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Diagram 1

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Maintenance Management Strategies
On failure maintenance.

Fixed time maintenance.

Condition based maintenance.

Risk Evaluation and Prioritization.

FRO ( New Concept of maintenance)

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 Condition Monitoring
Condition monitoring is a process of determining the
condition or Healthiness of rotating or static equipments.

In this system, Condition or health of the machine is

being monitored continuously or periodically to detect
and correct impending machine problem.

The aim is the optimize the availability of the equipments

at minimum cost.

The system allows to plan and take up maintenance

activity at a time that is most suitable for the process.

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 What is 80:20 Rule ?
Also known as "Pareto's Principle" after the Italian
sociologist and economist Vilfredo Pareto (1848-1923).
The Pareto Principle states that a small number of
causes is responsible for a large percentage of the
effect, often a ratio of approximately 20:80.
In the case of machinery management, it is often
found that a large percentage (80%) of a plant's
problems are caused by a relatively small
population (20%) of its machines.

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 Condition Based Maintenance
Allow shutdown before severe damage occurs.

Production can be modified to extend unit life.

Cause of failure can be analyzed.

Permits maintenance to be planned.

Manpower to be organized in a planned manner.

Spares to be assembled.

Modification of system can be planned.

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 Condition Monitoring Techniques
Human Senses.

Thermal Technique (Thermography IRT Images).

Wear Debris Analysis ( PQ, Ferrography, spectrograpgy).

Acoustic Analysis ( Sonic/ Ultrasonic Range).

Dissolve Gas Analysis for Transformer oil.

Motor Current Signature Analysis.

Noise Level Monitoring.

Vibration Analysis. 7
 Thermography
Infrared Thermography is simply a picture of infrared
radiation(Thermal Image).
An infrared device contains one or more detectors
that convert energy in the infrared spectrum into an
electrical signal.
Electrical signal are typically formatted into video
signal and displayed on CRT after analysis of
thermal information from non contact thermal
imaging devices.
All electrical components have a tendency to heat
up as their physical or electrical properties worsens.
An infrared camera is designed to detect this
overheating and interpret it as early warning sign of
imminent failures this is non contact technique.
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 Wear Debris Analysis
Wear Debris monitoring methodology aims at predicting the
upcoming failures of component.
Wear Debris analysis comprises of two parts. One relates
degradation of the lubricant & other is machine condition in
which that lubricant is in use.
Ferroscope ( a three- magnification dichromatic microscope)
is being used to identify and examine the wear particles
separated from all type of fluids.
There are six basics wear particle types generated through
the wear process e.g.
Normal rubbing wear (up to 5 )- Generate due to normal wear
Cutting particles (25 to 100)- Generate due to surface penetration
Spherical particles( 5 to 15)- Generate due to rolling fatigue.
Severe Sliding Particles ( 5 to 30)- Generates due to striations.
Bearing wear particles(Up to 100)- Distinct particles of bearing.
Gear Wear particles Pitch line fatigue particles from gear pitch.
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 Acoustic Analysis
Acoustic Emission (AE) analysis is a useful method for the
investigation of local damage in materials. One of the
advantages compared to other NDE techniques is the
possibility to observe damage processes during the entire
load history without any disturbance to the specimen.
Acoustic Emission (AE) is the class of phenomena
whereby an elastic wave, in the range of ultrasound
usually between 20 KHz and 1 MHz, is generated by the
rapid release of energy from the source within a material
The elastic wave propagates through the solid to the
surface and can be recorded through sensor. Sensors is a
transducer that converts the mechanical wave into an
electrical signal.
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 Dissolve Gas Analysis
Generally Thermal & Electrical disturbance produce
gases in an operating Transformer due to overheating or
dielectric problems or a combination of these.
Internal faults in oil produce the gaseous byproducts.
Each types of faults produce certain combustible gases.
The thermal decomposition of mineral oil from 150 to 500C
H2, CH4 and thermal decomposition of cellulose and other
solid insulation produces CO & C02 .
Electrical Faults such as Partial Discharge produce H2, CH4
& C2H2 & High Intensity Arcing produce temperature from
700 to 1800C, the quantity of Acetylene becomes pronounced.
The total of all combustible gases may indicate the existence of
any one, or a combination of thermal, electrical or corona faults.

