAK - RMS
OVERALL VALUE

BEARING AND GEAR PROBLEMS WILL NOT GIVE EARLY

WARNING WITH OVERALL ALARMS

ENVELOPE ALARMING
CONSTRUCTED FROM BASELINE SPECTRA

"VARIABLE SHAPE ENVELOPING"

EFFECTIVE IN FINDING SMALL CHANGES

0.1 in/sec
Increase
200 % rise
over Reference

0.3 in/sec
Absolute
Value
.02 in/sec
Minimum
Value

Diagnosing Machine Faults

Imbalance

Diagnosing Machine Faults

Imbalance

Misalignment

Diagnosing Machine Faults

Imbalance

Misalignment

General Looseness or Wear

Diagnosing Machine Faults

Imbalance

Misalignment

General Looseness or Wear

Bearing Defects

Diagnosing Machine Faults

Imbalance

Misalignment

General Looseness or Wear

Bearing Defects

Gear Defects

Diagnosing Machine Faults

Imbalance

Misalignment

General Looseness or Wear

Bearing Defects

Gear Defects

and many more...

What is Imbalance?
Center of Shaft = Center of Mass

Heavy Spot
Center of Mass

Center of Shaft

Rotation

Types of Imbalance

Imbalance can be separated into two

components:

Static Imbalance:

(constant across rotor)

Couple Imbalance:
o

(opposite across rotor)

IMBALANCE

CHARACTERISTICS

IMBALANCE

CHARACTERISTICS

HIGH RADIAL PEAKS AT 1 X SHAFT RPM

IMBALANCE

CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM

IMBALANCE

CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM
LOW HARMONICS OF SHAFT RPM

IMBALANCE

CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM
LOW HARMONICS OF SHAFT RPM
1 X RPM SINUSOIDAL PATTERN IN THE TIME WAVEFORM

IMBALANCE

CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM
LOW HARMONICS OF SHAFT RPM
1 X RPM SINUSOIDAL PATTERN IN THE TIME WAVEFORM
CAN CAUSE OTHER FAULTS TO SHOW UP, ESPECIALLY
LOOSENESS

IMBALANCE
RADIAL VIBRATION
AT 1 X TURNING
SPEED IS MUCH
MORE SIGNIFICANT
THAN IN THE AXIAL
DIRECTION

Freq: 60.04
Order: 1.010
Spec: .390

What is misalignment?
Deviation from a common centerline during operation.

GRRR!

BEFORE

hmmm
!

AFTER

Types of Misalignment
Offset

Angular

Both

MISALIGNMENT

CHARACTERISTICS

MISALIGNMENT

CHARACTERISTICS

2 X SHAFT RPM MAY DOMINATE

MISALIGNMENT

CHARACTERISTICS

2 X SHAFT RPM AXIAL DOMINATES

HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM

MISALIGNMENT

CHARACTERISTICS

2 X SHAFT RPM AXIAL DOMINATES

HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM

HIGH RADIAL AT 1, 2 AND 3 X SHAFT RPM

MISALIGNMENT

CHARACTERISTICS

2 X SHAFT RPM AXIAL DOMINATES

HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM

HIGH RADIAL AT 1, 2 AND 3 X SHAFT RPM

HARMONICS OF SHAFT RPM ABOVE 4 X ARE

USUALLY LOW

MISALIGNMENT

CHARACTERISTICS

2 X SHAFT RPM AXIAL DOMINATES

HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM

HIGH RADIAL AT 1, 2 AND 3 X SHAFT RPM

HARMONICS OF SHAFT RPM ABOVE 4 X ARE

USUALLY LOW

PHASE READINGS SHOW A 180 DEGREE SHIFT

ACROSS THE COUPLING

MISALIGNMENT
2X IS DOMINANT
LOCATION OF
VIBRATIONS
VANE PASS IS DUE TO 11
BLADE PUMP IMPELLER
VANE PASS
Freq: 59.50
Order: 2.010
Spec: .640

Using Phase to distinguish Imbalance

from Misalignment
Cross Coupling Phase
180 deg out

GRRR
!

In Phase

MECHANICAL LOOSENESS

MULTIPLE HARMONICS OF RUN SPEED

RUN SPEED HARMONICS

1X, 2X, 3X, 4X, 5X, 6X, 7X, 8X

2X
3X
1X

5X
4X

6X
8X
7X

Discuss "Harmonics"

Bearing Fault Frequencies

Function of the Geometry of the Bearing

Outer Race
(BPFO)

Inner Race
(BPFI)

Ball Spin
(BSF)
Cage
(FTF)

ROLLER BEARING EXAMPLE

Freq: 441.03
Order: 7.390
Spec: .180

Discussion Topics:
Fault frequencies

Inner -vs- Outer race defects

"Side-band" analysis

Severity stages

GEARMESH FAULT

Freq: 106.89
Order: 21.00
Spec: .062

RESONANCE
So much to say and so little time

(lead in to advanced topics)

Typical Periodic Vibration Survey Flow

Database
Exception
Report

Data
Analysis

Route

Data
Collector

Automated
Diagnosis
Report
Generation
& Machine
History

Maintenance
Action
3