Vibration Analysis Level

WarmestWelcometoVibration
AnalysisLevelICourse
VibrationAnalysisLevelI
y
IMRANAHMAD
DirectorTechnical
SUMICOTechnologies(Pvt)Ltd
+923214276092
imran.ahmad@sumico.com.pk
p
www.sumico.com.pk
Timings
1st Session
Session 0900 1045
09001045
TeaBreak 10451100
2nd Session
S i 1100 1300
11001300
Lunch/PrayerBreak 13001400
3rd Session 14001530
Tea Break
TeaBreak 15301545
1530 1545
4th Session 15451700
TypicalMachineryProblemsthatCanBeFoundUsing
VibrationAnalysis
Unbalance
Mi li
Misalignment t
Mechanicallooseness
Structural problems
Structuralproblems
Bentshaft
Bearingfaults
g
TypicalMachineryProblemsthatCanBeFoundUsingVibration
Analysis
Gearfaults
Beltproblems
Lubricationproblems
Electricalmotorfaults
Cavitationsandturbulence
others
WhatisCBM&Why?
What is CBM & Why ?
Totryandmaximisetheplantsproductionandincreasethe
meantimebetweenoutagesmanyindustriesaremoved
g y
towardsaConditionBasedMaintenanceapproach.
ConditionBasedMaintenanceorCBMisanactivitythat
attemptstopredictandtrendcomponentfailurenon
intrusivelygiventheenduservaluableadvancedwarningofthe
problemathand.
Maximisingassetreliabilityisoftheutmostimportancein
todaysglobaleconomy.
Ascompetitionandthepressuretoproduceproductscheaper
increasesthehigherconsequenceofmachine/productionfailure
becomes.
CBMOverview
Mostmachinefaultsgeneratesomekindofsignaturethatis
uniquetotheparticularfaultdeveloping.Byusingthe
correct technology to detect these signatures we can not
correcttechnologytodetectthesesignatureswecannot
onlytellthatafaultisdeveloping,butdistinguishwhatthe
faulttypeis.
Thereareseveraltechnologiesavailabletohelpdetermine
There are several technologies available to help determine
theconditionofthemachinebeingmonitoredandthetype
offaultdevelopingandtheseare:
VibrationAnalysis
y
Tribology
Sonics
Thermography
Diagnosingamachineisjustlikeaperson
Di i hi i j lik
Vibration: Oil: Thermography: Motor Current:

The pulse of the The life blood of Taking its The brain waves
machine the machine temperature of the machine
Total
Picture
OverviewofTechnologies
Overview of Technologies
VibrationAnalysis
UsedtoDetect,AnalyseandConfirmplantmachineryproblems.This
y p yp
canbedoneinthreeways:
Online(4500T&CSI6500)forautomatedandcontinuousmonitoringand
protectionofcriticalplantitems
Portable(2130Analyser)Routebaseddatacollectionandanalysis
Wirelessusedforremotemonitoringofmovingorinaccessibleequipment
g
Tribology
Istheanalysisofinteractivesurfacesinrelativemotion.
Lubricantsareanalysedonsiteusingthe5200minilabseries.
Theresultsareplottedinasimpletounderstandtrivectorplotshowingthe
ChemistryContaminationandWearofeachlubricant,thisallowingthe
lubricant to be changed on condition rather than on a time based interval
lubricanttobechangedonconditionratherthanonatimebasedinterval.
Wear
Contamination Chemistry
g
Sonics
ThroughaprocessknownasheterodyningUltrasonicsoundsthat
arenonaudibletohumanearsareconvertedbackdowntoa
d bl h db kd
frequencythatisaudibletohumanears,allowingtheoperatorto
hearandrecognisefaultsdevelopingwithinplantoperatingsystems,
such as:
suchas:
Mechanical Bearings,Rubs,GearDefectsetc
ElectricalDefects
ValveOperation
SteamTrapOperation
LeakDetection PressurisedSystemsandVacuumSystems
g
Thermography
ThermalImagingisusedtolocatepotentialproblemsbydetecting
g g p p y g
abnormaltemperaturefluctuationsataglance.
Thiscanbeusedinawidearrayofcircumstancesbutismostcommonly
usedinelectricalcontrolpanels
g
Correctivetechnologiesallowtheengineertosetupthemachinetotry
andpreventprematuremachinefailurefromsuchcausesasImbalance
andMisalignment
d Mi li t
Whentheseforcesareinduceduponamachinecomponentssuchas
bearings,sealsandevensupportsfailduetostress
TechnologiessuchasLaserAlignmentandBalancingpreventthesefrombeing
Technologies such as Laser Alignment and Balancing prevent these from being
somuchofaproblem
y g
MachineryHealthManager
A1 - Recirculation Pump #5
RCP#5
C # -M2H MOTOR
O O INBOARDO BRG.
G - HORIZONTA
O O
0.025 Trend Display
FAULT
PK In/Sec
0.020 36-65xTS
0.015
0.010
ALERT
0.005
0
0 The machines due to be monitored are defined within the
Eachtechnologyisstoredandanalysedfromasinglesoftwareplatform,
100 200 300 400 500
Days: 11-Aug-95 To 11-Dec-96
0.05 software.
software
allowingtheanalystto:
allowing the analyst to: Route Spectrum
PK In/Sec
0.04 11-Dec-96 17:33:57

0.03 OVERALL= .0604 V-DG
0.02
0.01
As much information as possible about the machines being monitored
Storealldataandinformationinonedatabase PK = .0605
LOAD = 100.0
RPM = 3593. (59.89 Hz)
0
0
40
isEasilycrossreferencedataforconformationofanalysis
preferred when building the database.
80 120 160 200 240
Frequency in kCPM
1.0 Route Waveform
Collaborate all data into one single report

Collaboratealldataintoonesinglereport.
Acc in G-s
s
0.5 11 D 96 17
11-Dec-96 17:33:57
33 57
0 RMS = .4233
-0.5 PK(+/-) = 1.13/1.22
CRESTF= 2.89
-1.0
-1.5
0 1 2 3 4 5 6 7
Revolution Number
Overview
O i
of
ConditionMonitoring
Maintenance Philosophies
MaintenancePhilosophies
DefinitionofMaintenance
Definition of Maintenance
The
Theactofcausingtocontinue
act of causing to continue
(Webster)
Keepingequipmentinrepair
(Oxford)
Maintenance
ReactiveMaintenance Planned Maintenance
OftencalledBreakdownMaintenance Also known as Shutdown
andhastheconceptfixitwhenit Maintenance. This is based upon
p
breaks.
breaks
Timed Intervals between
Thisisprobablythemostcommon
typeofmaintenanceinindustrytoday maintenance.
butcanbethemostcostly,especially Can be very effective if maintenance
oncriticalmachines. and resources are aimed at the
Maintenancecostsareusuallyhigher machines that need it the most.
duetothecatastrophicfailurethat
occurs. However it can be very difficult to
distinguish which machines actually
need maintenance.
Predictive Maintenance Proactive Maintenance
Also known as Condition Based Often referred to as Root Cause
Maintenance. Analysis.
This approach uses non-intru This philosophy works hand in hand
technologies to determine the actua with Predictive Maintenance,
condition of a machine and its rate of eliminating the source of the fault to
failure. try to prevent it from re-occurring.
This can be very effective in
extending machine life with big
financial savings if implemented
properly.
y
TodaysIndustrialDemand
Itshouldbeunacceptabletodeliver
lessperformanceformoremoney
l f f
sameperformanceformoremoney
Itcouldbeacceptabletodeliver
sameperformanceforlessmoney
same performance for less money
moreperformanceforthesamemoney
moreperformanceformoremoney
Thedesireis MorePerformanceforLessMoney!!!!
j
PredictiveMaintenanceObjectives
To
Toconfirmgood
confirm goodcondition
conditionmachines
machines
Todetectdevelopingproblems
Todeterminethenatureandseverityofthe
d i h d i f h
problem
Toschedulerepairsthatcanbestfitwith
productionandmaintenanceneeds
q
PredictiveMaintenanceTechniques
Vibrationmeasurement
Vibration measurement
Electricaltesting
Motorcurrentanalysis
l i
Reciprocatingmachinetesting
Thicknesstesting
Visual inspection
Visualinspection
Andmanymore
PredictiveMaintenanceBasicFacts
Every
Everymechanicalorelectricalfaultsona
mechanical or electrical faults on a
machinehasadistinctvibrationbehavior.
Anychangeinthevibrationsignature
Any change in the vibration signature
indicateschangesinthedynamicoperating
condition of the machine
conditionofthemachine
( )
PredictiveMaintenanceMechanism(VA)
Establish
Establishadatabaseofallthemachinesthat
a database of all the machines that
needtobemonitored
Establishadatacollectionroutethatbest
Establish a data collection route that best
optimizethedatacollectiontime
Downloadrouteintothedatacollector
D l d i h d ll
Collectdata
Uploadcollecteddataintothedatabase
PredictiveMaintenanceMechanism
Run
Runexceptionreportstodetectthe
exception reports to detect the
problematicmachines
Analyzeonlythemachinesintheexception
Analyze only the machines in the exception
reports
Generaterepairworktobeperformed
G i k b f d
Againcollectdataonthemachineonwhich
workisbeingdone.
PredictiveMaintenance
Predictive Maintenance
Rules
Start +
Experi
NO
YES
Create Regular Compare Fault Fault
Ref. Meas. limits Diagnostics correction
Input
m/c
specs
Create
New Ref. & Limits
VibrationFundamentals
Vibration Fundamentals
How Much Vibration is Too Much ?
1. Use Absolute Vibration Levels

- Given
Gi by
b machine
hi makers
k
- Published Vibration Severity Standards
eg. ISO 2372, VDI 2056, BS 4675
2. Use Relative Vibration Levels

ISO10816 3
ISO 108163
11 0 44
0.44
7.1 0.28
4,5 0.18
3,5
, 0.11
2,8 0.07
2,3 0.04
1.4 0.03
0,71 0.02
mm/s rms inch/s rms

rigid flexible rigid flexible rigid flexible rigid flexible Foundation
pumps > 15 kW medium sized machines large machines
radial, axial, mixed flow 15 kW < P 300 kW 300 kW < P < 50 MW Machine Type
integrated driver external driver motors motors
160 mm H < 315 mm 315 mm H
Group 4 Group 3 Group 2 Group 1 Group
A newly commissioned
B unrestricted long-term operation
C restricted long-term operation
D vibration causes damage
ISO10816 3
ISO 108163
140 5.51
113 4.45
90 3 54
3.54
71 2.80
56 2.20
45 1.77
36 1.42
28 1.10
22 0.87
18 0.71
11 0.43
m rms mil rms
rigid flexible rigid flexible rigid flexible rigid flexible Foundation
pumps > 15 kW medium sized machines large machines
radial, axial, mixed flow 15 kW < P 300 kW 300 kW < P < 50 MW Machine Type
integrated driver external driver motors motors
60 mm H < 3
160 315
5 mm 5 mm
315
3 H
Group 4 Group 3 Group 2 Group 1 Group
A newly commissioned
B unrestricted long-term operation
C restricted long-term operation
Vibrationstandardsareguidelines
Vibration standards are guidelines
ISO2372 ( BS 4675 , VDI 2056 )
45
Nott
N 28
Velociity mm//s RMS

es = 8dB
Not Not Permissible 18
Permissible
20dB
Permissible 11.2
Just Tolerable 71
7.1
10 times = 2
2.5 time
Just
Tolerable 4.5
Just Tolerable Allowable 2.8
All
Allowable
bl 18
1.8
Allowable Good 1.12
Good Large Machines
15 kW<
Medium Machines
with rigid and heavy 1.71
foundations whose
G d
Good <75kW
natural Frequency
0 45
0.45
Small <300 kW on special exceeds 0.28
Machines< 15 kW foundations machine speed
0.18
Group K Group M Group G
PredictiveMaintenanceDatabaseSetup
Predictive Maintenance Database Setup
Identify
Identifywhichmachinestomonitor
which machines to monitor
Identifyeachmachinecharacteristics
Defineanalysisrequirementsforeach
fi l i i f h
machine
Defineacceptablelevelsandalarmlimits
Definedatacollectionpointlocationsand
p
monitoringmethods
WhichMachinetoMonitor?
Which Machine to Monitor?
Machinethatarevitaltotheoperation
Machine that are vital to the operation
Machinesthatareexpensivetorepair
Machinesthataretroublemakers
hi h bl k
Machinesthatareinremoteorinaccessible
locations
WhyMachineCharacteristics?
Why Machine Characteristics?
Initially
Initially,theknowledgeofthemachinedesign
the knowledge of the machine design
anditsoperatingcharacteristicsismandatory
to successfully establish a good database
tosuccessfullyestablishagooddatabase
Later,thisknowledgewillprovidethebasis
for analyzing the data accurately
foranalyzingthedataaccurately
WhatMachineInformationIsneeded?
What Machine Information Is needed?
Machinespeed
p
Machineload
Bearingtype
g yp
Couplingtype
yp
Geartypeandteethcount
Bladesandvanes
g yp p g
Machinedrawingsandtypicaloperating
conditions
MachineAnalysisRequirements
Machine Analysis Requirements
List
Listallpossibleproblemsofthemachine
all possible problems of the machine
Determinetheparticulareffectsthateach
problem impose on the machine
problemimposeonthemachine
Determinethebestmethodtomonitorthe
severityoftheproblem
i f h bl
ManpowerRequiredDependson
Manpower Required Depends on
Numberofdatacollectionpoints:
Number of data collection points:
Complexityofthemachine
Numberofmachinestobemonitored
Number of machines to be monitored
ManpowerRequiredDependson
Manpower Required Depends on
Analysistimerequired
Analysis time required
Complexityofthemachine
Complexityoftheproblem
Complexity of the problem
Frequencyofanalysis
Machineclassification
Machinehistory
MachineComplexity
Machine Complexity
Simplexmachines
Simplex machines
Constantspeedandload
Directdrive(coupling)
Direct drive (coupling)
510measurementpoints
MachineComplexity
Machine Complexity
CompoundMachines:
Compound Machines:
Constantspeedandload
Intermediatedrive(gearboxandbelts)
Intermediate drive (gearbox and belts)
1020measurementpoints
MachineComplexity
Machine Complexity
ComplexMachines
Complex Machines
Variablespeedandload
Multiplecomponents
Multiple components
Morethan20measurementpoint
MachineClassifications:
Machine Classifications:
VitalMachines:
Vital Machines:
Irreplaceable
Halt production
Haltproduction
Hardtofindparts
E
Expensivetorepair
i t i
MachineClassification
Machine Classification
CriticalMachines:
Critical Machines:
Haltpartofproduction
Expensive to repair
Expensivetorepair
Costlyreplacement
H d t fi d
Hardtofindparts
t
Frequentrepairs
SupportMachines:
Support Machines:
Nottooexpensivetorepair
Parts are readily available
Partsarereadilyavailable
Affectbutdonthaltoperation
M d t l
Moderatelycostlyrepairorreplacement
tl i l t
OtherMachines:
Other Machines:
Partsarereadilyavailable
Replacement is easy and inexpensive
Replacementiseasyandinexpensive
Donotaffectoperationdirectly
N hi t
Nohistoryofrepair
f i
MonitoringFrequency
Monitoring Frequency
VitalMachines
OnlineMonitoringorevery12weeks
CriticalMachines
Every24weeks
SupportMachines
Every48weeks
OtherMachines
Every812weeks
E 8 12 k
MethodsofDataCollection
Methods of Data Collection
Online
On lineContinuousMonitoring
Continuous Monitoring
ManualDatacollectionthroughportabledata
collection
ContinuousMonitoring
Continuous Monitoring
Realtime
Real timedataacquisitionthroughdedicated
data acquisition through dedicated
sensorsandinstrumentationthatmonitorthe
machine during every second of its operation
machineduringeverysecondofitsoperation.
Sometimestheinstrumentationsuppliedwith
relays for automatic shutdown when alarm
relaysforautomaticshutdownwhenalarm
levelsareexceeded.
ManualDataAcquisition
Manual Data Acquisition
Using
Usingaportableinstrumentationwith
a portable instrumentation with
sensors,datacanbecapturedonascheduled
intervals
DatathenisdumpedbacktoaPCfor
trending analysis and reporting
trending,analysis,andreporting.
ManpowerRequiredforDataCollection
Manpower Required for Data Collection
Levelofexpertise:Tech
Level of expertise: Tech
Amountoftraining:Minimum
Frequencyoftraining:onceayear
f i i
Highlevelofcommitment
ManpowerRequiredforDataAnalysis
Manpower Required for Data Analysis
Level
Levelofexpertise:Engineerorhighly
of expertise: Engineer or highly
knowledgemechanic
Duties:analyzedataandrunandmanagethe
Duties: analyze data and run and manage the
program
Amountoftraining:Varies
A f i i V i
Highlevelofcommitment
PredictiveMaintenance
Results:
Increasemachine
availability
Saveonmaintenancecost
Reducespare parts
Reduce spareparts
inventory
Increasemachinelife
Avoid unnecessary repairs
Avoidunnecessaryrepairs
Organizemaintenance
activities
I
Improveplantsafety
l t f t
IntroductiontoVibration
Analysis
l
Introduction to Vibration Analysis
IntroductiontoVibrationAnalysis
GeneralDescription Vibration
General DescriptionVibration
Therearemanydifferentparameterswecanmeasuretohelpusdetermine
machineryhealth:
Voltage Current
Power Flow
Flow Temp
Pressure Torque Speed
Viscosity Density Emission
ParticlesLoad
Nonecontainsasmuchinformationasthevibrationsignature!!!
None contains as much information as the vibration signature!!!
Notonlydoesitprovidetheseverityoftheproblembutcanalsopointtothe
sourceoftheproblem
VibrationcanbesimplystatedasAresponsetosomeformofexcitation
TheexcitationisgenerallyreferredtoastheForcingFunction
Vibrationisthemotionofabodyaboutareferencepositioncausedbyaforce
GeneralDescription ForcingFunction
Whenaforcingfunctionisappliedtoa
shaft within a plain bearing the free
shaftwithinaplainbearingthefree
movementwillcausetheshaftto
vibratewithinthebearing
Herewearemeasuringactualshaft
movement
movement
When a forcing function is applied