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 Dissolve Gas Analysis
Probable cause of fault :
Fault Type Principal Gases
Thermal Decomposition( overheated ) Ethylene ( C2H4) 63%
in Oil
Thermal Decomposition ( overheated) Carbon Mono-oxide(CO)-92%
in Cellulose
Electrical Corona Hydrogen(H2)- 85%

Electrical Arcing Hydrogen(H2)- 60%

Acetylene(C2H4)- 30%

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 Motor Current Analysis
Motor Current signature analysis is a diagnostic and
technique that is used to analyze motors.

stator problems such as stator eccentricity, shorted

lamination and loose iron generally produce high vibration at
2 times line frequency( 2FL).

Eccentric rotors produce an uneven variable air gap and

generally produce high vibration at 2 times line frequency (
2FL ) with side bands of pole pass frequency.

Rotor problem such as broken or cracked rotor bars and

shorting rings, bad rotor bar to shorting ring connections and
shorted rotor laminations produce 1X vibration with
sidebands at pole pass frequency (Fp).
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Motor Current Analysis

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 Motor Current Analysis

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Machinery Condition Management System
A system that takes the data generated by a machinery data management
system and converts it into actionable information .
Machinery condition management systems are software products that
employ "expert system" technology consisting of knowledge bases, rule
sets, and other tools.
A proper machinery condition management system is able to continually
review the data fed to it by the machinery data management system rather
than waiting for alarms or other "events" to trigger it.
It can be used as a prognostic tool. When an "event" does occur, such as
an alarm, the machinery condition management system will also be able to
provide diagnostic information.

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 What is vibration ?
Vibration measurement is an oldest technique for machine
Health Monitoring.

Mechanical vibration is the oscillatory (back and forth)

motion of a physical object.

Vibration of an object as measured relative to an inertial

(fixed) reference frame.

Vibration can be periodic, random or transient.

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 What is vibration ?
Free Vibration
Vibration response of a mechanical system following an impulse
like initial perturbation (change of position, velocity or external
force).Depending on the kind of perturbation, the mechanical
system responds with free vibrations at one or more of its natural
frequencies.

Forced Vibration
The response vibration of a mechanical system due to a forcing
function (exciting force). Typically, forced vibration has the same
frequency as that of the exciting force.

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 Characteristics of Vibration
One of the common & oldest condition monitoring technique is
vibration monitoring.
Machine's condition and mechanical problems are determined
by measuring its vibration characteristics.
The Cause of vibration, regardless of the type must be
FORCE which is changing in either its direction or its amount.
Each Cause of vibration has its own individual characteristic.
The important characteristics are,

Frequency Displacement Velocity Acceleration Phase

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 Waveform Pattern
Acceleration ( Peak)
ONE CYCLE

A
M Velocity
P Displacement (PK)
L
I (Pk PK) TIME
T
U
D
E

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 Vibration Frequency
The amount of time required to Complete one cycle ( 360 )
of a Vibration pattern ( Sine Wave) is called the period of
Vibration.
Vibration frequency is typically expressed in units of cycles
per second (Hertz) or cycles per minute (to more easily relate
to shaft rotative speed frequency).

A Frequency = 1/ Period.
M One Cycle
P Time
L

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 Vibration Frequency
1X is a vibration with a frequency equal to shaft rpm, 2X
vibration is at twice shaft rpm, 0.5X vibration with a
frequency equal to one-half shaft rpm, etc.
Frequency of the vibration precession, ,of a rotor measured
in Hz, rad/s (circular frequency) or cpm is often related to
the rotative speed , measured in rpm or rad/s.
Natural Frequency
The frequency of free vibration of a mechanical system at
which a specific natural mode of the system elements
assumes its maximum amplitude.

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 Vibration Displacement
Total distance traveled by the vibrating part from one extreme
limit of travel to other extreme limit of travel is referred to as
peak-to-peak displacement.
Peak to Peak Displacement is usually expressed in microns
( ), where 1 microns ( ) is one thousand of millimeter
( 0.001 mm)
Displacement is more sensitive to low frequency vibration and
is best for measurement where stress related problem is
predominant.( < 600 CPM).

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 Vibration Velocity
Velocityis the time rate of change of displacement.
Typical units for velocity is millimeters / second(zero to peak).

Velocity measurements are used to evaluate machine

housing and other structural response characteristics.

Electronic integration of a velocity signal yields displacement,

but not position.

