XIV.

VIBRATION ANALYSIS
OF FANS

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Contents
1.

INTRODUCTION

2.

VIBRATION-CHARACTERISTICS

3.

MEASUREMENT LOCATIONS

4.

METHODS OF MEASUREMENT

5.

CAUSES OF VIBRATION

6.

VIBRATION IDENTIFICATION

7.

VIBRATION TOLERANCE AND RUN WORTHINESS

8.

IN-PLACE BALANCING OF FANS

FIG.XIV-1 SIMPLE SPRING MASS SYSTEM

FIG.XIV-2 CHARACTERISTICS OF VIBRATION
FIG.XIV-3 PHASE BETWEEN TWO VIBRATING PARTS
FIG. XIV-4 VIBRATION MEASURING LOCATIONS IN AXIAL FANS
FIG. XIV-5 VIBRATION MESURING LOCATIONS IN RADIAL FANS
FIG.XIV-6 VIBRATION RECORD (MANUAL)
FIG.XIV-7 VIBRATION RECORD (SEMI-AUTOMATIC)
FIG.XIV-8 VIBRATION RECORD (AUTOMATIC)
FIG. XIV-9 LIMITS OF VIBRATION AMPLITUDES FOR FANS
AND THEIR MOTORS
FIG. XIV-10 RUN WORTHINESS OF FANS
FIG. XIV-11 TWO POINT METHOD OF BALANCING
FIG. XIV-12 VECTOR DIAGRAM

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XIV. VIBRATION ANALYSIS OF FANS

1.

INTRODUCTION
The condition in a rotating machine which eventually result in breakdown and extensive
repairs can be detected by the vibration they cause. An increase in the severity of such
mechanical trouble is by increased vibration. These vibrations are often complex and
requires a capability to separate one from the other if the troubles to be found.
Vibration Analysis is the process of vibration measurement and subsequent data interpretation.
This process determines the mechanical condition of a machine, pinpoints any specific faults,
and provides
the basis for a course of action.
Vibration Analysis is based on the following facts :

2.

i)

All rotating machines vibrate ; may be to a lesser extent or to a greater extent.

ii)

Rotating machines vibrate due to defects with few exceptions.

iii)

Characteristics of vibration produced due to different defects are different.

VIBRATION-CHARACTERISTICS
i)

Displacement.

ii)

Velocity.

iii)

Acceleration.

iv)

Frequency.

v)

Phase.

The simplest way to understand a vibration is to follow the motion of a weight suspended
on aspring (See Figure XIV-1). By applying a force, the weight would move upward and
downward in a cyclic manner as long as the force is reapplied. By plotting the movement
of the weight against time we can study the characteristics of vibration. (See Figure XIV-2).
The motion of the weight from its neutral position to the top limit of travel back through the
neutral position to the bottom limit of travel and its return to the neutral position represents
one cycle of motion. The time required for one cycle is the period of vibration. From a
practical point, the number of cycles in a given time, which is the frequency of vibration is
very important for vibration analysis.
The total distance moved by the weight is the displacement of vibration (Peak to peak).
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Since the weight is moving, it must be moving with a velocity. This velocity changes with
position.
At the top limit of the motion, the velocity is zero and at the neutral position the velocity is
maximum. The maximum or the peak velocity is another characteristic of vibration. Velocity
is a function of displacement and frequency.
Another important characteristic of vibration is the acceleration.
The last parameter PHASE or PHASE ANGLE is used to describe vibration by comparing
the motion of a vibrating part with a fixed reference or comparing the motion between two
vibrating parts. Phase can be defined as an angle between the instantaneous position of a
vibrating part and a reference position, which is the fractional part of the vibration cycle
through which the part has advanced relative to the reference position.
Phase between two vibrating parts is the fractional part of a cycle thro which one has advanced,
compared to the fractional part of a cycle through which the other has advanced, expressed as
an angular difference. (See Figure XIV-3).
What these characteristics tell us:
Displacement,
Velocity
}
Acceleration

3.

Show how much vibration is present.

Frequency

Shows what is causing the vibration.

Phase

is useful in identifying from where the vibration is coming and

also used in field balancing.