to a shaft within a bearing housing
where there is very little free
movement, then the vibration will
transmit
i to the
h casing
i
Measuring the casing movement of
a specific component as result of
the forcing function
VibrationfromMechanicalFaults
b at o o ec a ca au ts
VibrationCharacteristics
Amplitude HowMuch
Frequency HowOften
Phase. When
GeneralDescription MeasuringResponse
YoucanalsolookatvibrationastheamountofTime ittakestocomplete
aparticularcycle
If
Ifweexaminethemotionofaforcingfunctiononafanblade
we examine the motion of a forcing function on a fan blade Heavy
HeavySpot
Spot over
over
aperiodoftimeadistinctsignaturewilloccur.
This motion is called a

sine wave.
The horizontal axis is
measuring Time
The vertical axis is
measuring Amplitude
This is known as a
Ti
Time Waveform
W f
Amplitude versus Time
TimeWaveforms
Time Waveforms
Unfortunatelytherearemultiplesourcesofforcingfunctionsthatcanemitfroma
machineorcomponent.
Thusresultinginthetimewaveformbecomingcomplexinnature
A8 - Example 15
Ex15 -F2V Fan Outboard Vertical
0.4
Route Waveform
Theplotshownontherightis 0.3
22-Aug-02 11:33:16
acomplextimewaveform.
l ti f PK = .1495
1495
LOAD = 100.0
RPM = 832. (13.86 Hz)
0.2
AmplitudeversusTime 1.0
EX 8
Los - Example 8
-P2V Pump Outboard Vertical PK(+) = .3263
Analyze
PK(-) =Spectrum
.3572
Thisisjustoneformat
Acceleration in G-s
0.1 15-Nov-95 10:00:16
CRESTF= 3.38
(domain)foranalysing 0.0
0.8
RMS = 1.27
LOAD = 100.0
RPM = 737.
vibration data
vibrationdata. RMS Velocity in mm/Sec
-0.1
RPS = 12.28
Datacanalsobeanalysedina 0.6
Spectrum (AmplitudeVs -0.2
Frequency) throughaprocess -0.3

0.4
known as the FFT
knownastheFFT
R
-0.4
Time: 120.44
0 50 100 150 200 250 300 350 Ampl: -.07595
0.2 Time in mSecs
0
Freq:
q 736.86
0 6000 12000 18000 24000 30000 Ordr: 1.000
Frequency in CPM Spec: .245
Label: Looseness
FastFourierTransform
Fast Fourier Transform FFTProcess
FFT Process
Whenaproblemstartstodevelopwithinarotatingcomponentitwill
generateavibrationsignature.Thissignatureshouldbecapturedinthe
timewaveform
Distinguishingthatsignaturecanbeverydifficultwhenlookingatatimeplot
Di ti i hi th t i t b diffi lt h l ki t ti l t
Tounderstandtheproblemweneedtounderstandthefrequency
Howoftenisitoccurring?
TheFFTisaprocessthatdeterminesthefrequencyofasignalfromatime
waveform.
f
TheFFTisnamedafteran18th centurymathematiciannamedJean
BaptiseJosephFourier. Heestablished:
Anyperiodicsignalcanberepresentedasaseriesofsinesandcosines.
Meaningifyoutakeatimewaveformandmathematicallycalculatethe
f k f d h ll l l h
vibrationfrequency,itcanbeconvertedtoamorefamiliarformat
How the Vibration Spectrum is Created
HowtheVibrationSpectrumisCreated
Amplitude
e
Ampliitude
Amplitude
e
Tim
e
q y
FrequencyDomain
Thefrequencydomain(Spectrum)plotsthedataasAmplitudeinthe(Y)
axisandFrequencyinthe(X)axis.Thisdataisderivedfromthetime
domain mathematicalmanipulationofthetimewaveform.
p
Recallthewaveformandspectrumfromthepreviousslide.Ifyoutriedto
determineallthefrequenciesfromthewaveformplot,youwouldneedall
dayjusttoanalyseonepointofdata.
AstheFFTplotsthefrequenciesfromthewaveformforyoutheanalysisof
thisdatabecomeseasierandreducestheamountoftimeneededfor
analysisofeachpoint.
A8 - Example 15 Los - Example 8
Ex15 -F2V Fan Outboard Vertical
0.4 EX 8 -P2V Pump Outboard Vertical
Route Waveform 1.0
Analyze Spectrum
22-Aug-02 11:33:16
15-Nov-95 10:00:16
0.3
PK = .1495
RMS = 1.27
LOAD = 100.0
0.8 LOAD = 100.0
RPM = 832. (13.86 Hz)
0.2 RPM = 737.
PK(+) = .3263
RPS = 12.28
m/Sec
PK(-) = .3572
G-s
0.1 CRESTF= 3.38

Acceleration in G
RMS Velocity in mm
0.6
0.0
-0.1 0.4
-0.2
0.2
-0.3
-0.4
Time: 120.44 0
0 50 100 150 200 250 300 350 Ampl: -.07595 Freq: 736.86
Time in mSecs 0 6000 12000 18000 24000 30000 Ordr: 1.000
Label: Looseness
Analysis
l
Units of Measurements
UnitsofMeasurements
MeasuringAmplitudeandFrequency
Measuring Amplitude and Frequency
Youcanmeasureamplitudefromatimewaveformasshown:
+ 0 to Peak
RMS
Average
de
Amplitud
Time t
-
Peak to Peak
Theperiodtisthetimerequiredforonerevolutionoftheshaftinthis
illustration which equals one cycle of the waveform
illustration,whichequalsonecycleofthewaveform
Duringthisperiod,theamplitudeofthewaveformreachesapositive(+)peak,
returnstorest,andreachesanegative()peakbeforereturningtorest
Peak(Pk) Amplitudemeasuredfromtheatrestposition(0)tothe
highestvalue(0toPeak)
Peak to Peak (Pk
PeaktoPeak (PkPk)
Pk) Amplitudemeasuredfromthepeakpositive(+)
Amplitude measured from the peak positive (+)
valuetothepeaknegative()value
RMS (RootMeanSquare) obtainedbyaveragingthesquareofthesignal
leveloveraperiodoftimeandthentakingthesquarerootresult
A
Average(Avg)
(A ) Amplitudevaluethataveragesthepeakvaluesofthe
A lit d l th t th k l f th
waveform
0 to Peak
Youcancalculatethedifferent
+
RMS
amplitudeswhenoneofthevaluesare Average
known:
Amplitude
Time tt
RMS=0.707timesthepeakvalue
RMS 0 707 times the peak value
Avg=0.637timesthepeakvalue
PkPk=2timesthepeakvalue -
Peak to
P k
Peak
Severityofavibrationproblemcanbedeterminedbytheamplitudeof
thevibration.
Wecanmeasureamplitudeinoneofthreeways
1. Displacement measuresthedistancetheshaftmovesinrelationtoa
referencepoint.
2. Velocity measuresthedisplacementoftheshaftinrelationtotime
3. Acceleration measuresthechangeinvelocityinrelationtotime
The most common industrial applications are:

Themostcommonindustrialapplicationsare:
1. Displacement Microns PeaktoPeakvalue
2. Velocity mm/sec RMS
3. Acceleration Gs Peakvalue
Gs=1xforceofgravity(Gforce)
g y( )
AmplitudeRelationships
Amplitude Relationships
Thethreetypesofamplitudemeasurementsusedtodisplaydataaredirectlyrelated
toeachother
Changingfromoneamplitudeunittothenextaltersthewayinwhichthedataisdisplayed
Velocityisthedefaultunit
forstandarddatacollection
0.35
5
140
Ex15
A8 - Example 15
-F1H Fan Inboard Horizontal techniques
Low frequencies require very
R t S
Route Spectrum
t
22-Aug-02 11:30:50 Highandlowfrequency
h dl f
Forlittle
normal eventscanbeseen
forceoperating speed
0.30
120 OVERALL= 3.45 V-DG
4 to move an object RMS==.3909
PK
P-P 3.44
104.98
ranges, velocity data LOAD = 100.0

RPM = 831. (13.85 Hz) Displacement measures
inMicrons
0.25
100
low frequency events
RMS Velocity in mm/Sec
provides the best indication of

G-s
3
ignoring high frequencies
nin
0.20
0 20
80
Increasing
hi the
machine frequency
condition
diti that
Acceleration
Displacement
0.15
60
the objects move with the Relative shaft motion
2
same velocity, the force
Acceleration accentuates
PK

P-P
0.10
40 needed to move it increases,
thereby reducing the distance it the high frequencies
1
0.05
20
can travel
ignoring the low frequencies
Good for early bearing
00
detection (Whenever there
0 20000
Frequency in CPM
40000 60000
is Metal to Metal Impacting
Label: Large Fan Unit - Easy
involve)
FrequencyUnits
Frequency Units
Frequencyreferstohowoftensomethingoccurs:
Howoftenashaftrotates?
Howoftenarollingelementhitsadefectedrace?
Therearethreewaystoexpressfrequency:
1. CPM CyclesPerMinute
1CPM=1RPM
y
2. Hz CyclesPerSecond
CPM/60
3. Orders MultiplesofTurningSpeed
Frequency/TurningSpeed
Consideramotorhasarotationalspeedof1485RPM,intermsof
frequencythisequatesto:
1485 CPM (1rpm=1cpm)
1485CPM (1rpm = 1cpm)
24.75Hz (1485/60)(minutestoseconds)
1Orders (1xrevolutionoftheshaft)
q y
FrequencyUnits
Shownbelowisatableshowingthe
relationship between all three frequency
relationshipbetweenallthreefrequency
unitswithreferencetotheturningspeed
Motor Turning Speed = 1500RPM

CPM 1500 2250 3000 6000 12000
Hz 25 37.5 50 100 200
Orders 1 1.5 2 4 8
FrequencyDomain
Frequency Domain
Thevibrationanalystcandividethefrequencydomaindata
intothreemajorareasofinterest
h f
1. Synchronous EqualtoTsorHarmonicsofTs
2. Subsynchronous <1xTs
3
3. N
Nonsynchronous
h >1xTsbutnotaninteger
1 T b t t i t
NoteTsistheturningspeedorrotationalfrequency(RPM)
oftheshaftatthepositionwhereyoumakethe
measurement
measurement
Eachdefectthatcanmaterialiseinthefrequencydomain
canbecategorisedintooneofthreetypesofenergylisted
above
Knowingthetypeofenergywithinthedatacanhelptheanalyst
quicklyeliminate2/3rd ofthefaulttypes
HarmonicOrders
Harmonic Orders
Harmonics arecursorsthatareexactmultiplesoftheprimaryfrequency
Theyareusedtolocateotherfrequenciesrelatedtotheprimarycursor
Los - Example 3
EX3 -P2V Pump Outboard Vertical
1.0
Analyze Spectrum
15-Nov-95 10:00:16
Here the primary cursor is at 1 RMS = 1.27

0.8 LOAD = 100.0
Order ((1xTs).
) All the other cursors RPM = 737.
RPS = 12.28
are harmonics (exact multiples of
Velocity in mm/Sec
0.6 the primary cursor)

RMS V
04
0.4
Therefore: 0.2
Whentheprimarycursorsislocatedon1Orderalltheharmonicswillbe
synchronous
h 0
Freq: 736.86
Harmoniccursorscanbeusedtoshownonsynchronousandsub
0 6000 12000 18000
Frequency in CPM
24000 30000 Ordr: 1.000
Spec: .245
synchronousharmonicsdependingupontheenergyoftheprimary
frequency
Energy in the Spectrum
EnergyintheSpectrum
C1 - Example 4
E4 -MOH MOTOR OUTBOARD HORIZONTAL
05
0.5
Route Spectrum
09-Feb-00 12:41:33
OVRALL= .5785 V-DG

0.4 RMS = .5716
LOAD = 100.0
RPM = 2937.
RPS = 48.95
0.3
0.2
01
0.1
0
Freq: 2.937
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .01038
y gy
SynchronousEnergy Los - Example 8
EX 8 -P2V Pump Outboard Vertical
1.0
Analyze Spectrum
15-Nov-95 10:00:16
Synchronousenergy relatedto RMS = 1.27

0.8 LOAD = 100.0
turningspeed.
i d RPM = 737.
RPS = 12.28
city in mm/Sec
Wecanseefromthe 0.6
spectrum that the first peak

spectrumthatthefirstpeak
RMS Veloc
isat1Orders(whichmeansit0.4
is1xturningspeed)
0.2
Alltheotherpeaksare
All th th k
harmonicsoff,whichmeans
theyarerelatedtothefirst 0
Freq: 736.86
peak 0 6000 12000 18000
Frequency in CPM
24000 30000 Ordr: 1.000
Spec: .245
245
Label: Looseness
Examples of synchronous energy:

1) Imbalance 2) Misalignment 3) Gearmesh
y gy
NonSynchronousEnergy
BF - Example 5
E5 -R4A ROLL BRG. #4 - AXIAL
2.0
Route Spectrum
12-Jul-96 17:16:42
Nonsynchronousenergy 1.8
OVRALL= 2.63 V-DG
RMS = 2.69
not related to turning speed
notrelatedtoturningspeed 1.6
LOAD = 100
100.0
MPM = 3225.
0
1.4 RPM = 380.

