MACHINERY VIBRATION

SIGNATURE ANALYSIS

PRESENTED BY- SONU PATIDAR

Proprietary & Confidential 1

 What Is Vibration ?

Vibration is a "back and forth" movement of a structure. It can also

be referred to as a "cyclical" movement

Proprietary & Confidential 2

What Is Vibration Caused By ?

Imperfections in the Machine:

Design Assembly
Manufacture Operation
Installation Maintenance

Proprietary & Confidential 3

 What Are Some Common Machine Problems

Misalignment Unbalance
Worn belts & pulleys Bearing Defects
Hydraulic Forces Aerodynamic Forces
Housing Distortion Reciprocating Forces
Bent Shafts Rubbing
Gear Problems
Certain Electrical
Problems

Some Common Machine Problems That Amplify Mechanical

Vibration
Resonance Looseness

Proprietary & Confidential 4

What Vibration "Characteristics" Do We Measure ?

Amplitude
Microns

MM/sec
G's

The 'amplitude' is a measure of the amount of movement.

The amount of movement is related to the severity of the vibration.

Proprietary & Confidential 5

 What Vibration "Characteristics" Do We Measure ?

HZ, CPM
Frequency

Frequency
Identifies The
Vibration Source

Frequency Tells Us:

How Often The Movement Occurs
(How many "cycles" in a period of time: a second or a minute)

Proprietary & Confidential 6

What Vibration "Characteristics" Do We Measure ?

Phase
It is timing relationship between two
signals occurring at the same frequency.

Phase Tells Us:

Phase helps determine how different component on the machine are moving
relative to one another

Proprietary & Confidential 7

 Phase

Phase is collected at ONE frequency at a time.

Absolute phase is measured Relative phase is measured on a multi-

with one sensor and one channel vibration analyzer using two or
tachometer referencing a more (similar type) vibration sensors.
mark on the rotating shaft It called cross channel phase.

Horizontal- 20 deg Horizontal to Verticle-90 deg

Verticle-110 deg RPM - 2955
RPM - 2955

For balancing we want Absolute phase

Proprietary & Confidential 8

 Natural Frequency

Free vibrations of any elastic body is called natural vibration and happens at a
frequency called natural frequency.

Natural Frequency of undamped spring-mass system

In other words, when an object is standing still and is impacted with one
short burst of energy, the object will vibrate at a series of frequencies which are
known as its natural frequencies

Proprietary & Confidential 9

 Critical speed

A "critical speed" is simply when the rotational speed (rpm) coincides with the
natural frequency of the rotor (rpm).

As the rotor approaches the critical speed , amplitudes increase drastically (10
to 30 times of normal vibration level )
As the rotor moves away from critical speed amplitudes decrease and return to
normal vibration level .

Proprietary & Confidential 10

 Resonance

A "resonance" is the condition that exists

when the exciting frequency matches the
natural frequency.

Resonance Symptoms Bode plot

Extremely high vibration in one direction.
180 Degree phase shift occurs when pass through resonance.

Correct a resonance problem

Increase the Stiffen - This method raises the resonant frequency
Mass addition- This method lowers the resonant frequency
Change the speed of the machine- in case of rotating equipment

Proprietary & Confidential 11

 VIBRATION SIGNATURE
ANALYSIS
TO DIAGNOSE MACHINE
PROBLEMS

Proprietary & Confidential 12

Time Domain Plots / Time waveform

The measured vibrations are always A time waveform is a graph of

in analog form (time domain) displacement, velocity or acceleration with
respect to time. The time span of such a
signal is normally in the millisecond range

Y-Axis Time waveforms display a short time

Units: interval of the raw vibration. Though not as
Amplitud
e versatile as the FFT, it still has particular
applications and can provide clues of a
machines condition that may not be evident
in the frequency spectrum

X-Axis Units:
Time (seconds or milliseconds)

Proprietary & Confidential 13

 Fast Fourier transform (FFT)

Fourier analysis is another term for the

transformation of a time waveform
into a spectrum of amplitude vs
frequency values.

Proprietary & Confidential 14

 FFT (Spectrum) Plot

Y-Axis Units:
Amplitude

X-Axis Units:
Frequency (number of cycles per minute or
per second)

Proprietary & Confidential 15

 Unbalance

Unbalance defined is the condition of a rotating component where the weight is

unevenly distributed from the centre of gravity.
The centre of rotation is not the same as the centre of mass.