Velocity is more sensitive to intermediate frequency

range ( 600 CPM to 60,000 CPM) vibration and is best for
measurement where fatigue related problem is
predominant.

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 Vibration Acceleration
Acceleration is the time rate of change of velocity.
Typical units for Acceleration is millimeters / second
(zero to peak).
Acceleration unit is g , Where 1g = 980.665 cm/ sec.

Acceleration is maximum at the instant where the Velocity is

minimum.
Acceleration is more sensitive to High frequency
range ( above 60,000 CPM) vibration and is best for
measurement where the Force related problem is
predominant.

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 Vibration Phase

Phase is the most vital and important characteristic of vibration.

Phase is measured of how one part is vibrating in relation to

other part.

Phase is measured in Degree by using either a Strobe or

Electronic Photo Cell .

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 Relative Phase
0 360
Signal A ONE CYCLE
(Y)
Amplitude

RELATIVE PHASE

Signal B
(X)

ONE CYCLE
0 360

Time

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 Cause of Vibration
The occurrence of vibration is wide- spread.
Vibration is the result of any minor fault that are the natural
consequences of manufacturing and material limitations.
Mechanical troubles in a machine cause vibration.
Some of the common causes of vibration are as follows.
I. Unbalance

2. Mis- Alignment.

3. Mechanical Looseness.

4. Defective Anti- Friction Bearings.

5. Resonance

6. Rubbing in Journal Bearing. 29

 Advantage of Vibration Measurement
Vibration monitoring and diagnostics systems have three
purposes.
First, the system should alert Operators to developing problems,
while they are still manageable.
Second, to minimize damage to the machine, the system should
provide shutdown capability in the event of a catastrophic failure.
Third, and perhaps most important, it should provide information
to help the Machinery Specialist quickly and accurately diagnose
machinery conditions.

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 Which parameter is more Important ?
Generally all the rotating machine are mounted with either
Journal Bearing or Anti-Friction Bearing.
Lighter weight( medium size) rotating machinery generally
mounted with Anti- Friction bearing.
Machine mounted with Anti- Friction bearing, Shaft Vibration due
to Shaft deflection is almost same as compared to Casing
vibration.
Machine mounted with Journal Bearing, Shaft Vibration due to
Shaft deflection is much more higher than Casing vibration
because casing weight is much more higher than rotor.
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 Shaft Deflection

Anti- Friction Bearing Mounted Journal Bearing Mounted

Machine Machine

Bearing
Rotor Housing

Outer Race

Shaft deflection is less because Shaft deflection is more because

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bearing internal clearance is less bearing internal clearance is more
 Importance of Shaft Vibration
Vibration waveform pattern
Anti-Friction Bearing.
Bearing Shell Absolute Shaft Relative Shaft
Vibration Vibration Vibration

Absolute Shaft Relative Shaft

Journal Bearing Vibration Vibration
Bearing Shell
Vibration

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Rotor Position Model

Bearing
Shaft

Load

Minimum Film
Thickness

Rotor Position Angle or Attitude Angle.

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Gap Voltage Measurement

Shaft Centerline Position

Shaft Attitude Angle
Eccentricity
Shaft Trend Plots
Alignment Along Shaft 35
 Unbalance
Machinery Unbalance is most common cause of Vibration.
It is caused by Unequal distribution of Mass in a rotating part.
Unbalance can be static or dynamic.
Predominant Vibration frequency due to Unbalance is 1x RPM.
Amplitude at 1X RPM will normally be greater than or equal to
80% of overall value.
Phase will be shifted 90 when the pickup is shifted 90 .
Phase difference between horizontal to Vertical will be 90 30

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 Unbalance
Unbalance can be categorized in three type.
Force Unbalance :
Force Unbalance is a condition where the mass center line
is displaced from shaft center line.
Amplitude due to unbalance will increases by the squire of
speed ( 2x speed increases = 9x higher vibration).
It is also known as Static Unbalance.
Horizontal to Horizontal & Vertical to Vertical Phase
difference will be 0 between inboard & outboard bearing
of the same shaft.
Unbalance can be corrected by placement of only one
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balance weight in one plane at rotor center of gravity.
 Unbalance
Couple Unbalance :
Couple Unbalance is a condition where the mass centerline
axis intersects the shaft centerline axis at the rotors center
of Gravity.
Horizontal to Horizontal & Vertical to Vertical Phase
difference will be 180 between inboard & outboard
bearing of same shaft.
Unbalance can be corrected by placement of
balance weight in at least two planes at rotor center of
gravity.
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 Unbalance
Dynamic Unbalance
Dynamic Unbalance is a condition where the mass
centerline is neither parallel to nor intersects the shaft
centerline axis.
It is combination of both force and couple unbalance.
Horizontal to Horizontal & Vertical to Vertical Phase
difference will be 180 between inboard & outboard
bearing of same shaft.
Unbalance can be corrected by placement of balance
weight in at least two planes at rotor center of gravity.
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Signature Pattern of Vibration due to Unbalance.