1.2
Wecanseefromthe 1.0
spectrum that the first
spectrumthatthefirst 0.8
peakisat10.24Orders. 0.6
Thisisnotrelatedto
0.4
turning speed.
turningspeed. 0.2
0
Freq: 3888.9
0 6000 12000 18000 24000 30000 Ordr: 10.24
Label: Outer Race Defect
Priority: 1
Examples of non-synchronous energy:

Bearings Multiples of belt frequency Other Machine Speeds
y gy
SubSynchronousEnergy
Subsynchronousenergy Less
than turning speed
thanturningspeed
Thespectrumshowsthefirst
impactingpeakbelow1Order.
Thisissubsynchronousenergy
Examplesofsubsynchronous
energyare:
BeltFrequencies
Other Machine Speeds
OtherMachineSpeeds
CageFrequencies
EnergyinaSpectrum
Energy in a Spectrum
Synchronous
N x RPM where N is an integer
g
Sub-synchronous
<1 x RPM
Non-synchronous
F x RPM where F is >1x RPM but not integer
g
y gy
CausesofSubSynchronousEnergy
Frequenciesthatshow
belowtherotational
frequency(Lessthan1
Order)aresubsynchronous.
Anothercomponent
Another component
Cagefrequencies
Primarybeltfrequency
Oilwhirl(plainbearings)
y gy
CausesofSynchronousEnergy
Frequenciesthatareequal
toooradirectmultipleof
runningspeedare
Synchronous
Possiblecausesof
Possible causes of
Synchronousenergyare: Los - Example 8
EX 8 -P2V Pump Outboard Vertical
Imbalance
1.0
Analyze Spectrum
15-Nov-95 10:00:16
RMS = 1.27
0.8 LOAD = 100.0
Misalignment RPM = 737.

RPS = 12.28

0.6
Looseness
0.4
Vane pass frequency

Vanepassfrequency
0.2
Gearsetc
0
Freq: 736.86
0 6000 12000 18000 24000 30000 Ordr: 1.000
Label: Looseness
y gy
CausesofNonSynchronousEnergy
Frequenciesabove(butnot
integermultiplesof)turning
speedarenonsynchronous.
Possiblecausesofnon
synchronous energy are:
synchronousenergyare:
Anothercomponent
Antifrictionbearings BF - Example 5
E5 -R4A ROLL BRG. #4 - AXIA
2.0
Electrical
Route Spectrum
12-Jul-96 17:16:42
1.8
OVRALL= 2.63 V-DG
1.6 RMS = 2.69
Systemresonances
LOAD = 100.0
MPM = 3225.
1.4 RPM = 380.
RMS Velocitty in mm/Sec

1.2
Multiples of belt frequency

Multiplesofbeltfrequency 10
1.0
0.8
0.6
0.4
0.2
0
Freq: 3888.9
0 6000 12000 18000 24000 30000 Ordr: 10.24
Priority: 1
LinesofResolution
Lines of Resolution
LOR
LinesofResolution
Lines of Resolution
LinesofResolution(LOR)determinehowclearthepeaks(data)are
definedwithinourspectrum.
ThemorelineswehaveoverthesameFmax(Maximumfrequency
scale).Themoreaccurateourdatawillbe
Example.
Thediagrambelowshowsdatathathasbeencollectedusing400LOR.
Noticehowthetopofthepeaksarecapped.WhentheLORare
increasedthedatabecomesmoreaccurate.
LinesofResolution
L2 - TA 16
TA16 -M1H Motor Outboard Horizontal
0.20
0.5
Analyze Spectrum
13-Mar-01 09:14:16
09:13:53
PK = .3852
3852
7078
.7078 Thespectrumshowndisplays
The spectrum shown displays
0.16
0.4 LOAD = 100.0
RPM = 1497.
1496.
RPS = 24.95
24.94
dataat800L.O.Rwithan
Fmaxof1600Hz
in G-s
Acceleration in G-s
0.12
0.3
PK Acceleration
0.08
0.2
The second spectrum
PK
displays the same data but

0.04
0.1 with 3200 L.O.R over the
same Fmax
0
0 400 800 1200 1600
Frequency in Hz
LinesofResolution
Lines of Resolution
TherangeofLORsettingsthatwecanchoosefromontheanalyzer
startsat100Linesandgoupto12800Lines.
100 Li d 12800 Li
TheaveragenumberofLORisaround1600Linesforatypical
The average number of LOR is around 1600 Lines for a typical
motor/pumpsetup
To change the LOR settings we need to alter our parameter set

set.
This is done in the Database Setup program
Remember. If you double your lines of resolution you double your

data collection time.
p y
SpectralSummary
BF - Example 5
E5 -R4A ROLL BRG. #4 - AXIAL
2.0
Route Spectrum
12-Jul-96 17:16:42
18
1.8 Energy Types H
Harmonics
i
Velocity Dissplacement
OVRALL= 2.63 V-DG

1.6 Synchronous Multiples of Primary
RMS = 2.69
LOAD = 100.0
MPM = 3225.
1.4 Non Synchronous Frequency RPM = 380.
Sec
S Velocity in mm/S
mplitudes
s
1.2 Sub Synchronous

Resolution
1.0
Clarity of the spectral
V
0.8
Am
d t
data
RMS
Accceleration,
0.6
0.4
0.2
0
Freq: 3888.9
0 6000 12000 18000 24000 30000 Ordr: 10.24

FrequencyFrequency in CPM Spec:
p .748
Priority: 1
Hz (CPS), CPM, Orders
Analysis
Data Collection
DataCollection
g q
TransducersandMountingTechniques
Althoughtherearemanydifferenttypesoftransducers
available,themostcommontypeusedfordaytodaydata
collectionareAccelerometers.
Thesetransducersprovideanelectricalchargeproportionalto
acceleration by stressing piezoelectric crystals typically
accelerationbystressingpiezoelectriccrystalstypically
100mV/gsensorsareused.
DataQualityy
Whetheritisyourjobtocollectthedataand/oranalysethe
dataitisimportanttounderstandthatthetechnologieswill
notgiveyoutheanswertoamachinesproblemunlessyou
havecollectedmeaningful,qualitydata
Therearecertainconsiderationsthatmustbetakenpriortoany
databeingcollected,theseare:
Agoodunderstandingoftheinternalmakeupofthemachine,inorder
A good understanding of the internal make up of the machine in order
tounderstandthebesttransmissionpathfordatacollection bearing
locations,loadzonesetc.
Ensuredataiscollectedinarepeatablemannersowecancompare
p p
twoormorereadingstoeachother trendingpurposes
Variablespeedmachines itisveryimportanttocollectdatawiththe
correctrunningspeedenterintotheanalyser
TransmissionPath
Damagedcausedtoamachinecomponentwillcauseacertain
amountofvibration/soundorheattopropagateawayfromthe
initial impact
initialimpact.
Itistheeffectoftheimpact/forcethatwearetryingtodetect
Inmanycasesthefurtheryouareawayfromtheinitialeventthe
weakerthesignalwillbecome,resultinginthedataappearingto
belowerinvalue.
Inmoreextremecasestheimpactcanbelostamongstothermachine
noisebythetimeithasreachedyourtransducer,resultinginno
detectionofamachineproblem.
Usuallythebestplacetoacquiredatafromamachine,isatthebearings.
Thisisbecausethebearingsaretheonlypartofthemachinethatconnectthe
internalrotatingcomponentstothestationarycomponents(Casing)
p
RepeatableData
Collectdatainthesamemannereachtime.
Thisconsistencywillallowyoutotrendthemachineryconditionand
y y y
properlyjudgetheprogressionoffaults
Inordertoaidwithrepeatabledatatheanalyserrequestsfor
d
datatobecollectedincertainlocationsonthemachine.
b ll d i i l i h hi
ThesearecalledMeasurementPoints
A measurement point is determined by three characters

and a description.
Each character refers to a particular place on the
machine being monitored
E.g.
E g M1H is a typical measurement point
MeasurementPoints
Measurement Points
Ameasurementpointisdefinedasthreealphanumericdigits
alongwiththeirrespectivedefinition
Orientationandlocationoneachcomponent
Orientation and location on each component
Theimageontherightis
takenfromthescreenof
the 2130 analyser during
the2130analyserduring
acollectionroute
Themeasurementpoint
identifiercanbeseenin
identifier can be seen in
thetoprightwhilethe
pointdescriptionis
shownjustbelow
j
MeasurementPoints
Measurement Points
ThefirstletterofthePointIdentifierreferstothetypeof
machinebeingmonitored
M
M =Motor
Motor P =Pump
P Pump F =Fan
F Fan
Thesecondcharacterrepresentedbyanumberindicatesthe
locationonthemachine
Inboard(DriveEnd) orOutboard(NonDriveEnd)
Thethirdletterreferstotheorientationofthesensoror the
typeofprocessingbeingdonebytheanalyser
H=Horizontal V=Vertical P=PeakvueChangeinDSPofAnalyser
MeasurementPoints
Measurement Points
Thefollowingexampleshowshowthenumberingsystem
changesasyoucrossfromonecomponenttothenext
M1H Motor Outboard Horizontal
M1P Motor Outboard Horizontal Peakvue 2
1
1
2
P1H Pump Inboard Horizontal
P1P Pump Inboard Horizontal Peakvue
Noticehowthe1isnotalwaystheOutboard
Thischangeswhenthenextcomponentisrequiredfordatacollection
Thenumberingsystemstartsfrom1again
The numbering system starts from 1 again
Analysis
Fault Diagnostics
FaultDiagnostics
Imbalance,Misalignment,Looseness
FaultDiagnostics
Fault Diagnostics
Eachtypeofmachinefault
yp f ordefect
f revealsaspecific
p
vibrationcharacteristic inthespectrumandtimewaveform
domainthatdistinguishthatfaultfromanother.
Si l b
Simplybygainingabasicknowledgeofthesepatternsand
i i b i k l d f th tt d
applyingafewrulesofthumb wecanstarttoanalyse
machinevibrationandpreventmachinefailure.
Thissectionconcentratesthecharacteristics/patternsand
rulesthatapplytodiagnosemachinefaultssuchas:
IImbalance
b l Misalignment
Mi li t LLooseness Gears
G
Bearings (Peakvue) Belts Electrical
Resonance
Imbalance
Imbalance
Imbalance(Unbalance)occurswhenthecentreofmassdiffers
fromthecentreofrotation.
Ifthecentreofmasschangesontherotorduetoaheavyspot
orsomeotherinfluencethenacentrifugalforceisproduced.
This results in the centre of rotation being offset from the
Thisresultsinthecentreofrotationbeingoffsetfromthe
centreofmasscausingthevibrationtoincreaseatthe
rotationalfrequency.
Imbalance(Types)
( yp )
Imbalance
CausesofImbalance
ImproperAssembly
Material build up / dirt
Materialbuildup/dirt
Weartocomponents
Brokenormissingparts
Alloftheaboveconditionswillresultinanunbalancedstate
DiagnosticRulesforImbalance
Periodicnon
Periodic nonimpacting
impactingsinusoidalwaveform
sinusoidal waveform
Spectralpeakat1xTs(1Order)
Verylittleaxialvibration
Similaramplitudesbetweenhorizontalandverticalplains
p p
Synchronousfaulttype
Amplitudeswillincreasewithspeed
Verylowharmonicsof1xTs
ImbalanceSpectralData
Imbalance Spectral Data
Thespectrumshownrepresentsasimpleunbalancestate
Singlepeakat1xTs(1Order)
Littleindicationofharmonics
Little indication of harmonics
IF - Example 2
Ex2 -F1H Fan Inboard Horizontal
6
Route Spectrum
16-Sep-99 08:36:29
5
Whatshouldthe OVRALL= 4.58 V-DG
RMS = 4.56
LOAD = 100.0
waveformshow? RPM = 3000.

