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Advisory
Revision #
3.1
Predictive
Maintenance
Vibration Analysis and Acceptance Standard
Page 1 of 21
Document #
Reviewed By: Richard Tyler
Approved by: PdM Steering Group
1.0
Issue Date
11.11.2004
6.24.2011
PURPOSE
The purpose of this standard is to describe the methods for the development,
implementation, and management of the PacifiCorp Generation routine vibration
analysis program. This standard provides engineering performance guidelines for
new/rebuilt equipment acceptance and continued operation parameters of rotating
equipment use by the PacifiCorp Generation fleet. The vibration limits establish a
common goal of acceptability and the methods required for data acquisition
excluding on-line data acquisition systems, turbines and generators.
This standard does not limit the analyst with required instrumentation or methods.
Rather, it defines the final orientation, outcome, and documentation required for
equipment history.
2.0
SAFETY
Safety is the number one priority. Be alert and move slowly, deliberately, and
cautiously when working around rotating equipment. Common sense is the
greatest safety tool that can be used. At a minimum, follow guidelines set forth in
the PacifiCorp Accident Prevention Manuals and manufacturers written
recommendations.
Ensure that cables, probes, clothing, and hands are kept clear of moving parts.
When testing is being performed under fluorescent lighting or using a strobe light,
exercise caution, because rotating machinery sometimes appears to be stopped or
rotating slowly when actually rotating at normal speeds.
Placing probes on some machines could be hazardous when the machine is
running. In such cases, the probes should be placed with long lead wires while
the machine is not running.
3.0
BACKGROUND
Vibration analysis is a nondestructive, diagnostic activity that encompasses the
acquisition and interpretation of the dynamic response of operating rotating
machinery in the form of vibration data samples to determine machine condition.
The rewards of accurate and precise vibration analysis will:
a. Reduce PacifiCorp Generation's operating costs by establishing acceptable
vibration levels for plant rotating equipment.
b. Improve the life and performance of the Generation fleet's rotating
equipment.
c. Provide a uniform procedure for evaluating the vibration characteristics of
the Generation fleet's rotating equipment.
d. Provides incipient fault and failure detection.
e. Reduces maintenance costs due to minimizing equipment damage.
Advisory
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Vibration Analysis and Acceptance Standard
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SCOPE
4.1.
4.2.
5.0
STANDARD
5.1.
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CORPORATE STANDARD
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Revision #
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Predictive
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Equipment ID-ABC
Identifier "B"
Identifier "C"
H Horizontal
I Inboard
V Vertical
O Outboard
A Axial
A Axial
X Radial-X (Horizontal)
Y Radial-Y (Vertical)
P PeakVue
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Application
Sleeve Bearings for
machines w/o vanes
Sleeve Bearing machine
with Vanes (or Blades)
Gear Box, Unknown # of
Teeth
Gear Box, known
# of Teeth
Electric Motor,
Rotor Pass
Electric Motor
Tapered or Spherical
Roller Bearings
Roller Bearings machines
> 1700 RPM
Roller Bearings machines
1400 - 1700 RPM
Roller Bearings machines
1100 - 1400 RPM
Roller Bearings machines
800 - 1100 RPM
Roller Bearings machines
600 - 800 RPM
Low Frequency
Cutoffs
Frequency
Maximum
Lines of
Resolution
Averages
Window Type
120 CPM
1600
Hanning
120 CPM
20xRPM
20xRPM or
1.2BPF
1600
Hanning
120 CPM
200xGMF
3200
Hanning
120 CPM
3.2xRPM
3200
Hanning
120 CPM
360,000 CPM
3200
Hanning
120 CPM
12,000 CPM
1600
Hanning
120 CPM
50xRPM
1600
Hanning
120 CPM
40xRPM
1600
Hanning
120 CPM
50xRPM
1600
Hanning
120 CPM
60xRPM
1600
Hanning
120 CPM
80xRPM
1600
Hanning
120 CPM
100xRPM
1600
Hanning
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Predictive
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Machine Type
Cooling Tower Drives
a) Long, hollow drive shaft
b) Close coupled belt drive
c) Close coupled direct drive
Compressors
a) Reciprocating
b) Rotary Screw
c) Centrifugal - with or W/O external gearbox
d) Centrifugal - Integrated gear (axial meas.)
e) Centrifugal - Integrated gear (radial meas.)
