EIT IDC Machinery Vibration Rev5

Machinery Vibration Analysis and Predictive Maintenance
23/08/2013
Practical Machinery Vibration Analysis and Predictive Maintenance

By Steve Mackay Dean of Engineering
www.eit.edu.au
Engineering Institute of Technology
EIT Micro-Course Series

Every two weeks we present a 35 to 45 minute interactive course Practical, useful with Q & A throughout PID loop Tuning / Arc Flash Protection, Functional Safety, Troubleshooting conveyors presented so far Upcoming:
Electrical Troubleshooting and much much more..
Go to http://www.eit.edu.au/freecourses You get the recording and slides
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Objectives
Give some background to vibration measurement Give some suggested techniques
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Maintenance Philosophies
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Vibration in everyday life
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Useful Vibration
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Vibration Monitoring
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Vibration Basics
Any external force has to overcome structures properties: - Mass

- Stiffness - Damping
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A force cause vibration!!!
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Vibration Basics
Vibration can be described in terms of:
- Acceleration - Velocity - Displacement
Single degree of freedom system:

- Forced vibration response - Free vibration response - Resonance is free vibration
Frequency is number of vibration cycles / time!

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Vibration Basics
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System Response
10N
2g
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Nature of Vibration - SHM

X = Xo sin t X = Disp. at instant t Xo = Maximum disp. = 2 .. f (rad/s) f = frequency (Hz) t = time (seconds)
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Wave Terminology
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Wave Terminology - Phase
A time lag of T is a phase angle of 360. A time lag of T/4 will be a phase angle of 90. The two waves are out of phase by 90 !
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A Fast Fourier Transform
Also called the Frequency Domain or Vibration Spectrum

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Harmonics
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Frequency and Time Domains
FFT is the Frequency Domain. Time Waveform is the Time Domain.
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Frequency Analysis
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Why do a Frequency Analysis?
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Overall Amplitude
It is the total vibration amplitude over a wide range of frequencies. Acceleration, Velocity, or Displacement.
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Which to choose?
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Real world vibration levels
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Vibration Terminology
Displacement [peak-peak] Velocity [peak] Velocity [rms]
Velocity rms tends to provide the energy content in the vibration, whereas the Velocity peak depicts more of the intensity of vibration.
Acceleration - peak
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Machinery Fault Diagnosis

Vibration analysis is used to monitor the state of a machine. Detailed analyses can be made concerning the health of the machine and any faults, which may be arising or may have already arisen. The need for higher reliability and availability of critical machinery forces the use of this technique of PdM.
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Common Machinery Faults

Unbalance Bent shaft Eccentricity Misalignment Looseness Belt drive problems Gear defects Bearing defects Electrical faults Oil whip / whirl Cavitation Shaft cracks Rotor rubs Resonance Hydraulic + aerodynamic forces
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Unbalance - Static
Amplitude due to unbalance will vary with the square of speed. The FFT will show 1 rpm frequency of vibration. It will be predominant. Phase difference is as shown
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Unbalance - Couple
Amplitude varies with square of speed. Predominant 1 peak. May cause high axial along with radial vibrations. Phase difference is 180 on shaft ends in both planes.
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Unbalance - Overhung Rotors

Amplitude varies with square of speed. Predominant 1 peak. May cause high axial along with high radial vibrations. Axial plane phase difference is 0. Radial direction phase is unsteady.
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Bent Shaft
Bend near centre: 1 is predominant. Bend at ends: 2 is predominant. No phase difference in radial direction at one location. 180 phase difference in axial plane.
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Misalignment
After unbalance, misalignment is the major cause for high vibrations. Two kinds of misalignment:
Angular - shaft ends meet an angle. Parallel - shaft ends are parallel but have an offset.
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Angular Misalignment
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Angular Misalignment
Predominant peak is 1. 1, 2 , 3 may be present. High axial vibration with 1 and 2. Axial phase difference across the coupling is 180.
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Bent Shaft - Angular Misalignment

Difference between angular misalignment and a bent shaft is differentiated only by phase difference. In misalignment, phase difference is 180 across the coupling.
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Parallel Misalignment
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The predominant peak is at 2. Vibrations in radial direction are higher than in the axial direction.
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Phase difference in radial direction across the coupling is 180.
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Misaligned Bearing
Cocked bearing show high axial vibrations Opposite ends have an axial plane phase difference of 180. FFT may show peaks of 1, 2 and 3.
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Misalignment - Orbits
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Mechanical Looseness
Internal assembly looseness:
Bearing liner in its cap. Sleeve or rolling element bearing. Impeller on a shaft.
Looseness at machine to base plate interface:

Loose bolts. Cracks in the frame structure or bearing pedestal.
Structure looseness:
Weakness of machine feet, baseplate or foundation. Loose hold-down bolts, distortion of frame or base.
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Internal Looseness
Phase is unstable. Radial vibrations taken at 30. Will see different spectrums for each (directional). FFT will show harmonics of or even .
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Looseness at Machine to Base Plate interface
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Structure Looseness
Measure each bolt, one at a time.

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Resonance
Every body has a resonance frequency. Frequency is dependant on mass, stiffness and damping. Forced and free vibrations (e.g. ringing of bell). Resonance is free vibrations. Bump test is simple technique to find resonant frequency of stationary mass or system.
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Bump Test
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Thank You For Your Interest

If you are interested in further training, please visit: IDC Technologies Short Courses: Two-day practical courses available to the public: http://idc-online.com/workshops IDC Technologies Conferences: http://idc-online.com/conferences-main The Engineering Institute of Technologies Online Certificate and Advanced Diploma programs: www.eit.edu.au
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EIT IDC Machinery Vibration Rev5

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Machinery Vibration Analysis and Predictive Maintenance

Practical Machinery Vibration Analysis and Predictive Maintenance

Engineering Institute of Technology

EIT Micro-Course Series

Go to http://www.eit.edu.au/freecourses You get the recording and slides

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Vibration in everyday life

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Any external force has to overcome structures properties: - Mass

A force cause vibration!!!

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Single degree of freedom system:

Frequency is number of vibration cycles / time!

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Nature of Vibration - SHM

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Wave Terminology - Phase

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

A Fast Fourier Transform

Also called the Frequency Domain or Vibration Spectrum

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Frequency and Time Domains

FFT is the Frequency Domain. Time Waveform is the Time Domain.

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Why do a Frequency Analysis?

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Real world vibration levels

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Machinery Fault Diagnosis

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Common Machinery Faults

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Unbalance - Overhung Rotors

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Bent Shaft - Angular Misalignment

IDC Technologies and EIT

Machinery Vibration Analysis and Predictive Maintenance

Phase difference in radial direction across the coupling is 180.