Some common causes of unbalance in

rotating equipment are:
Material build-up
Wear
Broken or missing parts
Improper assembly
Thermal distortions

Proprietary & Confidential 16

 Single Plane Unbalance

Radial vibration @ 1x rpm.

90 phase shift between horizontal and vertical direction.
Little or no phase shift between bearings [bearings vibrating "in-phase"]

Proprietary & Confidential 17

 Two-Plane Unbalance

Radial vibration @ 1x rpm.

90 phase shift between horizontal and vertical direction.
Significant phase shift (around 180) between bearings [bearings vibrating "out-of-
phase"]

Proprietary & Confidential 18

 Overhung Rotor Unbalance

Radial vibration @ 1x rpm.

Axial vibration @ 1x rpm.
For pure unbalance of an overhung rotor, the axial phase at
bearing 1 will approximately equal that at bearing 2 (30).

Proprietary & Confidential 19

 Shaft and coupling misalignment

The two basic types of misalignment are:

Offset
Angular

Perfect Alignment

Proprietary & Confidential 20

 Angular Misalignment

High axial vibration @ 1x rpm, possible harmonics at 2x & 3x.

Radial vibration, probably lower amplitude than the axial, at 1x, 2x and 3x.
Axial phase across coupling shows 180 out of phase.

Proprietary & Confidential 21

 Offset Misalignment

High radiual vibration @ 1x rpm, harmonics at 2x & 3x.

2x rpm component higher than 1x component.
Axial vibration, probably lower amplitude than Radial.
Radial phase across coupling shows 180 Degree out of phase.

Proprietary & Confidential 22

 Antifriction bearings defects

Proprietary & Confidential 23

 Antifriction bearings Defect frequencies

FTF = Fundamental Train Frequency

All bearing defect
BSF = Ball Spin Frequency
frequencies are Non-
BPFO = Ball Pass Frequency Outer race
synchronous
BPFI = Ball Pass Frequency Inner race

BEARING TYPE #B/R FTF BSF BPFO BPFI

------- ---- ---- --- --- ---- ----
1. d. SKF 6210 10 .409 2.664 4.093 5.907
FTF 1 cos F . RPM
2 D
2
D . d.
BSF 1 cos F . RPM RPM = Shaft rotation
2. d D
d = Rolling element diameter
BPFO N. FTF
D = Pitch diameter

BPFI N. ( RPM - FTF) N = No. of rolling elements

F = Contact angle

Proprietary & Confidential 24

 Bearing Failure Stages- 1

Earliest indications of bearing problems appear in the ultrasonic frequency

ranging from 1,200k to 3,600 kCPM.
Spike Energy, HFD, and Shock Pulse evaluate these frequencies.

Proprietary & Confidential 25

 Bearing Failure Stages- 2

Slight bearing defects begin to ring bearing component natural

frequencies, which predominantly occur in 30k to 120K CPM range.
Sideband frequencies appear above and below natural frequency
peak at the end of stage 2.

Proprietary & Confidential 26

 Bearing Failure Stages- 3

Bearing defect frequencies and harmonics appear.

More defect frequencies appear and no of sidebands grow, both around these and
bearing natural frequencies.

Proprietary & Confidential 27

 Bearing Failure Stages- 4
558 - 558-P22A
558-P22A -P2V Pump Outboard Vertical
4
Route Spectrum
15-Feb-14 11:30:44

OVERALL= 11.69 V-DG

RMS = 11.64
LOAD = 100.0
3 RPM = 3207. (53.45 Hz)
RMS Ve loc ity in m m/Sec

0 30 60 90 120 150 180 210

Frequency in kCPM

Towards the end-

Amplitude of 1X and other running speed harmonics will increase.
Discrete bearing defect and component natural frequencies actually begin to disappear
and are replaced by random, broad band high frequency noise floor.
Amplitude of both high frequency noise floor and spike energy may decrease, but prior
to failure, spike energy will usually grow to excessive amplitudes.