Fans/Blowers
a) Lobe-type rotary
b) Belt driven blower
c) General direct drive fans (with coupling)
d) Primary air fans
e) Forced draft fans
f) Induced draft fans
g) Shaft mounted integral fans
h) Vane-Axial fans
Turbine/Generators
a) 3600 RPM Turbine/Generators
b) 1800 RPM Turbine/Generators
Centrifugal Vertical Pumps
a) Vertical pumps (12'-20' high)
b) Vertical pumps (8'-12' high)
c) Vertical pumps (5'-8' high)
d) Vertical pumps (0'-5' high)
Centrifugal Horizontal Pumps
a) General purpose, direct coupled
b) Boiler feed pumps
c) Hydraulic Pumps
Good
Fair
Alarm 1
(Warning)
Alarm 2
(Fault)
0 - 0.4
0 - 0.3
0 - 0.2
0.4 - 0.6
0.3 - 0.4
0.2 - 0.3
0.6
0.4
0.3
0.9
0.7
0.5
0 - 0.3
0 - 0.3
0 - 0.2
0 - 0.2
0 - 0.2
0.3 - 0.5
0.3 - 0.5
0.2 - 0.3
0.2 - 0.3
0.2 - 0.3
0.5
0.5
0.3
0.3
0.3
0.8
0.7
0.5
0.5
0.4
0 - 0.3
0 - 0.3
0 - 0.3
0 - 0.3
0 - 0.2
0 - 0.2
0 - 0.2
0 - 0.2
0.3 - 0.5
0.3 - 0.5
0.3 - 0.4
0.3 - 0.4
0.2 - 0.3
0.2 - 0.3
0.2 - 0.3
0.2 - 0.3
0.5
0.5
0.4
0.4
0.3
0.3
0.3
0.3
0.7
0.7
0.6
0.6
0.5
0.4
0.4
0.4
0.3 - 0.5
0.3 - 0.4
0.2 - 0.4
0.2 - 0.3
0.5
0.4
0.4
0.3
0.8
0.6
0.5
0.5
0 - 0.2
0 - 0.2
0 - 0.1
0.2 - 0.3
0.2 - 0.3
0.1 - 0.2
0.3
0.3
0.2
0.5
0.5
0.3
* Note: the "Alarm1" and "Alarm2" overall levels given above apply only to in-service machinery which has been
operating for some time after initial installation and/or overhaul. See section 5.7.2 for Acceptance Criteria for New
and Rebuilt Machinery.
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Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Issue Date
11.11.2004
6.24.2011
Advisory
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Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Band
1
2
3
4
5
6
Band
1
2
3
4
5
Frequency Range
Alarm Setting
[0.4 1.2] x RPM
90% Overall Alarm
[1.2 2.2] x RPM
40% Overall Alarm
[2.2 3.2] x RPM
30% Overall Alarm
[3.2 12.2] x RPM
25% Overall Alarm
[12.2 20] x RPM
20% Overall Alarm
[20 50] x RPM
15% Overall Alarm
g) General Roller Element Bearing Machines
(without vanes)
Frequency Range
Alarm Setting
[0.4 1.2] x RPM
90% Overall Alarm
[1.2 2.2] x RPM
40% Overall Alarm
[2.2 3.2] x RPM
30% Overall Alarm
[3.2 12.2] x RPM
25% Overall Alarm
[12.2 20] x RPM
20% Overall Alarm
[20 Fmax] x RPM
15% Overall Alarm
h) Centrifugal Machines
(known number of vanes or blades & roller bearings)
Frequency Range
Alarm Settings
[0.4 1.2] x RPM
90% Overall Alarm
[1.2 2.2] x RPM
40% Overall Alarm
[2.2 (BPF-1.2)] x RPM
35% Overall Alarm
[(BPF-1.2) (BPF+1.2)] x RPM
60% Overall Alarm
[(BPF+1.2) 20] x RPM
35% Overall Alarm
[20 Fmax] x RPM
20% Overall Alarm
i) Centrifugal Machines
(unknown number of vanes or blades & roller bearings)
Frequency Range
Alarm Settings
[0.4 1.2] x RPM
90% Overall Alarm
[1.2 2.2] x RPM
40% Overall Alarm
[2.2 3.2] x RPM
30% Overall Alarm
[3.2 6.8] x RPM
60% Overall Alarm
[6.8 20] x RPM
35% Overall Alarm
[20 Fmax] x RPM
20% Overall Alarm
j) Centrifugal Machines
(known number of vanes or blades & sleeve bearings)
Frequency Range
Alarm Settings
[0.2 0.8] x RPM
20% Overall Alarm
[0.8 1.8] x RPM
90% Overall Alarm
[1.8 3.8] x RPM
40% Overall Alarm
[3.8 (BPF-1.2)] x RPM
30% Overall Alarm
[(BPF-1.2) (BPF+1.2)] x RPM
70% Overall Alarm
[(BPF+1.2) 20] x RPM
35% Overall Alarm
k) Centrifugal Machines
(unknown number of vanes or blades & sleeve bearings)
Frequency Range
Alarm Settings
[0.2 0.8] x RPM
20% Overall Alarm
[0.8 1.8] x RPM
90% Overall Alarm
[1.8 3.8] x RPM
40% Overall Alarm
[3.8 7.8] x RPM
70% Overall Alarm
[7.8 9.8] x RPM
25% Overall Alarm
Issue Date
11.11.2004
6.24.2011
CORPORATE STANDARD
Advisory
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6
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5.2.