RPS = 50.00
RMS Velocity in mm//Sec
0
Freq: 3000.0
0 20000 40000 60000 80000 Ordr: 1.000
Frequency in CPM Spec: 4.539
ImbalanceWaveformData
Imbalance Waveform Data
DespitethewaveformbeingdisplayedinAcceleration
Defaultunitforroutebasedwaveformdata
Thereisstillapredominantsinusoidalwaveformpattern
There is still a predominant sinusoidal waveform pattern
1xRevolutionsinewave
IF - Example 2
10
1.0
Waveform Display
02-Feb-00 15:13:51
0.8
PK = .5289
0.6 LOAD = 100.0
RPM = 2985.
RPS = 49.76
0.4
PK(+)) = .8332
PK( 8332
Acceleration in G-s
PK(-) = .8893
0.2
CRESTF= 2.38
-0.0
-0.2
A
-0.4
-0.6
-0.8
Ch
Changingtheunitstovelocitywouldreducetheamountofhigh
i th-1.0 it t l it ld d th t f hi h
frequencynoiseresidingonthewaveform
0 0.5 1.0 1.5 2.0 2.5 3.0
Revolution Number
3.5 4.0 4.5 5.0
ImbalanceTrendData
Imbalance Trend Data
Thetrenddataisagoodwayofdeterminingiftherehasbeen
achangeincondition,asthisplotsamplitudeagainsttime
( e e t e s days)
(wheretimeisindays)
Herethe1xTsparameterisbeingtrended
Vibrationhasbeensteadyat3mm/secforaperiodoftime
Asuddenchangeinstateshouldalerttheanalysttoafaultdeveloping
E02N - JB1420C CONDY RECOVERY PUMP
JB1420C -M1H Motor Outboard Horizontal
14
Trend Display
of
1xTS
12
-- Baseline --
Value: 3.063
10
Date: 07-Apr-00
ocity in mm/Sec
8
FAULT
RMS Velo
0
Date: 21-May-01
0 100 200 300 400 500 Time:14:24:29
Days: 07-Apr-00 To 21-May-01 Ampl: 11.21
Imbalance Problem Practical
ImbalanceProblem
Thefollowingfanunithasanimbalancepresentontherotor.
1xTsPeakintheSpectrum
1xTsPeakintheWaveform
1xTs Peak in the Waveform
Imbalance
IF - Example 2
6
Route Spectrum
16-Sep-99 08:36:29
5 OVRALL= 4.58 V-DG

RMS = 4.56
LOAD = 100.0
RPM = 3000.
RPS = 50.00
0
Freq: 3000.0
0 20000 40000 60000 80000 Ordr: 1.000
Frequency
eque cy in C
CPM Spec: 4 539
4.539
IF - Example 2
1.0
Waveform Display
02-Feb-00 15:13:51
0.8
PK = .5289
0.6 LOAD = 100.0
RPM = 2985.
RPS = 49.76
0.4
PK(+) = .8332
Acceleration in G-s
PK(-) = .8893
0.2
CRESTF= 2.38
-0.0
-0.2
-0.4
-0.6
-0.8
-1.0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Revolution Number
Whatwouldhappentothedataifthefollowingoccurredto
th f ?
thefan?
ImbalanceCaseStudy1
Imbalance Case Study 1
Background
ThefollowingdataistakenfromaRecirculationFandesignedtocirculate
thehotairthroughanOventoaidwithdryingtheprocess.Theovenis
verticallymountedandtheproductcomesintotheovenfromthetopand
exitsatthebottom.ThereisoneRecirculationFanandoneExtractFan.
L
Lossoffunctionfromeitherfanresultsintheovenbeingtakenoffline.
f f ti f ith f lt i th b i t k ffli
Bm/c - TOP RECIRC FAN
TRF B m/c -F2H Fan Outboard Horizontal
6
ROUTE SPECTRUM
08-Nov-04 14:16:45
Thespectralplotsshows
The spectral plots shows 5 OVERALL= 4.70
4 70 V
V-DG
DG
RMS = 4.70
adominant1xTspeak(1 LOAD = 100.0

RPM = 1246.
RPS = 20.77
ocity in mm/Sec
Order)withverylittle 4
othervibrationpresent 3
RMS Velo
0
Freq: 1246.3
0 20000 40000 60000 80000 100000 Ordr: 1.000
ImbalanceCaseStudy1
Thewaveformfromthisdatashownonthefollowingpage
representsasinusoidalwaveformclearlyshownonceper
revolutionoftheshaft
e o ut o o t e s a t herethewaveformisdisplayedin
e et e a eo s d sp ayed
velocity.
8
Route Waveform
All
Allindicationspoint
indications point 08-Nov-04 14:16:45
RMS = 4.66
towardsanimbalance 4 LOAD = 100.0

RPM = 1246.
RPS = 20.77
problem.The PK(+) = 7.03

m/Sec
PK(-) = 7.40
0
CRESTF= 1.59
Velocity in mm
amplitudesshouldbe
checkedinbothradial -4
directionstoconfirm -8
8
thisproblem
-12
0 1 2 3 4 5
Revolution Number
ImbalanceCaseStudy1
Theplotshownindicatesamultispectralplotshowingallthe
radialdirections.
TRF B m/c - Multiple Points (08-Nov-04)
Max Amp
4.27
Plot
Scale
TRF B m/c -F2V
5
city in mm/Sec
It
Itisclearthatthe
is clear that the TRF B m/c -F2H
RMS Veloc
amplitudesare
commontoboth 0 TRF B m/c -F1V
b i
bearing I b d
Inboard
andOutboardinall 0 8000 16000
TRF B m/c -F1H
24000
radialplains Frequency in CPM

ImbalanceCaseStudy1
Thetrenddataforthe1xTsparameterhasbeensteadyfora
considerableamountoftime.Thelasttworeadingshasshown
a s g ca t c ease a p tude
asignificantincreaseinamplitude

6
Trend Display
of
1xTS
5
-- Baseline --
Value: .428
Date: 24-Nov-00
y in mm/Sec
The
Thefanwas
fan was
RMS Velocity
recommendedtobe 2
FAULT
cleanedatthenext
1
availableopportunity
il bl t it
ALERT
andforittobere 0
0 300 600 900
Days: 24-Nov-00 To 08-Nov-04
1200 1500
Date: 08-Nov-04
Time: 14:16:38
Ampl: 4.688
testedafterwards
ImbalanceSummary
Imbalance Summary
DiagnosticRulesforImbalance
Diagnostic Rules for Imbalance
Periodicnonimpactingsinusoidalwaveform
Spectralpeakat1xTs(1Order)
Spectral peak at 1xTs (1 Order)
Verylittleaxialvibration
Similaramplitudesbetweenhorizontaland
Si il lit d b t h i t l d
verticalplains
Synchronous fault type
Amplitudeswillincreasewithspeed
Verylowharmonicsof1xTs
V l h i f1 T
Misalignment
Misalignment
Whentwomatingshaftsdonotsharethesamecollinearaxis
thenmisalignmentisinduced.
Misalignmentisoneoftheprimaryreasonsforpremature
machinefailure.Theforcesthatareexertedonthemachine
anditscomponentswheninamisalignedstatearegreatly
p g
increasedfromnormaloperatingconditions
Misalignment
OperationalDeflectionShape(ODS)isatechniquethat
machinemovementbaseduponthephaseandmagnitudeof
data co ected o t e a a yse S o be o s a
datacollectedfromtheanalyser.Shownbelowisanimage
age
fromtheODSillustratingtheforcesthatareexertedontothe
machineandcomponentswhenrunninginamisaligned
condition
Misalignment
Misalignmentcanbebrokenintothreebasiccategories,these
are:
Angular Wheretheshaftcentrelinescrossproducinga1xTspeakaxially
Offset Where the shaft centrelines are parallel but they do not meet
producing
p g a radial 2xTs p
peak
More commonly seen A combination of the above

Misalignment
g
Misalignment
g
Anothercommonproblem
associatedwithalignmentis
b i
bearingmisalignment.
i li t
Bearingmisalignmentoccurs
whenthebearingsarenot
mountedinthesameplain
t d i th l i
possiblydueto:
oneormoreofthebearings
being cocked in the housing
beingcockedinthehousing
Themachineitselfdistortsdueto
thermalgrowthorsoftfoot
conditions
Misalignmentatthedrivecauses
shaftbending.
Misalignment
DiagnosticRulesforMisalignment
Highaxiallevelsofvibrationat1xTs
g
Highradiallevelsofvibrationat2xTs
Repeatableperiodsinewaveformshowing1or2clearpeaksper
revolution (Most likely M
revolution(Mostlikely M or
or W
W shape)
shape)
Datacanusuallybeseenacrossthecoupling
DiagnosticRulesforBearingMisalignment
Diagnostic Rules for Bearing Misalignment
Highlevelsofvibrationat1xTsand2xTs
Repeatableperiodicsinewaveformshowing1or2clearpeaksper
revolution
l ti
Datausuallyshowneitherthedriverordrivencomponent
g p
OffsetMisalignmentSpectralData
Thespectraldatashownrepresentsasimplemisalignment
plot.
Theprimarycursordenotesthe1xTspeakwhiletheharmoniccursors
indicatealarger2xTspeak.Thistypeofdataiscommontothatof
OffsetMisalignment
ST.1 - Raw Water Pump
P029 -M2H
7
Route Spectrum
15-FEB-93 11:04:18
6
OVRALL= 6.50 V-DG
RMS = 6.47
LOAD = 100.0
MS Velocity in mm/Sec
c
5 RPM = 2976.
RPS = 49.61
3
RM
0
Freq: 2925.0
0 10000 20000 30000 40000 50000 Ordr: .983
g g p
AngularMisalignmentSpectralData
Thespectraldatabelowrepresentsasimplemisalignment
plot.
Theprimarycursordenotesthe1xTspeakwhilethedatawastaken
intheaxialdirection.ThistypeofdataiscommontothatofAngular
Misalignment
B29 - PUMP NO 3
3601PUM003-M2A Motor Inboard Axial
8
Route Spectrum
04-Aug-04 08:49:05
7
OVERALL= 6.33 V-DG
RMS = 6.31
LOAD = 100.0
6
RPM = 1071
1071. (17
(17.84
84 H
Hz))
S Velocity in mm/Sec
4
RMS
0
Freq: 1.071
0 30 60 90 120 Ordr: 1.000
Frequency in kCPM Spec: 5.966
g
OffsetMisalignmentWaveformData
Thewaveformaboveisshowingtwoclearpeaksper
revolutionoftheshaft.Thistypeofwaveformresemblingan
MorWshapeiscommontooffsetmisalignment.
o s ape s co o to o set sa g e t
Datashowninvelocity
ST.1 - Raw Water Pump

P029 -M2H
40
Waveform Display
26-MAR-93 13:32:52
30
RMS = 17.00
LOAD = 100.0
RPM = 2996.
20 RPS = 49
49.93
93
Velocity in mm/Sec
PK(+) = 30.66
PK(-) = 26.81
10
CRESTF= 1.82
-10
-20
-30
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Revolution Number
MisalignmentWaveform
Misalignment Waveform
Thewaveformdatashownaboveispredominantlyshowing
onesinusoidalwaveformperrevolutionoftheshaft.
HerethedataisshownAcceleration
Here the data is shown Acceleration
B29 - PUMP NO 3
3601PUM003-M2A
3601PUM003 M2A Motor Inboard Axia
0.8
Route Waveform
04-Aug-04 08:49:05
0.6
PK = .2596
LOAD = 100.0
RPM = 1071. (17.84 Hz)
0.4
PK(+) = .6277
PK(-) = .5683
Acceleration in G-s
0.2 CRESTF= 3.42
0.0
-0.2
-0.4
-0.6
-0 8
-0.8
Rev : .680
0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 Ampl: -.306
Revolution Number
y
CaseStudy3 KilnMainMotorGearbox
Introduction
TheKilndrivegearboxmotorhadbeenreplacedduringa
The Kiln drive gearbox motor had been replaced during a
plannedplantshutdown.
Duringthestartupoftheplantaftertheshutdownitwas
notedthatthemotorandgearboxwereexcessivelynoisy.
Vibrationdatawastakenduringtherunupoftheplantto
determinethecauseoftheproblem.
p
Main Motor
Kiln Gearbox
y
Thespectralplotshownaboveisthedatatakenfromthedrive
endofthemotor.Herethereisadominant2xTspeak.
04 - Kiln Drive
0804 -M2H Motor Inboard Horizontal
2.4
Route Spectrum
In addition to the misalignment the excessive forces 2.1

29-Mar-01 11:33:43
OVRALL= 2.47 V-DG

being applied to the machine were causing excessive RMS = 2.46
LOAD = 100.0
loading on the gears. 1.8

RPM = 1418.
RPS = 23.64
Velocity in mm /Sec
04 - Kiln Drive
1.5 0804 -G2A Shaft 01 Outboard Axial
5
Max Amp
5.98 4
3
1.2
2
1
RM S V
0
Amplitude - Mixed Units
0.9 29-Mar-01
09:40: 20
After 29-Mar-01
09:40: 09
0.6 Shutdown 26-Mar-01

12:11: 12
0.3 23-Jan-01
15:02: 00
0 Before 25-Oct-00
09:04: 17
Freq: 1418.3
0 20000 Shutdown 40000 08-Aug-00
60000 Ordr: 1.000
Frequency in CPM 14:06: 56 Spec: 1.346
0 60 120 180 240 300
Frequency in kCPM
y
Duringdatacollectionitwasalsoobservedthatthegrouting
aroundthefrontfeetofthemotorhadbeguntocrackasa
resultoftheexcessiveforcebeingappliedtothemotorbase
andfeetduetothemisalignment.
Conclusion
Itwasconfirmedtheengineersthatreplacedthemotorduringthe
shutdownandassumedasthemotorwasalikeforlikeswap,aslongas
th k t th hi i th
theykepttheshimsinthecorrectplacethenalignmentwasnot
t l th li t t
necessary.
Correctiveactionwasrequiredandproductionwasstoppedsothe
motorcouldberealignedandthemountingsresecured.
t ld b li d d th ti d
MisalignmentSummary
Misalignment Summary
DiagnosticRulesforMisalignment
Diagnostic Rules for Misalignment
Periodicnonimpactingsinusoidalwaveformwith
1 or 2 clear peaks per revolution (Most Likely M
1or2clearpeaksperrevolution(MostLikely M
orWshape)
Spectralpeakat1xTsand2xTs
Spectral peak at 1xTs and 2xTs
Axialvibrationat1xTs
Synchronous fault type
Datacanbeseenacrossthecouplingoracrossthe
component itself
componentitself
Looseness
Howwouldlooseness?
Looseness
Loosenesscanbebrokendownintotwomaincategories,
Structural andComponent
Structural looseness occurs when there is free
movement within the machines support structure causing
excessive vibration. This can be a result of:
Loose support bolts to the components feet and supports
Cracked welds
Deterioration of the base itself.
Component looseness generally occurs when there is
excessive clearance to the components
p within the
machine, such as:
Excessive clearance between the shaft and bearings
Excessive clearance between the shaft and an impeller etc
etc.
Looseness
DiagnosticRulesforLooseness
Multipleharmonicsofthe1xTspeak
p p Structural
MultipleHarmonicsofthecomponentthatisloose Component
Numberofharmonicswillincreaseastheloosenessprogresses
Random non periodic waveform Structural
Random,nonperiodicwaveform
Waveformshowspredominantimpacts Component
Raisednoiselevelaroundthe1xTs+harmonics
Halfharmonicsmayalsobepresent
CanbepresentinallDirections
p
LoosenessSpectralData((Structural))
ThespectralplotshownisdemonstratingLooseness.
The1xTspeakhasbeenhighlightedbytheprimarycursorandthe
p g g y p y
relevantharmonicshavebeendisplayed.
Multipleharmonicsof1xTsareshownuptoaround10ordersof1xTs.
40 - Kiln Main Drive

M4441 -G2H Shaft 01 Outboard Horizontal
4.0
Route Spectrum
06-Nov-02 11:02:11
3.5
OVERALL= 5.22 V-DG
RMS = 5.22
LOAD = 100.0
30
3.0
RPM = 635. (10.58 Hz)
2.5
2.0
1.5
1.0
0.5
0
Freq: 10.58
0 200 400 600 800 1000 Ordr: 1.000
Frequency in Hz Spec: 3.088
p
LoosenessSpectralData((Component)
p )
Thespectralplotshownisdemonstratingrotational
Looseness.
Theprimarycursorison5xTspeak
The5Orderpeakisvanepassfrequency(5vanesontheimpeller)
Multipleharmonicsof5xTsareshownindicatingtheimpellerhas
p g p
comeloose. Ex 9
L1 - Example 9
-P2A Pump Outboard Axial
1.5
Route Spectrum*
17-Aug-01 08:52:02
1.2
The raised noise level around
OVERALL= 6.62 V-DG
RMS = 6.13
the vane pass frequency is

LOAD = 100
100.0
0
RPM = 2974. (49.57 Hz)
Velocity in mm/Sec
0.9
common to a pumping
problem known as Cavitation
This would be the likely cause
RMS V
06
0.6
of the impeller problem

0.3
0
Freq: 14.88
0 40 80 120 160 200 240 Ordr: 5.002
Frequency in kCPM Spec: .742
Label: Centrifugal Pump - Medium
LoosenessWaveformData
Herethewaveformisdemonstratingalotofenergyand
appearstobemorerandomandnonperiodic.
Displayingthewaveforminvelocitymayhelptoshowtherandom
nonperiodicpattern.
1.2
Route Waveform
06-Nov-02 11:02:11
0.8 RMS = .3174

LOAD = 100.0
RPM = 635. (10.58 Hz)
PK(+) = .9797
0.4 PK(-) = .9874
Acceleration in G-s
CRESTF= 3.11
0.0
-0.4
-0.8
-1.2
0 50 100 150 200 250 300 350 400
Time in mSecs
LoosenessTrendData
Looseness Trend Data
Herethetrendplotisshowingtheparameterlabelledasthe3
15xTs.Thisismeasuringtheamountofenergyfrom3ordersto
15orders,whichiswheretheharmonicsofloosenesswill
5 o de s, c s e e t e a o cs o oose ess
appear.