1 X1 X RPM

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Orbit Plot Due Unbalance.

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 Mis- Alignment
Misalignment occurs when the axes of adjacent shaft are
not collinear when operating under normal load.
The most common type of Mis-alignment trouble is
attributed to faulty initial alignment.
The vibration frequency at 1xRPM, 2xRPM and 3xRPM if
the mis-alignment is severe.
In general the amplitude of axial direction is greater than
one half of the highest radial reading.
Vibration amplitudes will be high in axial direction as well
as in radial direction. Phase difference across the coupling
is in between 90 to 180. 43
 Mis- Alignment
Mis- alignment can be categorized in three basis types are
Angular, Off-set, and combination of Angular & Off-set,
Angular mis-alignment :
Angular mis-alignment generate high axial vibration.
Pre-dominant Vibration peaks at 1x RPM & 2x RPM.
Phase difference is 180 across the coupling in axial
direction.
These symptoms may also indicate coupling problem.

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 Mis- Alignment
Mis- alignment can be categorized in three basis types are
Angular, Off-set, and combination of Angular & Off-set,
Off-set Mis-alignment :
Off-set mis-alignment also known as parallel
mis-alignment as radial off-set misalignment.
Pre-dominant Vibration peaks at 2x RPM 50% high of 1X.
High amplitude in radial direction.
Phase difference is 180 across the coupling in radial
direction.

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Mis- Alignment

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Mis- Alignment- Orbit

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Mis- Alignment Orbit

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Shaft Centerline Plot Can Show Misalignment

1 2 3 4

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 Mechanical Looseness
Mechanical looseness is common problem in any industry.
It can be categorized in A B C type Mech. Looseness.
A type mechanical looseness is due to structural
looseness/ weakness of machine feet, baseplate or
foundation, deteriorated grouting, loose hold down bolts
at the base and distortion of the frame or base.
Phase difference is 180 between vertical measurement on
the machine foot, baseplate and base itself.
Generally Pre-dominant Vibration peaks at 1x RPM.

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 Mechanical Looseness
B type mechanical looseness is due to loose pillowblock
bolts, cracks in the frame structure or bearing pedestal.
Phase difference is 180 between vertical measurement on
the machine foot, baseplate and base itself.
Generally Pre-dominant Vibration peaks at 2x RPM & 0.5x,
1x, 3x also present in spectrum.

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 ORBIT SHAPE

A through F above are ORBITs shown at the same speed at different

bearings. Blue dashed line represent the ORBIT center line. The red
line connecting the Key phaser dots shown the apparent shaft
deflection shape. 52
 Mechanical Looseness
C type mechanical looseness is due to improper fit
between component parts which will cause many
harmonics due to non linear response of loose parts to
dynamic forces from the rotor.
Vibration time waveform is truncation.
Phase is unstable and may vary widely from one
measurement to the next.
some time it may caused by a bearing liner loose in its cap,
excessive clearance in either a sleeve or rolling element
bearing or a loose impeller on a shaft.
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 Physical Properties of Sub-Harmonics Frequency

1 1 1
3 3
5 3

5
5

6 6

6
4 4
4
2 2 2

Slightly Less Than Equal To Slightly Greater Than

W W W

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Partial Rub Detection by Orbits, 1/2X

1X + 1/2X = OBSERVED

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 Partial Rub Detection
by Orbits, 1/3X

Time

Time
X to Y (CCW) Rotation
Key Phaser

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 Nodal Point (Node)

A point of minimum (or zero) shaft deflection in a specific mode

shape. May readily change location along the shaft axis due to
changes in residual unbalance or other forcing functions, or due to
changes in dynamic stiffness, such as increased bearing clearance.
This is often a location of minimum shaft absolute displacement.
Vibration immediately on each side of the node is usually 180
degrees out of phase.

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Thank you

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