5.3.
5.4.
5.5.
Advisory
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900
1200
9/16
1800
1/4
3600
1/16
7200
1/64
Advisory
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Table 1
Completely assembled motors shall have a percentage separation
between the rotor shaft first actual critical speed and the rated motor
speed as specified:
ROTOR DESIGN
Rigid Shaft
Flexible Shaft
FIRST ACTUAL
CRITICAL SPEED LOCATION
At least 25% Above Rated Motor Speed
Maximum of 85% of Motor Speed
Table2
MAXIMUM ALLOWABLE VIBRATION LEVELS FOR ELECTRIC
MOTORS
BAND
FREQUENCY
VELOCITY LINE
ACCELERATION
RANGE
AMPLITUDE
BAND LIMITED
BAND LIMITS
OVERALL
(INCH/SEC
AMPLITUDE LIMITS
(gs PEAK)
PEAK)
1
0.3 x RPM
0.04
0.5
0.8 x RPM
2
0.8 x RPM
0.075
0.5
1.2 x RPM
3
1.2 x RPM
0.04
0.5
3.5 x RPM
4
3.5 x RPM
0.03
0.5
8.5 x RPM
5
8.5 x RPM
0.03
0.5
60,000 CPM
6
60,000 CPM
0.03
0.5
120,000 CPM
Table 3
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ELECTRIC MOTOR OVERALL
AMPLITUDE ACCEPTANCE LIMITS
ELECTRIC MOTOR
AMPLITUDE BAND LIMITS
Acceleration
(gs)
1.0
Velocity
(in/sec)
0.9
.10
0.8
.09
.08
0.7
.075
.07
.06
.05
.04
0.5
0.4
.04
0.3
.04
.03
.02
.01
0.6
BAND
1
BAND
2
BAND
3
.03
.03
.03
BAND
4
BAND
5
BAND
6
4 5 6 7 8 9 10 11
0.2
0.1
BAND 1
FREQUENCY (CPM)
Figure 1
Figure 2
Issue Date
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6.24.2011
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SECTION 5.7.3
5.6.3. FANS ANALYSIS and ACCEPTANCE
5.6.3.1.Fans are defined as:
All non-positive displacement air handling units including
Induced Draft (ID) Fans, Forced Draft (FD) Fans,
Overhung Fans, Centerhung Fans, Centrifugal, Vaneaxial,
Tubeaxial, Blowers, etc.
5.6.3.2.Shaft Tolerance
Fan shaft diameter shall meet bearing manufacturer
specifications for shaft tolerances.
5.6.3.3.Resonance
Natural frequencies of the completely assembled fan unit
shall not be excited at the operating speed. (Running speed
should be at least 25% removed from a natural frequency of
the system.)
5.6.3.4.Limits
New and Rebuilt/Repaired Fans shall conform to the
vibration limits specified in Table 4 when operating at
specified system CFM and Fan Static Pressure.
The frequency range for fan certification shall be from Fmin
= 0.3 X Running Speed of Fan to 60,000 cpm for velocity
and to 120,000 cpm for acceleration.
For fan speeds up to 3600 RPM, the maximum velocity
amplitude (inch/sec-Peak) of vibration at bearing locations
in any direction shall not exceed the Line Amplitude Band
Limit values specified in Table 4 and graphed in Figure 3.
For fan speeds up to 3600 RPM, the Band-Limited Overall
vibration level of acceleration (g's Peak) at bearing
locations in any direction shall not exceed the BandLimited Overall Amplitude Acceptance Limit values
specified in Table 4 and graphed in Figure 4.