8
Trend Display
of
7 3-15xTS
-- Baseline --
6
Value: .837
837
Date: 28-Feb-02
FAULT
4
ALERT
3
0
0 10 20 30 40 50
Days: 28-Feb-02 To 16-Apr-02
CaseStudy4
Case Study 4 ReciprocatorFan
Reciprocator Fan
Introduction
Datahadbeencollectedonthefollowingfanforseveral
Data had been collected on the following fan for several
monthsaspartofaroutineperiodicvibrationroutine.Duringa
routinevisittothemachineitwasobservedthattherewasa
lot of low frequency activity showing around the bearing on
lotoflowfrequencyactivityshowingaroundthebearingon
theinboardofthefan(F1H)
CaseStudy4
Reciprocator Fan
Themultipleplotsshownaboveindicatethechangeovertime
fromthedatatakenonF1H.
Itisquiteapparentthatthedatashownhereisindicatingmultiple
harmonicsofthe1xTsfrequency(theriseenergyasyoumovefurther
awayfromthe1xTs).
Thistypeofdataiscommontothatofaloosenessproblem.
40 - Precip Fan
M2237 -F1H Fan Inboard Horizontal
Max Amp 2.4

2.74 2.0
1.6
1.2
0.8
RMS Velocitty in mm/Sec
0.4
0
29-Oct-02
11:00:02
18-Sep-02
09:13:26
29-Aug-02
15:30:18
29-Oct-02
11:00:02
RPM= 998.9
22-Aug-02
11:14:48
Freq: 16.65
0 300 600 900 1200 Ordr: 1.000
Frequency in Hz Sp 4: 2.811
y
CaseStudy4 p
ReciprocatorFan
Thewaveformdatatakenforthisparticularpointisnot
showingarandomtypeofwaveformpatternwhichyou
wouldexpectfromStructurallooseness,
ou d e pect o St uctu a oose ess, but butthereisamore
t e e sa o e
arepeatable(timedinterval)pattern.
40 - Precip Fan
M2237 -F1H Fan Inboard Horizonta
3
Analyze Waveform
18-Sep-02 09:24:16
2 RMS = .3747
LOAD = 100.0
RPM = 998. (16.63 Hz)
1
PK(+) = 2.36
PK(-) = 2.83
Acceleration in G-s
CRESTF= 7.55
0
-1
A
-2
-3
-4
0 100 200 300 400 500 600 700 800
Time in mSecs
CaseStudy4
Reciprocator Fan
ThistypeofwaveformwouldmorebeindicatingComponent
loosenessandmayindicateaproblemwithaloosebearing.
Conclusion
Itwasrecommendedthatthebearingshouldbeinspectedat
thenextavailableopportunity.
Upon
Uponinspectionitwasfoundthatthebearingwasa
inspection it was found that the bearing was a TaperLock
Taper Lock
bearingandthetaperlockwasloose,thusresultinginexcessive
clearancebetweenthebearingandtherotor.
LoosenessSummaryy
DiagnosticRulesforLooseness
Diagnostic Rules for Looseness
Multipleharmonicsofthe1xTspeak
Numberofharmonicswillincreaseasthelooseness
progresses
Random,nonperiodicwaveform Structural
Waveformshowspredominantimpacts
f h d i i Component
Raisednoiselevelaroundthe1xTs+harmonics
Halfharmonicsmayalsobepresent
Half harmonics may also be present
CanbepresentinallDirections
Analysis
Fault Diagnostics
FaultDiagnostics
Gears,Bearings,Peakvue,Electrical,Belts,
Resonance
GearDefects
Gear Defects
Therearemanydifferenttypesofgearsandgearcombinations
availableforvariousspeedandpowerrequirements.
Regardlessofgeartypetheyallproducethesamebasic
Regardless of gear type they all produce the same basic
vibrationpatternsandcharacteristicswhenadefectispresent
Thefollowingtopicwilldiscussthe
basiccharacteristicsforthefollowing
typesofgears:
SpurGears
HelicalGears
BevelGears
SpurGears
Spur Gears
SpurGears aremostcommonlythoughtofwhendiagnosing
gears.Theteetharecutparalleltotheshaft.Thesegearsare
good at po e t a s ss o a d speed c a ges but a e o s e
goodatpowertransmissionandspeedchangesbutarenoisier
thanothergeartypes.
SpurGearAdvantages
Highefficiency
Lowheatgeneration
L h i
SpurGearDisadvantages
Canbeverynoisy
y y
HelicalGears
Helical Gears
HelicalGears haveteethcutatanangletotheshaft.These
gearsaremuchquieterthanspurgearsbutduetotheangular
natureofthegearmeshing,axialthrustandthereforeaxial
vibrationishigherthanthoseofspurgears
Sometimes
Sometimestocounteracttheaxialthrustthesegearscanbedoubleup
to counter act the axial thrust these gears can be double up
andareknownasDoubleHelicalorWishboneGears
HelicalGearAdvantages
QuietOperation
Quiet Operation
HelicalGearDisadvantages
Lesspowertransmissionefficiency
and greater heat generation than
andgreaterheatgenerationthan
spurgears
Axialloadingonbearings
BevelGears
Bevel Gears
BevelGears areusedtotransmitpowerandspeedtoan
outputshaftperpendiculartothedriveshaft.Thesegearsuse
abeveldesigntotransmitthepowerbetter.
Thesegearsaremostcommonlyseenonrightanglegearboxes(where
the input shaft is at 90 degrees to the output shaft)
theinputshaftisat90degreestotheoutputshaft)
BevelGearAdvantages
Bevel Gear Advantages
Convertsthedirectionofpowertransmission
BevelGearDisadvantages
Lessefficient
Higherheatgeneration
GearAnalysis
Gear Analysis
Vibrationanalysisofgearscanprovideawealthofinformationaboutthe
mechanicalhealthofthegears.Thissectiondiscussesthebasicfrequencies
thatmaybepresentwithinagearbox.
GearMeshFrequencySpectralData
G M hF S t lD t
Thegearmeshfrequency(GMF)referstothefrequencyatwhichtomating
gearsinteractwitheachotherandisthemostcommonlydiscussedgear
frequency.
However,GMFbyitselfisnotadefectfrequency.TheGMFshouldalways
bepresentinthespectraldataregardlessofgearcondition.Whatis
importantistheamplitudeasthismayvarydependingupongearcondition
orloadingofthegear.
Gears
Twomatinggearswillgenerateafrequencyknownasthe
GMFandwillshowinthespectraldataregardlessofgear
condition.
co d t o

M4441 -G1V Shaft 01 Inboard Vertical
1.2
Route Spectrum*
p
08-Jun-02 23:11:51
OVERALL= 2.22 V-DG

RMS = 2.14
LOAD = 100.0
0.9
RPM= 1548. (25.80 Hz)

0.6
0.3
0
Freq: 386.98
0 200 400 600 800 1000 Ordr: 15.00
Frequency in Hz Spec: .864
CalculatingGMF
Calculating GMF SingleReduction
Single Reduction
SingleReductionGearTrain
TheGMFissimplydefinedasthenumberofteethonagearmultiplied
py g p
byitsturningspeed
GMF=(#teeth)x(Turningspeed)
Example:
E l
Considerthefollowinggeartrain,
INPUT Input = 1490RPM
Gear 1 = 44 Teeth
OUTPUT
Gear 2 = 71 Teeth
GMF = #teeth x turning speed
GMF = 44teeth x 1490 RPM
GMF = 65560 CPM or 65560/60 = 1092.6 Hz

CalculatingGMF
Calculating GMF MultiReduction
Multi Reduction
CalculatingtheGMFforgearboxesthathavemultipletrainsuse
thefollowing.
GMF=(#teeth)x(Turningspeed)
GearRatio=(#teethin)/(#teethout)
Speed out = (Speed in) x (Gear Ratio)
Speedout=(Speedin)x(GearRatio)
Example:
Considerthefollowinggeartrain:
Input = 1490RPM
INPUT
Gear 1 = 15 teeth
Gear 2 = 21 teeth
Gear 3 = 19 teeth
Gear 4 = 54 teeth
OUTPUT
CalculatingGMF
Calculating GMF MultiReduction
Multi Reduction
Input = 1490RPM
INPUT
Gear 1 = 15 teeth
Gear 2 = 21 teeth
Gear 3 = 19 teeth
Gear 4 = 54 teeth
OUTPUT
Gear Ratio 1 = 15 teeth / 21 teeth = 0.714

p
Speed Out = 1490 RPM x 0.714 = 1064.28 RPM
Gear Ratio 2 = 19 teeth / 54 teeth = 0.351

Speed Out = 1064.28 RPM x 0.351 = 374.47 RPM
GMF 1 = 1490 RPM x 15 teeth = 22350 CPM

GMF 2 = 1064.28 RPM x 19 teeth = 20221.32 CPM
GMFCalculationExercise
GMF Calculation Exercise
UsingtheformulasonP153fromthemanualcalculate:
Speedsofallshafts
AllGMFfromthefollowinggearboxarrangement
All GMF from the following gearbox arrangement
Input = 1000 RPM

INPUT
Gear 1 = 10 teeth
Gear 2 = 40 teeth
Gear 3 = 10 teeth
Gear 4 = 20 teeth
OUTPUT
GearRatio1 =10/40 =0.25

Shaft2speed =1000x0.25 =250RPM
Gear Ratio 2
GearRatio2 =10/20
10/20 =0.5
05
Shaft3Speed =250x0.5 =125RPM
GMF1 =1000x10 =10000CPM
GMF2 =250x10 =2500CPM
Gears
Gears SidebandFrequencies
Sideband Frequencies
Sidebandsarethemostcommonindicationthatagearis
defected.
Sidebandsareequallyspacedfrequenciesinthespectraldatathat
materialiseeithersideofthemainGMFpeak.
Thesidebandfrequencyspacingisequaltoeithertheturningspeedof
The sideband frequency spacing is equal to either the turning speed of
theinputgearortheturningspeedoftheoutputgear.
Sidebandsshowinthedatawheneitherthe
gearisworn,looseoreccentric.
Thespeedoftheshaftwiththebadgearonitwill
p
producethemostdominantsidebandsinthe
spectraldata.
Gears
ThespectraldatashowsGMFwithsidebanddata.
Thesidebandsareequallyspacedatintervalsof310CPM.Thisis
indicatingthegearthatrotatesat310RPMistheonethatiswornor
g g
damaged.
FPP - SAND MILLS (OLD)A
X401A -G3A Shaft 02 Inboard Axial
1.0
Route Spectrum
07-Nov-02 09:11:53
(SST-Corrected)
0.8 OVERALL= 2.18 V-DG

GMF RMS = 2.17
LOAD = 100.0
RPM = 310. (5.17 Hz)
mm/Sec
0.6
RMS Velocity in m
0.4
Sidebands
0.2
0
Freq: 18363.
0 8000 16000 24000 Ordr: 59.23
Frequencyin CPM Spec: .564
Dfrq: 310.82
Gears
Gears WaveformData
Waveform Data
Gearscanproducedifferenttypesofwaveforms,theone
shownbelowisindicatinggearwear.
As
Asthedefectiveteethcomeintomeshthenoisegeneratedincreases
the defective teeth come into mesh the noise generated increases
showinganincreaseinamplitudeinthevibrationdata
FPP - SAND MILLS (OLD)A
X401A -G3A Shaft 02 Inboard Axial
1.5
Route Waveform
07 Nov 02 09:11:53
07-Nov-02
1.2
PK = .4580
0.9 LOAD = 100.0
RPM = 311. (5.19 Hz)
0.6 PK(+) = 1.27

PK(-) = 1.13
Acceleration in G-s
CRESTF= 3.91
0.3
-0.3
-0.6
-0.9
-1.2
-1.5
0 1 2 3 4 5 6
Revolution Number
CaseStudy5 Gearbox
Case Study 5 Gearbox
Thefollowingcasestudyisfromamotorgearboxunitthat
drivesaroller.
Product
Product(Fibre)isfedalongthetopoftherollwhilebeingwashed
(Fibre) is fed along the top of the roll while being washed
throughaseriesofbaths.
ThereareseveraloftheseWashNipRollersinacontinuousstream,
failureofanyoneofthemresultsinlostproduction
Dataiscollectedona
Data is collected on a
fortnightlybasisaspartof
aroutinedatacollection
route
CaseStudy5 Gearbox
Thespectraldatashownbelowistakenfromthemotorinthe
axialdirection
(As
(Asthemotorismounteddirectlyintothegearboxthefirsthelicalgear
the motor is mounted directly into the gearbox the first helical gear
ismountedontheendofthemotorshaft).
L1NG - WASH LINE NIP UNIT 3
3-32J03 -MIA MOTOR INBOARD AXIAL
0.6
Route Spectrum
EEEEE EEEEE 01-Aug-04
01 Aug 04 10:21:41
TheGMFishighlightedby
Th GMF i hi hli ht d b OVERALL= 1.08 V-DG
0.5
theprimarycursorat49 RMS = 1.07
LOAD = 100.0
RPM = 1175. (19.58 Hz)
Orders
0.4 >REN Wash Nip