Proprietary & Confidential 28

 Plain or tilt pad bearings instabilities

Bearing Wear (Looseness)

Most Common Symptoms:

High radial vibration @ 1x and numerous harmonics of rpm - like bearing
looseness. In severe cases, peaks may appear at 1/2 harmonics (0.5 x rpm, 1.5 x
rpm, etc.).

Proprietary & Confidential 29

 Oil Whirl

Oil Whirl, although unusual, can occur when bearing clearances

become excessive

it occurs in a very
precise sub-
synchronous
frequency range

High Radial Vibration at 0.42 - 0.48 x RPM.

Proprietary & Confidential 30

 Mechanical looseness

High radial vibration @ 1x, 2x rpm (often

higher at 2x)
Amplitude may be extremely high in
direction of looseness only (vertical or
horizontal)

Proprietary & Confidential 31

 Rubbing

When rotating parts contact stationary components it produce similar spectrum to looseness.
Rub may be either partial or throughout the entire shaft revolution
It usually generate a series of frequencies often excites integer fraction sub harmonics of
running speed(1/2, 1/3, 1/4, 1/5)
Rotor rub can excite many high frequencies similar to wide band noise.
Reverse precision observed in Orbit plot.

Proprietary & Confidential 32

 Gears defects

Gear mesh frequency- Running speed X no of teeth of gear

Gear mesh frequency is Load sensitive
Normal Gear Spectrum

Amplitude peaks at 1, 2 and 3x GMF.

Low amplitude and few sidebands around 1, 2 and 3x GMF at 1x rpm of gear
with problem

High GMF Amplitude do not necessarily indicates problem particularly if

sideband frequencies remain low level

Proprietary & Confidential 33

Gear Backlash

Proprietary & Confidential 34

 Gear Load

Proprietary & Confidential 35

Gear Misalignment

Proprietary & Confidential 36

 Electric motor defects

Electrical problems are detected by higher amplitudes at 2X electrical line frequency

Motor current signature analysis is special condition monitoring technic

for induction motors.

Stator Problems:
o Stator Eccentricity
o Shorted Laminations
o Loose Iron
High Amplitude at 2X line frequency

Proprietary & Confidential 37

 Eccentric Rotor and Variable Air Gap

An eccentric rotor produce a high vibration

at twice line frequency (2FL)
accompanied by sidebands spaced at pole
pass frequencies (FP = # Poles X slip
frequency).

An eccentric rotor may require

adjustment of bearing housings in
order to provide an air gap within
tolerance all around the
periphery.

Proprietary & Confidential 38

 Rotor Problems:

Broken/Cracked Rotor
Bars Loose Rotor Bars

Proprietary & Confidential 39

 BELT DRIVE PROBLEMS

Belt/Pulley Wear & Improper Tension

Proprietary & Confidential 40

 Pulley Misalignment

Proprietary & Confidential 41

 Pulley Eccentricity

High radial vibration @ 1x - can easily be misdiagnosed as unbalance

Phase will show 0 or 180 phase shift between horizontal and vertical direction

Proprietary & Confidential 42

 Transient Analysis

Transient Vibration. Temporarily sustained vibration of a mechanical system. It

may consist of forced or free vibration or both. Typically this is associated with
changes in machine operating condition such as speed or load

Transient Vibration analysis is more important in high speed machines

which runs above first critical speed.

Transient vibration plots-

Bode Plot-
Polar Plot
Average shaft centerline Plot
Full spectrum cascade plot-

Proprietary & Confidential 43

 Bode Plot

A Bode plot comprises of two graphs:

Amplitude vs machine speed
Phase vs machine speed.

Proprietary & Confidential 44

 Polar Plot

The polar is also a representation of the same three variables as considered in a

Bode plot. The variables are plotted on a single circular chart instead of Cartesian
axes

Proprietary & Confidential 45

Average shaft centerline Plot

shaft centreline plot display changes in radial rotor position with respect to a
stationary bearing over a range of speed

shows slight cantering / misalignment normal lift

issues

Proprietary & Confidential 46

 Full spectrum cascade plot-

The full spectrum is an additional diagnostic

tool and is also called the spectrum of an
orbit. It shows the same information as an
orbit but in a different format. Positive is defined
to be the forward
precession and the
negative
component as the
reverse precession

Proprietary & Confidential 47

 Thank You

Proprietary & Confidential 48