Acceptance limits for fans running over 3600 RPM shall be
specified by the purchaser.
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Table 4
BAND ACCEPTANCE LIMITS for FANS
.10
.09
V
.08
E
.07
L
.06
O
.05
C
.04
I
.03
T
.02
Y
(in/sec) .01
.075
.075
.04
.
04
.03
BAND 1 BAND 2
Fmin=0.3 RPM
BAND 3
BAND 4
10
Figure 3
Fmax =60K
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A
C
C
E
L
E
R
A
T
I
O
N
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.5g (Peak)
BAND 1
Fmax = 120K
FREQUENCY - CPM
Figure 4
5.6.3.5.Other Requirements
Variable speed or adjustable sheaves shall not be used in
the final installation.
Drive sheave and driven sheave should differ in size by 20
% or more to avoid "beat" vibration
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SECTION 5.7.4
5.6.4. PUMPS ANALYSIS and ACCEPTANCE
5.6.4.1.Pumps shall be defined in two (2) categories:
Positive Displacement --including, but not limited
to Piston, Gear, and Vane.
Centrifugal
5.6.4.2.Operating Conditions
Non-cavitating non-separating condition.
No piping strain.
Shaft coupling aligned.
Straight suction pipe to pump. (Reference Hydraulic
Institute Standard)
Certification shall be performed while pumps are
operating within design specifications.
5.6.4.3.Limits For Positive Displacement & Centrifugal Pumps
For purposes of Line Amplitude evaluations a "PUMPING
FREQUENCY" (PF) band will be established. The PF
Band will be centered on the Pumping Frequency (Number
of pumping elements X Pump RPM). The band will extend
+ 2 lines of resolution on either side of the line of
resolution containing the Pumping Frequency. (i.e.
Bandwidth = 5 lines of resolution)
Excluding the lines of resolution contained in the Pumping
Frequency (PF) Band, the Velocity Amplitude (Inch/secPeak) of any line of resolution, measured at bearing
locations in any direction shall not exceed the LineAmplitude Band Limit values specified in Table 5 and
graphed in Figure 5.
The Velocity Band-Limited Overall Amplitude (Inch/sec Peak) at bearing locations in any direction shall not exceed
the Pumping Frequency Band Limited Overall Amplitude
Acceptance Limit value specified in Table 5 and graphed in
Figure 5.
The Acceleration Band-Limited Overall Amplitude (g's
Peak) at bearing locations in any direction shall not exceed
the Band-Limited Overall Amplitude Acceptance Limit
values specified in Table 5 and graphed in Figure 6.
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MAXIMUM ALLOWABLE VIBRATION LEVELS FOR POSITIVE
DISPLACEMENT AND CENTRIFUGAL PUMPS
LINE-AMPLITUDE BAND LIMITS
FREQUENCY
VELOCITY
RANGE (CPM)
(INCH/SEC - PEAK)
0.3 x RPM
0.04
0.8 x RPM
0.8 x RPM
0.075
1.2 x RPM
1.2 x RPM
0.04
3.5 x RPM
3.5 x RPM
0.03
120,000 CPM
BAND
1
2
3
4
BAND
1
PUMPING FREQ.
BAND (PF)
FREQUENCY
RANGE (CPM)
VELOCITY
(INCH/SEC - PEAK)
BAND 5
5 Lines of resolution
centered on PF.
0.075 PISTON
0.05 VANE
Table 5
POSITIVE DISPLACEMENT & CENTRIFUGAL PUMPS
BAND AMPLITUDE ACCEPTANCE LIMITS
.10
V .09
.08
E
.07
L
O .06
C .05
.04
I
.03
T
Y .02
(in/sec) .01
.075 PISTON
.075
VANE
.03
BAND 1 BAND 2
Fmin=0.3
.05
.04
.04
BAND 3
2
BAND 5
4
BAND 4
9 10
11
Fmax = 120K
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Figure 5
POSITIVE DISPLACEMENT & CENTRIFUGAL PUMPS
BAND-LIMITED OVERALL AMPLITUDE ACCEPTANCE LIMITS
A
C
C
E
L
E
R
A
T
I
O
N
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
BAND 1
(gs)
Fmax = 300K
FREQUENCY - CPM
Figure 6
5.6.4.4.Vertical Mounted Pumps
Vertically mounted pump systems with a "Vertical Mount
Height" greater than 5 feet will have an allowable increase
in Velocity Amplitude Acceptance Limits in Bands 1, 2,
and 3 of 5% per foot of "Vertical Mount Height" greater
than 5 feet. (e.g. A 7 foot Vertical Mount Height would
yield a 10% increase [(7 ft - 5 ft) x 5%/ft] in the Table 9.4A
Velocity Amplitude Acceptance Limits specified for Bands
1, 2, and 3. Therefore the limit for Band 1 would be [0.4
Inch/sec + (0.4 Inch/sec x 0.1)] = 0.44 Inch/sec-Peak.