E=Gm(1>2)-S1
Th f lt f
Thefaultfrequencydata
d t
0.3
(dottedlines)indicatethe
sidebanddatashowing 0.2
gear wear on the first gear

gearwearonthefirstgear
inthegeartrain 0.1
0
Ordr: 49.00
0 10 20 30 40 50 60 70 80 Freq: 57551.
57551
Frequency in Orders Spec: .275
Dord: .00649
CaseStudy5 Gearbox
Thewaveformdataisshowingadistinctpatterncommonly
associatedwithgears.
TheamplitudeincreasesInnoiseasthedamagedteethcome
The amplitude increases In noise as the damaged teeth come
intomesh
Producingover2Gsofforceinboththepositiveandnegativedirection
CaseStudy5 Gearbox
Thegearswereinspectedduetothecriticalnatureofthe
asset.Itwasfoundthegeartobeseverelydamaged.
Anewgearboxwasfittedandnewdatawastakenshowingthe
A new gearbox was fitted and new data was taken showing the
differencebetweenthegoodandbadgear
BearingDefects
g
RollingElement
g
PlainBearings
Peakvue
RollingElementBearings
Rolling Element Bearings
Rollingelementbearingshavespecificbearingfailuremodes
thatcanbeobservedinthespectralandwaveformdata.
Bearingfrequenciesdifferfrommostotherfrequencies
present within the spectral data because unless the bearing
presentwithinthespectraldatabecauseunlessthebearing
hasadefecttherewillbenofrequencypeaksinthedata
relatingtothebearing.Onlyifthebearinghasadefectwill
frequenciesshowinthespectraldata.
There are four main fundamental bearing defect
frequencies
q these are:
g g
Outer Race
Inner Race
HowBearingFaultsGenerateVibration
g
HowBearingFaultsGenerateVibration
g
Bearingdefectfrequenciesarecalculatedbaseduponthegeometryofthe
bearingthesecalculationsmayinclude:
Numberofrollingelements
PitchCircleDiameter
Rollingelementdiameter
Contactangle
DefinedwithinMachineryHealthManagerthereareover100000predefinedbearing
storedintheCSIbearingwarehouse
BEARINGSinCSIWarehouse:
c:\RBMsuite\SysData\CSI_CMP.WH
****************************************************
BRGID BearingType #B/R FTF BSF BPFO BPFI
12143RHP6218110.4182.9674.5986.402
24421SKF6313E80.3761.8943.0094.991
25372 SKF I 26313
25372SKFI26313190.4333.5688.21910.781
19 0 433 3 568 8 219 10 781
CharacteristicsofBearingDefects
High
Highfrequencyraisednoiselevel(Humpofenergy)
frequency raised noise level (Hump of energy)
NonSynchronousharmonicpeaks(Bothlowandhigh
frequency)
Timewaveformwillshowalotofnoise/impacting
Earlystagesofbearingwearmayshowbetterifviewedin
accelerationinthefrequencydomain
l ti i th f d i
Fundamentalbearingdefectfrequency(Firstcalculable
q y) y p p
frequency)maynotbepresentinthespectraldata
Failure Mode 1
FailureMode1
Theearlystagesofbearingdefectsproducelow
amplitudesofvibrationathigherfrequencies
(Appearsontherighthandsideofthespectrum).
( pp g p )
Thesearenormallyhumpsofenergyorpeaks
thatareharmonicstothefundamental
frequency.
(Thefundamentalfrequencyshouldnotbe
visibleatthisstage).
i ibl hi )
FailureMode2
DistinctharmonicsofNonSynchronouspeaks
appear.
(Theseshouldappearlowerdownthescaleofthe
spectrum towardstheleft/middleoftheplot)
Sidebandsmayappeararoundthesefrequencies
usuallyequatingtoturningspeed.
(Thefaultfrequenciesmaynotmatchexactlywith
thepeaksinthespectrumduetothefactthatthe
bearing geometry will have changed)
bearinggeometrywillhavechanged).
FailureMode3
Thefundamentalfrequencynormallyappearsatthisstage
(Firstcalculablefrequencyofthebearing towardstheleft
handsideofthespectralplot).Thisisclassedasadvanced
stagesofbearingwear.
Sidebandsmaybevisiblethatequatetootherbearing
frequencies BSF,FTFetc).
)
FailureMode4
Failure Mode 4
Thebearingdegradessomuchthatthespectrum
The bearing degrades so much that the spectrum
becomesamassofnoise.Atthispointthebearing
willfailatanypoint(Ifitlastthislong mostfail
aroundMode3).
g g BPFI
Typicaldatashowingadefectedinnerrace
Fundamentalfrequencyshowing
Harmonicslowandhighfrequency+sidebands
g g BPFO
DatashowingadefectrelatedtotheBPFO
Thefundamentalfrequencyisshowing
Harmonicsfromlowtohighfrequency
Harmonics from low to high frequency
g g BSF
BearingdefectshowingtheBSF Rollingelements
SidebandsaroundtheBSF=FTF
Rolling Element Bearings FTF
TheFTFistheonlybearingfrequencythatissubsynchronous
Maynotdetectthenwithconventionalvibrationdata
FTFdefectat0.4ordersshowninPeakvue
Bearing
FTF&BSF
FTF & BSF
BPFI&BPFO
BPFI & BPFO
Rolling Element Bearings Waveform
Asabearingbecomesdefectedthentheamountof
noise/forcegeneratedastherollingelementsimpactthe
de ect e a ea c eases
defectiveareaincreases.
ThiscanshowsignificantGlevelsinthetimewaveform.Thisvalueis
trendedinthesoftwareasthePeakPeakvalue
Thisdataistakenfroma
pumpwithadamaged
bearing
Theforcelevelsare
reaching40Gs
y
CaseStudy6 g
BearingDefect
Thespectralplotbelowisshowingthedatafromthe
inboardverticaldirectionofthemotor.
Theprimarycursorisindicatingthefundamentaldefect
BPFO f
BPFOfrequency+harmonics.
+h i
Thefrequencyrangeoftheharmonicscoversbothlow
andhighfrequencyrangessuggestingthebearingismore
advancedstagesoffailure.
CaseStudy6
Case Study 6 BearingDefect
Bearing Defect
Thetimewaveformisshowingsignificantimpactinglevels
reachinginexcessof+/ 8Gsofforce.
This
Thislevelofimpactingishigherthanwouldbesuspectedforamotorof
level of impacting is higher than would be suspected for a motor of
thistype.
Therepetitiveimpacting
The repetitive impacting
patternshownaboveis
commontoantifriction
bearingdefects.
g
Inthisinstancetheimpacting
isrepresentingtherolling
elementsstrikingadefecton
therace.
CaseStudy6
Case Study 6 BearingDefect
Bearing Defect
Thetrendplotaboveisshowingtheincreaseinamplitudeof
thePeakPeakparameter.
The
Thepeak
peakpeak
peakparameterismeasuringtheamountofenergyinthe
parameter is measuring the amount of energy in the
timewaveformfromthePeak+tothePeak
Conclusion
C l i
Themotorwasreportedashavingabearing
defecttotheengineeringgroup.Asthe
f d
fundamentaldefectfrequencywaspresent
t ld f tf t
andthetrendhadshownsuddenincreasesit
wasrecommendedtochangethebearingat
the next available opportunity
thenextavailableopportunity.
BearingDefects
g
RollingElement
PlainBearings
Peakvue
PlainBearings
Plain Bearings
Rotatingelementsarenotusedinsleeve(plain)bearings;
rathertheshaftridesonalayeroflubricatingoilinsidethe
bea g jou a
bearingjournal.
Thereforethefundamentalfrequenciesseenfromantifrictionbearings
donotapplytosleevebearings.
Sincethereisnocontactbetweenthe
bearingandtheshaftmonitoringof
sleevebearingsforvibrationanalysis
usuallyrequirestheuseof
displacementprobesmounted45
p p
degreeseithersideoftopdeadcentre.
PlainBearings
Plain Bearings
Astherearenorotatingcomponentsinthebearingthat
producehighfrequencynoise(force)thereisnoneedto
monitorahighfrequencyrange.Usually10to15ordersof
turningspeedwillbesufficient.
Sleevebearingshavespecificdefectsthatcontribute
towardsbearingfailure,theseare:
Excessiveclearance
Excessive clearance
Hydraulicinstability(oilwhirl)
PlainBearings SpectralDiagnostics
ExcessiveClearance
Whenthereisexcessiveclearancebetweentherotorandthebearing
thenthiswillhaveaneffectonthesystemvibration.Whenthe
bearings have excessive clearance then a looseness
bearingshaveexcessiveclearancethena looseness occurs.
occurs
Thespectraldatashownbelowisindicatingasleevebearingwith
excessive clearance
excessiveclearance.Fu - Turbine Brg Thrust End
16
TBT
As the clearance increases then the
-R1Y Radial 'Y' Direction
Route Spectrum*
harmonics of 1xTs will increase and can
27-Jul-04 14:08:21
go up to 1015xTs. OVERALL= 2.93 V-DG

P-P = 22.71
12 Like looseness the more harmonics
LOAD = 100
100.00
RPM= 941. (15.69 Hz)
there are the more severe the problem
cement in Microns
will be.
8
A good sleeve bearing will still show
a few harmonics as there is a small
P-P Dis pla c
clearance
l between
b t the
th shaft
h ft andd
bearing
4
0
Ordr: 1.000
0 3 6 9 12 Freq: 15.68
Frequency in Orders Spec: 7.494
PlainBearings
Plain Bearings SpectralDiagnostics
Spectral Diagnostics
OilWhirl
Oneofthemajorproblemsencounteredwiththesetypesofbearingsis
j p yp g
thepossibilityofhydraulicinstabilityoftheshaftwithinthebearing;
knownasoilwhirloroilwhip.
OilWhirlisaresultofturbulentflowwithintheoilresultingintheoil
pushingtheshaftaroundofcentre.
Fu - Turbine Brg Thrust End Thedominantpeakwithinthespectral
16
TBT -R1Y Radial 'Y' Direction
Route Spectrum* datawillbetypicallyat0.4orders.(.40
27-Jul-04 14:08:21
.48)
Oil Whi
Whirll att 0
0.4
4 orders
d OVERALL= 2.93 V-DG
P-P = 22.71 Thisdefectissubsynchronousdata.
LOAD = 100.0
12
RPM= 941. (15.69 Hz)
Whentheamplitudeoftheoilwhirlis
P-P Dis pla c e m e nt in M ic rons
equaltoorgreaterthanthe1xTspeaka
problemexists
8
IInthisinstanceoilwhirlcanbe
thi i t il hi l b
correctedby:
Properlyloadingthebearing
4
Changetheoilviscosity
Changetheoilpressure
Ch th il
0
Ordr: 1.000
0 3 6 9 12 Freq: 15.68
Frequency in Orders Spec: 7.494
Oil Whirl
OilWhirl
BearingDefects
RollingElement
PlainBearings
Peakvue
PeakvueProcessing
Peakvue Processing
Thedetectionofbearingandgeardefectsisoneoftheprimary
expectationsofapredictivemaintenanceprogram.
Asanalystswecanspendalotoftimetyingtodeterminethesefaults.
Peakvueisaprocessthatconcentratesonthesedefectstohelptheanalysts
determinepotentialfaultsdeveloping
PeakvuestandsforthePeakValue andisatechniquethatdetectshigh
frequency stress waves generatedfrommetaltometalcontact,suchas:
frequencystresswaves generated from metal to metal contact such as:
Bearingdefects Rotatingelementsstrikingadefectontherace
Geardefects Damagedteethinmesh
Itisthedetectionofthesehighfrequencystresswavesthatwillaidwith
analysis
analysis
PeakvueProcessing
Peakvue Processing Filters
Inordertocapturethestresswavesignaltheprocessrequires
theuseofafiltertoremoveallunwantednoisethatcan
do
dominatethedata
ate t e data
1. Conventional Vibration 2. Peakvue filter removing

Signals that are filtered low frequency noise from
from the Peakvue Signal the stress wave data
Imbalance This is to prevent low
Misalignment
Misalignment frequency noise
Gears consuming the stress
Bearings wave activity
Resonance
3. High frequency stress wave

activity occurring in the 1000Hz -
20000Hz frequency range at a
rate governed by a low
frequency event
Bearings
Gears
PeakvueProcessing
Peakvue Processing Filters
Therearetwotypesoffiltersavailable
BandPassFilters
Band Pass Filters
f
Thebandpassfilterremovesallthedataaboveandbelowthefilter
cornervalues
HighPassFilter f
Thehighpassfilterremovesalldatalowerinfrequencytothatofthe
g p q y
filterselectionallowingonlythehighfrequencystresswavestopass
through
After
Afterthefilteringprocesswhatshouldremainisthehigh
the filtering process what should remain is the high
frequencystresswaveactivitythatisoccurringattherateof
theexcitation suchasfromabearing.
PeakvueProcessing
Peakvue Processing SpectralData
Spectral Data
ShownbelowisatypicalPeakvuespectrumwithadefect
present
Stress waves are showing Thefilterusedisshowninthetop
The filter used is shown in the top
clearly in the data at 4.6 Orders righthandcorner
Good
G d Spectrum
S t will
ill
show only a noise
level
Noise removed by
y
filter
PeakvueProcessing
Peakvue Processing WaveformData
Waveform Data
Asstresswavesaresmallinamplitudeseverityoftheproblem
canbejudgedusingthetimewaveform
PeakValueofforcefromtheimpact
Peak Value of force from the impact
Thewaveformcanresembleaspectrumasthereisno
negativehalftothedata
B42 - ZONE 5 DF FAN 1
16/16EXT01-M2P Motor Inboard Horz Peakvue
0.8
celeration in G-s
0.7 Route Spectrum