MEASUREMENT LOCATIONS
The measurement locations usually selected are, the bearing housings of a machine because
it is through these bearings that the vibration forces of the rotating elements are
transmitted.Typical measurements are made on the bearing housings in the horizontal, vertical
and axial directions, when an analysis is being conducted. Figures XIV-4 and XIV-5 show
typical location for vibration measurement for different types of axial and radial fans.
While most measurements are best made on the bearing housings, there are cases in which
other locations should be selected. When it is suspected that the machine is involved in a
resonance condition the pickup should be placed at various positions on the machine structure
and on the foundation to determine the mode shape of vibration.
In some cases it may be desirable to measure the vibration directly on the machine shaft. For
this purpose either contact type pickup with special Shaft Stick or Noncontact type pickups
are used.
In case of axial fans the inner bearing housings are not accessible for measuring vibration.
Hence suitable points on the fan casing must be selected for vibration reading.

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4.

METHODS OF MEASUREMENT
-Manually.
-Semi-automatically.
-Automatically.
i)Readings are taken from the meters of the measuring instruments and recorded properly for
further analysis. A sample data sheet is shown in Figure XIV-6.
ii)For semi-automatic recording the vibration analyser is connected with a X-Y Recorder and
the tuning is done manually. By this method the vibration displacement Vs. frequency is
automatically recorded. This method gives an accurate recording of the vibration. A vibration
signature is shown in Figure XIV-7.
iii)Automatic recording of vibration requires instruments in which even the tuning is done
automatically. Only we have to select the frequency range and set the instrument. One sample
data sheet of this type is shown in Figure XIV-8.
Upto this point the discussion has been primarily concerned with the characteristics of vibration
and parameters which must be considered in making measurements. The next step is the data
analysis.

5.

CAUSES OF VIBRATION
i)

Unbalance.

ii)

Misalignment.

iii)

Bent Shaft.

iv)

Mechanical Looseness.

v)

Eccentricity.

vi)

Rubbing.

vii)

Resonance.

viii)

Bad Bearings.

ix)

Bad gears.

x)

Bad drive belts/chains.

xi)

Electromagnetic forces

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xii)

Torque variations.

xiii)

Oil whirl.

xiv)

Aerodynamic forces.

xv)

Hydraulic forces.

All these causes can be reduced to one or a combination of five types of troubles.
a)

One or more parts will be unbalanced.

b)

One or more parts will be misaligned.

c)

One or more parts will be loose.

d)

One or more parts will be eccentric or out of tolerance.

e)

One or more parts will be reacting to some external exciting forces.

Regardless of how the causes of vibration are listed one basic thing must be true. This is the
cause of vibration must be generating a force which is changing either its direction or its
amount. It is this force which causes vibration and the resulting characteristics will be
determined by the manner in which the forces are generated. This is why each cause of vibration
has its own characteristics.
The forces which cause vibration are generated through the rotating motion of the machine
parts and thus change their amount and direction as the rotating part changes its position with
respect to the rest of the machine. Therefore the resulting vibration will have a frequency
depending upon the rotating speed of the part which has the trouble. This is why frequency
tells which part is at fault.
There are other peculiarities associated with each cause of vibration which includes the
relationship of phase observations at different points and the direction in which the vibration
occurs.
The displacement, velocity and acceleration of vibration tells us little regarding what the
cause of vibration is but it tells us the severity of the trouble.

6.

VIBRATION IDENTIFICATION
(i)

Unbalance

Displacement will be proportional to unbalance. Largest vibration will generally be in the

radial direction. Frequency in CPM will be equal to RPM.
(ii)

Misalignment

Large axial vibration will be observed:

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Frequency will be
1 x RPM usually and
2 and 3 x RPM sometimes.
As a general rule if the axial vibration is atleast 50% of the radial vibration misalignment
can be suspected.
(iii) Bad Antifriction Bearings
Displacement will be unsteady, use velocity measurements if possible. Frequency will be
very high. (Need not be an exact multiple of RPM).
(iv) Mechanical Looseness
Frequency will be 2 x RPM usually accompanied by unbalance and/or misalignment.
(v)

Oil Whip or Oil Whirl

Usually occurs only on high speed pressure lubricated machines with plain bearings.
Frequency will be roughly equal to 0.5 x RPM.
(vi) Bad Gears
Frequency will be gear teeth times RPM.
(vii) Bent Shaft
Characteristic similar to misalignment and unbalance.