Vertical Mount Height is defined as the furthest measurable
distance from the machine mounting to the end of the
driver or the end of the pump, which ever is greater.
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SECTION 5.7.5
5.6.5. GEARBOXES ANALYSIS and ACCEPTANCE
Gearboxes shall not exceed the Vibration Limits specified
table 6 and in Figures 7 and 8.
MAXIMUM ALLOWABLE VIBRATION LEVELS FOR GEARBOXES
LINE-AMPLITUDE BAND LIMITS
BAND
FREQUENCY
VELOCITY
RANGE (CPM)
(INCH/SEC - PEAK)
1
0.3 x RPM
0.04
0.8 x RPM
2
0.8 x RPM
0.075
1.2 x RPM
3
1.2 x RPM
0.04
3.5 x RPM
4
3.5 x RPM
0.03
120,000 CPM
BAND
1
Table 6
GEAR BOX
BAND AMPLITUDE ACCEPTANCE LIMITS
V
E
L
O
C
I
T
Y
(in/sec)
.10
.09
.08
.07
.06
.05
.04
.03
.02
.01
.075
.04
.04
BAND 1 BAND 2
Fmin=0.3
.03
BAND 4
BAND 3
2
9 10
Figure 7
11
Fmax = 120K
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GEAR BOX
BAND LIMITED OVERALL AMPLITUDE ACCEPTANCE LIMITS
A
C
C
E
L
E
R
A
T
I
O
N
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
(gs)
1.0g (Peak)
BAND 1
FREQUENCY - CPM
Figure 8
Issue Date
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Approved by: PdM Steering Group
Issue Date
11.11.2004
6.24.2011
SECTION 5.7.6
5.6.6. COMPRESSOR ANALYSIS and ACCEPTANCE
5.6.6.1. Centrifugal Compressors
Centrifugal compressors shall not exceed the Vibration
Limits specified in Table 7 and Figures 8 and 9.
5.6.6.2. Positive Displacement
Positive displacement compressors shall not exceed the
Vibration Limits specified in Table 7 and Figures 8 and 9.
MAXIMUM ALLOWABLE VIBRATION LEVELS FOR POSITIVE
DISPLACEMENT AND CENTRIFUGAL COMPRESSORS
BAND
1
2
3
4
BAND
1
Table 7
Advisory
CORPORATE STANDARD
Revision #
3.1
Predictive
Maintenance
Vibration Analysis and Acceptance Standard
Page 22 of 21
Document #
Reviewed By: Richard Tyler
Approved by: PdM Steering Group
Issue Date
11.11.2004
6.24.2011
.10
V .09
.08
E
.07
L
O .06
C .05
.04
I
.03
T
Y .02
(in/sec) .01
.075
.04
.04
BAND 1 BAND 2
Fmin=0.3
.03
BAND 4
BAND 3
2
9 10
11
Fmax = 120K
Figure 8
A
C
C
E
L
E
R
A
T
I
O
N
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
BAND 1
(gs)
Fmax = 300K
FREQUENCY - CPM
CORPORATE STANDARD
Advisory
Revision #
3.1
Predictive
Maintenance
Vibration Analysis and Acceptance Standard
Page 23 of 21
Document #
Reviewed By: Richard Tyler
Approved by: PdM Steering Group
Issue Date
11.11.2004
6.24.2011
Figure 9
6.0
REFERENCES
6.1.
PacifiCorp Employees. A special thanks to the dedicated plant
employees for their insight and input.
6.2.
General Motors Corporation. Specification No. V1.0a, GM_1761:
Vibration Standard for the Purchase of New and Rebuilt Machinery and
Equipment..
6.3.
"EPRI". Project 2817-01, TR103374: Predictive Maintenance Guidelines.
6.4.
"Technical Associates of Charlotte".
Level II Vibration Analysis
Handbook.