N N N N N N N N N 09-Jul-03 09:50:49
0.6 (PkVue-HP 1000 Hz)
0.5 OVERALL= 1.37 A-DG
0.4
RMS = 1.37
LOAD = 100.0
For Peakvue analysis
RMS Acc
03
0.3 RPM = 1342
1342. (22
(22.37
37 Hz)
0.2
0.1
>NTN 6217
N=BPFO -OB Use the Spectrum
0
0 200 400 600 800 1000
Diagnose the defect
Frequency in Hz
8 Route
R t W
Waveform
f
Use the Waveform
09-Jul-03 09:50:49
Acceleration in G-s
7
6
(PkVue-HP 1000 Hz)
RMS = 2.97
Determine the severity
5 PK(+) = 8.35
4 CRESTF= 2.81
3
2
1
0
Freq: 1.250
0 4 8 12 16 20 24 28 32 36 Ordr: .05587
Revolution Number Spec: .01367
Label: Bearing Fault - BPFO NTN6217
y
CaseStudy7 PeakvueonFanBearingg
Thefollowingmachineisa
preheater
pre heaterfandesignedto
fan designed to
heattheproductpriortoit
enteringaKiln
Thereisnostandbyforthis
machine
Failureresultsinstopped
production
Thefollowingdatawastakenfromtheabovefanunit.
Theproblembearingresidedonthefaninboardbearing.
Datawascollectedonamonthlybasis.Bothconventionalvibration
dataandPeakvuedataweretakenduringtheroutecollection.
y
Thedatashownbelowistakenusingconventionalvibration
methodsontheinboardbearingofthefan
1xpeakishighlightedshowingamplitudesof4mm/sec
1x peak is highlighted showing amplitudes of 4mm/sec
Waveformisshowinglessthan1Gofforceboth+/
40 - Preheater Fan
M4425 -F1H Fan Inboard Horizontal
5
Route Spectrum
R M S Ve lo c it y in m m /S e c
4 29-Oct-02 11:19:26
OVERALL= 4.18 V-DG
RMS = 4.18
3
LOAD = 100.0
RPM= 825. (13.75 Hz)
2
1 There
Thereareindicationsof
are indications of
0 bearingfrequencies
0 10 20 30 40
Frequencyin Orders
50 60 70 80
showinghighfrequency
1.5
10
1.0
Route Waveform
29-Oct-02 11:19:26
Thesemaybemisseddueto
y
theamplitudeofthe1xpeak
A c c e le ra t io n in G - s
RMS = .3837
0.5 PK(+/-) = 1.19/1.05
CRESTF= 3.11
0
-0.5
-1.0
10
-1.5
Ordr: 1.000
0 1 2 3 4 5 Freq: 13.75
Revolution Number Spec: 3.721
y
ThePeakvuedataaboveistakenfromthesamepointasthe
previousdata.
Thisparticularreadingisusinga1000HzHighPassfilter.
This particular reading is using a 1000 Hz High Pass filter.
40 - Preheater Fan
M4425 -F1P Fan Inboard Horz Peakvue
0.7
Route Spectrum
R M S A c c e le ra t io n in G - s
0.6 F F F F
29-Oct-02
29 Oct 02 11:15:59
0.5 (PkVue-HP 1000 Hz) Herethedataisshowingthere
H th d t i h i th
0.4
OVERALL= 1.10 A-DG
RMS = 1.10 isstresswaveactivityat8.176
0.3 LOAD = 100.0
RPM= 830. (13.84 Hz) orders.
0.2 >SKF 22240CC
01
0.1
F=BPFO -IO Thisisnotnonsynchronous
0
d
dataandthefrequency
d h f
0 5 10 15 20 25 30 35 40
matchesthatoftheBPFOfor
Frequency in Orders thebearing.
8
7 Route Waveform
29-Oct-02 11:15:59
Thewaveformdatais
measuringover7Gsofforce
i 7G ff
A c c e le ra t io n in G - s
6 (PkVue-HP 1000 Hz)

5
4
RMS = 3.31
PK(+) = 7.47 asopposetothe1Gfromthe
3
CRESTF= 2.25
DCoff = -3.08 previousdata.
2
1
0
Ordr: 8.176
0 10 20 30 40 50 Freq: 113.14
Revolution Number Spec: .194
CaseStudy7 PeakvueonFanBearing
Conclusion
Thereissignificantbearingdamagerelatingtheouterraceof
There is significant bearing damage relating the outer race of
thebearing.
Asthemachinewascriticaltotheprocess,thebearingwas
changedonthenextavailableopportunitythattiedinwith
processrequirements.
Electrical Defects
ElectricalDefects
ElectricalDefects
Electrical Defects
Amotorcanbesimplybrokendownintotwokeycomponents
Rotor
Stator The stator is stationary
Thestatorisstationary
Consistsofwirewoundincoils
andplacedinslotsofaniron
core.
Thestatorproducesarotating
magneticfield.
The rotor is not stationary

Consists laminations with solid conductors called rotor bars
A circular flow of current through these rotor bars causes
the rotor to become an electromagnet which will rotate in a
magnetic filed.
ElectricalDefects
Electrical Defects SpectralData
Spectral Data
Themostcommonelectricalfrequencythatmaterialisesinthe
spectraldataisthe2xLineFrequency.
For
Formostindustrialapplicationsthelinefrequencyusedtosupply
most industrial applications the line frequency used to supply
motorsis50Hz(Europe).
Thereforethefrequencyofconcernformostelectricalfaultswouldbe
100Hz(2xLf[Lf=linefrequency])
Ex7 - Example 7
Ex7 -M1H Motor Outboard Horizontal
0.6
Route Spectrum
08-Nov-00 14:27:35
0.5 OVERALL= .5613 V-DG

RMS = .5607
Thespectralplotis
LOAD = 100.0
RPM== 2967
RPM 2967. (49
(49.44
44 Hz) showing a peak at 100Hz
showingapeakat100Hz
Ve loc it y in mm /Se c
0.4
(6000cpm)
0.3
2xLf
RMS V
0.2
Thiscanbemistakenfor
misalignment
0.1
0
Freq: 100.00
0 500 1000 1500 2000 Ordr: 2.023
Frequency in Hz Spec: .386
ElectricalDefects
Electrical Defects WaveformData
Waveform Data
Thewaveformdatafroma100Hzpeakwillshowasinusoidal
patternlikethewaveformshownbelow
Ex7 - Example 7
Ex7 -M1H Motor Outboard Horizontal
1.5
Route Waveform Againthistypeofpattern
08-Nov-00 14:27:35
10
1.0 RMS = .5291
LOAD = 100.0
can be associated with
canbeassociatedwith
0.5
PK(+) = 1.50
misalignment.
RPM= 2967. (49.44 Hz)
PK(-) = 1.77
Usuallymisalignmentwould
Ve loc it y in m m /Se c
CRESTF= 3.31
0
producehigherforce(Higher
-0.5 waveformlevels)thanthose
fromelectricaldefectsdueto
-1.0
the stress being applied to
thestressbeingappliedto
-1.5 themachine
-2.0
0 1 2 3 4 5 6
Revolution Number
ElectricalDefects
Electrical Defects Causes
Commonfaulttypesthatcanproducethe2xLfpeakareas
follows:
DynamicEccentricity UsuallyRotorRelated
StaticEccentricity UsuallyStatorRelated
LooseIronorSlotDefect RotororStator
OpenorShortedWindings
InsulationBreakdownorImbalancedPhase
I l i B kd I b l d Ph
LooseConnectors
ElectricalDefects Peakvue
Peakvuedataalsoshowselectricaldefectsatthe2xLfpeak.
Thismaybeduetotherotororstatorbowing;duetoheatbuildup.
y g p
Thespectralplotbelowisindicatinga100Hzpeakusing
Peakvuewitha1000Hzfilter.
CaseStudy
Case Study ElectricalDefect
Electrical Defect
Thefollowingcasestudywastakenfromaglassmanufacturer.
ThedatawasfromtheElectricFrontWallCoolingFan.
This
Thisfanunitisacriticalfantotheprocessandhasnostandbyunit.
fan unit is a critical fan to the process and has no standby unit.
Inthisparticularinstancethemotorfailedshortlyafterthedatawas
collected.
ThePeakvuedatatakenon
themotornondriveendis
showing a dominant 100Hz
showingadominant100Hz
peak.
Thisfrequencyisat2xLfand
isassociatedwithelectrical
problems
CaseStudy
Case Study ElectricalDefect
Electrical Defect
Themultiplotaboveshowsthesamemeasurementpoint
goingbackoverthelast5routereadings.
Thisparticularplotisusefulfordeterminingrateofchange.
This particular plot is useful for determining rate of change.
Itisquiteclearhowthisparticularfrequencysuddenlyappeared
Conclusion
As
Asthemotorfailedshortlyafter
the motor failed shortly after
datacollectionnoactionwas
takentopreventfailure.
Theinvestigationinthemotor
showedoneoftheconnectorshad
comeloosecausingthemotorto
burnout.
Belt Defects
BeltDefects
VBelts
V Belts
TimingBelts
BeltDefects
Belt Defects
Beltsarethemostcommonlowcostwaytotransmitpower
fromoneshafttoanother.
Beltdrivesrelyonfrictionbetweenthebeltandpulleytotransmit
powerbetweendriveanddrivenshafts
The ability of belt to transmit power depends upon
Theabilityofbelttotransmitpowerdependsupon
1. BeltTension(tensiononthebeltholdsittightlyagainstthesheave)
2. Frictionbetweenthebeltandsheave
3. Thearcofcontactbetweenthebeltandsheave(Wrap)
4. Thespeedofthebelt
However,beltscanbeeasilydamagedbyheat,oiland
greaseandsincebeltsslipwithinthesheavestheycannot
b
beusedwhereexactspeedchangesarerequired(exceptfor
d h t d h i d( tf
timingbelts)
BeltDefects
Belt Defects
Beltdefectscanbeconsiderednoncriticalfaultsbymany
maintenancegroupsduetotherelativeeaseofreplacement
requiringminimumdowntime.
equ g u do t e
Butbeltdefectsareamajorcontributortotheoverallvibrationofthe
machineresultinginprematurefailureofothermachinecomponents.
Sourcesofbeltdrivedefects
Poor Maintenance
Enviromental Factors
Poor Installation
Poor Design
g
Other Defects
BeltDefects
Belt Defects BeltTypes
Belt Types
Therearemanydifferenttypesofbeltdrivesystems.This
sectioncoversthemostcommonlyusedtypesofbeltin
industrytoday.
dust y today
VBelts
Vbeltsarethemostcommontypeofbeltsused.TheyareVshapedin
crosssection
cross section,thisallowingthebelttowedgeagainstthesideofthe
this allowing the belt to wedge against the side of the
sheave.
Thisdesignallowsthebelttoberunfasterthanmostothertypeofbelt
applicationswithpowertransmissionefficienciesashighas95%
BeltDefects
TimingBelts
Theseareflatbeltswithequallyspacedteeththatmesh
These are flat belts with equally spaced teeth that mesh
withnotchesonthepulley.Timingbeltsaredifferentfrom
otherbeltdrivesastheydonotinduceanyslip.
M
Mostcommonlyusedwhereconstantvelocityandstricttiming
l d h l i d i i i
applicationisrequired.
BeltDefects
Belt Defects FaultCharacteristics
Fault Characteristics
Beltdefects,suchascracks,brokenormissingpieces,hardand
softspotscangeneratevibrationattheturningspeedofthe
belt(1xbelt)andharmonics
Duetothelengthofthebeltinrelationtothepulleys(sheaves)the
1xbelt frequency is subsynchronous
1xbeltfrequencyissub synchronous andveryoftenthe2xbelt
and very often the 2xbelt
frequencymaybesubsynchronousaswell
Thepredominantharmonicistypicallythe2xBeltfrequency
andcanbeseenintheradialplaininlinewiththebelts.
Severityisjudgedbythenumberandamplitudeoftheharmonics
seeninthespectraldata
BeltDefects
Belt Defects FaultCharacteristics
Fault Characteristics
Justliketwomatingshafts,beltdrivesystemscanalsobe
misalignedinbothangularandoffsetdirections.
When
Whenmisalignmentisinducedintoabeltdrivesystemthenthelifeof
misalignment is induced into a belt drive system then the life of
thebeltissignificantlyreducedaswellastheoverallvibrationofthe
systemincreases.
Offset Misalignment
Angular Misalignment
Pulleymisalignmentresultsinhighaxialvibration atthe
shaftturningspeed.
If
Ifthebeltisalsodefectedthen1xbeltfrequencyandharmonicsmay
the belt is also defected then 1xbelt frequency and harmonics may
alsoshowintheaxialdirection
BeltDefects
Belt Defects Calculations
Calculations
Thefundamentalbeltfrequencycanbecalculatedusingthe
followingequation:
BeltFreq.=(3.142*PulleyTs*PulleyPCD)
Belt(Length)
Where:
Ts=TurningSpeed
PCD=PitchCircleDiameter
Note: ThePCDandbeltlengthmustbeinthesameunits
Atimingwillbeltwillalsohaveaspecificfrequencyrelatedto
thenumberofteethonthepulley
TimingBeltFreq.=(PulleyTs)*(#PulleyTeeth)
BeltDefects
Belt Defects CalculationExample
Calculation Example
BeltFrequencyCalculation
Belt Frequency =(3.142
BeltFrequency (3.142 *1480
1480 *300)/(2000)
300) / (2000)
BeltFrequency=(1395048)/(2000)
BeltFrequency=697.524CPM
Thisissubsynchronoustothe1xTsofthepulley
Motor RPM = 1480 RPM

Pulley Diameter = 300 mm
Belt Length = 2000mm
BeltDefects
Belt Defects SpectralData
Spectral Data
ThespectraldataaboveisdatatakenofamotorfromanAir
HandlingUnit.
The
Thefrequencyhighlightedbytheprimarycursorisshowingthe1xTsof
frequency highlighted by the primary cursor is showing the 1xTs of
themotor(1Order)
Therearealotofsub
synchronouspeaksshowingin
this data
thisdata.
Thefirstpeakisthe
1 x Belt Frequency fundamentalfrequencyofthe
showing with harmonics beltrotation.
Dominant 2 x Belt
Thesecondpeakisthe2xbelt
The second peak is the 2xbelt
Frequency
frequencysuggestingthereis
damagetothebelt
Astheharmonicsofthebelt
increaseinnumberthey
surpass the 1xTs of the motor
surpassthe1xTsofthemotor
andinthiscasethethird
harmonicbecomesnon
synchronousdata.
CaseStudy9
Case Study 9 BeltDefect
Belt Defect
ThefollowingdatawastakenonanAirHandlingUnit.TheAir
HandlingUnitisasupplyfanfromsharedservices.Thisisa
sta d a o e u t t o sta d by capab ty
standaloneunitwithnostandbycapability
BL31 - 559 AHU Supply
559S -M2H Motor Inboard Horizontal
0.5
J J J J J J J J J J
Route Spectrum*
22-Feb-05 13:53:33
Thedatashowsthe
OVERALL= 1.22 V-DG
motorturningspeed
t t i d
0.4 RMS = .7701
LOAD = 100.0
alongwithasub
RPM = 1272. (21.21 Hz) synchronouspeakof
RM S Ve loc ity in mm /Sec
>Belt Freqs thebeltfrequency.