7.

VIBRATION TOLERANCE AND RUN WORTHINESS

Limits of vibration amplitudes for fans and their motors (Fig. BOLIVIA) gives the criteria
for assessing the mechanical fitness for successful operation of BARREL fans with their
motors, - on the basis of measurement of vibration of the bearings of these machines.
The vibration chart is valid for BHEL-Czech and BHEL-KKK fans which are on solid concrete
foundation in ground floor.
For assessing the condition of a machine, the maximum value of RMS velocity of vibration is
the criterion. The maximum value may be on any bearing in any position of measurement.
Single amplitude values of displacement of vibration (S) are given in the chart for the
synchronous speed of the motor. Double amplitude or Peak to Peak (D) value is twice the
value of single amplitude (D = 2.S).
Bearing may be, or may not be, or not only be, at fault. Bearing is a machine element, which
connects both static and dynamic parts; so the measurement done here will indicate most of
the faults ; (not necessarily all the possible faults).
Rejected bearings should be gas cut into pieces to avoid recirculation leading to spurious
bearings.

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Even the foundation is not beyond doubt - it may sink, develop crack etc. So the vibration at
the oundation bolts may also reveal faults which can be corrected by possible means.
The diagnostic parameters (viz.) temperature and vibrations keep on changing. Continuous
records are to be maintained to assist the trouble shooting - for successfully locating and
rectifying the fault to ensure safe run-worthiness for troublefree and successful operation.
Fig XIV-10 shows the run-worthiness of fans based on measurement of temperature and
vibration of the bearings. Corresponding recommended operating and maintenance
instructions are also furnished for guidance.

8.

IN-PLACE BALANCING OF FANS

(i)

General

A fan requires proper balance both static and dynamic to assure smooth and lasting service.
This condition should be checked after each maintenance shut-down. Fans can be thrown out
of balance by uneven deposits on the Impeller and hence before attempting balancing dirty
Impellers should be cleaned properly.
Fans handling gases with entrained abrasive dust particles are subjected to erosion of the
impeller which may create serious unbalance conditions.
Distortion and improper matching of parts also can create unbalance on a rotor which is
perfectly balanced at works.
The process of balancing a part without taking it out of the machine is called Inplace
Balancing . In-place balancing eliminates the need to disassemble the fan, transport it to a
balancing machine and balance it under artificial conditions.
The site balancing procedure is dependent on the following facts:
-The amount of vibration due to unbalance is proportional to the amount of unbalance.
-Unbalance will produce a vibration frequency equal to RPM
Phase angle is an important characteristic to be measured for carrying out site balancing.
Some portable vibration analysers/dynamic balancers provide strobe light for freezing a
reference mark and thereby measuring the phase angle. Others provide direct measuring
facilities.
Here we will discuss the following methods of balancing at site.
a)

Balancing by using a Vibrometer.

b)

Balancing by using Vibration Analysers/Dynamic Balancers,

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(ii)

Balancing by using a Vibrometer

In this method of balancing it is assumed that all the vibration is due to unbalance.
Hence before attempting the balancing to reduce vibration, physical checks and corrections
are to be carried out to eliminate other causes of vibration, if any.
Procedure:
a)

With the pick-up survey the part to be balanced for the location of maximum vibration
amplitude.

b)

Attach the vibration pick-up at the point of maximum amplitude.

c)

Measure and record the original unbalance vibration call this reading

d)

Choose a trial weight carefully weighand record the trial weight (T.W.)

e)

Add the trial weight at one location on the part to be balanced and run the
machine.Measure and record the vibration Call this reading T1.

f)

Move the trial weight to a location exactly 180' from the first spot and at the same
radius. Run the machine. Measure and record the vibration. Call this reading T,.

g)

With the above data proceed with the construction as shown in Figure XIV-11. (a)

h)

Measure the value of R from the construction.

j)

Balance weight -

0 x T.W.
R

k)

Measure the angle q from the construction.