J=Belt 1 Freq
0.3
The primary cursor is
Theprimarycursoris
X - M ot or s p e e d
highlightingthe1xbelt
x - Fa n spee d
0.2
withseveral
harmonics.
The 2xbelt is very
The2xbeltisvery
0.1 dominantsuggesting
thereisdamagetothe
belts.
0
Freq:
q 835.69
0 8000 4000 12000 16000 Ordr: .657
Label: Belt defect/worn belts & sheaves
CaseStudy9
Case Study 9 BeltDefect
Belt Defect
Asthisisacriticalmachineitwasrecommendedonthenext
availableopportunitythatthebeltsneededtobecheckedfor
da age a d e a g ed
damageandrealigned.
Themachinewasstoppedandthebeltswereinspectedbaseduponthe
recommendation.
Significantdamagewasfoundtoseveralofthebeltsduringthis
inspectionaswellaswornpulleys.Boththebeltsandpulleyswere
replacedandcorrectlyalignedbeforerestartingthemachine.
Resonance
Resonance
Resonanceisdefinedas:
An excitationofanaturalfrequencybyaperiodicforcing
excitation of a natural frequency by a periodic forcing
function.
All assetscontainnaturalfrequenciesthatvarydepending
uponthestiffnessandmass.
Resonance
Resonancecanbeconsideredtobeavibrationamplifier,thattakesthe
can be considered to be a vibration amplifier that takes the
forceleveloftheperiodicforcingfunctionandamplifiesit;which
significantlyincreasesthemovementoftheasset.
If Vibration is a Fire The Resonance is a Fuel
IfVibrationisaFire,TheResonanceisaFuel
ExampleofResonance
Example of Resonance
Theexampleshownrepresentstheeffectonamplitudeoftheforcing
functionwheninresonance.
Inplot1the1xtsisrunningbelowthenaturalfrequency(Fn).
Fncanbeseeninplot2.
Plot3showstheincreaseinamplitudeoftheforcingfunctionwhenrunatthe
naturalfrequency
t lf thi i
thisisresonance
Before Excitation
Frequency
Resonance Curve
Frequency
Amplified Signal
Frequency
Resonance
Therearetwofactorsthatdeterminethenaturalfrequencyof
anassettheseare;
1. Mass Theheavieranobjectthelowerthenaturalfrequency
2. Stiffness Themorerigidastructurethehigherthenaturalfrequency
Resonanceisbecomingmoreofaprobleminindustryin
ece t yea s due to
recentyearsdueto:
Olderequipmenthavingtorunfastertomeetcurrentproduction
demands(oftenabovewhatitwasdesignedfor)
Equipmentisbeingbuiltcheaperandlighter
Thisisresultinginamplificationoftheforcingfunction
creatingexcessivemachinemovementresultingpremature
machinefailure.
EffectsofResonance
TheODSdataisshowingasteelframestructuredeflectingat
onecornerintheverticaldirectionduetoaresonant
co d t o
condition.
CharacteristicsofResonance
Characteristics of Resonance
CharacteristicsofResonance
Resonanceisverydirectionalinnature(Movementmaybegreaterin
y ( y g
oneplainthantheother)
Vastlydifferentamplitudesoftheforcingfunctionfromonedirection
totheother(betweenHorizontalandVertical Ruleofthumbratiois
3:1difference)
Resonanceisveryspeedsensitive(smallchangesinspeedcanshow
largedifferencesinamplitudeoftheforcingfunction)
Resonancecanoccuratanyfrequencybutmostcommonlyassociated
withthe1xTs
ResolvingaResonance
Resolving a Resonance
Thereareanumberofalterationstothesystemthatcanbe
madetoresolvearesonancecondition.
Howeverifstructuralchangesaretobemadeyouneedtobecareful
youdontexciteanothernaturalfrequencyoncethechangehasbeen
made?
Onceyouaresureyouhavearesonantconditionitcanbe
correctedbyoneofthefollowingmethods:
ChangetheMass
Ch th M
ChangetheStiffness
Removetheforcingfunction
Dampenthestructure
Dampeningisamethodusedtoconvertmechanicalenergyinto
thermalenergy.Itdoesnotremovetheresonantconditiononly
gy y
controlstheamountofmovement.
Resonance
Resonance SpectralData
Spectral Data
Thespectrumisshowingthe1xTspeakofthemotorwithamplitudes
reaching19mm/sec.
Thisishighforthe1xTs.
VeryoftenthistypeofdatacanbemistakenforImbalanceasthisdefect
canalsoproduceahigh1xTspeak.
HoweverImbalanceisacentrifugalforceandshouldshowsimilaramplitudesin
bothradialplainswhereasresonanceisverydirectional.
40 - No 1 GCTCompressor
M4551 -M2H Motor Inboard Horizontal
27
Route Spectrum
24
13-Feb-03 10:14:46 Inordertohelpresolvethisissue
OVERALL= 19.95 V-DG
21
RMS = 19.85
LOAD = 100.0
weneedtochecktheamplitude
RPM= 1484. (24.73 Hz)
ofthe1xTs90degreestothis
R M S Ve loc it y in m m /Se c
18
15 point(horizontaltovertical)
12 Thiscaneasilybedonebyusing
9 themultipointplot inthe
6 software
3
0
Freq: 24.72
0 500 1000 1500 2000 Ordr: 1.000
Resonance
Resonance MultiPlot
Multi Plot
Themultipointplotallowstheanalysttodisplayseveralmeasurement
pointsonthesameplot.Hereweareshowingalltheradialpointsfromthe
motor.
motor
Itisveryclearthattheamplitudesofthe1xTspeakareexcessiveinthe
horizontaldirectionwhencomparedtothevertical.Thisisacharacteristicofa
resonantcondition. 40 - No 1 GCTCompressor
GCTCompressor
M4551 - Multiple Points (13-Feb-03)
24
Max Amp 20
22.0
16
12
8
R M S Vee lo c it y in m m /S e c
0
M2V 10:15
M2H 10:14
M1V 10:14
Point= M2H
13-Feb-03
10:14:46
RPM= 1484.
M1H 10:14
Freq: 25.00
0 500 1000 1500 2000 Ordr: 1.011
Frequency in Hz Sp 3: 19.35
CaseStudy10
Case Study 10 Resonance
Thefollowingcasestudyistakenfromamotoranda
reciprocatingcompressor.Theunitismountedonasteelframe
which,inturnsitsonspringmountsdesignedfordampening
c , tu s ts o sp g ou ts des g ed o da pe g
Recentlythemotorhadbeenreplacedduetobearing
defect; however the new motor was smaller and lighter but
defect;howeverthenewmotorwassmallerandlighterbut
deliveredthesamepowerasthepreviousmotor.
Whenthecompressorwasputbackintoserviceitwas
notedtherewasexcessivevibrationcomingfromtheunit.
Theunitwaslefttorunlikethisforseveralmonthsuntilthe
vibration became to excessive
vibrationbecametoexcessive.
CaseStudy10
Datawastakenacrosstheunitusingroutebaseddata
collection.
SL - Compressor
CP1 -M1H Motor Outboard Horizontal
60
Route Spectrum
02-Feb-04 15:09:54
50 OVERALL= 45.58 V-DG

PK = 45.32
LOAD = 100.0
RPM= 1490. (24.83 Hz)
40
PK Velocity in mm/Sec
30
20
P
10
0
Freq: 24.83
0 300 600 900 1200 1500 1800 Ordr: 1.000
Theplotaboveistakenfromthemotorshowinga1xTspeak
in excess of 40mm/sec
inexcessof40mm/sec.
CaseStudy10
Thisdataisveryhighinamplitude.
Thedatawasthendisplayedinamultiplotformattoshow
The data was then displayed in a multi plot format to show
howtheamplitudewasacrosstheradialplains.
Duetothevastlydifferentamplitudesatthe1xTsfrequency
thedefectonthismotorwasResonance.
SL - Compressor
CP1 - Multiple Points (02-Feb-04)
50
Max Amp
44.1
40
Amplitude differences between radial plains 30

PK V elo ccity in m m /Sec
20
10
0
M2H 15:26
M2V 15:26
0 4000 8000 12000 16000
Frequency in CPM
CaseStudy10
Recommendation
Itwasdeterminedthatthechangeinmotorsizemaybethe
It was determined that the change in motor size may be the
causeoftheresonanceasthemasshadbeenaltered.Avisual
inspectionoftheframeworkalsorevealedthatoneofthe
support beams had cracked along the weld thisalteringthe
supportbeamshadcrackedalongtheweld this altering the
stiffnessofthestructure.Thesupportwasweldedand
strengthenedandmoredatawasacquiredtodetermineifany
effectontheresonancehadoccurred.
CaseStudy10
Thespectra,showstheBeforeandAfterplotofthemotor
inboardhorizontal.Itshowsasignificantdropinamplitudeof
the1xTspeak.
Bystiffeningthestructurethenaturalfrequencyhadincreasedmoving
it away from the 1xTs peak thus resulting in a significant drop in
itawayfromthe1xTspeakthusresultinginasignificantdropin
amplitude. CP1
SL - Compressor
-M2H Motor Inboard Horizontal
50
Max Amp
44.1
40
30
PK Ve lo c it y in m m /Se c
20
10
0
07-May-04
10:08:05
02-Feb-04
15:26:38
0 1000 2000 3000 4000
Frequency in Hz
SummaryofFaults
Summary of Faults
Resonance
Imbalance
Electrical
Misalignmeent
Looseness Advanced Bearing Early Bearing Wear

Wear
Electrical Gearmesh Frequency
Lower Gearmesh
G
Frequency
Belt
Severe Electrical Slot Pass Frequency

Frequencies
Misalignment
Severe Looseness
c c c c c c c
F re q u e n c y
In T e rm s
Of RPM M o s t L ik e ly C a u s e s O t h e r P o s s ib le C a u s e s & R e m a rk s
1 x RPM U n b a la n c e 1 ) E c c e n t ric jo u rn a ls , g e a rs o r p u lle y s

2 ) M is a lig n m e n t o r b e n t s h a ft - If h ig h a x ia l vib ra t io n
3 ) B a d B e lt s - If R P M o f b e lt
4) Res onanc e
5 ) R e c ip p ro c a t in g fo rc e s
6 ) E le c t ric a l p ro b le m s
7) Loosenes s
8 ) D is t o rt io n - s o ft fe e t o r p ip in g s t ra in
2 x RPM M e c h a n ic a l 1 ) M is a lig n m e n t - if h ig h a x ia l vib ra t io n
Loosenes s 2 ) R e c ip ro c a t in g fo rc e s
3) Res onanc e
4 ) B a d b e lt s - if 2 x R P M o f b e lt
3 x RPM M is a lig n m e n t U s u a lly a c o m b in a t io n o f m is a lig n m e n t a n d e x c e s s ive a x ia l
c le a ra n c e s (lo o s e n e s s ).
Le s s th a n O il W h irl (le s s 1 ) B a d d rive b e lt s
1 x RPM t h a n 1/ 2 R P M 2 ) B a c k g ro u n d vib ra t io n
3 ) S u b -h a rm o n ic re s o n a n c e
4 ) " B e a t " V ib ra t io n
S y n c h ro n o u s E le c t ric a l C o m m o n e le c t ric a l p ro b le m s in c lu d e b ro k e n ro t o r b a rs , e c c e n t ric
(A . C . L in e P ro b le m s ro t o r u n b a la n c e d p h a s e s in p o ly -p h a s e s y s t e m s , u n e q u a l
F re q u e n c y ) a ir g a p .
2 x S ynch. T o rq u e P u ls e s R a re a s a p ro b le m u n le s s re s o n a n c e is e x c it e d
F re q u e n c y
M a n y T imi es RP M B a d G e a rs G e a r t e e t h t im
i es RP M of bad gear
(H a rm o n ic a lly A e ro d y n a m ic F o rc e s N u m b e r o f fa n b la d e s t im e s R P M
R e la t e d F re q . ) H y d ra u lic F o rc e s N u m b e r o f im p e lle r va n e s t im e s R P M
M e c h a n ic a l L o o s e n e s s M a y o c c u r a t 2 , 3 , 4 a n d s o m e t im e s h ig h e r h a rm o n ic s if
s e ve re lo o s e n e s s
R e c ip ro c a t in g F o rc e s
H ig h F re q u e n c y B a d A n t ii-F
F ric t io n 1 ) B e a rin g vib ra t io n m a y b e u n s t e a d y - a m p lit u d e a n d fre q u e n c y
(N o t H a rm o n ic a lly B e a rin g s 2 ) C a vit a t io n , re c irc u la t io n a n d flo w t u rb u le n c e c a u s e ra n d o m ,
R e la t e d ) h ig h fre q u e n c y vib ra t io n
3 ) Im p ro p e r lu b ric a t io n o f jo u rn a l b e a rin g s
(F ric t io n e x c it e d vib ra t io n )
4 ) R u b b in g
UsefulReferences
SimplifiedHandbookofVibrationAnalysisVolume1 Arthur
R.Crawford
SimplifiedHandbookofVibrationAnalysisVolume2 Arthur
R.Crawford
BSISO1337312002 ConditionMonitoringandDiagnostics
ofMachines GeneralProcedures
BS ISO 133732
BSISO13373 2 ConditionMonitoringandDiagnosticsof
Condition Monitoring and Diagnostics of
Machines Processing,PresentationandAnalysisofVibration
Data

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WarmestWelcometoVibration

Vibration: Oil: Thermography: Motor Current:

0.04 11-Dec-96 17:33:57

1.0 Route Waveform

Collaborate all data into one single report

1. Use Absolute Vibration Levels

2. Use Relative Vibration Levels

mm/s rms inch/s rms

Velociity mm//s RMS

When a forcing function is applied

This motion is called a

Spectrum (AmplitudeVs -0.2

Frequency) throughaprocess -0.3

0.1 CRESTF= 3.38

The most common industrial applications are:

ranges, velocity data LOAD = 100.0

provides the best indication of

Motor Turning Speed = 1500RPM

Here the primary cursor is at 1 RMS = 1.27

0.6 the primary cursor)

OVRALL= .5785 V-DG

Synchronousenergy relatedto RMS = 1.27

spectrum that the first peak

Examples of synchronous energy:

1.4 RPM = 380.

RMS Velocity in mm/Sec

Examples of non-synchronous energy:

Misalignment RPM = 737.

RMS Velocity in mm/Sec

Vane pass frequency

RMS Velocitty in mm/Sec

Multiples of belt frequency

displays the same data but

To change the LOR settings we need to alter our parameter set

Remember. If you double your lines of resolution you double your

OVRALL= 2.63 V-DG

1.2 Sub Synchronous

Label: Outer Race Defect

A measurement point is determined by three characters

waveformshow? RPM = 3000.

5 OVRALL= 4.58 V-DG

adominant1xTspeak(1 LOAD = 100.0

towardsanimbalance 4 LOAD = 100.0

problem.The PK(+) = 7.03

radialplains Frequency in CPM

Bm/c - TOP RECIRC FAN

More commonly seen A combination of the above

ST.1 - Raw Water Pump

0.2 CRESTF= 3.42

In addition to the misalignment the excessive forces 2.1

OVRALL= 2.47 V-DG

loading on the gears. 1.8

0.6 Shutdown 26-Mar-01

40 - Kiln Main Drive

the vane pass frequency is

of the impeller problem

0.8 RMS = .3174

40 - Kiln Main Drive

Max Amp 2.4

40 - Kiln Main Drive

OVERALL= 2.22 V-DG

RMS Velocity in mm/Sec