The actual spot to attach the balance weight is either clockwise or counterclockwise by the
angle q from the spot where the trial weight was added first.
Hence first add the correction weight in one direction and observe the effect. If the
vibration is reduced considerably the weight is added at the correct place. It not remove and
add the weight in the opposite direction.
(iii) Balancing by using a VibrationAnalyser/Dynamic Balancer
First analyse the vibration to determine that the vibration is due to unbalance.
The unbalance in the part at the start is called the original unbalance and the vibration
amount and phase which represents that unbalance is called the original reading . We
change theoriginal unbalance by adding a trial weight to the part. The new total unbalance
in the part will be represented by a new amount and phase of vibration. The change caused
by the trial weight can be used to learn the size and location of the original unbalance. For
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balancing purpose vibration readings are taken on the bearing housings. Locate the position
which gives the maximum vibration. Attach the vibration pick-up at that location. Care must
be taken to place the vibration pick-up at the same point and direction for all readings if the
pick-up is hand-held.
For measuring phase angle of vibration by using a strobe light provide one reference mark on
the rotating part which can be observed from outside.
Procedure :
Measure the initial vibration and the position of the reference mark (Freeze the reference
mark with the strobe light).
Let this reading be 0 at 450
Stop the machine. Add a trial weight (T.W.).
Mark the position of the trial weight.
(c)

Run the machine to speed.Measure the new vibration and phase angle.Let this
beO+Tat 1000.

(d)

Stop the machine and remove the trial weight.

(e)

Construct the vector diagram as shown in Figure XIV-12.

(f)

Measure the value of T from the construction.

T.W. x 0
Correction weight =
T

(g)

(h)

Measure the angle from the construction.

The correction weight is calculated to add at the same radius where the trial weight is added.
The position of the correction weight is 0 anticlockwise from the position of the trial
weight (since the reference mark has moved clockwise after adding the trial weight the
correction weight is to be added in the counterclockwise direction).
(iv) Two Plane Balancing
Cross effect must be taken into account when balancing in two planes. The simplest method
of two plane balancing at site is to treat each correction plane as a single plane problem using
the nearest bearing for the vibration readings.
Balancing each correction plane as a single plane problem is not always 100% effective due
to cross effect. The steps to be followed are:
i)

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Observe the amount and phase of vibration at each bearing.

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ii)

Select the one with the greatest vibration to balance the first.

iii)

Balance the first end down to an acceptable level. This will usually result in a different
amount and phase reading at the other end of the rotor. This gives a new original
reading to be used in balancing the second end.

iv)

Balance the second end to an acceptable level. The first end vibration will change
because of the elimination of cross effect.

v)

If the change is an increase to an unacceptable level it wilt have to be re-balanced.

This new reading is again a new Original reading . Do not disturb the earlier
correction.Start with a new trial weight and balance as a new problem.

vi)

If the cross effect is severe this procedure may have to be repeated several times.

NOTE:-When considerable amount of time is required to start and stop the machine that
requires balancing, it is convenient and time saving to solve the balancing problem by using
the Two plane vector method . But most of the site balancing problems of boiler fans can
be solved by using the Single plane vector method for Two plane balancing.

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FIG.XIV-1 SIMPLE SPRING MASS SYSTEM

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FIG.XIV-2 CHARACTERISTICS OF VIBRATION

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FIG.XIV-3 PHASE BETWEEN TWO VIBRATING PARTS

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FIG. XIV-4 VIBRATION MEASURING LOCATIONS IN AXIAL FANS

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FIG. XIV-5 VIBRATION MESURING LOCATIONS IN RADIAL FANS

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FIG.XIV-6 VIBRATION RECORD (MANUAL)

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FIG.XIV-7 VIBRATION RECORD (SEMI-AUTOMATIC)

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FIG.XIV-8 VIBRATION RECORD (AUTOMATIC)

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FIG. XIV-9 LIMITS OF VIBRATION AMPLITUDES FOR FANS

AND THEIR MOTORS

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FIG. XIV-10 RUN WORTHINESS OF FANS

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FIG. XIV-11 TWO POINT METHOD OF BALANCING

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FIG. XIV-12 VECTOR DIAGRAM

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